Patent Description:
The present invention finds advantageous application in the tobacco industry for the assembly of a transponder in a component of a disposable cartridge of an electronic cigarette, to which the following disclosure will refer without losing generality.

Normally, an electronic cigarette comprises a reusable part that is used several times and contains, among other things, an electric battery (which provides the energy necessary for the operation of the electronic cigarette) and an electronic processor that oversees the operation of the electronic cigarette. Furthermore, the electronic cigarette comprises a single use cartridge (namely, disposable that is therefore used only once and is then replaced), which is coupled to the reusable part.

Recently it has been proposed to insert, in each disposable cartridge, a component provided with a transponder provided with a memory in which the characteristics of the disposable cartridge are stored and in particular the characteristics of the active substance (liquid or solid) that must be heated to release the inhalable vapours; in this way, the reusable part of the electronic cigarette can read the characteristics of the disposable cartridge coupled thereto, thus adapting the heating to the characteristics of the disposable cartridge.

In most applications, the transponder comprises a single helical antenna (namely, a single coil acting as an antenna); however, in some applications the transponder can comprise a plurality of helical antennas (namely, a plurality of coils acting as an antenna) which have different orientations in space so as to guarantee the transponder to be able to communicate effectively in all possible positions.

A significant problem in making a helical antenna (namely, a coil that acts as an antenna) for a transponder is the need to use a very thin wire (having a diameter of the order of <NUM>-<NUM>) which therefore has an extremely low mechanical resistance (the breaking load is of the order of a few Newtons): if, during the winding of the wire, even a modest increase in traction occurs (<NUM>-<NUM> Newton in excess are enough), there is a risk of breaking the wire with the consequent stop of the automatic machine until the intervention of an expert operator (who in any case, takes several minutes to restore the continuity of the wire). Obviously, each stop of the automatic machine significantly reduces the daily productivity of the automatic machine and, at the same time, increases the direct costs of managing the automatic machine as a result of the intervention costs of an expert operator.

Patent application <CIT> describes a method to manufacture a conductive ring connected to a chip module for contactless chip card application.

The object of the present invention is to provide a method and a machine to manufacture a coil around a component of an article, which method and machine allow to work at a high operating speed (measured as the number of components produced in a unit of time) while maintaining, at the same time, a high production quality (generally measured as a percentage of defective pieces) and above all without frequent breakage of the wire during winding.

According to the present invention, a method and a machine are provided to manufacture a coil around a component of an article, as claimed in the attached claims.

The present invention will now be described with reference to the attached drawings, which illustrate a non-limiting embodiment thereof, wherein:.

In <FIG>, the reference number <NUM> denotes schematically and as a whole a disposable cartridge of an electronic cigarette comprising a series of components <NUM>-<NUM>.

<FIG> schematically illustrates a production plant designed for manufacturing the disposable cartridge <NUM>.

As illustrated in <FIG> and <FIG>, the component <NUM> of the disposable cartridge <NUM> has a roughly parallelepiped shape with six walls (faces): an upper wall <NUM>, a lower wall <NUM> parallel and opposite the upper wall <NUM>, a front wall <NUM>, a rear wall <NUM> parallel and opposite the front wall <NUM> and two side walls <NUM> and <NUM> parallel and opposite one another.

The component <NUM> comprises an integrated electronic circuit (not illustrated) that is arranged inside the component, is generally provided with its own electric battery (namely, with its own source of electrical energy) and has six pairs of electrical contacts <NUM>, which are arranged at the walls <NUM>-<NUM>: a pair of electrical contacts <NUM> is arranged at the side wall <NUM>, two pairs of electrical contacts <NUM> are arranged at the front wall <NUM>, a pair of electrical contacts <NUM> is arranged at the side wall <NUM>, and two pairs of electrical contacts <NUM> are arranged at the rear wall <NUM>.

Furthermore, component <NUM> comprises six coils <NUM>-<NUM> which are wound: two coils <NUM> and <NUM> of larger size (area) which surround the walls <NUM>-<NUM> and are arranged at opposite ends of component <NUM> (namely, the coil <NUM> is arranged near the upper wall <NUM> while the coil <NUM> is arranged near the lower wall <NUM>), two coils <NUM> and <NUM> of medium size (area) that surround the walls <NUM>-<NUM> and <NUM>-<NUM> and are arranged at the opposite ends of the component <NUM> (namely, the coil <NUM> is arranged near the front wall <NUM> while the coil <NUM> is arranged near the rear wall <NUM>), and two coils <NUM> and <NUM> of smaller size (area) that surround the walls <NUM>-<NUM> and are arranged at the opposite ends of the component <NUM> (namely, the coil <NUM> is arranged near the side wall <NUM> while the coil <NUM> is arranged near the side wall <NUM>).

Each coil <NUM>-<NUM> is wound and is made up of a plurality of turns of an externally insulated conductive wire <NUM> that form a winding; in the embodiment illustrated in the attached figures about <NUM>-<NUM> turns are provided for each coil <NUM>-<NUM> (but a greater number of turns could also be provided, such as for example <NUM>-<NUM> turns and preferably <NUM>-<NUM> turns). According to a preferred embodiment, the conductor wire <NUM> has a diameter ranging from <NUM> to <NUM> and preferably from <NUM> to <NUM> (even if in most applications the diameter ranges from <NUM> to <NUM>). Each coil <NUM>-<NUM> (namely, the wound wire <NUM> that makes up each coil <NUM>-<NUM>) has two ends (obviously an initial end and a final end depending on the winding direction) which are welded to a corresponding pair of electrical contacts <NUM>.

The electronic circuit of the component <NUM> uses, alternatively or simultaneously, the six coils <NUM>-<NUM> (or a part of the six coils <NUM>-<NUM>) to communicate in radiofrequency with other electronic devices arranged in the vicinity. Alternatively or in addition, the electronic circuit of component <NUM> could also use the six coils <NUM>-<NUM> (or a part of the six coils <NUM>-<NUM>) to generate electrical energy (designed for the operation thereof and/or to recharge the electric battery) exploiting an electromagnetic field generated by an electronic device arranged nearby; namely, the electronic circuit of the component <NUM> could also use the six coils <NUM>-<NUM> (or a part of the six coils <NUM>-<NUM>) to obtain an inductive (therefore contactless) electric recharge of its own electric battery. Consequently, the six coils <NUM>-<NUM> of the component <NUM> make up corresponding antennas that can be used to exchange (transmit) information by means of electromagnetic waves (in this case the antennas are part of a telecommunication device) and/or can be used to exchange electricity by means of electromagnetic waves (in this case the antennas are part of a charging device). Namely, each of the coils <NUM>-<NUM> of the component <NUM> makes up a helical antenna for electromagnetic interactions which can be intended for the exchange (transmission) of information or can be intended for generating electrical energy by means of electromagnetic induction.

The component <NUM> finally comprises six pairs of pins <NUM> and <NUM> (namely, two small columns) which project in a cantilevered manner (namely, perpendicularly) from the corresponding walls <NUM>-<NUM> and are arranged near corresponding pairs of electrical contacts <NUM>; the two ends (initial and final) of the wound wire <NUM> that makes up each coil <NUM>-<NUM> are bent at (approximately) <NUM>° around the corresponding pins <NUM> or <NUM> before joining the corresponding electrical contacts <NUM> (namely, before reaching the corresponding electrical contacts <NUM> on which the two ends are welded).

It is important to note that the positioning and shape of the electrical contacts <NUM> and the pins <NUM> and <NUM> could be completely different, thus being understood that two respective electrical contacts <NUM> and two respective pins <NUM> and <NUM> are associated with each coil <NUM>-<NUM> and that the pins <NUM> and <NUM> are arranged in (relative) proximity to the electrical contacts <NUM>.

In the embodiment illustrated in the attached figures, the component <NUM> comprises six coils <NUM>-<NUM>; according to other embodiments not illustrated, the component <NUM> has a different number of coils <NUM>-<NUM> that is generally comprised between two and five (but in some cases more than six coils <NUM>-<NUM> or even one single coil <NUM>-<NUM> could also be provided). In other words, the component <NUM> has at least one coil <NUM>-<NUM> and can have a plurality of coils <NUM>-<NUM>.

In <FIG> and <FIG>, the reference number <NUM> denotes as a whole a machine for manufacturing the coils <NUM>-<NUM> in the component <NUM>.

The winding machine <NUM> comprises a support body (namely, a frame) which rests on the ground by means of legs and has a vertical wall, on the front, on which the operating members are mounted. Furthermore, the winding machine <NUM> comprises a main conveyor <NUM> that moves the components <NUM> being processed along a working path P1, which develops between an input station S1 (in which the main conveyor <NUM> receives the components <NUM> where the coils <NUM>-<NUM> are formed) and an output station S2 (in which the main conveyor <NUM> transfers the completed components <NUM>, namely, provided with the coils <NUM>-<NUM>).

The working path P1 passes through a series of stations S3-S19 (better described in the following), in which the operations for manufacturing the six coils <NUM>-<NUM> are carried out. In the embodiment illustrated in the attached figures, the main path P comprises one single horizontal and linear section (namely, which extends substantially along a straight line arranged horizontally) arranged between the input station S1 and the output station S2; according to a different embodiment not illustrated, the working path P1 comprises: an upper section that is horizontal and linear, a lower section that is horizontal and linear (therefore it is parallel to the upper section), and a semi-circular connecting section which connects the upper section and the lower section to one another.

The main conveyor <NUM> comprises a plurality of carriages <NUM> which are moved along the working path P1; as better illustrated in <FIG>, <FIG> and <FIG>, each carriage <NUM> comprises a support plate <NUM> in which three different seats <NUM>, <NUM> and <NUM> are obtained, each designed to receive and house the same component <NUM> with different orientations. Namely, the seat <NUM> is designed to house the component <NUM> when the side wall <NUM> or the side wall <NUM> of the component <NUM> rests on the support plate <NUM>, the seat <NUM> is designed to house the component <NUM> when the front wall <NUM> or the rear wall <NUM> of the component <NUM> rests on the support plate <NUM>, and the seat <NUM> is designed to house the component <NUM> when the upper wall <NUM> or the lower wall <NUM> of the component <NUM> rests on the support plate <NUM>. Therefore, each support plate <NUM> is designed to support one single component <NUM> which can be arranged in three different orientations and in six different positions (each orientation has two different positions).

According to a preferred embodiment better illustrated in <FIG>, each seat <NUM>, <NUM> or <NUM> comprises a clamp <NUM> which is closed to firmly grip a component <NUM> resting on the support plate <NUM> and is opened to release a component <NUM> resting on the support plate <NUM>. Each clamp <NUM> comprises two opposing jaws <NUM> which are arranged at the opposite ends of the seat <NUM>, <NUM> or <NUM>, are movable by means of a linear movement (which develops parallel to the working path P1), and in use they move between a holding position in which the two jaws <NUM> are closer to one another and hold together a component <NUM> resting on the support plate <NUM> and a release position in which the two jaws <NUM> are further apart and release a component <NUM> resting on the support plate <NUM>. The clamps <NUM> are all controlled together by the same actuator device <NUM> (namely, all three clamps <NUM> open and close at the same time), which can be mounted on the support plate <NUM> or can be external to the support plate <NUM> and arranged in a fixed position next to the main conveyor <NUM>. Preferably, each clamp <NUM> is normally closed, namely, in the absence of the intervention of the actuator device <NUM> it naturally remains closed; this result is obtained due to the presence of a spring which tends to push the jaws <NUM> of each clamp <NUM> towards the closed position and is compressed by the action of the actuator device <NUM> (namely, the actuator device <NUM> must overcome the elastic force generated by the spring to move the jaws <NUM> of each clamp <NUM> towards the open position). According to a different embodiment, each clamp <NUM> has its own actuator device <NUM> which is separate and independent from the actuator devices <NUM> of the other two clamps <NUM>; in this way each actuator device <NUM> is optimized for the stroke of the jaws <NUM> of the corresponding clamp <NUM>.

It is important to note that the three clamps <NUM> of the three seats <NUM>, <NUM> and <NUM> of the same support plate <NUM> are functionally the same (namely, they are all designed to grip and hold the component <NUM> in three different positions) but could be structurally different (namely, have different shapes) in order to adapt to the conformation of the component <NUM>.

Obviously, the number of seats <NUM> obtained in the support plate <NUM> of each carriage <NUM> could be different from three, depending on the number of coils <NUM>-<NUM> to be made and on the conformation of the component <NUM>; therefore, the support plate <NUM> of each carriage <NUM> could have only one seat <NUM>, <NUM> or <NUM> or two seats <NUM>, <NUM> or <NUM> or even more than three seats <NUM>, <NUM> or <NUM>.

The main conveyor <NUM> is designed to cyclically move each carriage <NUM> along the working path P1 with an intermittent movement (at step) which provides for cyclical alternation of movement steps, in which the main conveyor <NUM> moves the carriages <NUM> and stop steps, in which the main conveyor <NUM> keeps the carriages <NUM> stopped. As illustrated in <FIG>, the main conveyor <NUM> is of the linear motor type and comprises an annular guide <NUM> (namely, closed in loop on itself), which is arranged in a fixed position along the working path P1; in particular, the annular guide <NUM> consists of one single fixed track (namely, devoid of movement), which is arranged along the working path P1. Furthermore, the main conveyor <NUM> comprises a plurality of slides <NUM>, each supporting a corresponding carriage <NUM> and coupled to the guide <NUM> so as to freely slide along the guide <NUM>. Finally, the main conveyor <NUM> comprises a linear electric motor <NUM>, which moves the slides <NUM> carrying the carriages <NUM> along the working path P1; the linear electric motor <NUM> comprises an annular stator <NUM> (namely, a fixed primary) which is arranged in a fixed position along the guide <NUM> and a plurality of movable sliders <NUM> (namely, movable secondaries), each electro-magnetically coupled to the stator <NUM> so as to receive, from the stator <NUM>, a driving force and is rigidly connected to a corresponding slide <NUM>.

According to a different embodiment not illustrated, the main conveyor <NUM> is a belt conveyor and comprises (at least) a flexible belt which supports the carriages <NUM> and is closed in a loop around two end pulleys (at least one of which is motorized). According to a further embodiment not illustrated, the main conveyor <NUM> is a wheel (arranged vertically or horizontally) which is mounted so as to rotate about a central rotation axis; obviously in this embodiment the working path P1 has a circular shape.

In the following description, the functions of the stations S1-S19 of the winding machine <NUM> are explained with reference to one single carriage <NUM> which moves one single component <NUM>.

As illustrated in <FIG> and <FIG>, at the starting of the production cycle of the coils <NUM>-<NUM> the main conveyor <NUM> moves the carriage <NUM> (carrying three seats <NUM> to be used alternatively) along the working path P1 to stop one single carriage <NUM> in the input station S1 in which one single component <NUM> is arranged in the seat <NUM> of the carriage <NUM> by resting the side wall <NUM> on the support plate <NUM> (namely, with the side wall <NUM> arranged horizontally and at the highest point). As illustrated in <FIG>, in the input station S1 a motorized arm <NUM> is provided, having a holding head <NUM>, which is designed to grip the component <NUM> by tightening the same on part of the walls <NUM> and <NUM> (namely, leaving the side walls <NUM> and <NUM> completely free); when the carriage <NUM> is stopped in the input station S1, the motorized arm <NUM> inserts a component <NUM> in the seat <NUM> of the carriage <NUM> by resting the side wall <NUM> on the support plate <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying only one component <NUM> within the seat <NUM>) along the working path P1 and from the input station S1 to the winding station S3, in which the carriage <NUM> stops and where a winding unit <NUM> (illustrated in greater detail in <FIG>) winds, around the component <NUM> carried by the carriage <NUM>, an externally insulated conductive wire <NUM> so as to form a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the winding station S3 to the welding station S4 (arranged downstream of the winding station S3), in which the carriage <NUM> stops and where the two opposite ends of the coil <NUM> that have been wound in the previous winding station S3, are welded (for example by way of ultrasound, by way of heat sealing or by way of laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (illustrated in greater detail in <FIG>).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the welding station S4 to the handling station S5 (arranged downstream of the welding station S4), in which the carriage <NUM> stops and where the component <NUM> is overturned (namely, rotated on itself by <NUM>°) in order to finally be arranged in the seat <NUM> of the carriage <NUM> by resting the side wall <NUM> on the support plate <NUM> (namely, with the side wall <NUM> arranged horizontally and at the highest point). As illustrated in <FIG>, in the handling station S5 a motorized arm <NUM> is provided, having a holding head <NUM> which is designed to grip the component <NUM> by tightening the same on part of the walls <NUM> and <NUM> (namely, leaving the side walls <NUM> and <NUM> completely free); when the carriage <NUM> is stopped in the handling station S5, the motorized arm <NUM> grips the component <NUM> arranged in the seat <NUM> of the carriage <NUM> and rotates the same on itself by <NUM>° so as to rest the side wall <NUM> on the support plate <NUM> (previously the side wall <NUM>, which is opposite the side wall <NUM>, was resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S5 a removal unit <NUM> is also provided which, while the motorized arm <NUM> modifies the position of the component <NUM> on the support plate <NUM>, removes (eliminates) the excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying only one component <NUM> within the seat <NUM>) along the working path P1 and from the handling station S5 to the winding station S6, in which the carriage <NUM> stops and where a winding unit <NUM> (completely identical to the winding unit <NUM> provided in the winding station S3) winds, around the component <NUM> carried by the carriage <NUM>, an externally insulated conductive wire <NUM> so as to form a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the winding station S6 to the welding station S7 (arranged downstream of the winding station S6), in which the carriage <NUM> stops and where the two opposite ends of the coil <NUM> that has been wound in the previous winding station S6, are welded (for example by way of ultrasound, by way of heat sealing or by way of laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> provided in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying only one component <NUM> within the seat <NUM>) along the working path P1 and from the welding station S7 to the handling station S8 (arranged downstream of the welding station S7), in which the carriage <NUM> stops and where the component <NUM> is rotated by <NUM>° in order to be finally arranged in the seat <NUM> of the carriage <NUM> by resting the front wall <NUM> on the support plate <NUM> (namely, with the rear wall <NUM> arranged horizontally and at the highest point). As illustrated in <FIG>, in the handling station S8 a motorized arm <NUM> is provided, having a holding head <NUM>, which is designed to grip the component <NUM> leaving the front wall <NUM> completely free; when the carriage <NUM> is stopped in the handling station S8, the motorized arm <NUM> grips the component <NUM> which is arranged in the seat <NUM> of the carriage <NUM> and rotates the same on itself by <NUM>° so as to rest the front wall <NUM> on the support plate <NUM> and by moving the component <NUM> from the seat <NUM> to the seat <NUM> (previously the component <NUM> was in the seat <NUM> and the side wall <NUM> was resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S8 a removal unit <NUM> (completely identical to the removal unit <NUM> provided in the handling station S5) is also provided which, while the motorized arm <NUM> modifies the position of the component <NUM> on the support plate <NUM>, removes (eliminates) the excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S7).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying only one component <NUM> within the seat <NUM>) along the working path P1 and from the handling station S8 to the winding station S9, in which the carriage <NUM> stops and where a winding unit <NUM> (completely identical to the winding unit <NUM> provided in the winding station S3) winds, around the component <NUM> carried by the carriage <NUM>, an externally insulated conductive wire <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the winding station S9 to the welding station S10 (arranged downstream of the winding station S9), in which the carriage <NUM> stops and where the two opposite ends of the coil <NUM> that has been wound in the previous winding station S9, are welded (for example by way of ultrasound, by way of heat sealing or by way of laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> provided in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the welding station S10 to the handling station S11 (arranged downstream of the welding station S10), in which the carriage <NUM> stops and where the component <NUM> is overturned (namely, rotated on itself by <NUM>°) in order to be finally arranged in the seat <NUM> of the carriage <NUM> by resting the rear wall <NUM> on the support plate <NUM> (namely, with the front wall <NUM> arranged horizontally and at the highest point). As illustrated in <FIG>, in the handling station S11 a motorized arm <NUM> is provided, having a holding head <NUM> which is designed to grip the component <NUM> leaving the walls <NUM> and <NUM> completely free; when the carriage <NUM> is stopped in the handling station S11, the motorized arm <NUM> grips the component <NUM> which is arranged in the seat <NUM> of the carriage <NUM> and rotates the same on itself by <NUM>° so as to rest the rear wall <NUM> on the support plate <NUM> (previously the front wall <NUM>, which is opposite the rear wall <NUM>, was resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S11 a removal unit <NUM> (completely identical to the removal unit <NUM> provided in the handling station S5) is also provided which, while the motorized arm <NUM> modifies the position of the component <NUM> on the support plate <NUM>, removes (eliminates) the excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S10).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the handling station S11 to the winding station S12, in which the carriage <NUM> stops and where a winding unit <NUM> (completely identical to the winding unit <NUM> provided in the winding station S3) winds, around the component <NUM> carried by the carriage <NUM>, an externally insulated conductive wire <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the winding station S12 to the welding station S13 (arranged downstream of the winding station S12), in which the carriage <NUM> stops and where the two opposite ends of the coil <NUM> that has been wound in the previous winding station S12 are welded (for example by way of ultrasound, by way of heat sealing or by way of laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> provided in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the welding station S13 to the handling station S14 (arranged downstream of the welding station S13), in which the carriage <NUM> stops and where the component <NUM> is rotated by <NUM>° in order to finally be arranged in the seat <NUM> of the carriage <NUM> by resting the upper wall <NUM> on the support plate <NUM> (namely, with the lower wall <NUM> arranged horizontally and at the highest point). As illustrated in <FIG>, in the handling station S14 a motorized arm <NUM> is provided, having a holding head <NUM> that is designed to grip the component <NUM> leaving the upper wall <NUM> completely free; when the carriage <NUM> is stopped in the handling station S14, the motorized arm <NUM> grips the component <NUM> arranged in the seat <NUM> of the carriage <NUM> and rotates the same on itself by <NUM>° so as to rest the upper wall <NUM> on the support plate <NUM> and by moving the component <NUM> from the seat <NUM> to the seat <NUM> (previously the component <NUM> was arranged in the seat <NUM> and the rear wall <NUM> was resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S14 a removal unit <NUM> (completely identical to the removal unit <NUM> provided in the handling station S5) is also provided which, while the motorized arm <NUM> modifies the position of the component <NUM> on the support plate <NUM>, removes (eliminates) the excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S13).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying only one component <NUM> within the seat <NUM>) along the working path P1 and from the handling station S14 to the winding station S15, in which the carriage <NUM> stops and where a winding unit <NUM> (completely identical to the winding unit <NUM> provided in the winding station S3) winds, around the component <NUM> carried by the carriage <NUM>, an externally insulated conductive wire <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the winding station S15 to the welding station S16 (arranged downstream of the winding station S15), in which the carriage <NUM> stops and where the two opposite ends of the coil <NUM> that has been wound in the previous winding station S15 are welded (for example by way of ultrasound, by way of heat sealing or by way of laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> provided in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the welding station S16 to the handling station S17 (arranged downstream of the welding station S16), in which the carriage <NUM> stops and where the component <NUM> is overturned (namely, rotated on itself by <NUM>°) in order to be finally arranged in the seat <NUM> of the carriage <NUM> by resting the lower wall <NUM> on the support plate <NUM> (namely, with the upper wall <NUM> arranged horizontally and at the highest point). As illustrated in <FIG>, in the handling station S17 a motorized arm <NUM> is provided, having a holding head <NUM> which is designed to grip the component <NUM>, leaving the upper wall <NUM> and the lower wall <NUM> completely free; when the carriage <NUM> is stopped in the handling station S17, the motorized arm <NUM> grips the component <NUM> arranged in the seat <NUM> of the carriage <NUM> and rotates the same on itself by <NUM>° so as to rest the lower wall <NUM> on the support plate <NUM> (previously the upper wall <NUM>, which is opposite the lower wall <NUM>, was resting on the support plate <NUM>).

According to a preferred embodiment, in the handling station S17 a removal unit <NUM> (completely identical to the removal unit <NUM> provided in the handling station S5) is also provided which, while the motorized arm <NUM> modifies the position of the component <NUM> on the support plate <NUM>, removes (eliminates) the excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S16).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying only one component <NUM> within the seat <NUM>) along the working path P1 and from the handling station S17 to the winding station S18, in which the carriage <NUM> stops and where a winding unit <NUM> (completely identical to the winding unit <NUM> provided in the winding station S3) winds, around the component <NUM> carried by the carriage <NUM>, an externally insulated conductive wire <NUM> in order to obtain a series of turns making up the coil <NUM>.

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the winding station S18 to the welding station S19 (arranged downstream of the winding station S18), in which the carriage <NUM> stops and where the two opposite ends of the coil <NUM> that has been wound in the previous winding station S18 are welded (for example by way of ultrasound, by way of heat sealing or by way of laser) to the two corresponding electrical contacts <NUM> by a welding unit <NUM> (completely identical to the welding unit <NUM> provided in the welding station S4).

Subsequently, the main conveyor <NUM> moves the carriage <NUM> (carrying one single component <NUM> within the seat <NUM>) along the working path P1 and from the welding station S19 to the output station S2 (arranged downstream of the welding station S19), in which the carriage <NUM> stops and where the component <NUM> is picked up from the seat <NUM> to be directed towards an outlet of the winding machine <NUM>. As illustrated in <FIG>, a motorized arm <NUM> provided with a holding head <NUM> is arranged in the output station S2 which is designed to grip the component <NUM> in order to pick up the component <NUM>.

According to a preferred embodiment, in the output station S2 a removal unit <NUM> (completely identical to the removal unit <NUM> provided in the handling station S5) is also provided which, while the motorized arm <NUM> picks up the component <NUM>, removes (eliminates) the excess parts of the two opposite ends of the coil <NUM> (cut in the previous welding station S19).

One single winding unit <NUM> is described in the following, since all six winding units <NUM> are substantially identical to one another and all work in the same way.

As illustrated in <FIG>, each carriage <NUM> comprises for each seat <NUM>, <NUM> or <NUM> two clamps <NUM> and <NUM> (better illustrated in <FIG>) which are mounted on the support plate <NUM> underneath the seat <NUM>, <NUM> or <NUM> and are arranged side by side relative to one another. Each clamp <NUM> or <NUM> is designed to grip and lock a corresponding end of the wire <NUM> which is wound around the respective component <NUM> and is provided with one single movable jaw which moves back and forth along a horizontal holding direction D1 and perpendicular to the working path P1 (illustrated in <FIG>). In other words, each clamp <NUM> or <NUM> opens and closes by means of a movement that develops along the holding direction D1 and is therefore perpendicular to the working path P1 so that the clamps <NUM> and <NUM>, by closing, bring the wire <NUM> into contact with the corresponding electrical contacts <NUM>. In particular, in use the clamp <NUM> is used to grip an initial end of the wire <NUM> at the starting of the winding of the wire <NUM> around the component <NUM> (namely, before winding the wire <NUM> around the component <NUM> its initial end is gripped by the clamp <NUM>); on the other hand, in use, the clamp <NUM> is used to grip a final end of the wire <NUM> at the end of the winding of the wire <NUM> around the component <NUM> (namely, after having completed the winding of the wire <NUM> around the component <NUM> its final end is gripped by the clamp <NUM>).

The movable jaw of each clamp <NUM> or <NUM> is moved along the holding direction D1 by means of a control rod <NUM> (illustrated in <FIG>) which is arranged across the support plate <NUM> and projects from the rear part of the support plate <NUM> so as to be pushed by an actuator device <NUM> (illustrated in <FIG>) which is in a fixed position (namely, mounted on the frame of the winding machine <NUM>) at each winding unit <NUM> (namely, at each winding station S3, S6, S9, S12 , S15, S18). Preferably, each clamp <NUM> or <NUM> is normally closed, or in the absence of the intervention of the actuator device <NUM> it naturally remains closed; this result is obtained due to the presence of a spring which tends to push the movable jaw of each clamp <NUM> or <NUM> towards the closed position and is compressed by the action of the actuator device <NUM> (namely, the actuator device <NUM> must overcome the elastic force generated by the spring to move the movable jaw of each clamp <NUM> or <NUM> towards the open position).

In each winding unit <NUM> two clamps <NUM> and <NUM> (illustrated in <FIG> and <FIG>) are provided, which are mounted (on the frame of the winding machine <NUM> and therefore outside the main conveyor <NUM> so as not to move together with the carriages <NUM>) underneath the support plates <NUM> of the carriages <NUM> and are arranged side by side relative to one another; in particular, the pair of clamps <NUM> and <NUM> is vertically aligned with a corresponding pair of clamps <NUM> and <NUM> carried by a carriage <NUM> that stops at the winding unit <NUM>.

Each clamp <NUM> or <NUM> is designed to grip and lock a corresponding end of the wire <NUM> which is wound around the respective component <NUM> and is provided with one single movable jaw which moves back and forth along a holding direction D2 (illustrated in <FIG>) horizontal and parallel to the working path P1 (namely, perpendicular to the holding direction D1 and illustrated in <FIG>). In other words, each clamp <NUM> or <NUM> opens and closes by means of a movement that develops along the holding direction D2 and is therefore parallel to the working path P1. According to a preferred embodiment illustrated in the attached figures, the clamps <NUM> and <NUM> share a common jaw devoid of movement arranged between the clamps <NUM> and <NUM>.

In particular, in use the clamp <NUM> is used to grip the initial end of the wire <NUM> at the starting of the winding of the wire <NUM> around the component <NUM> and (immediately) before the initial end of the wire <NUM> is gripped by the overlying clamp <NUM>; instead, in use the clamp <NUM> is used to grip the final end of the wire <NUM> at the end of the winding of the wire <NUM> around the component <NUM> and (immediately) after the final end of the wire <NUM> is gripped by the overlying clamp <NUM>.

Preferably, each clamp <NUM> or <NUM> is normally closed, namely, in the absence of the intervention of an actuator device it naturally remains closed; this result is obtained due to the presence of a spring which tends to push the movable jaw of each clamp <NUM> or <NUM> towards the closed position and is compressed by the action of the actuator device (namely, the actuator device must overcome the elastic force generated by the spring to move the movable jaw of each clamp <NUM> or <NUM> towards the open position).

Each winding unit <NUM> comprises a blade <NUM> (illustrated in <FIG>, <FIG> and <FIG>) which is mounted (on the frame of the winding machine <NUM> and therefore outside the main conveyor <NUM> so as not to move together with the carriages <NUM>) underneath the support plates <NUM> for the carriages <NUM> so as to be, in use, between a respective clamp <NUM> carried by a carriage <NUM> and a respective clamp <NUM>. Each blade <NUM>, in use, is movable along a cutting direction coinciding with the holding direction D2 (illustrated in <FIG>), namely, each blade <NUM> moves back and forth by means of a movement parallel to the working path P1. Due to its position, each movable blade <NUM> can cut a final end of a wire <NUM> which is locked at a higher position by a respective clamp <NUM> carried by a carriage <NUM> and is locked at a lower position by a respective clamp <NUM>.

Each winding unit <NUM> comprises a movable finger <NUM> (illustrated in <FIG>, <FIG> and <FIG>) which is used to bring the wire <NUM> (with a vertical movement) close to the component <NUM>, in order to wind (with a substantially horizontal movement) the wire <NUM> around the component <NUM>, and therefore to remove (with a vertical movement) the wire <NUM> from the component <NUM>. Each movable finger <NUM> has a tubular shape having a central hole which passes through the movable finger <NUM> from side to side and inside which the wire <NUM> is arranged; namely, the wire <NUM> enters from a rear opening of the movable finger <NUM> and exits from a front opening of the movable finger <NUM>. For each movable finger <NUM>, the wire <NUM> is progressively unwound from a coil contained in a suitable container, passes through a tensioning device provided with at least one movable dancer roller actuated by a spring and then reaches the movable finger <NUM>; each tensioning device is configured to apply a constant tension to the respective wire <NUM>.

The winding unit <NUM> comprises a common support body <NUM> (illustrated in <FIG>) on which the movable finger <NUM> is mounted to move the movable finger <NUM>; in particular, the movable finger <NUM> is rigidly mounted on the support body <NUM>, namely, the movable finger <NUM> always moves in a single piece with the support body <NUM> and never performs any type of movement relative to the support body <NUM>. The support body <NUM> is moved by one single actuator device <NUM> (schematically illustrated in <FIG>) provided with (at least) its own independent electric motor. In use, each movable finger <NUM> is arranged with a horizontal orientation when the wire <NUM> must be moved vertically to rise as it moves towards the component <NUM> or to descend thus moving away from the component <NUM>; moreover, in use, each movable finger <NUM> is arranged with a vertical orientation when the wire <NUM> must be horizontally moved in order to be wound around the component <NUM>.

Each winding unit <NUM> comprises a containment body <NUM> (better illustrated in <FIG>) which, in use, is arranged on the pin <NUM> so as to extend the pin <NUM> when the wire <NUM> must be bent around the pin <NUM> so as to prevent the wire <NUM> from accidentally escape from the pin <NUM>; namely, a little before the wire <NUM> is bent by <NUM>° around the pin <NUM>, the containment body <NUM> is arranged on the pin <NUM> to extend the pin <NUM> and thus prevent the wire <NUM> from accidentally escaping from the pin <NUM>. In this regard, it is important to note that the small pin <NUM> cannot have a too high extension (due to space problems that do not depend on the winding machine <NUM>) and, at the same time, the movable finger <NUM>, by moving, cannot pass too close to the component <NUM> to prevent that small positioning errors (combined with the constructive tolerances of the component <NUM>) can cause accidental impacts of the movable finger <NUM> against the component <NUM>.

Each winding unit <NUM> comprises a containment body <NUM> (better illustrated in <FIG>) which in use is rested on the pin <NUM> so as to extend the pin <NUM> when the wire <NUM> must be bent around the pin <NUM> so as to prevent the wire <NUM> from accidentally escape from the pin <NUM>; namely, a little before the wire <NUM> is bent by <NUM>° around the pin <NUM>, the containment body <NUM> is arranged on the pin <NUM> to extend the pin <NUM> and thus prevent the wire <NUM> from accidentally escaping from the pin <NUM>. In this regard, it is important to note that the small pin <NUM> cannot have a too high extension (due to space problems that do not depend on the winding machine <NUM>) and, at the same time, the movable finger <NUM>, by moving, cannot pass too close to the component <NUM> to prevent that small positioning errors (combined with the constructive tolerances of component <NUM>) can cause accidental impacts of the movable finger <NUM> against the component <NUM>.

According to a preferred embodiment illustrated in the attached figures, each winding unit <NUM> comprises a further movable finger <NUM> (better illustrated in <FIG>) which is arranged underneath the two clamps <NUM> and <NUM> and between the two clamps <NUM> and <NUM> (namely, underneath the common jaw devoid of movement arranged between the clamps <NUM> and <NUM>) and is moved vertically in order to remove the initial end of the wire <NUM> which can remain inside the clamp <NUM> even when the clamp <NUM> is opened (the initial end of the wire <NUM> is very light and therefore often does not naturally descend by gravity out of the clamp <NUM>); in this way, namely, due to the extraction action exerted by the movable finger <NUM>, it is avoided that the initial end of the wire <NUM> can remain undesirably inside the clamp <NUM> and therefore tear off when the carriage <NUM> moves at the end of the winding. In particular, the clamp <NUM> is opened after the initial end of the wire <NUM> has been engaged by the clamp <NUM> to start a new winding and at this point the movable finger <NUM> performs a vertical working stroke downwards to remove the initial end of the wire <NUM> from the clamp <NUM>.

The winding of a wire <NUM> around a component <NUM> in one single winding unit <NUM> is described in the following; obviously what happens in one single winding unit <NUM> takes place simultaneously and in exactly the same way also in the other winding units <NUM>.

Initially, the winding unit <NUM> is empty (namely, devoid of the component <NUM> carried by a carriage <NUM>), an initial end of the wire <NUM> is locked in the clamp <NUM>, and the movable finger <NUM> (arranged horizontally) is arranged underneath the clamp <NUM>. The initial end of the wire <NUM> locked in the clamp <NUM> is the initial end if referred to the new winding which will be made around the next component <NUM> that will arrive in the winding unit <NUM> and was, instead, the final end of the wire <NUM> if referred to the previous winding that has been completed around the previous component <NUM> that was previously in the winding unit <NUM>. When the winding machine <NUM> is started after a replacement of the coils from which the wire <NUM> is unwound, an operator manually places the initial end of the wire <NUM> in the clamp <NUM>.

Subsequently, the carriage <NUM> carries the component <NUM> into the winding unit <NUM>, the clamp <NUM> and <NUM> open, the movable finger <NUM> (still arranged horizontally) moves vertically from the bottom to the top in order to pass the initial end of the wire <NUM> first through the clamp <NUM> and subsequently through the clamp <NUM>, and finally the clamps <NUM> and <NUM> close to lock (in two different points) the initial end of the wire <NUM>; preferably, first only the clamp <NUM> closes while the clamp <NUM> is still open and then the clamp <NUM> also closes. It is important to note that the clamp <NUM> opens and closes by means of a movement along the holding direction D1 that is perpendicular to the working path P1 and then, in the closing movement, the clamp <NUM> moves the wire <NUM> perpendicular to the working path P1 by pulling the wire <NUM> against the component <NUM> so that the wire <NUM> rests on a corresponding electrical contact <NUM>.

Subsequently, the movable finger <NUM> rotates by <NUM>° to move from a horizontal to a vertical orientation and start to rotate around the component <NUM> with a helical (spiral) rotation movement to wind the wire <NUM> around the component <NUM> (in geometry a helix is a curve in three-dimensional space, represented by a line wound at a constant angle around a cylinder). Before starting to wind the wire <NUM> around the component <NUM>, the wire <NUM>, which rises vertically towards the component <NUM> is bent by the movable finger <NUM> around the pin <NUM> that horizontally projects from the component <NUM> to give the wire <NUM> a <NUM>° curve which deflects the wire <NUM> towards a horizontal orientation. In particular, the <NUM>° rotation of the movable finger <NUM>, which moves from a horizontal to a vertical orientation occurs at the same time as the wire <NUM> is bent around the pin <NUM>. As previously mentioned, in this step the containment body <NUM> rests on the pin <NUM> so as to extend the pin <NUM> when the wire <NUM> must be bent around the pin <NUM> in order to prevent the wire <NUM> from accidentally escaping from the pin <NUM>.

Subsequently, the movable finger <NUM> revolves several times around the component <NUM> to form, with the wire <NUM>, a series of (vertically offset) turns around the component <NUM>.

More or less when the winding of the wire <NUM> around the component <NUM> is started, the clamp <NUM> opens and the movable finger <NUM> performs a vertical working stroke downwards to remove the initial end of the wire <NUM> from the clamp <NUM>.

When the end of the winding of the wire <NUM> around the component <NUM> approaches (namely, before completing the last turn of the winding), the containment body <NUM> is moved away from the component <NUM> and (preferably) the clamp <NUM> is opened to release the initial end of the wire <NUM> (whereas the clamp <NUM> remains well closed).

After finishing the winding of the wire <NUM> around the component <NUM>, the movable finger <NUM> bends the wire <NUM> arranged horizontally around the pin <NUM> to give the wire <NUM> a <NUM>° curve that deviates the wire <NUM> towards a vertical orientation. Simultaneously with the bending of the wire <NUM> around the pin <NUM>, the movable finger <NUM> rotates by <NUM>° to move from a vertical orientation to a horizontal orientation. As previously stated, in this step the containment body <NUM> rests on the pin <NUM> so as to extend the pin <NUM> when the wire <NUM> must be bent around the pin <NUM> so as to prevent the wire <NUM> from accidentally escaping from the pin <NUM>.

When the end of the winding of the wire <NUM> around the component <NUM> approaches (namely, before completing the last turn of the winding), the clamp <NUM> is opened. The movable finger <NUM> by moving the wire <NUM> vertically from top to bottom after bending the wire <NUM> around the pin <NUM>, makes the final end of the wire <NUM> pass through the open clamp <NUM> which immediately closes, thus locking the final end of the wire <NUM>; subsequently, the movable finger <NUM> by moving the wire <NUM> vertically from top to bottom after bending the wire <NUM> around the pin <NUM> makes the final end of the wire <NUM> pass also through the open clamp <NUM> which immediately closes, thus locking the final end of the wire <NUM>. It is important to note that the clamp <NUM> opens and closes by means of a movement along the holding direction D1, which is perpendicular to the working path P1 and therefore in the closing movement the clamp <NUM> moves the wire <NUM> perpendicular to the working path P1 by pulling the wire <NUM> against the component <NUM> so that the wire <NUM> rests on a corresponding electrical contact <NUM>.

Subsequently, the containment body <NUM> moves away from the component <NUM> and the winding ends with the movement of the movable blade <NUM> which, by moving parallel to the working path P1, cuts the final end of the wire <NUM> after the final end of the wire <NUM> has been locked both by the clamp <NUM> and by the clamp <NUM> (namely, the movable blade <NUM> cuts the final end of the wire <NUM> between the portion locked at a higher position by the clamp <NUM> and the portion locked at a lower position by the clamp <NUM>).

According to a possible embodiment, the winding of the wire <NUM> around the component <NUM> is carried out from the bottom upwards, therefore, before starting to wind the wire <NUM>, the wire <NUM> that rises vertically towards the component <NUM> is bent around the pin <NUM> (arranged at a lower position) to give the wire <NUM> a <NUM>° curve which deflects the wire <NUM> towards a horizontal orientation; moreover, after finishing the winding of the wire <NUM>, the wire <NUM> arranged horizontally is bent around the pin <NUM> (arranged at a higher position) to give the wire <NUM> a <NUM>° curve that deviates the wire <NUM> towards a vertical orientation. According to a different embodiment, the winding of the wire <NUM> around the component <NUM> is carried out from top to bottom, therefore, before starting to wind the wire <NUM>, the wire <NUM> that rises vertically towards the component <NUM> is bent around the pin <NUM> (arranged at a higher position) to give the wire <NUM> a <NUM>° curve which deflects the wire <NUM> towards a horizontal orientation; furthermore, after finishing the winding of the wire <NUM>, the wire <NUM> arranged horizontally is bent around the pin <NUM> (arranged at a lower position) to give the wire <NUM> a <NUM>° curve that deviates the wire <NUM> towards a vertical orientation. In this embodiment, the winding of the wire <NUM> around the component <NUM> occurs over a vertical section of the wire <NUM> which reaches the pin <NUM> (arranged at a higher position) and therefore helps to lock the initial end of the wire <NUM> against the component <NUM>, thus ensuring greater winding stability.

As illustrated in <FIG>, the welding station S4 comprises a corresponding welding unit <NUM> which is arranged in a fixed position (namely, it does not move together with the main conveyor <NUM>) and is provided with a movable welding head <NUM> to move towards the component <NUM> carried by a carriage <NUM> stopped in the welding station S4 so as to be able to carry out the welding of the two ends of the wire <NUM> to the corresponding electrical contacts <NUM> and subsequently to move away from the component <NUM> carried by the carriage <NUM> once the welding is finished. The movement of the welding head <NUM> is always linear and can be oriented vertically (as occurs in the welding stations S4, S7, S10 and S13) or it can be oriented horizontally (as occurs in the welding stations S16 and S19) according to the orientation assumed by the component <NUM>. The welding head <NUM> is provided with two welding elements arranged side by side to simultaneously weld both ends of the wire <NUM> to the corresponding electrical contacts <NUM>. Preferably, the welding head <NUM> is also configured to cut the two ends of the wire <NUM> downstream of the welds with the two electrical contacts <NUM> so as to separate the excess part of the two opposite ends of the coil <NUM>-<NUM>; namely, the welding head <NUM> is also provided with blades which cut the wire <NUM> downstream of the welds with the two electrical contacts <NUM>.

As previously stated, in all six welding stations S4, S7, S10, S13, S16 and S19 the corresponding six welding units <NUM> are substantially identical to one another and the only relevant variation is the vertical orientation of the welding heads <NUM> in the welding stations S4, S7, S10 and S13 and the horizontal orientation of the welding heads <NUM> in the welding stations S16 and S19 to adapt to the different orientations of the components <NUM>.

As illustrated in <FIG>, the handling station S5 comprises a corresponding removal unit <NUM> provided with a blower device <NUM> which is connected to a common compressed air distributor and is configured to generate a jet of compressed air which is directed from top to bottom and strikes a corresponding component <NUM> carried by a carriage <NUM> stopped in the removal station S5. The jet of compressed air strikes from top to bottom a corresponding component <NUM> carried by a carriage <NUM> stopped in the removal station S5 and therefore pushes downwards the excess parts of the two opposite ends of the coil <NUM>-<NUM> (cut in the previous welding station S4); preferably, the excess parts of the two opposite ends of the coil <NUM>-<NUM> pushed downwards by a jet of compressed air are collected in a container <NUM> that is located under the carriage <NUM>. According to a preferred embodiment, the removal unit <NUM> also comprises a clamp <NUM> which is arranged in a fixed position (namely, externally to the main conveyor <NUM>) under the support plate <NUM> of a stopped carriage <NUM> and clamps the excess parts of the two opposite ends of the coil <NUM>-<NUM> waiting for the excess parts to be directed inside the container <NUM> by the jets of air.

As previously stated, in all five handling stations S5, S8, S11, S14, S17 and S19 and in the output station S2 the corresponding six removal units <NUM> are substantially identical to one another.

In the embodiment described above, in the five handling stations S5, S8, S11, S14, S17 and S19 each component <NUM> is rotated by <NUM>° or <NUM>° around a horizontal rotation axis; according to other embodiments, in one or more handling stations S5, S8, S11, S14, S17 and S19 each component <NUM> is rotated around several different rotation axes: for example each component <NUM> is first rotated by <NUM>° or <NUM>° (or even a different angle such as <NUM>°, <NUM>° or others) around a horizontal rotation axis and then is rotated by <NUM>° or <NUM>° (or even a different angle such as <NUM>°, <NUM>° or others) around a vertical rotation axis.

In the non-limiting embodiment described above, the component <NUM> is part of a disposable cartridge of an electronic cigarette, but the method to manufacture coils <NUM>-<NUM> described above can find application for the production of components for articles of any type (namely, of any merchandise category). For example, the method to manufacture coils <NUM>-<NUM> described above can be applied to the production of components for a machine, an equipment system, a construction unit, a product (e.g., a payment device) for example, but not only, in the tobacco, pharmaceutical, food or entertainment field; more in general, the method to manufacture coils <NUM>-<NUM> described above can be applied to the production of components for applications of any type.

As previously described, in each winding station S3, S6, S9, S12, S15, S18, the wire <NUM> is directly wound around the component <NUM> by revolving (with a helical rotation movement) the movable finger <NUM>, which slidingly engages the wire <NUM>, several times around the component <NUM>; in other words, each coil <NUM>-<NUM> is manufactured directly around the component <NUM> by making the movable finger <NUM>, which engages the wire <NUM> in a sliding manner, revolve several times around the component <NUM> with a helical rotation.

The automatic machine <NUM> works by performing in succession the work cycles (or machine cycles) which are repeated in always the same way in all the stations S1-S19 of the automatic machine <NUM> and all have the same time duration (namely, the same cycle time which is the unit of time between the occurrence of an event and its repetition). For example, when the automatic machine <NUM> works with <NUM> cycles/minute, then each work cycle (or machine cycle) lasts one second. All the stations S1-S19 of the automatic machine <NUM> are bound to the same time duration of the work cycles and therefore in each station S1-S19 of the automatic machine <NUM> all the operations carried out must have the same time duration equal to the time duration of each work cycle; it is therefore evident that the time duration of each work cycle is imposed by the station S1-S19 of the slowest automatic machine <NUM> (namely, by the winding stations S3, S6, S9, S12, S15, S18) and that all the other stations S1 -S19 of the automatic machine <NUM> must adapt by slowing down their operations or by inserting idle waiting times.

A work cycle of the automatic machine <NUM> (machine cycle) ranges from an initial instant in which a carriage <NUM> carrying the component <NUM> devoid of the coil <NUM>-<NUM> arrives at a winding station S3, S6, S9, S12, S15, S18 to a final instant, in which the carriage <NUM> carrying the component <NUM> provided with the coil <NUM>-<NUM> (recently manufactured) leaves the winding station S3, S6, S9, S12, S15, S18. In each winding station S3, S6, S9, S12, S15, S18, the wire <NUM> is directly wound around the component <NUM> being made to rotate around the component <NUM> with a helical rotation during a winding step which constitutes a fraction of the work cycle of the automatic machine <NUM>.

Namely, in each winding station S3, S6, S9, S12, S15, S18, during the work cycle of the automatic machine <NUM>, in addition to the winding step (in which the wire <NUM> is directly wound around the component <NUM> with a helical rotation) other steps must also be carried out, which precede or follow the winding step.

For example, before the winding step a carriage <NUM> must have time to stop in the correct position inside the winding station S3, S6, S9, S12, S15, S18, the clamp <NUM> must have time to open, and the finger <NUM> must have time to go upwards towards the component <NUM>; namely, before the winding step, the following steps are provided: a stopping step of the carriage, an opening step of the clamp <NUM>, and an upward step of the finger <NUM>.

On the other hand, after the winding step, the finger <NUM> must have time to descend by moving away from the component <NUM>, the clamp <NUM> must have time to close, the blade <NUM> must have time to cut the wire <NUM>, and the carriage <NUM> must have time to restart (set in motion) from the winding station S3, S6, S9, S12, S15, S18; namely, after the winding step, the following steps are provided: a downward step of the finger <NUM>, a closing step of the clamp <NUM>, a cutting step of the wire <NUM>, and a restarting step of the carriage <NUM>.

According to a preferred embodiment, the time duration of the winding step during which the wire <NUM> is directly wound around the component <NUM> with a helical rotation ranges from <NUM>% to <NUM>% of a total time duration of the work cycle (machine cycle) of the automatic machine <NUM>; namely, the great majority (more than half) of the total time duration of the work cycle (machine cycle) of the automatic machine <NUM> is involved in the winding step during which the wire <NUM> is directly wound around the component <NUM> with a helical rotation and the remaining time of the overall time duration of the work cycle (machine cycle) of the automatic machine <NUM> is dedicated to all the other necessary (peripheral) operations (that is, preparatory for carrying out the winding step and preparatory for allowing the new winding step to be carried out).

According to a preferred embodiment, the time duration of the winding step during which the wire <NUM> is directly wound around the component <NUM> with a helical rotation by revolving the movable finger <NUM> ranges from <NUM>% to <NUM>% of an overall time duration for the production of the component <NUM> consisting of several work cycles of the automatic machine <NUM>. Namely, the overall time duration of the production of the component <NUM> is constituted by the sum of all the machine cycles necessary to perform all the operations required for the production of the component <NUM> (at least the winding of the wire <NUM> and the subsequent welding of the wire <NUM> to which can be added, for example, quality controls) and the time duration of the winding step ranges from <NUM>% to <NUM>% of the total time duration of the production of the component <NUM>.

According to a different embodiment not illustrated, each winding station S3, S6, S9, S12, S15, S18 works in parallel to obtain, by winding, respective coils <NUM>-<NUM> at the same time, with a first number of components <NUM> that is an integral multiple, preferably double, relative to a second number of components <NUM> with which the welding station S4, S7, S10, S13, S16, S19 works, forming respective welds. In this embodiment, the first number ranges from two to ten and, hence, the second number ranges from one to five.

As illustrated in <FIG>, the production plant <NUM> comprises the winding machine <NUM> which forms the six coils <NUM>-<NUM> around each component <NUM> (but the number of coils <NUM>-<NUM> could be different).

In addition, the production plant <NUM> comprises a control machine <NUM> which is arranged immediately downstream of the winding machine <NUM> to directly receive the components <NUM> provided with the six coils <NUM>-<NUM> from the winding machine <NUM> (as better described in the following) and then carry out a control on the components <NUM> provided with the six coils <NUM>-<NUM> (in particular to verify that in each component <NUM> the six coils <NUM>-<NUM> are all functioning correctly).

The production plant <NUM> comprises a belt conveyor <NUM> which directly receives the components <NUM> controlled by the control machine <NUM> and moves the controlled components <NUM> towards a subsequent assembling machine <NUM> which composes (assembles) each disposable cartridge <NUM> by joining the components <NUM>-<NUM>. The assembling machine <NUM> comprises a conveyor <NUM> of the linear motor type (better illustrated in <FIG> and similar to the main conveyor <NUM> of the winding machine <NUM>) which moves each disposable cartridge <NUM> as it is assembled by joining the components <NUM>-<NUM>.

Coupled to the assembling machine <NUM> a control machine <NUM> is provided, which carries out a control on the disposable cartridges <NUM> during assembly by taking the cartridges <NUM> during assembly from the conveyor <NUM> of the assembling machine <NUM> and then re-introducing the disposable cartridges <NUM> during assembly on the conveyor <NUM> of the assembling machine <NUM>.

The production plant <NUM> comprises two belt conveyors <NUM> and <NUM>, which both originate from an outlet of the assembling machine <NUM> and diverge to feed the disposable cartridges <NUM> to two twin control machines <NUM> and <NUM> which carry out a control on the disposable cartridges <NUM>: half of the disposable cartridges <NUM> leaving the assembling machine <NUM> are fed to the control machine <NUM> by the conveyor <NUM> and the other half of the disposable cartridges <NUM> leaving the assembling machine <NUM> are fed to the control machine <NUM> by the conveyor <NUM>. The two twin control machines <NUM> and <NUM> are arranged aligned one behind the other with an arrangement that reduces the longitudinal bulk of the production plant <NUM>.

The production plant <NUM> comprises two twin control machines <NUM> and <NUM> which carry out a control on the disposable cartridges <NUM> and are arranged aligned one behind the other: the control machine <NUM> directly feeds the disposable cartridges <NUM> to the control machine <NUM> while the control machine <NUM> directly feeds the disposable cartridges <NUM> to the control machine <NUM>.

As better illustrated in <FIG>, the production plant <NUM> comprises two twin belt conveyors <NUM> and <NUM> which are parallel to one another and converge towards one another and a belt output conveyor <NUM> which is perpendicular to the belt conveyors <NUM> and <NUM> and is arranged between the two belt conveyors <NUM> and <NUM>: the belt conveyor <NUM> transfers the disposable cartridges <NUM> from the control machine <NUM> to the output conveyor <NUM> while the belt conveyor <NUM> transfers the disposable cartridges <NUM> from the control machine <NUM> to the output conveyor <NUM>.

The control machines <NUM>, <NUM> and <NUM>-<NUM> have the same identical structure and differ from one another only for a different location in the production plant <NUM>, for a different size, and for the type of controls that are carried out; for this reason, only the structure of the control machine <NUM> will be described in detail in the following, since this structure is found to be the same in all the other control machines <NUM> and <NUM>-<NUM>.

The peculiar characteristic of all the control machines <NUM>, <NUM> and <NUM>-<NUM> is to carry out the simultaneous control of a group of articles (which can be the single components <NUM> or the disposable cartridges <NUM>) formed by a relatively high number of articles: the control machine <NUM> simultaneously controls sixteen components <NUM>, the control machine <NUM> simultaneously controls twenty disposable cartridges <NUM>, each control machine <NUM> or <NUM> simultaneously controls fourteen disposable cartridges <NUM>, each control machine <NUM> or <NUM> simultaneously controls eight single-use cartridges <NUM>, and each control machine <NUM> or <NUM> simultaneously controls five single-use cartridges <NUM>. It is important to note that, in order not to form a "bottleneck" for the production plant <NUM>, a control machine <NUM>, <NUM> and <NUM>-<NUM> must simultaneously control how many articles there are as well as the length of time required to carry out the control.

As illustrated in <FIG> and <FIG>, the control machine <NUM> comprises an initial belt conveyor <NUM> configured to move the components <NUM> along an initial path P2 which starts in an input station S20 arranged at the end of the working path P1 defined by the main conveyor <NUM> of the winding machine <NUM>; the initial path P2 is perpendicular to the working path P1. Furthermore, the control machine <NUM> comprises a final belt conveyor <NUM> configured to move the components <NUM> along a final path P3 which is parallel and next to the initial path P2 (and therefore is perpendicular to the working path P1) and ends in an output station S2 arranged at the beginning of the conveyor <NUM> which carries the components <NUM> towards the assembling machine <NUM>. In other words, the two conveyors <NUM> and <NUM> are arranged side by side.

The control machine <NUM> comprises a control unit <NUM> configured to carry out the simultaneous control of all the components <NUM> of the group of components <NUM> (namely, of sixteen components <NUM> at a time). Furthermore, the control machine <NUM> comprises a transferring device <NUM> configured both to simultaneously transfer a whole group of (sixteen) components <NUM> to be controlled from the initial conveyor <NUM> to the control unit <NUM>, and to simultaneously transfer a whole group of (sixteen) components <NUM> controlled by the control unit <NUM> to the final conveyor <NUM>. Namely, the transferring device <NUM> alternately "loads" the control unit <NUM> by simultaneously transferring a whole group of (sixteen) components <NUM> to be controlled to the control unit <NUM> and "unloads" the control unit <NUM> by simultaneously transferring, from the control unit <NUM>, a whole group of (sixteen) controlled components <NUM> to the final conveyor <NUM>.

In the embodiment illustrated in the attached figures, one single transferring device <NUM> is provided, which alternately performs both functions: "loading" the control unit <NUM> by simultaneously transferring a whole group of (sixteen) components <NUM> to be controlled from the initial conveyor <NUM> to the control unit <NUM> and "unloading" the control unit <NUM> by simultaneously transferring, from the control unit <NUM>, a whole group of (sixteen) controlled components <NUM> to the final conveyor <NUM>. In this embodiment, preferably, the control unit <NUM> is arranged on the same side relative to the initial conveyor <NUM> and to the final conveyor <NUM> (namely, the control unit <NUM> is not arranged between the initial conveyor <NUM> and the final conveyor <NUM>).

According to a different embodiment not illustrated, two transferring devices are provided which are separate and independent from one another: a first transferring device "loads" the control unit <NUM> by simultaneously transferring a whole group of (sixteen) components <NUM> to be controlled from the initial conveyor <NUM> to the control unit <NUM>, and the second transferring device "unloads" the control unit <NUM>, by simultaneously transferring, from the control unit <NUM>, a whole group of (sixteen) controlled components <NUM> to the final conveyor <NUM>. In this embodiment, preferably, the control unit <NUM> is arranged between the initial conveyor <NUM> and the final conveyor <NUM>.

Therefore, in general, two transferring devices are provided which are different, separate and independent from one another or one single transferring device <NUM> is provided, which alternatively performs the function of the first transferring device and the function of the second transferring device (namely, the first transferring device coincides with the second transferring device).

The main conveyor <NUM> of the winding machine <NUM> moves a plurality of components <NUM> along a working path P1; in the input station S20 arranged along the main path P1, the components <NUM>, from the main conveyor <NUM> of the winding machine <NUM>, are transferred (by the motorized arm <NUM>) to the initial conveyor <NUM> of the control machine <NUM> until forming, in the initial conveyor <NUM> of the control machine <NUM>, the group of (sixteen) components <NUM> formed by a given number (sixteen) of components <NUM>. Preferably, in the input station S1 only one component <NUM> is transferred at a time from the main conveyor <NUM> of the winding machine <NUM> to the initial conveyor <NUM> of the control machine <NUM>.

In the output station S21, the components <NUM> are transferred from the final conveyor <NUM> of the control machine <NUM> to the conveyor <NUM> which moves a plurality of components <NUM> along a corresponding path. Preferably, in the output station S21 only one component <NUM> at a time is transferred from the final conveyor <NUM> of the control machine <NUM> to the conveyor <NUM>.

In the control machine <NUM>, the initial conveyor <NUM> moves the components <NUM> in the opposite direction relative to the final conveyor <NUM> and the input and output stations S20 and S21 are arranged next to one another at the same end of the initial and final conveyors <NUM> and <NUM>; in the control machine <NUM>, the input station S20 receives the components <NUM> from the main conveyor <NUM> of the winding machine <NUM> and the output station S21 transfers the components <NUM> to the conveyor <NUM>. Namely, in the control machine <NUM> the components <NUM> move back and forth along the control machine <NUM>.

In the control machine <NUM> and as illustrated in <FIG>, the initial conveyor <NUM> moves the disposable cartridges <NUM> in the opposite direction relative to the final conveyor <NUM> and the input and output stations S20 and S21 are arranged next to one another at the same end of the initial and final conveyors <NUM> and <NUM>; in the control machine <NUM>, the input station S20 receives the disposable cartridges <NUM> from the conveyor <NUM> of the assembling machine <NUM> and the output station S21 releases the disposable cartridges <NUM> back again to the conveyor <NUM> of the assembling machine <NUM>. In other words, the control machine <NUM> is inserted "inside" the assembling machine <NUM> to pick up the disposable cartridges <NUM> being processed from the conveyor <NUM> of the assembling machine <NUM> and then re-insert the disposable cartridges <NUM> being processed in the conveyor <NUM> of the assembling machine <NUM>. Namely, in the control machine <NUM> the cartridges <NUM> move back and forth along the control machine <NUM>.

In other words, in the assembling machine <NUM> the conveyor <NUM> moves a plurality of disposable cartridges <NUM> along a path which is perpendicular to the initial path P2 and to the final path P3 of the corresponding control machine <NUM>. In the input station S20 arranged along the path of the conveyor <NUM>, the disposable cartridges <NUM> are transferred from the conveyor <NUM> to the initial conveyor <NUM> until the group of (twenty) disposable cartridges <NUM> formed by a given number (twenty) of disposable cartridges <NUM> is formed in the initial conveyor <NUM>. In the output station S21 arranged along the path of the conveyor <NUM> downstream of the input station S1, the disposable cartridges <NUM> are transferred from the final conveyor <NUM> to the conveyor <NUM>.

As illustrated for example in <FIG>, in the control machines <NUM>-<NUM> the initial conveyor <NUM> moves the cartridges <NUM> in the same direction as the final conveyor <NUM> and therefore the input and output stations S20 and S21 are arranged at opposite ends of the initial and final conveyors <NUM> and <NUM>. Namely, in the control machines <NUM>-<NUM> the cartridges <NUM> cross from side to side along the control machines <NUM>-<NUM>.

According to a preferred embodiment, any defective component <NUM> is rejected while the defective component <NUM> is in the final conveyor <NUM>; in particular, the final conveyor <NUM> moves a defective component <NUM> beyond the output station S21 to a reject station arranged downstream of the output station S21 and in which the component <NUM> is fed (normally by gravity) towards an underlying collecting container <NUM> (illustrated in <FIG> and <FIG>).

To summarize, the control machine <NUM> carries out a control on a group of components <NUM> formed by a plurality (in particular sixteen) of components <NUM>. In the control machine <NUM> the initial conveyor <NUM> moves a plurality of components <NUM> along an initial path P2 starting in the input station S20, the transferring device <NUM> simultaneously transfers the whole group of (sixteen) components <NUM> to be controlled from the initial conveyor <NUM> to the control unit <NUM>, the control unit <NUM> carries out the simultaneous control of all (sixteen) components <NUM> of the group of components <NUM>; the transferring device <NUM> simultaneously transfers the whole group of (sixteen) components <NUM> controlled by the control unit <NUM> to the final conveyor <NUM>, and finally the final conveyor <NUM> moves the components <NUM> along the final path P3 which is parallel and beside the initial path P2 and ends at the output station S21.

In the embodiment illustrated in the attached figures, the wire <NUM> is electrically conductive, is externally insulated, and is wound to form (at least) one coil <NUM>-<NUM> which forms a helical antenna for electromagnetic interactions that can be intended for the exchange (transmission) of information or can be intended for generating electricity by electromagnetic induction. According to a different embodiment, the wire <NUM> is electrically conductive (and therefore is designed to be crossed by an electric current, although of low or very low intensity) but has a textile core (for example made of cotton), which is made conductive, for example by means of a doping with metal nanoparticles. According to a further embodiment, the wire <NUM> is not electrically conductive, it is of the textile type and the (at least) one coil <NUM>-<NUM> constitutes a wick (or the like) for an electric cigarette.

The embodiments described herein can be combined with one another without departing from the scope of the present invention.

The method to manufacture the coils <NUM>-<NUM> described above has numerous advantages.

First of all, the method to manufacture the coils <NUM>-<NUM> described above allows to work at a high operating speed (measured as the number of components produced in the unit of time).

Furthermore, the method to manufacture the coils <NUM>-<NUM> described above allows to maintain a high production quality (generally measured as a percentage of defective pieces).

The method to manufacture the coils <NUM>-<NUM> described above is relatively simple and inexpensive to implement.

Finally, the method to manufacture the coils <NUM>-<NUM> described above allows to avoid frequent breakages of the wire <NUM> during the winding of the wire <NUM>.

Claim 1:
A method to manufacture a coil (<NUM>-<NUM>) around a component (<NUM>) of an article (<NUM>) using an automatic machine (<NUM>) and comprising the steps of:
moving, by means of a main conveyor (<NUM>) of the automatic machine (<NUM>) and along a working path (P1), a carriage (<NUM>) provided with a seat (<NUM>, <NUM>, <NUM>) designed to house the component (<NUM>);
placing, in an input station (S1) of the automatic machine (<NUM>) arranged along the working path (P1), the component (<NUM>) in the seat (<NUM>, <NUM>, <NUM>) of the carriage (<NUM>); and
coupling, in a winding station (S3, S6, S9, S12, S15, S18) of the automatic machine (<NUM>) arranged along the working path (P1) downstream of the input station (S1), an electrically conductive wire (<NUM>) around the component (<NUM>) in order to obtain a series of turns making up the coil (<NUM>-<NUM>);
wherein a work cycle of the automatic machine (<NUM>) lasts from an initial instant, in which the carriage (<NUM>) carrying the component (<NUM>) devoid of the coil (<NUM>-<NUM>) reaches the winding station (S3, S6, S9, S12, S15, S18), to a final instant, in which the carriage (<NUM>) carrying the component (<NUM>) provided with the coil (<NUM>-<NUM>) leaves the winding station (S3, S6, S9, S12, S15, S18);
wherein the coil (<NUM>-<NUM>) is made up of a number of turns less than <NUM>; and
wherein the wire (<NUM>) is directly wound around the component (<NUM>) being made to rotate around the component (<NUM>) during a winding step which constitutes a fraction of the work cycle of the automatic machine (<NUM>);
the method is characterized in that:
the diameter of the wire (<NUM>) is less than <NUM>; and
the time duration of the winding step during which the wire (<NUM>) is made to rotate around the component (<NUM>) ranges from <NUM>% to <NUM>% of a total time duration of the work cycle of the automatic machine (<NUM>).