Patent ID: 12221316

DETAILED DESCRIPTION

The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which certain aspects of the invention are shown. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments and aspects set forth herein; rather, the embodiments are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Accordingly, it is to be understood that the present invention is not limited to the embodiments described herein and illustrated in the drawings; rather, the skilled person will recognize that many changes and modifications may be made within the scope of the appended claims. Like reference numerals refer to like elements throughout the description.

FIG.1illustrates a system1according to at least one exemplary embodiment of the present invention. The system1comprises a plurality of cylindrical elements2onto which a continuous elongate element4is to be winded (seeFIG.8andFIG.9). Each cylindrical element2will thus receive a respective portion of the continuous elongate element4. As explained previously in this disclosure, the cylindrical elements2may be of various different types. In this exemplary embodiment, the cylindrical elements2are illustrated in the form of spools. As also explained previously, the continuous elongate element4may be any suitable windable element, such as a filament, thread, wire, cable, etc.

As illustrated inFIG.1, the system1may suitably comprise a pre-winding section6, a winding section8and a post-winding section10. The pre-winding section6may, for instance, comprise storage arrangements12for holding cylindrical elements2before they are provided in position for receiving the continuous elongate element4. In this exemplary embodiment two storage arrangements12are illustrated, each one holding a respective stack of cylindrical elements2that are to be consecutively presented to the winding section8. As discussed previously in this disclosure, in some exemplary embodiments, the cylindrical elements may be reused (e.g. when being in the form of mandrels that are temporarily expandable for receiving the continuous elongate element4to form a coil, and thereafter returning to a non-expanded state for releasing the finished coil). In such cases, the storage arrangements12may be omitted, if desired. It should, however, be understood that the storage arrangements12inFIG.1are just illustrating one example out of many conceivable examples. The pre-winding section6may thus provide the cylindrical elements2to the winding section8in numerous ways.

The winding section8is here illustrated as having a central part14and two side parts16, which may be at least partly enclosed in a casing. The central part14of the winding section8is the location at which the cylindrical elements2are positioned when they receive the continuous elongate element4, i.e. when the continuous elongated element4is winded onto a cylindrical element2. The side parts16may include various actuating mechanisms, such as motors, for rotating and/or displacing the cylindrical elements2. However, motors and other actuating mechanisms may also be located in the central part14. Motors will be discussed in more detail below in connection with the discussion of other drawing figures.

The post-winding section10, which in some embodiments may be omitted, may be of any suitable form for receiving the cylindrical elements2after they have been provided with the thereon winded continuous elongate element4(or for receiving winded coils without the cylindrical elements). The post-winding section10is here illustrated as including a receiving rail, however other receiver or means of transport (such as conveyors) are conceivable to include in the post-winding section10.FIG.1merely presents a very general overview of the system1, and therefore the cylindrical elements2at the post-winding section10are not illustrated as having received the continuous elongate element4(which, as mentioned previously is shown inFIG.8andFIG.9).

As illustrated inFIG.1, the system1comprises a control unit20configured to control the operation of the system1. The control unit20may comprise or be operatively connected to a user interface, such as including a display, for providing information to an operator and/or for receiving input data from an operator. More detailed discussion of the control unit20will follow further below.

Turning toFIG.2, there is illustrated a cross-sectional view of a part of the system, more specifically the winding section8. The system comprises a feeder22from which the continuous elongate element4(shown inFIGS.8and9) may be provided to the cylindrical elements2. The feeder22is here illustrated as having a tubular shape, such as a pipe, however, other configurations are also conceivable. The feeder22may suitably receive the continuous elongate element4from a suitable source. For instance, in the case of the continuous elongate element4being a plastic filament, the feeder22may receive it at the end of an extrusion equipment which forms and extrudes the filament. However, any other suitable means of supply to the feeder22may be provided.

InFIG.2, there is illustrated a central rotatable member24. An example of the configuration of the central rotatable member24will be later discussed in connection withFIG.7. InFIG.2, on either side of the central rotatable member24there has been provided a respective cylindrical element. For simplicity, in this discussion, the cylindrical element on the right hand side in the drawing will be referred to as a first cylindrical element2a, and the cylindrical element on the left hand side will be referred to a as a second cylindrical element2b. It should, of course, be understood that the herein assigned order numbers of the cylindrical elements are not bound to the left or the right side of the central rotatable member24.

The feeder22is displacable such that it can be aligned with either one of the first cylindrical element2aand the second cylindrical element2b. For instance, if the feeder is aligned with the first cylindrical element2athen the continuous elongate element4would be providable from the feeder22to the first cylindrical element2a.

In order to operate the rotation of the cylindrical elements2,2a,2bfor winding the continuous elongate element4onto the cylindrical elements, a motor may suitably be provided on each side of the central rotatable member24. Thus, a first motor26ais provided for enabling rotation of the first cylindrical element2aand a second motor26bis provided for enabling rotation of the second cylindrical element2b(seeFIG.10).

Turning now toFIG.3andFIG.10, it may be noted thatFIG.3is a close-up view of details inFIG.2.FIG.10is a cross-sectional view of a part of the system, taken in a horizontal plane, thus viewed from above. As regardsFIG.3, the details on the left side have been zoomed in, i.e. the details relating to components affecting the operation of the second cylindrical element2b. It should be understood that, corresponding details are provided on the right side for affecting the operation of the first cylindrical element2a. As can be seen inFIG.10, the first motor26ais configured to drive a first rotatable shaft28aand the second motor26bis configured to drive a second rotatable shaft28b. As can be seen inFIG.3, the second rotatable shaft28bis configured to receive and hold a cylindrical element on the one side of the central rotatable member24, i.e. in this case the second cylindrical element2b(similarly, the first rotatable shaft28amay hold the first cylindrical element2aon the opposite side, as seen inFIG.10). The control unit20(seeFIG.1) is configured to control the operation of the first motor26aand the second motor26b.

Each one of said rotatable shafts is provided with a respective spindle. Thus, with reference toFIG.3, the second rotatable shaft28bis illustrated as being provided with a second spindle30bwhich is displaceable along the common geometrical rotational axis around which the cylindrical elements2a,2band the central rotatable member24are configured to commonly rotate (similarly, the first rotatable shaft is provided with a displaceable first spindle). The second spindle30bis provided with a second magnet32b, here illustrated at an end of the second spindle30b(similarly the first spindle is provided with a first magnet32a, which can be seen inFIG.3).

As best seen inFIG.7, the central rotatable member24may suitably be provided with one or more magnetic portions36, suitably presenting a magnetic surface on both sides of the central rotatable member24. The one or more magnetic portions36are provided for magnetically connecting the central rotatable member24to the first magnet32aand the second magnet32bto enable the central rotatable member24to rotate with the cylindrical elements2a,2bheld by the first rotatable shaft and the second rotatable shaft28b.

Thus, turning back toFIG.3, although the second spindle30bis displaceble in the axial direction relative to the part of the second rotatable shaft28bwhich holds the second cylindrical element2b, the second spindle30bmay suitably be configured to rotate with the second rotatable shaft28bin order to enable the second cylindrical element2b(driven by the second rotatable shaft28b) and the central rotatable member24(connected to the second magnet32b) to be rotated at the same speed. Corresponding relationship may, of course, suitably apply to the first rotatable shaft, the first spindle and the first magnet.

From the above, it can be understood that, in general terms, according to at least one exemplary embodiment, the first spindle and the second spindle are rotatably lockable to the first rotatable shaft and the second rotatable shaft, respectively. According to at least one exemplary embodiment, the first spindle and the second spindle are axially movably in a bore of the first rotatable shaft and the second rotatable shaft, respectively (as for example illustrated in the figures). According to at least one exemplary embodiment, the first spindle and the second spindle extend along the common geometrical axis (as for example seen in the figures).

When a cylindrical element is to be removed from the central rotatable member24, then suitably the associated magnet32aor32bis first disconnected from the mating magnetic portion36of the central rotatable member24. This is illustrated in for exampleFIGS.4and5.

FIG.4illustrates, similarly toFIG.2, a cross-sectional view of a part of the system, however, in a different state.FIG.5is a close-up view of details inFIG.4. As best seen inFIG.5, the first magnet has been disconnected from the magnetic portion36of the central rotatable member24. This is normally done when the continuous elongate element has been wound onto the first cylindrical element2a, and after a cutter38has cut the continuous elongate element. InFIG.5, the cutter38is illustrated as comprising a blade, however, other means of cutting may be conceivable. Thus, the control unit20(FIG.1) may be configured to do this disconnection action and also to axially remove the first cylindrical element2afrom the central rotatable member24which continues to rotate with the second cylindrical element2b. The action of removal of the first cylindrical element2afrom the central rotatable member24is illustrated inFIG.6.

Thus,FIG.6illustrates, similarly toFIG.2andFIG.4, a cross-sectional view of a part of the system, however now the first cylindrical element2ahas been removed by the first rotatable shaft28aand the first magnet32ahas been disconnected from the magnetic portion36of the central rotatable member24. In the illustrated embodiment, the shaft28ais fixed in a head part15. The head part15is movable along a track17. The movement of the head part15may be accomplished by a suitable actuator (not shown). By moving the head part15, the thereto fixed shaft28awill follow. It should be understood that in other exemplary embodiments the rotatable shafts28a,28bmay be arranged to be movable without fixing them to a respective head part15that is slidable along a track17.

From the above, it can be understood that, in general terms, according to at least some exemplary embodiments, the first rotatable shaft and the second rotatable shaft are movable in the axial direction (in this disclosure axial direction refers to the direction of the common geometrical rotational axis) in order to selectively retract the respective cylindrical element from the central rotatable member or advance the respective cylindrical element towards the central rotatable member.

After the first cylindrical element2ahas been removed from the central rotatable member24, it may be transferred to the post-winding section10(FIG.1) of the system. A new cylindrical element may therefore be received from the pre-winding section6(FIG.1). Thus, the control unit20may be configured to provide a third cylindrical element (for example from one of the stacks illustrated inFIG.1) to the first rotatable shaft28aso as to arrange the third cylindrical element at the previous winding position of the first cylindrical element2a. Thus, the second cylindrical element and the third cylindrical element will then be located on respective sides of the central rotatable member24such that the second cylindrical element, the third cylindrical element and the central rotatable member24have the same geometrical rotational axis and rotate with the same rotational speed.

The control unit20is suitably configured to control the first and second motor26a,26bin master-slave-synchronization mode in which the slave is synchronized with the rotational speed of the master, wherein at any given point in time, the one of the first and second motors26,26bthat is operating a cylindrical element onto which the continuous elongate element is currently being winded is the master, while the other one of the first and second motors is the slave.

FIG.7illustrates a central rotatable member24which may be used in a system according to at least some exemplary embodiments of the present invention. The central rotatable member24is here illustrated as a plate or a disc, however, as mentioned previously in this disclosure other configurations are also conceivable.FIG.7illustrates that the periphery of the of central rotatable member is provided with an engagement portion40, here illustrated in the form of shark-fin-shaped protrusions42. However, as discussed elsewhere in this disclosure the engagement portion40may be configured in other conceivable shapes. In the illustrated example, the central rotatable member24comprises a circular slit44extending along the periphery of the central rotatable member24. The circular slit is44configured to receive the cutter38(FIG.5) for enabling the cutter38to split the continuous elongate element into two portions. However, as discussed elsewhere in this disclosure, in other exemplary embodiments the continuous elongate element may be cut laterally of the central rotatable member24(i.e. at either side of the central rotatable member24), in which case the central slit44may suitably be omitted.

FIG.8illustrates the system winding a continuous elongate element onto cylindrical elements.FIG.9is a close-up view of details ofFIG.8. Thus, in the following, with reference toFIG.8andFIG.9, the general inventive concept included in the present method and system will now be discussed.

As mentioned previously with reference toFIG.1, the system1comprises a feeder22from which the continuous elongate element4may be provided to cylindrical elements2in consecutive order. The cylindrical elements2may thus be provided in the winding section8of the system1for receiving and winding the continuous elongate element4onto the cylindrical elements2. In the case of the cylindrical elements being mandrels used for producing coils of the continuous elongate element4, the same two mandrels may be reused over and over again, and thus the mandrels will alternatingly and repeatedly wind the continuous elongate element4(i.e. when one is fully wound, the coil is removed therefrom, while the empty one receives the continuous elongate element4). In the current illustrations inFIG.8andFIG.9, the cylindrical elements are in the form of spools. The first cylindrical element2ahas been fully winded, and the second cylindrical element2bhas started to receive the continuous elongate element4. Thus, initially, the feeder22was aligned with the first cylindrical element2a, but has inFIG.8andFIG.9been displaced to become aligned with the second cylindrical element2b. The displacement of the feeder is controlled by the control unit20(FIG.1). As best seen inFIG.9the continuous elongate element4has already been wound a few rotations/laps around a cylindrical winding portion46of the second cylindrical element2b.

The control unit is configured to provide the first cylindrical element2aand the second cylindrical element2bon respective sides of the central rotatable member24along the common geometrical rotational axis. This may, for example, be achieved by means of rotatable shafts and spindles such as the ones previously discussed. The control unit is also configured to rotate the first cylindrical element2a, the second cylindrical element2band the central rotatable member24with the same rotational speed. This may, for example, be achieved by means of motors, such as the ones previously discussed.

Accordingly, to achieve the situation illustrated inFIG.8andFIG.9, the control unit20(FIG.1) has first aligned the feeder22with the first cylindrical element2a, thereby winding the continuous elongate element4onto the first cylindrical element2aby rotating the first cylindrical element2a. Thereafter, while the first cylindrical element2a, the second cylindrical element2band the central rotatable member24rotate, the control unit20has caused the feeder22to be displaced from being aligned with the first cylindrical element2ato being aligned with the second cylindrical element2b. It should be understood that once it is aligned with the second cylindrical element2b, the feeder22may suitably move slightly back and forth in parallel with the geometrical rotational axis in order to better distribute the laying out of the continuous elongate element4over the cylindrical winding surface46of the second cylindrical element2b. The displacement of the feeder22from the first cylindrical element2ato the second cylindrical element2bcauses the continuous elongate element4to come into engagement with the engagement portion of the central rotatable member24. As best seen inFIG.9, one of the protrusions42of the engagement portion has engaged with the continuous elongate element4. The protrusions42present abutment surfaces for catching the continuous elongate element4as the feeder22is moved from being aligned with the first cylindrical element2ato being aligned with the second cylindrical element2b(or vice versa).

After this engagement has occurred, the control unit20continues to rotate the second cylindrical element2bfor winding the continuous elongate element4from the feeder22onto the second cylindrical element2b. Suitably the first cylindrical element2aand the central rotatable member24continuous to rotate with the second cylindrical element2bfor a sufficient number of rotations until the winding of the continuous elongate element4on the second cylindrical element2bhas become self-locking.

As best seen inFIG.9, the diameter of the central rotatable member24is suitably larger than the diameter of the cylindrical elements2a,2b. Thus, the radial distance between the common geometrical rotational axis and the engagement portion is larger than the radial distance between the common geometrical axis and a circumference of end wall portions48of the cylindrical elements2a,2b. This is beneficial as it counteracts unwinding from the first cylindrical element2awhen it rotates with the second cylindrical element2bafter the switch (displacement of the feeder22to the second cylindrical element2b) has been made.

When the continuous elongate element4has been sufficiently secured (self-locked) to the second cylindrical element2b, it may be cut by the cutter (shown inFIG.5) so that the first cylindrical element2awith its winding may be removed for further handling (e.g. transferring to the post-winding section). Thus, at this stage, as previously discussed in relation toFIG.6, the first magnet32amay be disconnected from the magnetic portion36of the central rotatable member24and the first rotatable shaft28amay be retracted to remove the first cylindrical element2afrom the central rotatable member24, which continues to rotate with the second cylindrical element2b.

With reference again toFIG.9, the control unit may suitably be configured to apply a roller50against the already winded portion of the continuous elongate element4before the continuous elongate element is cut, and the roller50may suitably be kept against the already winded portion after the continuous elongate element4has been cut, until the first cylindrical element2ahas decelerated sufficiently (thereby reducing the risk of the already winded portion unwinding after the cutting).

The control unit may thus suitably be configured to control the cutter38(FIG.5) to cut the continuous elongate element4at its engagement with the engagement portion so as to split it into two portions, a first portion already wound on the first cylindrical element2aand a second portion which is still being winded onto the second cylindrical element2b.

The method of the present inventive concept may suitably be performed by the control unit20. Thus, the above steps, actions, operations, etc. performed by the control unit20may suitably be included in the method of the present invention, including exemplary embodiments thereof.