Patent ID: 12230424

DETAILED DESCRIPTION OF THE INVENTION

Before explaining at least one disclosed embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in numerous ways. Also, it is to be understood that the phraseology and terminology employed are for purpose of description and should not be regarded as limiting.

It should be understood that any one of the features of the invention may be used separately or in combination with other features. Other systems, methods, features, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the drawings and the detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present invention, and be protected by accompanying claims.

The present disclosure is described below with reference to the Figures in which various embodiments of the present invention are shown. The subject matter of the disclosure may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. It is also understood that the term “wire” is not limiting, and refers to wires, cables, electrical lines, or any other materials.

The present disclosure provides for a system and method for improved bond wire payoff during the armoring process of armored cables and metal-clad cables.

Referring now toFIGS.1-6, by way of non-limiting example, and consistent with embodiments of the invention, an armoring of a wire or cable system150including a bond wire payoff system110is shown. The system for armoring a wire or cable150and the bond wire payoff system110may be constructed from any number of materials that are able to withstand the pressures and demands placed upon it. In one embodiment, the bond wire payoff system110is located before one or more armoring machines158, known in the art.

Referring toFIG.1, according to one embodiment, a standard payoff reel152to supply an internal conductor(s)151, such as a copper or aluminum wire is provided in system150. The standard payoff reel152supplies the internal conductor(s)151to an extruder153to apply an insulating material over the internal conductor(s)151. Extruder153may be a single extruder head, a plurality of extruders, a cross head, a co-extrusion head, or any combination thereof. The insulating material may be thermoset, thermoplastic, elastomeric, polymeric dielectric or a semiconductor compound or any combination thereof. Once the internal conductor(s)151have been insulated by the extruder153, the internal conductor(s)151proceed to the bond wire payoff system110. The bond wire138and the insulated internal conductor(s)151proceed to the armoring machine158. The armoring machine158includes, but is not limited to, a BX machine. After formation of the armored cable by the armoring machine158, the armored cable, a motor-driven reel162is provided to wind up the resulting armored wire or cable. In one embodiment, preformed insulated wire or cable is pulled by the armoring machine158in conjunction with pulling the bond wire138through the bond wire payoff system110.

Referring now toFIG.2, one embodiment of the bond wire payoff system110is shown. The bond wire payoff system110includes a bond wire payoff assembly112, a first and second sensor assembly114,116, a first and second controller118,120, and a first and second alarm assembly122,124. The bond wire payoff assembly112includes a first and second payoff wire path126,128, and a first and second series of sheaves (or pulleys)130,132and eyelets134,136. In this embodiment, the bond wire payoff system110is designed to payoff a bond wire138from a stem140by one or more armoring machines158in different armoring lines. In this embodiment, the bond wire payoff system110supports two (2) armoring wire or cable lines; each line runs exclusive of the other line. The first payoff wire path126, the first series of sheaves130and eyelets134, the first sensor assembly114, and the first controller118payoff the bond wire138from the stem140when a first armoring wire or cable line is in use and the second payoff wire path128, the second series of sheaves132and eyelets136, the second sensor assembly116, and the second controller120payoff the bond wire138from the same stem140and into a second armoring machine in a second armoring wire or cable line. In one embodiment, the bond wire138is a bare aluminum bond wire. The bond wire138may be constructed from a variety of other conductive metals including, but not limited to, copper, without detracting from the spirit of the invention. For example, bare aluminum bond wire is required by UL to be used in all AC and HCF metal clad products as a ground path. In another embodiment, multiple stems140may be implemented, one stem140for each armoring wire of cable line. In this embodiment, both armoring wire or cable lines may be in use simultaneously.

In one embodiment, the bond wire payoff system110includes one payoff wire path126, one series of sheaves130and eyelets134, one sensor assembly114, and one controller118to payoff the bond wire138from the stem140.

As shown inFIG.3, the bond wire payoff system110may utilize one or more sheaves130,132and eyelets134,136in various locations of the bond wire payoff assembly112. It should be understood that the bond wire payoff system110may utilize one or more of payoff wire paths126,128, sheaves130,132and eyelets134,136sensor assemblies114,116, controllers118,120, and alarms122,124in various locations of the bond wire payoff system110, depending on the particular application of the bond wire payoff system110.

The bond wire payoff system110pulls the bond wire138from the stem140along a variety of payoff wire path126,128including, but not limited to, horizontal, vertical, or angular. In one embodiment, the bond wire payoff assembly112is advantageous over the prior art where the bond wire138is pulled along a vertical payoff wire path126and through a series of sheaves130and eyelets134as it reduces the overall stress and tension on the bond wire138as it is being paid off from the stem140during the armoring process. Unlike the prior art, in this embodiment the bond wire payoff system's110reduction in overall stress and tension on the bond wire138minimizes the likelihood of the bond wire breaking during the armoring process.

As shown inFIGS.4A and4B, the bond wire payoff system110includes the first sensor assembly114which includes a first sensor310, a first sensor sheave320, and a second sensor sheave330. The first sensor sheave320is attached to the first sensor's shaft340. The second sensor sheave330is attached to the first sensor assembly114so that the second sensor sheave330is able to rotate freely. In this embodiment, the second sensor sheave330provides tension to the bond wire138as the bond wire138travels through the first sensor assembly114to prevent the bond wire138from slipping off the first sensor sheave320. The first sensor310of the first sensor assembly114is coupled to the first controller118. A second sensor350of the second sensor assembly116is coupled to the second controller120. In this embodiment, the second sensor assembly116includes a second sensor350, a second set of sensor sheaves, and a second controller120. The first and second sensor assemblies114,116may have the same equipment and function in the same manner or may be composed of different equipment and functionality. In one embodiment, the first and second sensors310,350are encoders. Each sensor assembly114,116may utilize a greater number of sensors310,350or sensor sheaves320,330, depending on the particular application of the bond wire payoff system110. It should be understood that the sensor assemblies114,116of the bond wire payoff system110may utilize a variety of types of sensors, including mechatronic sensors, without detracting from the spirit of the invention.

In operation, according to one embodiment, the bond wire138is first pulled from the stem140along the first payoff wire path126and through the first series of sheaves130and eyelets134of the bond wire payoff assembly112. Next, the bond wire138is pulled through the first and second sensor sheaves320,330of the first sensor assembly114by the armoring machine158. The first sensor shaft340is rotated when the bond wire138is pulled through the first and second sensor sheaves320,330of the first sensor assembly114. After the bond wire138has been pulled through the first and second sensor sheaves320,330of the first sensor assembly114, the bond wire138continues through the remaining sheave130of the bond wire payoff assembly112and into the first armoring machine158to be combined with one or more electrical wires or cables. During the use of the second armoring wire or cable line, the bond wire138is pulled from the stem140, through the second payoff wire path128and the second series of sheaves132and eyelets136of the bond wire payoff assembly112; through the first and second sensor sheaves of the second sensor assembly116; through the remaining sheave132of the bond wire payoff assembly112and into the second armoring machine to be combined with one or more electrical wires or cables.

Referring now toFIG.5, the first and second controllers118,120include control screens410,420which allow user input. In one embodiment, the first and second controllers118,120are dual set point controllers that are each programmed to set a first and a second defined speed value. For example, in this embodiment, the first dual set point controller118is programmed to set a defined minimum speed value and a defined line speed value. The first defined speed value programmed into the dual set point controller118is the minimum speed value. The second defined speed value is the line speed value. The line speed value is programed into the dual set point controller118and is calculated as a value that is below the average of either the speed at which the armoring machine158is pulling the first bond wire138; or the speed at which the armoring machine158is pulling one or more electrical wires or cables to be combined with the first bond wire138. The speed values may be determined in terms of revolutions per minute or feet per minute. To activate the alarm system, the speed of the bond wire138must exceed the line speed value. The minimum speed value is less that the line speed value. The bond wire payoff system110alarm functionality is not engaged until the line speed value is reached to prevent false alarms of a broken bond wire138during the initial start-up procedure. The purpose of minimum speed value is to prevent false alarms from occurring during either a normal operational slow down or shut down of each armoring machine158. In operation, according to one embodiment, the bond wire payoff system110alarm functionality is activated when the line speed value is reached by the first sensor310as a result of the bond wire138being pulled across the first and second sensor sheaves320,330of the first sensor assembly114by the armoring machine158for greater than thirty (30) seconds. Once activated, the alarm functionality is triggered once the bond wire138speed drops below the minimum speed value. This drop initiates the alarm functionality. In one embodiment, the alarm functionality is only triggered when the bond wire138speed drops from above the line speed value to below the minimum speed value in less than five (5) seconds. If the drops is greater than five (5) seconds, the alarm functionality is not triggered as the slower drops signifies the shutdown of the armoring wire or cable line. In another embodiment, the first and second controllers118,120are programmed to a single defined speed value that corresponds with either the speed at which the armoring machine158is pulling the bond wire138; or the speed at which the armoring machine158is pulling one or more electrical wires or cables to be combined with the bond wire138. In this embodiment, the alarm functionality is not activated until the speed value is met and the alarm functionality is not triggered until the bond wire138speed drops below the speed value. The bond wire payoff system110may utilize a variety of types of controllers without detracting from the spirit of the invention.

Referring now toFIG.6, the first and second alarm assemblies122,124of the bond wire payoff system110are shown. The first and second alarm assemblies122,124include siren speakers510,520and flashing strobe lights530,540. In operation, the bond wire payoff system110detects a break in the bond wire138when the bond wire138speed drops below the defined line or minimum speed value. In this embodiment, the bond wire payoff system110detects a break in the bond wire138when the speed of the sensor's shaft340is no longer rotating at the defined line or minimum speed value programed into the dual set point controllers118,120. For example, in the event of a break in the bond wire138, the first sensor's shaft340experiences a deceleration in its rotation because the bond wire138is no longer being pulled across the first and second sensor sheaves320,330of the first sensor assembly114by the first armoring machine158. In this embodiment, when a break occurs in the bond wire138, the rate of deceleration of the bond wire138falls below the defined line or minimum speed value programmed into the dual set point controller118. It is this decrease of the bond wire138speed to a value below the defined line or minimum speed value programmed into the dual set point controller118that triggers the alarm as described below. In the event of a break in the bond wire138, the sensor's shaft340experiences an improper deceleration in its rotation because the bond wire138is no longer being pulled across the sensor sheaves320,330of the sensor assembly114by the armoring machine158. In another embodiment, the determination of a bond wire138break is made by comparison of the speed of the bond wire138with the speed of one or more electrical wires or cables which has been programmed into the dual set point controller.

When an improper deceleration occurs in either of the sensors' shafts340, the bond wire payoff system110sets off the appropriate alarm assembly122,124equipped with flashing strobe lights530,540and loud repetitive alarm sound through the siren speakers510,520, correlating to the sensor shaft340that experienced the improper deceleration. For example, if the improper deceleration occurs in the first sensor's shaft340, the bond wire payoff system110sets off the loud repetitive alarm sound through the siren speaker510and flashing strobe530of alarm assembly122. If the improper deceleration occurs in the second sensor's shaft, the bond wire payoff system110sets off the loud repetitive alarm sound through the siren speaker520and flashing strobe540of alarm assembly124. If either alarm122,124is not acknowledged by the operator on the appropriate control screen430,440of the bond wire payoff system110, the bond wire payoff system110will shut the entire armoring line down corresponding to the broken bond wire.

Unlike the prior art, this system and method is independent of the operator's ability to maintain a continual visual inspection of the bond wire as it is being paid off from the stem and into the armoring machine and this system and method is also independent of the operator's ability to manually stop the entire armoring line once the operator notices a broken bond wire. This system further reduces the opportunity for an armored cable or metal-clad cable that is missing the required internal bond wire from being sent to a customer. Additionally, this system and method reduces the amount of scrap produced during the armoring process by immediately notifying the operator and those around that the bond wire is no longer being properly paid off into the armoring machine and further stopping the entire armoring line if the operator does not acknowledge the alarm.

Referring now toFIG.7, a flow chart of the bond wire payoff method is shown. The method begins with Start600. Next, in step610, the bond wire138is pulled from the stem and through the bond wire payoff system110by an armoring machine158, known in the art. The bond wire138is pulled through a series of sheaves130and eyelets134. The bond wire138may be pulled horizontally or vertically. Next, in step620, the bond wire payoff system110alarm functionality is activated when the line speed value programmed into the controller118are reached by determining the rotation of the sensor's shaft340as a result of the bond wire138being pulled across the sensor sheaves320,330of the sensor assembly114by the armoring machine158. As the bond wire138is pulled through the sensor sheaves320,330, the sensor sheave320is rotated which then rotates the sensor's shaft340. The speed of the bond wire138is determined through the measurement of the rotation of the sensor's shaft340. In one embodiment, the alarm functionality is not activated unless the bond wire138speed exceeds the line speed for more than thirty (30) seconds. Next in step630, the bond wire payoff system110detects and alerts the operator of a break in the bond wire138when the speed of the sensor's shaft340is no longer rotating at the defined minimum speed value programmed into the controller118. The bond wire payoff system110alerts the operator through either or both an audio and visual alert. Next, in step640, the bond wire payoff system110will shut the entire armoring line down if the alarm of the bond wire payoff system110is not acknowledged by the operator. Next, in step650, the defective section of the armored cable or metal-clad cable that is missing the required bond wire138is discarded. The method ends660.

Although the invention is described herein with reference to specific embodiments, various modifications and changes can be made without departing from the scope of the invention as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the invention. Any benefits, advantages, or solutions to problems that are described herein with regard to specific embodiments are not intended to be construed as a critical, required, or essential feature or element of any or all the claims.

From time-to-time, the invention is described herein in terms of these example embodiments. Description in terms of these embodiments is provided to allow the various features and embodiments of the invention to be portrayed in the context of an exemplary application. After reading this description, it will become apparent to one of ordinary skill in the art how the invention can be implemented in different and alternative environments. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this invention belongs.

The preceding discussion is presented to enable a person skilled in the art to make and use the invention. The general principles described herein may be applied to embodiments and applications other than those detailed below without departing from the spirit and scope of the invention as defined by the appended claims. The invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

In addition, while a particular feature of the invention may have been disclosed with respect to only one of several embodiments, such feature may be combined with one or more other features of the other embodiments as may be desired. It is therefore, contemplated that the claims will cover any such modifications or embodiments that fall within the true scope of the invention.

The various diagrams may depict an example architectural or other configuration for the invention, which is done to aid in understanding the features and functionality that can be included in the invention. The invention is not restricted to the illustrated example architectures or configurations, but the desired features can be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical, or physical partitioning and configurations can be implemented to implement the desired features of the invention. Also, a multitude of different constituent module names other than those depicted herein can be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.

Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one”, “one or more” or the like; and adjectives such as “conventional”, “traditional”, “normal”, “standard”, “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.

A group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although items, elements or components of the invention may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated.

The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term “module” does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, can be combined in a single package or separately maintained and can further be distributed across multiple locations.

Unless stated otherwise, terms such as “first” and “second” are used to arbitrarily distinguish between the elements such terms describe. Thus, these terms are not necessarily intended to indicate temporal or other prioritization of such elements.

Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration.

All publications and patents mentioned in the above specification are herein incorporated by reference. Various modifications and variations of the described method and system of the invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the field or any related fields are intended to be within the scope of the following claims.