Patent Document

RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/317,251, filed Apr. 1, 2016, which is hereby incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates generally to wire processing. More specifically, the invention relates to preparing a wire for processing during industrial manufacturing by removing residues deposited on the wire during manufacturing, storage, or transportation. 
       BACKGROUND 
       [0003]    Many industrial processes use metal wire as a raw material. These processes use different types of wire, composed of different materials, cross-sectional shapes, and sizes. For example, wires may be formed from numerous steel alloys, from brass, bronze, aluminum, copper, and numerous other metals. For purposes of this application, a wire can comprise a solid core, stranded wires, tubes, and other cross-sectional shapes. 
         [0004]    Typically, wire is fed directly from coil stock to a manufacturing machine, but wire may also be supplied in straight segments. During manufacturing, storage, and transportation of the wires described above, a variety of contaminants adhere themselves to the outer surfaces of the wires. Wire drawing compound used to lubricate the wire during drawing and forming of the wire may form scaly deposits on the surface of the wire. Other contaminants might include oil applied to the wire to prevent corrosion during transportation or storage. Oil attracts dirt and other debris, which may further contaminate the surface of the wire. 
         [0005]    All of the contaminants discussed above cause difficulties when the wire is processed in subsequent manufacturing steps. Wire may be subjected to one or more primary operations, including for example straightening, drilling, cutting, machining, cold-forming, threading, marking, stamping, or bending. Each of these primary operations may be hindered by scale or other debris adhered to the surface of the wire. Scale and debris become trapped in automated machinery and may damage tooling or reduce the efficiency of the machinery. Thus, it is desirable to clean the surface of the wire prior to performing these primary operations. 
         [0006]    Wires may also be subjected to secondary operations such as painting, surface-treatment, or assembly. These secondary operations often require parts that are free from all contaminants including scale, debris, and oil. Parts may be difficult to clean after they have undergone primary operations because they may have features and shapes that trap contaminants or that make it difficult to scrub the full surface of the part. Thus, it is desirable to clean the surface of the wire before the wire is subjected to any manufacturing operations, even if primary operations are not affected by contaminants on the wire. 
         [0007]    Manufacturing machines typically accommodate a variety of wire sizes. For example, automated wire bending machines are designed for use with a range of wire diameters. In many manufacturing machines no major tool changes are necessary even though wire diameter may change from job to job. It is therefore desirable that any wire processing equipment associated with these manufacturing machines be capable of easy adjustment to accommodate a similar range of wire diameters. 
         [0008]    Although methods are known for cleaning various contaminants from the surface of a wire, it is desirable to develop a machine or system designed to remove all contaminants. In particular, it is desirable to develop a machine or system designed to remove contaminants from the surface of a wire as the wire is fed from a coil and into a wire bending machine, such that the wire is cleaned on-demand. Further, it is desirable to develop a machine or system designed to clean wires having a variety of wire diameters or cross-sectional profiles, in keeping with the flexibility designed into many wire bending machines. 
       SUMMARY 
       [0009]    Generally speaking and pursuant to these various embodiments, a wire cleaning apparatus is provided, comprising a passive brush mechanism and an active brush mechanism. The passive brush mechanism surrounds and defines a wire path. The wire path defines a space where, during operation, a wire will be drawn through the wire cleaning apparatus. The passive brush mechanism comprises a helical brush having a plurality of first bristles affixed to a helical structure, the helical structure having a helical axis substantially coincident with the wire path, the plurality of first bristles generally oriented inwardly from the helical structure toward the wire path. The passive brush mechanism further comprises a first member slidably affixed to the passive brush mechanism and coupled to a first end of the helical brush. 
         [0010]    The active brush mechanism is disposed around the wire path and configured to rotate around the wire path. The active brush mechanism comprises at least one cylindrical brush having a plurality of second bristles disposed on a cylindrical surface such that one or more of the plurality of second bristles impinge upon the wire path. The at least one cylindrical brush comprises a cylindrical axis about which the at least one cylindrical brush is configured to rotate relative to the active brush mechanism. 
         [0011]    In one described example, the wire cleaning apparatus further includes a resilient wiper having an aperture concentric with the wire path, the aperture configured to receive a wire of a predetermined cross-sectional profile. 
         [0012]    In another described example, the wire cleaning apparatus further includes a wiper holder configured to receive the resilient wiper, the wiper holder disposed at a fixed location along the wire path. 
         [0013]    In another described example, the wire cleaning apparatus further includes at least one adjustably mounted nozzle disposed in the vicinity of the active brush mechanism and in fluid communication with a reservoir configured to receive an aqueous detergent solution. 
         [0014]    In another described example, the helical brush of the wire cleaning apparatus further includes a second end of the helical brush that is coupled to a fixed surface of the passive brush mechanism. 
         [0015]    In another described example, the second end of the helical brush of the wire cleaning apparatus further is coupled to a second member slidably affixed to the passive brush mechanism. 
         [0016]    In another described example, the passive brush mechanism of the wire cleaning apparatus further includes a plurality of slots arranged in the passive brush mechanism substantially parallel to the wire path; and at least one tension adjuster engaged through one of the plurality of slots with the first member, such that the tension adjuster secures the first member in a position relative to the plurality of slots. 
         [0017]    In another described example, the active brush mechanism of the wire cleaning apparatus further includes an annular gear and the at least one cylindrical brush further comprising a spur gear disposed to interact with the annular gear on the active brush mechanism such that the spur gear is configured to cause the cylindrical brush to rotate on the cylindrical axis when the active mechanism rotates around the wire path. 
         [0018]    In another described example, the active brush mechanism of the wire cleaning apparatus further includes a stationary pulley and a belt disposed on the stationary pulley, and the at least one cylindrical brush further comprising a pulley about which the belt wraps such that the belt is configured to cause the cylindrical brush to rotate on the cylindrical axis when the active mechanism rotates around the wire path. 
         [0019]    In another described example, the wire cleaning apparatus further includes a drying stage comprising a funnel disposed around the wire path, the funnel having a large end and a small end and an input configured to deliver high-speed air to the funnel. 
         [0020]    In another described example, the wire cleaning apparatus further includes a motion detection sensor configured to change a signal in response to motion of a wire traveling along the wire path; and a control device configured to activate the drying stage in response to the change in the signal from the motion detection sensor. 
         [0021]    In another described example, the wire cleaning apparatus further includes a motion detection sensor configured to change a signal in response to motion of a wire traveling along the wire path; and a control device configured to activate the active brush mechanism in response to the change in the signal from the motion detection sensor. 
         [0022]    Further pursuant to these various embodiments, a method is disclosed for cleaning an outer surface of a wire by passing the wire through a wire cleaning system, the method comprising: removing debris from the outer surface of the wire with a passive brush mechanism comprising a helical brush having a plurality of first bristles affixed to a helical structure, the helical structure having a helical axis substantially coincident with a long axis of the wire, the plurality of first bristles generally oriented inwardly from the helical structure to contact the outer surface of the wire; scrubbing the outer surface of the wire with an active brush mechanism disposed around the wire path and configured to rotate around the wire path, the active brush mechanism comprising at least one cylindrical brush having a plurality of second bristles disposed on a cylindrical surface such that one or more of the plurality of second bristles contact the outer surface of the wire, the at least one cylindrical brush having a cylindrical axis about which the at least one cylindrical brush rotates relative to the active brush mechanism. 
         [0023]    In another described example, the method further comprises cleaning an outer surface of a wire further includes impinging upon the outer surface of the wire with a resilient wiper that substantially encircles the wire. 
         [0024]    In another described example, the method further comprises cleaning an outer surface of a wire further includes spraying an aqueous detergent solution on the wire in the vicinity of the active brush mechanism using at least one nozzle disposed in the vicinity of the active brush mechanism. 
         [0025]    In another described example, the method disclosed for cleaning an outer surface of a wire further comprises detecting movement of the wire by a movement sensor and controlling the state of a device based on the output of the movement sensor. Based on the output of the movement sensor the active brush mechanism may be activated or deactivated. 
         [0026]    In another described example, the method is disclosed for cleaning an outer surface of a wire further comprising drying the outer surface of the wire at a drying station using high-speed air. 
         [0027]    In another described example, the method is disclosed for cleaning an outer surface of a wire further includes detecting movement of the wire by a movement sensor. In response to the change in the signal received from the movement sensor, activating the drying station. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]    The above needs are at least partially met through provision of a wire cleaning apparatus described in the following detailed description, particularly when studied in conjunction with the drawings, wherein: 
           [0029]      FIG. 1  comprises an isometric view of a wire cleaning apparatus, with enclosures shown in the open position; 
           [0030]      FIG. 2  comprises a front view of a wire cleaning apparatus, with enclosures shown in the open position; 
           [0031]      FIG. 3  comprises an isometric view of a wire cleaning apparatus, with enclosures shown in the closed position; 
           [0032]      FIG. 4  comprises an isometric view of a helical brush mechanism of a wire cleaning apparatus; 
           [0033]      FIG. 5  comprises a cut-away view of a helical brush mechanism of a wire cleaning apparatus; 
           [0034]      FIG. 6A  comprises an isometric view of a helical brush in a compressed state; 
           [0035]      FIG. 6B  comprises a perspective view of a helical brush, illustrating an inner diameter of the helical bristles in a compressed state; 
           [0036]      FIG. 7A  comprises an isometric view of a helical brush in an expanded state; 
           [0037]      FIG. 7B  comprises a perspective view of a helical brush, illustrating an inner diameter of the helical bristles in an expanded state; 
           [0038]      FIG. 8  comprises a perspective view of an orbital scrubbing mechanism of the wire cleaning apparatus; 
           [0039]      FIG. 9  comprises a perspective view of an orbital scrubbing mechanism of a wire cleaning apparatus, with supporting end plates removed; 
           [0040]      FIG. 10  comprises a front view of an orbital scrubbing mechanism of a wire cleaning apparatus, having supporting end plates removed; 
           [0041]      FIG. 11  comprises a perspective view of an orbital scrubbing mechanism of a wire cleaning apparatus, having supporting end plates, rotating brush housing, and driving plate removed; 
           [0042]      FIG. 12  comprises a perspective view of a cylindrical brush assembly with brush support shafts and quick release mechanisms; 
           [0043]      FIG. 13  comprises a cut-away perspective view of a cylindrical brush assembly, with brush support shafts and quick release mechanisms; 
           [0044]      FIG. 14  comprises a cut-away perspective view along line  14 - 14  illustrated in  FIG. 10 , illustrating a planetary gear mechanism of an orbital scrubbing mechanism of a wire cleaning apparatus, with supporting end plates removed; 
           [0045]      FIG. 15  comprises a cut-away end view along line  14 - 14  illustrated in  FIG. 10 , illustrating a planetary gear mechanism of an orbital scrubbing mechanism of a wire cleaning apparatus, with supporting end plates removed; 
           [0046]      FIG. 16  comprises a perspective view of a drying stage of a wire cleaning apparatus; 
           [0047]      FIG. 17  comprises a front view of a drying stage of a wire cleaning apparatus; 
           [0048]      FIG. 18  comprises a perspective view of a wire guide and movement detection mechanism of a wire cleaning apparatus; 
           [0049]      FIG. 19  comprises a cut-away view of a wire guide and movement detection mechanism along line  19 - 19  illustrated in  FIG. 17 , illustrating the movement detection mechanism of a wire cleaning apparatus in an open position; 
           [0050]      FIG. 20  comprises a cut-away view of a wire guide and movement detection mechanism along line  19 - 19  illustrated in  FIG. 17 , illustrating the movement detection mechanism of a wire cleaning apparatus in a closed position; 
       
    
    
       [0051]    Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted to facilitate a less obstructed view of these various embodiments. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein. 
       DETAILED DESCRIPTION 
       [0052]    In one embodiment, a wire cleaning apparatus is illustrated in  FIGS. 1-3 . A wire  5  passes through the wire cleaning apparatus  10  from left to right in the illustration. The wire cleaning apparatus  10  includes a passive helical brush mechanism  20 , which removes scale and debris from a wire  5  (not shown in  FIG. 1 ). Horizontal straighter  70 , and vertical straightener  75  remove minor bends from the wire  5 . An active rotating brush mechanism  40  removes oil and other surface deposits from the wire  5 . The active rotating brush mechanism  40  may use a soap or detergent solution stored in reservoir  77 , and sprayed on the wire  5  using adjustable nozzles  78 . 
         [0053]    The horizontal straightener  70  comprises three or more rollers  71   a - 71   c  arranged such that two rollers  71   a  and  71   c  support one side of the wire and a third roller  71   b  impinges upon an opposite side of the wire at a point between the contact points provided by the two rollers  71   a  and  71   c . By way of this orientation, the wire is worked horizontally and minor bends in the horizontal orientation are removed from the wire. Similarly, the vertical straightener  75  comprises three or more rollers  76   a - 76   c  arranged such that two rollers  76   a  and  76   c  support an upper side of the wire and a third roller  76   b  impinges upon the bottom side of the wire at a point between the contact points provided by the two rollers  76   a  and  76   c . By way of this orientation of the rollers  76   a - 76   c , the wire is worked vertically and minor bends in the vertical orientation are removed from the wire. The features of the illustrated straighteners  70  and  75  may additionally include adjustment mechanisms or allow for replacement of the rollers  71   a - 71   c  and  76   a - 76   c , as known in the art, so that the straighteners  70  and  80  may accommodate a variety of wire diameters. 
         [0054]    The reservoir  77  may be integrated into wire cleaning apparatus  10  or may exist as a separate unit which can be operably connected to one or more of the wire cleaning apparatus  10  to, for example, limit the amount of hose necessary to install multiple units in a workspace or to reduce the cost of purchasing multiple of the wire cleaning apparatus  10 . Similarly, the reservoir  77  may be removable from the wire cleaning apparatus  10  to enable cleaning. 
         [0055]    Optionally, the wire cleaning apparatus  10  includes a wire guide mechanism  90 , which is adjustable to accommodate varying sized wires. The wire guide mechanism  90  may also include a sensor, such as an encoder, for detecting movement of the wire  5 . The sensor is preferably a rotary encoder. The rotary encoder may utilize optical, mechanical or magnetic means to detect the movement of the wire. The wire cleaning apparatus  10  may also include a drying stage  80  designed to remove moisture from the wire by applying high-velocity stream of air to the surface of the wire such that residual moisture is blown off the wire. 
         [0056]    Exemplary features of the wire cleaning apparatus are illustrated in  FIGS. 1-20 , in which like numbers indicate like elements. The elements of the drawings are described as follows:
         5 : Wire     10 : Wire cleaning apparatus     20 : Helical brush mechanism     21 : Helical brush mechanism body     22 : Tension adjustment plate     231 : Wiper area debris passage     232 : Helical brush debris passage     233 : Drain     24 : Adjustment screws     245 : Adjustment slot     26 : Debris collection bin     27 : Wiper holder     28 : Wiper     285 : Wiper aperture     30 : Helical brush     32 : Helical bristle channel     33 : Bristles     35 : Inner diameter     40 : Rotating brush mechanism     41 : Pulley     42 : Rotating brush drive shaft     45 : Cylindrical brush assembly     46 : Bristles     47 : Quick release pin     475 : Quick release body     476 : Quick release button     48 : Shaft     485 : Hole (optionally slotted)     51 : Planetary gear housing     515 : Pin     525 : Rotating brush housing (drive end)     526 : Rotating brush housing (support end)     524 : Pin     535 : Seal cover (drive end)     536 : Seal cover (support end)     544 : Seal and bearing supporting a brush support shaft     545 : Rotating brush plate (drive end)     546 : Rotating brush plate (support end)     549 : Stabilizing member     55 : Annular gear     56 : Planetary gear     571 : Brush support shaft (drive end)     572 : Brush support shaft (support end)     575 : Brush shaft receiver (drive end)     576 : Brush shaft receiver (support end)     58 : Bearing     70 : Horizontal wire straightener     71 : Horizontal wire straightener roller     75 : Vertical wire straightener     76 : Vertical wire straightener roller     77 : Wash water reservoir     78 : Flexible nozzle     80 : Wire air wipe     90 : Wire guide and movement detection mechanism     901 : Wire guide adjustment knob     902 : Wire guide adjustment locking knob     903 : Wire guide adjustment screw     910 : Encoder     915 : Encoder idler roller     920 : Wire guide body     921 : Adjustment cam     922 : Cam follower     923 : Cam follower     924 : Spring     928 : Wire guide bottom plate     930 : Wire guide front body plate     940 : Wire guide rear body plate     951 : Wire guide roller     952 : Wire guide roller     953 : Encoder support member       
 
         [0127]      FIGS. 4 and 5  further illustrate the helical brush mechanism  20 . The helical brush mechanism is comprised of a body  21  and a debris collection bin  26 . The helical brush  30  is fastened at one end to the body  21 , and at the other end to the tension adjustment plate  22 . By loosening the adjustment screws  24 , the adjustment plate  22  can be moved along the adjustment slots  245  such that the helical brush is extended or compressed. As discussed further below, extending or compressing the helical brush  30  serves to adjust the inner diameter of the brush such that different sized wires may be accommodated by the same passive helical brush mechanism  20 . Adjustment screws and the adjustment slots are identically arranged on the wall opposite the wall on which they are illustrated in  FIG. 4 . Alternatively, the helical brush  30  may be adjustable at both ends through the use of a second set of adjustment slots, adjustment screws, and an adjustment plate fastened at the opposite end of the helical brush  30 . 
         [0128]    The passive helical brush mechanism  20  may include a wiper holder  27  with a wiper  28 . The wiper  28  may be fabricated from any resilient material, but is preferably fabricated from a sheet of rubber such that the wiper  28  removes oil and large debris from the surface of the wire  5 . As the wire passes through the wiper aperture  285  the removed oil and debris fall into the debris collection bin  26  through the wiper area debris passage  231 . The wiper holder may be removed from the body  21  to facilitate replacement of the wiper. Replacing the wiper  28  allows for the use of differently shaped and sized wipers that accommodate a variety of wire diameters and shapes. Similarly, as the wire passes through the helical brush  30 , removed oil and debris fall through the helical brush debris passage  232 . In various embodiments, the helical brush debris passage may have different lengths. A drain  233  is disposed at the bottom of the debris collection bin  26  such that the removed oil and debris may pass out of the bin. In some embodiments, a liquid spray may be used to flush debris from the passive helical brush mechanism  20  in a continuous or periodic fashion. 
         [0129]      FIGS. 6 and 7  further illustrate the behavior of the helical brush  30 , as it is extended or compressed. The helical brush  30  is comprised of a helical bristle channel  32  and bristles  33 . The helical bristle channel  32  forms a helix, having a series of coils, each of which is spaced from the last by a pitch distance P. The helical bristle channel  32  is a channel fabricated from a resilient material such as steel, aluminum, or high strength plastic. The bristles  33  are arranged with one end embedded and secured in the bristle channel  32 , and a second end of each bristle  33  extends to the opening  35  in the middle of the helical brush. The opening  35  extends along the axis of the helical brush  30 . The bristles  33  are preferably arranged in a substantially continuous row, although some embodiments may utilize tufts of bristles. 
         [0130]      FIGS. 6A and 6B  illustrate the helical brush  30  in a compressed position, in which the pitch between the coils is the distance P 1 .  FIG. 6B  illustrates that an inner diameter  35  of the helical brush  30  is compressed when the bristles  33  are displaced by compressing the helical bristle channel  32  as shown in  FIGS. 6A and 6B .  FIGS. 7A and 7B  illustrate the helical brush  30  in a compressed position, in which the pitch between the coils is the distance P 2 .  FIG. 7A  illustrates a helical brush having a pitch, P 2 , wider than the pitch between coils of the helical brush illustrated in  FIG. 6A .  FIG. 7B  illustrates that an inner diameter  35  of the helical brush  30  is enlarged as the pitch between the coils of the helical bristle channel becomes larger. Conversely, as is apparent from  FIGS. 6 and 7 , the inner diameter of the helical brush becomes smaller as the pitch between the coils of the helical bristle channel becomes smaller. 
         [0131]      FIGS. 8-15  illustrate an active rotating brush mechanism  40 , in which cylindrical brushes  45  scrub the wire  5  as the wire passes along the center axis of the rotating brush mechanism. In one embodiment, the active rotating brush mechanism  40  comprises three cylindrical brush assemblies  45 , each of which has bristles  46 .  FIG. 8  illustrates the active rotating brush mechanism  40 . The planetary gear housing  51  is stationary and connects to a wall (not shown in  FIG. 8 ) within the wire cleaning apparatus  10 . Pins  515  secure the planetary gear housing  51  to the wall. The drive end housing  525  and the support end housing  526  are both stationary. Pins  524  secure the drive end housing  525  to a wall (not shown in  FIG. 8 ) within the wire cleaning apparatus  10 . The rotating drive end brush plate  545  and rotating supporting end brush plate  546  are connected by three supporting members  549  that rotate with the two rotating plates  545  and  546 . The seal covers  535  (not shown in  FIG. 8 ) and  536  prevents fluid from entering space between the brush plates  545  and  546  from their respective housing  525  and  526 . 
         [0132]    The cylindrical brush assemblies  45  simultaneously orbit the wire  5  and rotate through the action of a planetary gear mechanism. The bristles  46  physically contact the outer surface of the wire  5  to remove oil and debris from the surface of the wire. The bristles  46  may be made of any resilient material suitable to remove dirt and debris from the surface of the wire  5 , including metal or high-temperature polymer. In a preferred embodiment, the bristles  46  are nylon. 
         [0133]    An input shaft  42  drives the rotating brush mechanism  40 . The input shaft  42  connects to the drive plate  545  to affect the orbital and rotary motion of the brush assemblies  45 . The input shaft  42  is driven by a pulley  41 . A belt (not shown in  FIG. 8 ) drives the pulley  42 . 
         [0134]    In one embodiment, at least one flexible nozzle  78  is disposed in the vicinity of the active brush mechanism  40  such that the nozzle  78  may be positioned to spray an aqueous detergent solution on the wire  5  and/or the active brush mechanism  40 . The flexible nozzle  78  is in fluid communication with a reservoir  77  configured to receive an aqueous detergent solution. The detergent is delivered into the housing of the brush mechanism through one or more apertures (see  FIGS. 1 and 2 —the apertures are not shown in  FIG. 8 ) and aids in the removal of oil and debris from the wire  5 . 
         [0135]      FIGS. 9 and 10  illustrates the active rotating brush mechanism  40 , with the components of the support end removed. Each of the brush assemblies  45  comprise a keyed shaft  48  having one or more flat such that a brush shaft receiver  575  comprising a yoke in the brush support shaft  571  interlocks the keyed shaft  48 . The keyed shaft  48  has a hole  485  through which a quick release pin  47  passes. In a preferred embodiment, the hole  485  is slotted. In  FIGS. 9 and 10  a quick release pin  47  is illustrated at the drive end of the cylindrical brush assembly  45 , but is not shown on the support end. 
         [0136]    The drive end rotating brush plate  545  is illustrated in  FIG. 9 , with three holes into which a bearing/seal  544  is pressed. The bearing/seal  544  encircles the brush support shaft  571 . The drive end seal cover  535  encircles the rotating brush drive plate  545 , as discussed above. 
         [0137]      FIG. 11  illustrates the active rotating brush mechanism  40 , with drive end housing  525 , drive end rotating brush plate  545 , and the components of the support end removed such that the planetary gear mechanism is shown. The planetary gear mechanism rotates each brush assembly  45  and causes each brush assembly  45  to orbit the wire  5 . As illustrated in  FIG. 11 , the drive end brush support shaft  571  is encircled by bearings  58 . Thus, when the drive end rotating brush plate  545  rotates, it bears against surface of the bearings  58 . A planetary gear  56  is disposed at the drive end of each brush support shaft  571 . The planetary gears  56  engage with an annular gear  55 , which is fixed in the static planetary gear housing  51 . As discussed above, the planetary gear housing  51  is fixed and does not rotate. The shaft  42  connects to the rotating brush drive plate  545  such that rotation of the shaft causes the drive plate  545  to rotate. Because the brush support shafts  571  are captured in the drive plate  545 , the rotation of the drive plate  545  causes the brush support shafts  571  to orbit the wire  5 . Thus, when the drive plate  545  rotates, the orbital motion of the brush support shafts  571  cause the planetary gears  56  to rotate along the annular gear  55 , thereby rotating the brush support shafts  571 . 
         [0138]      FIGS. 12 and 13  illustrate a single cylindrical brush assembly  45  and the support shafts  571  and  572  at either end of the cylindrical brush assembly  45 . The drive end support shaft  571  includes a yoke shaped brush shaft receiver  575 , and the support end support shaft  572  includes a yoke shaped shaft receiver  576 . Thus, the keyed shaft  48  at either end of each cylindrical brush assembly  45  interlocks with the brush support shafts  571  and  572  at the shaft receivers  575  and  576 . A quick release pin  47 , comprising a body  475  and a release button  476  secures the brush shaft  48  in brush shaft receivers  575  and  576 . The quick release pin  47  passes through a hole  485  in the brush shaft  48  such that the brush shaft  48  is secured. By pressing the release button  476 , the quick release pin  47  is released such that it may be removed from the hole passing through the respect shaft receiver ( 575  or  576 ) and the brush shaft  48 . For example, the quick release  47  may use a ball détente mechanism as is known in the art. The hole  485  may be slotted to facilitate removal of the brush shaft from the brush shaft receivers  575  and  576 . 
         [0139]    By using the quick release pin  47 , the brush assemblies  45  are easily replaced, for example with longer or shorter bristles  46  that accommodate a wire  5  that is smaller or larger in diameter. The brush support shafts  571  are captive within bearings  544  in the drive plate  526 . The spur gears  56  are secured within the planetary gear housing  51 , preventing the shafts  571  from sliding out of the drive plate  526 . Supporting members  549  rigidly connect the drive end plate  526  to the support end plate  546 . The support shafts  572  are captive within bearings  544  in the support end plate  546 . By incorporating a shoulder on the support shafts  572 , they are prevented from sliding out of the support end plate  546 . Because the shafts  571  and  572  are captive at either end of the active brush mechanism  40 , and held in rigid relation to each other by the supporting members, the brush assemblies  45  can be removed and replaced easily to accommodate a wire having a smaller or larger diameter. 
         [0140]      FIGS. 14 and 15  illustrate a cross-sectional view of the active rotating brush mechanism  40  along line  14 - 14  illustrated in  FIG. 10 , illustrating the planetary gear mechanism of an orbital scrubbing mechanism of the wire cleaning apparatus  10 , with supporting end plates  525  and  526 , and the brush assemblies  45  removed. As illustrate in  FIGS. 14 and 15 , the stationary planetary gear housing  51  includes the annular gear  55 . Spur gears  56  disposed at the ends of each brush support shaft  571  interface with the annular gear  55  and orbit around the drive shaft  42 . The wire  5  (not shown in  FIGS. 14 and 15 ) passes through a hole  421  in the drive shaft  42 . Thus, the planetary gears  56  simultaneously orbit the wire  5  and rotate, increasing the amount of cleansing action exerted by the bristles  46  on the surface of the wire  5 . 
         [0141]    In alternative embodiments the rotating brush mechanism  40  may use any other mechanism known to a person having ordinary skill in the art to rotate the cylindrical brushes  45  simultaneous to their orbital motion around the wire. For example, a system of belts and pulleys could accomplish a similar result. 
         [0142]      FIGS. 16 and 17  illustrate a drying stage, which may include a wire guide mechanism  90  and a wire drying apparatus  80 . The wire guide mechanism  90  includes a sensor  910  that detects movement of the wire through the wire cleaning apparatus  10 , and is adjustable to accommodate a variety of wire diameters. The drying apparatus  80  uses compressed air to blow moisture off the surface of the wire  5 . A valve (not shown) controls flow of the compressed air, turning off the flow of air when the wire stops moving. 
         [0143]    The wire wipe  80  comprises a funnel disposed around the wire path. The funnel has a large end, a small end and an input. The input is configured to deliver high-speed air to the funnel. The funnel and the input act as a pneumatic drying mechanism which remove fluid from the wire  5 . 
         [0144]    A threaded rod  903  adjusts the wire guide mechanism  90 . An adjustment knob  901  and a locking adjustment knob  902  serve to adjust and lock the wire guide mechanism  90 . The wire guide mechanism includes a body  920  that surrounds and encompasses the adjustment mechanism. A front body plate  930  and a back body plate  940  enclose the front and back of the adjustment mechanism, and a body bottom plate supports the sensor  910  on an encoder support member  953 . An idler roller  915  is mounted on the shaft of the encoder  910 . 
         [0145]      FIG. 18  provides an isometric view of the wire guide mechanism  90 , isolated from the wire cleaning apparatus  10 . In addition to the features already described,  FIG. 18  illustrates wire guide rollers  951  and  952 . The idler roller  915  comprises a compliant and resilient material such as hard rubber, and rolls along the surface of the wire guide roller  952 . 
         [0146]      FIGS. 19-20  show a cross-sectional view along line  19 - 19  illustrated in  FIG. 17 , illustrating the adjustment mechanism of the wire guide mechanism  90 . As discussed above, the wire guide mechanism  90  includes guide rollers  951  and  952 , which are adjustable to accommodate a variety of wire diameters. The threaded rod  903  drives an adjustment cam  921  down into the body  920  of the wire guide mechanism. The guide rollers  951  and  952  are mounted on cam followers  922  and  923  such that when the adjustment cam  921  drives downwards, the guide rollers  951  and  952  are driven together. A spring  924  provides a force to drive the cam followers  922  and  923  apart when the threaded rod  903  retracts. 
         [0147]      FIG. 19  illustrates the adjustment mechanism in an open position in which the wire guide rollers  951  and  952  are drawn away from each other. To achieve the open position of the wire guide rollers  951  and  952  the adjustment cam is raised as far as possible by the threaded rod  903 . The adjustment knob  901  and the locking knob  902  are rotated counter-clockwise (as viewed from above) to draw the threaded rod  903  upwards. The spring  924  drives the cam followers  922  and  923  apart. 
         [0148]      FIG. 20  illustrates the adjustment mechanism in a closed position in which the wire guide rollers  951  and  952  are squeezed towards each other. To achieve the closed position of the wire guide rollers  951  and  952  the adjustment cam is lowered as far as possible by the threaded rod  903 . The adjustment knob  901  and the locking knob  903  are rotated clockwise (as viewed from above) to push the threaded rod  903  downwards. The adjustment cam  921  drives the cam followers  922  and  923  together. By adjusting the position of the wire guide rollers  951  and  952 , the wire guide mechanism  90  can be sized easily to accommodate a wire having a smaller or larger diameter. 
         [0149]    The encoder  910  is mounted on the encoder support member  953 , which is mounted on a shaft running through the guide roller  952 . Thus, the encoder moves with the guide roller  952 . The encoder  910  provides a varying, repeating signal (e.g., quadrature pulses) in response to movement of the wire  5 . When the wire  5  is stationary, the encoder  910  does not provide the signal. The wire cleaning apparatus uses the encoder signal to identify movement of the wire  5  and to stop and start portions of the wire cleaning apparatus including the rotating brush mechanism  40  and the wire wipe  80 . For example, based on the signal output from the encoder, the rotating brush mechanism  40  or the pneumatic drying mechanism may be switched from an active to an inactive state. This conserves energy and prevents undue wear on the surface of the wire. By stopping the motion of the rotating brush mechanism  40  and turning off the flow of compressed air in the wire air wipe  80  electricity and compressed air are conserved. Further, by stopping the motion of the rotating brush mechanism  40  the active cleaning of the wire surface stops, which prevents the bristles  46  from scraping or polishing the surface of the wire  5 . 
         [0150]    Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.

Technology Category: b