Abstract: Apparatus and methods for winding flexible material include a rotatable plate assembly rotatably driven by a first rotary shaft, the assembly supporting second and third rotary shafts with corresponding first and second mandrel parts mounted thereon. The first and second mandrel parts each form at least part of a winding spool. The second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, the rotational axis of the first rotary shaft. The rotation of the plate assembly is coordinated with counter rotation of the first and second mandrel parts. In embodiments, such coordinated rotation occurs during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other. The flexible material can be cable, wire, tubing, hose, rope, or other filamentary material. Other aspects are described and claimed.

Abstract: A packaged wound coil assembly includes a coil of wire, a payout tube, two flat panels on either side of the coil of wire, and a retainer to secure the flat panels relative to the coil assembly. The package assembly uses significantly less materials than prior packages and as assembled can assume less overall space than prior packages for similar wire coils.

Abstract: An adjustable guide apparatus for guiding filamentary material from a reciprocating traverse onto a mandrel of a winding machine to form a coil. The adjustable guide apparatus includes a housing having a collar defining an inlet opening configured to receive filamentary material, and adjustable guides coupled to the housing defining a guide opening between the adjustable guides for passage of the filamentary material from the inlet opening. The apparatus also includes an adjuster configured to adjust relative spacing between the adjustable guides that defines the size of the guide opening.

Abstract: A payout tube has an inner end and an outer end. The inner end is disposable in an interior of a coil of filamentary material wound in a figure-eight configuration defining a payout hole. The outer end is configured to extend outwardly from the payout hole of the coil. The payout tube has a flange at the outer end and has a rounded edge at the inner end. The rounded edge has a radius between 0.20 and 0.30 inch. In some embodiments, the payout tube includes a tubular body that extends between the flange and the rounded edge. In other embodiments, the payout tube includes an outer ring having the flange, an inner ring having the rounded edge with the inner and outer rings aligned coaxially about a longitudinal axis in spaced relation, and a plurality of pillars extending longitudinally from the outer ring to the inner ring.

Abstract: A payout tube has an inner end and an outer end. The inner end is disposable in an interior of a coil of filamentary material wound in a figure-eight configuration defining a payout hole. The outer end is configured to extend outwardly from the payout hole of the coil. The payout tube has a flange at the outer end and has a rounded edge at the inner end. The rounded edge has a radius between 0.20 and 0.30 inch. In some embodiments, the payout tube includes a tubular body that extends between the flange and the rounded edge. In other embodiments, the payout tube includes an outer ring having the flange, an inner ring having the rounded edge with the inner and outer rings aligned coaxially about a longitudinal axis in spaced relation, and a plurality of pillars extending longitudinally from the outer ring to the inner ring.

Abstract: A spool endform assembly includes an endform with a central collar that are configured to rotate about a rotational axis. The spool endform assembly further includes a mount sub-assembly configured to be mounted in a fixed orientation on a mounting structure (such as movable arm). The spool endform assembly is further configured to permit misalignment of the fixed orientation of the mount sub-assembly relative to the rotational axis of the endform and central collar. In embodiments, controlled movement of the mounting structure can be used to connect the spool endform assembly to a rotatable mandrel of a wire winding spool and disconnect the spool endform assembly from the rotatable mandrel. By permitting misalignment of the fixed orientation of the mount sub-assembly relative to the rotational axis of the endform and central collar, the spool endform assembly makes it easier to connect the spool endform assembly to the rotatable mandrel and to disconnect the spool endform assembly from the rotatable mandrel.

Abstract: A spool endform assembly includes an endform with a central collar that are configured to rotate about a rotational axis. The spool endform assembly further includes a mount sub-assembly configured to be mounted in a fixed orientation on a mounting structure (such as movable arm). The spool endform assembly is further configured to permit misalignment of the fixed orientation of the mount sub-assembly relative to the rotational axis of the endform and central collar. In embodiments, controlled movement of the mounting structure can be used to connect the spool endform assembly to a rotatable mandrel of a wire winding spool and disconnect the spool endform assembly from the rotatable mandrel. By permitting misalignment of the fixed orientation of the mount sub-assembly relative to the rotational axis of the endform and central collar, the spool endform assembly makes it easier to connect the spool endform assembly to the rotatable mandrel and to disconnect the spool endform assembly from the rotatable mandrel.

Abstract: A system for winding wire includes a wire take-up unit and a wire cutter/grabber unit. The take-up unit includes rotatable first and second mandrel portions, and a wire directing traverse arranged to feed wire and alternately form coils on the first and second mandrel portions. The cutter/grabber unit is configured to cut the wire at a cut position between the traverse and a coil formed on the first mandrel portion and to grab a free end of the cut wire and move along a predefined cutter/grabber pathway to a hand-off position where the wire is transferred to the second mandrel portion. As the cutter/grabber is moved along the pathway from the cut to the hand-off position, a length of wire between the traverse and the free end of the wire does not decrease, and that length of wire is longer at the hand-off position than at the cut position.

Abstract: Systems and methods for winding wire are disclosed. A system includes a wire take-up unit and a wire tensioning unit. The take-up unit includes a rotating mandrel and a wire directing device, the wire directing device arranged to cause the wire to be wound in a figure-eight configuration on the rotating mandrel to form a coil having many layers of wire. The wire tensioning unit applies tension to said wire as it is wound, and applies a first amount of tension to a predetermined amount of wire constituting at least a first two layers of the coil, and a second amount of tension to the wire beyond the predetermined amount. In one embodiment, the wire tensioning unit includes digital self-relieving air regulator pneumatically coupled to and controlling a pressure in said pressurized chamber of a pre-lubricating cylinder that is coupled to the wire being wound.

Abstract: An apparatus for winding filamentary material includes a mandrel rotatable about a spindle axis of rotation and a traverse reciprocating at a distance with respect to the spindle axis to wind the filamentary material in a figure-eight coil configuration with a payout hole extending radially from the inner to the outer wind of the coil. The apparatus includes a measurement device for measuring the diameter of the coil as it is being wound around the mandrel, and a controller for controlling the reciprocating movement of the traverse with respect to the rotation of the mandrel based on the measured diameter of the coil. The measurement device may include a first sensor configured to measure a length of filamentary material wound about the mandrel and a second sensor configured to measure an angular displacement of said mandrel during the winding of the length of filamentary material about said mandrel.

Abstract: An apparatus for winding filamentary material includes a mandrel rotatable about a spindle axis of rotation and a traverse reciprocating at a distance with respect to the spindle axis to wind the filamentary material in a figure-eight coil configuration with a payout hole extending radially from the inner to the outer wind of the coil. The apparatus includes a measurement device for measuring the diameter of the coil as it is being wound around the mandrel, and a controller for controlling the reciprocating movement of the traverse with respect to the rotation of the mandrel based on the measured diameter of the coil. The measurement device may include a first sensor configured to measure a length of filamentary material wound about the mandrel and a second sensor configured to measure an angular displacement of said mandrel during the winding of the length of filamentary material about said mandrel.

Abstract: A system for winding wire includes a wire take-up unit and a wire cutter/grabber unit. The take-up unit includes rotatable first and second mandrel portions, and a wire directing traverse arranged to feed wire and alternately form coils on the first and second mandrel portions. The cutter/grabber unit is configured to cut the wire at a cut position between the traverse and a coil formed on the first mandrel portion and to grab a free end of the cut wire and move along a predefined cutter/grabber pathway to a hand-off position where the wire is transferred to the second mandrel portion. As the cutter/grabber is moved along the pathway from the cut to the hand-off position, a length of wire between the traverse and the free end of the wire does not decrease, and that length of wire is longer at the hand-off position than at the cut position.

Abstract: Systems and methods for winding wire are disclosed. A system includes a wire take-up unit and a wire tensioning unit. The take-up unit includes a rotating mandrel and a wire directing device, the wire directing device arranged to cause the wire to be wound in a figure-eight configuration on the rotating mandrel to form a coil having many layers of wire. The wire tensioning unit applies tension to said wire as it is wound, and applies a first amount of tension to a predetermined amount of wire constituting at least a first two layers of the coil, and a second amount of tension to the wire beyond the predetermined amount. In one embodiment, the wire tensioning unit includes digital self-relieving air regulator pneumatically coupled to and controlling a pressure in said pressurized chamber of a pre-lubricating cylinder that is coupled to the wire being wound.

Abstract: A locking ring is described that permits removal of filamentary material housed in a walled container through a payout tube defining a payout tube axis and through which a first end of the filamentary material extends. The ring includes an annular flange around a ring axis and a body having a tubular wall extending from an inner edge of the annular flange to a distal edge of the ring. The tubular wall is coaxial with the ring axis, and has a plurality of teeth circumferentially spaced around the tubular wall and extend from the tubular wall radially outwardly and toward the annular flange. Each tooth resiliently deflects radially inwardly in response to interference between the tooth and an inner wall of the payout tube. The curved edges form a thread permitting the ring to advance axially into and secure with the payout tube.

Abstract: A payout tube assembly is provided for unwinding filamentary material from a wound coil of filamentary material contained in a container having a wall panel with a hole that aligns with the payout tube assembly. The payout tube assembly includes a payout tube. The assembly also includes a generally planar payout panel affixed to the payout tube. The payout panel defines a central opening through which one end of the payout tube is received. In one embodiment, the payout panel defines a first set of arcuate slits and a second set of arcuate slits extending about the axis of the payout tube, the first and second sets of arcuate slits spaced radially and circumferentially from each other. In one embodiment, the payout panel defines radial slits extending from the central opening and defining payout panel fingers that are glued to the payout tube.

Abstract: Systems and methods for winding wire are disclosed. A system includes a wire take-up unit and a wire tensioning unit. The take-up unit includes a rotating mandrel and a wire directing device, the wire directing device arranged to cause the wire to be wound in a figure-eight configuration on the rotating mandrel to form a coil having many layers of wire. The wire tensioning unit applies tension to said wire as it is wound, and applies a first amount of tension to a predetermined amount of wire constituting at least a first two layers of the coil, and a second amount of tension to the wire beyond the predetermined amount. In one embodiment, the wire tensioning unit includes digital self-relieving air regulator pneumatically coupled to and controlling a pressure in said pressurized chamber of a pre-lubricating cylinder that is coupled to the wire being wound.

Abstract: A payout tube assembly is provided for unwinding filamentary material from a wound coil of filamentary material contained in a container having a wall panel with a hole that aligns with the payout tube assembly. The payout tube assembly includes a payout tube. The assembly also includes a generally planar payout panel affixed to the payout tube. The payout panel defines a central opening through which one end of the payout tube is received. In one embodiment, the payout panel defines a first set of arcuate slits and a second set of arcuate slits extending about the axis of the payout tube, the first and second sets of arcuate slits spaced radially and circumferentially from each other. In one embodiment, the payout panel defines radial slits extending from the central opening and defining payout panel fingers that are glued to the payout tube.