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: 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: 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: 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 trolley for moving heavy objects such as wire coils from a machine to a container at a packaging table is provided. The trolley includes spring-loaded spaced arms movably mounted for vertical height adjustment so that the arms are just below the coil when it is on the machine and rotational movement to separate the spaced arms with the spaced arms retaining the heavy object during movement of the trolley apparatus, and locking arms engaging the spaced arms during movement of the trolley apparatus to prevent separation thereof. The spring-loaded arms permit the heavy object to be manually pushed downward therebetween, thereby forcing the arms apart enabling the object to fall from the trolley into a container on a packaging table. The table includes a platform for supporting the container, a motor for raising/lowering the platform, and a mechanism for retaining the container and aiding its alignment with the coil.

Abstract: A trolley for moving heavy objects such as wire coils from a machine to a container at a packaging table is provided. The trolley includes spring-loaded spaced arms movably mounted for vertical height adjustment so that the arms are just below the coil when it is on the machine and rotational movement to separate the spaced arms with the spaced arms retaining the heavy object during movement of the trolley apparatus, and locking arms engaging the spaced arms during movement of the trolley apparatus to prevent separation thereof. The spring-loaded arms permit the heavy object to be manually pushed downward therebetween, thereby forcing the arms apart enabling the object to fall from the trolley into a container on a packaging table. The table includes a platform for supporting the container, a motor for raising/lowering the platform, and a mechanism for retaining the container and aiding its alignment with the coil.

Abstract: A trolley for moving heavy objects such as wire coils from a machine to a container at a packaging table is provided. The trolley includes spring-loaded spaced arms movably mounted for vertical height adjustment so that the arms are just below the coil when it is on the machine and rotational movement to separate the spaced arms with the spaced arms retaining the heavy object during movement of the trolley apparatus, and locking arms engaging the spaced arms during movement of the trolley apparatus to prevent separation thereof. The spring-loaded arms permit the heavy object to be manually pushed downward therebetween, thereby forcing the arms apart enabling the object to fall from the trolley into a container on a packaging table. The table includes a platform for supporting the container, a motor for raising/lowering the platform, and a mechanism for retaining the container and aiding its alignment with the coil.

Abstract: Apparatus and process for winding filamentary material in a figure 8 configuration including a rotatable spindle for retaining a mandrel upon which the filamentary material is wound; a traverse mechanism for controlling the laying of wound coils on the mandrel; and controlling the advance of the wound layers on the mandrel in accordance with the rotation of the spindle and the movement of the traverse mechanism to vary the angular displacement of the wound coil so that the number of crossovers of succeeding layers of the wound coils increases as the winding process progresses, thereby increasing the density of the wound coils.

Abstract: A machine for winding and boxing wound coils of filamentary material having a payout hole extending from the outer to the inner coil winding wherein a turret mechanism mounting two oppositely disposed end forms and corresponding collapsible mandrels and operative between first and second stations, wherein the first station enables filamentary material to be wound on one of the mandrels and associated end form and a second station wherein the mandrel and end form containing the wound coil is rotated to confront a boxing station; a boxing station including a platform having a movable back panel, a base panel and an inclined ramp facing the second station and being movable towards and away from the second station for receiving the wound coil from the collapsible mandrel; the boxing station receiving an unfolded box deposited on the base panel with a back panel folded against said back panel and including means for folding two opposite side panels of the box to enable reception of the wound coil in the partially

Abstract: A machine for winding and boxing wound coils of filamentary material having a payout hole extending from the outer to the inner coil winding, a turret mechanism mounting two oppositely disposed end forms and corresponding collapsible mandrels and operative between first and second stations, wherein the first station enables filamentary material to be wound on one of the mandrels and associated end form and a second station wherein the mandrel and end form containing the wound coil is rotated to confront a boxing station; a boxing station including a platform having a movable back panel, a base panel and an inclined ramp facing the second station and being movable towards and away from second station for receiving the wound coil from the collapsible mandrel; the boxing station receiving an unfolded box deposited on the base panel with a box back panel folded against the back panel and including means for folding two opposite side panels of the box to enable reception of the wound coil in the partially assemble

Abstract: A payout tube for insertion in a radial hole of a wound coil of filamentary material and the radial hole extending from the inner to the outer wind of the wound coil, the payout tube including an entrance and an exit opening in coaxial and spaced relationship with one another; the size of the entrance opening is determined by the following: Yc=3.5 sin x/Dm where Dm is a diameter of the mandrel on which the coil of filamentary material is wound, x is the length along the circumference of the wind and Yc is the substantially sinusoidal FIG. 8 coil pattern; Yc′=3.5Dm Cos x/Dm; at x=0; Yc′=3.51/Dm; and the slope H of the coil pattern=Tan−1 [3.5/Dm]=23.

Abstract: A payout tube for insertion in a radial hole of a wound coil of filamentary material and the radial hole extending from the inner to the outer wind of the wound coil, the payout tube including an entrance and an exit opening in coaxial and spaced relationship with one another; the size of the entrance opening is determined by the following:

Abstract: A machine for winding and boxing wound coils of filamentary material having a payout hole extending from the outer to the inner coil winding, a turret mechanism mounting two oppositely disposed end forms and corresponding collapsible mandrels and operative between first and second stations, wherein the first station enables filamentary material to be wound on one of the mandrels and associated end form and a second station wherein the mandrel and end form containing the wound coil is rotated to confront a boxing station; a boxing station including a platform having a movable back panel, a base panel and an inclined ramp facing the second station and being movable towards and away from second station for receiving the wound coil from the collapsible mandrel; the boxing station receiving an unfolded box deposited on the base panel with a box back panel folded against the back panel and including means for folding two opposite side panels of the box to enable reception of the wound coil in the partially assemble

Abstract: A payout tube for insertion in a radial hole of a wound coil of filamentary material and extending from the inner to the outer wind of the wound coil, the payout tube having entrance and exit openings in coaxial and spaced relationship with one another. The size of the entrance opening is determined by the following equation: Yc=3.5 sin×/Dm, where Dm is the diameter of the mandrel, X is the length along the circumference of the wind and Yc is the coil pattern. Yc′=3.5/Dm Cos×/Dm at x=0; Yc′=3.5/Dm, and the slope H of the coil pattern=Tan−1[3.5/Dm]=23.629 degrees. The length L of the payout hole is determined as: L=O×Dm×pie/360 degrees; where O is the payout hole opening; the width of the payout hole is W=L cos(H).

Abstract: A payout tube for insertion in a radial hole of a wound coil of filamentary material and extending from the inner to the outer wind of said wound coil, comprising:an entrance opening and an exit opening in coaxial and spaced relationship with one another;the size of said entrance and exit openings being large enough to allow room for the inherent twist in the filamentary material to exit the exit opening without kinking; anda flange member surrounding the exit opening for engaging a panel of a container retaining the wound coil.The payout tube may be constructed of corrugated fiber, pulp paper or plastic.

Abstract: A container for holding a wound coil of filamentary material and a payout tube formed integrally with the container for engaging a payout hole formed in the wound coil from the innermost winding to the outermost winding thereof and enabling filamentary material to be paid out through the payout hole and integrally formed payout tube wherein the container has six sides formed by twelve panels within four attached sections. A first of the sections including an end panel flanked on opposite sides thereof by a portion of an upper and bottom panel, the portion of the upper panel including a portion of the integrally formed payout tube. A second of the sections including a side panel flanked on opposite sides thereof by a portion of the bottom panel and the top panel, and the portion of the upper panel including a hole forming the exit opening of the integrally formed payout tube.

Abstract: A payout tube for enabling payout of filamentary material having inherent twist characteristics from a coil of the filamentary material wound in a figure 8 configuration with a payout hole extending from the inner layer to the outer layer of the coil, wherein the payout hole has an oval or diamond shape; an inner end of the payout tube being adapted for insertion into the payout hole and having an oval or diamond shape corresponding to the oval or diamond shape of the payout hole, the payout hole having a diameter of at least ninety degrees; the payout tube having an inner diameter increasing in size from the inner end to the outer end thereof; and a collar formed around the outer end to support the payout tube against the outer surface of a container.

Abstract: High speed traversing mechanism and method for winding filamentary material onto a rotating mandrel, wherein an indexer including a crank arm rotatable about a pivot point; a connecting rod connected to the crank arm at a second pivot point; a traverse guide connected to the connecting rod at a third pivot point located on the center line of the traverse guide and the traverse guide reciprocating within a support with rotation of the crank arm; the pivot point is positioned at a point on said center line spaced from the third pivot point; the connecting rod forming a given angle with the center line; the indexer means rotating the rotatable crank arm to displace the traverse guide along the center line within the support; and controlling the indexer to wind the filamentary material onto the mandrel.