Rectangular wire coiling machine

Abstract

A coiling machine configured to coil semi-rigid rectangular wires without using a core to wind the wire thereonto, yielding a free-standing coil is described herein. The coiling machine comprises a wire bending mechanism including a wire holding assembly for selectively immobilizing a wire and a wire bending assembly for bending a selected portion of the wire at an angle while the wire is immobilized by the wire holding assembly; a wire feeding mechanism for receiving the wire from a wire drawing mechanism and for feeding a length of the wire to the wire bending mechanism; and a controller coupled to the wire drawing mechanism, wire bending mechanism and wire feeding mechanism to control their operations for sequentially bending the wire at predetermined positions therealong so as to yield a coil of wire.

Description

FIELD OF THE INVENTION

The present invention relates to coiling machines. More specifically, the present invention is concerned with a machine to coil semi-rigid wire without using a core, resulting in a free-standing coil.

BACKGROUND OF THE INVENTION

Coiling machines are well known in the art. They usually are provided with a rotating core onto which wire is wound. In some cases, the core is part of the finished product. When this is the case, the coil is completed when a predetermined number of turns have been coiled thereto.

In other cases, for example when air coils are produced, the core is not part of the finished product. In such cases, the coil has to be removed from the core. Many techniques have been designed to accomplish this. For example, the core may be made of separable sections so designed as to allow the reduction of the core dimensions thereby facilitating the removal of the core from the coil.

This type of coiling machine is not well suited to coil relatively large rectangular wires or other non-circular semi-rigid wires. Indeed, the force required to maintain these types of wires onto a rotating core often weaken or damage the electrical insulation of the wire, leading to unusable coils.

OBJECTS OF THE INVENTION

An object of the present invention is therefore to provide an improved coiling machine for coiling rectangular wires and other relatively large non-circular wires.

Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of embodiments thereof, given by way of example only with reference to the accompanying drawings.

SUMMARY OF THE INVENTION

More specifically, in accordance with a first aspect of the present invention, there is provided a wire coiling machine comprising:

a wire bending mechanism including a wire holding assembly for selectively immobilizing a wire and a wire bending assembly for bending a selected portion of the wire at an angle while the wire is immobilized by the wire holding assembly;

a wire feeding mechanism for receiving the wire from a continuous feed and for feeding a length of the wire to the wire bending mechanism; and

a controller coupled to both the wire bending mechanism and the feeding mechanism to control operations of both the wire feeding mechanism and the wire bending mechanism for sequentially bending the wire at predetermined positions therealong so as to yield a coil of wire having a predetermined geometry.

According to a second aspect of the present invention, there is providing a wire coiling machine comprising:

a wire bending mechanism including a wire holding assembly for selectively immobilizing a wire and a wire bending assembly for bending a selected portion of the wire while the wire is immobilized by the wire holding assembly;

a wire feeding mechanism for receiving the wire from a continuous feed and for feeding the wire to the wire bending mechanism; and

a controller coupled to the wire feeding mechanism and the wire bending mechanism for controlling operations of both the wire feeding mechanism and the wire bending mechanism to form a coil of wire having a geometry characterized by a sequence of lengths of wire and intermediary angles of bends; the controller being configured to control the wire feeding mechanism to sequentially feed the sequence of lengths of wire to the wire bending mechanism, and, between two sequential feeds of lengths of wire, to control the wire bending mechanism to bend the wire of a corresponding intermediary angle.

According to a third aspect of the present invention, there is provided a wire coiling machine comprising:

a wire bending mechanism including a wire holding assembly for selectively immobilizing a wire and a wire bending assembly for bending a selected portion of the wire at an angle while the wire is immobilized by the wire holding assembly;

a wire feeding mechanism for receiving the wire from a continuous feed and feeding a length of the wire to the wire bending mechanism; and

a controller coupled to the wire feeding mechanism and to the wire bending mechanism for controlling the wire bending mechanism and the wire feeding mechanism according to a predetermined sequence so as to yield a coil of wire having a predetermined geometry characterized by a sequence of lengths of wire and intermediary angles of bends.

Finally, according to a fourth aspect of the present invention, there is provided a wire coiling machine comprising:

wire immobilizing means for selectively immobilizing a wire;

wire bending means for bending a selected portion of the wire at an angle while the wire is immobilized by the wire immobilizing means;

wire feeding means for receiving the wire from a continuous feed and for feeding a length of the wire to the wire bending means; and

controlling means coupled to the wire immobilizing means, the wire bending means and the wire feeding means; the controlling means being configured to control operations of both the wire feeding mechanism and the wire bending mechanism for sequentially bending the wire at predetermined positions along its length so as to yield a coil of wire having a predetermined geometry.

Other objects, advantages and features of the present invention will become more apparent upon reading the following non restrictive description of illustrated embodiments thereof, given by way of example only with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the appended drawings:

FIG. 1 is a front perspective view illustrating a rectangular wire coiling machine according to a first illustrative embodiment of the present invention;

FIG. 2 is a rear perspective view of the machine of FIG. 1;

FIG. 3 is a top plan view of the machine of FIG. 1;

FIG. 4 is a front elevational view of the machine of FIG. 1;

FIG. 5 is a perspective view of both the wire feeding mechanism and the wire bending mechanism of the machine of FIG. 1;

FIG. 6 is a side elevational view of the wire gripping portion of the wire feeding mechanism of FIG. 5;

FIG. 7 is a partly exploded view of the wire coiling mechanism of the machine of FIG. 1;

FIGS. 8 to 20 are top plan views of the wire coiling mechanism of FIG. 7 illustrating a sequence of coiling of one coil;

FIG. 21 is a perspective view of a finished rectangular wire coil;

FIG. 22 is a front perspective view illustrating a rectangular wire coiling machine according to a second illustrative embodiment of the present invention;

FIG. 23 is a top plan view of the machine of FIG. 22;

FIG. 24 is a front elevational view of the machine of FIG. 22;

FIG. 25 is front right perspective view of the wire stripping mechanism of the machine of FIG. 25;

FIG. 26 is a rear perspective view of the wire stripping mechanism of FIG. 25;

FIG. 27 is a front elevational view of the wire stripping mechanism of FIG. 25, illustrating the wire stripping mechanism in a resting position;

FIG. 28 is a front elevational view of the wire stripping mechanism of FIG. 25, illustrating the wire stripping mechanism in a wire engaging position;

FIG. 29 is a front elevational view of the wire stripping mechanism of FIG. 25, illustrating the wire stripping mechanism in a wire stripping position movement;

FIG. 30 is a front elevational close-up view taken along line 30-30 on FIG. 29, illustrating the striper claws and grater fingers of the wire stripping mechanism;

FIG. 31 is a perspective view of the wire cutting mechanism of the machine of FIG. 22;

FIG. 32 is a side elevational view of the wire cutting mechanism of FIG. 31;

FIG. 33 is a side elevational view similar to FIG. 32, illustrating the operation of the wire cutting mechanism; and

FIG. 34 is a top plan close-up view of both the wire bending mechanism and the wire cutting mechanism of the machine of FIG. 22 taken along line 34-34 on FIG. 23, further illustrating the operation of wire cutting mechanism.

DETAILED DESCRIPTION

Generally stated, the present disclosure is concerned with a coiling machine configured to coil semi-rigid wires without using a core to wind the wire thereonto, yielding a free-standing coil. The wiring machine includes a wire drawing mechanism, a wire feeding mechanism and a wire bending mechanism all controlled by a controller. In operation, the wire feeding is so controlled as to feed a predetermined length of the continuous wire from the wire drawing mechanism to the wire bending mechanism prior to the bending of a predetermined angle. This process is repeated until the coil is completed.

Turning now first to FIGS. 1 to 4 of the appended drawings, a rectangular wire coiling machine 10 according to a first illustrative embodiment of the present invention will be described. The coiling machine 10 includes a wire drawing mechanism 12, a wire feeding mechanism 14 and a wire bending mechanism 16 all controlled by a controller 18 provided with an interface 19. For safety purpose, a transparent cover 20 is removably positioned over the wire feeding mechanism 14.

The purpose of the wire drawing mechanism 12 is to uncoil a certain length of wire from the spool 22 in order to supply the wire to the feeding mechanism 14 at a generally constant and moderate tension. The wire feeding mechanism 14 then feeds a precise length of wire to the wire bending mechanism 16 that precisely bends the wire of a predetermined and controllable angle. The controller 18 controls these mechanisms so that a sequence is followed to yield a coil, such as coil 132 in FIG. 21, having the desired specifications and geometry.

As can be better seen from FIGS. 2 and 3, the wire drawing mechanism 12 includes a shaft 24 onto which the spool 22 is mounted. The shaft 24 is maintained to a frame 26 of the machine 10 via two pillow blocks 28 and 30. The shaft 24 includes a pulley 25 used to connect the shaft 24 to a motor 27 via a driving belt 29. The motor 27 is coupled to the controller 18 so that the controller 18 may control the unwinding of the wire from the spool 22 via the motor 27. The shaft 24, motor 27 and driving belt 29 can be replaced in parts, in whole or complemented by other spool driving means controllable by the controller 18.

The wire drawing mechanism 12 also includes a movable carriage 32 mounted to rails 34 via linear bearings 36 to allow longitudinal movements (see arrow 38) of the carriage 32 relative to the spool 22. The movable carriage 32 includes an arcuate wire guide 42 including two parallel plates 44 spaced by rollers 46. A pneumatic cylinder 40 biases the movable carriage 32 away from the spool 22 to keep a tension thereon. The cylinder 40 is a closed circuit. Limit switches (not shown) are used to supply carriage position data to the controller 18.

As will now become more apparent to a person skilled in the art, the carriage 32 allows supplying wire to the feeding mechanism 14 at a constant level relatively thereto. In operation, the movable carriage 32 further allows supplying the wire to the wire feeding assembly 14 at a generally constant and moderate tension by automatically adjusting the tension on the wire, following the spool 22 unwinding a certain length of wire. When limit switches (not shown) detect the limit position of the carriage 32, a signal is sent to the controller 18 which activates the motor 27 for unwinding another length of wire. This process is repeated so that the wire feeding mechanism 14 always has a sufficient length of wire for its operation. The carriage 32 further prevents the wire feeding assembly 14 from having to pull the full or variable load of the spool 22.

Turning to FIG. 4, the wire drawing mechanism 12 also includes an adjustable wire straightener 48 that straightens the drawn wire before supplying it to the wire feeding mechanism 14. The adjustable wire straightener 48 includes bottom rollers 50 and top rollers 52 adjustably biased towards the bottom rollers 50. It is believed that this type of straightener is know in the art and will therefore not be discussed in greater details herein. Of course, the straightener can have other form allowing to straight the wire.

One skilled in the art will understand that when the motor 27 rotates the spool 22, wire is uncoiled therefrom. When this happens, the carriage 32 is biased away from the spool by the cylinder 40, keeping tension on the drawn wire.

Even though the drawing mechanism according to the first illustrated embodiment of the present invention includes a carriage 32 which provides for both the above-described tensioning and leveling functions, a drawing mechanism according to a further embodiment of the present invention can be provided with two separate mechanisms, one for the leveling function and the other for tensioning the wire drawn from the spool 22. For example, any biasing pulley appropriately mounted to the frame can be used to insure that the wire is leveled with the feeding mechanism 14. The wire straightener 48 can also play the role of such leveler.

FIG. 5 of the appended drawings illustrates the wire feeding mechanism 14 and the wire bending mechanism 16. The purpose of the wire feeding mechanism 14 is to repeatedly feed predetermined lengths of the wire to the bending mechanism 16 under control of the controller 18 to yield a coil having predetermined dimensions.

The wire feeding mechanism 14 includes an elongated wire guide 72 to guide the wire 70 from the wire drawing mechanism 14 to the wire bending mechanism 16 and a wire feeder 53. The elongated wire guide 72 includes a slot 73 configured and sized to receive the wire 70.

The wire feeder 53 includes a linearly movable table 54 actuated by an electric servo motor. For example linearly movable tables made by the company THK CO., LTD have been found suitable. The table 54 may therefore move in the directions of arrow 55 under the control of the controller 18. It is to be noted that the movable table 54 is shown at its leftmost position in FIG. 5.

A gripping arm 56 is pivotally mounted to the movable table 54. More specifically, the gripping arm 56 is fixedly mounted to a shaft 58 pivotally mounted to two pillow blocks 60 (only one shown) which are secured to the table 54.

The first end 62 of the arm 56 is further pivotally mounted to an actuator 64 that is itself pivotally mounted to the table 54. Accordingly, the actuator 64 may pivot the arm 54 about the shaft 58 (see arrow 59 in FIG. 6).

As can be better seen from FIG. 6, the second end 66 of the arm 56 includes a friction pad 68 configured to positively and frictionally engage the wire 70 onto the wire guide 72 when the arm 56 is in the wire gripping position, shown in broken lines in FIG. 6.

One skilled in the art will understand that when the arm 56 is in the wire gripping position shown in broken line in FIG. 6 and the table 54 remains immobile, the wire 70 is prevented from moving towards the wire bending mechanism 16, allowing the wire drawing mechanism 12 to draw some wire from the spool 22 under the action of the motor 27 without feeding undesired length of wire to the wire bending mechanism 16.

Furthermore, when the arm 56 is in the wire gripping position, and the movable table 54 is moved in the direction of the wire bending mechanism 16, the wire 70 will be fed to the wire bending mechanism 16. Since the actuator of the movable table 54 is very precise, it is possible to feed precise lengths of wire to the wire bending mechanism 16.

The wire bending mechanism 16 will now be described in more detail with reference to FIG. 7. The mechanism 16 includes a wire holding assembly 74 for selectively immobilizing the wire 70 during the bending process and a wire bending assembly 76 for bending a selected portion of the wire 70.

The wire holding assembly 74 includes a bracket 78, defining a wire-receiving support, to which is mounted an actuator 80 provided with a piston 82, defining a movable friction element, that may slide through an aperture of the bracket 78. The assembly 74 also includes a channel element 84 provided with a longitudinal channel 85 configured and sized to receive the wire 70 and defining a fixed friction element, and a top plate 86 interconnecting the element 84 and the bracket 78.

The wire 70 is prevented from moving when it is frictionally engaged by the piston 82 when it is extended through the aperture of the bracket 78.

The wire holding assembly 74 may be oriented differently relatively to the wire bending assembly 76 than what is illustrated in FIG. 7. For example, the wire holding assembly 74 as illustrated in FIG. 7 could be turned upside down.

The wire bending assembly 76 includes a base 87 secured to the frame 26, a fixed roller 88 fixedly mounted to the based 87 and a pivotable roller 90 that can pivot about a pivot axis defined by the fixed roller 88. More specifically, the pivotable roller 90 is fixedly mounted to an actuator 92, which is mounted to the base 87. Both the rollers 88 and 90 include circumferential channels, respectively 89 and 91, sized to snugly receive the wire 70.

Turning now to FIGS. 8 to 20 of the appended drawings, the operation of the feeding and bending assemblies 14 and 16 will be described with reference to steps allowing to produce a single turn of the coil 132 illustrated in FIG. 21.

As will now be described in more detail, a predetermined geometry of coil is achieved by successively feeding a predetermined length of wire and then bending the wire of a predetermined angle and then repeating these two steps as necessary with a series of lengths and angles.

FIG. 8 illustrates the feeding (see arrow 94), by the wire feeding mechanism 14, of a first predetermined length of wire. This first length of the wire fed is equal to the length of the first long leg of the coil plus the length of the lead of the coil. When the precise length had been fed, the wire feeding mechanism 14 stops and the piston 82 is actuated to prevent wire movement.

Then, in FIG. 9, the pivotable roller 90 is pivoted (see arrow 96) of a first predetermined angle to yield the first bend of the coil. It is to be noted that the radius of curvature of the bend is equal to the radius of the channel of the fixed roller 88. Also, the gap between the fixed and pivotable rollers 88 and 90, including the circumferential channels 89 and 91 is such that the wire 70 is snuggly fitted between the two rollers 88 and 90, allowing for a precise bending.

In the step presented in FIG. 10, the roller 90 is returned to its resting place by the actuator 92 (see arrow 98), the piston 82 returns to its resting position and a second predetermined length of wire 70 is fed (see arrow 100) by the feeding mechanism 14. Again, when the precise length had been fed, the wire feeding mechanism 14 stops and the piston 82 is actuated to prevent wire movement. It is to be noted that this last step is similar to the step illustrated in FIG. 8, where only the second predetermined length of wire fed to the bending mechanism 14 differs from the first predetermined length of wire.

One skilled in the art will understand that the piston 82 is actuated to prevent wire movement during the bending process and returns to its resting position while wire is fed to the bending mechanism. For concision purposes, these movements of the piston 82 of the actuator 80 will not be repeated hereinbelow.

FIG. 11 illustrates the bending of the second bend of the coil. To form this second bend, the pivotable roller 90 is pivoted (see arrow 102) of a second predetermined angle. It is to be noted that while the bending radius of the second bend is the same as the bending radius of the first bend, since it is the fixed roller 88 that determines the bending radius, the angle formed by the second bend is smaller than the angle formed by the first bend since the movement of the pivotable roller 90 is greater in the second bend.

As can be seen from FIG. 12, the pivotable roller 90 returns to its original position (see arrow 104) and a third predetermined length of wire is fed (see arrow 106).

The third bend is then formed by the movement of the pivotable roller 90 (see arrow 108 in FIG. 13).

It is to be noted that the third predetermined length is equal to the second predetermined length and the third bend is identical to the first bend in order to yield a coil 132 as illustrated in FIG. 21.

Obviously, since the coil 132 is symmetrical, the sequence of operations illustrated in FIGS. 8 to 13 is repeated to form the second half of the coil 132 as will now be only briefly described with reference to FIGS. 14 to 19:

• • FIG. 14: return of the roller 90 (arrow 110); wire feeding of a fourth predetermined length (arrow 112);
  • FIG. 15: bending of the fourth bend (arrow 114);
  • FIG. 16 return of the roller 90 (arrow 116); wire feeding of a fifth predetermined length (arrow 118);
  • FIG. 17: bending of the fifth bend (arrow 120);
  • FIG. 18 return of the roller 90 (arrow 122); wire feeding of a sixth predetermined length (arrow 124); and
  • FIG. 19: bending of the sixth bend (arrow 126).

Once the sixth bend is done, a first turn of the coil is completed. The process may then be repeated a predetermined number of times to yield a coil having the predetermined number of turns. When the process is repeated to yield additional number of turns, the first predetermined length or wire fed to the bending mechanism 16 is of course less than for the first turn since no additional length has to be provided for the length of the lead of the coil.

As can be seen from FIG. 20, once the predetermined number of turns of wire is coiled, a predetermined length of wire is fed to complete the coil (arrow 130). Then, the wire may automatically or manually be cut (not shown) to yield a coil 132 illustrated in FIG. 21.

A rectangular wire coiling machine 134 according to a second illustrative embodiment of the present invention will now be described with reference to FIGS. 22 to 24. Since the machine 134 is very similar to the machine 10, and for concision purposes, only the difference between the two machines 10 and 134 will be described herein in more detail.

In addition to a wire drawing mechanism 12, a wire feeding mechanism 14, a wire bending mechanism 16, and a controller 18, the wire coiling machine 134 further comprises a wire stripping mechanism 136 and a wire cutting mechanism 138.

The wire stripping mechanism 136 is mounted to the frame 26 between the wire drawing mechanism 12 and the wire feeding mechanism 14. However, as will become more apparent upon reading the following, the wire stripping mechanism 136 can be located anywhere downstream from the spool 22 and upstream from the wire cutting mechanism 138. Of course, the wire stripping mechanism 136 is also operatively position relatively to the wire.

The wire stripping mechanism 136 will now be described in more detail with reference to FIGS. 25 to 29.

The wire stripping mechanism 136 includes two opposite stripper claws 138 mounted to a common stripper claw actuating mechanism 140 which is slidably mounted to a frame member in the form of a beam 141, two grater fingers 142, each one mounted to a respective stripper claw 138, a wire clamping mechanism 144 secured to the beam 141, a linear actuator 146 for selectively moving the stripper claw actuating mechanism 140 along the beam 141 and a vacuum (not shown).

The beam 141 is parallel to the elongated wire guide 72 of the wire feeding mechanism 14.

Each stripper claw 138 is pivotally mounted to a mounting assembly 148 part of the stripper claw actuating mechanism 140 via respective interlocking gears 150 for pivotal movement in unison between a resting position and a wire engaging position. The stripper claws 138 are positioned relative to the wire feeding path so as to be symmetrically facing each other relative to the wire 70. Each stripper claw 138 includes a cutting edge 139 at its distal end.

The stripper claw actuating mechanism 140 further includes a lever arm 152 integrally mounted to one of the two stripper claws 138 and an actuator, in the form of a cylinder 154, operatively coupled to the lever arm 152. More specifically, the distal end 156 of the lever arm 152 is pivotally mounted to the piston 158 of the cylinder 154. The cylinder 154 is mounted to the mounting assembly 148 via an L-shaped bracket 160.

As can be better seen from FIG. 26, the stripper claw actuating mechanism 140 is slidably mounted to the beam 141 via sliding elements 162 and 164 secured to the beam 141 and an L-shaped bracket 166 securing the mounting assembly 148 to the sliding element 164.

The linear actuator 146 includes a cylinder 167 whose piston 168 is coupled to the sliding element 164 for selectively causing reciprocal relative movement of the sliding elements 162-164. More specifically, the piston 168 is fixedly mounted to the first longitudinal end 170 of an elongated plate 172, the second longitudinal end of which being secured to the sliding element 164 via a length-adjustable bolt 174. Two mechanical stops 176-178 are secured to the beam 141 for limiting the course of the stripper claw actuating mechanism 140 along the beam 141.

Each grater finger 142 includes a blade 180 at its distal end. Each grater finger 142 is mounted to a respective stripper claw 138 so that its blade 180 is leveled with the cutting edge 139 of the stripper claw 138 when the stripper claws 138 are in the wire engaging position.

The wire clamping mechanism 144 includes a first friction plate 182 fixedly mounted to the beam 141, and a second friction plate 184 for selectively abutting against the first friction plate 182 by mean of a clamping actuator assembly 186. The clamping actuator assembly 186 includes a cylinder 188 mounted to the beam 141 via a mounting bracket 190. The piston 192 of the cylinder 188 is coupled to the second friction plate 184 via an adjustable-length assembly 194. Since such adjustable-length assembly is believed to be within the reach of a person skilled in the art, and for concision purposes, it will not be described herein in more detail.

The stripper claw actuating mechanism 136, the wire clamping mechanism 144, and the linear actuator 146 are all controlled by the controller 18.

The operation of the wire stripping mechanism 136 will now be described in more detail with reference to FIGS. 27-30.

FIG. 27 illustrates the wire stripping mechanism 136 in a resting position with a wire 70 passing between its stripper claws 138. According to this position, the cylinder 154 of the stripper claw actuating mechanism 140 is fully extended, the claws 138 are apart from one another, and the cylinders 167 and 192 of respectively the linear actuator 146 and the wire clamping mechanism 144 are fully retracted.

When the controller 18 detects the position where the wire 70 is to be stripped (FIG. 28), the wire clamping mechanism 144 is actuated causing the second friction plate 184 to move towards the first friction plate 182 until it comes into contact with therewith (see arrow 196) thereby clamping and immobilizing the wire 70.

The stripper claw actuating mechanism 140 is also actuated, resulting in the retraction of the piston of the cylinder 154 (see arrow 198). This raises the lever arm 152, closing together and onto the wire 70 the two stripper claws 138 (see arrow 200).

Turning now to FIGS. 29 and 30, the linear actuator 146 is energized, causing the extension of the cylinder 167 (see arrow 202) which causes the displacement of the wire clamping mechanism 144 and therefore of the stripper claws 138 with the finger graters 142 attached thereto (see arrow 204). The linear displacement is done over a predetermined length of wire 70 so as to strip the corresponding length of wire 70. The finger graters 142, being positioned behind the claws relative to the stripping movement, allow removing any residual sheath and core materials 206 resulting from the stripping process. Moreover, the vacuum (see in broken line in FIG. 29) allows the removal of the residue.

It is to be noted that, since the controller 18 precisely controls the operation of the wire drawing mechanism 12, of the wire feeding mechanism 14, and of the wire bending mechanism 18, and their relative positions, it can easily determine the relative position of where the wire 70 should be stripped.

Following this step, the wire stripping mechanism 136 returns to its resting position of FIG. 27.

Different mounting arrangements can be provided for the different components of the wire stripping mechanism 136 without departing from the spirit and nature of the present invention.

The stripper claws 138 can take other forms allowing to precisely cutting a thin layer of the wire 70. Also, a wire stripping mechanism according to the present invention is not limited to rectangular wires. Of course, the stripper claws can be adapted to strip wires having other geometries.

The stripper claw actuating mechanism can take other form allowing selectively bringing together and apart the two stripper claws 138. Furthermore, the two stripper claws 138 need not to be mounted on a common actuating mechanism or be movable by a common linear actuator. Indeed, separate mechanisms can be provided therefore.

The claws 138 can be so configured and sized as to either partially or totally strip the wire 70 over its periphery.

Returning briefly to FIGS. 22-24, the wire cutting mechanism 138 is mounted to the frame 26 adjacent the wire bending mechanism 16.

Turning now to FIGS. 31 to 34, the wire cutting mechanism 138 will now be described in more detail.

The wire cutting mechanism 138 includes a cutter 208 which is mounted to the frame 26 so as to be movable between a retracted position relative to the wire bending mechanism 16 and an extended position for cutting the wire 70. The cutter 208 includes jaw cutting elements 209 operable from the controller 18. It is to be noted that the wire cutting mechanism 138 is so configured and positioned relatively to the wire bending mechanism 16 so that the cutting elements 209 of the cutter 208 intersect the axis defined by the channel of the channel element 84 of the wire bending mechanism 16, and therefore the path of the wire 70, when the wire cutting mechanism 138 is in its extended position.

The cutter 208 is pivotally mounted to a support bracket 210, which is slidably mounted to a frame member 212 via sliding elements 214-216. More precisely, the cutter 208 is fixedly mounted to a post 218. The post 218 is pivotably mounted to the support bracket 210 via a pivot pin 220. A first cylinder 222, having its proximate end 224 mounted to the support bracket 210 and whose piston 228 is pivotally mounted to the post 218, allows pivoting the cutter 208. A second cylinder 230 secured to the frame member 212 allows for translating the support bracket 210 along the frame member 212. The first and second cylinders 222 and 230 are controlled by the controller 18.

The operation of the wire cutting mechanism 138 will now be described with reference to FIGS. 33 and 34.

The wire cutting mechanism 138 is initially in its retracted position relative to the wire bending mechanism 16 as illustrated in solid line in FIGS. 33 and 34. While in this position, the top of the cutter 208 is lower than the elongated wire guide 73 and more generally to the level of the wire 70 so as to yield a clearance for the operation of the wire bending mechanism 16. The relative position of the cutter 208 and the wire bending mechanism 16 can be better seen from FIG. 24.

When a full cycle of the wire bending mechanism 16 is completed and a coil 132 is fully formed (see in broken line in FIG. 34) the second cylinder 230 of the wire cutting mechanism 138 is first actuated so as to raise the cutter 208 (see arrow 232) and then the first cylinder is actuated so as to pivot the cutter 208 towards the coil 132 (see arrow 234). The cutting elements 209 then close to cut the wire 70 (see arrow 236 and in broken line in FIG. 33). The wire cutting mechanism 138 then returns to its retracted position illustrated in FIGS. 24 and 31).

As can be better seen from FIG. 34, the cutter 208 is further so positioned relatively to the axis defined by the path of the wire 70 as to define an angle therewith. This allows positioning the cutting elements 209 perpendicularly to said axis.

The wire cutting assembly 138 can be either mounted to the frame 26 or provided with its own independent support structure (not shown). The same can also be said to wire drawing mechanism 12, wire feeding mechanism 14, wire bending mechanism 16, controller 18 and wire stripping mechanism 136.

One skilled in the art will understand that the machines described herein may easily be adapted to bend different sizes of rectangular wires by changing the dimensions of the various pieces in contact with the wire.

Similarly, the shape and dimensions of the coil may easily be adjusted by modifying the bending angles and feeding lengths via the interface 19 of the controller 18.

Even though a wire coiling machine according to the present invention has been described with reference to a rectangular wire, it is believed to be within the reach of a person skilled in the art to use the present teaching to adapt the coiling machine 10 or 134 for a wire having a different geometry.

Also, as will easily be understood by one skilled in the art, even though the actuators discussed hereinabove are pneumatic actuators, other technologies such as hydraulic or electric could be used.

Even though both, the wire coiling machines 10 and 134 have been described as having a single controller 18 controlling the operation of the wire drawing mechanism 12, wire feeding mechanism 14, wire bending mechanism 16, wire splitting mechanism 136 and wire cutting mechanism 138, a plurality of controllers (not shown) can be used to control their operation, wherein either a central controller (not shown) is used to coordinate their operation or a communication protocol is used therefore.

Finally, one skilled in the art will understand that even though a wire bending machine including a wire drawing mechanism, a wire feeding mechanism, a wire bending mechanism, a wire cutting mechanism and a wire splitting mechanism is described herein, some of these elements could be modified or omitted.

Although the present invention has been described hereinabove by way of illustrated embodiments thereof, it can be modified, without departing from the spirit and nature of the subject invention as defined in the appended claims.

Claims

1. A wire coiling machine comprising:

a wire bending mechanism including a wire holding assembly for selectively immobilizing a wire and a wire bending assembly for bending a selected portion of said wire at an angle while said wire is immobilized by said wire holding assembly;

a wire feeding mechanism for receiving said wire from a continuous feed and for feeding a first length of said wire to said wire bending mechanism; and

a controller coupled to both said wire bending mechanism and said feeding mechanism to control operations of both said wire feeding mechanism and said wire bending mechanism for sequentially bending said wire at predetermined positions therealong so as to yield a coil of wire having a predetermined geometry.

2. A wire coiling machine as recited in claim 1, further comprising a wire drawing mechanism for receiving a spool of wire and for uncoiling said wire from said spool for supplying to said wire feeding mechanism as said continuous feed.

3. A wire coiling machine as recited in claim 2, wherein said wire drawing mechanism includes a spool shaft for receiving said spool of wire and spool driving means coupled to said spool shaft for motorizing said spool shaft; said spool driving means being further coupled to said controller for precisely unwinding said spool of wire under control of said controller.

4. A wire coiling machine as recited in 3, wherein said spool driving means includes a motor and a pulley assembly for coupling said spool shaft to said motor.

5. A wire coiling machine as recited in claim 3, wherein said wire drawing mechanism further includes a self-tensioning assembly located downstream from said shaft and upstream from said wire feeding mechanism for supplying a predetermined second length of wire to said wire feeding assembly at a generally constant tension; said self-tensioning assembly being coupled to said controller so as to be controllable thereby.

6. A wire coiling machine as recited in claim 5, wherein said spool shaft is mounted to a frame; said self-tensioning assembly including a carriage mounted to said frame for longitudinal movement relative to said spool shaft, and a cylinder mounted to both said spool shaft and said carriage in a closed circuit for biasing said carriage from said spool shaft to keep said generally constant tension onto said uncoiled wire; said carriage being further for receiving uncoiled wire from said spool and for supplying said uncoiled wire to said wire feeding mechanism.

7. A wire coiling machine as recited in claim 6, wherein said wire drawing mechanism further comprises limit switches coupled to said controller for supplying positions of said carriage to said controller.

8. A wire coiling machine as recited in claim 6, wherein said wire feeding mechanism includes an elongated wire guide to guide said wire from said wire drawing mechanism to said wire bending mechanism; said carriage being configured and positioned relative to said elongated wire guide so as to supply said uncoiled wire levelled with said elongated wire guide.

9. A wire coiling machine as recited in claim 2, wherein said wire drawing mechanism further includes a wire straightener to straighten said wire from said spool, yielding a straightened wire and for supplying said straightened wire to said wire feeding mechanism.

10. A wire coiling machine as recited in claim 1, wherein said wire feeding mechanism includes an elongated wire guide to guide said wire from said continuous feed to said wire bending mechanism.

11. A wire coiling machine as recited in claim 10, wherein said elongated wire guide includes a slot for receiving said wire.

12. A wire coiling machine as recited in claim 10, wherein said wire feeding mechanism further includes a table movable along said elongated wire guide and a gripping arm mounted to said table and being movable between a resting position and a wire gripping position wherein said gripping arm grips said wire onto said elongated wire guide; both said table and said gripper arm being coupled to said controller so as to be controllable thereby; whereby, in operation, said wire feeding mechanism feeding a second length of wire to said wire bending mechanism includes i) said continuous feed being stopped, ii) said gripping arm gripping said wire onto said elongated wire guide, and iii) said table moving towards said wire bending mechanism from a distance corresponding to said second length.

13. A wire coiling mechanism as recited in claim 12, wherein said gripping arm includes a first end provided with a friction pad for engaging said wire onto said elongated wire guide and a second end; said gripping arm being pivotally mounted to said table through an intermediary point defining a fulcrum between said first and second ends; said gripping arm further comprising an actuator mounting said second end to said table for causing said gripping arm to pivot about said fulcrum between said resting position and said wire gripping position; said actuator being coupled to said controller so as to be controllable thereby.

14. A wire coiling machine as recited in claim 1, wherein said wire holding assembly includes i) a wire-receiving support, having an aperture, for receiving said wire from said wire feeding mechanism, ii) a fixed friction element mounted to said wire-receiving support on one side thereof, and iii) a movable friction element for selectively bring into engagement therewith through said aperture said wire in said wire-receiving support and said fixed friction element.

15. A wire coiling machine as recited in claim 1, wherein said wire bending assembly includes a base, a fixed roller mounted to said base, and a pivotable roller mounted to said base so as to pivot about said fixed roller.

16. A wire coiling machine as recited in claim 15, wherein said pivotable roller is fixedly mounted to an actuator which is pivotally mounted to said base.

17. A wire coiling machine as recited in claim 15, wherein both said fixed and pivotable rollers include a circumferential channel sized to snugly receive said wire; said fixed and pivotable rollers being so distanced so as to snugly receive said wire therebetween.

18. A wire coiling machine as recited in claim 1, further comprising a wire stripping mechanism to strip a second length of said wire from said continuous feed.

19. A wire coiling machine as recited in claim 18, wherein said wire stripping mechanism is coupled to said controller so as to be controllable thereby; said second length being determined by said controller.

20. A wire coiling machine as recited in claim 18, wherein said wire stripping mechanism further includes at least one stripper claw, a stripper claw actuating mechanism for moving said at least one stripper claw between a resting position relative to said wire to a wire engaging position, a wire clamping mechanism for selectively immobilizing said wire, and a linear actuator for moving said at least one stripper claw along said wire for said second length while said wire is immobilized by said wire clamping mechanism; said stripper claw actuating mechanism, said wire clamping mechanism and said linear actuator being coupled to said controller so as to be controllable thereby.

21. A wire coiling machine as recited in claim 20, wherein said at least one stripper claw includes a cutting edge; said wire stripping mechanism further includes at least one grater finger including a blade and being so mounted to a respective one of said at least one stripper claw that said blade and said cutting edge are levelled when said wire stripping mechanism is in said wire engaging position.

22. A wire coiling machine as recited in claim 20, wherein said wire stripping mechanism further includes a mounting assembly for mounting said at least one stripper claw to said stripper claw actuating mechanism and at least one lever arm for pivotally mounting a respective one of said at least one stripper claw to said mounting assembly; said stripper claw actuating mechanism including a first cylinder secured to said mounting assembly, being operatively coupled to said lever arm and being coupled to said controller so as to be controllable thereby.

23. A wire coiling machine as recited in claim 20, wherein said wire stripping mechanism is mounted to a frame including a frame member positioned parallel said second length; said stripper claw actuating mechanism being slidably mounted to said frame member.

24. A wire coiling machine as recited in claim 23, wherein said linear actuator includes a second cylinder secured to said frame member and coupled to said controller so as to be controllable thereby; said second cylinder having a movable piston secured to said stripper claw actuating mechanism to allow reciprocal movement of said stripper claw actuating mechanism along said frame member.

25. A wire coiling mechanism as recited in claim 24, wherein said wire stripping mechanism further including two mechanical stops secured to said frame member to limit a course of said stripper claw actuating mechanism along said frame member.

26. A wire coiling machine as recited in claim 20, wherein said wire stripping mechanism is mounted to a frame including a frame member positioned parallel said second length; said wire clamping mechanism including a first friction plate fixedly mounted to said frame member and a second friction plate for selectively abutting against said first friction plate by mean of a clamping actuator secured to said frame and for immobilizing said wire therebetween.

27. A wire coiling machine as recited in claim 26, wherein said clamping actuator includes a cylinder coupled to said controller so as to be controllable thereby and operatively coupled to said second friction plate for allowing reciprocal movement of said second friction plate towards and away said first friction plate.

28. A wire coiling machine as recited in claim 18, wherein said wire stripping mechanism includes a vacuum for removing residue from said wire caused by said wire stripping mechanism.

29. A wire coiling machine as recited in claim 1, further comprising a wire cutting mechanism to cut said wire; said wire cutting mechanism being mounted to a frame adjacent said wire bending mechanism.

30. A wire coiling mechanism as recited in claim 29, wherein said wire cutting mechanism includes a cutter mounted to said frame so as to be movable between a retracted position relative to said wire bending mechanism and an extended position for cutting said wire; said cutter being coupled to said controller so as to be controllable thereby.

31. A wire coiling mechanism as recited in claim 30, wherein said cutter is fixedly mounted to a post; said post being pivotally mounted to a support bracket; said support bracket being slidably mounted to a frame member of said frame; said wire cutting assembly further including a first cylinder fixedly mounted to said frame member for selectively sliding said support bracket along said frame member towards and away said wire bending mechanism, and a second cylinder secured to said support bracket and having a movable piston secured to said post for selectively pivoting said post towards and away said wire bending mechanism; both said first and second cylinders being coupled to said controller so as to be controllable thereby.

32. A wire coiling machine as recited in claim 1, wherein said controller includes a first controller coupled to said wire feeding mechanism for controlling said operation of said wire feeding mechanism, and a second controller coupled to said wire bending mechanism and to said wire feeding mechanism for controlling said operation of said wire bending mechanism.

33. A wire coiling machine as recited in claim 1, wherein said wire is a semi-rigid wire.

34. A wire coiling machine as recited in claim 1, wherein said wire is a rectangular wire.

35. A wire coiling machine comprising:

a wire bending mechanism including a wire holding assembly for selectively immobilizing a wire and a wire bending assembly for bending a selected portion of said wire while said wire is immobilized by said wire holding assembly;

a wire feeding mechanism for receiving said wire from a continuous feed and for feeding said wire to said wire bending mechanism; and

a controller coupled to said wire feeding mechanism and said wire bending mechanism for controlling operations of both said wire feeding mechanism and said wire bending mechanism to form a coil of wire having a geometry characterized by a sequence of lengths of wire and intermediary angles of bends; said controller being configured to control said wire feeding mechanism to sequentially feed said sequence of lengths of wire to said wire bending mechanism, and, between two sequential feeds of lengths of wire, to control said wire bending mechanism to bend said wire of a corresponding intermediary angle.

36. A wire coiling machine comprising:

a wire bending mechanism including a wire holding assembly for selectively immobilizing a wire and a wire bending assembly for bending a selected portion of said wire at an angle while said wire is immobilized by said wire holding assembly;

a wire feeding mechanism for receiving said wire from a continuous feed and feeding a length of said wire to said wire bending mechanism; and

a controller coupled to said wire feeding mechanism and to said wire bending mechanism for controlling said wire bending mechanism and said wire feeding mechanism according to a predetermined sequence so as to yield a coil of wire having a predetermined geometry characterized by a sequence of lengths of wire and intermediary angles of bends.

37. A wire coiling machine comprising:

wire immobilizing means for selectively immobilizing a wire;

wire bending means for bending a selected portion of said wire at an angle while said wire is immobilized by said wire immobilizing means;

wire feeding means for receiving said wire from a continuous feed and for feeding a length of said wire to said wire bending means; and

controlling means coupled to said wire immobilizing means, said wire bending means and said wire feeding means; said controlling means being configured to control operations of both said wire feeding mechanism and said wire bending mechanism for sequentially bending said wire at predetermined positions along its length so as to yield a coil of wire having a predetermined geometry.