Apparatus and method for winding coil
阅读说明:本技术 用于缠绕线圈的装置和方法 (Apparatus and method for winding coil ) 是由 F.W.科楚尔 于 2018-05-17 设计创作,主要内容包括:一种用于缠绕丝状材料的装置,包括可绕主轴旋转轴线旋转的心轴和相对于主轴轴线在一定距离处往复运动的导线器,从而以8字形线圈配置缠绕丝状材料,其中放线孔从线圈的内绕组径向延伸到外绕组。该装置包括测量设备和控制器,测量设备用于在线圈缠绕在心轴上时测量线圈的直径,控制器用于基于测量的线圈直径控制导线器相对于心轴旋转的往复移动。测量设备可以包括第一传感器和第二传感器,第一传感器被配置为测量围绕心轴缠绕的丝状材料的长度,第二传感器被配置为在围绕所述心轴缠绕所述长度的丝状材料期间测量所述心轴的角位移。(An apparatus for winding filamentary material comprising a spindle rotatable about a spindle axis of rotation and a wire guide reciprocating at a distance relative to the spindle axis to wind filamentary material in a figure-8 coil configuration with a wire discharge aperture extending radially from an inner winding to an outer winding of the coil. The apparatus includes a measuring device for measuring a diameter of the coil as the coil is wound on the mandrel, and a controller for controlling the reciprocating movement of the wire guide in rotation relative to the mandrel based on the measured diameter of the coil. The measuring device may include a first sensor configured to measure a length of filamentary material wound around a mandrel and a second sensor configured to measure an angular displacement of the mandrel during winding of the length of filamentary material around the mandrel.)
1. A device for winding filamentary material comprising:
a mandrel rotatable about a spindle axis of rotation and a wire guide reciprocating at a distance relative to the spindle axis to wind the filamentary material in a figure-8 coil configuration with a wire discharge hole extending radially from an inner winding to an outer winding of the coil;
a measuring device for measuring a diameter of the coil as the coil is wound around the mandrel, the measuring device comprising a first sensor configured to measure a length of filamentary material wound around the mandrel and a second sensor configured to measure an angular displacement of the mandrel during winding of the length of filamentary material around the mandrel; and
a controller for controlling the reciprocating motion of the wire guide relative to the rotation of the mandrel based on the measured diameter of the coil to wind the coil of filamentary material in a figure-8 configuration on the mandrel to form the radial wire-releasing hole having a constant diameter.
2. The apparatus of claim 1, wherein:
the measuring device comprises a diameter determination unit for determining the diameter of the coil based on the length of filamentary material wound around the mandrel measured by the first sensor and the angular displacement of the mandrel measured by the second sensor.
3. The apparatus of claim 1, wherein:
the first sensor includes an encoder configured to generate a series of pulses corresponding to a length of filamentary material wound around the mandrel.
4. The apparatus of claim 3, wherein:
the second sensor includes an encoder configured to generate a series of pulses corresponding to the angular displacement of the mandrel.
5. The apparatus of claim 4, wherein:
the measuring device comprises a diameter determination unit for determining the diameter of the coil based on the amount of pulses generated by the second sensor between two consecutive pulses generated by the first sensor.
6. The apparatus of claim 5, wherein:
the amount of pulses generated by the second sensor is a running average of the number of degrees subtended by the length of filamentary material between two successive pulses generated by the first sensor.
7. The apparatus of claim 1, wherein:
the controller is configured to control the wire guide to wind the wire material around the mandrel in the coils in a figure-8 configuration and form the radial wire holes having a straight configuration.
8. The apparatus of claim 1, wherein:
the controller is configured to control the wire guides such that the number of figure-8's in each layer of the coil increases from an inner layer of the coil to an outer layer of the coil.
9. The apparatus of claim 8, wherein:
the number of 8-shapes in each layer increases linearly from the inner layer to the outer layer of the coil.
10. The apparatus of claim 9, wherein:
the number of 8-shapes in each layer increases non-linearly from the inner layer to the outer layer of the coil.
11. A method of winding a filamentary material on a mandrel rotatable about a spindle axis of rotation and a wire guide reciprocating at a distance relative to the spindle axis to wind the filamentary material in a figure-8 coil configuration with radial wire release holes extending radially from an inner winding to an outer winding of the coil, the method comprising:
controlling rotation of the mandrel about the spindle axis of rotation to wind filamentary material around the mandrel;
measuring the diameter of the coil as the filamentary material is wound around the mandrel; and
controlling the reciprocating motion of the wire guide relative to the rotation of the mandrel based on the measured value of the diameter to wind the filamentary material on the mandrel to form the radial wire hole having a constant diameter.
12. The method of claim 11, wherein:
the measuring the diameter of the coil comprises:
measuring the length of filamentary material wound around the mandrel; and
measuring an angular displacement of the mandrel during winding of the length of filamentary material around the mandrel.
13. The method of claim 12, wherein:
the measuring the diameter of the coil includes determining the diameter of the coil based on the measured length of the filamentary material wound around the mandrel and the angular displacement of the mandrel measured during winding of the length of filamentary material around the mandrel.
14. The method of claim 11, wherein:
said controlling reciprocation of said wire guide comprises winding said coil of said filamentary material in a figure-8 configuration around said mandrel to form said radial wire-release aperture having a straight configuration.
15. The method of claim 11, wherein:
said controlling reciprocation of said wire guide comprises winding said coils of said filamentary material in a figure-8 configuration on said mandrel such that the number of figures-8 in each layer of the coil increases from an inner layer to an outer layer of the coil.
16. The method of claim 15, wherein:
the number of 8-shapes in each layer increases linearly from the inner layer to the outer layer of the coil.
17. The method of claim 15, wherein:
the number of 8-shapes in each layer increases non-linearly from the inner layer to the outer layer of the coil.
18. A device for winding filamentary material comprising:
a mandrel rotatable about a spindle axis of rotation and a wire guide reciprocating at a distance relative to the spindle axis to wind the filamentary material in a figure-8 coil configuration with a pay-off hole extending radially from an inner winding to an outer winding of the coil;
a measuring device for measuring the diameter of the coil as it is wound around the mandrel; and
a controller for controlling the reciprocating motion of the wire guide relative to the rotation of the mandrel based on the measured diameter of the coil to wind the coil of filamentary material in a figure-8 configuration on the mandrel to form the radial wire-releasing hole having a constant diameter.
19. The apparatus of claim 18, wherein:
the measuring device includes a first sensor configured to measure a length of filamentary material wound around the mandrel, and the first sensor includes an encoder configured to generate a series of pulses corresponding to the length of filamentary material wound around the mandrel.
20. The apparatus of claim 19, further comprising:
a second sensor comprising an encoder configured to generate a series of pulses corresponding to an angular displacement of the mandrel during winding of the length of filamentary material.
Technical Field
The present application relates to an apparatus and method for winding coils. More particularly, the present application relates to an apparatus and method for controlling coil winding parameters.
Background
U.S. patent #2,634,922 to Taylor describes winding a flexible wire, cable or filamentary material around a mandrel in a figure 8 pattern to obtain a package of filamentary material having multiple layers surrounding a central core space. By rotating the mandrel and by controllably moving the wire guide that laterally guides the wire relative to the mandrel, the layers of the figure-8 pattern are provided with aligned holes (cumulatively "payoff holes") so that the inner end of the flexible material can be pulled through the payoff holes. When wrapping the package of wire in this manner, the wire can be unwound through the payoff hole without rotating the package, without imparting rotation (i.e., twisting) into the wire about its axis, and without kinking. This provides a great advantage to the user of the cord. A coil wound in this manner and dispensed from the inside out without twisting, tangling, snagging or over-limit is known in the art as a REELEX (trademark of REELEX packaging solutions, inc.). The REELEX-type coil is wound to form a substantially short hollow cylinder with a radial opening formed at one location in the middle of the cylinder. The pay-off tube may be located in the radial opening and the end of the wire constituting the coil may be fed through the pay-off tube for easy dispensing of the wire.
Us patent 5,470,026 describes a coil having a payout hole with a larger angular opening in a first layer and a reduced angular size in the layer wound around the inner layer, and also describes correction of the payout hole angle due to natural shifting of the coil layer during coil winding. The reduction in the size of the angle controls a parameter called "hole taper", while the correction of the angle of the payoff hole controls a parameter called "hole transfer". Previously, hole taper and hole transfer were calculated based on the predicted diameter of the coil as it was wound. The assumed or predicted diameter of the coil is based on counting the number of layers of wire laid on the winding mandrel and multiplying this number by the diameter of the wire, hereinafter referred to as the "per layer" method or scheme.
U.S. patent 7,249,726 describes another coil winding parameter known as "density". The Reelex coil is produced by radially placing a plurality of 8-patterns around the circumference of the coil using a coil parameter called "gain" or "wire guide velocity shift" or "velocity shift". For example, if a coil is produced using a speed offset that separates the 8-shapes by 30 °, then the 8-shapes will be separated by 2.094 inches on a mandrel having a diameter of 8 inches and 4.188 inches when the coil diameter reaches 16 inches. As a result, the "density" of the coils is lower in terms of the number of figure-8's in the outer (radial with respect to the center of the coil) layers of the coils. The density parameter has been used to control (i.e., reduce) the speed shift after winding each layer of the coil so that as the number of coil layers increases, an increasing number of figure-8 coils can be formed. As a result, as the coil layer count increases, the angular space between the figure-8 s decreases and the layer density after the first layer increases.
When using existing methods of winding filamentary material into a coil, each of the parameters, i.e., hole transfer, retention taper, density and wire guide speed excursion, interact. It is well known to adjust hole transfer, density and hole taper parameters after winding each layer of the coil to obtain a relatively compact coil having relatively straight (radial) pay-off holes of relatively uniform diameter. The amount of adjustment to the hole transfer, density and hole taper parameters for each layer is based on the predicted coil diameter, which is based on the diameter of the filamentary material being wound and the number of layers in the coil.
Disclosure of Invention
This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
The actual measurement of the coil diameter is derived and tracked during the coil winding process. The actual measurements of coil diameter can be used with existing functional relationships between coil diameter, velocity offset, hole transfer, density and hole taper to control the winding of the coil. However, by measuring the actual coil diameter at any point in the winding process, the determination of other winding parameters is not as commonly affected as when using predicted values of coil diameter. Thus, by measuring the actual diameter of the coil, each winding parameter can be independently varied to achieve a particular coil configuration.
According to one aspect of the present disclosure, further details of the disclosure are provided herein, an apparatus for winding filamentary material includes a spindle rotatable about a spindle axis of rotation and a wire guide reciprocating at a distance relative to the spindle axis to wind the filamentary material in a figure-8 coil configuration with a pay-off hole extending radially from an inner winding to an outer winding of the coil. The apparatus includes a measuring device for measuring a diameter of the coil as the coil is wound around the mandrel, and a controller for controlling a reciprocating motion of the wire guide relative to a rotation of the mandrel based on the measured coil diameter to wind the coil of filamentary material in an 8-shaped configuration on the mandrel to form a radial wire laying hole having a constant diameter. The measuring device includes a first sensor configured to measure a length of filamentary material wound around a mandrel and a second sensor configured to measure an angular displacement of the mandrel corresponding to the length of filamentary material wound around the mandrel.
In one embodiment, the first sensor includes an encoder configured to generate a series of pulses corresponding to the length of the filamentary material wound around the mandrel. In one embodiment, the second sensor comprises an encoder configured to generate a series of pulses corresponding to the angular displacement of the mandrel. In one embodiment, the measuring device comprises a diameter determination unit for determining the diameter of the coil based on the length of the filamentary material wound around the mandrel by the first sensor and the angular displacement of the mandrel measured by the second sensor.
In one embodiment, the controller is configured to wind the filamentary material on the mandrel in a figure-8 configuration of coils to form radial wire holes having a straight configuration. In one embodiment, the controller is configured to wind the coil of filamentary material in a figure-8 configuration on the mandrel such that the number of figures-8 in each layer of the coil increases from the inner winding of the coil to the outer winding of the coil. In one embodiment, the number of figure-8 shapes in each layer increases linearly from the inner winding of the coil to the outer winding of the coil. In one embodiment, the number of glyphs in each layer increases non-linearly from the inner winding of the coil to the outer winding of the coil.
According to another aspect, further details thereof are described herein, a method of winding filamentary material on a mandrel rotatable about a spindle axis of rotation and a wire guide reciprocated at a distance relative to the spindle axis to wind the filamentary material in a figure 8 coil configuration with radial wire release holes extending radially from an inner winding to an outer winding of the coil, the method comprising controlling rotation of the mandrel about the spindle axis of rotation to wind the filamentary material around the mandrel. Further, the method includes measuring a diameter of the coil as the filamentary material is wound around the mandrel and controlling a reciprocating motion of the wire guide relative to the rotation of the mandrel based on the measured value of the diameter to wind the filamentary material on the mandrel to form a radial payoff hole having a constant diameter.
Drawings
Fig. 1 shows a prior art coil formed with offset payoff holes.
FIG. 2 is a schematic view of a portion of an embodiment of a winding system according to one aspect of the present disclosure.
Fig. 3 illustrates, in block diagram format, an embodiment of a winding apparatus in accordance with an aspect of the present disclosure.
Figure 4 shows the relationship between the various parameters involved in creating a constant diameter payoff hole during coil winding.
FIG. 5 is a graph of relative spindle displacement versus total travel distance for any wire guide movement.
Fig. 6 illustrates a coil formed using the winding apparatus of the present disclosure, the coil having a straight wire discharge hole.
Detailed Description
Before describing the improved winding system, it is useful to understand some of the underlying theories underlying the winding system. As discussed previously, to wind the figure-8 coil, it is known to adapt the hole transfer, density, and hole taper. The amount of adjustment for each layer is based on the predicted coil diameter. However, the coil diameter is predicted based on the inaccurate assumption that the coil diameter increases linearly with each layer of the coil (assuming each layer is neatly stacked on the previous inner layer) and based only on a predictable amount of the diameter of the wire being wound. For various reasons, this assumption is inaccurate based on the configuration of the wire being wound, and because it does not hold when the above parameters deviate from a certain range where they predict the coil diameter more accurately.
For example, the properties of the wound filamentary material ("stiffness", slidability, compressibility), wire tension and wire guide speed excursions may be factors that cause deviations between the predicted and actual coil diameters. In the case of a speed shift, increasing the speed shift may result in a reduction in the number of 8-shapes wound in each layer of the coil, so that there may be open space in each layer occupied by the 8-shapes of the outer layers (i.e. in all cases the layers are not stacked neatly one on top of the other). For example, if twelve 8-shapes were wound on an 8 inch diameter mandrel in the first layer, the winding length could be calculated to be 50.27 feet (ignoring the space that would be used by the payoff holes). Based on the 12 glyphs, the space between the glyphs is 2.09 inches of the circumference (since the 12 glyphs translate to a 30 ° pitch, which corresponds to 2.09 inches of the circumference). Since the space between the figure-8 shapes is 2.09 inches, a reasonable assumption may be that the layer wound on top of this first layer may have enough ground from the first layer to allow one to assume that the next layer will be at a larger diameter equal to the sum of the mandrel diameter plus twice the diameter of the filamentary material (i.e., wire or cable). This allows the calculation that the length of product wound in the next layer will be equal to another 50.27 ft + (2. pi. 8 number. 2. filamentous diameter) ft. Thus, if the product diameter is 0.3 inch and 12 8-shapes are wound on the next layer, the next layer will be 3.77 feet (2. pi. 12. 2. 0.3/12) more than the layer immediately below it. However, if the first layer is wrapped with only five figure-8 shapes, the space between the figures-8 is more than 5 inches. This means that when the first layer is on a solid mandrel, the second layer experiences a long span between the underlying figure-8 where it is unsupported by the filamentary material and thus may be compressed inwardly as additional filamentary material is wound thereon. In this case, the third layer will not have a solid foundation because the second layer will be supported with little or no support. Furthermore, due to the variability of the support of the second and third layers, it is difficult to know the actual diameters of the second and third layers, and the uncertainty of the diameter measurement increases as additional layers are wrapped and compressed against the underlying layers.
This becomes more complicated with variations in winding wire tension and product compressibility. In fact, some filamentary materials are relatively easy to compress such that, for example, a material having a diameter that may measure, for example, 0.230 inches in the uncompressed state compresses or flattens to 0.210 inches.
The following examples illustrate the interplay of some of the coil forming parameters and the formulas used in the prior art patents cited herein. Table 1 below lists the parameters used for this example.
Diameter of mandrel
8 inch
Diameter of product
0.25 inch
Wire guide speed offset
4.0%
Pore size
90°
Length of coil
1000 feet
Table 1.
Given example parameters, based on prior art calculations, a coil diameter of about 16.36 inches (about 16 layers of wound product) would be expected. If the wire guide speed offset is doubled from 4% to 8%, the number of 8-shapes in each layer will be halved, thus requiring more layers (about 27 layers) to fully wind the entire length of filamentary material. Specifically, in this case, the prior art Reelex formula for predicting coil diameter would predict that the final coil diameter would be 21.71 inches. However, empirically, such predicted diameter size changes do not actually occur. Instead, the linear tension of the wire during winding radially compresses the coil such that the actual diameter of the coil is less than the predicted diameter.
Furthermore, since the diameter of the coil is used as an input to determine other parameters for winding the coil, these parameters may also be affected by inaccuracies in the coil diameter, resulting in a wound coil having wire holes that are not radially aligned (the wire holes may bend in a radial direction, as shown in fig. 1) and/or a coil having an unexpected size (the final diameter may be less than predicted).
Using the parameters in the example above, if the payoff hole needs to be shifted 64 ° from the beginning of a mandrel 8 inches in diameter to its completion point 16 inches in diameter, the payoff hole needs to be "corrected" or offset at a rate of about 4 ° per layer (or 16 ° per inch of coil wall). During the winding process, the winding machine transfers the completed pay-off holes (or layers) of each layer by 4 °. However, if the speed offset is doubled to 8.0%, the payoff holes will be shifted 108 ° (27 layers 4 ° per layer). While this is true for a 21 inch coil diameter, as mentioned above, this may not be true because the coil may be less than 21 inches due to linear tension. If, based on past empirical evidence, it is assumed that the diameter of the actual finished coil is 17.5 inches (instead of 21 inches), a suitable total hole transfer is approximately 76 °. However, if each layer is shifted by 4 °, this would result in shifting too far of the wire hole by about 32 °. To compensate for this excess, one trend is to use a slightly lower hole transfer value of 2.8 ° per layer on the wound 27 layers (27 layers · 2.8 ° = 75.6 °).
Furthermore, due to the compressibility of the coil, while the first layer will have the wire holes in the correct locations, the second layer will be close to the correct diameter and should have a 4 ° transition, but only a 2.8 ° transition. In contrast, the second layer may require a transfer of 3.9 ° instead of 2.8 °. At some point during the winding process, the required and actual transfer will be the same, after which the situation will reverse. If there is no transfer of the adjustment hole during winding, the payoff hole will be transferred first away from the wire guide (instead of radially) and will continue to be transferred in this manner, but less and less until the point at which the coil diameter increases at the rate of the correct amount of transfer of 2.8 °. It will then begin to tilt towards the wire guide. Thus, the coil will have a curved payout hole instead of a straight payout hole; first in the same direction of coil winding and then in the opposite direction, as shown in fig. 1.
Similar problems exist with this per layer approach when applied to hole taper. One problem associated with hole taper is that when the payout hole is made smaller, the coil diameter may decrease slightly because the area of the coil in which the wound filamentary material is placed increases. Repeating the parameters in table 1 of the above example, if it is assumed that the starting payoff hole angle size is 90 °, the opening created on the surface of the 8 inch mandrel will have a diameter of 6.28 inches and will correspond to an opening size of 12.56 inches for a coil diameter of 16 inches. If it is desired to maintain a 6.28 inch payoff hole size throughout the radial length of the payoff hole, the payoff hole angle size needs to be 45 ° when the coil diameter reaches 16 inches. However, according to theoretical calculations, the coil diameter will be reduced by about 1/2 inches. This would require a slightly larger final payoff hole angle size of 46.4 °. By applying the same reasoning for hole taper as for hole transfer and using a wire guide speed offset of 8.0%, a final payout hole angle size of approximately 34 (for a 21 inch diameter coil) can be calculated. The payoff hole angle needs to be reduced by 2.07 deg. per layer over 27 layers. However, the coil diameter will not be 21 inches-perhaps slightly closer to 17 inches (based on empirical evidence) given the reduction in diameter caused by bore taper, which means that the final payoff bore angle size should be about 42 °. The difference (8 deg.) corresponds to a pay-off hole that is about 1.18 inches smaller than the perimeter of the hole from which it would have been. Thus, when the coil diameter reaches 17 inches, a hole taper of about 1.78 ° per layer is required for a finished, properly sized wire relief hole. Thus, the use of a per-layer solution will produce a wire hole that is correct at the beginning, enlarges in the middle, and becomes smaller as the coil winding process progresses. If the effect of the hole transfer is combined with the effect of the hole taper, the result is that the side of the hole closest to the wire guide may start straight, then bend away from the wire guide and return again. The other side of the payout hole will slope further outward away from the wire guide and then back in the outer layer.
In the above example, the wire guide speed excursion remains constant throughout the coil winding process, which means that the radial spacing between each figure 8 is the same between the layers. The density parameter is related to the wire guide speed offset because the density parameter effectively adjusts (e.g., decreases) the wire guide speed offset on a per layer basis of the coil, thus decreasing the radial spacing between the figure-8 s as the number of coil layers increases during winding. The result is that more filamentary material is wound per pass, not only because the coil diameter is larger for each layer, but also because the number of figure-8 shapes increases as the coil diameter grows. Thus, the coils are more "dense" than if the wire guide speed offset was kept constant during winding. One effect of making the coil denser is that it reduces the number of layers required to complete the coil and thus reduces the coil diameter, which in turn changes the above-described Reelex calculation for hole transfer and hole taper. Further, the coil grows faster in the inner layer and slower as the diameter of the coil grows.
The prior density embodiments have limitations in that the wire guide speed offset decreases with each layer in proportion to a constant factor. This problem is as follows. As described in patent # 7,249,726, for a 3.0% wire guide offset speed, the number of glyphs that would be distributed radially around the coils of the first layer would be 16.67 (1/(2.3%/100). for this explanation, the amount of filamentary material used around the payoff hole would be ignored, since for this analysis, only the spacing between the glyphs around the circumference of the coil (or mandrel) in degrees is of interest. if a 0.2% density factor is applied to the wire guide speed offset, the second layer would be produced using a 2.8% (3% -0.2%) wire guide speed offset, which produces a second layer having 17.8571 glyphs, the number of glyphs per layer would vary as follows, 19.23, 20.83, 22.73, 25.00, 27.78, 31.25, 35.71, 41.67, 50.00, 62.50, 83.33.33, if the wire guide speed offset were continuously reduced in the same manner by a density factor of 0.06, 125.00 and 250.00.
Thus, as the number of layers increases, a small change of 0.2% in velocity shift caused by a density factor of 0.2% has a greater effect on the number of glyphs in each layer. For example, by layer 15, the machine will use only 0.2% of the wire guide speed offset and will attempt to place 250 glyphs in that layer. In addition, for the sixteenth layer, the equation of 8-shape becomes undefined (denominator becomes zero). Therefore, the method of controlling the density by decreasing the velocity shift of each layer by a constant may generate a runaway situation in the calculation. The most obvious inconsistencies can be seen in the example of layer 15 above. There are 250 glyphs in this layer (assuming a 15 inch coil diameter), and the amount of material wound in this layer alone is almost 2000 feet, which is meaningless because the calculations made in these examples are for a 1000 foot coil.
These problems and deficiencies are overcome with the
The
The encoder 33 is connected to the
While the measurement of the coil diameter is more accurate than predicting the coil diameter based on the coil layer and the filamentary material diameter, the measurement may still have limited inaccuracies due to the details of the winding system, as described in more detail below.
For example, due to the reciprocating motion of the
The operation of the
Another factor that can affect the accuracy of the coil diameter measurement is that the
Once the coil diameter is measured (and/or scaled) as described herein, the coil diameter can be used to calculate and update the above parameters hole transfer, hole taper, and density. For example, in U.S. patent 5,470,026, the entire contents of which are incorporated herein by reference, the coil diameter (D) is a variable in the following formula to determine the pay-off hole diameter and the hole angle "a" between the wound material and the coil centerline at the pay-off hole. However, rather than predicting the coil diameter based on coil layer and filamentary material diameter (per layer approach) as done previously, the hole angle "a" may be determined continuously based on real-time (running average) measurements of the coil diameter.
Since the diameter of the coil is known using the above method, the following equation can be solved as a system of equations for determining the angle "a", wherein the following variables and constants are used in the equations and are shown with reference to the payoff holes shown in fig. 4.
P0
Initial stringing hole size
P
Size of wire releasing hole
MW
Width of mandrel
D
Mandrel/coil diameter
W
Width of wire hole
w
W/2
r
Radius of the discharge pipe
L
Length of wire releasing hole
H
L/2
a
Angle between wound filamentary material and coil centerline at payoff hole
In one embodiment, it is assumed that the wire guide output is sinusoidal, so that the coil pattern is also sinusoidal. The sinusoidal displacement is shown in fig. 5 and is defined by the following equation:
wherein Y iscIs defined as the displacement of the wire guide relative to the center position of the wire guide and x is defined as the cumulative displacement of the wire guide for the figure 8.
Wherein
And
so that when x = 0, equation (4) reduces to
Further, if the length of the payoff hole (L) on the coil surface is known, and the coil diameter is determined according to the methods described herein, the payoff hole angle P can be calculated from the following equation,
the remaining equations of the system include:
。
equation (8) shows the pay-off hole angle size (P), mandrel width (M)w) The coil diameter (D) and the radius (r) of the payoff tube. The coil diameter (D) used in equation (8) is measured according to the methods described herein. Using equation (8), the pay-off hole angle size (P) can be calculated continuously throughout the winding process.
In one embodiment, the payoff hole opening size (L) remains constant throughout the length of the payoff hole. The following example method may be used to form a coil having a constant aperture opening size. If an 8 inch diameter mandrel is used and the wire hole angle size is ninety (90) degrees, the opening (L) on the mandrel surface would be 6.28 inches. As described above, to produce a payoff hole of substantially uniform diameter, the payoff hole angle magnitude is reduced for each layer of the coil according to the calculated coil diameter of the process. By way of example, if the next layer diameter is determined to be 8.55 inches, the corresponding hole angle size required to maintain a 6.28 inch opening would be 84.2 degrees ((360 · 6.28)/(8.55 · pi)) according to equation (6). Furthermore, if the next measured diameter is 9.04 inches, the pay-off hole angle size will be reduced to 79.6 degrees ((360 · 6.28)/(9.04 · 3.14)) and so on.
The density of the coils can also be increased by accurately determining the coil diameter as described herein. As mentioned above, a common use of the density parameter is to keep the spacing between the figure-8 s substantially constant in each layer of the coil. Existing coil winding methods are not practical to achieve due to inaccuracies in predicting coil diameters based on the number of coil layers and the diameter of the filamentary material. The wire guide speed offset is typically specified by two parameters, an upper speed offset (also referred to as an "upper ratio" and a "positive advance") and a lower speed offset (also referred to as a "lower ratio" and a "negative advance"). The coil winding process uses an upper speed offset when winding the first layer (and odd layers) of the coil and a lower speed offset when winding the second layer (and even layers) of the coil.
The following example illustrates the use of an upper velocity offset and a lower velocity offset. The spacing between the 8-shapes in any layer of the coil can be calculated by the following equation:
pitch =2 speed offset percent/100. D. pi (10)
In this example, the upper speed offset is set to 3.5% and the lower speed offset is set to 3.2%. Further, for purposes of this example, assume that the mandrel has a diameter of 8 inches, and the circumference and diameter of the coil is calculated approximately 100 times per second. Thus, for the first layer of coils, the spacing between the figure-8 s (e.g., in inches) is calculated based on the calculated coil/mandrel diameter and the 3.5% initial upper velocity offset. In this example, the spacing between glyphs is calculated to be 1.76 (2 · (3.5%/100) · 8 inches · pi). For the second layer, when the process switches to the lower speed shift, the same calculation (e.g., equation (10)) is repeated, but the updated coil diameter is larger than the diameter used in the previous calculation (i.e., the initial diameter is equal to the mandrel diameter) because the first layer is in place and the second layer is wound on top of it. In this example, if the diameter of the second layer is determined to be 8.46 inches, the spacing between the 8-shapes is 1.70 inches (2 · 3.2%/100 · 8.46 inches · pi). For the third layer in this example, the coil diameter may be calculated to be 8.92 inches. If the spacing between the 8-shapes is maintained at 1.76 inches, then the upper velocity offset must change from 3.5% to 3.1% (1.76 inches/2 · 8.92 inches · pi · 100) based on solving equation (10) for velocity offset. Table 2 below lists the offsets, the 8-pattern spacing, and the number of 8-patterns per layer.
Layer(s)
Offset (%)
8-shaped interval (inch)
Number of 8-shaped
1
3.5
1.76
14.28
2
3.2
1.70
15.63
3
3.14
1.74
15.92
4
2.88
1.71
17.33
5
2.85
1.79
17.56
6
2.63
1.68
19.03
7
2.60
1.76
19.21
8
2.41
1.69
20.73
9
2.40
1.76
20.85
10
2.23
1.68
22.43
11
2.22
1.74
22.49
12
2.07
1.72
24.13
Table 2.
The coil formed using the example dimensions shown in fig. 6 has a straight (radial)
While a constant diameter of the payoff hole and a constant figure-of-8 spacing are typically required when winding the coil, there may be situations where it may be desirable to produce coils with different parameters. For example, it is well known that some high speed data transmission cables may suffer from wire wrap (which suffers from transmission characteristics). More specifically, with regard to the Reelex coil, it is known that even if the wire guide speed offset is set to a value within the "normal" range of non-signaling cables of similar diameter, such damage may result. When the cable is wound, it will bend slightly at the intersection of the figure 8. If there are too many figure-8's radially distributed around the circumference of the coil, the close proximity of the crossing points causes a more severe bending of the cable, which may damage the cable. Thus, most of the damage occurs on the first inner layer of the wound cable. One solution to this problem is to use a constant, very high wire guide speed excursion throughout the coil winding process. This solution results in a coil that is larger than when the wire guide speed excursion is lower. However, by accurately knowing the diameter of the coil using the methods and apparatus described herein, the wire guide speed offset can be changed from a higher value when winding the inner layer to a lower value when winding the outer layer, thereby protecting the inner layer from excessive bending without producing a coil having a diameter as large as a prior art coil of the same length that was wound using a uniform, larger wire guide speed offset. Furthermore, this can be achieved without affecting the hole taper or hole transfer.
In one example, a predetermined wire guide speed shift versus coil diameter distribution may be used to produce a coil with very high spacing between the inner windings or figures-8 of the inner layer of the coil and reduced spacing between the outer windings or figures-8 of the outer layer of the coil. Such a distribution relationship may be implemented as a look-up table or as a functional relationship to facilitate computer implementation. An example of a method of calculating the velocity offset versus the coil diameter is as follows. Assume that the inner layer requires a velocity excursion of 8% and that the velocity excursion will decrease proportionally with the coil diameter until the coil reaches 13 inches. After reaching 13 inches, the coils will have a constant figure-8 spacing of 1.76 inches. The velocity offset between coil diameters of 0 to 13 inches is formulated as:
velocity offset = 6.2 · (13-D)/5 +1.8 (11)
Then, for diameters greater than 13 inches, a method of calculating the velocity offset based on the constant spacing between the glyphs as described herein above can be implemented. Therefore, the density distribution relationship (% layer vs. velocity shift) can be shown in table 3 below.
Layer(s)
Velocity offset%
1
8
2
7.4
3
6.9
4
5.7
5
5.1
6
4.6
7
4
8
3.4
9
2.9
10
2.3
11
2.2
12
2.1
13
2.1
14
2.0
Table 3.
With respect to the schematic block diagram of the winding
The controller 30 reads the position of the
Controller 30 receives input of the respective positions of the thread guide motor 38 and the spindle motor via
In one aspect, the winding
Further, it should be understood that the term "controller" should not be construed to limit the embodiments disclosed herein to any particular device type or system. The controller may include a computer system. The computer system may also include a computer processor (e.g., a microprocessor, microcontroller, digital signal processor, or general purpose computer) for performing any of the above-described methods and processes.
The computer system may also include memory, such as a semiconductor memory device (e.g., RAM, ROM, PROM, EEPROM, or flash programmable RAM), a magnetic memory device (e.g., floppy or fixed disk), an optical memory device (e.g., CD-ROM), a PC card (e.g., PCMCIA card), or other memory device. The memory may be used to store data from, for example, the transmitted light signal, the relative light signal, and the output pressure signal.
As listed above, some of the methods and processes described above may be implemented as computer program logic for use with a computer processor. The computer program logic may be implemented in various forms, including source code form or computer executable form. The source code may include a series of computer program instructions in various programming languages, such as object code, assembly language, or a high-level language, such as C, C + + or JAVA. Such computer instructions may be stored in a non-transitory computer readable medium (e.g., memory) and executed by a computer processor. The computer instructions may be distributed in any form as a removable storage medium with accompanying printed or electronic documentation, such as packaged software, preloaded with a computer system, e.g., on system ROM or fixed disk, or distributed from a server or electronic bulletin board over the communication system, e.g., the internet or world wide web.
The controller may include discrete electronic components coupled to a printed circuit board, an integrated circuit (e.g., an Application Specific Integrated Circuit (ASIC)), and/or a programmable logic device (e.g., a Field Programmable Gate Array (FPGA)). Any of the above methods and processes may be implemented using such logic devices.
Several embodiments of an apparatus and method for winding filamentary material into a coil have been described and illustrated herein. While specific embodiments have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. Thus, while a particular type of apparatus has been disclosed for determining the length of filamentary material wound on a mandrel during winding, it should be understood that other length counting apparatus may be used. Accordingly, it will be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.
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