阅读说明：本技术 卷绕和切割线或线缆的设备和方法 (Apparatus and method for winding and cutting wire or cable ) 是由 S.W.科楚尔 于 2018-03-19 设计创作，主要内容包括：一种用于卷绕线的系统,包括线收紧单元和线切割器/抓取器单元。收紧单元包括可旋转的第一和第二心轴部分以及线导向横动件,该线导向横动件被布置成馈送线并在第一和第二心轴部分上交替地形成线圈。切割器/抓取器单元被构造成在横动件和形成在第一心轴部分上的线圈之间的切割位置处切割线,并且抓取所切割的线的自由端并沿着预定的切割器/抓取器路径移动到移交位置,在移交位置线处,线被转移到第二心轴部分。当切割器/抓取器沿着路径从切割位置移动到移交位置时,横动件和线的自由端之间的线长度不减小,并且线长度在移交位置处比在切割位置处更长。(A system for winding wire includes a wire takeup unit and a wire cutter/grabber unit. The takeup unit includes rotatable first and second spindle portions and a wire-guiding traverse arranged to feed the wire and alternately form coils on the first and second spindle portions. The cutter/grasper unit is configured to cut a wire at a cutting position between the traverse and the coil formed on the first mandrel portion, and grasp a free end of the cut wire and move along a predetermined cutter/grasper path to a handover position where the wire is transferred to the second mandrel portion. When the cutter/grabber moves along the path from the cutting position to the handoff position, the length of the line between the sled and the free end of the line does not decrease, and the line length is longer at the handoff position than at the cutting position.)

1. A system for winding wire, comprising:

A) a wire takeup unit including a rotatable first spindle portion; a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first and second mandrel portions to form a complete mandrel on which wire is wound into a coil; and a wire-guiding crossmember arranged to feed the wire and alternately forming coils on the first and second spindle portions when the first and second spindle portions are engaged to the third spindle portion, wherein each coil is wound in a number 8 configuration; and

b) a wire cutter/grabber unit configured to cut the wire and grab a free end of the cut wire at a cutting position between the sled and a coil formed on the first mandrel portion, and move along a predetermined cutter/grabber path to a handover position at which the wire is transferred to the second mandrel portion,

wherein a length of the thread between the sled and the free end of the thread does not decrease when the cutter/gripper moves along the cutter/gripper path from the cutting position to the handoff position, and a length of the thread between the sled and the free end of the thread is longer at the handoff position than at the cutting position.

2. The system of claim 1, wherein:

the cutter/grabber is configured to move from a waiting to cut position to the cutting position, wherein the waiting to cut position is within six inches of the sled.

3. The system of claim 2, wherein:

the waiting to cut position is within three inches of the crossmember.

4. The system of claim 1, wherein:

the second mandrel portion includes a clamp configured to hold the wire when the cutter/grasper and the sled are in the handoff position.

5. The system of claim 1, further comprising:

a cutter/gripper positioning system disposed vertically above the cutter/gripper and configured to position the cutter/gripper along the cutter/gripper path.

6. The system of claim 5, wherein:

the positioning system includes: a multi-joint arm configured to bend in a plane that is transverse to a plane in which the cross piece is configured to move; and a first driving unit configured to bend the arm.

7. The system of claim 5, wherein:

the positioning system includes a second drive unit configured to translate the arm and the first drive unit in a direction parallel to an axis along which the sled is configured to move.

8. The system of claim 5, wherein:

the positioning system is configured to maintain the cutter/gripper in a horizontal orientation as the cutter/gripper moves throughout the cutter/gripper path.

9. A cutter/grasper system for resetting a wire takeup unit after forming a coil of wire, the wire takeup unit comprising: a rotatable first spindle portion and a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first and second mandrel portions to form a complete mandrel on which wire is wound into a coil; and a wire-guiding crossbar arranged to feed wire and alternately forming coils on the first and second spindle portions when the first and second spindle portions are engaged to the third spindle portion, wherein each coil is wound in a number 8 configuration, the cutter/gripper system comprising:

a wire cutter/grabber unit configured to move along a cutter/grabber path to separate a coil formed on the first mandrel portion from the traversing piece, and to provide the second mandrel portion for said winding and forming of the wire into another coil,

the path includes a plurality of different positions including a waiting to cut position, a transfer position, a handoff position, and a ready to wind position within six inches of the crossmember,

wherein the cutter/gripper is configured to move between the waiting-to-cut position, the cutting position, the transfer position, the handover position, the ready-to-wind position in a loop that starts and ends at the waiting-to-cut position.

10. The system of claim 9, wherein:

when the cutter/grabber moves along the cutter/grabber path from the cutting position to the handoff position, a length of the line between the sled and the free end of the line does not decrease, and a length of the line between the sled and the free end of the line is longer at the handoff position than at the cutting position.

11. The system of claim 9, wherein:

at the cutting position, the cutter/grasper is configured to cut the wire between the loop on the first mandrel portion and the sled and grasp a free end of the cutting wire from the sled.

12. The system of claim 11, wherein:

at the transfer position, the cutter/grasper holds the free end of the wire when the first and second spindle sections are switched positions relative to the traverse.

13. The system of claim 9, wherein:

at the handoff position, the cutter/grasper and the traverse are relatively positioned such that the wire extends across the grasper of the second mandrel portion.

14. The system of claim 12, wherein:

the ready-to-wind position is vertically below the handoff position.

15. The system of claim 9, further comprising:

a cutter/gripper positioning unit coupled to and extending upwardly therefrom to a support position vertically spaced above the cutter/gripper unit, the cutter/gripper positioning unit configured to support and suspend the cutter/gripper unit below the support position.

16. A system for winding wire, comprising:

A) a wire takeup unit including a rotatable first spindle portion and a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first and second mandrel portions to form a complete mandrel on which wire is wound into a coil; and a wire-guiding crossmember arranged to feed a wire and alternately forming coils on the first and second spindle portions when the first and second spindle portions are engaged to the third spindle portion, wherein each coil is wound in a number 8 configuration;

b) a wire cutter/grabber unit configured to cut the wire at a cutting position between the traverse and a coil formed on the first spindle portion, grab a free end of the cut wire, and move along a predetermined cutter/grabber path to a handover position where the wire is transferred to the second spindle portion,

wherein a length of the thread between the sled and the free end of the thread does not decrease when the cutter/gripper moves along the cutter/gripper path from the cutting position to the handoff position, and a length of the thread between the sled and the free end of the thread is longer at the handoff position than at the cutting position; and

c) a cutter/grabber positioning system coupled to the wire takeup unit at an upper end and to the cutter/grabber at a lower end, the cutter/grabber positioning system being disposed vertically above the cutter/grabber and configured to position the cutter/grabber along the cutter/grabber path,

the positioning system comprises a multi-joint arm having an upper arm and a lower arm configured to pivot relative to each other in a common plane of the upper and lower arms, and a first drive unit configured to rotate at least one of the upper and lower arms, and

the positioning system includes a second drive unit configured to translate the arm and the first drive unit in a direction parallel to the traversing member,

wherein the positioning system is configured to maintain the cutter/gripper in a horizontal orientation as the cutter/gripper moves throughout the cutter/gripper path.

17. The system of claim 16, wherein:

the arm includes a belt drive transmission system driven by the first drive unit.

18. The system of claim 17, wherein:

the first drive unit comprises a shoulder drive unit configured to rotate the upper arm about a shoulder joint of the arm and an elbow drive unit configured to rotate the lower arm about an elbow joint of the arm between the upper arm and the lower arm, wherein the first drive unit is mounted on a fixed rail for translation of the first drive unit in a direction parallel to the crossmember.

19. The system of claim 18, wherein:

the shoulder drive unit includes a shoulder driver including a stepper motor configured to drive a geared belt connected to a geared shoulder pulley fixed to the upper arm, and

the elbow drive unit includes an elbow driver including a stepper motor configured to drive a geared drive belt connected to a geared elbow pulley secured to the lower arm.

20. The system of claim 19, wherein:

the second drive unit includes a cylinder configured to translate the first drive unit and the arm.

21. A method of winding a wire with a wire takeup unit, the takeup unit comprising: a rotatable first spindle portion; a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first and second mandrel portions to form a complete mandrel on which the wire is wound into a coil; and a thread-guiding crossmember arranged to feed a thread and alternately forming a coil on the first and second spindle portions when the first and second spindle portions are engaged to the third spindle portion, the method comprising:

feeding wire from said traverse and winding the fed wire in a number 8 configuration to form a coil on a complete mandrel formed by joining said first and third mandrel portions; and is

At the time of the formation of the coil,

positioning a wire cutter/grabber unit at a cutting position between the crossmember and the formed coil, the cutter/grabber being configured to cut the wire and grab a free end thereof, and

cutting the wire at the cutting location and grasping a cut end of the wire extending from the traverse;

separating the first mandrel portion from the third mandrel portion, leaving the formed coil only on the first mandrel portion, and exchanging positions between the first mandrel portion and the second mandrel portion; and

moving the cutter/gripper along a predetermined cutter/gripper path to a handoff position at which the wire is transferred from the cutter/gripper to the second mandrel portion;

engaging the second mandrel portion with the third mandrel portion to form another complete mandrel; and

moving the cutter/gripper along the cutter/gripper path from the handoff position to a ready to wind position,

wherein a length of the thread between the sled and the free end of the thread does not decrease when the cutter/gripper moves along the cutter/gripper path from the cutting position to the handoff position, and a length of the thread between the sled and the free end of the thread is longer at the handoff position than at the cutting position.

22. The method of claim 21, wherein:

engaging the second mandrel portion with the third mandrel portion while moving the cutter/gripper from the handoff position to the ready-to-wind position.

23. The method of claim 21, further comprising:

when the cutter/grabber is moved to the ready-to-wind position, winding wire is wound in a figure 8 configuration to form a coil on another complete mandrel comprising the second and third mandrel portions joined together.

Technical Field

The present application relates to an apparatus and method for winding a coil and dispensing the coil after the coil is wound. More particularly, the present application relates to a device and method for resetting a coil winding device between windings of a coil.

Background

U.S. patent No. 2,634,922 to Taylor describes winding a flexible wire, cable or filamentary material (hereinafter referred to as "wire", which is to be broadly understood in the specification and claims) in a figure 8 pattern around a mandrel such that a bale of material is obtained having multiple layers surrounding a central core space. By rotating the mandrel and by controllably moving the traversing means which laterally guides the wire relative to the mandrel, the layers of the figure-8 pattern are provided with aligned holes (cumulatively "tap holes") so that the inner end of the flexible material can be pulled through the tap holes. When a covered wire is wound in this manner, the wire can be unwound through the payout holes without rotating the wire package, without imparting rotation (i.e., twisting) to the wire about its axis, and without kinking. This provides a major advantage to the user of the cord. A coil wound in this manner and dispensed from the inside to the outside without twisting, tangling, snagging or overrun (over) is known in the art as a relex (trademark of Reelex Packaging Solutions corporation) type coil. The REELEX-type coil is wound to form a substantially short hollow cylinder, with a radial opening formed at a location in the middle of the cylinder. A bleeder tube may be located in the radial opening and the end of the wire constituting the coil may be fed through the bleeder tube in order to dispense the wire.

A relex model D2000 winder (manufactured by Reelex Packaging Solutions) may be used to wind the wire into a relex type coil. The machine has a set of mandrels alternating between a winding position and a wrapping position. The coil is wound in the winding position and the finished coil is moved away from the mandrel to be packaged in the packaging position. These positions are alternated by a rotating turret to which the spindle is attached. Between the windings of each coil, a reset procedure is performed to prepare the machine for winding another coil. Generally, the process comprises: cutting a supply wire for manufacturing a first wound coil at one end of the coil; grasping a free end of a supply line; and handing over the free end of the supply line to the mandrel as the start of a new coil to be wound.

The D2000 machine uses a "cutter/gripper" device that is supported below the cutter/gripper on a linear guide of a support structure that can move the cutter/gripper in three orthogonal directions. The cutter/grabber device is configured to cut the wire and grab the cable. When the first coil on the mandrel is completed winding, the cutter/gripper moves to the cutting position and cuts the wire to separate the coil from the supply line, and the gripper grips the free end of the supply line. The mandrel is a two-part assembly that separates to move the outer portion axially away from the inner portion holding the coil. Next, the cutter/grabber removes the coil and the inner portion of the mandrel mounted on the rotating turret. The turntable is then rotated in a horizontal plane to exchange positions with the empty inner spindle portion. The cutter/grabber is then moved back toward the empty inner mandrel portion to deliver the wire to be grabbed by the inner mandrel portion. Once the inner mandrel portion has grasped the wire (hand over), the cutter/grasper releases the wire and moves out of the path of the mandrel so that the outer portion of the mandrel can engage with the inner portion of the mandrel to form a complete mandrel in order to begin rotation to wind the wire. The reset process takes about 6 to 7 seconds, which is about 10 percent of the total time to wind the coil. Such a relatively lengthy process may affect the overall throughput of the winding machine.

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.

One embodiment of a system for winding wire includes a wire takeup unit and a wire cutter/grabber unit. The wire takeup unit includes: a rotatable first spindle portion; a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first mandrel portion and the second mandrel portion to form a complete mandrel on which the wire is wound into a coil; and a wire guide traverse member. The traverse is arranged to feed the wire and alternately form a coil on either of the complete mandrels. Each coil is wound in a number 8 configuration. The wire cutter/grasper unit is configured to cut a wire at a cutting position between the traverse and the coil formed on the first mandrel portion, and grasp a free end of the cut wire, and move along a predetermined cutter/grasper path to a handover position where the wire is transferred to an empty second mandrel portion. When the cutter/gripper moves along the cutter/gripper path from the cutting position to the handoff position, the length of the line between the sled and the free end of the line does not decrease, and the length of the line between the sled and the free end of the line is longer at the handoff position than at the cutting position.

In one embodiment, the cutter/grasper is configured to move from a waiting to cut position to a cut position, and the waiting to cut position is within six inches of the traverse, and preferably within three inches of the traverse. In one embodiment, the first and second mandrel portions may each include a grasper configured to grasp the wire when the cutter/grasper is in the handoff position.

In one embodiment, the system includes a cutter/gripper positioning system disposed vertically above the cutter/gripper and configured to position the cutter/gripper along the cutter/gripper path. The positioning system may include a multi-joint arm configured to articulate in a plane transverse to a plane in which the traverse is configured to move, and may include a first drive unit configured to articulate the arm.

The positioning system can include a second drive unit configured to translate the arm and the first drive unit in a direction parallel to an axis along which the traverse is configured to travel. In one embodiment, the positioning system is configured to maintain the cutter/gripper in a horizontal orientation as the cutter/gripper moves throughout the cutter/gripper path.

According to one aspect, the wire cutter/grasper unit is configured to move along the cutter/grasper path to separate a coil wound around the first mandrel portion from a supply wire drawn through the moving traverse, and to provide a second, empty mandrel portion for winding the supply wire around the second mandrel portion into another coil. The first and second mandrel portions alternately engage the third mandrel portion to form a complete mandrel for winding a supply of wire into a coil. The path includes a plurality of different positions including a waiting-to-cut position, a cutting position, a transfer position, a handover position, and a ready-to-wind position. The cutter/gripper can be moved in sequence from the waiting cutting position to the cutting position, to the transfer position, to the hand-over position, to the ready-to-wind position, and back to the waiting cutting position.

At the cutting position, the cutter/grasper may cut the supply wire between the coil on the first mandrel portion and the traversing member and grasp the free end of the cut wire from the traversing member. In the transfer position, the cutter/grasper may hold the free end of the wire while the first and third spindle portions are separated, and then the first and second spindle portions exchange positions with respect to the traverse. At the handoff position, the cutter/grasper and the traverse may be relatively positioned such that the wire extends across the grasper of the second mandrel portion.

In one embodiment, the ready-to-wind position is vertically below the handoff position and the second mandrel portion. When the cutter/grabber is in the ready to wind position, the third mandrel portion may engage the second mandrel portion to form a complete mandrel on which the coil may be wound. In one embodiment, the length of the line between the sled and the free end of the line is not reduced when the cutter/grabber moves along the cutter/grabber path from the cutting position to the handoff position, and the length of the line between the sled and the free end of the line is longer at the handoff position than at the cutting position.

According to another aspect, a system for winding a wire includes a wire take-up unit, a wire cutter/grabber unit, and a cutter/grabber positioning system as described above. The wire cutter/grasper unit is configured to cut a wire at a cutting position between the traverse and the coil, grasp a free end of the cut wire, and move along a predetermined cutter/grasper path to a handoff position where the wire is transferred to an empty second mandrel portion. When the cutter/gripper moves along the cutter/gripper path from the cutting position to the handoff position, the length of the line between the sled and the free end of the line does not decrease, and the length of the line between the sled and the free end of the line is longer at the handoff position than at the cutting position.

The cutter/grabber positioning system is coupled to the wire takeup unit at an upper end and to the cutter/grabber at a lower end. A cutter/gripper positioning system is disposed vertically above the cutter/gripper and is configured to position the cutter/gripper along the cutter/gripper path. The positioning system includes a multi-joint arm having an upper arm and a lower arm configured to pivot relative to each other in a common plane of the upper and lower arms. The positioning system further includes a first drive unit configured to rotate at least one of the upper arm and the lower arm, and a second drive unit configured to translate the arm and the first drive unit in a direction parallel to the traverse. The positioning system is configured to maintain the cutter/grabber in a horizontal orientation as the cutter/grabber moves throughout the cutter/grabber path.

The arm may comprise a belt drive transmission system driven by the first drive unit. The first driving unit may include a shoulder driving unit and an elbow driving unit. The shoulder drive unit may be configured to rotate the upper arm about the shoulder joint of the arm. The elbow drive unit may be configured to rotate the lower arm about an elbow joint of the arm between the upper arm and the lower arm. The first drive unit may be mounted on a fixed guide rail for translation of the first drive unit in a direction parallel to the traverse.

The shoulder drive unit may include a shoulder driver including a stepper motor configured to drive a geared belt connected to a geared shoulder pulley fixed to the upper arm, and the elbow drive unit includes an elbow driver including a stepper motor configured to drive a geared belt connected to a geared elbow pulley fixed to the lower arm. The second drive unit may include a cylinder configured to translate the first drive unit and the arm.

Drawings

Fig. 1 is a schematic view of a REELEX type winding system.

Fig. 1A is an embodiment of a REELEX-type winding apparatus of the winding system shown in fig. 1.

Fig. 2 is a perspective view of portions of the traverse and the spindle of fig. 1A.

FIG. 2A is an illustration of an interior portion of the mandrel shown in FIG. 2 shown in a distinct collapsed configuration.

FIG. 2B is an illustration of the mating outer portion of the mandrel shown in FIG. 2A as it is approaching a mating position with the inner portion of the mandrel.

Fig. 2C shows a top view of the device shown in fig. 2B.

Figure 2d is a detailed view of a portion of the outer portion of the mandrel shown in figure 2C.

Figure 2E is a detailed view of a portion of the interior portion of the mandrel shown in figure 2C.

Fig. 3 is an example workflow of a cutting and grasping process.

Fig. 3A is a schematic diagram showing the path of the cutter/grabber as it moves during the workflow of fig. 3.

Fig. 4 shows the wound coil on the mandrel with the cutter/grabber in a waiting to cut position.

Fig. 4A shows a view transverse to the view of fig. 4 of the cutter/gripper in a waiting cutting position.

Fig. 5 shows the cutter/grabber in the cutting position.

Fig. 5A shows a view of the cutter/gripper in the cutting position, transverse to the view of fig. 5.

Fig. 6 illustrates the turret rotated to switch the spindle position, transfer the cutting coils, and the cutter/grabber moved to the transfer position.

Fig. 7 shows the cutter/gripper in the handoff position.

Fig. 7A shows a view of the cutter/gripper in the handoff position, transverse to the view of fig. 7.

Figure 8 shows the mandrel in the fully engaged configuration with the mandrel portions in their respective expanded configurations and with the cutter/grabber in the ready to wind position.

Fig. 8A shows a view transverse to the view of fig. 8 of the cutter/gripper in a ready-to-wind position.

Fig. 8B to 8D show top views of the position of the mandrel portion of fig. 8 as a progression between the handover position and the ready-to-wind position.

Figure 9 shows a view of the mandrel and cable after an initial period of spooling.

Fig. 10A and 10B illustrate a cutter/gripper positioning system.

Fig. 10C is an exploded assembly view of the cutter/gripper positioning system shown in fig. 10A and 10B.

Fig. 11 illustrates an arm of the system of fig. 10A-10C, shown with a cutter/grabber.

FIG. 11A is an exploded assembly view of a portion of the arm of FIG. 11 shown without the drive train of the arm.

FIG. 11B is an exploded assembly view of the arm of FIG. 11 shown as a drive train with the arm.

Fig. 12 illustrates a first drive unit of the system of fig. 10A to 10C.

Fig. 12A is an exploded assembly view of the stepper drive assembly of fig. 12.

Fig. 12B is an exploded view of the shoulder driving unit and the elbow driving unit shown in fig. 12A.

Fig. 13 illustrates a second drive unit of the system of fig. 10A-10C, and the electrical and pneumatic connections of the arms of fig. 10A-10C.

Fig. 14 is an exploded assembly view of the cutter/grabber shown in fig. 10A, 10B, 10C, 11 and 11B.

Fig. 14A is an isometric view of the cutter/grabber of fig. 14 in its assembled configuration.

Detailed Description

One embodiment of a winding system 100 for winding a wire 110 is shown in fig. 1. The system 100 is a REELEX type winding system and is shown with a payout or pay-out unit 112, a dancer/accumulator (tensioner) 114, a take-up unit 116 (hereinafter "winder"), and a controller 118. Each of these elements will be described in more detail below.

First, it should be appreciated that payoff unit 112 is shown as including a large source spool 122 of line 110 and a motor 124 for controlling the speed at which line 110 is dispensed out of spool 122. The dancer/accumulator or tensioner 114 is shown having: an upper sheave 142 and a lower sheave 144, the line 110 looped around the upper sheave 142 and the lower sheave 144 b; a cylinder 146 that applies pressure to the lower sheave 144 of the tensioner 114 to achieve a desired tension; and a distance or height sensor 148 (e.g., a laser system) that senses the position of the lower sheave 144 relative to the upper sheave 142. The height sensor 148 is coupled to the payout unit 112 and may provide feedback information to the payout unit 112 to inform the payout unit to increase its speed if the amount of wire in the accumulator is low and to decrease its speed if the amount of wire in the accumulator is high. In another embodiment, feedback information may be provided to tightening unit 116 and used to reduce or increase its speed. In one embodiment, the air cylinder 146 that applies tension to the wire 110 may be controlled by a digital self-release air regulator 150, the digital self-release air regulator 150 including a digital regulator 152 that conforms to a self-release pressure relay 154.

Fig. 1A and 2 show one embodiment of the tightening unit 116. The tightening unit 116 includes a buffer 162 (fig. 1A), a cross member 164 (fig. 2), an electric spindle 166 (fig. 1A and 2), and a set of spindles 170 (fig. 1A, 2A and 2B), which will be described in more detail with reference to fig. 2, 2A and 2B.

As will be described in greater detail below, the mandrel 170 is a two-part assembly, and the mandrel 170 shown in fig. 2B is shown in an unassembled configuration. The inner spindle 170 portions 170a are connected to the turret 171, the inner spindle portions 170a can be rotated in a horizontal plane about the turret 171 to a change position below the traverse 164, and each inner spindle portion 170a can alternately cooperate with an outer (with respect to the turret 171) spindle portion 170b to form a complete spindle 170, as described in more detail below. The crossmember 164 is configured to traverse in a track in the beam 164a above the surface of the mandrel 170 as the mandrel rotates on the spindle 166, such that the wires 110 are directed onto the mandrel 170 in a desired pattern.

The cross member 164 is formed as a cantilevered beam 164a, the cantilevered beam 164a having a longitudinal slot (not shown) through which the guide tube 164b extends. The guide tube 164b terminates in a wire guide 164c located closest to the mandrel 170. The wire 110 passes through the guide tube 164b and exits the wire guide 164 c. The guide tube 164b travels at a desired speed (i.e., reciprocates within) the longitudinal slot of the beam 164a and travels along a desired distance as controlled by the tightening system 116 as communicated by the controller 118 to form a figure 8 pattern in a manner that forms a tap hole extending radially from the mandrel 170. Controller 118 is coupled to tightening system 116 and may provide speed control information to direct tightening system 116 to operate at a desired rate. For example, controller 118 may direct tightening system 116 to operate spindle 166 at a constant speed, or may cause tightening system 116 to have a constant linear speed, requiring the spindle speed to slow down over a period of time as the coil diameter increases.

Fig. 2A and 2B show more details of the construction of the mandrel 170, both mandrels being identical. Specifically, each mandrel 170 is a two-piece assembly that includes a radially (relative to the turntable 171) inner portion 170a (fig. 2A and 2B) that mounts to the turntable 171 (fig. 2) and a radially outer portion 170B (fig. 2B) that operably mates with the inner portion 170a to assemble the mandrel 170.

As best shown in fig. 2A, the inner portion 170a of the mandrel 170 includes a plurality of segments 170a ', the segments 170 a' being connected at their proximal ends to an end structure 177. Each segment 170 a' is shown as having an outer surface that curves (bulges) outward in two directions. Each segment 170 a' also has an inner surface that is concave in at least one direction. Each segment 170a ' is arranged to move from a first, contracted position (as shown in fig. 2A), in which the segments 170a ' are closer to the central axis a-a and closer to each other, to a second, expanded or extended position, as shown in fig. 2B, in which the segments 170a ' are further from the central axis and spaced further apart from each other in the circumferential direction. The segment 170a 'has an inner (relative to the turret 171) end that can be slid radially in and out by operating the chuck (in a manner similar to operating the chuck on a lathe) to facilitate expansion and contraction of the segment 170 a'. In the first, retracted position, the segments 170 a' may be in contact with one another or in close proximity to one another. In the first retracted position, section 170 a' takes the shape of a rugged bucket. In the second expanded or extended position shown in fig. 2A, the segments 170 a' are spaced from each other in the circumferential direction, and their outer surfaces appear to define a circle at any cross-section, although the circle may also be somewhat uneven. In one embodiment, the inner portion 170a is configured such that once the segment 170 a' is positioned diametrically, further movement of the segment 170a can only occur by applying a force to the chuck. Alternatively, in one embodiment, a lock may be provided to hold the section 170 a' in the expanded position and/or the contracted position.

One of the mandrel segments 170 a' includes a clamp 170a ″ for gripping the wire 110 and holding it with the mandrel 170 prior to winding. Specifically, the clamp 170a ″ may have a pivoting arm to operably grasp the wire. The pivot arms of the clamp 170a ″ may have curved notches (as shown in fig. 2A) or other retaining features (e.g., teeth) at their distal ends for clamping the wire as the pivot arms are closed. The clip 170a ″ may be configured to grip the wire as the section 170 a' is further separated from the contracted configuration to the expanded configuration. When the section 170 a' is in the expanded configuration, the clip 170a ″ securely retains the wire.

The outer portion 170b of the mandrel 170 has a section 170b 'similar to the section 170 a' of the inner portion 170 a. However, unlike section 170 a', outer portion 170b does not have a clip like clip 170a ". Further, the central shaft 170b "extends axially through the outer portion 170 b. The shaft 170b "helps to position and align the inner portion 170a and the outer portion 170b during assembly of the mandrel 170. Further, as the mandrel 170 rotates during winding, the shaft 170b "transfers torque from the drive spindle 166 coupled to the shaft 170b" (and the outer portion 170 b) to the inner portion 170a of the mandrel 170. The inner portion 170a and the outer portion 170B are configured to mate together as shown in fig. 2B when the outer portion 170B is moved axially along axis a-a in fig. 2B into the first portion in the manner shown by the arrows. The mandrel segments 170b 'of the outer portion 170b are inserted between the mandrel segments 170 a' of the inner portion 170a and the distal end of each portion 170a and 170b is coupled with the end structure 177 of the other portion such that the mandrel 170 forms a complete assembly as shown, for example, in fig. 4.

In the embodiment of fig. 2A and 2B, the end structure 177 is substantially shaped as a cymbal and is arranged on the mandrel 170 such that they face away from each other. The portions 170a and 170b of the mandrel may be separated from each other by contracting the section 170b 'and moving the outer portion 170b outwardly along the axis a-a so that the coil of wire on the mandrel 170 may be retained on the section 170 a' of the inner portion 170a after winding is complete, as will be described in more detail below.

Fig. 2C illustrates additional details of the inner portion 170a and the outer portion 170b of the mandrel. For example, the outer portion 170b includes a roller 170b '"connected to one of the sections 170 b'. The rollers 170 b' ″ are configured to engage and guide a portion of the wire 110 when the outer portion 170b mates with the inner portion 170a, which will be described in more detail below. Fig. 2D shows a detailed view of the section 170b ' shown in fig. 2C, and in particular shows more detail of the roller 170b ' attached to the section 170b '.

Additionally, fig. 2C illustrates a spring-loaded latch mechanism 170a "", which is shown in more detail in fig. 2E. The latch mechanism 170 a' ″ includes a spring-loaded latch 173, the latch 173 being mountable on an end structure 177 for movement parallel to the axis a-a. A section 170 a' of the inner portion 170a of the mandrel 170 adjacent the latch 173 defines a notch 175, the notch 175 being partially blocked by the flexible flap 178. The latch 173 is configured to move between a first, blocking position (shown in fig. 2E) and a second, unblocking position, in which the latch 173 is moved toward the end structure 177 (e.g., downward in fig. 2E). In the blocking position, the surface of the latch 173 and the section 170 a' of the notch 175 and/or the space between the flap 178 is less than the diameter of the wire 110 so that the wire will be held while the wire is in the notch 175 until the wire 110 applies sufficient pressure to the flap 178 to flex the flap 178 and allow the wire 110 to exit the notch 175.

In winding the number 8 coil of wire, the starting end of the wire 110 is captured by the spindle 170, and the spindle 166 is rotated by the spindle 166 as the traverse 164 reciprocates and guides the wire onto the spindle in a number 8 pattern using the escape aperture. The functions of the sled 164, payout unit 112, dancer/accumulator (tensioner) 114 and controller 118 may be the same as those described in U.S. patent application 14/740,571 (Kotzur et al), the entire contents of which are incorporated herein by reference. When winding is complete, the wire is cut, the portions 170a and 170b of the mandrel 170 are separated as described above, and the turret 171 is rotated to switch the position of the inner portion 170a so that the empty mandrel portion 170a is located below the trolley 164 where it is ready to wind another coil, and the complete mandrel portion 170a (holding the wound coil) is on the unloading area 180 (fig. 1A). In the unloading area 180, the wound coil may be removed from the inner portion 170a of the mandrel 170 for packaging.

The following describes the processing steps of the reset process that occur between winding of coils on the machine 116 (e.g., between the end of winding a first coil and the beginning of winding a second coil). In this regard, fig. 3 and 3A are directed to such processing steps and illustrate the workflow of the reset process, which preferably employs the cutter/grabber 1001 described herein with reference to fig. 10A-13. During the workflow, the cutter/gripper 1001 moves through a number of different positions in the route or path 350 shown in fig. 3A. At the beginning of the workflow, at 302, the distal end of the cutter/grasper 1001 is in the first "waiting to cut" position 350 a. When the coil is finished winding, the cutter/grabber waits at the positions to be cut. When the coil is fully wound, at 304, the cutter/gripper 1001 moves from the waiting to cut position to a second "cut" position 350b, at which the cutter/gripper 1001 cuts the wire from the coil of supply wire fed by the crossmember 164 and grips the free cut end of the supply wire from the crossmember 164. To allow the turret 171 to rotate the mandrel 170 with clearance, at 306, the cutter/gripper 1001 moves from the cutting position to a third "transfer" position 350c while the turret 171 rotates to position the empty inner mandrel portion 170a below the traverse 164 and in front of the cutter/gripper 1001. At 308, it is determined whether another coil is manufactured. If it is determined that the coil is no longer being manufactured (NO at 308), the workflow ends at 310. However, if it is determined that another coil is to be manufactured (yes at 308), the workflow proceeds to 312. At 312, the cutter/grasper 1001 moves from the transfer position 350c to a fourth "handoff position" 350d, where the wire 110 is pulled from the traverse 164.

When the cutter/grasper 1001 is moved to the handoff position (or possibly after the cutter/grasper has been in the handoff position), the traverse 164 may be moved in a direction along the beam 164a such that the wire extends through the grasper 170a ″ of the inner portion 170a of the mandrel 170. The gripper 170a "exerts pressure on the wire to hold the wire, and the cutter/gripper 1001 releases the end of the wire, thereby completing the handoff of the wire from the cutter/gripper 1001 to the inner portion 170a of the mandrel 170. When the cutter/grasper 1001 moves through a series of positions between the cutting position 350b and the handoff position 350d, the wire length between the traverse 164 and the wire free end is not reduced, and the wire length between the traverse 164 and the wire free end is longer at the handoff position 350d than at the cutting position 350 b. The length of the line between the sled 164 and the line end may be about 18 inches when the cutter/grabber 1001 is at the handoff position. In other words, as the cutter/grabber 1001 moves through a series of positions between the cutting position 350b and the handoff position 350d, the wire is not retracted relative to the trolley 164, and thus, there is no need to reverse the direction of the buffer 162 (fig. 1 and 1A) during the reset process.

At 314, the cutter/grabber 1001 moves down to a fifth "ready to wind" position 350e, while the inner portion 170a of the mandrel 170 moves up into a coaxial position with the outer portion 170b of the mandrel 170. The outer portion 170B of the mandrel 170 is moved axially (radially inward relative to the turntable 171) in the direction shown in fig. 2B into a position to mate with the inner portion 170a of the mandrel 170 to fully assemble the mandrel 170 so that the assembled mandrel 170 is ready to wind another coil. At 316, the mandrel 170 may begin rotating to wind another coil while the cutter/gripper 1001 moves from the ready-to-wind position 350e back to the waiting-to-cut position 350 a. Thereafter, the workflow proceeds to 304 and repeats or ends as described above.

It is preferred that the cutter/gripper 1001 move as quickly as possible throughout the path 350 in order to reduce the reset time between the end of winding one coil and the beginning of winding another coil. Thus, for example, it is preferable to quickly lower the cutter/gripper 1001 from the handoff position 350d down to the ready to wind position 350e so that the cutter/gripper 1001 is out of the path of the mandrel 170 so that the winding process can quickly begin after the handoff of the wire to the mandrel 170 is complete.

In contrast to the aforementioned prior art D2000 machine, the cutter/grabber 1001 is supported from above, rather than from below, by the positioning system 1000 (e.g., as shown in fig. 4). The positioning system 1000 does not interfere with the assembly of the mandrel 170, thereby reducing the reset time between wound coils and increasing the overall throughput of the machine 116. The position of positioning system 1000 relative to cutter/grabber 1001 may be based on the geometry of tightening unit 116, and more specifically, the geometry of mandrel portions 170a and 170b and sled 164. Thus, based on the geometry of the mandrel portions 170a and 170b and the crossmember 164 in the tightening unit 116 described herein, positioning the positioning system 1000 above the cutter/grabber 1001 positions the positioning system 1000 and the cutter/grabber 1001 such that they do not interfere with any movement of the mandrel 170 (and any coils thereon) between the cutting position 350b and the handoff position 350 d. While the cutter/gripper 1001 and/or positioning system 1000 may occupy the space between the mandrel 170 and the traverse 164 during the cutting operation and handoff, the distance and time required to move the cutter/gripper 1001 and/or positioning system 1000 away from interference with the mandrel 170 and traverse after these operations (i.e., from the cutting position 350b to the transfer position 350c, and from the handoff position 350d to the ready-to-wind position 350 e) may be minimized.

Note that fig. 3A shows a two-dimensional view of path 350. It should be appreciated, however, that the movement of the cutter/grabber 1001 along the path 350 may be three-dimensional. Further, while the positions described in the workflow 300 have been described as the positions of the cutter/grabber 1001, it should be noted that the sled 164 may move along the beam 164a during the workflow 300 and also have different positions along its longitudinal travel path associated with each position of the cutter/grabber 1001 recorded in the workflow 300. This relative movement between the cutter/grasper 1001 and the traverse 164 will be described below with reference to fig. 4 to 8B.

Fig. 4 shows a front view of coil 175 on mandrel 170 and cutter/grabber 1001 in waiting to cut position 350 a. The cutter/grabber 1001 is shown in fig. 4 to the rear and right of the cross piece 164. Fig. 4A is a side view and illustrates the position of the cutter/grabber 1001 with respect to the trolley 164 and the mandrel 170 when the cutter/grabber 1001 is in the waiting for cut position 350 a. As shown in fig. 4A, cutter/gripper 1001 is coupled to multi-joint arm 1002 and is positioned by multi-joint arm 1002, and multi-joint arm 1002 is part of positioning system 1000, additional details of which are provided below. In the waiting to cut position 350a, the cutter/grasper 1001 may be within about 6 inches, preferably within 3 inches, of the traverse 164 to minimize the movement time of the cutter/grasper 1001 between the waiting to cut position 350a and the cutting position 350 b.

Fig. 5 and 5A show the cutter/grasper 1001 in the cutting position 350 b. The trolley 164 may or may not move as the arm 1002 moves the cutter/gripper 1001 from the waiting to cut position 350a to the cutting position 350 b. Once the wire 110 is cut in the cutting position 350b, the cutter/grasper 1001 cuts the wire 110 and grasps the free end of the wire 110 extending from the traverse 164, and the arm 1002 moves the cutter/grasper 1001 into the transfer position 350c (into the page in fig. 6) while the mandrel portions 170a and 170b of the mandrel 170 below the traverse 164 are separated to allow the turntable 171 to rotate, as shown in fig. 6. The rotation of the turntable 171 occurs quickly, for example, within two seconds, and preferably within one second or less. Rotation of the turntable 171 switches the position of the two inner portions 170a of the mandrel 170 so that the free inner portion 170a moves into a position below the cross beam 164 (as shown in fig. 7) and the inner portion 170a of the holding coil moves into a position in the coil unloading area 180 (fig. 1A). Once the inner portion 170a is located below the sled 164, the arm 1002 moves the cutter/grabber 1001 to the handoff position 350d and the sled 164 moves to the left in fig. 7 to position the wire 110 through the grabber 170a ″ of the inner portion 170 a. Once the grabber 170a "of the inner portion 170a grabs the wire 110, the handoff is complete, allowing the arm 1002 to release the end of the wire 110 and move the cutter/grabber 1001 down to the ready to wind position 350e while the outer portion 170b of the mandrel 170 engages the inner portion 170a of the mandrel 170, as shown in fig. 8 and 8A. Between the handoff position 350D and the ready-to-wind position 350e of the cutter/grabber 1001, the traverse 164 moves to a "main shaft track" position (fig. 8B) that positions the wire 110 such that when the outer portion 170B moves into a position of engagement with the inner portion 170a (i.e., in the direction of the arrow in fig. 8B), the wire 110 may be guided by the roller 170B' "(fig. 2C, 2D) of the outer portion 170B of the mandrel 170. Specifically, as shown in fig. 8C, when roller 170b '"engages wire 110 between gripper 170 a" and traverse 164, roller 170 b' "directs a portion of wire 110 toward notch 175 of inner portion 170 a. As shown in fig. 8D, when the inner portion 170a and the outer portion 170b of the mandrel 170 are mated together, the wire 110 is pushed into the notch 175 and is retained in the notch 175 by the roller 170 b' ", the latch 173, and the flap 178. The length of wire between the clip 170a ″ and the latch 173 may be used during packaging.

Also, as shown in fig. 8 and 8A, the cutter/grabber 1001 is positioned below the mandrel 170 such that the cutter/grabber 1001 does not interfere with the rotation of the mandrel 170. Therefore, the winding process can be started even when the cutter/gripper 1001 is not at the waiting-to-cut position 350 a. Thus, when the arm 1002 returns the cutter/grabber 1001 from the ready to wind position 350e to the waiting to cut position 350a, the mandrel may wind the coil, further reducing the reset time and increasing the overall throughput of the coil.

The start of the winding process can be seen in fig. 9, where it can be seen that a first layer of wire 110 is laid on mandrel 170, wherein portions of the surface of mandrel segments 170a 'and 170 b' are still visible. In fig. 9, the first layer is complete because the movement of the crossheads has completed a "super-cycle" so that further laying of the line will be positioned directly above the place where the previous line was laid (i.e. radially away from the mandrel). This can also be understood by recognizing that the escape aperture 172 is fully defined. In one embodiment, the dancer or tensioner 114 places the tension on at least the first two layers of wire 110 laid on the mandrel 170 by the traversing members 164 at a relatively low tension relative to the tension applied on the remainder of the wire as it is wound onto the mandrel 170. In another embodiment, the tension on a predetermined length of wire laid as the first two to four layers of wire is tensioned at a lower tension than the tension applied to the remainder of the wire.

As should be appreciated, to effect winding of a coil having the first two or more layers or desired length of wire at a first, lower tension and winding of the subsequent layer at a higher tension, the controller 118 may be programmed to send a signal to the digital pressure regulator 152 of the dancer 114 to control the pressure in the lower chamber of the air cylinder 146. In particular, at the beginning of winding the coil, the controller 118 may send a signal to the digital pressure regulator 152 to provide a low tension on the line 110. Then, based on the monitoring of the winding, for example, by using an encoder to monitor the amount of line exiting the accumulator, the controller 118 may send a signal to the digital pressure regulator 152 to increase the tension on the line 110 according to any desired profile.

Fig. 10A to 13A illustrate details of the aforementioned cutter/gripper positioning system 1000. The positioning system 1000 is configured to position the cutter/gripper 1001 along the path 350 while maintaining the cutter/gripper 1001 in a substantially horizontal and level orientation. Positioning system 1000 includes a multi-joint arm 1002, a first drive unit 1004, and a second drive unit 1006. The multi-joint arm 1002 is configured to bend in a single x-y plane by the action of a first drive unit 1004 (see fig. 10A). The arm 1002 and the first drive unit 1004 are coupled together and suspended from a set of rails 1008, the rails 1008 being fixed to the takeup unit 116 at a location above the arm 1002. The guide track 1008 extends parallel to the z-axis (see fig. 10A), perpendicular to the plane of the arm 1002 (i.e., the x, y, and z axes are orthogonal). The guide 1008 allows the arm 1002 and the first drive unit 1004 to move parallel to the z-axis. The second drive unit 1006 is also configured to be fixed to the tightening unit 116 above the guide rail 1008, and is configured to drive the movement of the arm 1002 and the first drive unit 1004 along the guide rail 1008, i.e., in the z-axis direction parallel to the moving direction of the traverse 164. Thus, the positioning system 1000 enables three-dimensional movement of the cutter/grabber 1001. Further details of portions of the positioning system 1000 will now be described with reference to fig. 11, 11A, 11B, 12A, 12B, and 13.

As shown in fig. 11 and 11A (and also 11 b), the arm 1002 includes an upper arm 1010 and a lower arm 1012 pivotally connected to a shaft 1014 extending parallel to the z-axis. The connection of the upper arm 1010 and the lower arm 1012 at the axis 1014 defines an elbow joint. The cutter/grasper 1001 is pivotally connected to the lower arm 1012 at a wrist joint at the distal end of the lower arm 1012. A shaft 1016 pivotally connects the lower arm 1012 to the cutter/grabber 1001. Returning briefly to fig. 10A, the proximal end of the upper arm 1010 is pivotally connected to the first drive unit 1004 by a shaft 1018, thereby defining a shoulder joint of the arm 1002.

The upper arm 1010 and the lower arm 1012 are structurally formed as respective frames as shown in fig. 11A. The upper arm 1010 includes side links 1010a and rear and front plates 1010c and 1010d, the side links 1010a being spaced apart and connected by a bracket 1010 b. The bracket 1010b and the plates 1010c, 1010d hold the side links 1010a fixed to each other so that the entire upper arm 1010 moves as a unitary member.

The lower arm 1012 includes a side link 1012a, and a rear plate 1012c and a front plate 1012d, the side link 1012a being spaced apart and connected by a bracket 1012 b. The bracket 1012b and the plates 1012c, 1012d hold the side links 1012a fixed to each other so that the entire lower arm 1012 moves as a unitary member.

The side link 1010a of the upper arm 1010 defines a bore 1010a 'at its proximal end and a shaft 1018 extends through the bore 1010 a'. Further, side link 1010a defines a hole 1010a ″ at its distal end, and side link 1012a defines a hole 1012 a' at its proximal end. The holes 1010a "and 1012 a' are aligned with each other to receive the shaft 1014. Retaining collars 1020 are connected to respective ends of the shaft 1014. The side link 1012a defines a bore 1012a "at its distal end, and the shaft 1016 extends through the bore 1012 a". The retaining collars 1022 are attached to respective ends of the shaft 1016.

The upper arm 1010 and the lower arm 1012 are configured to articulate in a common x-y plane due to the arrangement of the geared belt and the geared pulleys shown in fig. 11B driven by the first drive unit 1004.

Various pulleys are disposed on the shaft 1018. A pair of driven geared shoulder pulleys 1024 are fixedly attached to the outer surface of the proximal end of the side link 1010a of the upper arm 1010 by fasteners (e.g., screws) 1026. The shoulder pulley 1024 is fastened to the side link 1010a with screws 1026 so that the shoulder pulley 1024 and the upper arm 1010 rotate in unison about axis 1018. The shoulder pulley 1024 is not fixed to the shaft 1018. Advancing inwardly along the shaft 1018 from the shoulder pulley 1024 are a spacer 1027 and a geared idler elbow pulley 1028 that are not secured to the shaft 1018. A spacer 1027 separates the idler elbow pulley 1028 from the shoulder pulley 1024 along the shaft 1018. The hole 1010a 'in the proximal end of side link 1010a is large enough so that the inner edge of side link 1010a surrounding hole 1010 a' does not contact spacer 1027. A geared upper elbow drive belt 1074 wraps around the idler elbow pulley 1028. The belt 1074 is geared like an automotive timing belt.

Advancing inwardly along the shaft 1018 from the idler elbow pulley 1028 is a spacer 1029 and a geared idler wrist pulley 1030, which are also not fixed to the shaft 1018. A spacer 1029 separates the idler elbow pulley 1028 from the idler elbow pulley 1030 along the shaft 1018. The idler wrist pulley 1030 defines a through-hole 1032, the through-hole 1032 configured to receive a pin 1034 (fig. 12A) to secure the idler wrist pulley 1030 to the first drive unit 1004.

Various pulleys are also disposed on the shaft 1014. The driven geared elbow pulley 1036 is sandwiched between the distal end of the side link 1010a and the proximal end of the side link 1012 a. Each driven elbow pulley 1036 is fixedly attached to an outer surface of the proximal end of each side link 1012a by fasteners 1038 (e.g., screws) such that the elbow pulley 1036 and the lower segment 1012a move in unison about the axis 1014. A lower geared elbow drive belt 1076 wraps around the elbow idler pulley 1028 and the driven elbow pulley 1036. As the upper elbow drive belt 1074 moves, it moves the lower elbow drive belt 1076, which causes the driven elbow pulley 1036 to rotate in unison with the lower arm 1012 about the axis 1014, which in turn changes the angle between the lower arm 1012 and the base orthogonal plane.

Advancing inwardly along the shaft 1014 from the elbow pulley 1036 are side links 1012, spacers 1037, and geared idler wrist pulleys 1040 that are not secured to the shaft 1014. A spacer 1037 separates the idler wrist pulley 1040 from the elbow pulley 1036 along the shaft 1014. The aperture 1012a 'in the proximal end of the side link 1012a is large enough so that the inner edge of the side link 1012a surrounding the aperture 1012 a' does not contact the spacer 1037. The idler wrist pulley 1040 is connected to an idler wrist pulley 1030 on the shaft 1018 via a geared upper wrist belt 1042.

A driven wrist pulley 1044 is disposed on shaft 1016 on either side of mount 1046 of cutter/grabber 1001. Wrist pulley 1044 is not fixed to shaft 1016. The driven wrist pulley 1044 is secured to a mount 1046 of the cutter/grasper 1001 with fasteners 1048 (e.g., screws). The driven wrist pulley 1044 is connected to the idler wrist pulley 1040 on the shaft 1014 by a geared lower wrist belt 1050. Regardless of the rotation of the upper and lower arms 1010 and 1012, the wrist pulleys 1030, 1040, and 1044 and the upper and lower belts 1042 and 1050 are arranged to maintain the cutter/grasper in a horizontal position, as will be described in more detail below.

Fig. 12 to 12B show details of the first driving unit 1004. The first drive unit 1004 includes a carrier plate 1060, and a shoulder drive unit 1062 and an elbow drive unit 1064 mounted to the carrier plate 1060. As described above, the first driving unit 1004 is configured to move along the guide rail to position the arm 1000. To provide this movement, bearings 1066 are positioned on the front side 1060c of the carrier plate 1060, and bearings 1068 are positioned on the back side 1060b of the carrier plate 1060.

A bearing 1070 is mounted to the rear side 1060b of the carrier plate 1060, and the bearing 1070 is spaced from the rear side by a spacer 1072. The bearing 1070 is configured to receive and retain an end of the shaft 1018. Wrist brake bracket 1077 extends from back side 1060b of carrier plate 1060 and is centered between bearings 1070. The aforementioned pin 1034 extends through the distal end of the bracket 1077. As described above, the pins 1034 interlock with the holes 1032 (fig. 11B) in the wrist pulleys 1030 and fix the position of those pulleys relative to the carrier plate 1060.

A shoulder drive unit 1062 is mounted to the back side 1060b of the carrier plate 1060 and an elbow drive unit 1064 is mounted to the front side 1060c of the carrier plate 1060. The carrier plate 1060 defines an opening 1060a, which opening 1060a provides clearance for passage of an upper elbow drive belt 1074 driven by the elbow drive unit 1064.

A pair of blocks 1075 are mounted to the rear side 1060b of the carrier plate 1060. The blocks 1075 are spaced a distance apart from each other to receive a carrier guide 1302 (fig. 13) of a drive 1300 (fig. 13) mounted to the second drive unit 1006, as described in more detail below.

Fig. 12B shows details of the shoulder drive unit 1062 and the elbow drive unit 1064. The shoulder drive unit 1062 includes a shoulder driver 1080, the shoulder driver 1080 preferably being an electric stepper motor that may be coupled to a speed reducer to achieve a desired torque. The shoulder drive unit 1062 also includes a key shaft 1082, the key shaft 1082 being coupled to the shoulder driver 1080 and driven by the shoulder driver 1080. The shoulder drive unit 1062 includes a key arm drive pulley 1084 that is fixed to and rotates in unison with the shaft 1082. The shaft 1082 is supported by a set of bearings 1086, the bearings 1086 being attached to the rear side 1060b of the carrier plate 1060. The shoulder drive unit 1062 is connected to the shoulder pulley 1024 (fig. 11 b) by a shoulder belt 1088 so that when the shoulder driver 1080 drives and rotates the shaft 1082 and shoulder drive pulley 1088, rotation of the shoulder drive pulley 1088 will result in rotation of the shoulder pulley 1024 and the upper arm 1010.

The elbow drive unit 1064 includes an elbow driver 1090, and the elbow driver 1090 is preferably an electric stepper motor that may be coupled to a speed reducer to achieve a desired torque. The elbow drive unit 1064 further includes a key shaft 1092, the key shaft 1092 being coupled to the driver 1090 and driven by the driver 1090. The elbow drive unit 1064 includes a key elbow drive pulley 1094, the key elbow drive pulley 1094 being fixed to and rotating in unison with the shaft 1092. The shaft 1092 is supported by a set of bearings 1096, the bearings 1096 being attached to the front side 1060c of the carrier plate 1060 via spacers 1097 and the plate 1099. The elbow drive unit 1064 is coupled to the idler elbow pulley 1028 (fig. 11B) by an upper elbow strap 1074 (fig. 11B) such that as the elbow driver 1090 drives the rotation of the shaft 1092 and elbow drive pulley 1094, the rotation of the elbow drive pulley 1094 will cause the rotation of the elbow pulleys 1028 and 1036 and the lower arm 1012.

Fig. 13 shows details of the second drive unit 1006. The second driving unit 1006 includes a driver 1300, which is preferably an air cylinder. A carrier guide 1302 is mounted to the drive 1300 for linear movement along the z-axis. The movement of the carrier drive 1302 is driven by the drive 1300. The drive 1300 is secured to the machine 116 by a bracket 1304. The carrier guide 1302 is configured to be positioned between blocks 1075 (fig. 12A) on the back side 1060b of the carrier plate 1060, and movement of the carrier guide 1302 by the drive 1300 will result in movement of the carrier plate 1060 and arm 1000 along the rail 1008 (fig. 10C) in the z-axis direction.

The bracket 1304 also supports a flexible electrical and pneumatic conduit 1306, the conduit 1306 being connected at one end to the carrier plate 1060 via a bracket 1307 and fixed at the other end to a connection box 1308. The flexible tube 1306 may flex and move with the carrier plate 1060 as the carrier plate 1060 moves along the z-axis. The conduit 1306 may distribute power and compressed air to the shoulder driver 1080 and elbow driver 1090. In one embodiment, the tubing houses air lines (e.g., compressed air) for at least one of the electrical wires for the aforementioned stepper motor, switch, and pneumatic valve, as well as the air cylinder supplying cutter driver 1418.

Fig. 14 is an exploded view of the cutter/grasper 1001 shown in fig. 10A, 10B, 10C, 11, and 11B. The cutter/grabber 1001 includes a base 1416, to which 1416 is attached a cutter/grabber holder 1406, a strike plate 1411, a driver 1418, and a mount 1046 (FIG. 11 b). A knife cutter 1404 for cutting the supply line and a gripper 1405 for gripping the free end of the cut supply line extend axially along axis a-a and are housed between a cutter/gripper holder 1406 and a cover 1403, the cover 1403 holding the cutter 1404 and gripper 1405 parallel to each other and to axis a-a. The cutter 1404 and the grabber 1405 are configured to selectively move, under control of the driver 1418, axially from a retracted position (as shown in fig. 14) toward the strike plate 1411 to an extended position in which the cutter cuts the wire and the grabber grabs the wire. A slot 1416a is formed in base 1416 parallel to axis a-a, and cutter 1404 and gripper 1405 move in slot 1416 a.

Driver 1418 may be a double-acting pneumatic cylinder configured to selectively actuate and thereby cause axial translation of its shaft 1418a along axis a-a from a retracted position (shown in fig. 14) corresponding to the retracted position of cutter 1404 and gripper 1405 to an extended position corresponding to the extended position of cutter 1404 and gripper 1405.

The cutter 1404 and the gripper 1405 are connected to the drive block 1401 by bolts 1417, and are all configured to move axially along axis a-a relative to the base 1416. Gripper 1405 has elongated apertures 1405a and 1405b, which allow some relative axial movement between cutter 1404 and gripper 1405. This relative movement between cutter 1404 and gripper 1405 is controlled by the arrangement of bolts 1407, 1408 and spring 1432. A proximal bolt 1408 is secured to the grabber 1405 at a location slightly distally spaced from the elongated aperture 1405 a. Cover 1403 defines a proximal notch 1403a, which proximal notch 1403a is configured to engage proximal bolt 1408 and act as a positive stop that limits axial movement of catch 1405 in the distal direction (i.e., toward strike plate 1411) when catch 1405 is in its extended position. Further, the cover 1403 defines an axially extending elongated slot 1403 b. Proximal bolt 1407 extends through elongated slot 1403b, through elongated slot 1405b in catch 1405 and is connected to cutter 1404. Elongated slot 1403b serves as a track for proximal bolt 1407, and the end of slot 1403b provides a positive stop for proximal bolt 1407 and cutter 1404 attached thereto. Spring 1432 is connected at its ends to bolts 1407 and 1408. When the cutter 1404 and the grabber 1405 are positioned in their retracted positions, the spring 1432 has an unextended neutral position. Spring 1432 extends to allow relative axial displacement between cutter 1404 and grabber 1405, as will be described in more detail below.

Drive block 1401 is coupled to thrust plate 1412, and thrust plate 1412 is coupled to shaft 1418a of driver 1418. Thrust plate 1412 remains perpendicular to axis A-A and is prevented from rotating about axis A-A by bearing surface 1402 attached to base 1416. Thus, drive block 1401, bolt 1417, thrust plate 1412, cutter 1404, grabber 1405, bolts 1407 and 1408, and spring 1432 may be driven axially together by shaft 1418a of driver 1418 as driver 1418 moves from its retracted position to its extended position, but grabber 1405 and bolt 1408 may move relative to the rest as permitted by the elongation of spring 1432.

The wire cutter guide 1409 is secured to the cutter/grabber holder 1406 by a mounting plate 1410. Wire cutter guide 1409 and cutter/grabber retainer 1406 are axially spaced a predetermined distance from strike plate 1411, thereby defining a wire receiving channel 1416b (FIG. 14A) for receiving wire to be cut that spans channel 1416 b. For example, when cutter/grabber 1001 is at cutting position 350b (fig. 3A), the supply line to be cut may be received in channel 1416b (fig. 14A), and may extend in a direction transverse to axis a-a and be positioned to span slot 1416a in the path of axial movement of cutter 1404 and grabber 1405. The strike plate 1411 defines a slot 1411a positioned in alignment with the slot 1416a and the cutter 1404 such that when the cutter 1404 is moved from its retracted position to its fully extended position, the distal end of the cutter 1404 (i.e., its blade) will cut through the wire in the channel 1416b (fig. 14A) (e.g., like a guillotine) and through the slot 1411 a.

Shock absorber 1431 is attached to mounting plate 1410. Shock absorber 1431 is configured to engage the distal shoulder 1401a of drive block 1401 only when cutter 1404 is in its extended position after wire 110 is severed. Shock absorber 1431 provides an adjustable positive stop to control the distance cutter 1404 travels distally through slot 141la of strike plate 1411. The full force of the driver 1418 should be transferred to the wire 110 until it is cut off. Once the wire 110 is cut, the shock 1431 slows down the drive 1418 and drive block 1401 so the final stop is not so abrupt.

The operation of the cutter/grabber 1001 is as follows. As described above, the cutter/grabber 1001 moves to the cutting position 350b to cut and grab the wire. When the cutter/grabber 1001 is in the cutting position 350b (fig. 3A), the line extends across the channel 1416b and slot 1416a in the path of the cutter 1404 and grabber 1405. When the wire is so positioned in the channel 1416a, the driver 1418 can be actuated to move its shaft 1418a from its retracted position to its extended position. As described above, the shaft 1418a is directly connected to the drive block 1401 and the bolt 1417 such that initially upon movement of the shaft 1418a, the bolt 1417 (and the cutter 1404 and the grabber 1405) will begin to move axially in a distal direction toward the strike plate 1411. When the cutter 1404 and the grabber 1405 are initially moved axially, the spring 1432 will prevent relative axial displacement between the cutter 1404 and the grabber 1405, so that they will both move distally together until the distal bolt 1408 engages the proximal notch 1403 a. When the distal bolt 1408 engages the proximal notch 1403a, the grabber 1405 cannot advance further in the distal direction due to its connection with the distal bolt 1408. This situation corresponds to the fully extended position of the gripper 1405. It is contemplated that in the fully extended position of gripper 1405, the distal end of gripper 1405 compresses the wire in channel 1416b against strike plate 1411 to retain wire 110 before wire 110 is cut by cutter 1404.

Furthermore, because slots 1405a and 1405b are elongated, cutter 1404 can slide relative to gripper 1405 and continue to advance distally beyond gripper 1405 to cut the wire and move through slot 1411a even when gripper 1405 is in an extended position where it holds the wire against strike plate 1411. Thereafter, cutter 1404 is advanced distally until bolt 1417 engages the distal end of slot 1405a in gripper 1405, or the limit of bumper 1431 is reached, at which time cutter 1404 cannot be moved further in the distal direction, which corresponds to the fully extended position of cutter 1404. When cutter 1404 is in the fully extended position, spring 1432 will extend an amount that will exert a distally pulling force on grabber 1405, causing grabber 1405 to maintain a pressure on wire 110 that begins to be exerted upon contact with grabber 1405 and increases as cutter 1404 continues to move distally and the spring continues to elongate. Retraction of the shaft 1418a of the driver 1418 will cause the cutter 1404 and the grabber 1405 to return to their retracted positions shown in FIG. 14.

The arm 1000 operates as follows. The arm 1000 may be controlled by the controller 118 to operate the first drive unit 1004 and the second drive unit 1006 to move the cutter/grasper 1001 along the path 350. The belt and pulley are arranged to maintain the orientation of the upper arm, lower arm and gripper independent of each other. To facilitate this capability, the straps 1088 and 1074 remain stationary and substantially locked in place when the corresponding shoulder drive unit 1062 and elbow drive unit 1064 of the straps 1088 and 1074 are not operating. Further, as described above, the idler wrist pulley 1030 remains fixed to the carrier plate 1060 such that the belt 1042 remains stationary throughout the rotational movement of the upper and lower arms 1010, 1012. For example, in the example shown in fig. 11B, the angle between the lower arm 1012 and the horizontal plane (e.g., floor) is about 30 degrees. If in the example position of fig. 11b only the upper arm 1010 is rotated 90 degrees counter clockwise, the angle between the lower arm 1012 and the horizontal will remain at 30 degrees, as described below.

When the elbow drive unit 1064 is turned off, the upper elbow belt 1074 and the elbow idler pulley 1028 remain stationary with respect to the upper arm 1010. When the upper arm 1010 is rotated by 90 degrees by the shoulder drive unit 1062, the driven elbow pulley 1036 and the belt 1076 travel in a 90 degree arc about the shaft 1018. However, the pulley 1036 and lower arm 1012 are supported by the axle 1014, which axle 1014 is also connected to the upper arm 1010. Thus, as the belt 1076 and upper arm 1010 oscillate about the shaft 1018, the geared belt 1076 cannot slide or slip and the geared teeth of the pulley 1036 will ride (rotate) along the internal geared surface of the belt 1042 to maintain the angular position of the lower arm 1012. Thus, when upper arm 1010 has swung 90 degrees counterclockwise, pulley 1036 will have rotated 90 degrees clockwise relative to upper arm 1010.

The above principle is also applicable to wrist joints. When the upper arm 1010 is rotated 90 degrees about the axis 1018, the idler wrist pulley 1040 and belt 1042 travel in a 90 degree arc, similar to the elbow pulley 1036 described above. As with the elbow pulley 1036, the belt 1042 is stationary and cannot slide or slip, but the geared idler elbow pulley 1040 is free to move and rotate along the geared inner surface of the belt 1042. Movement of the pulley 1040 along the belt 1042 will result in movement of the belt 1050 and wrist pulley 1044 about the shaft 1016 in fixed relation to the cutter/grasper 1001. In this example, movement of belt 1050 will maintain the angular level of cutter/grabber 1001 even when upper arm 1010 is rotated 90 degrees.

Further, it should be appreciated that the cutter/grabber 1001 will maintain its horizontal position when the elbow drive unit 1064 and shoulder drive unit 1062 are in operation. Thus, cutter/gripper 1001 will maintain its horizontal position regardless of which portion of arm 1002 is moved. For example, in the example shown in figure 11b, if the lower arm 1012 were to be rotated counterclockwise about the axis 1014 by operation of the elbow drive unit 1064, the shaft 1016, pulley 1044 and belt 1050 would travel in an arc about the axis 1014 along with the lower arm 1012. As the geared pulleys 1044 travel in their arcs, they will travel along the geared inner surfaces of the respective belts 1050 such that as the lower arm 1012 rotates counterclockwise, the pulleys 1044 and the cutter/grabber 1001 will rotate clockwise relative to the lower arm 1012 to maintain the cutter/grabber 1001 in the horizontal orientation in fig. 11B.

It should be appreciated that the system 100 has been described as including the controller 118. The controller 118 is shown as a separate unit, but it should be understood that the controller may also be present with the take-up unit 116, the dancer 114, or the payout unit 112, or may be distributed therebetween. The controller 118 may have a touch screen or other interface that allows a user to select the tension control profile for the coil, the position and speed of the arm and various other components of the system, and includes a processor or processing system. The processing system may also include a memory, such as a semiconductor memory device (e.g., RAM, ROM, PROM, EEPROM, or flash programmable RAM), a magnetic memory device (e.g., a floppy disk or fixed disk), an optical memory device (e.g., a CD-ROM), a PC card (e.g., a PCMCIA card), or other memory device A tension parameter, a length of the coil at which the tension is varied, and instructions for performing the above-described method.

Any of the methods described above may be implemented as computer program logic for use with a processing system. Computer program logic may be embodied 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 FORTRAN, C + +, or JAVA. Such computer instructions may be stored in a non-transitory computer readable medium (e.g., memory) and executed by a processing system. The computer instructions may be distributed in any form as a removable storage medium with accompanying printed or electronic documentation (e.g., shrink wrapped software), preloaded with a computer system (e.g., on system ROM or fixed disk), or distributed via internet protocol.

Several embodiments of an apparatus and method for winding coils 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, it will be appreciated by those skilled in the art that modifications may be made to the provided invention without departing from the spirit and scope of the claimed invention. In the claims, means-plus-function clauses, if any, are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Applicants' explicit intent is not to cite any limitations to any claim herein from U.S. codex 35, clause 112, clause 6, unless the claim explicitly uses "means for … …" and related functionality.

The claims (modification according to treaty clause 19)

1. A system for winding wire, comprising:

A) a wire takeup unit including a rotatable first spindle portion; a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first and second mandrel portions to form a complete mandrel on which wire is wound into a coil; and a wire-guiding crossmember arranged to feed the wire and alternately forming coils on the first and second spindle portions when the first and second spindle portions are engaged to the third spindle portion, wherein each coil is wound in a number 8 configuration; and

b) a wire cutter/grabber unit configured to cut the wire and grab a free end of the cut wire at a cutting position between the sled and a coil formed on the first spindle portion, and move along a predetermined cutter/grabber path with the free end of the wire to a handover position where the free end of the wire is transferred to the second spindle portion,

wherein a length of the thread between the sled and the free end of the thread does not decrease when the cutter/gripper moves along the cutter/gripper path from the cutting position to the handoff position, and a length of the thread between the sled and the free end of the thread is longer at the handoff position than at the cutting position.

2. The system of claim 1, wherein:

the cutter/grabber is configured to move from a waiting to cut position to the cutting position, wherein the waiting to cut position is within six inches of the sled.

3. The system of claim 2, wherein:

the waiting to cut position is within three inches of the crossmember.

4. The system of claim 1, wherein:

the second mandrel portion includes a clamp configured to hold the wire when the cutter/grasper and the sled are in the handoff position.

5. The system of claim 1, further comprising:

a cutter/gripper positioning system disposed vertically above the cutter/gripper and configured to position the cutter/gripper along the cutter/gripper path.

6. The system of claim 5, wherein:

the positioning system includes: a multi-joint arm configured to bend in a plane that is transverse to a plane in which the cross piece is configured to move; and a first driving unit configured to bend the arm.

7. The system of claim 5, wherein:

the positioning system includes a second drive unit configured to translate the arm and the first drive unit in a direction parallel to an axis along which the sled is configured to move.

8. The system of claim 5, wherein:

the positioning system is configured to maintain the cutter/gripper in a horizontal orientation as the cutter/gripper moves throughout the cutter/gripper path.

9. A cutter/grasper system for resetting a wire takeup unit after forming a coil of wire, the wire takeup unit comprising: a rotatable first spindle portion and a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first and second mandrel portions to form a complete mandrel on which wire is wound into a coil; and a wire-guiding crossbar arranged to feed wire and alternately forming coils on the first and second spindle portions when the first and second spindle portions are engaged to the third spindle portion, wherein each coil is wound in a number 8 configuration, the cutter/gripper system comprising:

a wire cutter/grabber unit configured to move along a cutter/grabber path to separate a coil formed on the first mandrel portion from the traversing piece, and to provide the second mandrel portion for said winding and forming of the wire into another coil,

the path includes a plurality of different positions including a waiting to cut position, a transfer position, a handoff position, and a ready to wind position within six inches of the crossmember,

wherein the cutter/gripper is configured to move between the waiting-to-cut position, the cutting position, the transfer position, the handover position, the ready-to-wind position in a loop that starts and ends at the waiting-to-cut position.

10. The system of claim 9, wherein:

when the cutter/grabber moves along the cutter/grabber path from the cutting position to the handoff position, a length of the line between the sled and the free end of the line does not decrease, and a length of the line between the sled and the free end of the line is longer at the handoff position than at the cutting position.

11. The system of claim 9, wherein:

at the cutting position, the cutter/grasper is configured to cut the wire between the loop on the first mandrel portion and the sled and grasp a free end of the cutting wire from the sled.

12. The system of claim 11, wherein:

at the transfer position, the cutter/grasper holds the free end of the wire when the first and second spindle sections are switched positions relative to the traverse.

13. The system of claim 9, wherein:

at the handoff position, the cutter/grasper and the traverse are relatively positioned such that the wire extends across the grasper of the second mandrel portion.

14. The system of claim 12, wherein:

the ready-to-wind position is vertically below the handoff position.

15. The system of claim 9, further comprising:

a cutter/gripper positioning unit coupled to and extending upwardly therefrom to a support position vertically spaced above the cutter/gripper unit, the cutter/gripper positioning unit configured to support and suspend the cutter/gripper unit below the support position.

16. A system for winding wire, comprising:

A) a wire takeup unit including a rotatable first spindle portion and a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first and second mandrel portions to form a complete mandrel on which wire is wound into a coil; and a wire-guiding crossmember arranged to feed a wire and alternately forming coils on the first and second spindle portions when the first and second spindle portions are engaged to the third spindle portion, wherein each coil is wound in a number 8 configuration;

b) a wire cutter/grabber unit configured to cut the wire at a cutting position between the traverse and a coil formed on the first spindle portion, grab a free end of the cut wire, and move along a predetermined cutter/grabber path to a handover position where the wire is transferred to the second spindle portion,

wherein a length of the thread between the sled and the free end of the thread does not decrease when the cutter/gripper moves along the cutter/gripper path from the cutting position to the handoff position, and a length of the thread between the sled and the free end of the thread is longer at the handoff position than at the cutting position; and

c) a cutter/grabber positioning system coupled to the wire takeup unit at an upper end and to the cutter/grabber at a lower end, the cutter/grabber positioning system being disposed vertically above the cutter/grabber and configured to position the cutter/grabber along the cutter/grabber path,

the positioning system comprises a multi-joint arm having an upper arm and a lower arm configured to pivot relative to each other in a common plane of the upper and lower arms, and a first drive unit configured to rotate at least one of the upper and lower arms, and

the positioning system includes a second drive unit configured to translate the arm and the first drive unit in a direction parallel to the traversing member,

wherein the positioning system is configured to maintain the cutter/gripper in a horizontal orientation as the cutter/gripper moves throughout the cutter/gripper path.

17. The system of claim 16, wherein:

the arm includes a belt drive transmission system driven by the first drive unit.

18. The system of claim 17, wherein:

the first drive unit comprises a shoulder drive unit configured to rotate the upper arm about a shoulder joint of the arm and an elbow drive unit configured to rotate the lower arm about an elbow joint of the arm between the upper arm and the lower arm, wherein the first drive unit is mounted on a fixed rail for translation of the first drive unit in a direction parallel to the crossmember.

19. The system of claim 18, wherein:

the shoulder drive unit includes a shoulder driver including a stepper motor configured to drive a geared belt connected to a geared shoulder pulley fixed to the upper arm, and

the elbow drive unit includes an elbow driver including a stepper motor configured to drive a geared drive belt connected to a geared elbow pulley secured to the lower arm.

20. The system of claim 19, wherein:

the second drive unit includes a cylinder configured to translate the first drive unit and the arm.

21. A method of winding a wire with a wire takeup unit, the takeup unit comprising: a rotatable first spindle portion; a rotatable second spindle portion; a third mandrel portion configured to alternately engage the first and second mandrel portions to form a complete mandrel on which the wire is wound into a coil; and a thread-guiding crossmember arranged to feed a thread and alternately forming a coil on the first and second spindle portions when the first and second spindle portions are engaged to the third spindle portion, the method comprising:

feeding wire from said traverse and winding the fed wire in a number 8 configuration to form a coil on a complete mandrel formed by joining said first and third mandrel portions; and is

At the time of the formation of the coil,

positioning a wire cutter/grabber unit at a cutting position between the crossmember and the formed coil, the cutter/grabber being configured to cut the wire and grab a free end thereof, and

cutting the wire at the cutting location and grasping a cut end of the wire extending from the traverse;

separating the first mandrel portion from the third mandrel portion, leaving the formed coil only on the first mandrel portion, and exchanging positions between the first mandrel portion and the second mandrel portion; and

moving the cutter/grasper along a predetermined cutter/grasper path with the free end of the wire to a handoff position where the free end of the wire is transferred from the cutter/grasper to the second mandrel portion;

engaging the second mandrel portion with the third mandrel portion to form another complete mandrel; and

moving the cutter/gripper along the cutter/gripper path from the handoff position to a ready to wind position,

wherein a length of the thread between the sled and the free end of the thread does not decrease when the cutter/gripper moves along the cutter/gripper path from the cutting position to the handoff position, and a length of the thread between the sled and the free end of the thread is longer at the handoff position than at the cutting position.

22. The method of claim 21, wherein:

engaging the second mandrel portion with the third mandrel portion while moving the cutter/gripper from the handoff position to the ready-to-wind position.

23. The method of claim 21, further comprising:

when the cutter/grabber is moved to the ready-to-wind position, winding wire is wound in a figure 8 configuration to form a coil on another complete mandrel comprising the second and third mandrel portions joined together.