Wire coil winding apparatus and method

Abstract

Apparatus and method is provided for converting a long indefinite length of wire from a supply bundle into a measured length, tightly wound coil. The wire is driven from the supply by a constant speed capstan to a winding station. A measured length of wire is wrapped around a mandrel between a pair of flanges under controlled tension conditions. After winding, a series of bands are passed through the coil bore and respective ends of banding material are twisted together and flattened against the coil surface. The banded coil is ejected from the mandrel to a conveyor or container.

What is claimed is:  
     
         1 . Apparatus for coil winding, comprising: 
 (a) a supply of wire;    (b) a winding station for forming the wire into a coil having a bore and an outer diameter;    (c) means for driving the wire from the supply to the winding station;    (d) a banding supply for supplying a length of banding material having a first end and a second end;    (e) means for passing the first end of the length of banding material through the bore of the coil; and    (f) means for securing the second end to the first end of the length of banding material so as to snugly band a portion of the coil.    
     
     
         2 . The apparatus for coil winding described in  claim 1 , wherein the winding station comprises a mandrel extending between a pair of flanges and the means for passing the first end of banding material through the bore of the coil comprises a banding material supply device and a channel formed in the flanges and the mandrel, the channel being inwardly open.  
     
     
         3 . The apparatus for coil winding described in  claim 2 , further comprising a bar positioned adjacent the winding station for orienting the secured first and second ends of the length of banding material close to a peripheral surface of the coil.  
     
     
         4 . The apparatus for coil winding described in  claim 1 , further comprising a ram operable for forcing a secured second end and first end of the banding material into contact with an outer diameter of the coil.  
     
     
         5 . The apparatus for coil winding described in  claim 1 , further comprising a sensor positioned adjacent the wire for detecting whether the wire is present.  
     
     
         6 . The apparatus for coil winding described in  claim 1 , further comprising a detector for detecting whether the wire is operating under excessive tension.  
     
     
         7 . Apparatus for coil winding, comprising: 
 (a) a wire supply holder;    (b) a winding station for forming a selected length of the wire into a coil having a bore and an outer diameter, the winding station comprising a pair of opposed flanges and a mandrel;    (c) means for driving the wire from the wire supply holder to the winding station    (d) a banding supply for supplying a length of banding material having a first end and a second end;    (e) the flanges and mandrel being formed with a channel for passing the first end of the length of banding through the bore of the coil; and    (f) a rotatable clamp for twisting the second end and the first end of the length of banding material so as to snugly band the coil.    
     
     
         8 . The apparatus for coil winding described in  claim 7 , wherein the channel in the flanges and mandrel is open in a direction facing the coil.  
     
     
         9 . The apparatus for coil winding described in  claim 7 , wherein the banding material is a wire.  
     
     
         10 . The apparatus for coil winding described in  claim 7 , further comprising a ram operable for forcing the twisted second end and first end into contact with an outer diameter of the coil.  
     
     
         11 . The apparatus for coil winding described in  claim 7 , further comprising a positionable guide mounted between the means for driving the wire and the winding station.  
     
     
         12 . The apparatus for coil winding described in  claim 7 , further comprising means for applying a controlled tension to the wire.  
     
     
         13 . The apparatus for coil winding described in  claim 12 , wherein the means for applying a controlled tension to the wire comprises a magnetic brake positioned for contacting the wire to apply tension thereto.  
     
     
         14 . The apparatus for coil winding described in  claim 7 , wherein the means for driving the wire comprises a drive capstan operable to drive the wire at a substantially constant linear speed.  
     
     
         15 . The apparatus for coil winding described in  claim 7 , further comprising means to drive the mandrel to apply tension to the wire.  
     
     
         16 . The apparatus for coil winding described in  claim 15 , wherein the mandrel is configured to receive and grip a starting end of the wire.  
     
     
         17 . A method for winding a wire to form a coil, comprising the steps of: 
 (a) threading the wire along a path from a wire supply holder to a winding station;    (b) attaching a starting end of the wire to a mandrel;    (c) moving the length of wire along the path at a substantially constant linear speed;    (d) causing the mandrel to rotate;    (e) causing the wire to move in an axial direction relative to the mandrel at a selected traversing speed;    (f) stopping the rotation and traversing at the completion of winding a pre-determined length of wire to form a coil;    (g) banding the coil of wire in a plurality of places; and    (h) ejecting the banded coil.    
     
     
         18 . The method for winding a wire as described in  claim 17 , wherein the step of banding the coil of wire comprises passing a first end of a length of banding material through a bore of the coil and securing a second end to the first end.  
     
     
         19 . The method for winding a wire as described in  claim 17 , wherein the step of banding the coil of wire comprises passing a first end of a length of banding material through a channel formed in the mandrel and securing a second end to the first end.  
     
     
         20 . The method for winding a wire as described in  claim 17 , further comprising cutting an end of the wire and bending the end of wire back to maintain the coil as wound.  
     
     
         21 . The method for winding a wire as described in  claim 17 , wherein the step of causing the mandrel to rotate comprises varying the mandrel rotating speed so as to match the rotation of the mandrel to the substantially constant linear speed of movement of the length of wire.  
     
     
         22 . The method for winding a wire as described in  claim 17 , wherein the step of causing the mandrel to rotate further comprises causing the mandrel to rotate slowly for a selected number of revolutions and thereafter to rotate more quickly.  
     
     
         23 . The method for winding a wire as described in  claim 22 , further comprising causing the mandrel to rotate slowly during a period when a quantity of wire on the mandrel approaches the pre-determined length of wire and thereafter to stop.  
     
     
         24 . The method for winding a wire as described in  claim 17 , wherein the step of banding the coil of wire in a plurality of places comprises banding the coil of wire in four places.  
     
     
         25 . The method for winding a wire as described in  claim 17 , wherein the step of causing the wire to move in an axial direction relative to the mandrel further comprises adjusting the speed of the relative movement in the axial direction in relation to the rotation of the mandrel.  
     
     
         26 . The method for winding a wire as described in  claim 18 , wherein the step of securing comprises twisting the first and second ends together and the method further comprises causing the twisted ends into close contact with a peripheral surface of the coil.  
     
     
         27 . The method for winding a wire as described in  claim 26 , wherein the step of causing the twisted ends into close contact with a peripheral surface of the coil comprises impacting the twisted ends with a ram.