Rewinder method and apparatus

Abstract

A rewinder method and apparatus. The payout assembly of a rewinder machine comprises a spool having optical fiber wrapped about it, a motor that turns the spool as fiber is unwound from the spool, a first sheave having a surface along which the unwound fiber passes, a load cell in direct contact with the first sheave, and a motion mechanism for producing relative motion between the spool and the first sheave. The load cell senses stress exerted on the first sheave by the fiber as the fiber passes along a surface of the. The load cell produces electrical signals relating to the fleeting angle between the first sheave and the position on the spool from which fiber is being unwound. A controller receives the electrical signals and generates control signals that cause the motion mechanism to produce relative motion between the spool and the first sheave in a direction substantially parallel to an axis of rotation of the spool to reduce the fleeting angle.

What is claimed is:  
     
         1 . A rewinder machine comprising: 
 a payout assembly, the payout assembly comprising: 
 a spool having optical fiber wrapped thereabout;  
 a motor that turns the spool as fiber is unwound from the spool;  
 a first sheave having a surface along which the unwound fiber passes;  
 a load cell in direct contact with the first sheave, the load cell sensing stress exerted on the first sheave by the fiber as the fiber passes along a surface of the first sheave, the load cell producing an electrical signal relating to an angle between the first sheave and a position on the spool from which fiber is being unwound;  
 a motion mechanism, the motion mechanism producing relative motion between the spool and the first sheave in accordance with control signals received by the motion mechanism; and  
 a controller, the controller receiving the electrical signals produced by the load cell and generating the control signals based on the received electrical signals, the controller outputting the electrical signals to the motion mechanism to cause the motion mechanism produce relative motion between the spool and the first sheave in a direction substantially parallel to an axis of rotation of the spool and such that the angle is reduced;  
   a prooftest assembly, the proof test assembly receiving unwound fiber from the payout assembly and exerting a predetermined amount of stress on the fiber; and    a takeup assembly, the takeup assembly receiving fiber from the prooftest assembly that has been prooftested and taking the fiber up on a takeup spool.    
     
     
         2 . The rewinder machine of  claim 1 , wherein the load cell is embedded in the first sheave.  
     
     
         3 . The rewinder machine of  claim 1 , wherein the motion mechanism is mounted on a follower component and comprises a screw and a motor, the follower component being movably mounted on the screw, the motor receiving the control signals from the controller and rotating the screw to cause the follower component to be moved in said direction substantially parallel to an axis of rotation of the spool such that said angle is reduced.  
     
     
         4 . The rewinder machine of  claim 3 , wherein the first sheave is rotationally attached to an attachment component, and wherein the attachment component is fixedly secured to the follower component.  
     
     
         5 . The rewinder machine of  claim 1 , wherein the motion mechanism receives the control signals from the controller and causes the spool to be moved in said direction substantially parallel to an axis of rotation of the spool such that said angle is reduced.  
     
     
         6 . The rewinder machine of  claim 1 , further comprising: 
 a second sheave, the second sheave being fixedly attached to the follower component by an attachment member, wherein the fiber that is unwound from the spool passes underneath the first sheave and then over the second sheave, and wherein as the fiber passes underneath the first sheave, the load cell senses stress in the first sheave and converts the sensed stress into said electrical signal.    
     
     
         7 . A follower assembly for use in a payout assembly of a rewinder machine, the follower assembly comprising: 
 a follower component movably mounted on a screw such that when the screw is turned, the follower assembly moves along the screw;    a first sheave fixedly attached to the follower component by an attachment component, the first sheave being rotationally mounted to the attachment component, wherein fiber unwound from a spool rotationally mounted in the payoff assembly passes along a surface of the first sheave; and    a load cell in direct contact with the first sheave, the load cell sensing stress exerted on the first sheave by the fiber as the fiber passes along the surface of the first sheave, the load cell producing an electrical signal relating to an angle between the first sheave and a position on the spool from which fiber is being unwound.    
     
     
         8 . The follower assembly of  claim 7 , wherein the load cell is embedded in the first sheave.  
     
     
         9 . The follower assembly of  claim 7 , further comprising: 
 a second sheave, the second sheave being fixedly attached to the follower component by an attachment member, wherein, the fiber that is unwound from the spool passes underneath the first sheave and then over the second sheave, and wherein as the fiber passes underneath the first sheave, the load cell senses stress in the first sheave and converts the sensed stress into said electrical signal.    
     
     
         10 . A method for use in a rewinder machine for sensing a fleeting angle and for reducing the fleeting angle, the fleeting angle corresponding to an angle between a position on a spool from which optical fiber is being unwound and the location of a first sheave along which unwound optical fiber passes, the method comprising: 
 sensing the fleeting angle with a load cell that is in direct contact with the first sheave, wherein the passage of unwound fiber along the first sheave causes stress to be exerted on the first sheave;    producing electrical signals with the load cell relating to the angle between the position on a spool from which optical fiber is being unwound and the location of the first sheave; and    processing the electrical signals to determine the amount of relative motion needed between the first sheave and the spool to reduce the fleeting angle; and    generating control signals based on the determination as to the amount of relative motion needed between the first sheave and the spool to reduce the fleeting angle.    
     
     
         11 . The method of  claim 10 , further comprising: 
 delivering the control signals to a motion mechanism, the motion mechanism producing relative motion between the spool and the first sheave in accordance with control signals received by the motion mechanism, and wherein the relative motion produced by the motion mechanism causes the fleeting angle to be reduced.    
     
     
         12 . The method of  claim 10 , wherein the motion mechanism is mounted on a follower component and comprises a screw and a motor, the follower component being movably mounted on the screw, the motor receiving the control signals from the controller and rotating the screw to cause the follower component to be moved in a direction substantially parallel to an axis of rotation of the spool to reduce the fleeting angle.  
     
     
         13 . The method of  claim 10 , wherein the first sheave is rotationally mounted on an attachment member, and wherein the attachment member is fixedly attached to the follower component.  
     
     
         14 . The method of  claim 10 , wherein the motion mechanism receives the control signals from the controller and causes the spool to be moved in a direction substantially parallel to an axis of rotation of the spool to reduce the fleeting angle.