Wire tie systems and methods

Abstract

A wire tie looping system including a twist cylinder including an elongated semicylindrical member having a cylindrical face portion and a planar face portion, and a peg extending from the planar face portion and adapted to rotate about a twist axis, a bend cylinder including a peg extending therefrom and adapted to rotate about a bend axis oriented transverse to the twist axis and translate along the bend axis, an edge sensor adapted to sense proximity of an edge defined by an intersection of the cylindrical and planar face portions and laterally offset from the twist axis to enable a length of wire to pass vertically into a looping position including the length of wire adjacent the planar face portion oriented vertically, and a control system to control the twist cylinder, the bend cylinder, and the edge sensor to form a looped wire tie from a length of wire.

What is claimed is: 
     
         1 . A wire tie looping system, comprising:
 a twist cylinder comprising:
 an elongated semicylindrical member comprising:
 a cylindrical face portion; and 
 a planar face portion; and 
 
 a looping peg extending transverse from the planar face portion, 
 the twist cylinder configured to rotate about a twist axis defined by a longitudinal axis of the elongated semicylindrical member; 
   a bend cylinder comprising:
 a bending peg, 
 the bend cylinder configured to:
 rotate about a bend axis that is oriented transverse to the twist axis; and 
 translate along the bend axis; 
 
   an edge sensor configured to sense proximity of an edge defined by an intersection of the cylindrical face portion and the planar face portion, the edge sensor laterally offset from the twist axis to enable a length of wire to pass vertically into a looping position comprising the length of wire adjacent the planar face portion oriented vertically;   an index wheel configured to rotate about an index axis to guide lengths of wire into and out of a looping position, the index axis oriented parallel to the twist axis;   a twist motor configured to drive rotation of the twist cylinder about the twist axis;   a bend motor configured to drive rotation of the bend cylinder about the bend axis;   a bend slide motor configured to drive translation of the bend cylinder along the bend axis;   an index motor configured to drive rotation of the index wheel about the index axis;   a wire tie control system configured to:
 drive rotation of the twist motor to drive rotation of the twist cylinder about the twist axis; 
 monitor, during rotation of the twist cylinder, a proximity signal output by the edge sensor; 
 determine, based on the monitoring of the proximity signal, that the twist cylinder is at a first angular position comprising the planar face portion oriented at an angle relative to vertical; 
 drive, in response to determining that the twist cylinder is in the first angular position, rotation of the twist motor to drive rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to a second angular position comprising the planar face portion oriented vertically; 
 drive, in response to rotation of the twist cylinder to the second angular position, rotation of the index motor to drive rotation of the index wheel about the index axis to deposit a length of wire into a looping position, the looping position comprising the length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the length of wire extends to a first side of the looping peg and a central portion of the length of wire extends to a second side of the looping peg; 
 drive, in response to depositing the length of wire into the looping position, the bend slide motor to drive translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the length of wire; 
 drive, in response to moving the bending peg proximate the length of wire, rotation of the bend motor to drive rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the length of wire about the looping peg of the twist cylinder such that the end of the length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the length of wire; 
 drive, in response to bending of the end of the length of wire about the looping peg, rotation of the twist motor to drive rotation of the twist cylinder about the twist axis to cause twisting of the end of the length of wire about the central portion of the length of wire to form a looped end on the length of wire; and 
 drive, in response to forming of the looped end on the length of wire, rotation of the index motor to drive rotation of the index wheel about the index axis to eject the length of wire out of the looping position. 
   
     
     
         2 . The wire tie looping system of  claim 1 , the wire tie control system further configured to:
 in response to ejection of the length of wire out of the looping position:
 drive rotation of the twist motor to drive rotation of the twist cylinder about the twist axis; 
 monitor, during rotation of the twist cylinder, the proximity signal output by the edge sensor; 
 determine, based on the monitoring of the proximity signal, that the twist cylinder is at the first angular position comprising the planar face portion oriented at an angle relative to vertical; 
 drive, in response to determining that the twist cylinder is in the first angular position, rotation of the twist motor to drive rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to the second angular position comprising the planar face portion oriented vertically; 
 drive, in response to rotation of the twist cylinder to the second angular position, rotation of the index motor to drive rotation of the index wheel about the index axis to deposit a second length of wire into the looping position, the looping position comprising the second length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the second length of wire extends to the first side of the looping peg and the central portion of the second length of wire extends to the second side of the looping peg; 
 drive, in response to depositing the second length of wire into the looping position, the bend slide motor to drive translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the second length of wire; 
 drive, in response to moving the bending peg proximate the second length of wire, rotation of the bend motor to drive rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the second length of wire about the looping peg of the twist cylinder such that the end of the second length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the second length of wire; 
 drive, in response to bending of the end of the second length of wire about the looping peg, rotation of the twist motor to drive rotation of the twist cylinder about the twist axis to cause twisting of the end of the second length of wire about the central portion of the second length of wire to form a looped end on the second length of wire; and 
 drive, in response to forming of the looped end on the second length of wire, rotation of the index motor to drive rotation of the index wheel about the index axis to eject the second length of wire out of the looping position. 
   
     
     
         3 . A wire tie looping system, comprising:
 a twist cylinder comprising:
 an elongated semicylindrical member comprising:
 a cylindrical face portion; and 
 a planar face portion; and 
 
 a looping peg extending transverse from the planar face portion, 
 the twist cylinder configured to rotate about a twist axis defined by a longitudinal axis of the elongated semicylindrical member; 
   a bend cylinder comprising:
 a bending peg, 
 the bend cylinder configured to:
 rotate about a bend axis that is oriented transverse to the twist axis; and 
 translate along the bend axis; 
 
   an edge sensor configured to sense proximity of an edge defined by an intersection of the cylindrical face portion and the planar face portion, the edge sensor laterally offset from the twist axis to enable a length of wire to pass vertically into a looping position comprising the length of wire adjacent the planar face portion oriented vertically;   an index wheel configured to rotate about an index axis to guide lengths of wire into and out of a looping position, the index axis oriented parallel to the twist axis;   a wire tie control system configured to:
 drive rotation of the twist cylinder about the twist axis; 
 monitor, during rotation of the twist cylinder, a proximity signal output by the edge sensor; 
 determine, based on the monitoring of the proximity signal, that the twist cylinder is at a first angular position; 
 drive, in response to determining that the twist cylinder is in the first angular position, rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to a second angular position; 
   drive, in response to rotation of the twist cylinder to the second angular position, rotation of the index wheel about the index axis to deposit a length of wire into a looping position, the looping position comprising the length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the length of wire extends to a first side of the looping peg and a central portion of the length of wire extends to a second side of the looping peg;
 drive, in response to depositing the length of wire into the looping position, translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the length of wire; 
 drive, in response to moving the bending peg proximate the length of wire, rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the length of wire about the looping peg of the twist cylinder such that the end of the length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the length of wire; 
 drive, in response to bending of the end of the length of wire about the looping peg, rotation of the twist cylinder about the twist axis to cause twisting of the end of the length of wire about the central portion of the length of wire to form a looped end on the length of wire; and 
 drive, in response to forming of the looped end on the length of wire, rotation of the index wheel about the index axis to eject the length of wire out of the looping position. 
   
     
     
         4 . The system of  claim 3 , the wire tie control system further configured to:
 in response to ejection of the length of wire out of the looping position:
 drive rotation of the twist cylinder about the twist axis; 
 monitor, during rotation of the twist cylinder, the proximity signal output by the edge sensor; 
 determine, based on the monitoring of the proximity signal, that the twist cylinder is at the first angular position; 
 drive, in response to determining that the twist cylinder is in the first angular position, rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to the second angular position; 
 drive, in response to rotation of the twist cylinder to the second angular position, rotation of the index wheel about the index axis to deposit a second length of wire into the looping position, the looping position comprising the second length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the second length of wire extends to the first side of the looping peg and the central portion of the second length of wire extends to the second side of the looping peg; 
 drive, in response to depositing the second length of wire into the looping position, translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the second length of wire; 
 drive, in response to moving the bending peg proximate the second length of wire, rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the second length of wire about the looping peg of the twist cylinder such that the end of the second length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the second length of wire; 
 drive, in response to bending of the end of the second length of wire about the looping peg, rotation of the twist cylinder about the twist axis to cause twisting of the end of the second length of wire about the central portion of the second length of wire to form a looped end on the second length of wire; and 
 drive, in response to forming of the looped end on the second length of wire, rotation of the index wheel about the index axis to eject the second length of wire out of the looping position. 
   
     
     
         5 . The system of  claim 3 , further comprising:
 a twist motor configured to drive rotation of the twist cylinder about the twist axis;   a bend motor configured to drive rotation of the bend cylinder about the bend axis;   a bend slide motor configured to drive translation of the bend cylinder along the bend axis; and   an index motor configured to drive rotation of the index wheel about the index axis,
 the wire tie control system further configured to:
 drive rotation of the twist motor to drive rotation of the twist cylinder about the twist axis; 
 drive rotation of the bend motor to drive rotation of the bend cylinder about the bend axis; 
 drive rotation of the index motor to drive rotation of the index wheel about the index axis; 
 drive the bend slide motor to drive translation of the bend cylinder along the bend axis. 
 
   
     
     
         6 . The system of  claim 3 , wherein the first angular position comprises the planar face portion oriented at an angle relative to vertical. 
     
     
         7 . The system of  claim 3 , wherein the second angular position comprises the planar face portion oriented vertically. 
     
     
         8 . The system of  claim 3 , wherein the length of wire is sized, heat-treated, and coated wire. 
     
     
         9 . The system of  claim 3 , wherein the controller is configured to operate a cutter to cut the length of wire from a strand of wire. 
     
     
         10 . The system of  claim 3 , further comprising a bale of material secured by way of the length of wire having the looped end. 
     
     
         11 . A method of producing looped wire ties, comprising:
 driving rotation of a twist cylinder about a twist axis,
 the twist cylinder comprising:
 an elongated semicylindrical member comprising:
 a cylindrical face portion; and 
 a planar face portion; and 
 
 a looping peg extending transverse from the planar face portion, 
 the twist cylinder configured to rotate about the twist axis defined by a longitudinal axis of the elongated semicylindrical member; 
 
   monitoring, during rotation of the twist cylinder, a proximity signal output by an edge sensor, the edge sensor configured to sense proximity of an edge defined by an intersection of the cylindrical face portion and the planar face portion, the edge sensor laterally offset from the twist axis to enable a length of wire to pass vertically into a looping position comprising the length of wire adjacent the planar face portion in a vertical orientation;   determining, based on the monitoring of the proximity signal, that the twist cylinder is at a first angular position;   driving, in response to determining that the twist cylinder is in the first angular position, rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to a second angular position;   driving, in response to rotation of the twist cylinder to the second angular position, rotation of an index wheel about an index axis to deposit a length of wire into a looping position, the looping position comprising the length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the length of wire extends to a first side of the looping peg and a central portion of the length of wire extends to a second side of the looping peg, the index wheel configured to rotate about the index axis to guide lengths of wire into and out of the looping position, the index axis oriented parallel to the twist axis;   driving, in response to depositing the length of wire into the looping position, translation of a bend cylinder along a bend axis toward the planar face portion of the twist cylinder to move a bending peg proximate the length of wire, a bend cylinder comprising:
 the bending peg, 
 the bend cylinder configured to:
 rotate about the bend axis, the bend axis oriented transverse to the twist axis; and 
 translate along the bend axis; 
 
   driving, in response to moving the bending peg proximate the length of wire, rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the length of wire about the looping peg of the twist cylinder such that the end of the length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the length of wire;   driving, in response to bending of the end of the length of wire about the looping peg, rotation of the twist cylinder about the twist axis to cause twisting of the end of the length of wire about the central portion of the length of wire to form a looped end on the length of wire; and   driving, in response to forming of the looped end on the length of wire, rotation of the index wheel about the index axis to eject the length of wire out of the looping position.   
     
     
         12 . The method of  claim 11 , further comprising:
 in response to ejection of the length of wire out of the looping position:
 driving rotation of the twist cylinder about the twist axis; 
 monitoring, during rotation of the twist cylinder, the proximity signal output by the edge sensor; 
 determining, based on the monitoring of the proximity signal, that the twist cylinder is at the first angular position; 
 driving, in response to determining that the twist cylinder is in the first angular position, rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to the second angular position; 
 driving, in response to rotation of the twist cylinder to the second angular position, rotation of the index wheel about the index axis to deposit a second length of wire into the looping position, the looping position comprising the second length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the second length of wire extends to the first side of the looping peg and the central portion of the second length of wire extends to the second side of the looping peg; 
 driving, in response to depositing the second length of wire into the looping position, translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the second length of wire; 
 driving, in response to moving the bending peg proximate the second length of wire, rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the second length of wire about the looping peg of the twist cylinder such that the end of the second length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the second length of wire; 
 driving, in response to bending of the end of the second length of wire about the looping peg, rotation of the twist cylinder about the twist axis to cause twisting of the end of the second length of wire about the central portion of the second length of wire to form a looped end on the second length of wire; and 
 driving, in response to forming of the looped end on the second length of wire, rotation of the index wheel about the index axis to eject the second length of wire out of the looping position. 
   
     
     
         13 . The method of  claim 11 , further comprising:
 driving rotation of a twist motor to drive rotation of the twist cylinder about the twist axis;   driving rotation of a bend motor to drive rotation of the bend cylinder about the twist axis;   driving rotation of an index motor to drive rotation of the index wheel about the index axis;   driving a bend slide motor to drive translation of the bend cylinder along the bend axis.   
     
     
         14 . The method of  claim 11 , wherein the first angular position comprises the planar face portion oriented at an angle relative to vertical. 
     
     
         15 . The method of  claim 11 , wherein the second angular position comprises the planar face portion oriented vertically. 
     
     
         16 . The method of  claim 11 , further comprising sizing, heat treating, and coating the length of wire. 
     
     
         17 . The method of  claim 11 , further comprising operating a cutter to cut the length of wire from a strand of wire. 
     
     
         18 . The method of  claim 11 , further comprising securing a bale of material using the length of wire having the looped end. 
     
     
         19 . The method of  claim 18 , further comprising transporting the bale of material secured using the length of wire having the looped end.