Note: Descriptions are shown in the official language in which they were submitted.
The invention relates to the field of supply packages
of tape material which are sometimes referred to in the trade as
spools or cops. More particularly, the invention relates to the
field of traverse, universal or level winding a plurality of
S different tapes into packages. The invention relates to the
field of the method and apparatus for wrapping elongated struc-
tures such as electrical conductors or cables with a plurality
of different tapes from the package of the invention. The in-
vention also relates to the field of tape-wrapped constructions.
In the past a variety of different methods and machines
have been used for the wrapping of tape material around a length
of an electrical conductor or cable. One of the methods used is
the wrapping of the conductor with a single tape supplied fro~ a
pad. A pad is flat roll of tape with each turn of tape thereon
completely overlapping a prior turn. In wrapping, the pad is
revolved concentrically or eccentrically about the circumference
of the conductor to be wrapped while the conductor is advanced
along its longitudinal axis. This method although quite reliable
is inherently limited in rate of production since the speed of
rotating the pad flyer or winding head which carries the tape
pad and winds the tape around the conductor is limited by the
maximum speed which the pad can withstand as it is revolved
around the conductor. Overlapping of each wrap of tape also
effects the production rate. For example, if a fifty percent
overlap of tape on the conductor is desired the conductor must
be advanced at a slower speed as compared to that where a ten
percent overlap is desired.
It is also known in the art to wrap tapes around a
construction such as conductor from two or more separate pads
concentrically or eccentrically mounted on a common winding
head. Thus, the different tapes are applied from a plurality
of pads at a single station in a rotational manner with respect
to the length of the conductor or cable being wrapped. This
method results in the first of a plurality of different tapes
being wrapped directly around the conductor, the second tape
of the plurality being wrapped directly around the first tape,
and so forth. Since the length of tape on each of a plurality
of pads will vary one from another, one pad becomes exhausted
of tape before the others. Since it then becomes necessary to
shut down and reload the wrapping machine with all new pads of
tape, the tape remaining on the unexhausted pads is simply `
wasted.
Still another method known in the art is to wrap one
or more single tapes around a conductor or cable by the use of
pads of single tapes mounted on a plurality of different winding
heads disposed at different stations spaced along the line of
travel of the conductor or cable being wrapped. This method
enables more layers of tape to be applied during a single pass
of the conductor through the plurality of winding heads. ~
Whether a winding head carries one or a plurality of -
pads, the pads of tape are subjected to high rotational speed
in being revolved concentrically or eccentrically around the
longitudinal axis of the cable. Accordingly, the tape pads,
must be capable of withstanding an appreciable level of cen-
trifugal force during the wrapping operation without coming
apart. If the tape being used is comparatively narrow and if
wound in a complètely overlapping manner, the pad is quite
unstable and can easily fall apart from the core upon which
is is wound. A pad having each layer of tape completely over-
lapping adjacent layers necessarily requires a large diameter
- 3.
.: . . ~ , .... . .
pad for a large supply of tape. Due to the maximum diameter
of a pad which a wrapping machine is cable of accepting, the
time period of operation is severely limited by the length of
tape which can be mounted on the winding head, thus limiting the
length of conductor which can be wrapped before stopping the
head to install new pads.
These problems have been reduced by winding the tape
packages in a traverse, universal, or level wound manner, that
is to say the turns of tape advance along the length of the
package alternately from one end to the other thereof. Thus
as one end of the package is reached by the winding of the tape,
the tape is wound toward the opposite end of the package. Tra-
verse winding of the tape package enables an appreciable length
of tape material to be furnished in a single package without
having the excess diameter for the same length of tape material
which would result if the tape was wound in a fully overlapping
fashion into a pad. Also, a tape package which is traverse
wound can better resist centrifugal and windage forces at high
winding speeds.
U.S. Patent No. 533,934, which issued on Fe~ruary 12,
1895 disclose~ a traverse wound cop having a plurality of
parallel threads wound in a traverse manner. This patent also
discloses and appaxatus for winding the cop which includes a
feed mechanism and friction wheel for varying the rate of move-
ment of the threads in the traverse direction as the diameter
of ~he cop increases during winding.
U.S. Patent No. 2,372,400, which issued on March 27,
1945, disloses traverse winding of strands ~r yarns of fibres
of silk, cotton or the like, wherein one turn of a plurality of
adjacent strands is partially overlapping upon the previous
4.
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~3~1'7~ ~
turn of a plurality of adjacent strands in order to interlock
the strands on the package.
Machines for wrapping electrical conductors with a
plurality of tapes each from a different pad of tape are manu-
factured by Aimco Division of The Entwistle Company, Bigelow St.Hudson, Mass. 01749. This company manufactures a Concentric Pad
Type Taping Machine in which a single flyer or winding head at a
single taping station carries as many as four pads, each having
a single tape, mounted concentrically with the axis of rotation
of the winding head. Such a machine can wrap a conductor with
a pair of tapes from one pair o pads in an overlapping relation-
ship such as half lapped and a second pair of tapes from another
pair of pads, again in an overlapping relationship such as half
lapped.
The Aimco Division manufactures an Eccentric Pad Type
Tape Machine having a winding head with a number of different
pads mounted about the periphery of the head with each pad having
a single tape. Such a machine can apply, by way of example, four
different tapes, each from a different one of four separate pads.
Aimco Division also manufactures a Concentric Cop Type
Tape Machine which wraps a single tape from a traverse or uni-
versal wound supply package having its core disposed about the
axis of rotation of the winding head.
An object of the invention is to provide a tape supply
package, spool or cop having a plurality of different tapes tra-
verse wound therèon.
Another object of the invention is to provide a method
and apparatus for winding the tape supply package of the in-
vention.
A further object of the invention is to provide a
5.
machine and method for simultaneously applying a plurality of
different tapes to an elongated structure such as an electrical
conductor.
An additional object of the invention is to provide
a wrapping for an elongated structure in which the wrapping
comprises two or more different tapes simultaneously applied
to the structure.
` The invention is directed to packages, often referred
to as cops or spools, of a plurality of different tapes, the
method and apparatus for making and using such packages in the
wrapping of elongated structures such as conductors or cables
with such tape material, and the resulting wrapped structure.
The supply package of the invention comprises a plurality
of different tapes simultaneously traverse wound with the tapes
in a given turn thereof being spaced apart, abutting or partially
overlapping one another. The supply package is wound on a
winding machine having a multiple tape guiding head and a mul-
tiple tape feed. The guiding head has a plurality of slots or
channels for guiding the individual tapes of the plurality of
20 tapes simultaneously into the package in a predetenmined -
relationship.
The packages are placed in an apparatus for wrapping
the tape around an elongated conductor. The wrapping apparatus
or machine includes a device for guiding the plurality of differ-
ent tapes during the application of the tapes and onto a con-
ductor from traverse wound multiple tape packages. The guiding
device is mounted on a rotating winding head of a wrapping
machine. The winding head also carries the multiple tape supply
package or packages. The multiple guide device comprises end
plates with guide bushings spaced apart from one another by a
6.
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1~ 1'7~ ~
plurality of rods symmetrically spaced around the plates.
Slidingly mounted on each rod is an adjustable tape guide which
is adapted to accept one of the plurality of tapes from a tra-
verse wound tape package. In operation the conductor being
wrapped extends through the center of the end plates parallel
to the rods.
During wrapping of the conductor, the guide device a~
well as the multiple wound tape package are rotated around the
longitudinal axis of the conductor by the winding head as the
conductor moves through the guiding device, thereby effecting a
wrapping of the conductor.
In accordance with one aspect of the present invention,
there is provided a supply package for tape material to be heli-
cally wrapped about a length of an elongated structure comprising
a plurality of different tapes of substantially equal length,
traverse wound together in turns disposed about the longitudinal
axis of the package to form a plurality of tubular layers, each
layer being wound about the layer previously wound, each tape
in a turn of the plurality of tapes traverse wound together in
each layer being with respect to the tape of the plurality
adjacent thereto in one of the predetermined conditions of
spaced apart, substantially abutting, and overlapping, the con-
dition of overlapping being that of overlapping a predetermined
portion of the width of the tape adjacent thereto with the
predetermined portion being less than the total width of the
tape, the plurality of tapes when unwound together from each
layer of the package being adapted to be helically wrapped
about an elongated structure, the plurality of tapes in response
to being traverse wound and being in one of the predetermined
conditions enabling the plurality of tapes to be wrapped to-
gether around a length of a structure without the creation
of a surplus or shortage in any of the plurality of tapes.
~-7-
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In accordance with a further aspect of the present
invention, there is provided a method of winding a supply pack-
age for tape material to be helically wrapped about a length of
an elongated structure having the steps of traverse winding a
tape to form a plurality of tubular layers, each layer being
disposed about the layer previously traverse wound, positioning
each turn of tape in a layer during the traverse winding to
overlap a predetermined portion of the width of the tape in the
turn of tape adjacent thereto, the predetermined portion of
overlapping being less than the total width of the tape, sup-
porting the package in rotation as it is being traverse wound,
guiding the tape when being advanced from a supply of tape to a
package being wound, the guiding including reciprocating the tape
being advanced in a direction extending substantially parallel
to the axis of rotation of the package to cause the tape to be
traverse wound upon the package, wherein the improvement com-
prises the step of providing a plurality of tapes of substan-
tially equal length to be traverse wound together during the
guiding step placing each tape in a turn of the plurality of
different tapes with respect to the tape of the plurality ad-
jacent thereto in a selected one of the predetermined conditions
of spaced apart, substantially abutting, and overlapping, the
condition of overlapping being that of overlapping a predeter-
minded portion of the width of the tape of the plurality adja-
cent thereto, the predètermined portion of overlapping being
less than the total width of the tape, and during the traverse
winding step maintaining the selected predetermined condition
overlapping relationship of the plurality of tapes. :.
For a fuller understanding of the invention reference :
is made to the following description taken in connection with .
the accompanying drawings of the preferred embodiment in which:
Figure 1 is a perspective view of the multiple tape ~-
guide device of the invention for use with a multiple tape
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supply package mounted on the winding head of a wrapping machine,
Figure 2 is a side elevational view of the guide de-
vice with the multiple tape supply package of the invention
mounted on the winding head:
Figure 3 is a front elevational view of the guide
device showing the threading of the tapes from a multiple tape
supply package:
Figure 4 is perspective view of the guide device with
two guides for simultaneously guiding two tapes from a two tape
supply package:
Figure 5 is a perspective view of the guide device
with four guides for simultaneously guiding four tapes from a
four tape supply package:
Figure 6 is a fragmentary view of an individual guide
-7b- :
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block showing the variation of the tape delivery angle;
FIG. 7 is a perspective view of a section of elongated
rectangular conductor being wrapped with two partially overlap- . -
ping tapes applied simultaneously;
FIG. 8 is a vertial section view of a single tape
flat wound tape supply pad of the prior art;
FIG. 9 is a side elevational view of a single tape
traverse wound tape supply pad of the prior art;
FIG~ 10 is a side elevational view of a partially
overlapping, two tape, traverse wound tape supply package of
the invention;
FIG. 11 is a side elevational view of a partially
overlapping, three tape, traverse wound tape supply package of
the invention;
FIG. 12 is a side elevational view of a partially
overlapping, four tape, traverse wound tape supply package of
the invention;
FIG. 13 is a vertial section view of a first tape
wrapped about an elongated conductor and a second tape wrapped
20 about the first state by employing a method known in the prior .
art; :
FIG. 14 is a vertical section view of an elongated
conductor wxapped with two partially overlapping tapes from a
traverse wound tape supply package in accordance with the in-
vention;
FIG~ 15 is a vertical section view of an elongatedconductor wrapped with three partially overlapping tapes from
a traverse wound tape supply package of the invention;
FIG. 16 is a vertical section view of an elongated :
conductor wrapped with four partially overlapping tapes from
. 8.
, -
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... .. ..
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a traverse wound tape supply package of the invention;
FIG. 17 is a perspective view of the front of the
winding apparatus having an overlapping multi-feed head for
traverse winding partially overlapping multiple tapes into
the tape supply package of the invention;
FIG. 18 is a perspective view of the side of the
winding apparatus having an overlapping multi-feed tape head to
simultaneously traverse wind partially overlapping multiple
tapes into the tape supply package of the invention;
FIG. 19 is a schematic drawing of the drives of the
apparatus shown in FIGS. 17 and 18;
FIG. 20 is a perspective view of the two tape feed
guide of the invention;
FIG. 21 is a vertical section view of a two tape feed
guide of the invention;
FIG. 22 is a vertical section view of a four tape feed
guide of the invention;
FIG. 23 is a side elevational view of a traverse wound
tape supply pack~ge of the invention having a plurality of
20 different tapes substantially abutting one another; -.
FIG. 24 is a side elevational view of a traverse wound ~ ~:
tape supply package of the invention in which the different : :
tapes of the plurality of tapes are spaced from one another; ~;
FIG. 25 is a schematic representation of a tape winding ~ ~.
apparatus in accordance with the invention having a provision
for eccentrically mounting a plurality of tape supply packages,
each having a plurality of different tapes and provisions for
wrapping the different tapes around a conductor; ~:
FIG. 26 is a schematic representation of a tape winding ::
apparatus having a plurality of traverse wound tape supply
.: , . , , ~ : . ~, -, .. . ,. :
~V~17~
packages each having a plurality of different tapes, offset
from the axis of rotation of the winding head with the core
of each supply package extending substantially parallel to
the axis of rotation of the winding head; and
FIG. 27 is a vertical section view of an elongated
conductor wrapped with two pairs of two partially overlapping
tapes each from different traverse wound tapes supply packages.
In the embodiment described herein, the method and
apparatus of the invention is employed to wrap tape around an
electrical conductor being in a strip~like form having a rect-
angular cross-section. The method and apparatus can be used
in wrapping elongated constructions having various different
traverse cross-sections~ By way of example, the conductor being
wrapped is of the type usèd in the windings of a power trans-
former of the type used by a public utility. The conductorsare wrapped with layers of tape in order to prevent contact of
one conductor within the transformer with another. Thus, in
a typical application the wrapped conductors are separated by
the wrapping and are electrically insulated from one another
by the tape wrapping and by transformer oil surrounding the
conductors. In such an application the tape material can be
rope fiber which comprises approximately 90% hemp material
and 10~ pulp material, kraft paper, or other suitable insulating
materials~ Thermally upgraded rope fiber material and various
~5 other papers which can withstand a temperature rise of approxi-
mate~y 6~5C can also be used. In addition, where higher tem- ~
peratures are encountered, the conductors can be wrapped with ~ ~ -
tape insulating material, one type of which consists of nylon
fibers and is marketed by E. I. DuPont DeNemours of Wilmington,
Delaware, under the trademark NOMEX.
`` 10.
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i1'7~
Depending upon the particular application, the multiple
partially overlapping tapes can be applied by one or more
winding heads of the wrapping machine. For example, a wrapping
machine having double winding heads can be provided with a tape
supply package of four tapes on the first winding head and a
tape supply package of three tapes on the second winding head.
As a result the conductor is wrapped with a total layer of
seven tapes comprising the sum of four overlapping tapes plus
three overlapping tapes. Various combinations of the number of
tapes in each multiple tape supply package and the number of
winding heads on the wrapping machine provide an appreciable
range of the number of total tapes which can be applied to the
conductor during a single pass through the wrapping machine.
The total number of tapes could extend to at least as high as
65 or 70 tapes.
Referring now more particularly to the accompanying
drawings wherein like numerals designate similar parts through- ;
out the various views, attention is directed first to FIG. 1
wherein the guiding head 20 of the present invention is shown
mounted on the winding head of a cable or conductor wrapping
machine. The guide device 20 of the present invention comprises
two circular end plates 22 and 23. These end plates are connec-
ted to one another in axial alignment and parallel to one another
by a plurality of rods 24. In the center of end plates 22 and
23 which can be formed of low friction material are apertures -
25 and 26, respectively. The apertures are in axial alignment
with one another and are of a size to receive and yet clear the
elongated conductor 35 being wrapped to pass through them.
Slidably mounted on rods 24 are guide holders 28. The guide
holders are adapted to be positioned along rods 24 and then
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11 . " ' ' -' '
~. ... .
to be locked in a predetermined position relative to each
other by means of set screws 29. The position at which the
guide holders 28 are positioned and secured on rods 24 rela-
tive to each other determines the amount of tapes partially over-
lapping one another when wrapped around the elongated conductor.
Guides 30 in turn are pivotally mounted on guide holders 28 to
enable the taping angle at which the guides feed the tape to
the elongated conductor to be varied. The taping angle, which
is the acute angle between the longitudinal axis of the con-
ductor and the longitudinal axis of the tape, is determined
by the extent or percentage of the tape partial overlap which
is desired.
The guide device 20 of the invention is mounted con- -
centrically on the winding head 21 of the wrapping machine
which drives the guiding device. The winding head carries
multiple tape supply package 31. Guide pins 32 for directing
the different individual tapes to thèir respective guides 30 are
pivotally mounted on support rods 21a extending from flange 21b
of the winding head. The ends of support rods 21a are supported
by capscrews 21c extending through holes in ring 21d of the -
winding head. Concave rollers 33 are rotatably mounted along
their longitudinal axis on shafts 34. These rollers function
to support the individual tapes being delivered from the
multiple tape supply package to their respective guide pins
and guides.
As indicated by the arrow in FIG.2, the elongated
conductor 35 being wrapped is moved along its longitudinal axis
through the winding head 21 and guide device 20 by means of a
driving means (not shown). Guide rollers 40 and 40a position
and support the conductor as it advances through the guide x-
12.
: ...... . .
~evice and into tubular support 40b. The driving means is
located to the left of the end of support 40a as shown in
FIG. 2 . Also shown in FIG. 2 are variable length bushings
of low friction material 36 and 37 located within the end plates
22 and 23 which serve to guide the elongated conductor if it
should momentarily sag or otherwise approach contact with the
guide device.
Referring to FIG. 3, the threading of the individual
tapes can be seen. Thus, tape 31a is taken from the two tape
supply package 31, first at point 41. It is then threaded over
a pair of concave rollers 33 and is wrapped around guide pin 32
which directs the tape onto guide 30 and to the elongated
conductor 35. Tape 31b is similarly passed over a different ;`-
pair of concave rollers 33, guide pin 32, and guide 30 to the
conductor.
When setting up the machine for operation, a multiple
tape supply package 31 is slipped over the center spindle 42 of
the winding head 21. The guide device which is secured to the
center spindle 42 by means of set screws 43, as shown in FIG . 1,
2~ has an outside diameter smaller than the inside diameter of the
core of the supply package. The multiple tapes are then threaded
as discussed above and the ends thereof are attached to the
elongated conductor by means of any suitable adhesive. The
machine is then started. It should be noted that the guide
device 20, guide pins 32, concave rollers 33, tape supply
package 31, and the center spindle 42 of rotating head 21 are
all in a fixed position relative to each other throughout the
full arc of rotation about the center line of the conductor.
As a result, all rotate concentrically about the longitudinal
axis of the elongated conductor as the elongated conductor is
13.
, .: ; . :
pulled through the center of the rotating head by the drive means
of the wrapping machine at a variable selected speed directly
proportional to the rotating speed of the guide head.
FIG. 4 shows a two-tape guide device 20, while FIG.5
shows a four-tape guide 2Oa. The configuration and number of
support rods 24 varies as a direct function of the number of
tapes on the supply package. For example, a six-tape supply
package, that is a supply package having six partially overlapping
tapes, would have six support rods extending between end plates
22 and 23 and spaced apart from one another by arcs of 60 . Such
a configuration could also be used for a tape supply package
having three partially overlapping tapes. Theoretically, such a
device could be used for application of two, three, four, five
or six tapes; however, as a practical matter, for better dynamic
characteristics at the relatively high rotating speeds of the
winding head, it is preferred to have guides 30 on guide
device 20 in a symmetrical and consequently dynamically
balanced configuration as shown in FIGS. 4 and 5.
The guides 30 as used in the present invention can be
formed from low friction material such as nylon resin material,
while the support shafts 24 can be formed of polished steel.
Referring to FIG. 6 wherein a detail view of a tape
guide 30 is shown, it should be noted that the tape receiving
end 30a of the slot 30b of the guide is tapered outwardly. It
should also be noted that the angle at which the tape can be
delivered to the guide 30 from the guide pin 32 can vary through
a tape delivery angle designated 30c. The possible range of the
tape delivery angle 30c from guide pin 32 is caused by the
constant change of the angle of issuance of each of the multiple
overlapping tapes from the supply package during operation. The
14. ~ -
change in the angle of issuance is due to the fact that the tapes
are traverse wound on the supply package and the diameter of the
package at any instant during unwinding affects the issuance of
angle. Hence, the function of the funnel-shaped receiving end is
to accommodate the variable tape delivery angle from the guide
pin 32. Tape guides 30 may then deliver the tape at a constant
taping angle to the elongated conductor.
The taping angle is a function of the selecting of the
degree of overlap for the multiple tapes and the geometry and
size of ~he cross-section of the conductor being wrapped.
The slot in each of guides 30 may be varied in width
to fit different widths of tape. For a limited range of different
uniform tape sizes, different guides 30 are made available for
whatever tape size is desired. As can be seen from FIG. 4 and
5/ guides 30 are secured to guide holders 28 by means of
fasteners 43 and therefore can be readily interchanged.
By using the apparatus and method of the invention, it
is possible to increase the production rate of wrapping conductors
since the length of the tapes along the longitudinal axis of the -
conductor for each rotation of the winding head can be increased
without increasing the head speed. As a result the rate of travel
of the conductor through the machine is increased. The extent to
which the speed of the conductor can be increased depends upon the
number of tapes from the multiple tape supply package that are
~5 being sàmultaneously applied. For example, using a 1/2 inch wide
single tape supply of the prior art with a selected overlap of 50%
on the conductor, the conductor would advance an increment for
each complete rotation of the winding head which is a function of
the tape width and an inverse function of the target of the taping
angle. If however, a four-tape supply package is used, in accord- -;
15.
ance with the invention, the conductor would be advanced four times
the increments of the single tape for each complete rotation of
the winding head.
As can be seen by comparing FIGS. 13, 14, 15 and 16,
a feature of the multiple tape wound conductor is that each of
the multiple tapes of the invention are applied with a portion
of each in contact with the conductor regardless of the number
of tapes being applied. Thus, in each of the three constructions
shown in FIGS. 14, 15 and 16, one edge portion of each tape is in
contact with the surface of the bare conductor and is progressi-
vely laid over each of the other tapes coming from the multiple
group of tapes wound on the supply package. In FIG. 13 only
tape 31e contacts the conductor while tape 31f simply overlies
tape 31c.
By use of a multiple station winding machine, the
output of more than one multiple tape package may be simul-
taneously and consecutively applied about the conductor. A
double-headed machine, for example, may have on its first
winding head a four-tape supply package while on its second
winding head may have a three-tape supply package. The re-
sulting number of layers of tape would be seven, the sum of
a four tape construction plus a three tape construction.
FIG. 13 shows a conductor which has been double
wrapped by using two single tapes of the prior art and running
the conductor through the winding machine twice or through two
separate winding stations or through two tape pads a single
head winding machine having two tape pads either concentrically
or eccentrically mounted thereon. Such a machine would overlap
one tape upon another to the extent of about 50% of the width
of the tape. FIG. 16 shows a conductor wrapped according to
: :. -
16.
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.he present invention using a four-tape supply package. A
comparison of the two shows that although there exists sub-
stantially the same total thickness of tape covering the
conductor, the latter can be obtained by simply running the
conductor through a single winding head in accordance with the
invention while the arrangement of the prior art shown in FIG. 13
requires either two passes through a single winding head, through
two separate winding heads, or through a winding head having two
separate pads. The resulting pattern of the multiple tapes in
FIG. 16 has the advantage that each of the different tapes are
in engagement with all of the other tapes. The pattern has the
further advantage that it can accommodate bending of the conductor
because the nested multiple tapes can each comply to the movement
of the others. The pattern resulting in FIG. 13 has no such engage-
ment between the individual tapes. Instead, one tape is simply
wrapped on top of the other.
By way of example, tapes used in wrapping electrical con-
ductors for electrical power equipment have standard widths in a
range extending upwardly from approximately .375 inches in incre-
ments of .125 inches. Such a range can extend up through a tape
width of at least 1.250 inches. Tapes in this range of tape widths
can be used with various sizes of conductors such as round conduc-
tors in a range extending upwardly from about .808 inches in diame-
ter and through a range of rectangularly shaped conductors extending
from about .124 inches wide to about 1.25 inches wide and in thick-
ness from .030 inches to .250 inches. In accordance with the
invention, even thicker and wider structures than these can be
wrapped with multiple tapes.
Further by way of example, the conductors to be wrapped
in accordance with the invention can be various round, square or
17.
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rectangular conductors having corss-sectional areas in the range
from about .0051 square inches to about .4420 square inches. Much
larger cross sectional areas than these can also be wrapped with
multiple tapes in accordance with the invention. I~he wrapped cable
or construction of the invention is not limited to this range;
however, this range is indicative of the present commercial range
for tape-covered magnet wire used in industry which can be wrapped
in accordance with the invention.
When wrapping an elongated conductor using a single
tape supply, whether it be a flat wound or traverse, the tape
will simply issue forth as needed. If an attempt was made to
wrap a conductor with two different tapes from a single pack-
age on which the tapes were not simultaneously wound, an in-
surmountable problem would result. The problem would be that
a difference in the length of the tape being taken from one
of the two separate windings on a common core would result. As
soon as the difference existed, either one tape would break, or
slack in the other tape would result.
As is well known in the art, if two or more tapes are
simultaneously wound around the core of a supply package such
that they are 100% overlapping, the tape which is outside for
each turn about the core would be longer than the other tape.
Hence, if the multi-tape supply package described above were
applied to a conductor, there would be an excess length of
shortage of one tape relative to the other. This would cause
~5 an uneven winding and eventually breakage or tangling of the
excess tape within the rotating head lead.
The partially overlapping multi-tape supply package
of the invention has succeeded in eliminating these problems
30 of wrapping multiple tapes from a single supply. Thus in
18.
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accordance with the invention simul~aneously traverse winding
of multiple tapes on a single core with the same nominal
degree of overlap as is to be on the wound conductor enables
the multiple tapes to be wrapped without accumulating a sur-
plus or shortage of any tape. For example, if a conductoris to be wrapped with three tapes simultaneously with each over-
lapping the tape adjacent thereto by one-third, then a tape supply
package containing three tapes with a corresponding overlap may be
used. In this way it is insured that when the three tapes are taken
from the supply package they will ail be of equal length.
FIG. 8 shows a prior art single tape supply pad flat
wound on a hollow core. FIG. 9 depicts a prior art single tape
supply pad traverse wound on a hollow core to form a spool or
cop. FIG. 10 shows a two-tape partially overlapping traverse
wound tape supply package 31 of the invention. In package 31
of FIG. 10, tape 31a is of the same length as that of tape 31b
since neither tape 31a nor 31b in package 31 is consistently
closer to the core than the other. If a pair of the prior art
pads were to be used or the pad of FIG. 8 was to be provided
with multiple tapes, a surplus or shortage of either tape would
necessarily occur. The invention eliminates this problem.
FIG. 11 shows a three-tape supply package 31~' of the
invention. It can be seen that one part of each of individual
tapes 31'a, 31'b, 31'c is partially overlapping the tape
ad~acent to it with the result that the other part of the
tape is in direct contact with the layer of tapes beneath.
For example, the left side of tape 31'b is partially over-
lapping the right side of tape 31'a as viewed in FIG. 11. Thus
the right side of tape 31'b is in contact with the layer beneath
it and is being itself overlapped by tape 31'c. On the next
19. ,',. . ~
, . .. ..
layer of the three tapes, the left side of tape 31'a will
partially overlap the right side of tape 31'c. Hence all
three tapes are in partial contact with the layer below and
are overlapping each other in the same amount. Accordingly,
all three tapes in the set are at any instant wound about
the same diameter and this results in each of the tapes being
of equal length.
FIG. 12 shows a supply package 31" of the present inven-
tion containing four individual tapes, all being of equal length.
FIGS. 17, 18 and 19 disclose apparatus which can be
used to wind the partially overlapping, abutting or separated
traverse wound, multi-tape supply package 31 of the invention.
Winding machine 49 comprises a modification of a winding machine
used in the prior art to traverse wind a single tape into pads.
In FIGS. 17 and 18 and more particularly in FIG. 19 which is a
schematic view of the tape feed of machine 49, it can be seen
that power source or motor 50, by means of a belt rotates drive
roller 51 by means of drive 50a and shaft 52. The roller 51 can
be formed of rubber-like material to provide adequate friction ;
with respect to the package to rotate it throughout the winding
process. Supply package 53 is mounted on spindle 54 and is
biased aganst the roller 51 by means of weight 55 tFIGS. 17
and 18). Spindle 54 by means of chains and sprockets 56 rotates
cylindrical cam 63 which in turn transmits horizontal movement
to pivotally mounted lever 57 (FIG. 19) by means of follower 58
engaged with cam track 62. Pivotally mounted lever 57 in turn
moves a guide holder 59 which is slidably mounted on bars 60
(FIGS. 17, 18 and 19). Removably attached to the guide holder
59 is multiple tape guide head 61 of the invention.
Guide head 61 as shown in FIGS. 20 and 21 contains two
20.
narrow passages 64 each of which extends through the length of
the head. These passages are adapted to guide the individual
tapes 31a and 31b to be wound on the multiple tape supply package
31. As can be seen from FIGS. 20 and 21, the passages 64 extend
through the head in different planes and are partially overlapping
each other. The degree of overlap can be selected to corres-
pond substantially to the degree of overlap of the multiple
tapes when wound on the conductor. Thus guide head 61 is con-
ditioned by not only the number of tapes to be wound on a pack-
age, but also by the amount that the tapes are to overlap each
other.
In operation of the winding apparatus as shown in the
drawings, two tapes are threaded through the tape guide head as
shown in FIG. 19. The tapes are delivered to machine 49 from
two separate supply sources (not shown) which can be flat-wound
pads or rolls of tape. The tapes 31a and 31b are then threaded
under drive roller 51 and between a core mounted on spindle 54
and the~rear side of roller 51. The tapes are then attached
to the core. The power source 50 is then energized. Since the
tapes and core are forced againstthe rear side of drive
roller 51 as seen in FIGS. 17-19, rotation of roller 51 in
the direction of the arrow rotates the core by friction en-
gagement. The rotation of the core on spindle 54 causes tapes ~
31a~ and 31b to be pulled from their individual supply packages -
and to be wound around the core. The individual tapes after pass-
ing through guide head 61 are aligned in a partially overlapping
fashion and will be wound in that manner on the core. Guide
head 61 can be formed from low friction material such as resin
materials which are suitable for bearing.
At the same time as the tapes are being wound on the
21.
:
core, the rotation o the cam drum 63 will cause the lever 57 to
move the guide head 61 back and forth across the surface of rubber
roller 51. This horizontal movement will result in the tapes
being traverse wound upon the core of the supply package. Since
the drive to cam 63 and thereby arm 57 which carries the guide
head originates with spindle 54, it can be seen that the move-
ment of the guide head is synchronized with the surface speed of
the package or the core regardless of the instantaneous diameter
of the pad. In this way the number of turns of overlapping
combinations of tapes is the same for all layers of the traverse
wound package.
FIG. 22 depicts a four tape feed guide head of the
present invention. By way of example, four-tape packages in ac-
cordance with the invention have been prepared by the use of paper -
tape one-half inch in width and approximately .0025 inches thiGk.
The traverse wound package is formed about a core approximately
three inches in diameter with a package width of approximately
three and one-half inches and an outside diameter of approximate-
ly eight inches. The degree of overlap of adjacent tapes can
be, in the example, approximately seventy-five percent. An
eight inch diameter package would include approximately thirty-
three hundred total yards of tape. A ten and one-half inch
package of this type would contain approximately sixty-six
hundred total yards while a twelve and one-half inch package
would include approximately ninety-nine hundred yards.
Further in accordance with the invention, the supply
package can comprise a plurality of different tapes which are
traverse wound with the edges of each different tape substantially -
abutting the tape adjacent thereto. Thus, the plurality of dif-
ferent tapes are not overlapping in the supply package. As shown
- . : . .. . . , . :
in FIG. 23, supply package 70 comprises traverse wound tapes
70a, 70b, and 70c which have their edge portions in an abutting
arrangement. Thus, in supply package 70, the plurality of tapes
are not overlapping one another. Tapes 70a-c can be applied to
an elongated c~nductor by the method and appartus of the
invention for wrapping tapes. In wrapping tapes 70a-c, the differ-
ent tapes can be applied to the conductor in an abutting, separa-
ted, or overlapping arrangement as determined by the setting of
the guide device of the winding head.
In the traverse wound supply package of the invention,
the plurality of tapes making up the package can have their edge
portions spaced apart from one another. As shown in FIG. 24,
supply package 71 is formed by different tapes 71a and 71b which
are traverse wound with their adjacent edges spaced apart from
one another by an interval designated "X" in the drawing.
Although it is possible for the interval X between the different
tapes being traverse wound to be greater than the width of a
tape designated "W" in FIG. 24, it is preferred than interval X
be less than the tape width W.
In the art it is know to mount a plurality of pads of
tape on a flyer or winding head eccentrically with respect to
the axis of rotation of the head. In such an arrangement the
plurality of flat pads have been mounted with the flat side of
the pad facing the axis of rotation of the winding head and the
~5 conductor being wrapped. Thus, the axis of the pad about which
the tape is wound thereon extends at substantially a right angle
with respect to the axis of rotation of the head. As shown in
FIG. 25, in accordance with the invention, the winding head 72
comprises a base portion 73 and supports 74 extending at a con-
verging angle with respect to one another from the face of the
23.
`
. .
b
-
base portion. Spindles 75 extend from each of supports 74 and
are each adapted to support a different traverse wound multiple
tape supply package 76 thereon. Guides 77 direct the plurality
of ~apes 76a' and 76a" from the supply packages as the plurality
of tapes from each different package are simultaneously wrapped
about conductor 78. The resulting configuration of tapes is
shown in FIG. 27. Since supports 74 extend toward one another
and at an angle to base 73, the distance which the traverse wound
multiple tape supply packages extend outwardly in a radial direc-
tion can be reduced.
As shown in FIG. 26, flyer or winding head 79 comprises -
base portion 80 through which conductor 81 is advanced. Winding
head 79 is adapted to carry a plurality of traverse wound multiple
tape packages 82 which are supported by spindles 83 extending
from base portion 80. In FIG. 26, packages 82 contain a tra-
verse wound pair of different tapes 82a' and 82a". These differ-
ent pairs of tapes can be simultaneously wrapped about the
conductor 81 in an abutting, separated or overlapping arrange-
ment.
~5
24. ;
