Note: Descriptions are shown in the official language in which they were submitted.
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This application is divided out of Copending Canadian Application
No. 247 974, filed March 16, 1976.
The invention pertains to improvements to machinery to wind capa-
citors, and particularly those capacitors which in~orporate more than one
capaci~or in the same winding. Machines have heretofore been designed to
wind capacitors of this type. In particular, one prior ar~ machine has~met
considerable commercial success. That machine, the semi-automatic Hilton
Capacitor Winding ~achine, manu-factured by Hilton Industries, Inc., Glen
~`alls, New York, provided a partial answer to the industry's need for a
capacitor winding machine. Specifically, this machine incorporated means
~or supplying the necessary dielectric layers, foil, and terminals to an
arbor which was winding the capacitor. The machine automatically fed the
proper lengths of foil to form the various capacitor electrodes and, at
approximately the proper time, ~ed foils with metallic tabs which Eormed
the terminals of the capacitor.
Unfortunately, this machine~ despite some automatic operations,
required the full-time attendance of an operator. Among the functions that
this operator had to p0rform were threading the severed ends of the di-
electric layers onto the arbor to allow the machine to wind another capa-
citor, sealing the ends of the wound capacitor to prevent it ~rom unraveling,and removing the wound capacitor from the arbor. The operator also had to
reorient the capacitor tabs so that they assumed the proper angular rela-
tionship, and, when the finished capacitors tended to collapse, manually
insert a structural reinorcement at the beginning of the winding of the
succeeding capacitors.
Beside the cost of the labor necessitated by this machine, manual
operations are subject to human error. Therefore, it has been a long-
standing goal in the capacitor winding industry to reduce the amount of
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manual labor needed to produce wound capacitors.
Prior a-ttempts to design an automatic capacitor winding machine
have not met wi~h commercial success. These attemp-ts have encountered num-
erous problems.
One major problem is automatically removing the wound capacitor
from the winding arbor withou~ telescoping of the capacitor, i.e. the inner
~indings of the capacitor body pulling out of and extending past the main
~ody of the capacitor. This problem seems to be caused by the friction be-
tween the innermost winding and the arbor, which tends to keep the inner-
most winding on the arbor. Unfortunately, normal lubrication techniques
~oil, grease) cannot be used to reduce the friction since they would degrade
the capacitor. Attempts to strip the capacitor off the arbor by close tol-
erance strippers have previously failed because of the wear suffered by these
parts, destroying the tolerances.
Another problem left unsolved by the prior art machines is auto-
matically preventing the collapse of the capacitor when stripped of~ the
arbor. In the semi-automatic machines, structural inserts were manually
fed into the capacitor. However, in automating the machine, prior a*tempts
have not been successful in designing an automatic structural insert device.
An~ther problem is to insert the tabs (terminals) of the capacitor
in the proper angular relation. This requires that the machine know the
e~act angular position of the first tab, SG that later tabs can be properly
inserted. Prior art machines attempted to solve this problem by counting
arbor rotations. However, this system has proved expensive and unreliable.
Moreover, most prior art attempts to design an automatic capacitor
winding machine have involved designing a machine from scratch. This has
resulted in expensive, complicated, and unreliable machines. The present
invention can be used to modify prior art machines, and in fact, such a
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modification is the preferred em~odiment of the present invention.
Consequently, it is an o~ject of the present invention to attain
an automatic capacitor winding machine, preferably in a form that permits
modification of prior art semi-automatic machines.
Altl1oug11 the features of the present invention are embodied in a
specific automatic capacitor winding machine and the component systems there-
of, from the below description, one skilled in the art will be able to
embody these features into other environments, not limited to capacitor
~inding Inachines.
IO In accordance with one aspect of the present invention, the inven-
tion consists of a photoelectric device for sensing when an object which
travels a predefined path and which crosses a line a plurality of times is
at a irst point of crossing on the path which is nearest a first end of said
line comprising: a light detector having a relatively narrow angle of
light acceptance located proximate said first end of said line and respon-
sive to light impinging thereon; and a light source proximate the second
end of said line or transmitting a beam of light, which is wider at a
point of crossing on the path which is furtller from said first end of ~he
line than said first point of crossing than the widest portion of the
~0 object, along said line, whereby said object prevents said beam from
impinging on the detector only when said object is at said first point of
crossing on the path closest to said firs~ end of said line.
According to another aspect of the invention there is provided:
n photoelectric device for sensing the position of an object rotated by
a rotating arbor comprising: means for producing a light beam directed
along a line which lies in a plane perpendicular to the axis of rotation
of said arbor which is crossed only twice by said rotating object, the
width of said light beam bei~g greater than the width of said object at
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the line crossing nearest said light beam producing means; and light
detector means positioned to receive light directed along said line and
responsive to light impinging thereon, said light beam detector means having
an angle of light acceptance such that said light beam is prevented from
impinging on it only when said object is at the light crossing nearest said
responsive means.
In the accompanying drawings:-
Figure l is a plan view of a capacitor wound on a machine embodyingthe present invention.
Figures 2A and B are front views of a schematic representation o~ a
machine embodying the present invention.
Pigure 3 is a side view taken along line 3-3 of Figure 2A showing in
detail a structural insert means.
Figure 4 is a plan sectional view along line 4-4 in Figure 3 of the
structural insert guide means.
Figure 4A is a side sectional view along line 4A-4A of Figure 3 of
the structural insert means.
Figure 5 is a plan view taken along line 5-5 of Figure 3 showing a
knife assembly for severing the structural insert.
Figure 6 is a front view of the arbor and elevator apparatus.
Pigure 7 is a side sectional view taken along line 7-7 of Figure 6
the ~ifurcated arbor and lateral transport means in the machine embodying
the present invention.
Figure 8 is a rear view of the machine embodying the present
invention showing the rotational motor means and registering means Eor the
bifurcated arbor.
Figures 9-14 are schematic representations of the machine embodying
the present invention during different stages of its operation.
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Fi~ure 1 illustrates a capacitor wound on the machine of the
preferred embodiment of the present invention. Capacitor 1 is a dielec-
tric-conductive layer sandwich rolled into a rïght cylindrical shape. In
the pre~erred em~odiment, capacitor 1 comprises outer dielectric layers 3
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and 5 and inner dielectric layers 7 and 9. Dielectric layers 3-9 may be
made from paper approximately .0003 inch thick. Disposed between inner di-
electric layer 9 and outer dielectric layer 5 is common electrode 11. Dis-
posed between inner dielectric layer 7 and outer dielectric layer 3 are ca-
pacitor electrodes 13 and 15. In the preferred embodiment, common electrode
11 and capacitor electrodes 13 and 15 are constructed of aluminum foil about
.0002 inch thick.
Capacitor electrode 13 is located near the center o~ the capacitor
l; whereas capacitor electrode 15 is placed after electrode 13 and spaced
some distance therefrom. In contact with common electrode 11 and capacitor
clectrode 13 and 15 are tab webs 17, 19 and 21, respectively. Bonded to and
e~tending axially from tab webs 17, 19 and 21 are tabs 23, 25 and 27~ res-
pectively. For reasons that will become evident below, tabs 23, 25 and 27
are located near the end of their respective tab webs farthest from the cen-
ter of the capacitor. These tabs are bonded to the contacts that extend
through the top of the metal capacitor can.
Capacitor 1 actually contains two capacitors: a relatively small
capacitor is formed by capacitor electrode 13 and common electrode 11, here-
inafter referred to as first capacitor section 12; and a relatively large
capacitor is formed by capacitor electrode 15 and common electrode 11, here-
inafter referred to as second capacitor section 14. One will also note that
there are two dielectric layers between the common electrode and capaci~or
electrodes.
Capacitor 1 also has a structural insert 29. Insert 29 is appro~-
imately .003 inch thick. Structural insert 29 is preferably located in se-
cond capacitor section 14, i.e., the larger capacitor. This insures that
the reduction in capacitance caused by the additional separation of the res-
pective capacitor electrodes is negligible compared with the total capaci-
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tance of the capacitor.
In additionJ structural insert 29 is preferably placed as near as
possible to the interior of capacitor 1. Structural insert 29 provides
structural support for capacitor 1 and helps prevent the collapse of capa-
citor 1 after it is stripped from the arbor upon which it is wound.
Capacitor 1 is the capacitor wound on the preferred embodiment of
the present invention. From the specification below a person skilled in
the art will recognize that the present invention is adaptable to automatic-
ally wind capacitors made from other materials and even adaptable for ma-
chines that serve other purposes. For example~ plastic layers could be usedfor the dielectric layers in capacitor 1, or vacuum deposited metal on a
plastic carrier could be substituted for both a dielectric layer and elec-
trode.
Figure 2 is an illustration of the capacit~r winding machine of
~he present invention. Figure 2 is in two parts - Figures 2A and 2B. The
preferred embodiment of the present invention is a modified prior art capa-
citor winding machine. For the most part, the modifications comprising the
present invention appear in Figure 2B, as will be more fully understood from
the description below. Except as noted below, Figure 2A is a schematic re-
presentation of the prior art semi-automatic Hilton Capacitor Winding Ma-
chine .
In keeping with the schematic nature of Figure 2, many detailshave been omitted, in part or in whole. For example, generally tension arms
for the layers have been omitted from the figure. The friction brakes
associated with dielectric layer supply hubs are another example of the
omission of items readily supplied by one skilled in the art.
The central timing means to which reference will often be made
below is also not shown. It causes each of the elements of capacitor wind-
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ing machine 1 to operate at the proper tim~ in conformity with the descrip-
tion of the operation o~ the machine. In the pre~erred embodiment, the
timing means comprises both timing relays, electronic timing ~eans~ and
other well-known timing techniques. These items, and similar items not
shown or described, and their application ~o this invention are well-known
to those skilled in the art.
In Figure 2A, the apparatus supplying the dielectric layers,
electrodes, and tab webs for capacitor 1 is schematically diagrammed. Each
component of capacitor 1 is supplied ~rom a continuous roll of that compo-
nent. That is, outer dielectric layer 3 is provided from dielectric ~paperin tl~e pre~erred embodiment? layer roll 31. Similarly, dielectric layers 5,
7 and 9 are provided from continuous dielectric layer rolls 33, 35 and 37.
Common electrode 11 is supplied from continuous foil roll 39; capacitor
electrode 13 and 15 are supplied from continuous foil rolls 41. Tab web 17
is supplied from continuous web roll ~3 with tabs 23 ~not shown) periodically
bonded thereto. Similarly, continuous web roll 45 provides tab webs 19 and
21. Structural lnsert 29 is supplied from paper roll 47.
The path of the various dielectric layers, webs and clectrodes is
clearly shown in Figure 2A. By way of example, outer dielectric layer 5
comes off dielectric layer roll 33. Dielectric layer roll 33 is mounted
upon a rotatable hub 49. Dielectric layer 5 is threaded upwards around
idler roller 51. Idler roller 51 is mounted UpOTI arm 53 which in turn is
pivoted on shaft 55 to provide constant tension in dielectric layer 5 iTI
accordance with teachings well-known to one skilled in the art.
From idler roller 51, dielectric layer 5 is ~hreaded downwards
around idler roller 57 and between guide rollers 59. Guide rallers 59 do
not touch, or even coDpress the layers passing therebetween. The path ta-
~en by dielectric layer 3 is the mirror image of that taken by dielectric
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layer 5.
The path taken by dielectric layers 7 and 9 are also mirror imagesof one another. Dielectric layer 9 is supplied by dielectric layer roll 37
~hich is ~nounted upon hub 61. From dielectric layer roll 37~ dielectric
layer 9 is threaded around idler rollers 62, 63, 65, alongside knife assembly
501 and between guide rollers 59.
The path of common electrode 11 and capacitor electrodes 13 and 15
are also clearly shown in Figure 2A. For example, common electrode 11 is
supplied rom continuolls foil roll 39. Foil roll 39 is mounted upon hub 67.
From colltinuous foil roll 39, common electrode 11 is threaded up around
idler roller ~9, against idler roller 71, throu~h drive assembly 73 and be-
tween guide rollers 59.
A hub brake means 66 is provided for hub 67. It includes idler
roller 69 which is mounted on one end of arm 68. The oth0r end of arm 68
is rotatably mounted on shaft 70. Also pinned to arm 68 is piston rod 72
of air cylinder 74 and one end of cable 76. The other end of cable 76 is
grounded at 78. Normally the ¢enter portion of cable 76 passes around the
periphery of bra~e drum 80 of hub 67 without engaging its surface. How-
ever, wllen air cylinder 74 is operated to withdraw piston rod 72, arm 6~
`20 rotates about shaft 70 and draws cable 76 against the surface of brake drum
~0, imparting a frictional drag sufficient to stop the rotation of hub 67.
Drive assembly 73 consists in a per*inent part of a drive roller
75 and idler roller 77~ Common electrode 11 is fed between drive roller 75
and idler roller 77. Idler roller 77 is biased by means not shown agalnst
drive roller 75 and drive roller 75 is driven, at the appropriate times, as
described below. Drive roller 75 also has a slip clutch that permits the
electrode to be pulled through the engaged drive roller 75 and idler roller
77 faster than drive roller 75 is being driven.
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There are means, also not shown, for moving bo~h drive roller 75and idler roller 77 out of contact with capacitor electrode 15 and common
electrode 11. As ~ill become clearer after the description below, these
means are provided to remove unnecessary drag on capacitor electrode 15 and
common electrode 11 when these electrodes are drawn from supply rolls 39 and
41 by arbor 117 at high speed.
Immediately following drive assembly 73 is a rotary cutter 79.
Rotary cutter 79 comprises a blade 81 mounted upon shaft 83. Rotary cutter
79 is driven by means not shown at the appropriate time. secause of its
location above and adjacent to the path of common electrode 11, when driven,
blade 81 of rotary cutter 79 will pass thro~gh and sever common electrode 11.
Drive assembly 73 also includes guide plate 85. A~ter common elec-
trode 11 has been severed by rotary cutter 79 and upon the ac~ivation of
drive roller 75 forcing common electrode 11 to move downward, guide plate
85 and the outside surface of knife assembly 501 direct common electrode 11
downward and into guide rollers 59.
The tab webs are supplied in a like manner. For example, tab web
17 is continuously supplied from tab roll 43. Tab roll 43 is rotatably
mounted upon hub 87. From tab roll 43 tab webs 17 are threaded into drive
assembly 89.
~ rive assembly 89 includes a drive roller 91 and an idler roller
93. Idler roller 93 is biased against drive roller 91 by means not shown;
drive roller 91 is driven by means schematically shown by gear 95.~ As more
fully explained below, tab web 17 is periodically driven by drive assembly
89~ under control of the central timing control.
Between idler roller 93 and drive roller 91, tab web 17 is thread-
ed across ledge 97. Mounted above ledge g7 is reciprocating cutter 99.
Reciprocating cutter 99 includes a blade 101 mounted upon a rotating shaft
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103. When driven, by means not shown, shaft 103 rotates causing the cut-
ing edge of blade 101 to sever tab we~ 17 as a result of the shearing ac-
tion between blade 101 and the leading edge of ledge 97.
Disposed some distance in front of drive assembly 89 is photode-
tector assembly (shown only on drive assembly 89 for tab webs 19 and 21
~hich are supplied from the same supply roll). Photodetector assembly in-
cludes a light source 107 and a light sensitive element 109. Photodetector
assembly is positioned so that only tabs 23, 25 and 27 pass therebetween and
t}~e solid foil portions of tab webs 17, 19 and 21 do not pass therebetween.
~t`ter passing fron~ drive assembly 89, tab web 17 is directed between guide
rollers 59.
Drive assemblies 89 associated with tab web 17 and 21, respectively
are not equidistant from the centerlin0 of the capacitor winding machine.
Drive assembly 89 associated with tab web 17 is closer to the centerline
than is drive assembly 89 associated with tab web 21. The difference in
distance to the centerline is equal to the distance between tabs 23 and 27
in wound capacitor 1. Thus, when reciprocating cutters 99 cut both tab webs
17 and 21 sin~ultaneously, tab 23 will be inserted the proper distance in
front of tab 27 into capacitor 1. One skilled in the art will recognize
2~ that the same result could be attained by having drive assemblies 89 equi-
distant rom the centerline but operating reciprocating cutters 99 sequen-
tially, the time between the operation of the two cutters 99 selected so as
to insure that tab 23 is inserted the proper distance in front o~ tab 27.
The description of the apparatus as shown in Figure 2A to this
point has primarily involved the apparatus of the prior art. There has not
been included any of the principal modifications that form the present in-
vention. A principal improvement provided by the present invention is auto-
matically inserted structural insert 29 and its associated apparatus.
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The following description of the structural insert means can be
best mderstood by referring to Figures 2A, 3, 4 and ~A. From structural
insert roll 47, structural insert 29 is threaded into the drive assembly 301.
Dxive assembly 301 includes a drive roller 303 and idler roller 305. Drive
roller 303 is moun~ed upon shaft 307 which is attached to the shaft of mo-
tor 309 by drive chain 311. Motor 309 is activated in accordance with the
description below by the central timing means. Idler roller 305 is biased
against drive roller 303 by means also not shown.
Structural insert 29 is driven into guide 313 as illustrated both
ln in ~igure 3 and Figure 4. Guide 313 includes two face plates 315 and 317.
Facc plate 315 has an L-shaped extension 319 which serves as a mounting
bracket for guide 313. Separators 321 and 323 are disposed between face
plates 315 and 317 to hold them in a parallel relationship and to form a
channel 325. Structural insert 29 passes through channel 325.
Upon exiting from channel 325, structural insert 29 is guided down-
ward by tongue 327 of back plate 317 into knife means 501 (Figure 4A~.
Structural insert 29 passes through a channel 503 in knife body 505. Slid-
ably mounted on knife body 505 is shearing blade 507. Shearing blade 507
has a rectangular notch 509 on one face through which structural insert 29
20 normally moves. Shearing blade 507 also has two slots 511 and 513 through
~hicll bolts 515 pass. Bolts 515 are fixed in knife body 505. Bolts 515
carry springs 517 wh;ch bear against the underface of the head of bol~s 515
atld the top surface o shearing blade 507, biasing shearing blade 507 against
the top of knife blade 505.
Particularly important to the design of kni~e means 501 is the
shape of slots 511 and 513. Slot 511 is a straight and oriented at an angle
to the long surface 510 of rectangular notch 509. Slot 513 is arcuate and
oriented substantially parallel to slot 511.
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Shearing blade 507 is moved by the combined action o~ air cylinder
519 and spring 521. As a person familiar with pneumatics will clearly rec-
ognize, when the piston of air cylinder 519 is forced outwards by air intro-
duced into the cylinder under con~rol of the central timing means, shearing
blade 507 will be forced to the right (as viewed in Figure 5) compressing
spring 521. Contrariwise, when the pressure in air cylinder 519 returns to
the ambient, then compressed spring 521 will force shearing blade 507 back
to its rest position, the position shown in Figure 5.
Tongue 327 extends downward in a curved fashion toward shearing
blade 507. In the preferred embodiment, the tip of tongue 327 does not con-
tact shearing blade 507 when shearing blade 507 is in its unoperated position
~lowever, shortly after shearing blade 507 begins its forward movemen*, sur-
face 510 contacts the tip of tongue 327 springing it outward. When shear-
ing blade 507 returns to its unoperated posi~ion, ~ongue 327 springs back to
its rest position.
Because of the angular relationship of slots 511 with that of the
long surface 510 of notch 509 and sides of channel 503, shearing blade 507
will completely cover channel 503 when it has moved to its extreme operated
position. However, because of the arcuate nature of slot 513 in contrast to
the straight slot 511, surface 510 of rectangular notch 509 does not proceed
to cover channel 503 in a uniformly parallel manner. Rather, the right-hand
end of channel 503, as viewed in Figure 5, is covered first. As shearing
blade 507 proceeds to its fully operated positionl it progressively c~vers
more and more of channel 503 until it inally covers the left-hand end.
Thus, structural insert 29 i5 sheared by knîfe assembly 501 in much the same
nature as an ordinary scissor shears a sheet of paper. Because of this de-
sign, much less force is needed to cut structural insert 29 than if shearing
blade 507 traveled in a parallel fashion across slot 511. Moreover, because
of the relatively narrow design of knife means 501, the en~ire assembly can
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be accommodated Oll an ~mmodified p~ior art machine.
From knife assembly 501, structural insert 29 continues downward
~nto guide rollers 59. A guide plate 329 (Figure 3) provides a surface
whic}l aids the leading edge of insert 29 between guide rollers 59.
It should ~e noted that structural insert 29, despite its relative
lack of body ~paper approximately .003 inch thick), is driven from above by
drive assembly 3O1J guide 313 and knife means 501, and between guide rollers
59. "Pushing" structural insert 29 through guide 313 and kni~e means 501,
rather than pulling it through knife means 501, permits placing drive assem-
bly 301 near structural insert roll 47 and provides space for knife assembly
501 without major reconstruction of the dielectric layer and electrode paths
of the prior art machine.
The length of structural insert 29 wound into capacitor 1 is de-
termined empirically. Structural insert 29 serves to provide support for
capacitor 1 to prevent its collapse. However, it should not be overly long
or, even when it is located in second capacitor section 14, i~ will unduly
affect the capacitanc~.
Figure 2B illustrates the lower portion of the capacitor winding
machine of the present invention. Repeated in Figure 2B are guide rollers
59 and idler rollers 57 of Figure 2A. Also shown are dielectric layers 3,
5, 7 and 9. All four dielectric layers enter guide rollers 59. From guide
rollers 59, the dielectric layers are threaded downwards around idler rol-
lers 114, and 115 and around bi~urcated arbor 117. Arbor 117 includes two
tangs 119 and 121 with a slot 123 (Figure 6).
Idler roller 115 is offset sligh~ly more to th~ right than idler
roller 114, as viewed in Figure 2B. These two rollers cause the various
layers to be wound to be brought closer together and "smoothed" out. This
latter f~mction is most important to insure that the layers are not wrinkled
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in wound capacitor 1.
In accordance with this invention arbor 117 both ro~ates around
its axis and translates axially, i.e., moves laterally along its axis. For
this purpose, rotational motor means and lateral transport means are pro-
vided.
Arbor 117 is mounted on shaft 125. Shaft 125 is pressed into the
inner race of bearings 127 and 129. The outer race of bearings 127 and 129
bear on the interior surface of hollow piston rod 131 of air cylinder 133.
Shaft 125 can both translate axially and rotate. A commercially
available uni~ marketed by Alkon Products, Wayne~ New Jersey, is called an
air extensible drill unit. This unit is shown schematically in Figure 7.
As shown in Figure 7, shaft 125 is hollow and has splines 135 on
its inner diameter. Meshing with splines 135 are complementary splines 137
carried on a shaft 139. Shaft 139 is affixed to pulley 141. Pulley 141
carries timing belt 143. Under the movement of timing belt 1~3, arbor 117
will rotate upon its axis. Further, under the control of the central timing
nleans, arbor 117 moves axially in accordance with the movement of piston rod
131 in air cylinder 133.
As previously described, a principal object of the present inven-
tion is to automatically produce capacitance whose inner windings have nottelescoped beyond the capacitor body. Consistent with this object the pre-
sent invention strips wound capacitor 1 off arbor 117 without causing the
inner windings of capacitor 1 to extend beyond the body of capacitor 1. A
review of tlle difflculties in accomplishing this objec~ wi]l lead to a ful-
ler understanding of the device described herein.
Some prior art machines also attempted to s~rip wound capacitors
off an arbor by "pushing" the capacitor o-ff the arbor. Although these ma-
chines sometimes worked initially, they eventually began to telescope the
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stripped capacitor. Their problem arose from the high wear o~ their parts.
For example, in the method of the present invention, i.e., retracting the
arbor axially through an opening in a plate, which blocks the capacitor and
strips it off the arbor, the opening in the plate has to be only slightly
larger tllan the diameter of the arbor. Otherwise, the inner windings of the
capacitor could be dra~n between the arbor and the plate, i.e., "telescope"
the capacitor.
However, in prior art machines, the opening in the stripper plate
would not maintain its dimensions. It is subject to wear from at least
these sources. First, the arbor rotates at high speed within the opening
causing rotational frictional forces to wear and enlarge the opening. Se-
cond, the arbor's high acceleration and deceleration flexes the arbor and
causes it to bear against the sides of the opening and further enlarge it.
A third cause of wear is the arbor's axially translation through the opening.
However, the arbor translates axially at relatively low speed.
It has been found that the wear due to the arbor's low speed ax-
ially translation is not significant. It is the wear from the arbor's
flexing that appears most serious, closely followed by the wear caused by
the arbor's high rotational speeds.
The present device greatly reduces the wear to which the stripper
means from the arbor's flexing and rotation. Thus, it consistently pro-
duc~s good capacitors over relatively long periods.
The stripper means includes a stripper plate 145 held in a spaced
relationship from machine support plate 30 by spacers 1~7. At the center
of stripper plate 145 is a circular opening 149 whose inner diameter is
only slightly larger than the outer diameter of arbor 117. Coaxial with the
center of opening 1~9 is a counterbore 151 in the rear surface o~ stripper
plate 1~5. Inserted in counterbore 151 is a ball bearing 153. The inner
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race of bearing 153 carries a sleeve bearing 155. The inner diameter of
sleeve bearing 155 slidably supports arbor 117.
Mounted on the front of stripper pla~e 145 are hooks 157. Hooks
157 are arranged in a circle concentric with the center of opening 149.
Riding on arbor 117 is stripper washer 159, preferably nlade of bronze.
As shown in Figures 6 and 7, arbor 117 passes through the center
hole 161 of stripper washer 159. The stripper washer is restrained from
moving axially along arbor 117 by stripper plate 145 and hooks 157. More-
over, since hole 161 is slightly larger than the outside diameter of arbor
117, stripper washer 159 is free to rotate on arbor 117. However, because
of the linlited friction between stripper wa~her 159 and arbor 117, after
arbor 117 has rotated at a steady speed for a short period, stripper washer
159 ~ill be rotating at approximately the sàme speed.
Both stripper plate 145 and stripper washer 159 are preferably
made of bronze, arbor 117 is preferably made of stainless steel. Thus, the
sliding action of arbor 117 on stripper plate 145 and stripper washer 159
will not score arbor 117. Although this sliding action may cause both strip-
per washer 159 and stripper plate 145 to wear, enlarging the clearance be-
tween arbor 117 and openings 149 and hole 161, as described above, because
of the low lateral speeds of arbor 117, this wear is not excessive.
~ lowever, stripper washer 159 has substantially no wear due to ar-
bor 117's flexing and rotation. Although arbor 117's rotational speed is
higll, stripper washer 159 rotates with arbor 117 so that there is little or
no relative rotational motion between the two. Also, s~ripper washer 159
flexes with arbor 117, preventing wear to stripper washer 159 from this
source. Thus~ the clearance between stripper washer 159 and arbor 117 re~
mains constant.
When arbor 117 translates laterally to its retracted position, the
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rear face of capacitor 1 bears against stripper washer 159. Because of the
constant nominal clearance between arbor 117 and hole 161, there is no room
for the inner windings of capacitor 1 to travel between the stripper washer
159 and arbor 117 and "telescope" out of the main body of capacitor 1. And,
as just noted, this nominal clearance is not subject to a large variation
because of wear. Of course, if for some reason undesirable wear does occur
to stripper washer 159, it is easily and inexpensively removed and replaced.
Figure 8 shows the motor for driving the arbor 117 and the regis-
tering means ~or registering arbor 117 so that slot 123 is in an absolutley
vertical orientation. This orientation is necessary for proper "threading"
o~ the arbor. Timing belt 143 engages pulleys 141 and 801. Pulley 801 is
af~ixed to shaft 803 of motor 805. Pulley 801 also carries two cylindrical
detents 807. Detents 807 are located on the same diemeter of pulley 801 on
either side of sha~t 803. In the preferred embodiment, pulley 801 and pulley
141 have the same diameter. Thus, there is a one-to-one correspondence in
the rotation of shaft 803 and arbor 117.
A pawl 809 is rotatably mounted on pin 811. When pawl 809 is ro-
tated into a vertical orientation, shoulder 813 on pawl 809 will engage one
20 of the two cylindrical detents 807 as *hey are carried by pulley 801 and
prevent further ro~ation of pulley 801. The relationship o~ the detents is
such that when pawl 809 engages either of the two detents 807, arbor 117 is
stopped with slot 1~3 in a vertical orientation.
Pawl 809 is rotated by piston rod 815 of air cylinder 817. Air
cylinder 817 is under the control of the central timing means.
In the preferred embodiment, in order to prevent unnecessary
shock *o the apparatus, before pawl 809 is rotated in*o position to engage
detent 807 motor 805 is momentarily deenergized, which stops the rotation of
pulley 801. Pawl 809 is then rotated into engagement position and motor
80S i5 re-energized to drive one of detents 807 into engagement with pawl
- 18 -
809, Because the most that mo~or 805 can rotate before it is stopped by
pawl ~09 engaging detent 807 is 180, motor 805 does not reach a high speed.
Thus, detent 807 contacts shoulder 813 o~ pawl 809 positively, but without
e~cessive force~
Motor 805, under proper control of the central timing means, pro-
vides t~o speeds: a jog (low) speed and a high speed. The jog speed is
used until capacitor 1 has sufficient integrity in its inner windings to
prevent the higher tension in the outer windings generated by the high wind-
ing speed to prevent capacitor l's collapse when it is removed from arbor
117. In the pre~erred embodiment, the jog speed is maintained until after
structural insert 29 is in place.
Jog speed is also used near the completion of capacitor 1. Short-
ly prior to the severing of capacitor electrode 15 and common electrode 11,
motor 805 returns to jog speed. Time is provided for motor 805 to stahilize
at this low speed. Then, as described below, motor 80S is momentarily de-
energized, stopping its rotation and halting the winding of capacitor 1.
This stoppage allows drive rollers 75 and idler rollers 77 to move into con-
tact with stationary electrodes 11 and 15. This procedure avoids moving
non-rotating drive rollers 75 and idler rollers 77 into contact with the
moving electrodes 11 and 15, and thus avoids the consequent damage that
mi~h~ occur to electrodes 11 and 15.
igures 2B and 6, the paper transport means can be seen. An el-
~vator apparatus 601 is illustrated. Air cylinders 603 and 605 move piston
rods 607 and 609 under control o~ the central timing means. A~tached to pis-
ton rods 607 and 609 are support plates 611 and 613. Carried by support
plates 611 and 613 are the following: transpo~t means 615, capacitor seal-
ing means 617~ dielectric layer severing means 619 and conveyor control bar
621. Each of these means is now described in greater detail.
- 19 -
- . ,- ,
.
. . . . . .. . . . .
~s
Paper transport means 615 includes two air cylinders 623 and 625.
Air cylinder 623 is larger than air cylinder 625. These cylinders have
piston ro~s 627 and 629 respectively, each of which carries a clamp 631.
Clamps 631 comprise a rectangular portion 633, a rectangular rubber cushion
635 and a stainless steelface 637.
As one skilled in the art will recognize, when pistons 623 and
625 extend, faces 637 will automatically align because of the compress-
ibility of rubber cushions 635 (rubber cushion 635 in the preferred embodi-
ment has a hardness o~ around 60 durometer). Further, since air is supplied
at the same pressure to both cylinders, piston rod 627 of larger air cylin-
del~ 625 will extend fully presenting a predetermined position for clamping
dielectric layers 3-9. Moreover, one skilled in the art will recognize
that the stainless steel faces 637 which contact paper layers 3 and 5 will
not be corroded by the resins and other chemicals which might be present
dielectric layers~
Capacitor sealing means 617 includes a water ejector 639. The
water is supplied to water ejector 639 through conduit and fittings 641
which lead from pump 643. Pump 643 is also connected to water supply 647
by tube 645~ Whenever elevator apparatus 601 descends (as described below).
20 surface 642 of elevator apparatus 601 depresses piston 644 of pump 643 to
p~ p a few drops o~ water from water supply 647 to water ejector 639.
Located directly below water ejector 639 is wetting roller 649.
Wetting roller 649 includes a Delrin axle 651 mounted in a brass yoke 653.
Rotating ~reely on axle 651 is a stainless steel cylinder 655 which is co-
vered by a water retaining cork cylinder 657. These materials are selected
both according to their function and their resistance to corrosion~ One
skilled in the art could substi*ute other materials having similar func-
tionsJ For example. if water did not properly seal the capacitor, an adhe-
- 20 -
. . .
3~5
sive or heat seal method could be substituted.
Yoke 653 is carried by piston rod 659 of air cylinder 661. Air
cylinder 661 is mounted upon support plate 611 as shown in Figure 6. In
operation, when activated by the central timing means, piston rod 659 ex-
tends wetting roller 649 to contact the outer surface of rotating capacitor
1, thereby wetting and sealing it.
Dielectric layer severing means 619 includes an air cylinder 663
with an associated piston rod 665. Attached to piston rod 665 is a serrated
blade 667. At the appropriate time under control of the central timing me-
chanism, piston rod 665 extends causing blade 667 to contact the then taut
dielectric layers 3,~5, 7 and 9 and thereby sever them.
Also shown in Figures 2B and 6 is the capacitor conveyor means 669.This means includes a conveyor belt 671 which catches ~he wound capacitor
after it is stripped off arbor 117. Motor 679 powers belt 671. Belt 671
conveys the capacitor to ramp 673. Gate 675, normally in the raised posi-
tion, blocks ramp 673 and causes the leading end of capacitor to strike the
side of ramp 673 with the cylinder's axis perpendicular to the length of
ramp 673.
Air cylinder 677 lowers gate 675, under control of the center tim-
ing means, at the same time that dielectric layer severi~ng means 619 isoperated, thereby allowing wound capacitor 1 to roll down ramp 673. Thus,
gate 675 prevents capacitor 1 from starting to slide down ramp 673 until the
entire capacitor 1 is present in front of ramp 673. If not for gate 675,
capacitor 1 might slide down ramp 673 askew.
The axle under arbor 117 upon which belt 671 rotates is attached
to conveyor control bar 621. Ramp 673 also ~as seen in Figure 2B) is ro-
tatably pinned on axle 672. Thus, belt 671 and ramp 673 follow the motion
of elevator mechanism 601. That is~ when the elevator mechanism descends,
- 21 -
. : : . . . .
- ~ . ..
. ,, . : . ' ' . - : ,
' ' '`' ' ' ' . ' . ~ ' ,. : ' ~:
as described below, belt 671 also descends.
Also clearly shown in Figure 2s is ~he tab sensing mechanism 201,
which is a key part of the tab insert means. As has already been described,
capacitol~ 1 has three tabs which must be accurately oriented with respect to
each other. ~Iowever, as long as the tab webs with which the tabs are asso-
ciated contact the proper capacitor electrode, the relative position of the
webs with respect to the capacitor is unimportant. Therefore, as will be
n~ore fully understood after reading the "Operation" below, the first tab 25
is inserted arbitrarily during the time when its tab web 19 will be in posi-
tion to contact capacitor electrode 13. Upon insertion of tab 25, *he cen-
tral timing mechanism counts an appropriate number of turns of arbor 117.
IYI~en the appropriate number of turns have occurred, it is the approximate
time for the insertion of the remaining two tabs 23 and 27.
To insure that they are inserted at the precisely correct position,
the e~act rotational position of already inserted tab 25 must be known.
This is accomplished through means of phototransistor 203 and light source
205. Light source 205 emits a relatively wide beam of light whereas photo-
transistor 203 is sensitive to a relatively narrow beam of light. During
its ro~ation, tab 25 will cross light beam 205 twice; once when tab 25 is
20 closest to light source 205, and once when tab 25 is closest to phototran-
sistor 203. However, because of the wide beam emitted by light source 205,
wlIell tab 25 is closest to light source 205, tab 25 is not large enough to
completely block the light rom reaching phototransistor 203. But when tab
25 is closest to phototransistor 203, because of the narrow acceptance angle
of phototransistor 203, it will block all light reaching phototransistor
203.
Thus, although tab 25 crosses the light beam twice) the light to
~hototransistor 203 is blocked only at one unique position of tab 25 during
- 22 -
93~.~
its rotational travels. This position is sensed by the central ~iming
means and, as desc~ibed below, causes tabs 23 and 27 to be inserted. More-
over, because bo~h phototransistor 203 and light source 205 lie in a plane
parallel to machine back 30, they are located as close as possible to ma-
chine back 30, which reduces the likelihood that an operator will accident-
ally strike and damage them.
Op~ation of_the Preferred Embodiment
Figures 9-14 show a capacitor being wound in various stages on the
machine of the present invention. Figure 9 shows the stage after a previ-
ously wound capacitor has been removed from arbor 117 and the mach~ne is a-
bo~t to wind the subsequent capacitor. Dielectric layers 3, 5, 7 and 9 are
shown led through guide roller 59, past idler rollers 11~ and 115 and between
closed clamps 631.
Common electrode 11 and capacitor electrode 13 have been fed so
that their leading edges are near the convergence of dielectric layers 5 and
9 and layers 3 and 7, respectively. In this position when the converging
dielectric layers are in motion, they exert a frictional pull on the elec-
trodes. This frictional pull would cause the electrodes to advance if they
were not restrained. The restraint is provided by hub brake means 66. That
20 is, arm 68 has been rotated clockwise to draw cable 76 against brake drum ~0
of hub 67, preventing the rotation of hub 67 and the advancement of elec-
trode 11 (and 13).
Similarly, the leading edge of structural insert 29 is located be-
tween converging dielectric layers 7 and 9. Locked drive roller 303 res-
trains the movement of structural insert 29.
Clamps 631 are lowered by elevator apparatus 601. That is, piston
rods 607 and 609 recede into air cylinders 603 and 605 respectively, carry-
ing clamps 631 and their associated apparatus downward. This is illustrated
- 23 -
- . ' : ... . :
: . . : . . .
- ' ' ~:- . . - , ', , :,
.: . , ., :, . , . . :, .:
., ' ' .'.. ', .' ,, ' ~ . '
.. . . . .. . . . . .... . .. . .... . . . . .
3~S
in Figure 10, where clamps 631 have carried the ends of dielectric layers
3, 5, 7 and 9 below arbor 117 which, until this point, has been retracted
into the face of stripper plate 145. Arbor 117 has also been locked with
its slot 123 in a vertical orientation by pawl 809 engaging one of detents
807.
When elevator assembly 601 has lowered clamps 631 to the furthest
downward position, arbor 117 moves axially from behind stripper plate 145
through the action of air cylinder 133. Tangs 119 and 121 envelope dielec-
tric layers 3, S, 7 and 9 ~see Figure 10).
IVhen arbor 117 is fully extended, the pressure in air cylinders
G23 and 6~5 is reduced, thereby relieving to a predetermined extent the pres-
sure between clamps 631. This predetermined lesser pressure is empirically
determilled to be sufficient to hold dielectric layers 3-9 between clamps 631
but permit withdrawal of dielectric layers 3 9 from between clamps 631 with-
out damage to the dielectric layers.
Next, pawl 809 disengages detent 807 through means of air cylin-
der 817 and pistoll rod 815, and motor 805 is energized. ~rbor 117 is dri-
ven through timing belt 143, pulley 141, sha~t 139 and 125.
~otor 805 first rotates at a slow or jog speed. ~eferring to Fi-
gure 11, as dielectric layers 3~9 begin to wrap around arbor 117, they will
~oth be dra~ from between clamps 631 and from supply rolls 31, 33, 35 and
37 .
When the arbor has made a predetermined number of revolutions, and
thus has a predetermined number of wraps of dielectric layers 3-9 around it,
piston rod 72 is extended from air cylinder 74 to relieve the pressure cable
76 exerts on brake drum 80. Simultaneously, drive rollers 75 drive elec-
trodes 11 and 13. Eventually, the leading edges of electrodes 11 and 13 ~
~ill wrap around arbor 117. Since the rate at which rotating arbor 117 pulls
- 24 -
... , . . . :, ' '' ', ' ., ~ ' -, '
- . ,'''~ . ' '.' ~ ' ' ' , ' :
3~i
electrodes 11 and 13 is greater than ~he rate at which drive rollers 75
drive electrodes 11 and 13, and since the slip clutches in drive rollers 75
allow electrodes 11 and 13 to be pulled faster through drive roller 75 and
idler rollers 77 than the driven rota~ional speed of drive rollers 75, the
feed speed of electrodes 11 and 13 is then governed by the rotation of arbor
117.
During this period, elevator apparatus 601 has caused transport
means 615, dielectric layer severing mechanism 619, and capacitor sealing
means 617 to be raised to their upper position. The capaci~o~ winding ma-
chine at this stage is shown in Figure 12.
Approximately at the same time that electrodes 11 and 13 are fed,
tab web 19 is extended. Drive assembly 89 is energized, causing drive rol-
ler 91 to drive tab web 19 toward converging dielectric layer 3 and capa- "
citor electrode 13, Tab web 19 is driven un~il photodetector assembly 105
senses the presence of tab 25. At this point, drive roller 91 is locked.
However, the leading edge of tab web 19 has been fed to the point where di-
electric layer 3 and capacitor electrode 13 converge. However, since tab
web 19 has not yet been severed from its supply roll 45, it is prevented
from being drawn down past guide rollers 59 and wound into capacitor 1.
70 Figure 12 illustrates the capacitor winding machine at this stage.
When the appropriate time arrives for tab web 19 ~o be inserted,
reciprocating cutter 99 is energized, severing tab web l9~from supply roll
45 and allowing it to be drawn into capacitor 1~ As previously men~ioned,
the e~act location of web 25 is not critical. The only necessary criteria
is that it overlie capacitor electrode 13.
When a predeterlllined length of capacitor electrode 13 has been
wound upon arbor 117j determined by the number of arbor rotations, rotary
cutter 79 severs capacitor electrode 13. Drive assembly 73 associated with
- 25 -
'' '''' - ', ' : ~: .
' -. ' ,,, ' ,`:, ` ', `
~Q~6~i
electrode supply roll 41 continues to drive that electrode toward the con-
verging dielectric layers 3 and 7 to form capacitor electrode 15.
Since arbor ll7 has been pulling electrode 13 at a rate greater
than drive assembly 73 can feed electrode 15, there will be a space between
the end of electrode 13 and the beginning of electrode 15. That is, arbor
117 does not begin to pull electrode 15 until the leading edge is about to
be wound into capacitor 1. Therefore, until this point electrode 15 moves
slower than electrode 13, causing a space between the two electrodes.
At the same time the beginning of electrode 15 starts to wind into
capacitor 1, structural insert 29 is inserted. Since the previous cycle the
leading edge of structural insert has been waiting at the convergence of di-
electric layers 7 and 9. At the proper instantJ shearing blade 507 is dri-
ven forward by the piston rod of air cylinder 519 to sever structural insert
29. This instant of operation is shown in Figure 13. Structural insert 29
is drawn between guide rollers 59 by the friction created between structural
insert 29 and converging dielectric layers 7 and 9 and wound into the capa-
citor around arbor 117.
After structural insert 29 is in place in capacitor 1, drive rol-
lers 75 are l~ithdrawn from contact with capacitor electrode 15 and common
20 electrode 11. Motor 805 is then energi~ed to run at full speed -- approxi-
mately 1600 rpm. As previously explained, the initial capacitor windings
are now sufficiently stable to prevent collapse of capacitor 1 when it is
stripped off arbor 117. Also, because drive rollers 75 are no longer in
contact with capacitor electrode 15 and common electrode 11, no unnecessary
drag is placed on these fragile electrodes.
After a predetermined number of arbor 117 rotations, the time to
insert ~abs 23 and 27 arrives. The angular location of these tabs with re-
spect to each other and tab 25 is critical. Therefore~ their insertion is
- 26 -
.
.
-. ' :- : .. : . .
.. : ,,
: .
-: :
365
closely regulated.
Shortly before tabs 23 and 27 are inserted, drive assemblies 89
associated with foil rolls 43 and 45 are energized, causing the respective
drive rollers 91 to drive tab webs 17 and 21. Tab webs 17 and 21 are dri-
ven until photodetector assemblies 105 associated with each drive assembly
S9 sense tabs 23 and 27, respectively. The associated drive rollers 91 are
locked, leaving the leading edges of their associated tab webs in slip en-
gagement with the converging common or capacitor electrode and dielectric
laycr.
tO Wllen suficient time has elapsed for the tab webs to have assumed
a position with their tabs beneath photodetec~or assemblies 105, tab sensing
mPchanism 201 is activated. As previously described, tab sensing mechanism
detects the presence of tab 25 when it is directly in ront of and closest to
phototransistor 203. When tab 25 reaches this position, this information is
conveyed to the central timing means. The central timing means, after a pre-
determined delay, causes reciprocating cutters 99 associated with tab webs
17 and 21 to be energized, severing tab webs 17 and 21 from tab rolls 43 and
45, and allowing them to be drawn into capacitor 1. Because of the previ-
ously described offset o the leading edge of tab web 17 and tab web 21, tab
2~ web 17 enters capacitor 1 before tab web 21, and tabs 23 and 27 are properly
displaced from each other and tab 25.
After the predetermined lengths of capacitor electrode 15 and com-
mon electrode 11 have been drawn from their respective supply rolls 39 and
41~ they must be severed from their supply rolls. Motor 805 is first slowed
and then momentarily deenergized, resulting in'a momentary halt of all paper
and foil movement. Drive rollers 75 and idler rollers 77 are moved into con-
tact with capacitor electrode 15 and common electrode 11, motor 805 is re-
energized to operate at ~og speed, and rotary cutters 79 associated with
- 27 -
.-
.. . . ..
:
' ~ ' .~ ~ ,....... ..
. .
- ' : . . ' ' . :
3~iS
capacitor electrode 13 and common electrode 11 are energized, severing com-
mon electrode 11 and capacitor electrode 15. As previously described, this
procedure permits drive rollers 75 and idler rollers 77 to grasp stationary
electrodes 1l and 15 and avoid damage to those electrodes that could be caus-
ed by contact between nonsynchronous sur~aces.
After common electrode 11 and capacitor electrode 15 have been
wound around arbor 117, and after a predetermined number of additional rota-
tions of arbor 117, which deposits additional layers of dielectric layers
3-9 on capacitor 1, motor 805 is again deenergized. This causes arbor 117
to halt its rotation.
Transport means 615 is then energized. Air cylinders 623 and 625
cause piston rods 627 and 629, respectively, to carry clamps 631 toward each
other to firmly grasp dielectric layers 3-9. Any alignment difficulties be-
tween clamps 631 are automatically corrected by rubber cushions 635.
Dielectric layer severing mechanism 619 is then energized. Air
cylinder 663 causes piston rod 665 to extend, carrying serrated blade 667
into and through dielectric layers 3-9.
Subsequently, motor 805 is reenergized at jog speed to rotate ar-
bor 117. Capacitor sealing means 617 is energized, causing cylinder 655
and its covering cork cylinder 657 to contact capacitor 1 and wet capacitor
l's outer surface. This is shown in Figure 1~. The moisture imparted to
capacitor 1 by wet cork cylinder 657 causes the outer layers of dielectric
layers 3-9 to adhere to each other.
Capacitor sealing means 617 is then deenergized, withdrawing cy-
linder 655 from capacitor 1. Subsequentlyg motor 805 is deenergized and
pawl 809 is rotated into position to engage detents 807. Mo~or 805 is en- -
ergized, rotating pulley 801 to engage one of the de~ents 807. This halts
the rotation of arbor 117 with slot 123 in a vertical orientation.
- 28 -
- ' -' ' ',':" ~ " ' ' .
' ' ~ ' - '
36~i
Arbor 117 is then moved axially towards its retracted position by
the piston rod 1~1 receding into air cylinder 133. As arbor 117 withdraws,
the rear flat surface of capacitor 1 bears against stripper washer 159.
Thus, stripper washer 159 forces capacitor 1 off arbor 117. Because of the
close clearance between stripper washer 159 and arbor 117, none of the inn0r
windings of capacitor 1 can be pulled betw0en stripper washer 159 and arbor
117, pr0venting "tel0scoping" of capacitor 1.
Ev0ntually, arbor 117 is completely withdrawn from capacitor 1,
allowing capacitor 1 to fall onto capacitor conveying means 669. Belt 671
carries capacitor 1 to ramp 673. Capacitor 1 is stopped from rolling down
ramp 673 by gate 675.
Near the end of the cycle drive assemblies 73 and drive assembly
301 are energized. They drive electrodes 11 and 13 and structural insert 29
to the position which they assume at the beginning of the next cycle. That
is, electrodes 11 and 13 are driven into converging dielectric layers 5 and
9 and dielectric layers 3 and 7, respectively, at guide rollers 59.
The leading 0dge of structural insert 29 is fed through guide 313
and knife means 501. Structural insert 29 is then guided into channel 503
by tongue 327 and through knife means 501 to a point around guide rollers
2Q 59, where dielectric lay0rs 7 and 9 convergeO Cables 76 engage brak0 dru~
80 and driv0 whe01 303 is loc~0d to prevent el0ctrod0s 11 and 13 and struc-
tural ins0rt 29 rom feeding :Eurther by means of the fricional pull 0x0r~ed
by dielectric layers 3-9.
Capacitor 1 waits at gate 675 until the next cycle. When dielec-
tric lay0r severing means 619 is operat0d, air cylind0r 677 caus0s gate 675
to fall, allowing capacitor 1 to roll to the bottom o~ ramp 673.
29
- , ' : .:
'
~'
