Note: Descriptions are shown in the official language in which they were submitted.
~22~384~
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to method and apparatus for
transferring flexible material from one rotating winding
diameter to another, automatically, and more particularly
to such apparatus in which flexible materials can be wound
- upon one of two spindles and the winding automatically trays-
furred to the second of the two spindles automatically without
interruption so as to coincide with equipment feeding material
non-stop at a constant rate.
Prior Art
- Automatic yarn transfer systems for effecting auto-
matte transfer of running yarn from one chuck, upon forming
of the yarn package thereon, to another chuck are well known
lo to the textile industry. Exemplary of such automatic yarn
transfer systems is U. S. patent 3,876,161, which is directed
to a winder for yarn and similar materials, having an automatic
yarn transfer system which includes a drive roll and at least
two rotatable chucks, each of which is adapted to carry a
bobbin tube and is movable into and out of driven engagement
with a drive roll. A transversing arrangement traverses a
running yarn which is being wound onto one of the chucks, so
as to form a yarn package on the latter. A transfer mechanism
automatically effects transfer of the running yarn from one
chuck to another of the chucks. When the yarn package has
been formed on the other chuck, the running yarn is then
automatically transferred again to the first-mentioned chuck.
-- 2 --
84~
The yarn transfer mechanism of the above-identified patent
utilizes top an bottom guide mechanisms as well as yarn
pushers, each having individual pneumatically operated
cylinders and piston units for their actuation. The bottom
and top guides operate in a direction transverse to the yarn
pushers such that the bottom and top guides can position the
yarn for pick-up by the yarn pushers which pick up the
respective running yarns and push them out of engagement
with a traverse guide towards a swing arm for pick-up by a
guide plate.
However, notwithstanding such automatic yarn transfer
systems, there is a need in the art of automatic on-line
winding apparatus to simplify such equipment and to enhance
its operation by making such automatic winding apparatus more
versatile such that it can handle an unlimited number of
flexible materials.
SUMMARY OF THE INVENTION
The primary object of the present invention is to
provide winding apparatus for automatically transferring
- flexible material from one rotating winding diameter to
another so as to enable material to be wound as it is being
produced in a non-stop fashion at a substantially constant
rate.
Another object of the present invention is to provide
such automatic winding apparatus which can be used in the
winding of a wide variety of flexible materials, such as
electrical wire, optical fiber material, flat ribbon-like
cable, etc.
12288~
Yet a further object of the present invention is to
provide such winding apparatus which can be operated in
either a fully automatic mode, requiring minimum operator
attention, or semi-automatically, in which the operator can
perform various functions in accordance with that dictated
by the type of material being wound, for example.
And still yet another object of the present invention
is to provide an automatic winding machine which provides
consistent winding down-time to increase the productivity of
the winding operation, as well as to enable such automatic
winding equipment to coincide with equipment feeding material
at a non-stop, relatively constant rate, without interruption
of the feeding process in the winding process.
And still yet a further object of the present invent
lion is to provide such automatic winding apparatus which can
be controlled by micro-processors, thereby enabling a greater
versatility in the winding process, as well as the type of
winding that is performed by the machine.
And yet still another object of the present invention
is to provide automatic winding apparatus that will enable
winding of flexible material continuously and in which the
flexible material is transferred from a first mandrel to a
second mandrel upon completion of winding of the first mandrel
and subsequent automatic transfer of the flexible material to
the first mandrel upon completion of winding of the material
on the second mandrel and removal of the previously wound
material on the first mandrel.
-- 4
~22884~:
The on-line winding machine incorporates a pair
of spaced lower and upper spindles each including a
mandrel having a removable end form. Each of the spindles
is mounted on a table which is movable between an IN position
adjacent the traverse mechanism and an OUT position adjacent
an operator position for removal of the wound material on
either one of the mandrels. A pair of transfer arms are
mounted for vertical movement in a direction parallel to
the axes of the two mandrels and a pair of transfer arms
are mounted for horizontal movement between the mandrels
from an It position adjacent the traverse mechanism to an
OUT position adjacent the operator position.
A central processing unit is programmed to reset
the components of the on-line winding machine prior to
either a manual or an automatic mode of operation such that
these components occupy known predetermined positions from
which either the manual or automatic mode of operation can
be carried out. The central processing unit controls not
only the movement of the spindles and the vertical and
horizontal transfer arms, but also the traverse guide and
a grabber and cutter mechanism on the fixed end forms of
each of the lower and upper mandrels.
In the automatic mode of operation the flexible
material is automatically transferred by cooperating
movement of the horizontal and vertical transfer arms
122~
such that the flexible material is transferred from
a wound mandrel onto the unwound mandrel and the
material is severed from the wound mandrel. Subsequent
to a transfer of the flexible material, the end form is
S removed from the wound mandrel and the spindle containing
that mandrel is moved to the operator position such that
the wound material can be removed from the mandrel.
During the manual mode of operation, the vertical
and hori70ntal transfer arms are de-activated and the
I transfer of the material is carried out by the operator
who also initiates the rotation of the spindles, as well
as the movement between their inner and outer positions.
The on-line winding machine is capable of winding
material in any known winding format including the
15 universal wind containing a radial hole extending from
the exterior of the wind to the interior core thereof
such that the wound material may be paid out from the
inside of the winding through the radial hole.
- 6 -
~228842
BRIEF DESCRIPTION OF THE DRAWING
The above objects, advantages and features of
the invention are readily apparent from the following
description of a preferred embodiment representing the
best mode of carrying out the invention when taken in
conjunction with the drawings, wherein:
Figure 1 is an oblique elevation Al view of the
essential components of the on-line winding machine;
Figure 2 is a side elevation Al view of the
essential components of the on-line winding machine;
Figure 3 (on the sheet of Figure 1) is a cross-
section taken along line 3-3 of Figure 2 showing the
relationship of the mandrel and spindles and the driving
motor and interconnections for the same of the on-line
winding machine;
Figure 4 (on the sheet of Figure 2) is a cross-
section taken along lines 4-4 of Figure 2 illustrating the
relationship of the traverse mechanism to the mandrels;
Figure 5 is a section taken along lines 5-5 of
Figure 4 illustrating the relationship of the spindles and
the vertical transfer arms immediately prior to transfer of
the flexible material from one spindle to the other spindle;
Figures 6-13 respectively illustrate the operation
of the vertical and horizontal transfer arms in transferring
the flexible material from the low to the upper spindle and
from the upper spindle to the lower spindle upon completion
of the respective windings thereof;
1228842
Figure 14 ton the sheet of Figure 5) is a detail
view illustrating the construction of a vertical transfer
arm;
Figure 15 (on the sheet of Figure 5) is a detail
view illustrating the dual horizontal transfer arms;
Figure 16 (on the sheet of Figure I is another
detail view illustrating the structure of a vertical transfer
arm;
Figure 17 it a partial cross-sectional view of the
spindle and the cutter and grabber assembly;
Figure 18 shows the control functions for the reset
mode of operation;
Figures lea and lob are flow charts illustrating
manual control of the various components of the on-line
winding machine;
Figures aye and 20b are a flow chart illustrating
the automatic mode of operation of the on-line winding
machine;
and
Figure 21 is a schematic block diagram of the control
circuitry for the on-line winding machine.
DETAILED DESCRIPTION
With reference to Figures 1-3, and with particular
reference to Figure 1, main frame 20 includes side frame 22
attached thereto, the latter supporting vertical transfer arm
support 24. The main frame 20 includes shelves 26,28 and
30 for supporting various components of the on-line machine.
In particular, shelves 26,28 each include respective paired
~2~:8~34~:
rail assemblies 32 and 34 for supporting the upper and
lower spindle drive motor and gear assemblies 36, 38,
respectively. Suspended from shelf 26 is horizontal transfer
arm carriage assembly 40, which includes spaced guide rails
I and 44 on which are movably mounted horizontal transfer
arm assembly 46, the structure, operation and function of
which will be described more fully hereinafter.
Viper mandrel 48 is appropriately mounted to spindle
shaft 49 and includes fixed end form 50, which incorporates a
lb cutter and grabber assembly (more fully described hereinafter
with respect to Figure 17), as well as removable end form 52,
the function of which will be described more fully with regard
to that which is illustrated in Figure 4. Similarly, lower
mandrel 54 is mounted on spindle shaft 55 and includes fixed
end form 58, which also incorporates a cutter and grabber
assembly, and removable end form 56 which is similar to remove
able end form 52 of the upper mandrel 48. The traverse
mechanism 60 (more fully illustrated in Figure 4) is mounted
to reciprocate between upper and lower mandrels 48, 54 in a
direction parallel to spindle drive shaft I and 55 so as to
wind flexible material on each of upper and lower mandrels 48,
54, respectively. As shown in Figure 1, the horizontal transfer
arm carriage 46 is adapted to move horizontally inwardly and
outwardly with respect to upper and lower mandrels 48, 54.
25- Vertical transfer arm assembly 62 is mounted to be
vertically moved between upper micro switch position sensor
64 and lower micro switch sensor 66 as illustrated in Figure
1. Upper and lower shock absorbers 68, 70 are mounted to
vertical transfer arm support 24 to cushion the stopping of
1~288~ -
the vertical transfer arm assembly 62 at its respective upper
and lower positions. The vertical transfer arm assembly
includes two spaced parallel extending support members 72
and 74, each containing at the end portion thereof the
vertical transfer arm 76 (only one of which is illustrated
in Figure 1 to preclude crowding the drawing).
In the end view of the support frame 20 as thus-
treated in Figure 2, spindle drive assemblies 36 and 40 each
include respective mutters, 76, pulley 78, 80, respectively
attached to spindle drive shafts 49 and 55. Pulleys 78 and 80
are respectively driven by belts 82 and 84 connected to the
shaft of motors 74, 76, respectively. As illustrated in the
full lines of Figure 2, spindle drive assemblies 36 and 40
are illustrated in their fully inward position in which the
respective upper and lower mandrels 48, 54 are rotated so
as to wind material on the mandrels. In the phantom position
of spindle drive assemblies 36 and 40 as illustrated in Figure
2, such assemblies are shown in their outward position, to
which the respective spindle assemblies are moved subsequent
to-a completion of winding of flexible material on the respective
upper or lower mandrel to enable an operator to remove the
material from the mandrel while flexible material is being
continuously wound on the other mandrel. It is to be under-
stood that spindle drive assemblies 36 and 40 are alternatively
positioned in either an IN or an OUT position in accordance
with a program (to be described more fully hereinafter) and
by appropriate piston elements which may be pneumatically or -
hydraulically driven, for example, and which are not illustrated
as such elements are well known to those skilled in the art
to which the invention is directed.
-- 10 --
8842
Also illustrated in Figure 2 is traverse drive motor
86 and the traverse cam mechanism 84 which is interconnected
to the traverse drive motor by pulleys 90 interconnecting the
traverse mechanism 88 with a gear assembly 92 which in turn
is connected to the traverse motor 86 via belt 94. As is more
clearly illustrated in Figure 4, the guide mechanism 60 includes
a guide tube 96 through which flexible material 98 is fed
- from a source (not illustrated) to either the upper or lower
mandrel for winding of the flexible material thereon. Flexible
material 98 may be provided through an accumulator which is
fed directly from the machinery that is manufacturing the
flexible material, such as wire cable. This enables such wire
cable or other flexible material to be directly wound as it
is manufactured. The purpose of storing the flexible material
in the accumulator is to account for down-time of either the
on-line winding machine or the manufacturing equipment so as
to enable the material to be continuously wound.
Finally, with respect to Figure 2, solenoid and valve
assembly 100 is shown mounted on shelf 30 of main frame 20.
Such solenoids and valves are used in the hydraulic or
pneumatic control of the inward and outward movement of the
mandrels as well as to control the inward and outward movement
of the horizontal transfer arms.
Figure 3 illustrates the relative position of the
horizontal transfer arm assembly 46 between upper and lower
mandrels 48, 54, respectively. Also illustrated in that
Figure is pneumatic or air cylinder 100 and piston 104, which
is in turn attached to removable end form 52 of upper mandrel 48.
-- 11 --
- ~22~3842
Actuation of cylinder 100 retracts movable piston 104 and
end form 52 from mandrel 48. This enables upper mandrel 48
to be moved backwardly (with respect to Figure 3) such that
the operator can remove wound flexible material from the
mandrel. Lower spindle 55 also includes a similar cylinder
106 and piston 110 which is attached to removable end form 56
of lower mandrel 54 as is illustrated in Figure 3. As further
illustrated in Figure 3, the horizontal transfer arm assembly
includes two transfer arms 112 and 114, the function and
operation of which will be described more fully hereinafter.
The phantom position of removable end form 52 in
Figure 4 illustrates the operation of cylinder 100 in moving
the removable end form from its attachment to upper spindle 48.
The IN position of removable end form 52 is illustrated in
the full line shown in Figure 4 wherein the removable end form
is affixed to the end of upper spindle 48 such that flexible
material may be wound thereon from guide mechanism 60. As
is further illustrated in Figure 4, the horizontal transfer
arm mechanism 46 is movable along spaced rails 42, 44 (only
one of which is illustrated) between an IN position sensed by
micro switch 118 and an OUT position sensed by micro switch 120.
The OUT position of transfer arm assembly 46 is illustrated
in phantom in Figure 4. As will be described more fully herein-
after, flexible material is transferred from the upper to the
lower mandrel and from the lower mandrel to the upper mandrel
by means of cooperating coxswain between the upper and vertical
transfer arm mechanisms. Figure 4 illustrates the relative
horizontal positioning of horizontal transfer arm assembly 46
and one member of vertical transfer arm assembly 62 as they
~228842
are positioned immediately prior to initiating a transfer
operation.
Figure 5 illustrates a vertical transfer arm assembly
- 62 in its lowermost position where it is in abutting relation-
ship on cushion 70 in which lower position micro switch 66 is
actuated so as to indicate that the vertical transfer arm
assembly 62 is indeed in the lowermost position. This position
of the vertical transfer arm mechanism is used so as to position
arm 72 containing one transfer finger 120 in position to
engage the flexible material at a point between exit from
the guide assembly and the lower mandrel 54 such that the
flexible material can be transferred from lower mandrel 54
to upper mandrel 48 at the completion of winding the flexible
material on lower mandrel 54. In the uppermost position of
vertical transfer arm assembly 62, in which upper sensing
micro switch 64 is actuated to provide a control signal to the
control circuitry (to be more fully described hereinafter),
arm 74 including flexible transfer finger 122 is in position
to engage the flexible material which extends from mandrel 48 -.
tooth guide mechanism such that the flexible material can be
transferred from the upper mandrel 48 to the lower mandrel 54.
The function and operation of the transfer fingers 120, 122
and their coxswain with the spaced transfer fingers 112, 114
of the horizontal transfer arm assembly 46 will be described
more fully hereinafter. Suffice it to say that by appropriate
vertical movement of the vertical transfer arm assembly 62
and appropriate horizontal movement of horizontal transfer
arm mechanism 46, in timed relation to one another, flexible
~228842
material can be transferred from the upper mandrel 48 to
the lower mandrel 54 and vice-versa. Such transfer operation
is made in conjunction with a cutter and grabber mechanism
which will be described more fully hereinafter with respect
to that which is illustrated in Figure 17.
The transfer of flexible material from lower mandrel
54 to upper mandrel 48 is illustrated in Figures 6-9. As is
illustrated in Figure 6, upon completion of winding the
flexible material on lower mandrel 54, the traverse is sent
to its innermost position nearest horizontal transfer assembly
46. The lower mandrel 54 is rotated through two revolutions
to ensure that the flexible material is against the innermost
end form 58 (Figure 6). Then, the lower horizontal transfer
finger 114 of horizontal transfer arm assembly 46 is brought
outwardly from an inward position so as to engage the flexible
material 98. Continued outward movement of horizontal transfer
arm assembly 46 causes the flexible material to be brought
into a position as illustrated in Figure 7 wherein the flexible
material 98 extends above vertical transfer finger 120 of upper
arm 72. During the movement of horizontal transfer assembly
46 from the position shown in Figure 6 to the position shown
in Figure 7, horizontal transfer finger 114 is caused to encage
vertical transfer finger 120, which is releasable so as to
enable the flexible material 98 and horizontal transfer finger
114 to reach the position illustrated in Figure 7. Subsequently,
as is illustrated in Figure 8, upper transfer arm 72 is moved
vertically such that vertical transfer finger 120 engages
flexible material 98 to move it upwardly. Sometime subsequent
to the vertical movement of vertical transfer arm 72, horizontal
transfer arm assembly 46 is moved inwardly so as to enable
- 14 -
~228842
flexible material 98 to be released from horizontal transfer
finger 114 so as to move upwardly towards upper mandrel 48.
Continued upward movement of vertical transfer arm 72 causes
the flexible material 98 to engage the portion of upper mandrel
48 at the point where it meets with fixed end form 50, in which
is located a grabber and cutter mechanism. The flexible
material 98 is grabbed by the grabber mechanism and upon
actuation of the cutter mechanism, the flexible material is
. severed as is illustrated in Figure 9.
10 Prior to the transfer of the flexible material 98
from lower mandrel 54 to upper mandrel 48, the spindle drive
for lower mandrel 54 has been stopped and the position of the
- cutter mechanism on mandrel assembly 48 is sensed, and if .
necessary, mandrel 48 is jogged such that the cutter and
grabber mechanism is in position to receive the flexible
material.
The transfer of flexible material from a completely
wound upper mandrel 48 to lower mandrel 54 is illustrated in
Figures 10-13. As illustrated in Figure 10, upon completion
of winding of the flexible material on upper mandrel 48,
horizontal transfer arm assembly 46 is caused to move outwardly
such that upper horizontal transfer finger 112 engages flexible
material 98 and during its outward transfer movement, upper
horizontal transfer finger 112 engages vertical transfer
finger 122 of lower vertical transfer arm 74. Vertical transfer
finger 122 is also flexible such that horizontal transfer
finger 112 upon engagement therewith will retract it to enable
horizontal transfer finger 112 and the attached flexible
material 98 to pass vertical transfer finger 122 to reach the
~LZ28~a~2
position illustrated in Figure 11. Simultaneous continued
outward movement of horizontal transfer arm assembly 46 and
a lowering downward movement of lower vertical transfer arm
74 and vertical transfer finger 122 causes the flexible
material 98 to be engaged by vertical transfer finger 122
such that the flexible material is engaged by upper horizontal
transfer finger 112 and vertical transfer finger 122 as
illustrated in Figure 11.
As illustrated in Figure 12, horizontal transfer
assembly 46 is moved inwardly so as to disengage the flexible
material 98 from horizontal transfer finger 112 and continued
downward movement of lower vertical transfer arm 74 and
vertical transfer finger 122 causes the flexible material 98
to be engaged in the grabber and cutter assembly mounted
within inform 58 of lower mandrel 54. The flexible material
is grabbed by the grabber mechanism and cut by the cutter
mechanism such that the flexible material is now retained on
a lower mandrel 54 and outward movement of horizontal transfer
arm assembly 46 causes the cut material wound on upper mandrel
48 to be removed from the vicinity of lower mandrel 54, such
that upon rotation of the lower mandrel 54 to wind the flexible
material thereon, the freed portion of the flexible material
from upper mandrel 48 will not become entangled with the
flexible material being wound on lower mandrel 54.
Figure 14 illustrates the manner in which vertical
transfer finger 122 is mounted to lower transfer arm 74 so as
to be retractable when engaged by the outward movement of a
horizontal transfer finger during transfer of flexible material
from one spindle to another. As illustrated in Figure 14,
- 16 -
~288~
vertical transfer finger 122 is mounted to a rotatable shaft
130 which causes the tension of spring 132 to increase such
that upon release of the force causing flexible finger 122
to retract, that finger is then brought into its normal
operating position as illustrated in Figure 14.
Figure 15 illustrates the relative spatial displace-
mint of lower and upper horizontal transfer fingers 112 and
114, which are also mounted in a manner identical to that
described above with respect to vertical transfer finger 122
as illustrated in Figure 14, such that horizontal transfer
fingers 112 and 114 are retractable upon engagement with
vertical transfer fingers during inward movement of vertical
transfer arm assembly 46. It is also noted that with respect
to the vertical transfer fingers, such fingers are retractable
upon engagement with the horizontal transfer fingers during
outward movement of horizontal transfer assembly 46.
Figure 16 is a detail view illustrating the manner
in which horizontal transfer finger 112 is attached to
rotatable shaft 140 and in which spring 142 is caused to be
tensioned upon counterclockwise rotation of horizontal transfer
finger 112 about axis 144.
Figure 17 is a partial cross-sectional view of a
mandrel illustrating the structure and operation of the grabber
and cutter mechanism located in the fixed end form 50 thereof.
As illustrated in Figure 17, piston cylinder 150 inwardly
moves flange 152 which is engaged between projections 154, 156
of piston 158 of the cylinder. Inward movement of flange 152
causes arm 160 to also move inwardly, which grabs the flexible
1~28~4~:
material. Continued actuation of piston 158 then causes
a cutter mechanism to sever the flexible material while
still being retained by the grabber. After the spindle has
been rotated several times such that the flexible material
is engaged by its own windings upon mandrel 48, the cylinder
150 is released such that the grabber mechanism is also
released.
The grabber-cutter mechanism can be made to cause
the grabber to stay in place and the cutter to retract. If
LO the grabber contains a slight piercing edge, the material
(if it is insulated wire) can remain electrically connected
to the winder. This is important if certain tests are to be
performed while the flexible material is being wound.
Although not specifically illustrated, the flexible
material wound on a spindle is withdrawn therefrom by retraction
of the removable end form, such as removable end form 52 from
mandrel 48, thereby enabling mandrel 48 and associated spindle
drive mechanism 36 to be moved outwardly along guide rails 32
(reference Figure 1). When mandrel 48 is completely removed
from its operating position, the operator can then actuate
mechanism which causes the middle portion of mandrel 48 to
contract, thereby freeing the flexible material thereon for
easy removal. Such retraction mechanism is well known to
those skilled in the art such that it need not be described
herein in order for the invention to be carried out. A
retractable mandrel is disclosed in Canadian Patent No.
1,171,834, issued July 31, 1984, assigned to the same
Assignee as the present application. In a similar manner,
- 18 -
12~
flexible material wound on lower mandrel 54 is removed
upon separation of removable end form 56 from the spindle
and outward movement of mandrel 54 and its associated
spindle drive mechanism 38.
The control of the various components of the on-line
winding machine to cause transfer of the material from an
upper spindle to the lower spindle or from the lower spindle
to the upper swindle is illustrated in Figures lea and lob,
as well as Figures aye and 20b.
The following is a description of the reset operation
of the on-line winding machine which is undertaken prior to
either a manual or automatic operation of the machine. The
reset operation is under control of a central processing
unit (CPU), which is part of the control circuitry illustrated
in Figure 18. with respect to the control functions thus-
treated in Figure 18, upon power-up and release of the CPU
reset line the CUP sets stack 180, which stores the necessary
information in the CPU. The CPU turns all the control valves
within the on-line machine off as indicated by control function
181. These valves are, for example, air or pneumatic solencic
valves that control the motion of the various components within
the winding machine such as, the end forms, spindle tables,
cutters, vertical and horizontal carriages, etc. The CPU
then checks if the valves are indeed off, which is sensed by
sensor 182.
It should be noted that during power-up there may be
considerable electrical noise such that control function 181
for turning off all solenoid valves may not have been
-- 19 --
~22~38~2
accomplished due to interference. Thus, if all the valves
have not been turned off, control function 181 is repeated,
us indicated in Figure 18, as often as is necessary. It is
necessary that all of the control valves be turned off to
avoid damage from resultant movement of the various components
of the on-line winding machine and the possibility of collision
amongst those components.
Control function 183 clamps all of the motors and
turns all of the indicators off. The INTERRUPT is set to no-
star the CPU at a particular address. The aforementioned
steps in the reset process are necessary to maintain the
machine from powering-up in a random fashion. The reset
- functions require only several microseconds, such that the
components of the on-line winding machine do not have any time
to move before the CPU turns the various motors and valves off.
The reset function continues with a control function 184 in
which the valves that move the upper end form out, upper cutter
out, lower end form out, lower cutter out, and horizontal arm
cylinder in, are all energized. The upper end form OUT sensor
is-checked and if the upper en dorm is out as sensed by sensor
185, the lower end form OUT sensor is checked by sensor 186,
the upper spindle IN sensor is checked by sensor 187 and if
the upper spindle is not in the IN position it is sent to the
OUT position at the operator station by control function 188.
Next, the lower spindle IN sensor is checked and if the lower
spindle is not in the IN position it is sent to the OUT position
at the operator station by control function 190. The reset
mode of operation then inters approximately a two-second time
- 20 -
~;2;28~342
delay as provided by the CPU in timer function 191 and
subsequent to that time interval, both the upper and lower
spindle tables or carriages are moved to the IN position by
control function 192. The upper and lower spindle positions
are respectively checked by sensors 193 and 194.
The aforementioned procedures are necessary since
the actual position of the upper and lower spindles are not
known by the CPU unless either or both of the upper and lower
spindles are in the IN position and have actually been detected
as being at such position. The aforementioned procedures merely
send the various components of the on-line winding machine
such as the upper and lower end forms and the upper and lower
spindles to a known position. Each spindle table or carriage
contacts a shock absorber at the end of its motion. The shock
absorber at the OUT position (the operator position) is a
spring return device. However, the shock absorber in the IN
position (the position closest to the traverse mechanism) is
an air return device. Since the state of the IN shock absorber
is not known, the spindle table or carriage must be sent OUT
if-it is known not to be in the IN position. The two-second
time interval afforded by control function 191 ensures that
the IN shock absorbers are OUT.
Continuing with the reset mode of operation as thus-
treated in Figure 18, a one and one-half second time delay is
then provided by timer control function 195 to allow the
spindle tables or carriages to stop oscillating at their IN
positions once having contacted the aforementioned shock
absorbers. Next, the CPU checks the status of the on-line
- 21 -
~2~884~
winding machine for either an automatic or manual operation
by sensing the condition of the manual/auto switch 196.
If the automatic mode of operation has been selected,
both the upper and lower end forms are put in the IN position
by control function 197 and the successful completion of the
respective operations are checked by sensors 198 and 199.
Next, the vertical arm cylinder is sent to the DOWN position
by control function 200 and the position of the vertical arm
cylinder is sensed by checking the vertical DO sensor as
indicated by sensor 201. Next, the horizontal arm cylinder
is sent to the OUT position by control function 202 and the
position of the horizontal arm is checked by the horizontal
arm OUT sensor indicated by numeral 203 in the function control
diagram of Figure 18. If the horizontal arm is indeed sensed
as being in the OUT position, the CPU waits for the RUN button
to be depressed and therefore the start of the automatic
on-line winding operation as will be described more fully
hereinafter with respect to the control functions illustrated
in Figures aye, 20b.
If the operator has selected the manual mode of
operation, both the upper and lower end forms are sent to the
IN position by control function 204 as illustrated in Figure
18. Power is removed from the horizontal arm cylinder by
control function 205 and the CPU then waits for the RUN button
indicated by control function 206 to be pressed and therefore
the start of the manual operation of the on-line winding
machine.
- 22 -
aye
In the manual mode of operation of the on-line
winding machine, a sensor 207 checks the position of the
vertical cylinder on vertical transfer mechanism 24. This
sensor 207 corresponds to micro switch 64 illustrated in
Figure 1. Prior to this time, the operator has manually
attached the flexible material to the lower mandrel 54 of the
winding machine. If the upper cylinder is in the proper
position (as indicated by a YES output of sensor 207), the
- lower cylinder is turned on by control function 208 such that the
lower spindle motor is jogged after the wire is manually
attached thereto by the operator to wrap the wire to retain
it on lower mandrel 54. In the event that the upper cylinder
is not in the appropriate position, the control function turns
off the digital-to-analog converter that jogs the motor.
Depression of the start button BY by the operator turns off
the digital analog converter via function 209 and the upper
removable end form 52 from mandrel 48 is moved outwardly by
function 210. Appropriate sensor 212 (not illustrated in the
drawings to avoid cluttering thereof) then checks the position
of the removable end form. If the removable end form 52 of use
mandrel 48 is indeed in its outward most position, upper mandrel
48 is moved outwardly by control function 214 such that the
material that may have been wound thereon can be removed by
the operator. The program thin moves the upper mandrel 48
inwardly into a wound position which is checked by an appropri-
ate sensor indicated by block 216 in Figure lea. The timer
function is then entered for approximately two seconds to
prevent the end of the flexible material from entangling in
the lower mandrel as it starts winding. Such timer function
is represented by block 218. After a time interval of
12Z8~342
approximately two seconds, the lower mandrel 54 is caused
to wind by control function 220 which actuates the spindle
drive motor and the control system is then caused to enter
a five second timer interval as indicated by control function
224 to allow proper time for the operator to release the start
button which was depressed before the upper spindle motor was
turned off at process function 209. The system then checks
to see that the starter button is depressed and then the
control functions to set the upper spindle in the IN position
which is the wind position of that spindle by control function
226. The IN position of the spindle is checked by appropriate
sensors as indicated by sensor block 228 and then the system
again enters a five second timer interval as indicated by
control function 230 to ensure that the spindle carriage is
not bouncing. The program continues with the subsequent move-
mint of the removable end form 52 of upper mandrel 48 into its
wind position such that it is attached to the mandrel. This
function is initiated by control function block 232 and the
position of the removable end form of upper mandrel 48 is
checked by sensor function 234. The control system then
checks the footage counter and when the appropriate amount
of flexible material has been wound on lower mandrel 54 and
checked by sensor 236, the rotation of the lower mandrel is
stopped by control function 2~8.
Then, the operator manually cuts the flexible material,
and hooks the end to the upper mandrel. The operator then
depresses button BY to jog the upper mandrel to ensure that
there is sufficient material wound on the mandrel. If the
starter/mandrel return button By is depressed, then the D/A
converter is turned off by control function 240 to start the
- 24 -
~228~3~2
upper mandrel to wind by control function 242. In the
event that the starter mandrel return button BY is not
depressed, then the machine remains in the control loop
between control functions 238 and 240.
With the upper mandrel winding, the lower end form
is removed by control function 244 and successful completion
of that operation is sensed by sensor function 246. The lower
spindle can now be brought out to the operator's position my
control function 248. A five-second time interval to allow
proper time for the operator to release the starter/mandrel
button BY which was depressed before control function 240
is then provided by control function 250. Upon depression
of starter/mandrel button BY the empty lower spindle is now
sent back IN by control function 252 and the successful
completion of that operation is checked by sensor 254. A five-
second time delay is afforded by time function 256 to ensure
that the lower spindle carriage is not bouncing. The lower
end form is then moved onto the lower mandrel by control
function 25~ and the completion of that operation is checked
by sensor 260. The footage counter of the mandrel on which
the material is being wound is then checked by control function
262 and the upper spindle drive is stopped by control function
264 when the proper footage is reached. Then the program
enters the original starting point.
The following is a description of the automatic opera-
lion of the on-line winding machine with the control functions
as illustrated in Figures aye and 20b. The CPU turns on the
lower spindle to wind by program function 310. The CPU turns
on a solenoid valve to send the upper movable end form out
(off the upper mandrel). Then switch 312 closes if the upper
lZ~8~
end form is in the OUT position, i.e., away from the mandrel.
The position of the upper end form is sensed by sensor 314
and the program continues by positioning the upper mandrel
in the OUT position by program function 316. The program
then enters a four and one-half second time delay which is
initiated by timer 318. It is noted that all time functions
are provided by software and are executed by the CPU. The
initiation program then continues by positioning the lower
cutter in the OUT position by program function 320.
- 10 It is further noted that function 310 has two entry
points, one of which has been described above. The other
entry point is from the end of the program. Control functions
318 and 320 are needed because the lower cutter was sent in
by the CPU at function 438. The first time through the program
has not caused function 440 to be operative. The functions
318 and 320 are unnecessary the first time, but are required
every time thereafter.
The program then senses the spindle return button 322
and the program continues by placing the upper mandrel in the
IN position by program function 324. The position of the
upper mandrel is sensed by sensor 326 and then the program
enters an approximately two and one-half second time delay
by timer 328. The program continues to initiate the on-line
winder by positioning the upper end form in the IN position by
program function 330 and that position is sensed by sensor 332.
The operating program then continues by positioning the upper
spindle cutter by subroutine 334 and the footage counter is
checked by sensor 336 such that if the footage counter contacts
are open, then the lower spindle motor is turned off by program
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~2;2~3~4X
function 338. The horizontal cylinder is sent in (toward
the traverse) at this time by function 3~0. Next, the
traverse cam is positioned by function 342. The position
of the horizontal cylinder is checked by sensor 344 to make
sure that it is not in the OUT position. Then the lower
spindle motor is turned on by program function 346 to begin
winding material from the traverse guide onto the lower
spindle to ensure that the material is against the inner
- end form. The ?rosram then enters a one-half second time
delay by timer function 348 and the lower spindle motor is
turned off by function 350. The horizontal cylinder is then
placed in the outer position by program function 352 and the
position of the horizontal cylinder is then checked by sensor
354. The vertical cylinder is then sent to the upper position
by program function 356 and the position of that cylinder is
then checked by sensor 358.
It is noted that the vertical cylinder is sent UP TV
at control function 356, but the program is sensing whether
the vertical transfer mechanism is still Dylan. In any control
system time is required for the controlled components to
function. Function 358 ensures that the vertical transfer
mechanist is not Dylan. It is still not known if it is UP.
What is known is that it is on its way. The time between the
energizing of the valve controlled by function 356 and the
opening of switch 358 is counted by counter 359. This time
is required to prevent the vertical and horizontal transfer
fingers from colliding as their paths intersect.
The program continues by putting the horizontal arm
IN by function 360. The position of the vertical cylinder is
- 27 -
~28~34;~
then checked by sensor 362, and if it is in the upper
position, then the program continues by positioning the
spindle through program function 364. This is a check to
ensure that the cutter has not been moved in the transfer
process just described. The program then continues by
placing the upper cutter in the IN position by program
function 366. The position of the upper cutter is then
checked by sincere and if it is in the IN position, the
program proceeds to turn on the lower spindle drive motor
with a digital/analog converter (which will be described
more fully with respect to Figure 21). This function is
performed by program function 370. Then the program enters
a one-half second time delay which is provided by timer 372.
This is required to cause sufficient tension on the wound
material to cause it to flip free of the cutter and upper
mandrel. Subsequently, the lower spindle motor is turned
off by program function 374. Then the upper spindle motor is
turned on by program function 376 and the upper spindle winds.
The program then moves the lower end form to the OUT position
and the position of the lower end form is subsequently checked
by sorcery 380. Then the lower spindle is moved to the OUT
position such that the material wound thereon can be removed by
- the operator and the program enters a four and one-half second
time delay which is provided by timer 384. The upper cutter
is then placed in the OUT position by program function 386
and the spindle return button is then checked by sensor 388.
Subsequently, the lower spindle is then placed in the IN
position by program function 390 and the position of the lower
spindle is checked by sensor 392. The program then enters a
- 28 -
122~384~
two and one-half second time delay which is provided by
timer 394. The program then places the lower end form in
the IN position by program function 396 and the position of
the lower end form is checked by sensor 398. The spindle is
then positioned by program function 400 and the footage
counter is checked by sensor 402 (the same as sensor 336).
Subsequently, the upper spindle motor is turned off by
program function 404. The traverse cam position is then
provided by program function 406 and subsequently the upper
spindle motor is turned on by the digital/analog converter
(which will be described mare fully hereinafter with respect
to Figure 21) by program function 408. The program then
enters a one second time delay which is provided by timer 410
and the upper spindle motor is turned off by program function
412. Then the horizontal cylinder is placed in the OUT post-
lion by program function 414 and the position of the horizontal
cylinder is checked by sensor 416. When the sensor indicates
that the horizontal cylinder is indeed in the OUT position,
then the program function to place the vertical cylinder in
DOWN position by program function 418 and the position of the
vertical cylinder is checked by micro switch sensor 420. Then
the program proceeds to a one-half second time delay (for the
same function as previously described) which is provided by
timer 422. The program then proceeds to place the horizontal
cylinder in the IN position by program function 424 and the
position of the horizontal cylinder is subsequently checked
by sensor 426 such that the program proceeds when that sensor
indicates that the horizontal cylinder is indeed in the IN
- 29 -
384~:
position. This IN position for the horizontal cylinder is
approximately mid-way to the traverse mechanism to the OUT
position of the horizontal cylinder. The horizontal cylinder
is then turned off by program function ~28 and the position
of the vertical cylinder is then checked to see if it is in
the DOWN position by sensor 430. When the sensor indicates
that the vertical cylinder is indeed in a DOWN position, then
the horizontal cylinder is placed in the OUT position by
- program function 432 and the position of the horizontal
cylinder is checked by sensor 434. This process of sending
the horizontal cylinder OUT the second time prevents the
hanging severed material from entangling with the lower
mandrel. when sensor 434 indicates that the horizontal
cylinder is OUT, then the spindle position is checked by
function 436 and the lower cutter is driven to the IN position
by function ~38 to sever the material and when sensor 440
indicates that the material has been severed the program
enters a one-half second time delay which is provided by timer
4~2. The program then proceeds to the function block 310 to
turn on the lower spindle to wind the material and the entire
program is repeated whereby material is wound on the upper and
lower mandrels with the appropriate transfer of the material
between the mandrels when it has been wound thereon.
Figure 21 illustrates a block diagram of the control
circuitry of the on-line winding machine. The entire control
functions are provided by a central processing unit (CPU) 500
which includes a clock, ROM 501 and RAM 503 with the central
processing unit 500 receiving operator inputs functions of the
various limit switches that detect the position of the vertical
cylinder and the horizontal cylinder spindle tables, cutters,
- 30 -
122~4~
start/mandrel return buttons, footage counters, etc., and
the various solenoid valves for positioning the horizontal
and vertical cylinders spindle tables, cutters, end forms,
etc. CPU 500 also receives the upper and lower spindle
positions as well as the position of the cam on the traverse
mechanism and provides suitable outputs to the cam digital/analog
converter and scaling circuitry 502. The CPU 500 also receives
an interrupt signal. The CPU 500 reads the cam position port
- and the spindle position port (depending upon which spindle is
wound). The thumb wheel settings and INTERRUPT determine where
the traverse cam should be. The CPU then writes to the cam
digital/analog converter. The output will be plus if the
actual cam position is less than the computed cam position,
negative if more than the computed cam position, and zero if
the actual and computed cam positions are identical. The CPU
500 also provides an input to the spindle digital/analog
converter 504.
Spindle digital/analog converter 504 provides an
input to spindle select multiplexer 506 which controls the
upper and lower spindle drives 508 and 510, respectively.
The master speed for the lower and upper spindle drives is
provides by master speed potentiometer 512 through linear ramp
513.
Each of the upper and lower spindle motors includes
dual channel encoders each provided with anti-jitter circuitry
as is well known to those skilled in the art. With respect to
upper-spindle motor 514, the output of encoder 516 is dual
channel, namely, channels A and B with a 90 phase shift between
the A and B channels. The output of encoder 516 in both the
- 31 -
~2~88~
A and B channels is provided to up/down counters 5180 A
Hall sensor mechanism 520 provides an indication of the
rotation of upper spindle motor 514 and the output thereof
is divided by two and provided to up/down counter 518. The
count in the up/down counter 518 is indicated in hundreds,
tens and ones position in degrees. This constitutes an upper
spindle position port. An output of the up/down counter 518
is also provided to interrupt multiplexer 52?.
Similarly, lower spindle motor 524 includes encoder
lb `526 which has dual A and B channels which are provided as an
input to up/down counter 528. The Hall detector circuitry 530
provides an input through a divide-by-two circuit into up/down
counter 528. The output of up/down counter 528 indicates the
position of the spindle shaft in the hundreds, tens and ones
position. An output of up/down counter 528 is also provided to
interrupt multiplexer 522, the output of which constitutes a
mask able INTERRUPT 536 to the CPU 500.
The output of upper spindle motor encoder 516 and
lower spindle motor encoder 526 is also input to lack selector
and frequency to voltage converter circuit 540, the output of
which is input to a speed error circuit 542. Speed error
circuit also receives a position error output from the cam
digital/analog converter 502.~
Traverse motor 550 also includes a dual channel encoder
552 which provides A and B channel outputs to up/down counter
554, the output of which provides a cam position port output
indicating in the hundreds, tens and ones position. The A
channel output of dual channel encoder 552 is also input into
frequency/voltage converter 556, the output of which is an
input into speed error circuit 542. Speed error circuit 542
- 32 -
lZ~38~ .
provides an output to traverse drive 558 which controls
traverse motor 550. A Hall sensing mechanism 560 provides
pulses indicating the rotation of traverse motor 550 and
that output is input into up/down counter 554. The Hall
devices reset the up/down counters to zero at the same place
or position every time. This ensures that any noise pulses
are purged every Hall pulse output.
Each of the Hall sensing devices 520. 530 and 560
includes a reset mechanism which resets at one traverse
count from the up/down counter which is approximately seven
hundred twenty counts.
Another output of INTERRUPT multiplexer 522 comprises
a selection line output 570 which is input to tune indicator
! port 572 as well as to the selector and acceleration circuitry
506.
The flexible material may be wound in any manner
known to the winding industry, such as a universal wind, and
such a wind including one or more radial holes extending from
the exterior of the wind to the inner central core thereon
such that the flexible material may be paid out from the
inside of the winding through the radial opening. The central
processing unit of the on-line winding machine described herein
can be programmed to vary the spindle drive mechanisms as well
as the traverse guide mechanism so as to accommodate any
desired winding of the flexible material.
Those skilled in the art will also recognize that the
on-line winding device of the present invention as described
herein is capable of being modified in accordance with known
~28t3~Z
principles and techniques applicable to the winding art,
and therefore the present invention is not intended to be
limited by the specific embodiment herein described, but
the scope of the invention is to be determined by the
following claims with consideration being given to the
equivalence of the claimed components, individually and
collectively in combination.
- 34 -
