Note: Descriptions are shown in the official language in which they were submitted.
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PROCESS AND APPARATUS FOR FORMING A COIL OF SCRAP TUBING
BACKGROUND
1. Field
[1] The following relates to coiled tubing. More particularly, the following
relates to apparatus
and processes for forming a coil of scrap tubing. Additionally, the following
relates to processes
and apparatus whereby a coil of scrap tubing may be formed and provided
without the need for a
spool.
2. Description of Related Art
[2] Coiled tubing is a term referred to metal piping that is used in the oil
and gas drilling
industry. Coiled tubing is a metal pipe that usually comes in small sizes,
varying from less than
one inch to several inches in outer diameter. Because of its small size,
coiled tubing is bendable.
This is contrast to conventional drilling tubulars which are larger in outer
diameter and not
flexible. Because it is bendable, coiled tubing is stored on a spool prior to
and after its use. A
spool can typically hold great lengths of coiled tubing, with some lengths of
reaching even over a
mile of coiled tubing on one single spool. On advantage of coiled tubing over
traditional drilling
tubulars is that the entire length stored on a spool is continuous. This is
contrast to traditional
drilling tubular that come in sixty to ninety foot increments and must be
patched end-to-end
while drilling.
[3] Coiled tubing has many uses. Coiled tubing can be used to circulate fluid
within a wellbore.
It may also be used to pump a fluid to a specific location in a well for
purposes such as
cementing perforations in a wellbore or performing chemical washes of downhole
components.
Coiled tubing can also be used for drilling a well. A drillbit can be attached
to an end of the
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coiled tubing and the coiled tubing is pushed into the ground so as to drill a
wellbore for a well.
[4] As a result of the many uses of coiled tubing, it is used frequently
within the oil and gas well
drilling industry. One problem associated with the use of coiled tubing in the
oil and gas industry
is that disposal of used coiled tubing. Normally, used coiled tubing is wound
back around a
spool. The spool is then taken to a disposal location, the spool is simply
left at that location.
Thus, after disposal there is normally no further utilization of coiled
tubing. Because used coiled
tubing is almost never utilized once it is used, it because a worthless scrap
metal. Scrap coiled
tubing becomes a financial burden on oil and gas drilling companies because
not only is the
scrap coiled tubing worthless, it is useless and requires additional costs for
its disposal.
[5] One of the problems with the disposal of the scrap tubing is the expense
of the reel upon
which the scrap tubing is placed after the tubing has exceeded its life
expectancy. Typically, the
oil and gas production company will simply wrap the coiled tubing around a
reel for an extended
length. Since the cost of the reel can be up to $15,000, it is not practical
to dispose of the coiled
tubing after it is been wrapped around the reel. Typically, the reel and the
scrap tubing is
maintained in storage for an extended time. Ultimately, the tubing should be
removed from the
reel prior to disposal. This avoids the cost of the lost reel.
[6] In prior U.S. Patent No. 7,958,762, issued to the present inventor on June
14, 2011, the scrap
coiled tubing was formed into a length of straight tubing. The straight scrap
coil is then utilized
in the cattle and ranching industries for the purposes of continuous fences
and cattleguards. As
such, the scrap coiled tubing was actually repurposed for another use.
[7] In other circumstances, it is simply desirable to provide the scrapped
coiled tubing for
recycling. Typically, at present values, the scrap tubing will be worth
fifteen dollars per pound. If
it were possible to provide the scrapped tubing without the use of a spool or
reel, then the
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economic benefit to the recycler or to the scrapper would be significantly
improved. As such, a
need has developed so as to provide the scrap tubing in a compact form without
a spool or reel so
that the scrap coiled tubing can maximize returns to the scrapper or recycler.
[8] In the past, various patents have issued relating to techniques for
coiling tubing. For example,
U.S. Patent No. 3,605,541, issued on September 20, 1971 to Ruben et al.,
describes a method for
rotary shear and scrap preparation of tubing. Elongated scrap material to be
cut to length is fed
radially inwardly toward the axis of rotation of a drum between a fixed blade
and the drum
mounted blade. A cutting force is uniform across the full length of the
cutting blades. Material
feed is controlled both as to speed and presentation. The rotary drum sweeps
cut material toward
discharge means.
[9] U.S. Patent No. 6,264,128, issued on July 24, 2001 to Shampine et al.,
discloses a levelwind
system for a coiled tubing reel. The levelwind system includes an arcuate
guide arm extending
over the upper surface of the reel. A universal joint mounts the lower end of
the arm for pivotal
movement both vertically and horizontally. A guide member is supported on the
free end of the
guide arm for guiding the coiled tubing to an on-and-off reel. A hydraulic
fluid circuit is
responsive to a position sensor and a microprocessor for controlling the
movement of the coiled
tubing guide arm.
[10] U.S. Patent No. 6,435,447, issued on August 20, 2002 to Coats et al.,
describes a coiled
tubing winding tool. This winding tool is operable in conjunction with a
levelwind so as to spool
coiled tubing into a helical pattern onto a reel. The winding tool includes a
plurality of rollers
that are urged against the winds of the coiled tubing with a biasing member. A
driver provides
controlled oscillatory translational movement for the rollers.
[11] U.S. Patent No. 6,460,796, issued on October 8, 2002 to Berning et al.,
discloses a reel for
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supporting composite coiled tubing. The coiled tubing is wound onto the reel
and pressurized for
pumping fluid through the coiled tubing into a subterranean well. The wheel
includes a portable
base, a hub mounted on the base and rotatable about a hub axis, and end flange
adjacent to each
end of the hub for retaining the coiled tubing on the hub and between the end
flanges, and a
compliant material covering at least a portion of the exterior surface of the
hub for engagement
with the coiled tubing. As a result, radially inward compressive forces
exerted by the coiled
tubing are absorbed by the compliant material.
[12] U.S. Patent No. 8,393,079, issued on March 12, 2013 to M. A. Parmer,
discloses a method
for salvaging scrap by initially placing a partially completed coil on a reel.
An end of a straight
tube that is helically wrapped with a spine being stripped to an end of a
partially completed coil
is connected to an end of a straight tube. The reel is rotated after
completing the connection until
the partially completed spin fin coil is complete.
[13] U.S. Patent Publication No. 2011/0167973, published on July 14, 2011 to
L. W. Wadsworth,
shows an apparatus for cutting tubular members. This apparatus includes a
support structure, a
control system, the cutting station, a guide, and an extracting assembly. The
cutting station
includes a first wheel having at least one cutting member located on the
circumference of the
first wheel and a second wheel having at least one projection located on the
circumference of the
second wheel. The extracted assembly has a cylindrical member with a first end
and a second
end.
BRIEF SUMMARY
[14] It is an object of some embodiments disclosed herein to provide a process
and apparatus that
may effectively provide a coil of scrap tubing without a reel or a spool
connected thereto.
[15] It is another object of some embodiments disclosed herein to provide a
process and
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81775394
apparatus whereby the scrap coiled tubing may be easily formed into a coil.
[16] It is still another object of some embodiments disclosed herein to
provide a process
and apparatus that may maximize the return for the delivery of scrap coiled
tubing.
[17] It is still further object of some embodiments disclosed herein to
provide a process
and apparatus that may simplify the disposal of scrap coiled tubing.
[18] It is still a further object of some embodiments disclosed herein to
provide a process
and apparatus that may be easy-to-use, easy to manufacture and relatively
inexpensive.
[18a] According to one embodiment of the invention, there is provided a
process for
forming a coil of scrap tubing, the process comprising: forming a turntable
having at least one
longitudinal member extending upwardly therefrom, said at least one
longitudinal member
comprising a plurality of panels pivotally attached to and extending upwardly
from said
turntable and a plurality of arms respectively pivotally connected to upper
ends of said
plurality of panels; supplying a reel of the scrap tubing to a location
adjacent to said turntable;
extending an end of the scrap tubing toward said turntable; fixing the end of
the scrap tubing
at said turntable; rotating said turntable such that the scrap tubing wraps
around said plurality
of panels so as to form the coil; pivoting said plurality of panels inwardly
and said plurality of
arms upwardly after said scrap tubing wraps around said plurality of panels,
said plurality of
arms being pivoted from a substantially horizontal orientation to a
substantially vertical
orientation by the pivoting of said plurality of panels; clamping the scrap
tubing in a fixed
position; cutting the scrap tubing so as to separate the coil of the scrap
tubing from a
remainder of the scrap tubing; and lifting the coil from said turntable and
above said plurality
of arms with a forklift after said plurality of arms are in the substantially
vertical orientation,
the step of lifting being after the step of cutting.
[19] According to one embodiment of the present invention, there is
provided a process
for forming a coil of tubing that comprises the steps of: (1) forming a
turntable having at least
one longitudinal member extending upwardly therefrom; (2) extending a length
of the tubing
to said turntable; (3) rotating said turntable such that the tubing wraps
around the longitudinal
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member so as to form the coil; and (4) lifting the coil from the turntable and
above the
longitudinal member.
[20] In some embodiments, a reel of the tubing is supplied in a location
adjacent to the
turntable. An end of this tubing is extended toward the turntable. This end of
the tubing is
fixed to the turntable prior to the step of rotating.
[21] In some embodiments, the longitudinal member includes a panel that
extends
upwardly from the turntable and an arm pivotally mounted adjacent an end of
the panel
opposite the turntable. The arm is pivoted upwardly as the tubing wraps around
the panel. The
arm is movable between a substantially horizontal orientation and a
substantially vertical
orientation. The arm is moved to the substantially vertical orientation prior
to the step of
lifting. The arm is moved to the substantially horizontal orientation prior to
the step of
rotating. The coil is lifted above an upper end of the arm when the arm is in
the substantially
vertical orientation. The panel is pivotally
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attached to the turntable. The panel is movable between a vertical position
and an inwardly
angularly inclined position. The panel is moved to the inwardly angularly
inclined position prior
to the step of lifting.
[22] In some embodiments of the process of the present invention, the tubing
can extend through
a levelwind. The levelwind is positioned adjacent to the turntable. The
levelwind moves while
the turntable rotates so as to evenly distribute and helically wind the tubing
around the
longitudinal member. The tubing is clamped in a fixed position prior to the
step of lifting. The
tubing can then be cut so as to separate the coil of tubing from a remainder
of the tubing from the
reel.
[23] In some embodiments, the present invention is also an apparatus for
forming a coil of
tubing. This apparatus comprises a base, a turntable rotatably mounted upon
the base, and at least
one longitudinal member extending upwardly from the base. The longitudinal
member has an
outer surface suitable for allowing the tubing to wrap therearound as the
turntable rotates.
[24] In some embodiments of the apparatus of the present invention, the
turntable has a slotted
area therein. The turntable includes a clamp positioned adjacent to the
slotted area. The clamp is
suitable for fixing an end of the tubing to the turntable.
[25] In some embodiments, the at least one longitudinal member includes a
panel extending
upwardly from the turntable and an arm pivotally mounted adjacent an end of
the panel opposite
the turntable. The arm is movable between a substantially horizontal
orientation and a
substantially vertical orientation. The panel is pivotally mounted to the
turntable so as to be
movable between a vertical position and an inwardly inclined position. An
actuator is
cooperative with the panel. The actuator is actuable so as to move the panel
between the vertical
position and the inwardly inclined position. The arm is in the substantially
vertical orientation
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when the actuator moves the panel to the inwardly inclined position. In
particular, the at least one
longitudinal member includes a plurality of panels positioned on the turntable
so as to generally
form chords of a circle. Each of the plurality of arms is movable between a
substantially
horizontal orientation and a substantially vertical orientation. A plurality
of cams are respectively
pivotally connected to the plurality of arms. The plurality of cams are
respectively cooperative
with a surface of the plurality of arms such that an inward movement of the
plurality of panels
causes the plurality of arms to move toward the substantially vertical
orientation.
[26] In some embodiments of the apparatus of the present invention, a
levelwind is positioned in
spaced relation to the turntable. The levelwind is movable so as to cause the
tubing to evenly
wrap into a coil around the longitudinal member. A winch is positioned in
spaced relation to the
turntable. The winch is suitable for drawing the tubing over the turntable.
[27] This foregoing Section is intended to describe, with particularity, the
preferred embodiments
of the present invention. It is understood that modifications to these
preferred embodiments can
be made within the scope of the present claims. As such, this Section should
not to be construed,
in any way, as limiting of the broad scope of the present invention. The
present invention should
only be limited by the following claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[28] FIGURE 1 is a side elevational view showing the process of one embodiment
of the present
invention for forming a coil of tubing.
[29] FIGURE 2 is a plan view showing the process of one embodiment of the
present invention
for forming the coiled of' tubing.
[30] FIGURE 3 is a perspective view of the apparatus of one embodiment of the
present
invention showing the arms in a substantially horizontal orientation.
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[31] FIGURE 4 is a perspective view of the apparatus of one embodiment of the
present
invention showing the arms in a substantially vertical orientation.
DETAILED DESCRIPTION
[32] Referring to FIGURE 1, there is shown the system 10 for the formation of
a coil of scrap
tubing. In particular, in FIGURE 1, it can be seen that there is a reel 12
having scrap tubing 14
wrapped therearound. Reel 12 is rotatably mounted to a frame 16 mounted upon a
base 18. The
reel 20 is supplied by the oil and gas production company. After the coiled
tubing 14 has been
used for a period of time and after the coiled tubing 14 exceeds its life
expectancy or has become
damaged, the oil and gas production company will wrap the scrap tubing around
the reel 12. As
such, the reel 12 will contain an extremely long length of tubing 14. This
large reel 12 of tubing
can be delivered by truck or rail to a destination. At the destination, the
reel 12 is unloaded from
the truck or train and then placed upon the frame 16. As a result, the tubing
14 on the reel 12 can
be unwound therefrom.
[33] FIGURE 1 illustrates the apparatus 20 of one embodiment of the present
invention for
forming a coil 22 of the tubing 14. In particular, a base 24 is provided. A
turntable 26 is rotatably
mounted upon the base 24. Typically a motor 28 is provided so as to cause the
rotary motion of
the turntable 26. A winch 30 extends upwardly from the base 24. Winch 30 is
supported by a
frame 32. A motor can be drivingly connected to the winch 30 so as to cause
the requisite rotary
motion of the winch 30. Additionally, FIGURE 1 shows that there is a levelwind
34 positioned
on a post 36 extending upwardly from the base 24. Also, a clamp 38 in the
nature of a vise is also
provided on a beam 40 extending upwardly from the base 24. The levelwind 34
moves along the
post 36 so as to assure an even helical wrapping of the tubing 14 upon the
turntable 26.
[34] As can be seen in FIGURE 1, and as will be described hereinafter, there
are a plurality of
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longitudinal members 42 extending upwardly from the turntable 26. Longitudinal
members 42
are positioned within the interior of the coil 22 so as to provide a structure
whereby the coil 22
can be wrapped therearound. The plurality of longitudinal members 42 are
created so as to form
a temporary spool so that the coil 22 can be formed therearound. After the
tubing 14 is properly
formed into a coil 22, the longitudinal members 42 can be manipulated so that
a forklift can be
utilized so as to lift the coiled 22 from the turntable 26 and upwardly over
the longitudinal
members 42.
[35] In the process of one embodiment of the present invention, the tubing 14
from the reel 12
can be fastened to a line extending to the winch 30. Typically, holes are
formed diametrically
through the end of the tubing 14. A suitable fastener can be affixed within
these holes. The line is
connected to the fastener and connected to the winch 30. The winch 30 can be
suitably actuated
so as to pull the tubing 14 across the upper surface of the turntable 26 so
that an end 44 resides in
an area generally beyond the turntable 26. This end 44 can then be released
from the winch 30
and moved downwardly so as to be received within the turntable 26 and clamped
by clamp 46
thereto. As a result, the rotation of the turntable 26 will cause the tubing
14 to wrap around the
longitudinal members 42 into the form of the coil 22.
[361 The tubing 14 can extend through the levelwind 34. During the wrapping of
the tubing 14
around the longitudinal members 42, the levelwind 34 can move correspondingly
upwardly and
downwardly so as to create a helical coil 22. Typically, the levelwind 34 will
serve to form a
helical pattern of the coil 22 over the longitudinal members 42.
[37] After the coil 42 has been properly formed, the vise 38 is clamped upon
the portion 48 of
the tubing 14. As a result, the portion 48 will be in a fixed position. The
portion 38 can then be
cut so as to separate from the remainder of the tubing 14 on the reel 12. The
vise 38 will serve to
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assure that there is no "spring-back'' effect. Once portion 48 has been cut,
the portion 48 can be
tack-welded to the exterior of the coil 22 so as to remain in a fixed
position. Additionally, the
end 44 can be unclamped from the clamp 46 and moved so as to be tack-welded to
the exterior
surface of the coil 22.
[38] Ultimately, after this is been completed, a forklift can be provided
adjacent to the apparatus
20. The forks of the forklift will enter below the bottom of the coil 22 and
lift the coil 22 over the
longitudinal members 42. As a result, the coil 22 can be provided without the
need for a spool or
reel. As such, the cost of the spool or reel is effectively avoided.
[39] FIGURE 2 shows a plan view of the system 10 of one embodiment of the
present invention.
In particular, in FIGURE 2, the frame 16 is supported upon the base 18. The
reel 12 is rotatably
mounted within the frame 16. The tubing 14 is illustrated as wrapped around
the reel 12. A
portion of the tubing 14 and will extend outwardly of the reel 12.
[40] The tubing 14 can extend through the levelwind 34 that is supported by
post 36. As such,
the tubing 14 can be guided in the desired manner toward the turntable 26. The
vise 38 is
illustrated as positioned between the levelwind 34 and the turntable 26.
1411 In FIGURE 2, it can be seen that the turntable 26 has a generally
circular configuration. The
longitudinal member 42 is illustrated as having a panel 50 and an arm 52. In
particular, a
plurality of panels 50 extend upwardly from the turntable 26 within the
interior of the coil 22.
The panels 50 are generally configured so as to form chords of a circle. The
generally stiff nature
of the tubing 14 will cause the tubing to wrap around the panels 50 in a
circular pattern, despite
the planar nature of the panels 50. The arms 52 are illustrated as extending
in a generally
horizontal orientation. In this position, the arms 52 provide a containment
area for the coil 22.
The arms 52 also serve to limit the height of the coil 22. The specific
configuration of the panels
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50 and the arms 52 are shown in FIGURES 3 and 4 herein.
[42] The turntable 26 can include a slot 54 formed through a surface thereof.
The clamp 46 is
illustrated as oriented adjacent to the slot 54. Ultimately, the end 44 of the
tubing 14 can be
introduced into and through the slot 54. Once the end 44 is introduced through
the slot 54, the
clamp 46 can be clamped thereon. The turntable 26 can then rotate so as to
cause the formation
of the coil 22.
[43] The winch 30 is provided on a side of the turntable 26 opposite the
levelwind 34 and the
vise 38. A motor 58 is illustrated as cooperative with the winch 30. The winch
30 is particularly
useful for drawing the coil 44 across the upper surface of the turntable 26.
The winch 34 can be
connected by a line to the end 44 of the tubing 14. As such, the winch 30 can
facilitate the ability
to place the end 44 of the tubing 14 within the slot 54. Once the end 44 is
received within the slot
54 and the clamp 46 is clamped upon this end 44, a cutting tool can be used so
as to separate the
end 44 from the line extending to the winch 30. Under other circumstances, the
fastener can be
unbolted from the holes formed in the end 44 of the tubing 14 so as to allow
the end 44 to remain
free. It can be seen that as the turntable 26 will rotate in a clockwise
direction, the tubing 14 will
wrap around the panels 50 and within the constraints formed between the upper
surface of the
turntable 26 and the arms 52 so as to form the coil 22.
[44] After the coil 22 has been formed, the arms 52 can be moved to a
generally vertical
orientation. Additionally, and as will be described hereinafter, the panels 50
will angularly
incline inwardly so that the no longer exert any force upon the inner surface
of the coil 22. As a
result, it is relatively easy for a forklift to lift the coil 22 from the
turntable 26. The coil 22 can
then be delivered to the recycler, delivered as scrap, or delivered for
disposal in a neat compact
coil form.
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1451 FIGURE 3 shows the coiling apparatus 20 of one embodiment of the present
invention. In
the coiling apparatus 20, the arms 52 are illustrated in their generally
horizontal orientation. It
can be seen that there is a base 24 having a plurality of struts 60 that serve
to support the
turntable 26 thereon. A suitable motor (not shown) can be provided so as to
effectively rotate the
turntable 26 relative to the base 24. The turntable 26 is illustrated as
having shims or spacers 62
on a top surface thereof. The shims or spacers 62 facilitate the ability for
the forks of a forklift to
enter the space between the bottom of the coil 22 and the top surface of the
turntable 26. As
such, the bottom of the coil 22 will be slightly spaced from the top surface
of the turntable 26.
The turntable 26 further includes the slot 54 formed therein. Slot 54 has a
width suitable for
accommodating the diameter of the coil 14 therein. The clamp 46 is illustrated
as positioned at
the periphery of the turntable 26 adjacent to the slot 54. As such, once the
tubing 14 has entered
the slot 54 and extends outwardly therefrom, the clamp 46 can be closed so as
to secure the end
44 of the tubing 14 within the slot 54. The turntable 26 will then be ready
for rotation.
[46] FIGURE 3 shows that there are a plurality of panels 50 that extend
vertically upwardly from
the turntable 26. The panels 50 are configured in spaced relationship to each
other. Panels 50 are
generally of a curved configuration or a planar configuration so as to form
chords or segments of
a circle. An actuator 66 is located centrally of the turntable 26. Actuator 66
is cooperative with
the arms 52. Arms 52 are pivotally connected adjacent to a top of each of the
panels 52. In
FIGURE 3, the arms 52 are configured to extend horizontally outwardly from the
center of the
turntable 26. As a result, the arms 52 form a limiting area for the formation
of the coil 22. Cams
68 are pivotally connected to the arms 52 and also have a surface that resides
against the panels
50. As will be described hereinafter, as the panels 50 pivot inwardly so as to
have an inwardly
inclined orientation, the cams 68 will cooperate with the arms 52 so as to
move the arms 52 into
I 2_
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a substantially vertical orientation.
14'71 The levelwind 34 is supported upon a post 36. A structure 70 has
horizontal beams 72 and
74 which support post 36. The levelwind 34 can move upwardly and downwardly
along post 36
and also along post 76. The parallel arrangement of the posts 36 and 76 assure
that the levelwind
34 is always in a proper orientation relative to the interior structure of the
turntable 26. A pair of
rollers 78 are mounted on the levelwind 34. As a result, the tubing 14 can
extend between the
pair of rollers 78. A weight 80 is illustrated as in an upper position. Weight
80 will bear against
the tubing as it moves between the pair of rollers 78. A sensor 82 is provided
so as to measure a
length of tubing passing between the rollers 78 and onto the turntable 26. As
such, some
embodiments of the present invention may effectively measure the length of
tubing that is placed
upon the turntable 26 and formed into the coil as the coil is being formed.
[48] Winch 30 is illustrated as supported upon the base 24 and extending
upwardly therefrom.
Motor 58 is cooperative with the winch 30 so as to cause rotational movement
of the winch 30.
[49] FIGURE 4 shows the apparatus 20 in which the arms 52 are illustrated in
their substantially
vertical orientation. It can be seen that the panels 50 are pivotally mounted
at their bottoms to the
turntable 26. In FIGURE 4, the actuator 66 has been actuated so as to pivot
the panels 50 from
the generally vertical position to the angularly inwardly inclined position.
The upper ends of
each of the panels 50 will bear upon the cams 68. This will correspondingly
cause the arms 52 to
move to the substantially vertical orientation.
[50] Typically, the panels 50 will move to their inwardly angularly inclined
position after the coil
22 has been formed or during the formation of the coil 22. If the panels 54
are maintained in their
vertical position during the formation of the coil 22, than the coil 22 will
have a generally
constant outer diameter. Importantly, when the panels 52 are moved angularly
inwardly after the
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coil 22 has been formed, this will release any pressure or forces between the
outer surfaces of the
panels 50 and the inner surfaces of the coil 22. Additionally, the arms 52 are
moved to the
substantially vertical orientation. The outer diameter of the arms 52, when in
the substantially
vertical orientation, will be less than the inner diameter of the coil 22. As
a result, a forklift can
be introduced between the top surface of the turntable 26 and the bottom of
the coil 22. The
forklift can then lift the coil from the panels 50 and up and over the arms
52. The arms 52 can be
lowered to the horizontal orientation and the panels 50 can be moved back to
the vertical position
so that another coil can be formed.
1511 The foregoing disclosure and description of embodiments of the invention
is illustrative and
explanatory thereof Various changes in the details of the illustrated
construction or the steps in
the described method can be made within the scope of the present claims. The
present invention
should only be limited by the following claims.
4
