Automatic wire dispenser
First Claim
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1. A variable speed, motorized wire dispenser for automatically dispensing wire from a coil of wire to a wire using machine under variable wire feed rate conditions comprising:
- a frame including support means for rotatably supporting the wire for dispensing wire to the wire using machine in a predetermined direction;
an electric motor mounted in the frame so as to rotate the coil of wire;
a regenerative controller that produces an electrical output that controls the operation of the electric motor and causes the motor to both accelerate and decelerate the wire coil, the regenerative controller producing forward and reverse torques in the electric motor that automatically vary such that the speed of the motor is changed at predetermined acceleration and deceleration rates;
wire accumulation means mounted in the frame for producing an accumulation loop of wire to supply or store wire under rapidly changing demand conditions, the wire accumulation means comprising a wire engaging guide movably positioned in the frame such that wire extends over the guide in extending from the wire coil to the predetermined direction, the guide being movable in relation to the predetermined direction so as to produce an accumulation loop in the wire, the guide being biased to increase the accumulation loop between predetermined limits; and
control means responsive to the position of the guide for generating a continuously variable electric control signal representative of guide position, the control means changing the control signal gradually as the loop size increases and decreases, the control signal being transmitted to the regenerative motor controller so as to produce a change in motor speed at a rate representative of the rate of change of the control signal, the control means causing the motor to decrease the rate of wire feed as wire supply requirements decrease and increase the rate of wire feed as wire supply requirements increase, the rate of change in the control signal resulting from guide movement being more gradual than the rate of change in wire feed from the wire dispenser, the accumulation loop being sufficiently large that the rate of motor acceleration and deceleration caused by the regenerative controller is gradual enough to minimize damage to the drive components and to restrain the wire from jumping off the guide.
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Abstract
A machine for dispensing wire according to the momentary needs of a wire-utilizing device has a wire guide mounted for oscillating movement in response to changes in wire tension, and has a drive and control system responsive to the position of the wire guide to progressively increase the rate of rotation of the spool to pay out wire faster in response to an increase in wire tension, and decrease the rate of rotation on reduction of wire tension.
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Citations
34 Claims
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1. A variable speed, motorized wire dispenser for automatically dispensing wire from a coil of wire to a wire using machine under variable wire feed rate conditions comprising:
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a frame including support means for rotatably supporting the wire for dispensing wire to the wire using machine in a predetermined direction; an electric motor mounted in the frame so as to rotate the coil of wire; a regenerative controller that produces an electrical output that controls the operation of the electric motor and causes the motor to both accelerate and decelerate the wire coil, the regenerative controller producing forward and reverse torques in the electric motor that automatically vary such that the speed of the motor is changed at predetermined acceleration and deceleration rates; wire accumulation means mounted in the frame for producing an accumulation loop of wire to supply or store wire under rapidly changing demand conditions, the wire accumulation means comprising a wire engaging guide movably positioned in the frame such that wire extends over the guide in extending from the wire coil to the predetermined direction, the guide being movable in relation to the predetermined direction so as to produce an accumulation loop in the wire, the guide being biased to increase the accumulation loop between predetermined limits; and control means responsive to the position of the guide for generating a continuously variable electric control signal representative of guide position, the control means changing the control signal gradually as the loop size increases and decreases, the control signal being transmitted to the regenerative motor controller so as to produce a change in motor speed at a rate representative of the rate of change of the control signal, the control means causing the motor to decrease the rate of wire feed as wire supply requirements decrease and increase the rate of wire feed as wire supply requirements increase, the rate of change in the control signal resulting from guide movement being more gradual than the rate of change in wire feed from the wire dispenser, the accumulation loop being sufficiently large that the rate of motor acceleration and deceleration caused by the regenerative controller is gradual enough to minimize damage to the drive components and to restrain the wire from jumping off the guide. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 29, 30, 31, 32, 33, 34)
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14. A wire dispensing machine for dispensing wire from a spool wherein wire is wound on an axial core extending between enlarged circular spool ends, the spool having an axial hole therethrough, the wire dispensing machine comprising:
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a frame having a base and upright sides spaced apart on the base, the spool fitting between the sides with the spool axis extending transversely between the sides; a drive axle that fits through the axial opening in the spool and extends to outer portions protruding from the ends of the spool, the drive axle including attachment means for positively attaching the spool to the axle for rotation therewith, the axle having a drive wheel mounted on the axle on one outer portion for rotation with the axle; spool support surfaces positioned on the sides of the frame so as to receive the axle and suspend the spool by the axle for rotation in the frame when the spool is rolled into the frame; motorized drive means mounted on the frame and having an output drive shaft with a drive wheel thereon that lies in the same plane as the drive wheel on the axle, a flexible tension member extending around the drive wheel so as to transfer torque from the motor drive wheel to the axle drive wheel to rotate the spool; and pivotal mounting means for attaching the drive motor to the frame for pivotal movement of the drive motor about a pivot axis parallel to but displaced from the drive wheel axis, pivotal movement of the motor causing the motor drive wheel to be moved toward and away from the axle drive wheel, the motor being pivotal between released and driving positions, the tension member being relaxed and being easily removable from the drive wheels when the motor is in its released position, facilitating removal of the spool from the frame, the tension member being sufficiently tight to effect driving engagement between the motor and axle when the motor is pivoted to its driving position, the pivotal mounting means further including a pivoting linkage means actuated by a lever for moving the motor between its released and driving positions. - View Dependent Claims (15, 16, 17, 18)
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19. A wire dispensing machine for dispensing wire from a spool wherein wire is wound on an axial core extending between enlarged circular spool ends, the spool having an axial hole therethrough, the wire dispensing machine comprising:
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a frame having a base and upright sides spaced apart on the base, the spool fitting between the sides with the spool axis extending transversely between the sides; a drive axle that fits through the axial opening in the spool and extends to outer portions protruding from the ends of the spool, the drive axle including attachment means for positively attaching the spool to the axle for rotation therewith, the axle having rollers rotatably mounted on the outer portions and having a drive wheel mounted on the axle on one outer portion for rotation with the axle, the drive wheel being axially spaced from the rollers; spool support surfaces positioned on the sides of the frame so as to receive the rollers on the axle and suspend the spool by said rollers for rotation in the frame when the spool is rolled into the frame, the frame including upwardly extending edges adjacent the support surfaces that restrain the axle from axial dislodgement from the support surfaces, the support surfaces being formed so as to permit the spool to be rolled on and off the support surfaces, the support surfaces having an open front side and a closed rear side such that the spool axle is received through the front side as the spool is rolled into the frame and the closed back side restraining the rollers from rolling off the back side; mechanical latch means operatively associated with the support surfaces for preventing the axles from rolling off the support surfaces out of the front side without the latch means first being released; and motorized drive means mounted on the frame and having an output drive shaft with a drive wheel thereon that lies in the same plane as the drive wheel on the axle, a flexible tension member extending around the drive wheel so as to transfer torque from the motor drive wheel to the axle drive wheel to rotate the spool. - View Dependent Claims (20, 21, 22, 23)
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24. A wire dispensing machine for dispensing wire from a spool wherein wire is wound on an axial core extending between enlarged circular spool ends, the spool having an axial hole therethrough, the wire dispensing machine comprising:
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a frame having a base and upright sides spaced apart on the base, the spool fitting between the sides with the spool axis extending transversely between the sides; a drive axle that fits through the axial opening in the spool and extends to outer portions protruding from the ends of the spool, the drive axle including attachment means for positively attaching the spool to the axle for rotation therewith, the axle having a drive wheel mounted on the axle on one outer portion for rotation with the axle; spool support surfaces positioned on the sides of the frame so as to receive the outer portions of the axle and suspend the spool by rollers interposed between the axle and the support surfaces for rotation in the frame when the spool is rolled into the frame, the support surfaces being formed so as to permit the spool to be rolled on and off the support surfaces on the edges of the spool, the support surfaces having an open front side and a closed rear side such that the spool axle is received through the front side as the spool is rolled into the frame and the closed back side restraining the rollers from rolling off the back side; and motorized drive means mounted on the frame and having an output drive shaft with a drive wheel thereon that lies in the same plane as the drive wheel on the axle, a flexible tension member extending around the drive wheel so as to transfer torque from the motor drive wheel to the axle drive wheel to rotate the spool. - View Dependent Claims (25, 26, 27, 28)
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Specification