Automatic wire dispenser

• US 4,899,945 A
• Filed: 05/02/1988
• Issued: 02/13/1990
• Est. Priority Date: 07/03/1986
• Status: Expired due to Term

• Current Assignee: Jones, Johnnie L.
• Original Assignee: Jones, Johnnie L.
• Inventors: Jones, Johnnie L.
• Primary Examiner(s): Gilreath, Stanley N.
• Application Number:
  US07/189,422
• Time in Patent Office: 652 Days
• Field of Search: 242/45, 242/75.5, 242/75.51, 242/54 R, 242/58.6, 242/78, 242/78.1, 242/78.6, 242/79, 242/128, 242/129
• US Class Current: 242/420.6
• CPC Class Codes: B65H 49/34 Arrangements for effecting positive rotation of packages
• CPC Class Codes: B65H 59/387 Regulating unwinding speed

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.

Claims

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.

2. A variable speed motorized wire dispenser according to claim 1 wherein the guide movement produces an accumulation loop of at least one (1) foot.

3. A variable speed motorized wire dispenser according to claim 2 wherein the guide movement produces accumulation loop of at least two (2) feet.

4. A variable speed motorized wire dispenser according to claim 3 wherein the guide movement produces accumulation loop of at least three (3) feet.

5. A variable speed motorized wire dispenser according to claim 1 wherein the guide comprises a pulley mounted on one end of an arm, with an opposite end of the arm being pivotably mounted in the frame, pivotal movement of the arm increasing and decreasing the accumulation loop, the control means being responsive to pivotal movement of the arm to generate a control signal that varies between minimum and maximum levels as the arm pivots between its limits of pivotal movement.

6. A variable speed motorized wire dispenser according to claim 5 wherein the control means is a rotary potentiometer with an output shaft and drive sprocket thereon being positioned for rotation in the plane of pivotal movement of the pivotal arm but being spaced from the axis thereof, the potentiometer being rotated by a drive belt interconnecting the sprocket with the pivotal arm, the drive belt having one end drivingly connected to the arm at a position spaced from the axis and extending around the drive sprocket and then having another end attached through a resiliently extendable tension member to the frame, the arm pulling the belt to rotate the sprocket as the arm pivots in one direction and the tension member pulling the other end to rotate the sprocket in the other direction as the arm pivots in the opposite direction.

7. A variable speed motorized wire dispenser according to claim 1 wherein the wire accumulation means and guide comprise a fixed position pulley rotatably mounted in the frame and a coplanar pivot pulley rotatably mounted on an upper end of an arm extending upwardly from the frame, the arm being pivotally mounted at a lower end thereof in the frame and being inclined from the vertical such that gravity urges the pivot pulley to increase the accumulation loop, the wire passing from the spool and then over both the fixed position pulley and the pivot pulley before extending to the wire using machine, the control means being responsive to movement of the pivot pulley.

8. A variable speed motorized wire dispenser according to claim 7 wherein the fixed position pulley being mounted on a fixed arm extending upwardly from a front portion of the frame, the pivoting arm being positioned such that the pivot pulley thereon is positioned in a rearward direction from the fixed position pulley and pivots within a predetermined arc that is rearwardly inclined from a vertical position, providing a gravity bias in a rearward direction, the wire extending from the coil over the fixed position pulley and then over the pivotal pulley before extending in the predetermined direction.

9. A variable speed motorized wire dispenser according to claim 1 wherein the wire accumulation means and guide comprise a fixed position arm assembly extending upwardly from the frame, with first and second parallel transverse fixed axles being mounted at spaced apart locations on the arm assembly and rotatable fixed pulleys being mounted on each of the axles, a pivot arm extending generally in a forward direction from the frame, the pivot arm being mounted at an inner portion in the frame for pivotal movement in a vertical plane and having a transverse pivot axle mounted at an outer portion of the pivot arm, the transverse pivot axle being parallel to the axles on the fixed position arm assembly, at least one pivot pulley being mounted on the pivot axle and being pivotably movable on the pivot arm in a generally upward and downward direction toward the fixed pulleys, the wire from the wire coil being looped around the pulleys on the first fixed axle and pivot axle and then extending over the fixed pulley on the second fixed axle before extending in the predetermined direction to the wire using machine, the control means being responsive to movement of the pivot arm.

10. A variable speed, motorized wire dispenser according to claim 9 wherein there are at least two pulleys on the first fixed axle and at least two pulleys on the pivot axle, the wire being looped from pulley to pulley in multiple loops over the pulleys on the first fixed axle and the pivot axle before extending over the pulley on the second fixed axle and to the wire using machine.

11. A variable speed, motorized wire dispenser according to claim 9 wherein pulleys and arms are constructed so as to provide at least a four (4) foot accumulation of wire.

12. A variable speed, motorized wire dispenser according to claim 9 wherein pulleys and arms are constructed so as to provide at least a six (6) foot accumulation of wire.

13. A variable speed, motorized wire dispenser according to claim 10 wherein the pulleys and arms are constructed so as to provide at least a twelve (12) foot accumulation of wire.

29. A wire dispenser according to claim 9 and further comprising a vertically movable wire level control guide positioned in the dispenser so as to receive wire as it is dispensed from the dispenser and convey it to an adjustable height according to the dispenser height requirements.

30. A wire dispenser according to claim 29 wherein the wire level control guide comprises an arm mounted at an inner end on the second axle at an adjustable radial position thereon, with a guide axle being mounted at an outer end of the arm in a position parallel with the second axle, a guide pulley being mounted on the guide axle and receiving wire from the second pulley as it extends to the wire-using machine.

31. A wire dispenser according to claim 9 and further comprising counterbalance weight means for reducing the effective weight of the pivot arm assembly.

32. A wire dispenser according to claim 31 wherein the counterbalance weight means comprises a cable attached at one end to the outer portion of the pivot arm, the cable having an outer end that extends upwardly from the arm, over, a fixed position pulley rotatably mounted in the dispenser and downwardly on the other side of the pulley, weights being releasably attachable to the outer end of the cable to create an upward force on the pivot arm that partially offsets the weight of the pivot arm assembly.

33. A wire dispenser according to claim 9 and further, comprising means for removably adding weight to the pivot arm so as to increase the effective weight of the pivot arm.

34. A wire dispenser according to claim 33 wherein the means for adding weight to the pivoting arm comprises a right angle arm having one leg that extends perpendicularly from the pivoting arm, and another leg that extends parallel to the pivoting arm, the parallel leg having a free end on which the weights are mounted.

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:

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.

15. A wire dispensing machine according to claim 14 wherein the motor is mounted below the linkage means and is supported thereby, the lever being pivotally mounted above the linkage means at one end thereof, with an opposite end serving as a handle, the linkage means comprising a link that extends upwardly from the motor and is attached to the lever at a position between the ends, the lever being pivotal upwardly between released and driving positions, the link being raised so as to pivot the motor from its released to its driving position when the lever is moved from its released to its driving position, the linkage means including stop means for holding the lever in its released or driving position until manually moved to the other position.

16. A wire dispensing machine according to claim 15 wherein the lever pivots in an arc between its released position on one side of a vertical orientation to its driving position on the other side of a vertical orientation and the stop means contrains the lever from moving past the ends of the arc, the weight of the motor pulling down on the lever holding the lever in its released or driving position until the lever is lifted and moved to its other position.

17. A wire dispensing machine according to claim 16 wherein the linkage means includes a threaded length adjustment mechanism for varying the effective length of the link connecting the motor with the lever, such that the driving position of the motor can be adjusted to tighten or loosen the tension on the flexible tension member.

18. A wire dispenser according to claim 14 wherein rollers are mounted on the ends of the axle and ride on the support surfaces, the axle drive wheel being mounted inward of the rollers and being positioned such that it lies inside the sides of the frame when the spool is mounted in the frame, the motor drive mechanism being mounted on an outer side of one of the frame sides, with the drive shaft extending through the frame, the motor drive wheel being positioned adjacent an inner side of the frame side and being coplanar with the axle drive wheel.

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:

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.

20. A wire dispenser according to claim 19 wherein the support surfaces are substantially flat surfaces and are oriented between a horizontal position to a slightly downwardly and rearwardly inclined position, such that the spool can easily be rolled forwardly off the support surfaces to remove the spool from the frame.

21. A wire dispenser according to claim 19 wherein the rollers are mounted on the ends of the axle and the axle drive wheel is mounted inward of the rollers, the axle drive wheel being positioned such that it lies inside the sides of the frame when the spool is mounted in the frame, the motor drive mechanism being mounted on an outer side of one of the frame sides, with the drive shaft extending through the frame, the motor drive wheel being positioned adjacent an inner side of the frame side.

22. A wire dispenser according to claim 21 wherein each roller is mounted on a shaft that has a threaded end protruding from one side of the roller, the threaded end engaging a threaded opening in the end of the axle to mount the roller on the axle.

23. A wire dispenser according to claim 22 wherein the outer diameter of at least one roller is such that the roller fits through the axial opening in the spool, thus making it possible to mount and dismount the spool on the axle without removing a roller from the axle.

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:

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.

25. A wire dispensing machine according to claim 24 wherein the support surfaces are positioned to suspend a thirty (30) inch spool for rotation in the frame and the frame includes an elevated portion that lifts the spool and axle up to the support surfaces as the spool is rolled into the frame.

26. A wire dispenser according to claim 24 and further comprising an inclined ramp mounted on the frame for guiding a spool upwardly to the support surfaces as the spool is rolled into the frame.

27. A wire dispenser according to claim 26 wherein the ramp is removable and mountable at a plurality of spaced vertical positions on the sides of the frame such that spools of different diameters can be mounted in the frame, the ramp elevation being adjustable to raise the axles for spools of differing diameters to the support surfaces, the end of the ramp terminating at a position such that the spool rotates freely in the frame when the spool is mounted on the support surfaces in the frame.

28. A wire dispenser according to claim 27 wherein the base of the frame includes a raised portion that can serve to elevate a spool of yet a larger diameter than the spools mountable with the assistance of the ramp, the ramp being removable for such use, the wire dispensing apparatus being capable of supporting spools of diameters of twenty-four (24), twenty-six (26), and thirty (30) inches at least, with the support surfaces being more than fifteen (15) inches above the ground and the raised portion on the base serving to guide the axle of a thirty (30) inch spool onto the support surfaces, the ramp having adjustable mounting positions that are capable of raising twenty-four (24) and twenty-six (26) inch spools to the support surfaces.