Systems and methods for wrapping coils - Patents.com

Abstract

Various embodiments of the present disclosure provide a coil wrapping system (30) that simultaneously uses multiple individual film rolls (FR1, FR2) to simultaneously wrap the individual films around a single coil while the coil is rotated about its longitudinal axis.

Description

[Technical field]

[0001] The present disclosure relates to a system and method for wrapping a coil with a film. [Background technology]

[0002] Many steel manufacturers produce relatively large coils of steel plate or strip which are then used or shipped to customers for further processing. 1 shows an example of such a coil C. Coil C has a cylindrical outer surface OS, a relatively flat annular first side SS1, a relatively flat annular second side SS2 opposite the first side SS1, and a cylindrical inner surface IS extending between sides SS1 and SS2. The cylindrical inner surface IS is referred to herein as the "eye" E of coil C and defines a cylindrical central opening extending between the opposing sides SS1 and SS2. Coil C has a longitudinal axis LA extending through the center of the eye E.

[0003] To prevent the coil from unwinding, typically a circumferential strap (not shown) is attached around the outer cylindrical surface OS of the coil C and / or a through-the-eye strap (not shown) is attached through eye E around the outer surface OS of the coil C to engage the inner surface IS and outer surface OS of the coil C. These straps prevent the coil from unwinding, but do not protect the coil from the elements or damage during shipping. If the customer desires this additional protection, the manufacturer will typically wrap the coil in a plastic stretch film. To do so, the manufacturer will typically install one of several known coil wrapping systems on the production line. All of these known systems use a strip of plastic stretch film to wrap the coil. Although these known systems vary, they typically involve passing a roll of film through the eye of the coil and then transferring the film in repeated loops around the outside of the coil as the coil is rotated along its longitudinal axis. These wrapping processes are relatively slow and may require operators to exchange an empty film roll for a replacement film roll during the coil wrapping process. Summary of the Invention [Means for solving the problem]

[0004] Various embodiments of the present disclosure provide a coil wrapping system and method that uses multiple separate film rolls simultaneously to simultaneously wrap separate films (such as plastic films) around a coil while the coil is rotated about its longitudinal axis.

[0005] Various embodiments of the present disclosure provide a mandrel for a film roll that helps maintain tension on the film before, during, and after the wrapping process with a coil wrapping system.

[0006] Various embodiments of the present disclosure provide a mandrel gripper that receives, holds, and releases a mandrel and a film roll attached to the mandrel.

[0007] Various embodiments of the present disclosure provide a film roll replacement system and associated methods for automatically replacing an empty film roll with a new film roll. [Brief description of the drawings]

[0008] [Figure 1] FIG. 2 is a perspective view of an example of a coil that can be wrapped by the coil wrapping system of the present disclosure. [Figure 1A] FIG. 1 is a top perspective view of a coil wrapping system including a coil wrapping apparatus and a film changing system according to one embodiment of the present disclosure. [Figure 1B] FIG. 1B is another top perspective view of the coil wrapping system of FIG. 1A and a coil positioned relative to the coil wrapping system. [Figure 1C] FIG. 1B is an end perspective view of the coil wrapping system of FIG. [Figure 1D] FIG. 1B is a perspective view of the top of the coil wrapping apparatus of FIG. [Figure 1E] FIG. 1B is a top perspective view of the coil wrapping apparatus of FIG. [Figure 1F] FIG. 1B is a bottom perspective view of a first wrapper of the coil wrapping system of FIG. 1A. [Figure 1G] FIG. 1F is a top perspective view of a first applicator arm of the first wrapper of FIG. [Figure 1H] 1B is a perspective view of a second wrapper, a second wrapper cutting, clamping and seaming system, and a second wrapper tip holder of the coil wrapping apparatus of FIG. 1A. [Figure 1I] FIG. 1C is a rear perspective view of the cutting, clamping and seaming system of the second wrapper of FIG. [Figure 1J] 1B is a rear perspective view of a second wrapper of the coil wrapping apparatus of FIG. 1A and a cutting, clamping and seaming system of the second wrapper engaging the coil. [Figure 1K] FIG. 1B is a rear perspective view of the second wrapper cutting, clamping and seaming system of the coil wrapping apparatus of FIG. 1A. [Figure 1L] FIG. 1B is a block diagram showing certain components of the coil wrapping system of FIG. 1A. [Figure 1M]1B is a side view of the positions of the coil and the film roll and the leading end of the film roll at the start of a coil wrapping process by a coil wrapping device of the coil wrapping system of FIG. 1A. [Figure 1NA] FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1NB] FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1NC] FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1ND] FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1NE] FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1NF] FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1NG]FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1NH] FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1NI] FIG. 1B shows a coil (in cross section) being wound by a film roll (shown in simplified form) carried by an applicator arm (shown in simplified form) in a coil wrapping apparatus of the coil wrapping system of FIG. 1A during the wrapping process. [Figure 1NJ] FIG. 2 shows a fully wrapped coil. [Figure 1O] 1B is a top perspective view of a first wrapper and a second wrapper of the coil wrapping device of the coil wrapping system of FIG. 1A prior to beginning wrapping of a coil located between the first wrapper and the second wrapper. [Figure 1P] FIG. 1B is a top perspective view of the first wrapper and the second wrapper of the coil wrapping apparatus of the coil wrapping system of FIG. 1A , showing a point during the wrapping process when the first applicator arm and the third applicator arm of the first wrapper and the second wrapper are in their respective first film roll transfer positions. [Figure 1Q] FIG. 1B is a top perspective view of the first wrapper and the second wrapper of the coil wrapping apparatus of the coil wrapping system of FIG. 1A , showing a point during the wrapping process when the first applicator arm and the third applicator arm of the first wrapper and the second wrapper are in their second, respective, film roll transfer positions. [Figure 2A] FIG. 1B is a perspective view of a first replacement film roll holder of the film replacement system of the coil wrapping system of FIG. 1A without a replacement film roll. [Figure 2B] FIG. 2B is a perspective view of one of the replacement film roll supports of the first replacement film roll holder of FIG. 2A, without the replacement film roll. [Figure 2C] FIG. 2B is a perspective view of the first replacement film roll holder of FIG. 2A, holding a replacement film roll. [Figure 2D] FIG. 2B is an enlarged perspective view of one of the replacement film roll supports of the first replacement film roll holder of FIG. 2A, holding a replacement film roll. [Figure 3A] FIG. 1B is a perspective view of a first film roll supply of the film changing system of the coil wrapping system of FIG. 1A. [Figure 3B] 3B is a perspective view of a main part of the first film roll supply body of FIG. 3A, showing its film roll moving body. [Figure 3C] FIG. 3B is a perspective view of a main portion of the first replacement film roll holder and the first film roll supplier of the film replacement system of FIG. 3A, showing a film roll mover positioned to remove the replacement coil from the support of the first replacement film roll holder. [Figure 3D] FIG. 3B is an enlarged partial perspective view of the first replacement film roll holder and first film-roll supplier of the film replacement system of FIG. 3A, showing the film roll mover at the initial point of the process of removing the replacement coil from the support of the first replacement film-roll holder. [Figure 3E] FIG. 3B is a perspective view of the first replacement film roll holder and first film roll supplier of the film replacement system of FIG. 3A, showing the film roll mover at an initial point in the process of removing the replacement coil from the support of the first replacement film roll holder. [Figure 3F] FIG. 3B is an enlarged perspective view of the first replacement film roll holder and the first film roll supply of the film changing system of FIG. 3A, showing the film roll mover after removing the replacement coil from the support of the first replacement film roll holder. [Figure 4A]FIG. 2 is a top perspective view of an example mandrel of the present disclosure that serves as a mount for a film roll. [Figure 4B] FIG. 4B is a bottom perspective view of the mandrel of FIG. 4A. [Figure 4C] FIG. 4B is a perspective view of the top of the mandrel of FIG. 4A. [Figure 4D] FIG. 4B is a perspective view of the bottom of the mandrel of FIG. 4A. [Figure 4E] FIG. 4B is a partially exploded view of the mandrel of FIG. 4A. [Figure 4F] 4F is a cross-sectional perspective view of the mandrel of FIG. 4A taken along line 4F-4F of FIG. 4B. [Figure 4G] FIG. 4B is a cross-sectional side view of the lower portion of the mandrel of FIG. 4A. [Figure 4H] 4B is a cross-sectional plan view of the spring housing of the mandrel of FIG. 4A at various stages of film application. [Figure 4I] 4B is a cross-sectional plan view of the spring housing of the mandrel of FIG. 4A at various stages of film application. [Figure 4J] 4B is a cross-sectional plan view of the spring housing of the mandrel of FIG. 4A at various stages of film application. [Figure 4K] 4B is a cross-sectional plan view of the spring housing of the mandrel of FIG. 4A at various stages of film application. [Figure 4L] 4B is a cross-sectional plan view of the spring housing of the mandrel of FIG. 4A at various stages of film application. [Figure 5A] FIG. 1B is an enlarged perspective view of the mandrel gripper of the coil wrapping system of FIG. [Figure 5C] 5C is a cross-sectional perspective view of a portion of the upper mandrel jaw of the mandrel gripping portion of FIG. 5A, holding the film roll attached to the mandrel of FIG. 4A, taken partially along line 5C-5C of FIG. 5D. [Figure 5D] FIG. 5B is a partial view of a portion of the upper mandrel jaw of the mandrel gripper of FIG. 5A, holding a film roll mounted on the mandrel of FIG. 4A. [Figure 6]FIG. 2 is a diagrammatic view of two mandrel grippers of the coil wrapping system of FIG. 1 showing a film roll mounted on a mandrel being transferred from one mandrel gripper to the other. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] While the systems, devices, and methods described herein may be implemented in various forms, the drawings show certain exemplary and non-limiting embodiments and illustrate the present specification. Not all of the components shown in the drawings and described in the specification are required, and certain implementations may include additional, different, or fewer components. Changes in the arrangement and type of components, the shape, size, and material of the components, and the manner of connection of the components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any direction referred to in this specification reflects the orientation of the components shown in the corresponding drawing and does not limit the scope of the present disclosure. Furthermore, terms referring to attachment methods, such as attaching, connecting, and the like, are not limited to direct attachment methods, but should be broadly interpreted to include indirectly and operably attaching, connecting, and similar attachment methods. This specification is intended to be interpreted as a whole and in accordance with the principles of the present disclosure, as understood by those skilled in the art.

[0010] Coil Wrapping System Various embodiments of the present disclosure provide a coil wrapping system that wraps a coil (such as coil C described above) in film by simultaneously moving multiple film rolls through an eye E and around the outer surface OS of the coil C while rotating the coil C about its longitudinal axis LA. 1A, 1B, 1C, and 1L illustrate an example coil wrapping system 20 and its components according to the present disclosure. The coil wrapping system 20 includes a coil wrapping device 30 for winding a coil, such as coil C (discussed above), an in-feed and out-feed coil mover (not shown) for moving the coil to the coil wrapping device 30 for winding and for removing the coil from the coil wrapping device 30 after winding, a coil rotator 500 for supporting and rotating each coil about its longitudinal axis during winding, a film roll exchange system 50 for receiving an empty film roll from the coil wrapping device 30 and supplying a new film roll to the coil wrapping device 30, a number of sensors S, an operator interface OI, and a controller CR. For purposes of this disclosure, an empty film roll can be a completely empty film roll (no film remaining) or a near empty film roll (such as a film roll having an insufficient amount of film to wrap the next coil).

[0011] As mentioned above, movements and components (described below) of the exemplary coil wrapping system 20 that extend in the same direction as the longitudinal axis of the coil C (e.g., parallel to the longitudinal axis LA) are sometimes described herein as longitudinal movements or components. Also, movements and components of the exemplary coil wrapping system 20 that extend transversely to the longitudinal axis LA of the coil C (e.g., perpendicular to the longitudinal axis LA) are sometimes described herein as transverse movements or components.

[0012] Coil Wrapping Machine 1A, 1B, 1C, 1D, 1E, and 1L show a coil wrapping apparatus 30 and its components configured to simultaneously wrap each coil C with multiple film rolls (such as film rolls FR1 and FR2). The coil wrapping apparatus 30 includes a mechanical frame 60, a first wrapper 100 slidably mounted to the mechanical frame 60, a first carriage actuator 110 operably connected to the first wrapper 100 via a first drive system 111 and configured to slide the first wrapper 100 vertically relative to the mechanical frame 60, a second wrapper 300 slidably mounted to the mechanical frame 60, and a second carriage actuator 310 operably connected to the second wrapper 300 via a second drive system 311 and configured to slide the second wrapper 300 vertically relative to the mechanical frame 60.

[0013] Mechanical frame, coil rotator, feed and delivery coil mover 1D and 1E, is formed from a number of tubular and / or solid members and other elements (not individually labeled) to support certain of the components of the coil wrapping apparatus 30, in particular to movably support the first wrapper 100 and the second wrapper 300. The mechanical frame 60 includes four spaced apart upright legs 62, 64, 66, and 68, and four cross bars 72, 74, 76, and 78. The cross bar 72 connects the leg 62 to the leg 64, the cross bar 74 connects the leg 64 to the leg 66, the cross bar 76 connects the leg 66 to the leg 68, and the cross bar 78 connects the leg 68 to the leg 62. The legs 62 and 64 and the cross bar 72 support the first wrapper 100, including its actuator 110 and its drive train 111. Specifically, opposing vertically extending rails (not numbered) are connected to legs 62 and 64 and slidably support opposite ends of first wrapper 100. Similarly, legs 66, 68 and crossbar 76 support second wrapper 300, including its actuator 310 and its drive train 311. Specifically, opposing vertically extending rails (not numbered) are connected to legs 66 and 68 and slidably support second wrapper 300.

[0014] Mechanical frame 60 defines (a) a rectangular inner coil wrapping area (not labeled) bounded by four spaced apart upright legs 62, 64, 66, and 68, (b) an outer coil feed area on one side of frame 60, particularly adjacent legs 62 and 64, and (c) an outer coil delivery area (not labeled) on the opposite side of frame 60, particularly adjacent legs 66 and 68. Figure 1B shows a first coil CA at the outer coil feed area (waiting to be moved into the coil winding area), a second coil C at the inner coil winding area (on coil wheel 500 in position to be wound), and a third coil CW at the outer coil delivery area (after being wound and moved out of the coil winding area).

[0015] The illustrated mechanical frame 60 is merely one example configuration and any suitable configuration for a mechanical frame may be employed in accordance with the present disclosure.

[0016] 1A, 1B, 1C, and 1J, the coil rotator 500 includes a coil rotator frame 510 (partially shown), two cylindrical coil engagers 520 and 530 supported by the coil rotator frame 510, and one or more coil engager actuators 540 supported by the coil rotator frame 510 and operatively coupled to one or both of the coil engagers 520 and 530. Under the control of a controller CR, the coil rotator 500 causes the coil engager actuators 540 to rotate the coils C positioned on the cylindrical coil engagers 520 and 530 about the longitudinal axis LA of the coils C at a desired speed during winding of the coils C.

[0017] The coil wrapping device 30 includes or operates in conjunction with an associated feed coil mover 550 which, under the control of the control device CR, moves each waiting coil requiring wrapping (such as coil CA) from the outer coil feed area beneath the first wrapper 100 into the inner coil wrapping area and onto the coil engagement bodies 520 and 530 of the coil rotator 500 for wrapping by the first and second wrappers 100 and 300 when the first wrapper 100 is in a raised position (not shown, described below). The coil wrapping device 30 also includes, or operates in conjunction with, an associated delivery coil mover 560 which, under the control of the control device CR, moves the wrapped coil from the coil rotator 500 in the coil wrapping region below the second wrapper 300 to the outer coil delivery region after the coil C has been wrapped when the second wrapper 300 is in a raised position (not shown but described below). The wrapped coil (such as coil CW) is then transported.

[0018] The first wrapper 100 and the second wrapper 300 are supported by a mechanical frame 60 allowing the first wrapper 100 and the second wrapper 300 to each independently move vertically upward to their respective raised positions, with each coil moving underneath the wrapper (as described above), and then moving vertically downward to their respective wrapping positions. More specifically, the first wrapper 100 is slidably mounted to and vertically movable relative to the mechanical frame 60 between a raised position (not shown) in which the first wrapper 100 is adjacent the crossbar 72, a coil wrapping position below the raised position (shown in FIGS. 1A-1E), and a film changing position below the raised position. When the first wrapper 100 is in the raised position, there is sufficient clearance below the first wrapper 100 to allow the feed coil mover 550 to move the coil onto the coil rotator 500. When the second wrapper 300 is in the coil wrapping position, the first wrapper 100 is operable, under the control of the controller CR, to wrap a coil C in a coil wrapping area (as described below) together with the second wrapper 300. When the first wrapper 100 is in the film changing position, the first wrapper 100 is operable to transport an empty (or nearly empty) film roll to the film changing device 50.

[0019] Similarly, the second wrapper 200 is slidably mounted to and vertically movable relative to the mechanical frame 60 between a raised position (not shown) in which the second wrapper 300 is adjacent the crossbar 76, a coil wrapping position below the raised position (shown in FIGS. 1A-1E), and a film exchange position below the raised position. When the second wrapper 300 is in the raised position, there is sufficient clearance below the second wrapper 300 to allow the delivery coil mover 560 to move the coil from the coil rotator 500. When the second wrapper 300 is in the coil wrapping position, the second wrapper 300 is operable to wrap the coil C in a coil wrapping area (as described below) together with the first wrapper 100 under the control of the controller CR. When the second wrapper 300 is in the film exchange position, the second wrapper 300 is operable to receive a replacement film roll from the film exchanger 50.

[0020] a first carriage actuator for a first wrapper, a first drive system A first carriage actuator 110 and a first drive system 111, as best shown in Figures 1E and 1F, are operatively connected to the first wrapper 100 and configured to move the first wrapper 100 relative to the mechanical frame 60 between its raised position, coil wrapping position, and film change position. The first carriage actuator 110 includes an electric motor in this exemplary embodiment, but may include any other suitable actuator in other embodiments. The first drive system 111 includes drive shafts 112a and 112b each having one end connected to the first carriage actuator 110, spaced apart drive wheels 116a and 116b respectively connected to the other ends of the drive shafts 112a and 112b and rotatably supported on the mechanical frame 60, spaced apart driven wheels 118a and 118b respectively connected to the mechanical frame 60 and rotatably supported, and a drive belt 120 wound around the wheels 116a and 118a and extending between the wheels 116a and 118a. 10a, a drive belt 120b wrapped around and extending between wheels 116b and 118b, first carriage connectors 122a and 124a (numbered but not shown for clarity) that connect the drive belt 120a to a first end of the carriage 102 of the first wrapper 100, and carriage connectors 122b and 124b (not shown for clarity) that connect the drive belt 120b to a second end of the carriage 102 of the first wrapper 100. In operation, to raise the first wrapper 100, the first carriage actuator 110, under the control of the controller CR, simultaneously rotates each of the drive shafts 112a and 112b to rotate each of the spaced apart upper wheels 116a and 116b, which in turn rotates each of the drive belts 120a and 120b. The rotation of the drive belts 120a and 120b causes the upward movement of the first carriage connectors 122a and 124a, which in turn causes the upward movement of the first carriage 102 of the first wrapper 100 by the carriage connectors 122b and 124b. The process is reversed to move the first carriage 102 of the first wrapper 100 downward.

[0021] First Rapper 1D, 1E, 1F and 1G, the first wrapper 100 includes a first carriage 102, a first applicator arm 130 slidably mounted to the first carriage 102, and longitudinal and lateral first arms supported by the first carriage 102 and operatively connected to the first applicator arm 130 via a drive system (described below) and configured to move the first applicator arm 130 longitudinally and laterally relative to the coils C on the coil rotor 500. The coil rotor 500 includes applicator arm actuators 150a and 150b, a second applicator arm 180 slidably mounted to the first carriage 102, and longitudinal and lateral second applicator arm actuators 200a and 200b supported by the first carriage 102, operably connected to the second applicator arm 180 via a drive system (described below), and configured to move the second applicator arm 180 longitudinally and laterally relative to the coil C on the coil rotor 500.

[0022] First carriage of the first wrapper As best illustrated in FIG. 1F, the first carriage 102 of the wrapper 100 has a carriage frame 104 having a first end 103a, an opposing second end 103b, an inner side 103c, and an outer side 103d. The carriage 102 extends laterally (with respect to a longitudinal axis LA of the coil C on the coil rotor 500) from the first end 103a to the second end 103b. The carriage 102 extends longitudinally (with respect to the longitudinal axis of the coil) from the inner side 103c to the outer side 103d. The carriage frame 104 supports the first applicator arm 130 and associated first applicator arm actuators 150a and 150b and the second applicator arm 180 and associated second applicator arm actuators 200a and 200b. Carriage 102 includes two spaced, laterally extending tracks 106 and 108 coupled to the bottom of carriage frame 104. A first applicator arm 130 and a second applicator arm 180 are slidably coupled to tracks 106 and 108, respectively, and are independently movable laterally along tracks 106 and 108, respectively, as described below.

[0023] First applicator arm of first wrapper The first applicator arm 130 includes an elongated frame 132, an elongated track 134 connected to an upper portion of the elongated frame 132, and a gripper 5000 (described in more detail below) connected to an inner end of the elongated frame 132, as best illustrated in FIGS. 1F and 1G. The first applicator arm 130 is slidably mounted to the carriage 102 via a trolley 160. Specifically, the trolley 160 is slidably mounted to the tracks 106 and 108 such that the trolley 160 can slide laterally relative to the carriage frame 104. The trolley 160 is slidably mounted to the track 134, which allows the first applicator arm 130 to slide longitudinally relative to the tracks 104 and 106.

[0024] The lateral first applicator arm actuator 150b is connected to the bottom of the carriage frame 104 and operably coupled to the first applicator arm 130. The lateral first applicator arm actuator 150b, under the control of the controller CR, moves the first applicator arm 130 on the tracks 106 and 108 laterally (with respect to the coil being wound) between an outer position adjacent to the first end 103a of the carriage 102 and an eye position aligned with the longitudinal rotation axis of the coil. In other words, the lateral first applicator arm actuator 150b, under the control of the controller CR, moves the first applicator arm 130 laterally with respect to the coil between an outer position adjacent to the first end 103a of the carriage 102 and an eye position adjacent to the longitudinal center axis of the coil.

[0025] Although not shown, first lateral applicator arm actuator 150b is similar to second lateral applicator arm actuator 200b, which is shown in more detail in FIG. 1F.

[0026] The longitudinal first applicator arm actuator 150a, under the control of the control device CR, moves the first applicator arm 130 longitudinally relative to the longitudinal axis of the coil C on the coil rotor 500, moving the carriage 102 between a transport position and a retracted position relative to the carriage 102. In other words, the longitudinal first applicator arm actuator 150a moves the arm 130 longitudinally relative to the coil and carriage 102 between the transport position and the retracted position at each of the outer positions, the eye position, and each of the positions between.

[0027] More specifically, as best shown in FIG. 1G, the first longitudinal applicator arm actuator 150a includes an actuator 152a controlled by a control device CR and operably connected to a trolley 160 slidably connected to the carriage 102, a drive pulley 154a controlled by the actuator 152a, two control pulleys 155a and 156a, and a belt 158a connected to the frame 132 of the applicator arm 130. In operation, to move the applicator arm 130 longitudinally, the actuator 152a, under the control of the controller CR, rotates the drive pulley 154a to engage the belt 158a, causing the first applicator arm 130 to move longitudinally relative to the trolley 160. This rotation of the drive pulley 154a is reversed to reverse the longitudinal movement of the applicator arm 130.

[0028] Second applicator arm of first wrapper Similarly, as best illustrated in FIGURE 1F, the movable second applicator arm 180 includes an elongated frame 182, an elongated track 184 connected to an upper portion of the elongated frame 182, and a gripper 5000 connected to an inner end of the elongated frame 182. The second applicator arm 180 is slidably mounted to the carriage 102 via a trolley (not shown) that is slidably mounted to the track (not shown) such that the trolley can slide laterally relative to the carriage frame 104. The trolley is slidably mounted to the track 184 such that the second applicator arm 180 can slide longitudinally relative to the tracks 104 and 106.

[0029] The lateral second applicator arm actuator 200b is fixedly connected to the bottom of the carriage frame 104 and is supported by the carriage frame 104 of the carriage 102. The lateral applicator arm actuator 200b, under the control of the controller CR, moves the second applicator arm 180 on the tracks 106 and 108 laterally relative to the coil on the coil rotor 500 and moves the carriage 102 between an outer position adjacent to the second end 103b of the carriage 102 and an eye position aligned with the longitudinal rotation axis of the coil. In other words, the lateral second applicator arm actuator 200b, under the control of the controller CR, moves the second applicator arm 180 laterally relative to the longitudinal axis of the coil and laterally relative to the carriage 102 and between an outer position adjacent to the second end 103b of the carriage 102 and an eye position aligned with the longitudinal center axis of the coil.

[0030] More specifically, as best shown in FIGURE 1F, lateral second applicator arm actuator 200b includes an actuator 202b connected to carriage frame 104 and controlled by controller CR, a first pulley 204b connected to actuator 202b, a second pulley 206b connected to carriage frame 104, a drive belt 208b wrapped around and extending between pulleys 204b and 206b, and a trolley 210 connected to drive belt 208a and coupled to track 184 of second applicator arm 180. In this manner, trolley 210 movably supports applicator arm 180 for lateral movement while simultaneously facilitating independent longitudinal movement of second applicator arm 180. In operation, to move the applicator arm 180 laterally, the actuator 202b, under the control of the controller CR, rotates the pulley 204b which rotates the drive belt 208b to move the trolley 210 laterally and thus the second applicator arm 180. This rotation of the pulley 204b and the drive belt 208b is reversed to move the trolley 210 and the second applicator arm 180 laterally in the opposite direction.

[0031] The longitudinal second applicator arm actuator 200a, under the control of the controller CR, moves the second applicator arm 180 longitudinally relative to the carriage 102 between a transfer position against the interior side 103c of the carriage 102 and a retracted position against the interior side 103c of the carriage 102. In other words, the longitudinal second applicator arm actuator 200a, under the control of the controller, moves the arm 180 perpendicularly (and thus longitudinally) relative to the carriage 102 between the transfer position and the retracted position at each of the outer position, the eye position, and positions therebetween.

[0032] In an alternative embodiment, first applicator arm 130 and second applicator arm 180 are movably connected to two or more separate carriages instead of a single carriage 102.

[0033] A second wrapper, a second carriage of the second wrapper, and a second carriage actuator of the second wrapper Similar to the first carriage 102, the second carriage 302 of the wrapper 300 has a first end (not labeled), an opposite second end (not labeled), an inner side (not labeled), and an outer side (not labeled), as best shown in Figures 1D, 1E, 1H, and 1J. The carriage 302 extends laterally from the first end to the second end. The carriage 302 extends longitudinally from the inner side to the outer side. The carriage 302 includes a carriage frame 304 that supports a third applicator arm 330 and longitudinal and lateral third applicator arm actuators 350a and 350b, as well as a fourth applicator arm 380 and longitudinal and lateral fourth applicator arm actuators 400a and 400b. Carriage 302 includes two spaced apart, laterally extending tracks 306 and 308 coupled to a bottom of frame 304. A third applicator arm 330 and a fourth applicator arm 380 are movably coupled to tracks 306 and 308, respectively, and are independently movable laterally along tracks 306 and 308.

[0034] Similar to the first wrapper 100, the second wrapper 300 is vertically movable between a coil wrapping position and a raised position above the coil wrapping position. Similar to that described above for the first wrapper 100 and the first carriage actuator 110, the second carriage actuator 310, under the operation of the controller CR, moves the second wrapper 300 upwardly and downwardly to these respective positions.

[0035] Similar to the first carriage actuator 110, the second carriage actuator 310 and second drive train 311 are operatively connected to the second wrapper 300 and configured to move the second wrapper 300 relative to the mechanical frame 60 between an elevated coil wrapping position and a film change position, as best shown in Figures 1E and 1F. The second carriage actuator 310 includes an electric motor in this exemplary embodiment, but may include any other suitable actuator in other embodiments. The second drive system 311 includes drive shafts 312a and 312b connected to the crossbar 76 of the frame 60 and having inner ends respectively connected to the second carriage actuator 310, spaced apart upper drive wheels 316a, 316b connected to opposite ends of the drive shafts 312a and 312b respectively and connected to the crossbar 76 and rotatably supported thereon, spaced apart lower driven wheels 318a, 318b connected to be rotatably supported by the legs 68, 66 respectively, and a pair of spaced apart driven wheels 318a, 318b wrapped around the wheels 316a and 318a and connected to the wheels 316a, 318b. The second wrapper 300 further includes a drive belt 320a extending between wheels 316a and 318a, a drive belt 320b wrapped around wheels 316b and 318b and extending between wheels 316b and 318b, carriage connectors 322a and 324a (numbered but not shown) that connect the drive belt 320a to a first end of the carriage 302 of the second wrapper 300, and carriage connectors 322b and 324b (numbered but not shown) that connect the drive belt 320b to a second end of the carriage 302 of the second wrapper 300. Similar to the first carriage actuator 110, in operation, the actuator 310, under the control of the controller CR, simultaneously rotates the drive shafts 312a and 312b which rotate the spaced upper wheels 316a and 316b, which in turn rotate the drive belts 320a and 320b, respectively. The rotation of the drive belts 320a and 320b causes the first carriage connectors 322a and 324a, and carriage connectors 322b and 324b, to move upwardly, which causes the second carriage 302 of the second wrapper 300 to move upwardly. The process is reversed to cause the second carriage 302 of the second wrapper 300 to move downwardly.

[0036] Similar to the first wrapper 100, the second wrapper 300 includes a third applicator arm 330 slidably mounted to the second carriage 302, and longitudinal and lateral third applicator arms 330 supported by the second carriage 302 and operatively connected to the third applicator arm 330 via a drive system (described below) and configured to move the third applicator arm 330 longitudinally and laterally relative to the coils C on the coil rotor 500, as best illustrated in FIGS. 1D, 1E and 1H. The coil rotor 500 includes applicator arm actuators 350a, 350b, a fourth applicator arm 380 slidably mounted to the second carriage 302, and longitudinal and lateral fourth applicator arm actuators 400a, 400b supported by the second carriage 202 and operably connected to the fourth applicator arm 380 via a drive system (described below) and configured to move the fourth applicator arm 380 longitudinally and laterally relative to the coil C on the coil rotor 500.

[0037] Third applicator arm of second wrapper As best shown in Figures 1D, 1E and 1H, the third applicator arm 330 includes an elongated frame 332, an elongated track 334 connected to an upper portion of the elongated frame 332, and a gripper 5000 (described in detail below) connected to an inner end of the elongated frame 332. The third applicator arm 330 is slidably mounted to the second carriage 302 via a trolley (not shown). Specifically, the trolley is slidably mounted to the track (not shown) such that the trolley can slide laterally relative to the carriage frame 304. The trolley is slidably mounted to the track 334 such that the third applicator arm 330 can slide longitudinally relative to the track.

[0038] The lateral third applicator arm actuator 350b is connected to the bottom of the carriage 302 and operably coupled to the third applicator arm 130. The lateral third applicator arm actuator 350b moves the third applicator arm 330 laterally (with respect to the coil being wound) (in the manner described above) under the control of the control device CR between an outer position adjacent to the first end of the carriage 302 and an eye position aligned with the longitudinal rotation axis of the coil. In other words, the lateral third applicator arm actuator 350b moves the third applicator arm 330 laterally to the coil C on the coil rotor 500 between an outer position adjacent to the first end of the carriage 302 and an eye position adjacent to the longitudinal center axis of the coil C under the control of the control device CR.

[0039] The longitudinal third applicator arm actuator 350a, under the control of the controller CR, moves the third applicator arm 330 longitudinally relative to the longitudinal axis of the coil C on the coil rotor 500, and moves the carriage 302 between a transport position and a retracted position relative to the carriage 302. In other words, the longitudinal third applicator arm actuator 350a moves the arm 330 longitudinally relative to the coil and carriage 302 between the transport position and the retracted position, under the control of the controller, at each of the outer position, the eye position, and positions therebetween.

[0040] The fourth applicator arm of the second wrapper Similarly, the movable fourth applicator arm 380 includes an elongated frame 382, ​​an elongated track 384 connected to an upper portion of the elongated frame 382, ​​and a gripper 5000 connected to an inner end of the elongated frame 382, ​​as best illustrated in Figures 1D and 1E. The fourth applicator arm 380 is slidably mounted to the second carriage 302 via a trolley (not shown). Specifically, the trolley is slidably mounted to the track (not shown) such that the trolley can slide laterally relative to the carriage frame 304. The trolley is slidably mounted to the track 384, and the fourth applicator arm 380 slides longitudinally relative to the track.

[0041] The lateral fourth applicator arm actuator 400b is stationary and connected to the bottom of the carriage 302 and supported by its carriage frame (not shown or labeled). The lateral applicator arm actuator 400b, under the control of the controller CR, moves the fourth applicator arm 380 laterally relative to the coil C on the coil rotor 500, and moves the carriage 102 between an outer position adjacent to the second end of the carriage 302 and an eye position aligned with the longitudinal rotation axis of the coil C. In other words, the lateral fourth applicator arm actuator 400b, under the control of the controller CR, moves the fourth applicator arm 380 laterally relative to the longitudinal axis of the coil C and laterally relative to the carriage 302, and between an outer position adjacent to the second end of the carriage 302 and an eye position aligned with the central longitudinal axis of the coil.

[0042] The longitudinal fourth applicator arm actuator 400a, under the control of the control device CR, moves the fourth applicator arm 380 longitudinally relative to the carriage 302 between a transfer position against the inner side of the carriage 302 and a retracted position against the inner side of the carriage 302. In other words, the longitudinal fourth applicator arm actuator 400a moves the arm 380 vertically (and thus longitudinally) relative to the carriage 302 between the transport position and the retracted position under the control of the control device at each of the outer position, the eye position, and positions therebetween.

[0043] In an alternative embodiment, third applicator arm 330 and fourth applicator arm 380 are movably connected to two or more separate carriages instead of the single carriage 302.

[0044] Second wrapper cutting, clamping and seaming system The second wrapper 300 further includes a cut, clamp and splice system 420 (and associated cut, clamp and splice system actuators, not shown) operably connected to the second carriage 302. The cut, clamp and splice system 420 is connected to the second carriage 302 of the second wrapper 300, as best shown in Figures 1H, 1I, 1J, and 1K, and under the control of the controller CR, clamps, seals, and cuts the film of the film roll at the end of the coiling process. The cutting, clamping and seaming system 420 includes (i) a sealer / cutter frame 422 connected to and supported by the carriage 302, (ii) a first sealer / cutter 430 movably connected to the sealer / cutter frame 422, (iii) a second sealer / cutter 440 movably connected to the sealer / cutter frame 422, (iv) a first actuator (not shown) operably connected to the sealer / cutter frame 422 and connected to the first sealer / cutter 430, and (v) a second actuator (not shown) operably connected to the second sealer / cutter frame 422 and connected to the second sealer / cutter 440. The first sealer / cutter 430 includes a first arm 432, a first coil engager 434 connected to an inner end of the first arm 432, and a first sealer / cutter hand 436 pivotally connected to the first coil engager 434. Similarly, the second sealer / cutter 430 includes a second arm 442, a second coil engager 444 connected to an inner end of the second arm 442, and a second sealer / cutter hand 446 pivotally supported on the second coil engager 444.

[0045] At the end of the coil winding process, when the films F1 and F2 of film rolls FR1 and FR2, respectively, are ready to be clamped, sealed and cut, as described below, the first and second actuators of the cutting, clamping and splicing system 420, under the control of the controller CR, move the first and second sealer / cutter 430 and 440, respectively, into engagement with the first and second films F1 and F2 adjacent side SS1 of the coil C. The films are then wrapped around the first and second coil engagers 434 and 444. The first and second actuators of the cutting, clamping and splicing system 420, under the control of the control device CR, rotate the first sealer / cutter hand 436 and rotate the second sealer / cutter hand 446 to engage with the first film F1 and the second film F2 wrapped around the first coil engager 434 and the second coil engager 444 adjacent the side SS1 of the coil C, respectively, to seal and cut such films F1 and F2.

[0046] First and second film end holders of the second wrapper The second wrapper 300 further includes first and second film end holders 450a and 450b (and associated actuators (not shown)) mounted to the second carriage 302. As best shown in FIG. 1H, the first and second film end holders 450a and 450b of the second wrapper 300 grip the leading edge of the film of any replacement film roll received from the film roll supplies 900 and 1900, respectively, for subsequent coil winding.

[0047] The first film end holder 450a comprises (i) a first track mounting portion 452a slidably mounted on the laterally extending track 305 of the second carriage 302, (ii) a first film end holder arm 454a connected to the first track mounting portion 452a, (iv) a first outer film engaging portion 458a pivotally connected to the first film end holder arm 454a, (v) a first arm actuator (not shown) operably connected to the film end holder arm 454a and configured to move the first film end holder arm 454a laterally on the track 452a under the control of the control device CR, and (vi) a first film engaging portion actuator (not shown) operably connected to the outer film engaging portion 458a, which pivots the first outer film engaging portion 458a to open the first outer film engaging portion 458a and release the leading edge of the film under the control of the control device CR. In this embodiment, the first outer film engaging portion 458a is configured to pivot to engage the first inner film engaging portion 456a to hold the leading edge of the film. In an alternative embodiment, one or both of the first inner film engaging portion 456a and the first outer film engaging portion 458a include one or more magnets (not shown) that attract the first outer film engaging portion 458a to the first inner film engaging portion 456a and maintain the engagement portions together to hold the leading edge of the film. In such an embodiment, the first film end holder 450a is thus a magnetic holder for the leading edge of the film of the film roll.

[0048] Similarly, the second film end holder 450b includes (i) a second track mounting portion 452b slidably mounted on the laterally extending track 307 of the second carriage 302, (ii) a second film end holder arm 454b connected to the second track mounting portion 452b, (iv) a second outer film engagement portion 458b pivotally connected to the second film end holder arm 454b, and (v) a second arm 454b operably connected to the second film end holder arm 454b. (vi) a second arm actuator that moves the second film end holder arm 454b longitudinally on the track 452b under the control of the controller CR; and (vi) a second film engagement actuator (not shown) operably connected to the second outer film engaging portion 458b, which pivots the second outer film engaging portion 458b between a film engaging position and a film releasing position under the control of the controller CR. In this embodiment, the second outer film engaging portion 458b is configured to pivot to engage the second inner film engaging portion 456b to hold the leading edge of the film. In an alternative embodiment, one or both of the second inner film engaging portion 456b and the second outer film engaging portion 458b include one or more magnets (not shown) that attract the second outer film engaging portion 458b to the second inner film engaging portion 456b and maintain the engagement portions together to hold the leading edge of the film. In these embodiments, the second film end holder 450b is thus a magnetic holder for the leading edge of the film of the film roll.

[0049] Coil wrapping method and wrapping operation of coil wrapping system The coil wrappers 100 and 300 of the coil wrapping apparatus 30 of the coil wrapping system 20 cooperate to simultaneously use two separate film rolls FR1 and FR2 to wrap a single coil C simultaneously as the coil C is rotated about its longitudinal axis LA by the coil rotator 500 under the control of the control device CR. During the wrapping process, as generally shown in Figures 1NA to 1NI, the coil wrapping apparatus 30, under the control of the control device CR, for each wrapping cycle, (i) moves the first film roll FR1 longitudinally outside the eye E of the coil C while moving the second film roll FR2 longitudinally through the eye E of the coil C, (ii) then moves the first film roll FR1 laterally outside the eye E of the coil C while moving the second film roll FR2 laterally outside the eye E of the coil C, (iii) then moves the first film roll FR1 longitudinally through the eye E of the coil C while moving the second film roll FR2 longitudinally outside the eye E of the coil C, and (iv) then moves the first film roll FR1 laterally outside the eye E of the coil C and moves the second film roll FR2 laterally outside the eye E of the coil C. Coil wrapping system 50, under the control of controller CR, repeats this process with alternating film rolls FR1, FR2 being conveyed longitudinally past eye E of coil C while each film F1 and F2 from each film roll FR1 and FR2 is wrapped around the respective exterior, side and interior surfaces of coil C such that each of the first and second film rolls FR1, FR2 is used to wrap approximately half of coil C. This simultaneous wrapping of coil C with two film rolls FR1 and FR2 substantially reduces the amount of time required to wrap each coil C and reduces the amount of film each roll uses to wrap each coil, such that each roll lasts a longer period of time before needing to be replaced.

[0050] The coil wrapping method includes the following general steps (and in various embodiments, the specific substeps of each of these general steps are described subsequently): (1) positioning a coil C in a coil wrapping area and positioning the first and second wrappers 100 and 300 to wrap the coil C; (2) positioning the film rolls FR1 and FR2 held by the third and fourth applicator arms 330 and 380 of the second wrapper 300 and the leading ends of the individual films of each of the individual film rolls FR1 and FR2 relative to the coil C; and (3) wrapping the coil C with separate films F1, F2 from both film rolls FR1, FR2 simultaneously using the first, second, third and fourth applicator arms 130, 180, 330, 380 of the first and second wrappers 100, 300, respectively. (4) simultaneously sealing, clamping, and cutting the individual films F1 and F2 from both film rolls FR1 and FR2 using a cutting, clamping, and splicing system 420, and (5) removing the wrapped coil C from the coil area. The method may further include preparing for wrapping the next coil, as described further below.

[0051] Coil positioning in the coil wrapping area The steps of positioning the coil C in the coil wrapping area and positioning the first and second wrappers 100 and 300 for wrapping the coil C include (a) lifting the first wrapper 100 to its raised position, (b) moving the unwrapped coil C longitudinally from the coil feed area below the first wrapper 100 and onto the coil rotator 500 (thus positioning the unwrapped coil within the coil wrapping area on the coil rotator 500), and (c) moving the unwrapped coil C longitudinally from the coil feed area below the first wrapper 100 and onto the coil rotator 500. and (c) lowering the first wrapper 100 to its coil wrapping position (and, if not previously done, lowering the second wrapper 300 to its coil wrapping position) in which the applicator arms 130, 180, 330, and 380 are each at a vertical height such that the gripping portion 5000 of each of the arms 130, 180, 330, and 380 is vertically aligned with the longitudinal axis of the coil C on the coil rotor 500 in the coil wrapping area.

[0052] Positioning of film rolls and positioning of the leading edge of the film on the film roll Each step of positioning of each of the applicator arms 130, 180, 330 and 380 of the first and second wrappers 100 and 300 described below involves longitudinal movement of the respective applicator arm by a respective longitudinal applicator arm actuator for that applicator arm, and lateral movement of the respective applicator arm by a respective lateral applicator arm actuator for that applicator arm. All of these movements are controlled by a controller CR based on a particular point in the coil wrapping process. Additionally, one or more of these movements may be monitored by one or more sensors S, and one or more of these movements are effected by the controller CR based on feedback from the one or more sensors S.

[0053] The wrapping process after the film rolls have been changed (as described below) is described below. The process of positioning the film rolls FR1 and FR2 held by the third and fourth applicator arms 330 and 380 of the second wrapper 300 and the leading ends LE1 and LE2 of the films F1 and F2 of the film rolls FR1 and FR2 on the coil C is best shown in Figures 1M, 1NA, and 1O as follows: (a) positioning the fourth applicator arm 380 longitudinally and laterally at the first wrapping start position to apply the leading ends LE1 and LE2 of the films F1 and F2 of the film roll FR1 held by the fourth applicator arm 380 to the coil C; (b) positioning the end LE1 of the film F2 of the film roll FR2 held by the third applicator arm 330 in the longitudinal and lateral directions at one side of the eye E of the coil C so that the end LE2 of the film F2 of the film roll FR2 is positioned approximately adjacent to the second area FA2 of the side SS1 of the coil C on the opposite side of the eye E of the coil C. This step includes (c) positioning the end LE2 of the film F2 of the film roll FR2 by the first film end holder 450a in the first area FA2 adjacent to the side SS1 of the coil C, and (d) positioning the end LE1 of the film F1 of the film roll FR1 adjacent to the second area FA1 of the side SS1 of the coil C by the second film end holder 450b. Steps (a), (b), (c), and (d) can be performed simultaneously in the illustrated embodiment.

[0054] This further includes, as best shown in FIG. 1NA and FIG. 1O, (e) positioning the first applicator arm 130 longitudinally and laterally adjacent to side SS2 of the coil C (i.e., the side of the coil opposite the first wrapper 100) (not holding any film roll at this time) to laterally align with the third applicator arm 330 of the second wrapper 300; and (f) positioning the second applicator arm 180 longitudinally and laterally adjacent to side SS2 of the coil C (not holding any film roll at this time) to laterally align with the fourth applicator arm 380 of the second wrapper. Steps (e) and (f) can be performed simultaneously in the illustrated exemplary embodiment. Steps (e) and (f) can also be performed simultaneously with any of steps (a) and (b) and / or steps (c) and (d) in the illustrated exemplary embodiment.

[0055] The process of wrapping coils with film from a film roll The process of wrapping coil C with films F1 and F2 from both film rolls FR1 and FR2 simultaneously involves the following sequence of steps.

[0056] The first series of steps includes (a) starting the rotation of the coil rotator 500 about its longitudinal axis LA (if not already started before), (b) moving the fourth applicator arm 380 and the film roll FR1 held by its gripper longitudinally inwardly in the area adjacent to the coil C so that the film F1 of the film roll FR1 is applied to the area of ​​the outer surface OS of the coil C, (c) moving the third applicator arm 330 and the film roll FR2 held by its gripper longitudinally inwardly into the eye E of the coil C so that the film F2 of the film roll FR2 is applied to the area of ​​the inner surface IS of the coil C, (d) moving the second applicator arm 180 (not holding a film roll at this point) longitudinally inwardly in the area adjacent to the outer surface OS of the coil C, and (e) moving the first applicator arm 130 (not holding a film roll at this point) longitudinally inwardly into the eye E of the coil C. In the illustrated embodiment, steps (b), (c), (d), and (e) are performed simultaneously.

[0057] As best shown in FIG. 1NB, the next series of steps includes (f) continuing to move the film roll FR1 held by the fourth applicator arm 380 and its gripper inwardly in the longitudinal direction to a film roll transfer position (while continuing to apply the film F1 of the film roll FR1 to the area of ​​the outer surface OS of the coil C), (g) continuing to move the film roll FR2 held by the third applicator arm 330 and its gripper inwardly in the longitudinal direction to a film roll transfer position at the eye E of the coil C (while continuing to apply the film F2 of the film roll FR2 to the area of ​​the inner surface IS of the coil C), (h) continuing to move the second applicator arm 180 inwardly in the longitudinal direction to a film roll transfer position in an area adjacent the outer surface OS of the coil C, and (i) continuing to move the first applicator arm 130 (now not holding a film roll) inwardly in the longitudinal direction to a film roll transfer position at the eye E of the coil C. These applicator arms and film roll transfer positions are also shown in FIG. 1P. Steps (f), (g), (h), and (i) may be performed simultaneously in the illustrated exemplary embodiment.

[0058] 1NC, the next series of steps includes (j) transferring the film roll FR1 held in the gripper of the fourth applicator arm 380 to the gripper of the second applicator arm 180 at a film roll transfer location in the region of the outer surface OS of the coil C, and (k) transferring the film roll FR2 held in the gripper of the third applicator arm 330 to the gripper of the first applicator arm 130 at a film roll transfer location in the eye E of the coil C. Steps (j) and (k) can be performed simultaneously in the illustrated embodiment.

[0059] 1ND, the next series of steps includes (l) moving the second applicator arm 180 and the film roll FR1 held by its gripper longitudinally outward in a region adjacent to the coil C, so that the film F1 of the film roll FR1 is subsequently applied to a region of the outer surface of the coil C, (m) moving the first applicator arm 130 and the film roll FR2 held by its gripper longitudinally toward the outside of the eye E of the coil C, so that the film F2 of the film roll FR2 is subsequently applied to a region of the inner surface IS of the coil C, (n) moving the fourth applicator arm 380 longitudinally outward in a region adjacent to the outer surface OS of the coil C, and (o) moving the third applicator arm 330 longitudinally outward of the eye E of the coil C. Steps (l), (m), (n) and (o) are performed simultaneously in the illustrated embodiment.

[0060] As best shown in FIG. 1NE, the next series of steps includes (p) moving the second applicator arm 180 and the film roll FR1 held in its gripper laterally adjacent to the side SS2 of the coil C, and terminating such lateral movement when the film roll FR1 held by the gripper is in a plane longitudinally aligned with the eye E of the coil C; (q) moving the first applicator arm 130 and the film roll FR2 held in its gripper laterally adjacent to the side SS2 of the coil C, such that the film F2 of the film roll FR2 is applied to the area of ​​the side SS2 of the coil C; (r) moving the fourth applicator arm 380 laterally adjacent the side SS1 of the coil C and stopping such lateral movement when its gripper is in a plane longitudinally aligned with the eye E of the coil C; and (s) moving the third applicator arm 330 laterally adjacent the side SS1 of the coil C and stopping such lateral movement when its gripper is in a plane longitudinally adjacent to the outer surface OS of the coil C. Steps (p), (q), (r), and (s) may occur simultaneously in the illustrated embodiment.

[0061] As best shown in FIG. 1NF, the next series of steps includes: (t) moving the first applicator arm 130 and the film roll FR2 held in its gripper longitudinally inward to a film roll transfer position while applying the film F2 of the film roll FR2 to an area adjacent to the outer surface OS of the coil C; (u) moving the second applicator arm 180 and the film roll FR1 held in its gripper longitudinally inward to a film roll transfer position in the eye E of the coil C while applying the film F1 of the film roll FR1 to an area of ​​the inner surface IS of the coil C; (v) moving the fourth applicator arm 380 (not holding a film roll at this point) longitudinally inward to a film roll transfer position in the eye E of the coil C; and (w) moving the third applicator arm 330 (not holding a film roll at this point) longitudinally inward to a film roll transfer position in the area adjacent to the outer surface OS of the coil C. These applicator arms and film roll transfer locations are also shown in Figure 1Q. Steps (t), (u), (v), and (w) can occur simultaneously in the exemplary embodiment shown.

[0062] As best shown in FIG. 1NG, the next series of steps includes (x) transferring the film roll FR2 held in the gripping portion of the first applicator arm 130 to the gripping portion of the third applicator arm 330 at a film roll transfer position in an area adjacent to the outer surface OS of the coil C, and (y) transferring the film roll FR1 held in the gripping portion of the second applicator arm 180 to the gripping portion of the fourth applicator arm 380 at a film roll transfer position within the eye E of the coil C, which steps (x) and (y) can be performed simultaneously in the illustrated embodiment.

[0063] 1NH, the next series of steps includes (z) moving the third applicator arm 330 and the film roll FR2 held by the gripper longitudinally outward in a region outside the eye E of the coil C, with the film F2 of the film roll FR2 being subsequently applied to a region of the outer surface of the coil C, (aa) moving the fourth applicator arm 380 and the film roll FR1 held by the gripper longitudinally outward of the eye E of the coil C, with the film F1 of the film roll FR1 being subsequently applied to a region of the inner surface IS of the coil C, (bb) moving the first applicator arm 130 longitudinally outward in a region adjacent the outer surface OS of the coil C, and (cc) moving the second applicator arm 180 longitudinally outward of the eye E of the coil C. Steps (z), (aa), (bb) and (cc) can be performed simultaneously in the illustrated embodiment.

[0064] As best shown in FIG. 1NI, the next series of steps includes (dd) moving a fourth applicator arm 380 and a film roll FR1 held in its gripper laterally adjacent to a side SS1 of the coil C such that the film F1 of the film roll FR1 is applied to an area of ​​the side SS2 of the coil C, and stopping such lateral movement when the film roll FR1 held by the gripper is in a plane longitudinally adjacent to the outer surface OS of the coil C; and (ee) moving a fourth applicator arm 330 and a film roll FR2 held in its gripper laterally adjacent to a side SS1 of the coil C such that the film F1 of the film roll FR1 is applied to an area of ​​the side SS2 of the coil C, and stopping such lateral movement when the film roll FR1 held by the gripper is in a plane longitudinally adjacent to the outer surface OS of the coil C. 2 is applied to the region of the side SS2 of the coil C, and includes the steps of (ff) moving the second applicator arm 180 laterally adjacent the side SS2 of the coil C and stopping such lateral movement when the film roll FR2 held by the gripper is in a plane longitudinally aligned with the eye E of the coil C, and (gg) moving the first applicator arm 130 laterally adjacent the side SS2 of the coil C and stopping such lateral movement when its gripper is in a plane longitudinally aligned with the eye E of the coil C. In the illustrated embodiment, steps (dd), (ee), (ff) and (gg) can be performed simultaneously. At this point, the films F1 and F2 overlap themselves, as somewhat shown in FIG. 1NI.

[0065] Each of the series of steps (b) through (gg) is then repeated while coil C continues to rotate about its longitudinal axis until approximately half of coil C is wrapped by film F1 and approximately half of the coil is wrapped by film F2. After repeating steps (b) through (gg) an appropriate number of times, such as two or three, films F1 and F2 are held by leading ends LE1 and LE2 of films F1 and F2, respectively, and film end holders 450a and 450b can release leading ends LE1 and LE2 of films F1 and F2.

[0066] Seal, clamp and cut both films from both film rolls After the above steps are repeated several times so that the coil C is completely wrapped by the two films F1 and F2, the steps of sealing, clamping and cutting both the films F1 and F2 from both the film rolls FR1 and FR2 start. After steps (dd), (ee), (ff) and (gg) are last performed, the method includes positioning the cutting, clamping and splicing system 420 in an active position adjacent to the side SS2 of the coil C, as shown in Figures 1J and 1K.

[0067] More specifically, this includes (i) positioning the first coil engager 434 at a first sealing / cutting position to engage the film F2 of the film roll FR2 disposed in a first region of the side SS1 of the coil C adjacent to the eye E of the coil C with the sealer / cutter 436 in an open position as shown in Figures 1J and 1K, and (ii) positioning the second coil engager 444 at a second sealing / cutting position to engage the film F1 of the film roll FR1 disposed in a second region of the side SS1 of the coil C adjacent to the eye E of the coil C with the sealer / cutter 446 in an open position as shown in Figures 1J and 1K. Steps (i) and (ii) can be performed simultaneously in the illustrated exemplary embodiment.

[0068] This further includes the steps of (iii) pivoting the first sealer / cutter 436 inward to engage and seal and cut the film F2 of the film roll FR2 located in a first region of the side SS1 of the coil C adjacent to the eye E of the coil C, (iv) pivoting the second sealer / cutter 446 inward to engage and seal and cut the film F1 of the film roll FR1 located in a first region of the side SS1 of the coil C adjacent to the eye E of the coil C, (v) holding the leading edge of the film F2 of the film roll FR2, and (vi) holding the leading edge of the film F1 of the film roll FR1. Steps (v) and (vi) can be performed simultaneously in the illustrated exemplary embodiment. Steps (iii) and (iv) can be performed simultaneously in the illustrated exemplary embodiment. Steps (v) and (vi) can be performed before or simultaneously with steps (iii) and (iv).

[0069] This step includes raising the second wrapper 300 so that the wrapped coil can move under the second wrapper 300. This step also includes, or alternatively includes, (vii) retracting the first coil engager 434 from the first sealing / cutting position, and (viii) retracting the second coil engager 444 from the second sealing / cutting position. These steps (vii) and (viii) can be performed simultaneously in the illustrated exemplary embodiment. At this point, the ends of films F1 and F2 are held for application to the next coil.

[0070] FIG. 1NJ shows the coil after it has been completely wrapped.

[0071] Removal of wrapped coils from the coil wrapping area The method of removing the wrapped coil from the coil wrapping area includes the steps of (a) causing the coil rotator 500 to stop rotating the coil C (if not previously done), (b) lifting the second wrapper 300 to a raised position, (c) moving the completely wrapped coil longitudinally onto the coil rotator 500 within the coil wrapping area, beneath the second wrapper 300, and into the coil discharge area (and thereafter allowing the wrapped coil to be transported as desired), and (d) lowering the second wrapper 300 to a coil wrapping position for wrapping the next coil.

[0072] Next, an exemplary film roll changing system 50, an exemplary method of preparing for wrapping the next coil, an exemplary mandrel 4000, and an exemplary mandrel gripper 5000 of this exemplary embodiment of the present disclosure will be described.

[0073] Film Roll Exchange System The film roll replacement system 50 removes an empty or nearly empty film roll from the coil wrapping apparatus 30 and supplies a new film roll to the coil wrapping apparatus 30. The film roll replacement system 50 includes a first replacement film roll holder 600, a first replacement film roll holder track 610, a first empty film roll holder 800, a first empty film roll holder track 810, a first film roll supply body 900, a first empty film roll remover body 1000, a second replacement film roll holder 1600, a second replacement film roll holder track 1610, a second empty film roll holder 1800, a second empty film roll holder track 1810, a second empty film roll supply body 1900, and a second empty film roll remover body 2000, as shown in Figures 1A, 1B, 1C, 2A, 2D, 3A, and 3F.

[0074] The first replacement film roll holder track 610 and the first empty film roll holder track 810 are disposed adjacent to a first outer region of the mechanical frame 60 and each extend laterally relative to the coil rotor 500. The first replacement film roll holder track 610 is aligned with the second wrapper 300, and the first empty film roll holder track 810 is generally aligned laterally with the first wrapper 100. The first replacement film roll holder 600 is slidably mounted on the first replacement film roll holder track 610 and is laterally movable from a supply position (FIG. 1A) to a reload position (FIG. 1B). FIG. 1B shows the first replacement film roll holder 600 after it has been loaded with a replacement roll and before it is returned to the supply position shown in FIG. 1A. A first empty film roll holder 800 is slidably mounted on a first empty film roll holder track 810 and is laterally movable from an empty film roll receiving position (FIG. 1A) to an empty film roll unloading position (FIG. 1B).

[0075] Similarly, the second replacement film roll holder track 1610 and the second empty film roll holder track 1810 are located adjacent to the second exterior region on the opposite side of the mechanical frame 60 and each extend laterally relative to the coil rotor 500. The second replacement film roll holder track 1610 is generally aligned with the second wrapper 300 and the second empty film roll holder track 1810 is laterally aligned with the first wrapper 100. The second replacement film roll holder 1600 is slidably mounted on the second replacement film roll holder track 1610 and is laterally movable thereon from a supply position (FIG. 1A) to a reloading position (FIG. 1B). The second empty film roll holder 1800 is slidably mounted on the second empty film roll holder track 1810 and is laterally movable thereon from an empty film roll receiving position (FIG. 1A) to an empty film roll unloading position (FIG. 1B).

[0076] Suitable protective structures, such as fences (not shown), may be used around the components of coil wrapping system 20 to create a protective barrier around the various components thereof to restrict personnel access to the working area of ​​coil wrapping system 20. The loading and unloading positions described above are outside of such protective structures and allow personnel to load replacement film rolls onto respective replacement film roll holders 600 and 1600 and unload empty film rolls from respective empty film roll holders 800 and 1800 without entering such protected working area.

[0077] Each of the first replacement film roll holder 600, the first empty film roll holder 800, the second replacement film roll holder 1600, and the second empty film roll holder 1800 is (i) manually movable and lockable on its respective track 610, 810, 1610, and 1810 toward and away from the inside / outside of the respective wrappers 100 and 300 and protective structure, or (ii) automatically movable and lockable under the control of the control device CR by a respective actuator, such as the exemplary actuator described below, on its respective track 610, 810, 1610, and 1810 toward and away from the inside / outside of the respective wrappers 100 and 300 and protective structure. Each of the first replacement film roll holder 600, the first empty film roll holder 800, the second replacement film roll holder 1600, and the second empty film roll holder 1800 can be manually locked into their respective positions on their respective tracks 610, 810, 1610, and 1810, or can be automatically locked under the control of the control device CR by a respective actuator, such as the exemplary actuators described below.

[0078] The first film roll supply body 900 and the first empty film roll remover body 1000 are disposed adjacent to a first exterior region of the mechanical frame 60, and each extends transversely relative to the coil rotator 500. The first film roll supply body 900 and the first empty film roll remover body 1000 are disposed between the first replacement film roll holder track 610 and the first empty film roll holder track 810, and thus between the first replacement film roll holder 600 and the first empty film roll holder 800 when the holders are located in their respective supply and empty film roll receiving positions, as shown in Figures 1A and 1C. The first film roll supply 900 is also aligned with the first replacement film roll holder 600 (when that holder is in the film roll supply position) and, under the control of the control device CR, the first film roll supply 900 can obtain a replacement film roll (on the mandrel 4000) from the first replacement film roll holder 600 and supply the replacement film roll (on the mandrel 4000) to the third applicator arm 330 of the second wrapper 300. Also, the first empty film roll remover 1000 is aligned with the first empty film roll holder 800 (when that holder is in a position to receive an empty film roll) and, under the control of the controller CR, the first empty film roll remover 1000 can obtain an empty film roll (on the mandrel 4000) from the first applicator arm 130 of the first wrapper 100 and provide the empty film roll (on the mandrel 4000) to the first empty film roll holder 800. As the first empty film roll remover 1000 obtains an empty film roll from the first applicator arm 130 of the first wrapper 100, in response to a determination by the controller CR that the film roll held by the third applicator arm 330 is empty, the controller CR causes the third applicator arm 330 to transfer the empty film roll to the first applicator arm 130 of the first wrapper 100 for removal, as described below.

[0079] Similarly, the second film roll supply body 1900 and the second empty film roll remover body 2000 are disposed adjacent to a second exterior region of the mechanical frame 60, each extending transversely relative to the coil rotator 500. The second film roll supply body 1900 and the second empty film roll remover body 2000 are disposed between the second replacement film roll holder track 1610 and the second empty film roll holder track 1810, and thus between the second replacement film roll holder 1600 and the second empty film roll holder 1800 when the holders are located in their respective supply and empty film roll receiving positions, as shown in FIGS. 1A and 1C. The second film roll supply 1900 is also aligned with the second replacement film roll holder 1600 (when that holder is in the film roll supply position) and, under the control of the control device CR, the second film roll supply 1900 can obtain a replacement film roll (on the mandrel 4000) from the second replacement film roll holder 1600 and supply the replacement film roll (on the mandrel 4000) to the fourth applicator arm 380 of the second wrapper 300. The second empty film roll remover 2000 is also aligned with the second empty film roll holder 1800 (when that holder is in the empty film roll receiving position) such that, under the control of the controller CR, the second empty film roll remover 2000 can obtain an empty film roll (on the mandrel 4000) from the second applicator arm 180 of the first wrapper 100 and provide the empty film roll (on the mandrel 4000) to the second empty film roll holder 1800. As the second empty film roll remover 2000 obtains an empty film roll from the second applicator arm 180 of the first wrapper 100, in response to a determination by the controller CR that the film roll held by the fourth applicator arm 380 is empty, the controller CR causes the fourth applicator arm 380 to transfer the empty film roll to the second applicator arm 180 of the first wrapper 100 for removal.

[0080] 1st Replacement Film Roll HolderMore specifically, as best shown in Figures 2A, 2B, 2C, and 2D, the first replacement film roll holder 600 is configured to hold a replacement film roll RFR that can be provided individually and separately by the first film roll supply 900 to the third applicator arm 330 of the second wrapper 300 when the controller CR determines to replace each empty film roll held by the third applicator arm 330 of the second wrapper 300 (and transferred to the first applicator arm 130 of the first wrapper 100 for removal). The first replacement film roll holder 600 includes a replacement film roll holder frame 620 movably coupled to a track 610. The replacement film roll holder frame 620 includes a lower portion 630 and an upper portion 640. The lower portion 630 includes a plurality of legs (not numbered) coupled to the track 610 and slidable on the track 610. The upper portion 640 includes a plurality of upright, longitudinal frame members (not numbered) that support a plurality of film roll holders 700, as described below. The track 610 is fixed in position on a support surface (such as a floor) and extends laterally outward in a first region adjacent the mechanical frame 60 and is laterally aligned with the second wrapper 300, as described above. The replacement film roll holder frame 620 is movable on the track 610 by a replacement film roll holder actuator 650 under the control of a control device CR from a supply position shown in FIG. 1A to a reload position shown in FIG. 1B outside the supply position. In the supply position, the replacement film roll holder 600 is configured to supply a replacement film roll on the mandrel, if necessary, to the third applicator arm 330 of the second wrapper 300 via the first film roll supply 900. In the reload position, the replacement film roll holder 600 is configured to reload an additional replacement film roll onto the mandrel. The replacement film roll holder actuator 650 is connected to the replacement film roll holder frame 620. The replacement film roll holder actuator 650, under the control of the control device CR, moves the replacement film roll holder frame 620 on the track 610 between the supply position and the reload position.This exemplary embodiment further includes a replacement film roll-holder lock actuator 660 connected to the replacement film roll holder frame 620. The replacement film roll holder lock actuator 660 is configured, under the control of the controller CR, to move the lock pin 665 to lock into the track 610 to lock the replacement film roll holder frame 620 in the supply or reload position.

[0081] FIG 2A shows twelve film roll holders 700 that do not hold a film roll. FIG 2C shows film roll holders 700 that hold twelve replacement film rolls (each mounted on a mandrel 4000). In this exemplary embodiment, the twelve film roll holders 700 are arranged in two rows of six film roll holders. Thus, the first replacement film roll holder 600 holds twelve replacement film rolls before being reloaded with an additional replacement film roll as shown in FIG 2C. The quantity and arrangement of film roll holders can vary.

[0082] Each film roll holder 700 includes an upper mandrel holder 710, a lower mandrel holder 740, and a film end holder 780. The upper mandrel holder 710 is connected to the upper portion 640 of the frame 620 and includes a bracket shaped and sized to receive, hold, and release the upper handle 4116 of the upper handle assembly 4110 of the mandrel 4000 (described below). The lower mandrel holder 740 is connected to the upper portion 640 of the frame 620 below the upper mandrel holder 710 and is aligned with and spaced from the upper mandrel holder 710. The lower mandrel holder 740 includes a bracket shaped and sized to receive, hold, and release the lower handle 4156 of the lower handle assembly 4150 of the mandrel 4000. The lower mandrel holder 740 also includes one or more magnets (not numbered) that hold the mandrel in place. The film end holder 780 is connected to the upper portion 640 of the frame 620 at the same level as, aligned with, and spaced apart from the upper mandrel holder 710. The film end holder 780 includes a first film engaging body 782 connected to the frame 600 and a second film engaging body 790 pivotally connected to the first film engaging body 782. The second film engaging body 790 is pivotable between a film holding position shown in Figures 2A, 2B, 2C, 2D and a film open position (not shown). The second film engaging body 790 is biased toward the film holding position by a biasing member (not shown). In certain embodiments, one or more magnets hold the second film engaging body 790 in the closed position. 2C and 2D, the film end holder 780 is configured to hold the leading end of the replacement film roll while the replacement film roll is held by the first replacement film roll holder 600. The film end holder 780 is configured to release the leading end of the replacement film roll when the replacement film roll is removed from the first replacement film roll holder 600 by the first replacement film roll supply 900.

[0083] Second replacement film roll holder The second replacement film roll holder 1600 is a mirror image of the first replacement film roll holder 600, and therefore will not be described in detail herein for the sake of simplicity. In general, as best illustrated in Figures 1A, 1B, and 1C, the second replacement film roll holder 1600 is configured to hold a replacement film roll that is individually supplied by the second film roll supply 1900 to the fourth applicator arm 380 of the second wrapper 300 when the controller CR determines that an empty film roll held by the fourth applicator arm 380 should be replaced (and then transferred to the second applicator arm 180 of the first wrapper 100 for removal). Similar to above, a replacement film-roll holder actuator (not shown) connected to the replacement film roll holder frame of the second replacement film roll holder 1600 moves the replacement film roll holder frame on the track 1610 between the supply position (shown in FIG. 1A) and the reload position (shown in FIG. 1B) under the control of the controller CR. This exemplary embodiment further includes a replacement film roll holder lock actuator (not shown) connected to the replacement film roll holder frame. The replacement film roll holder lock actuator is configured to move a lock pin (not shown) to engage the track 1610 under the control of the controller CR to lock the replacement film roll holder frame in the supply or reload position.

[0084] 1st empty film roll holder The first empty film roll holder 800, as best illustrated in Figures 1A, 1B, and 1C, is configured to hold an empty film roll (on the mandrel 4000) that is obtained by the first empty film roll remover 1000 from the first applicator arm 130 of the first wrapper 100, respectively, when the controller CR determines to replace an empty film roll held by the third applicator arm 330 or the first applicator arm 130, as described above. The first empty film roll holder 800 is substantially a mirror image of the empty first replacement film roll holder 600 (but does not initially hold any replacement film roll on the mandrel). Thus, the first empty film roll holder 800 will not be described in detail herein for the sake of brevity. The first replacement film roll holder 600 may include an optional film end holder (such as the film end holder 780 of the first replacement film roll holder 600) since the first empty film roll holder 800 is not required to hold the leading edge of the film of such an empty film roll, but this is not required. As described above, an empty film roll holder actuator (not shown) connected to the empty film roll holder frame moves the empty film roll holder frame on a track 810 under the control of the control device CR between an empty film roll receiving position (shown in FIG. 1A) and an unloading position (shown in FIG. 1B). This exemplary embodiment additionally includes an empty film roll holder lock actuator (not shown) connected to the empty film roll holder frame. The empty film roll holder lock actuator is configured to move a lock pin (not shown) to engage the track 810 under the control of the control device CR to lock the empty film roll holder frame in the empty film roll receiving position or the unloading position.

[0085] Second empty film roll holder The second empty film roll holder 1800 is similarly a mirror image of the first empty film roll holder 1800 and therefore will not be described herein for the sake of brevity. The second empty film roll holder 1800 is configured to hold an empty film roll that is individually obtained by the second empty film roll remover 2000 from the second applicator arm 180 of the first wrapper 100 when the controller CR determines to replace the empty film roll held by the fourth applicator arm 380 and transferred to the second applicator arm 180 for removal, as described above. As above, an empty film roll holder actuator (not shown) connected to the empty film roll holder frame moves the empty film roll holder frame on a track 1810 between an empty film roll receiving position and an unloading position under the control of the controller CR. This exemplary embodiment additionally includes an empty film roll holder lock actuator (not shown) connected to the empty film roll holder frame configured to move a lock pin (not shown) into engagement with track 1810 under control of controller CR to lock the empty film roll holder frame in an empty film roll receiving or unloading position.

[0086] First film roll supplier The first film roll supply 900, as best shown in Figures 3A-3E, is disposed between the first replacement film roll holder 600 and the first empty film roll remover 1000, and extends laterally partially within the interior region of the mechanical frame 60. The first film roll supply 900 includes a supply frame 920 and a film roll mover 950 supported by the supply frame 920.

[0087] The supply frame 920 is fixed and includes a lower portion 922 and a track 924 attached to an upper portion of the lower portion 922. The supply frame 920 is longitudinally aligned with the first replacement film roll holder 600 to allow the film roll mover 950 to reach each replacement film roll holder support location of the first replacement film roll holder 600. The supply frame 920 also extends laterally into an area within the mechanical frame 60 to longitudinally align the film roll mover 950 with the third applicator arm 330 of the second wrapper 300 to allow the transfer of a replacement film roll to the third applicator arm 330.

[0088] The film roll mover 950 includes an upright support arm 952 movably coupled to a track 924 mounted on the supply frame 920, and a support arm actuator 956 operatively coupled to the support arm 952 and movable on the track 924. The support arm actuator 956 moves the support arm 952 (and its support components, as described herein) laterally along the track 924 under the control of a controller CR. This enables the film roll mover 950 to interact with the first replacement film roll holder 600 and with the third applicator arm 330. In this manner, under the control of the control device CR, the support arm actuator 956 moves the support arm 952 and the entire film roll mover 950 along the track 924 to longitudinally align with a different film holder support position of the first replacement film roll holder 600, and to longitudinally align with the third applicator arm 330 when the third applicator arm 330 is in the film roll receiving position as shown in FIG. 1A.

[0089] The film roll moving body 950 further includes a film roll transfer arm 960 extending in the longitudinal direction and connected to the support arm 952 for longitudinal movement, and a transfer arm actuator 966 connected to the support arm 952 and operably connected to the transfer arm 960. The transfer arm actuator 966 moves the film roll transfer arm 960 inwardly and outwardly in the longitudinal direction relative to the support arm 952 under the control of the control device CR. The film roll moving body 950 further includes a gripper 5000 (described below) connected to an end of the film roll transfer arm 960. The film roll mover 950 further comprises a film roll tip holder 980 and a film roll mover actuator 986 configured to pivot a finger 984 of the holder 980. The film roll mover 950 further comprises a film roll tip holder 980 fixedly connected to a film roll transfer arm 960. The film roll mover 950 further comprises a film roll tip holder 980 and a film roll mover actuator 986 fixedly connected to the arm 960 by a bracket 981 and thus movable longitudinally with the arm 960. The film roll tip holder 980 is otherwise similar to the film roll tip holder 450a described above and therefore will not be described herein for the sake of brevity. The film roll mover 950 includes an actuator 976 configured to move the film roll transfer arm 960 and the film roll tip holder 980 upwardly and downwardly along a track 958 attached to the support arm 952.

[0090] The first film roll supply 900 is configured, in response to the controller CR determining that the film roll held by the third applicator arm 330 is empty and needs to be replaced, under the control of the controller CR, to obtain a replacement film roll from the first replacement film roll holder 600 and move the replacement film roll to the third applicator arm 330 of the second wrapper 300 after the empty film roll has been transferred by the third applicator arm 330 to the first applicator arm 130 for removal.

[0091] Second film roll supplier The second film roll supply 1900 is disposed between the second replacement film roll holder 1600 and the second empty film roll remover 2000, and extends laterally partially within the interior region of the mechanical frame 60. The second film roll supply 1900 is a mirror image of the first film roll supply 900, and therefore will not be described here for the sake of brevity.

[0092] The second film roll supply 1900 is configured, in response to the controller CR determining that the film roll held by the fourth applicator arm 380 is empty and needs to be replaced, to obtain a replacement film roll from the second replacement film roll holder 1600 and move the replacement film roll to the fourth applicator arm 380 of the second wrapper 300 under the control of the controller CR after the empty film roll has been transferred by the fourth applicator arm 380 to the second applicator arm 180 for removal.

[0093] First empty film roll remover The first empty film roll remover 1000 is substantially similar to the first film roll supply 900 and therefore will only be briefly described herein for the sake of brevity.

[0094] The first empty film roll remover 1000 includes a remover frame 1020 and a film roll carrier 1050 (shown in FIGS. 1B and 1C) supported by the remover frame 1020. The remover frame 1020 is stationary and similar to the supply frame 920. The remover frame 1020 is aligned longitudinally with the first empty film roll holder 800 so that the film roll carrier 1050 can reach the support position of each empty film roll holder of the first empty film roll holder 800. The remover frame 1020 also extends laterally within an area within the mechanical frame 60 so that the film roll carrier 1050 is aligned longitudinally with the first applicator arm 130 of the first wrapper 100 so that the first applicator arm 130 can transfer the empty film roll to the film roll carrier 1050. The film roll moving body 1050 is substantially similar to the film roll moving body 950, but its longitudinally extending film roll transport arm is longitudinally movable and longitudinally inwardly and outwardly movable in opposite directions under the control of the control device CR, and does not need to have a film roll tip holder.

[0095] Second empty film roll remover The second empty film roll remover 2000 is substantially similar to the first empty film roll remover 1000 and therefore will only be briefly described herein for the sake of brevity.

[0096] The second empty film roll remover 2000 comprises a remover frame 2020 and a film roll carrier 2050 (shown in FIG. 1C ) supported by the remover frame 2020. The remover frame 2010 is fixed and similar to the remover frame 1010. The remover frame 2020 is longitudinally aligned with the second empty film roll holder 1800 so that the film roll carrier 2050 can reach each empty film roll holder support location of the second empty film roll holder 1800. The remover frame 2020 also extends laterally into an area within the mechanical frame 60 so that the film roll carrier 2050 is longitudinally aligned with the second applicator arm 180 of the first wrapper 100 so that the second applicator arm 180 can transfer the empty film roll to the film roll carrier 2050. The film roll moving body 2050 is substantially similar to the film roll moving body 950, but its longitudinally extending film roll transport arm is longitudinally movable and longitudinally inwardly and outwardly movable in opposite directions under the control of the control device CR, and does not need to have a film roll tip holder.

[0097] How to prepare coil wrapping and change film rolls The method for preparing a coil for wrapping and replacing an empty film roll with a replacement film roll using film roll changing system 50 will now be described in more detail.

[0098] The method of preparation for wrapping the next coil (i.e., before the next coil wrapping process begins) includes the controller CR determining whether both of the film rolls FR1 and FR2 to be used by the first and second wrappers 100 and 300 to wrap the next coil have sufficient film to wrap the next coil. If either of these film rolls FR1 or FR2 does not have enough film to wrap the next coil, the controller CR replaces the insufficient film coil with a replacement film roll from the respective replacement film roll holder 600 or 1600. Such insufficient film rolls are considered to be empty or are considered to be empty as described above.

[0099] These determinations may be based on data received by the controller CR from one or more sensors S and / or data relating to the amount of coil C wound since each film roll FR was previously replaced and began to be used. In various embodiments, the controller CR makes these determinations based on signals received from sensors S mounted on the grippers 5000 of each applicator arm 330 and 380 of the second wrapper 300, where the signals indicate a reading of the amount of film F remaining on the films F1 and F2 of each of the film rolls FR1 and FR2 (after the previous coil C has been wrapped). In other embodiments, the controller CR makes these determinations based on usage data tracked and maintained by the controller CR for each of the currently used film rolls FR1 and FR2, and the quantity and size of the coils C (and the amount or length of film on each film roll) previously wrapped using the currently used film rolls FR1 and FR2. In other embodiments, the controller CR makes these decisions based on signals received from the sensors S and based on such usage data.

[0100] In response to the controller CR determining that the film roll FR2 held by the third applicator arm 330 is insufficient for wrapping the next coil, the controller CR generally (1) causes the third applicator arm 330 to transfer the empty film roll FR2 to the first applicator arm 130, (2) causes the first applicator arm 130 to transfer the empty film roll FR2 to the first empty film roll remover 1000, (3) causes the first empty film roll remover 1000 to transfer the empty film roll FR2 to the first empty film roll holder 800, (4) causes the first film roll supply body 900 to obtain a replacement film roll RFR from the first replacement film roll holder 600, and (5) causes the first film roll supply body 900 to transfer the obtained replacement film roll RFR to the third applicator arm 330. Steps (2) and (3) can be carried out simultaneously with steps (4) and (5) in this embodiment.

[0101] Similarly, in response to the control device CR determining that the film roll FR1 held by the fourth applicator arm 380 is insufficient to wrap the next coil, the control device CR (A) causes the fourth applicator arm 380 to transfer the empty film roll FR1 to the second applicator arm 180, (B) causes the second applicator arm 180 to transfer the empty film roll FR1 to the second empty film roll remover 2000, (C) causes the second empty film roll remover 2000 to transfer the empty film roll FR1 to the second empty film roll holder 1800, (D) causes the second film roll supply body 1900 to obtain a replacement film roll RFR from the second replacement film roll holder 1600, and (E) causes the second film roll supply body 1900 to transfer the obtained replacement film roll to the fourth applicator arm 380. Steps (B) and (C) can be performed simultaneously with steps (D) and (E) in this embodiment. In addition, steps (B) and (C), (2) and (3), (C) and (D), and (4) and (5) can be performed simultaneously in this exemplary embodiment.

[0102] Since the methods for replacing the film rolls FR1 and FR2 are substantially identical in this exemplary embodiment, only the method for replacing the empty film roll FR2 will be described in more detail herein for the sake of brevity. The method for replacing the empty film roll FR2 described below includes positioning of each of the first and second wrappers 100 and 300, the applicator arms 130 and 330 of the first and second wrappers 100 and 300, and the film roll movers 950 and 1050. This positioning can include any necessary vertical, longitudinal, and / or lateral movement of these respective components by the respective actuators described above. All of these operations are controlled by the controller CR based on a particular point in the film roll replacement process. Furthermore, one or more of these movements can be monitored by one or more sensors S, and one or more of these movements can be triggered by the controller CR based on feedback from one or more of the sensors S.

[0103] More specifically, this method of initially replacing an empty film roll FR2 includes vertically moving each of the first wrapper 100 and the second wrapper 300 to respective vertical film replacement positions, as needed, where the third applicator arm 330 is vertically aligned (i.e., at the same vertical height) with the first applicator arm 130, the third applicator arm 330 is vertically aligned (i.e., at the same vertical height) with the film roll mover 950, and the first applicator arm 130 is vertically aligned (i.e., at the same vertical height) with the film roll mover 1050.

[0104] The method then includes the steps of having the third applicator arm 330 transfer the empty film roll FR2 to the first applicator arm 130, which steps include (a) moving the third applicator arm 330 inward in the longitudinal direction to position its gripper 5000 and the film roll FR2 held by it in a film roll transfer position, and (b) moving the first applicator arm 130 inward in the longitudinal direction to position its gripper 5000 (which is not currently holding a film roll) in the longitudinal direction to position the first applicator arm 130 in the longitudinal direction. (c) transferring the film roll FR2 from the gripper 5000 of the third applicator arm 330 to the gripper 5000 of the first applicator arm 130 at the film roll transfer position, (d) moving the third applicator arm 330 outward in the longitudinal direction with its gripper 5000 empty, and (e) moving the first applicator arm 130 outward in the longitudinal direction with its gripper 5000 holding the film roll FR2. Steps (a) and (b) can be performed simultaneously, and steps (d) and (e) can be performed simultaneously in this embodiment.

[0105] Next, the method includes the step of the first applicator arm 130 transferring the empty film roll FR2 to the first empty film roll removal body 1000, and the first empty film roll removal body 1000 transferring the empty film roll FR2 to the first empty film roll holder 800. This step includes the steps of (f) laterally moving the film roll carrier 1050 of the first empty film roll remover 1000 to longitudinally align its gripping portion with the first applicator arm 130; (g) moving the gripping portion 5000 of the film roll carrier 1050 longitudinally outward to the film roll transfer position; (h) if necessary, moving the first applicator arm 130 longitudinally inward to position its gripping portion 5000 and film roll FR2 at the film roll transfer position; (i) transferring the film roll FR2 from the gripping portion 5000 of the first applicator arm 130 to the gripping portion of the film roll carrier 1050; (j) moving the first applicator arm 130 longitudinally outward with its gripping portion 5000 empty; and (k) transferring the film roll FR2 from the gripping portion 5000 of the first applicator arm 130 to the gripping portion of the film roll carrier 1050 with its gripping portion 5000 currently holding the film roll FR2. (l) moving the film roll moving body 1050 laterally (and vertically, if necessary) with its gripping portion 5000 currently holding the film roll FR2 to an aligned position of one of the empty film roll supports of the first empty film roll holder 800; (m) moving the film roll moving body 1050 longitudinally outward to position its gripping portion and transfer the empty film roll FR2 to the selected empty film roll support of the first empty film roll holder 800; (n) transferring the empty film roll FR2 from the gripping portion of the film roll moving body 1050 to the selected empty film roll support of the first empty film roll holder 800; and (o) with the gripping portion empty, moving the film roll moving body 1050 longitudinally inward.

[0106] The method also includes a step of causing the first film roll supply 900 to acquire a replacement film roll RFR from the first replacement film roll holder 600 and causing the first film roll supply 900 to transfer the acquired replacement film roll to the third applicator arm 330. This includes the steps of: (q) moving the film roll transfer arm 960 and its gripping portion 5000 (not holding a film roll at this point) of the film roll moving body 950 to a position longitudinally aligned with one of the film roll supports 700 of the replacement film roll holder 600 holding the replacement film roll RFR (which also includes moving the film roll transfer arm 960 vertically), as shown in FIG. 3C; (r) moving the film roll transfer arm 960 longitudinally outward to position its gripping portion 5000 in a position for transferring (here, gripping) the replacement film roll RFR from the film roll support of the first replacement film roll holder 600, as shown in FIG. 3D or FIG. 3E, and longitudinally moving the film roll leading end holder 980 attached to the film roll transfer arm 960 to transport (here, grip) the leading end of the replacement film roll from the first replacement film roll holder 600; and (s) moving the film roll transfer arm 960 longitudinally outward to position (here, grip) the leading end of the replacement film roll from the first replacement film roll holder 600, as shown in FIG. 3D or FIG. 3E. As shown in FIG. 3E, a step of transferring (here, gripping) the replacement film roll RFR from the first replacement film roll holder 600 and transferring (here, gripping) the leading end of the replacement film roll RFR from the leading end holder 780 of the first replacement film roll holder 800; (t) as shown in FIG. 3F, a step of moving a film roll transfer arm 960 having a gripping portion 5000 holding the replacement film roll RFR inward in the longitudinal direction and simultaneously moving a film roll leading end holder 980 holding the leading end of the replacement film roll RFR inward in the longitudinal direction; and (u) a step of moving the film roll transfer arm 960 together with the gripping portion 5000 holding the replacement film roll RFR laterally and moving the film roll leading end holder 980 holding the leading end of the replacement film roll RFR laterally to a position aligned with the third applicator arm 330 and the first leading end holder 450a, respectively, in the longitudinal direction (including vertically moving these components, if necessary);(v) if necessary, moving the third applicator arm 330 inward in the longitudinal direction to position its gripping portion 5000 at the film roll transfer position; (w) if necessary, moving the first tip holder 450a inward in the longitudinal direction to the film tip transfer position; (x) transferring the replacement film roll RFR from the gripping portion 5000 of the film roll carrier 950 to the gripping portion 5000 of the third applicator arm 330; and (y) transferring the film tip of the replacement film roll RFR from the film roll tip holder 980 to the first tip holder 450a. (z) moving the third applicator arm 330 having the gripping portion 5000 holding the replacement film roll RFR outward in the longitudinal direction and moving the first tip holder 450a holding the tip of the replacement film roll RFR outward in the longitudinal direction, (aa) moving the film roll moving body 950 together with the gripping portion 5000 and the currently empty film roll holder 980 inward in the longitudinal direction, and (bb) moving the film roll moving body 950 together with the gripping portion 5000 and the currently empty film roll holder 980 laterally.

[0107] Mandrel 4A-4L show a mandrel 4000 configured to support a film roll according to an exemplary embodiment of the present disclosure. As described above, multiple film rolls are used with the coil wrapping system 50. Each film roll is mounted on a mandrel, such as mandrel 4000. Mandrel 4000 includes an inner mandrel assembly 4100 and an outer mandrel assembly 4200. While the inner mandrel assembly 4100 and the outer mandrel assembly 4200 are rotatable relative to one another, the inner mandrel assembly 4100 is held stationary by a mandrel gripper, such as mandrel gripper 5000, described below, and the outer mandrel assembly 4200 and the film roll mounted on the outer mandrel assembly 4200 are rotatable in tension (as described below) to release the film from the film roll onto the coil in the manner described above. The mandrel 4000 maintains the film in tension as the film is applied to the coil by the respective applicator arms. Mandrel 4000 is further configured to be held by the mandrel grippers of each of the applicator arms and transferred from one applicator arm to another, as described above.

[0108] Inner Mandrel Assembly The inner mandrel assembly 4100 includes an upper handle assembly 4110 , a shaft 4130 , an inner rotating assembly 4140 , and a lower handle assembly 4150 .

[0109] Top Handle Assembly The upper handle assembly 4110 includes an upper handle retaining screw 4112 , an upper handle retaining washer 4114 , an upper handle 4116 , an upper handle locking nut 4126 , and an upper handle locking washer 4128 .

[0110] An upper handle retaining screw 4112 and an upper handle retaining washer 4114 secure the upper handle 4116 to the shaft 4130 such that the upper handle 4116 and shaft 4130 are rotatably locked together.

[0111] The upper handle 4116 is sized, shaped, positioned, oriented, and otherwise configured to be removably engaged by the upper mandrel jaws 5210 of the mandrel gripper 5000, as described below. The upper handle 4116 is secured to the shaft 4130 by a keyed connection such that the upper handle 4116 and the shaft 4130 rotate together. The upper handle 4116 includes an outer handle cylinder 4118, an outer handle block 4120, an inner handle cylinder 4122, and an inner handle block 4124. The outer handle cylinder 4118 is cylindrical and aligned with the longitudinal axis 4130A of the shaft 4130. The outer handle cylinder 4118 is sized, shaped, positioned, oriented, and otherwise configured to be engaged by the mandrel engagers 5230 of the upper mandrel jaws 5210. The outer handle block 4120 is rectangular in shape and includes an upper surface (not numbered) and a lower surface (not numbered). The upper surface is sized, shaped, positioned, oriented, or otherwise configured to be engaged by the fingers 5520 and 5520 of the upper mandrel jaw 5210. The inner handle cylinder 4122 may be similar or identical to the outer handle cylinder 4118 in that it is cylindrical in shape and coaxial with the central axis of the shaft 4130. The inner handle cylinder is also sized, shaped, positioned, oriented, or otherwise configured to be engaged by the upper mandrel jaw 5210. The inner handle block 4124 may be similar or identical to the outer handle block 4120 in that it is square in shape and includes an upper surface (not numbered) and a lower surface (not numbered). The upper surface is sized, shaped, positioned, oriented, and otherwise configured to be engaged by the fingers 5520 and 5520 of the upper mandrel jaws 5210 .

[0112] An upper handle locking nut 4126 and an upper handle locking washer 4128 secure the upper handle 4116 to the shaft 4130 such that the upper handle 4116 and shaft 4130 are locked from rotation together.

[0113] The upper handle assembly 4110 is rotationally locked to the fingers 5520 and 5520 of the upper mandrel jaws 5210 of the mandrel gripper 5000 when the mandrel 4000 is gripped by the mandrel gripper 5000 .

[0114] shaft The shaft 4130 of the inner mandrel assembly 4100 provides a central support structure to which the upper handle assembly 4110, the inner rotating assembly 4140, and the lower handle assembly 4140 are attached. The shaft 4130 is cylindrical. The shaft 4130 includes an upper portion, a middle portion, and a lower portion having different diameters. The diameter of the upper portion is smaller than the middle diameter such that the transition between the upper portion and the middle portion of the shaft 4130 defines an upper shelf 4132. The upper shelf 4132 is configured to engage with the upper handle assembly 4110. Similarly, the diameter of the lower portion is smaller than the diameter of the middle portion such that the transition between the lower portion and the middle portion of the shaft 4130 defines a lower shelf 4134. The lower shelf 4134 is configured to engage with the lower handle assembly 4140. The shaft 4130 is secured to the upper handle assembly 4110, the inner rotating assembly 4140, and the lower handle assembly 4140. The shaft 4130 is sized, shaped, positioned, oriented, and otherwise configured to mate with the various bearings of the outer mandrel assembly 4200 , including an upper bearing 4240 , a lower bearing 4242 , and a pivot bearing 4244 .

[0115] Inner Rotating Assembly The inner rotating assembly 4140 includes a fixed clutch disc 4142, a fixed disc abutment plate 4144, and upper and lower disc springs 4146A and 4146B, respectively.

[0116] The fixed clutch disk 4142 is attached to the shaft 4130 via a keyed, splined, or other suitable connection such that they are both rotatably fixed to the upper handle assembly 4110. The fixed clutch disk 4142 includes an upper surface (unnumbered) and a lower surface (unnumbered). The upper surface of the fixed clutch disk 4142 is sized, shaped, positioned, oriented, or otherwise configured to engage the lower surface of the rotating clutch disk 4238 of the outer mandrel assembly 4200 to provide a force resisting rotation of the outer mandrel assembly 4200 relative to the inner mandrel assembly 4100 about the longitudinal axis 4130A.

[0117] The fixed disc abutment plate 4144 provides support for the fixed clutch disc 4142 and is sized, shaped, positioned, oriented, or otherwise configured to engage an underside of the fixed clutch disc 4142. The fixed disc abutment plate 4144 is mounted to the shaft 4130 so as to be rotatably fixed to the upper handle assembly 4110. The fixed disc abutment plate 4144 includes an upper surface (unnumbered) that engages the fixed clutch disc 4142 and a lower surface (unnumbered) that engages the upper disc spring member 4146A.

[0118] The upper and lower disc springs 4146A and 4146B comprise two spring components: the upper disc spring 4146A is sized, shaped, positioned, oriented, or otherwise configured to engage the underside of the fixed disc abutment plate 4144, and the lower disc spring 4146B is sized, shaped, positioned, oriented, or otherwise configured to be engaged by the lower handle lock washer 4152.

[0119] During operation of the mandrel 4000, the inner rotating assembly 4140 is rotatably fixed to the upper handle assembly 4110. The inner rotating assembly 4140 engages the outer mandrel assembly 4200 via contact between the stationary clutch disk 4142 of the inner rotating assembly 4140 and the rotating clutch disk 4238 of the outer mandrel assembly 4200, and is sized, shaped, positioned, oriented, or otherwise configured to provide a desired amount of resistance to rotation of the outer mandrel assembly 4200 relative to the inner mandrel assembly 4100.

[0120] Lower Handle Assembly The lower handle assembly 4150 includes a lower handle locking washer 4152 , a lower handle locking nut 4154 , a lower handle 4156 , a lower handle retention washer 4158 , and a lower handle retention screw 4160 .

[0121] The lower handle lock washer 4152 is sized, shaped, positioned, oriented, and otherwise configured to engage the lower disc spring 4146B and provide a force that is transferred through the disc springs 4146A and 4146B to the fixed clutch disc 4142. Together with the lower handle lock nut 4154, the lower handle lock washer 4152 secures the lower handle 4156 to the shaft 4130, which in turn rotatably secures the lower handle 4156 and shaft 4130 to the upper handle assembly 4110.

[0122] The lower handle 4156 may be similar or identical to the upper handle 4116. Therefore, for the sake of brevity, only the upper handle will be described in detail herein.

[0123] A lower handle retaining washer 4158 and a lower handle retaining screw 4160 secure the lower handle 4156 to the shaft 4130, which in turn rotatably secures the lower handle 4156 and shaft 4130 to the upper handle assembly 4110. To increase or decrease the tension on the disc springs 4146A and 4146B (and thus the fixed clutch disc 4142), the lower handle retaining screw 4160 can be screwed or unscrewed to increase or decrease the force on the disc springs 4146A and 4146B. This can increase or decrease the friction between the fixed clutch disc 4142 and the rotating clutch disc 4238.

[0124] Outer Mandrel Assembly The outer mandrel assembly 4200 includes a film roll holding assembly 4210, an outer mandrel body 4220, an outer rotating assembly 4230, and a number of bearings and support structures (not numbered).

[0125] Outer mandrel body The outer mandrel body 4220 includes an upper surface 4222 and a lower lip 4224 that defines a rotational stop slot 4226 .

[0126] The top surface 4222 is the surface of the outer mandrel body 4220 to which the retaining core 4216 is secured. The bottom lip 4224 extends from the bottom of the outer mandrel body 4220 and provides a surface for the bottom of the film roll to rest on. The bottom lip 4224 prevents the film roll from slipping off the bottom of the mandrel 4000.

[0127] The rotational stop slot 4226 is an opening defined by the outer mandrel housing 4220 that receives a rotational stop 4232 of the outer rotational assembly 4230, as described below.

[0128] The outer mandrel body 4220 rotates relative to the inner mandrel assembly 4100 .

[0129] Film Roll Holding Assembly The film roll retaining assembly 4210 includes a retaining core screw 4212 , a spring retaining pin 4214 , and a retaining core 4216 .

[0130] The retaining core screws 4212 rotatably secure the retaining core 4216 to the outer mandrel body 4220, and in particular to a top surface (not numbered) of the outer mandrel body 4220. The spring retaining pin 4214 is sized, shaped, positioned, oriented, or otherwise configured to engage a first end (not shown) of a spring (not shown), the second end of which is attached to the outer mandrel body 4220. The spring retaining pin 4214 is attached to the retaining core 4216. The retaining core 4216 is rotatably attached to the outer mandrel body 4220 by the retaining core screws 4212 and is biased by the spring (not shown) to a first position extending radially outward from the outer mandrel body 4220.

[0131] In operation, the retaining core screw 4212, spring retaining pin 4214, spring (not shown), and retaining core 4216 bias the retaining core 4216 to a first position extending radially outward from the outer mandrel body 4220. When a film roll is positioned on the mandrel 4000, the underside of the retaining core 4216 prevents the film roll from sliding upward. To remove or add a film roll to the mandrel 4000, the retaining core 4216 is pivoted to a second position where the retaining core 4216 extends along the curve of the outer mandrel body 4220. In the second position, the retaining core 4216 is rotated inward and does not prevent a roll from sliding in or out of the mandrel 4000.

[0132] Outer Rotating Assembly The outer rotating assembly 4230 includes a rotating stopper 4232 , a tension spring 4234 , a spring housing 4236 , and a rotating clutch disc 4238 .

[0133] The rotational stop 4232 is attached to a first end of a tension spring 4234 and is disposed in a rotational stop slot 4226 in the outer mandrel body 4220. Positioning of the rotational stop 4232 in the rotational stop slot 4226 causes the rotational stop 4232 to rotate around the outer mandrel body 4220.

[0134] The tension spring 4234 is attached at a first end to the rotation stop 4232, extends into the spring housing 4236, and is attached at a second end to the spring housing 4236. The tension spring 4234 provides a biasing force between the rotation stop 4232 and the spring housing 4236.

[0135] The spring housing 4236 defines an opening for the tension spring 4234 to extend circumferentially around the inside of the outer mandrel body 4220. The spring housing 4236 includes an upper surface (unnumbered) that is sized, shaped, positioned, oriented, or otherwise configured to engage the pivot bearing 4244 and a lower surface (unnumbered) that is sized, shaped, positioned, oriented, or otherwise configured to engage the rotating clutch disc 4238.

[0136] The rotating clutch disc 4238 is sized, shaped, positioned, oriented, or otherwise configured to engage the fixed clutch disc 4142. The rotating clutch disc 4238 includes an upper surface (unnumbered) and a lower surface (unnumbered). The upper surface of the rotating clutch disc 4238 is sized, shaped, positioned, oriented, or otherwise configured to engage the spring housing 4236. The lower surface of the rotating clutch disc 4236 is sized, shaped, positioned, oriented, or otherwise configured to engage the fixed clutch disc 4142 to provide a force resisting rotation of the outer mandrel assembly 4200 relative to the inner mandrel assembly 4100 about the longitudinal axis 4130A.

[0137] Bearings and Support Structure The outer mandrel assembly 4200 includes several bearings and support structures, including an upper bearing 4240 , a lower bearing 4242 , a pivot bearing 4244 , a number of leaf springs 4246 A- 4248 H, and a retaining ring 4248 .

[0138] The upper and lower bearings 4240, 4242 each comprise a ball bearing disposed between the shaft 4130 and the outer mandrel body 4220. The upper and lower bearings 4240, 4242 allow rotation of the outer mandrel assembly 4200 relative to the inner mandrel assembly 4100.

[0139] The pivot bearing 4244 is disposed between the shaft 4130 and the outer mandrel body 4220. The pivot bearing 4244 allows rotation of the outer mandrel assembly 4200 relative to the inner mandrel assembly 4100. The pivot bearing 4244 also provides vertical support to the outer mandrel body 4220 relative to the shaft 4130.

[0140] The leaf springs 4246A-H are each attached to the outer surface of the outer mandrel body 4220. The leaf springs 4246A-H are arranged in pairs, perpendicular to and spaced apart around the circumference of the outer mandrel body 4220. This exemplary embodiment includes eight leaf springs, although more or less than eight leaf springs can be used. Additionally, other types of springs can be used. The leaf springs 4246A-H urge the film roll outward against the inner surface of the film roll and rotatably secure the film roll to the outer mandrel body 4220.

[0141] The retaining ring 4248 is sized, shaped, positioned, oriented, and otherwise configured to engage the lower bearing 4242 and secure the lower bearing 4242 in place relative to the outer mandrel body 4220.

[0142] The inner mandrel assembly 4100 and the outer mandrel assembly 4200 together provide a rotational force to the film of the film roll, allowing the film to be applied to the coil and wrapped around the coil under a relatively constant tension (or tension within a specified range).

[0143] The spring housing 4236 is rotatably fixed to a rotational clutch disc 4238, which ensures that the spring housing 4236 (and the second end of the tension spring 4234 attached thereto) rotates with the rotational clutch disc 4238. A first end of the tension spring 4234 is fixed to a rotational stop 4232, which is positioned within a rotational stop slot 4226 of the outer mandrel housing 4220, such that the first end of the tension spring 4234, the rotational stop 4232, and the outer mandrel housing 4220 are rotatably fixed to one another.

[0144] Thus, there are three distinct groups of components that are rotatably fixed to other components within their respective groups: (1) the inner mandrel assembly 4100, which is rotatably holdable by the upper and lower mandrel jaws 5210, 5250 of the mandrel gripper 5000, (2) the rotating clutch disk 4238 and spring housing 4236, and (3) the remaining components of the outer mandrel assembly 4200. There are also three bearings respectively connected to two of these three groups, including (1) an upper bearing 4240 disposed between the shaft 4130 and the outer mandrel body 4220 of the inner mandrel assembly 4100, (2) a lower bearing 4242 disposed between the shaft 4130 and the outer mandrel body 4220 of the inner mandrel assembly 4100, and (3) a pivot bearing 4244 disposed between the spring housing 4236 and the outer mandrel body 4210.

[0145] Figures 4H, 4I, 4J, 4K, and 4L show cross sections of the rotational stop 4232, tension spring 4234, and spring housing 4236. Figures 4H, 4I, 4J, 4K, and 4L show the positions of these parts at rest and during the process of wrapping the film around the coil.

[0146] FIGURE 4H illustrates the rotation stop 4232, tension spring 4234, and spring housing 4236 in a stationary state. A film roll can be attached to a mandrel in this stationary state. No external rotational forces are applied. In this state, the spring housing 4236 is held in place and prevented from rotating by the rotation clutch disc 4238. The tension spring 4234 is in equilibrium and presses the rotation stop 4232 into a stationary position as shown in FIGURE 4H.

[0147] Figure 4I shows the position of the rotation stop 4232 after it has rotated counterclockwise. The counterclockwise rotation of the rotation stop 4232 is caused by the film being pulled away from the film roll as it is wrapped around the coil. As seen in Figure 4I, the spring housing 4236 remains stationary, but the tension spring 4234 and rotation stop 4232 extend and move counterclockwise in response to an external torque.

[0148] 4J shows the position of the rotational stop 4232 as the external torque continues to be applied. The rotational stop 4232 reaches the end of the spring housing 4236, causing the movement of the rotational stop 4232 to stop. The spring housing 4236 is still held stationary by the rotational clutch disc 4238.

[0149] 4K illustrates the positions of the rotational stopper 4232, tension spring 4234, and spring housing 4236 as external torque continues to be applied after the rotational stopper 4232 reaches the end of the spring housing 4236. The spring housing 4236 begins to rotate counterclockwise. The rotational stopper 4232 remains in contact with the end of the spring housing 4236, and the tension spring 4234 remains fully tensioned. Instead of continuing to tension the rotational stopper 4232 and tension spring 4234, the external torque causes the spring housing 4236, tension spring 4234, and rotational stopper 4232 to all rotate counterclockwise at the same time.

[0150] During the coil wrapping process, the positioning of the film roll relative to the coil follows a path that creates inconsistent forces on the film roll. For example, as the film roll moves from wrapping around the outside of the coil to wrapping around the surface that forms the eye of the coil, the path of travel of the film roll creates slack in the film that is pulled from the film roll. To ensure that a consistent tension is applied to the film roll, the mandrel is configured to rotate clockwise (i.e., rotate in the opposite direction to the direction that the film is pulled from the film roll) to rewind the slack film.

[0151] Figure 4L shows the positions of the rotation stop 4232, tension spring 4234, and spring housing 4236 after the external torque has decreased and the film has slackened. The spring housing 4236 remains in the same position as shown in Figure 4K, held in place by the rotation clutch disc 4238. The tension spring 4234 pulls on the rotation stop 4232 in a clockwise direction. The clockwise rotation of the rotation stop 4232 also causes the outer mandrel body 4220 to rotate in a clockwise direction, thereby rewinding the slack film onto the film roll.

[0152] In this example, the tension spring 4234 has a spring constant that results in a threshold force that must be overcome to extend the tension spring. The rotating clutch disc 4238 also has a threshold torque that must be applied to rotate the spring housing 4236. In this example, the torque of the rotating clutch disc is greater than the spring force. As a result, the external torque caused by the film being pulled away from the film roll first overcomes the spring force and extends the spring, and then overcomes the torque of the rotating clutch disc 4238 and rotates the spring housing 4236.

[0153] In a particular example, the travel of the tension spring 4234 is approximately 90-100 degrees of rotation about the spring housing 4236. This rotation allows for approximately 90-100 degrees of clockwise rotation (i.e., a 90-100 degree rewind to place the slack film back onto the film roll).

[0154] Mandrel gripping part Each mandrel gripper 5000 is connected to a respective frame of a respective applicator arm (such as frame 132 of applicator arm 130) and is configured to hold and release a mandrel, such as mandrel 4000 described above, onto which a film roll is attached. The grippers may alternatively be configured in accordance with the present disclosure.

[0155] Figures 5A, 5C, and 5D illustrate a mandrel gripper 5000 of one exemplary embodiment of the present disclosure configured to receive, hold, and release a mandrel, such as mandrel 4000. Figure 6 illustrates the transfer of mandrel 4000 (and the film roll thereon) from a first mandrel gripper 5000 to a second mandrel gripper 5000, as described further below.

[0156] Mandrel gripper 5000 includes a base 5100, an actuator 5130 attached to base 5100, and a mandrel engager 5200. Base 5100 is sized, shaped, positioned, oriented, and otherwise configured such that the applicator arms can be connected to their respective frames to move mandrel gripper 5000 as needed to perform the various functions described herein. Mandrel engager 5200 includes upper mandrel jaws 5210 and lower mandrel jaws 5250 which cooperate under the control of a controller to grip a mandrel, such as mandrel 4000 described above.

[0157] More specifically, the base 5100 includes an arm connecting bracket 5110 .

[0158] The arm connecting bracket 5110 comprises a first side panel 5112, a second side panel 5114, and a center panel 5116. The first side panel 5112 and the second side panel 5114 are each sized, shaped, positioned, oriented, and otherwise configured to connect to a respective frame of a respective applicator arm that moves the mandrel gripper 5000. The first side panel 5112 and the second side panel 5114 are parallel to each other and are also connected to the center panel 5116.

[0159] The center panel 5116 defines an upper mandrel claw opening 5118, a lower mandrel claw opening 5120, and includes an upper mandrel claw track 5122 and a lower mandrel claw track 5124. The upper mandrel claw opening 5118 and the lower mandrel claw opening 5120 are elongate openings that extend in the direction of movement of the upper mandrel claw 5210 and the lower mandrel claw 5250, respectively, during operation. The upper mandrel claw opening 5118 and the lower mandrel claw opening 5120 allow a portion of the upper mandrel claw 5210 and the lower mandrel claw 5250, respectively, to pass therethrough for operative connection to an actuator 5130, as described below. The upper mandrel claw track 5122 and the lower mandrel claw track 5124 are disposed above and below the upper mandrel claw opening 5118 and the lower mandrel claw opening 5120, respectively, as best shown in FIG. 5A. The upper mandrel jaw track 5122 is sized, shaped, positioned, oriented, or otherwise configured to engage with the track-engaging support member 5216 of the upper mandrel jaw 5210. Similarly, the lower mandrel jaw track 5124 is sized, shaped, positioned, oriented, or otherwise configured to engage with the track-engaging support member of the lower mandrel jaw 5250.

[0160] In the illustrated view, the actuator 5130 is attached to the base 5100 and is located between the first side panel 5112 and the second side panel 5114 on the opposite side of the center panel 5116 from the mandrel engager 5200. Alternatively, the actuator 5130 can be attached to the applicator arm or another component. The actuator 5130 operably engages and enables movement of the upper mandrel claw 5210 and the lower mandrel claw 5250. The actuator 5130 enables the upper mandrel claw 5210 and the lower mandrel claw 5250 to maintain a centered positioning in the erect orientation such that the vertical center point between the upper mandrel claw 5210 and the lower mandrel claw 5250 remains constant. The actuator 5130 enables mirrored movement of the upper mandrel claw 5210 and the lower mandrel claw 5250 such that the claws move away from or towards each other.

[0161] The upper mandrel jaws 5210 and the lower mandrel jaws 5250 are similar or identical mirror images of one another, and therefore, only the upper mandrel jaws 5210 will be described in detail herein for the sake of brevity.

[0162] The upper mandrel claw 5210 includes an actuator engaging arm 5212 , a vertical support bracket 5214 , a track engaging support member 5216 , and a lateral mandrel engaging member 5218 .

[0163] The actuator engagement arm 5212 is sized, shaped, positioned, oriented, or otherwise configured to extend through the upper mandrel jaw opening 5118 and engage the actuator 5130 at a first end of the actuator engagement arm 5212. A second end of the actuator engagement arm 5212 is connected to a vertical support bracket 5214. The vertical support bracket 5214 is connected at a first end to the actuator engagement arm 5212. The vertical support bracket 5214 extends upwardly and is connected at a second end to a track engagement support member 5216.

[0164] The track-engaging support members 5216 are sized, shaped, positioned, oriented, or otherwise configured to engage the upper mandrel jaw tracks 5122 and together provide lateral support to the upper mandrel jaws 5210. The track-engaging support members 5216 and the upper mandrel jaw tracks 5122 also allow for smooth vertical movement of the upper mandrel jaws 5210. The track-engaging support members 5216 are also connected to lateral mandrel engaging members 5218.

[0165] The lateral mandrel engaging member 5218 includes a first finger 5220, a second finger 5222, a finger connecting bar 5224, and a U-shaped mandrel engager 5230. The first finger 5220 and the second finger 5222 are shaped and sized to engage one of the outer handle block 4120 or the inner handle block 5124 of the mandrel 4000. The finger connecting bar 5224 extends between and connects the first finger 220 and the second finger 5222.

[0166] A U-shaped mandrel engager 5230 extends inwardly from the first finger 5220 and the second finger 5222. The U-shaped mandrel engager 5230 is positioned such that the open end of the U faces away from the base 5100. The U-shaped mandrel engager includes a mandrel facing surface 5232, a first handle lock catch 5234, and a second handle lock catch 5236. The mandrel facing surface 5232 extends along the inside of the U-shaped mandrel engager 5230 and is sized, shaped, positioned, oriented, or otherwise configured to engage the outer handle cylinder 4118 or the inner handle cylinder 4122 of the mandrel 4000. The first and second handle lock catches 5234, 5236 are located on the underside of the U-shaped mandrel engager 5230 adjacent the first and second fingers 5220, 5222, respectively. Both the first and second handle lock catches 5234, 5236 are sized, shaped, positioned, oriented, and otherwise configured to engage / receive either the outer handle block 4120 or the inner handle block 4124 when the mandrel 4000 is positioned to be held by the gripper 5000.

[0167] To move the top mandrel claw 5210 and the bottom mandrel claw 5250, the actuator 5130 actuates both claws simultaneously and in opposite directions. To move the claws apart, the actuator is actuated in a first direction, moving the top mandrel claw 5210 upward and simultaneously moving the bottom mandrel claw 5250 downward. To move the claws together, the actuator is actuated in a second direction opposite the first direction, moving the top mandrel claw 5210 downward and simultaneously moving the bottom mandrel claw 5250 upward. The actuator can include a piston or other mechanism configured to move the claws as shown herein.

[0168] Mandrel gripper operation When the gripper 5000 is operated, the upper mandrel jaws 5210 and the lower mandrel jaws 5250 are sized, shaped, positioned, oriented, and otherwise configured to engage the upper and lower handles 4116, 4156, respectively, of the mandrel 4000. As described above, the upper and lower handles 4116, 4156 each include an inner handle block and an outer handle block. Each mandrel jaw can engage one of two handle blocks at a time (i.e., either the inner handle block or the outer handle block). Thus, there are several combinations of engagement of the upper and lower mandrel jaws 5210, 5250 with the handle blocks of the mandrel 4000. These combinations include (i) an upper mandrel claw 5210 that engages with the outer handle block 4120 and a lower mandrel claw 5250 that engages with a corresponding outer handle block of the lower handle 4156, (ii) an upper mandrel claw 5210 that engages with the inner handle block 4124 and a lower mandrel claw 5250 that engages with a corresponding inner handle block of the lower handle 4156, (iii) a lower mandrel claw 5210 that engages with the outer handle block 4120 and a lower mandrel claw 5250 that engages with the inner handle block of the lower handle 4156, and (iv) an upper mandrel claw 5210 that engages with the inner handle block 4124 and a lower mandrel claw 5250 that engages with the outer handle block of the lower handle 4156.

[0169] The mandrel gripper 5000 thus allows for a number of operations to be performed, including receiving a mandrel 4000 and a film roll mounted thereon, transferring the mandrel and the film roll thereon to another mandrel gripper 5000, and removing the mandrel and film roll from the mandrel gripper 5000.

[0170] More specifically, each of the combinations of engagement between the upper mandrel claws 5210 and the lower mandrel claws 5250 and the outer handle block and the inner handle block of the mandrel can occur, but for simplicity, only the engagement of the upper mandrel claws 5210 and the lower mandrel claws 5250 with the respective outer handle blocks of the mandrel 4000 is described below.

[0171] As an initial step, the actuator 5130 is actuated by the controller, thereby moving the upper mandrel jaws 5210 and the lower mandrel jaws 5250 apart in opposite directions.

[0172] The mandrel gripper 5000 is moved into position relative to the mandrel 4000 such that the upper and lower handles 4116, 4156 of the mandrel 4000 are positioned between the first and second fingers of the upper and lower mandrel jaws 5210, 5250, respectively.

[0173] The mandrel-facing surface 5232 of the U-shaped mandrel engager 5230 of the upper mandrel claw 5210 is sized, shaped, positioned, oriented, and otherwise configured to engage with the outer handle cylinder 4118 of the upper handle 4116, resulting in mirror image engagement between the corresponding U-shaped mandrel engager of the lower mandrel claw 5250 and the outer handle cylinder of the lower handle 4156.

[0174] The actuator 5130 is again actuated by the controller, causing the upper and lower mandrel jaws 5210, 5250 to move towards each other. Movement of the upper and lower mandrel jaws 5210, 5250 continues until the first and second handle lock catches 5234, 5236 of the upper mandrel jaws 5210 receive and engage the outer handle block 4120 of the upper handle 4116. On the lower side, a similar engagement occurs between the first and second handle lock catches of the lower mandrel jaws 5250 and the outer handle block of the lower handle 4156.

[0175] The mandrel 4000 is then locked into the mandrel gripper 5000. The first handle lock catch 5234 and the second handle lock catch 5236 engage with an outer surface of the outer handle block 4120 (e.g., the surface facing away from the gripper 5000), thereby preventing the claws from moving away from each other and preventing the mandrel 4000 and the film roll thereon from being removed from the mandrel gripper 5000. The tolerances and geometry of the first handle lock catch 5234, the second handle lock catch 5236 and the handle of the mandrel 4000 located therebetween prevent rotation of the handle of the mandrel 4000, prevent rotation of the inner mandrel assembly 4100 of the mandrel 4000 (by preventing rotation of the handle), and prevent the mandrel 4000 from pivoting or tilting during operation.

[0176] Each combination of engagement between the upper and lower mandrel jaws 5210, 5250 and the outer and inner handle blocks of the mandrel can occur, but for simplicity, only the movement of the mandrel from a first mandrel gripping portion engaged with the respective outer handle block to a second mandrel gripping portion engaged with the respective inner handle block will be described with respect to FIG. 6.

[0177] Initially, the first mandrel gripper 5000F engages with the respective outer handle blocks of the upper handle 4116 and the lower handle 4156 of the mandrel 4000. At this point, the mandrel gripper 5000 has sole control over the mandrel 4000.

[0178] Next, the actuator of the second mandrel gripping portion 5000S is operated by the control device CR to separate the upper mandrel claw and the lower mandrel claw, which are appropriately spaced apart to engage with the inner handle block of the mandrel 4000.

[0179] The second mandrel gripper 5000S is moved to a position around the mandrel 4000 so that the upper handle 4116 and the lower handle 4156 of the mandrel 4000 are respectively positioned between the first and second fingers of the upper mandrel jaw 5210 and the lower mandrel jaw 5250 of the second mandrel gripper 5000S.

[0180] The mandrel-facing surface 5232 of the upper mandrel jaw of the second mandrel gripping portion 5000S engages the inner handle cylinder 4122 of the mandrel 4000, resulting in a mirror image engagement of the U-shaped mandrel engager of the lower mandrel jaw of the second mandrel gripping portion 5000S with the inner handle cylinder of the lower handle 4156.

[0181] The actuator of the second mandrel gripper 5000S is then activated by the controller CR, causing the upper and lower mandrel jaws of the second mandrel gripper 5000S to move towards each other until both the first and second handle lock catches of the upper mandrel jaw of the second mandrel gripper 5000S engage with the inner handle block 4120 of the top handle 4116 and the first and second handle lock catches of the lower mandrel jaw of the second mandrel gripper 5000S engage with the inner handle block 4156 of the bottom handle 4156. The first handle lock catch and the second handle lock catch of the gripper engage with the inner handle block 4120 to lock the mandrel in place on the second mandrel gripper 5000S.

[0182] At this point in the transfer process, both the first mandrel gripper 5000F and the second mandrel gripper 5000S are engaged with the mandrel holding the film roll. To complete the transfer to the second mandrel gripper 5000S, the actuator of the first mandrel gripper 5000F is then activated by the controller CR, moving the upper and lower mandrel jaws of the first mandrel gripper 5000F out of engagement with the outer handle block of the mandrel 4000. The second mandrel gripper 5000S then has sole control of the mandrel 4000.

[0183] Sensors The coil wrapping system 20 includes a number of sensors S configured to sense various conditions of the coil wrapping system 20, the positions of components of the coil wrapping system 20, and the amount of film remaining on each film roll held by the gripper of the applicator arm. The sensors S are communicatively connected to a controller CR. The sensors S may be any suitable sensor.

[0184] Operator Interface The coil wrapping system 20 includes an operator interface OI configured to receive input from an operator and, in certain embodiments, output information to the operator. The operator interface OI includes one or more input devices configured to receive input from the operator. In various embodiments, the one or more input devices include one or more buttons (such as hard or soft keys), one or more switches, and / or a touch panel. In various embodiments, the operator interface OI includes a display device configured to display information to the operator, such as information about the coil, the status of the wrapping operation, or settings of the coil wrapping system 200. The operator interface may include other output devices, such as one or more speakers and / or one or more light sources instead of or in addition to the display device. In certain embodiments, the operator interface is formed as part of the coil wrapping system 20, e.g., attached to the mechanical frame 60. In other embodiments, the operator interface is separate from the mechanical frame 60.

[0185] Control device The coil wrapping system 20 includes a controller CR that includes a processing device communicatively coupled to a memory device. The processing device may include any suitable processing device, such as, but not limited to, a general purpose processor, a special purpose processor, a digital signal processor, one or more microprocessors, one or more microprocessors associated with a digital signal processor core, one or more application specific integrated circuits, one or more field programmable gate array circuits, one or more integrated circuits, and / or a state machine. The memory device may include any suitable memory device, such as, but not limited to, a read only memory, a random access memory, one or more digital registers, a cache memory, one or more semiconductor memory devices, a magnetic medium such as an integrated hard disk and / or a removable memory, a magneto-optical medium, and / or an optical medium. The memory device stores instructions executable by the processor to control the operation of the coil wrapping system 10 (e.g., to perform the coil moving process, the coil rotating process, the carriage moving process, the film supply roll loading process, the coil wrapping process, and the film roll unloading described herein). The control device CR is communicatively and operably connected to the operator interface OI, the multiple sensors S, the actuators that move the first wrapping carriage 100 and its components, the second wrapping carriage 300 and its components, the coil rotator 500, the first replacement film roll holder 600, the first empty film roll holder 800, components of the first replacement film roll supply body 900, components of the first empty film roll remover body 1000, the second replacement film roll holder 1600, the second empty film roll holder 1800, components of the second film roll supply body 1900, components of the second empty film roll remover body 2000, and the feed and unfeed coil movers 550 and 560.

Claims

1. 1. A coil wrapping apparatus comprising: A mechanical frame; a first wrapper supported by a mechanical frame; a second wrapper supported by the mechanical frame and opposed to the first wrapper, the second wrapper defining a coil wrapping region between the second wrapper and the first wrapper; and a controller operatively connected to the first and second wrappers and configured to simultaneously use the first and second wrappers to simultaneously wrap first and second films from first and second film rolls onto a coil disposed within the coil wrapping area while the coil rotates about a longitudinal axis of the coil.

2. 2. The coil wrapping apparatus of claim 1, wherein the first wrapper is vertically movable relative to the mechanical frame to a raised position such that the coil can be moved beneath the first wrapper into the coil wrapping area.

3. 2. The coil wrapping apparatus of claim 1, wherein the second wrapper is vertically movable relative to the mechanical frame to a raised position such that after the coil is wrapped, the coil can move under the second wrapper and out of the coil wrapping area.

4. the first wrapper includes first and second applicator arms; the second wrapper includes third and fourth applicator arms; The controller is operatively connected to the first, second, third, and fourth applicator arms, and the first and fourth applicator arms rotate the coil about its longitudinal axis while moving the first roll of film through the eye of the coil and around the outer surface of the coil in a plurality of loops to wrap the first film around the coil; 2. The coil wrapping apparatus of claim 1, wherein the second and third applicator arms move the second roll of film through the eye of the coil and around the outer surface of the coil in a plurality of loops while the coil rotates about its longitudinal axis to wrap the second film around the coil.

5. 5. The coil wrapping apparatus of claim 4, wherein each loop of the first roll of film comprises a generally rectangular path and each loop of the second roll of film comprises a generally rectangular path.

6. 6. The coil wrapping apparatus of claim 5, wherein when one of the first and second film rolls is inside the eye of the coil, the other of the first and second film rolls is outside the eye of the coil.

7. The coil wrapping apparatus of claim 4 , wherein the control device is configured such that the first and second wrappers longitudinally move the first and second film rolls together during wrapping.

8. 5. The coil wrapping apparatus of claim 4, wherein the control device is configured such that the first and second wrappers move the first and second film rolls during wrapping such that the lateral spacing of both film rolls is substantially the same.

9. The coil wrapping apparatus of claim 8 , wherein the control device is configured such that the first and second wrappers move the first and second film rolls together longitudinally during wrapping.

10. the controller operates the first and fourth applicator arms during one of the loops of the first film roll; while the first applicator arm holds the first roll of film and the first and fourth applicator arms are generally aligned with the longitudinal axis of the coil, moving the first and fourth applicator arms into the eye of the coil and toward each other to apply the first film to a portion of the inner surface of the coil; transferring the first roll of film within the eye of the coil to a fourth applicator arm; moving the first and fourth applicator arms away from each other and out of the eye of the coil to apply the first film to another portion of the inner surface of the coil; moving the first and fourth applicator arms laterally to apply a first film to a portion of a first side of the coil; moving the first and fourth applicator arms toward each other to apply a first film to a portion of an exterior surface of the coil; transferring a first roll of film to a first applicator arm; 5. The coil wrapping apparatus of claim 4, configured to move the first and fourth applicator arms away from each other to apply the first film to another portion of the outer surface of the coil, and move the first and fourth applicator arms laterally to generally align the first and fourth applicator arms with a longitudinal axis of the coil to apply the first film to a portion of a second side of the coil.

11. the control device moves the second and third applicator arms during one loop of the second roll of film; a second applicator arm holding a second roll of film, and moving the second and third applicator arms toward each other while the second and third applicator arms are spaced laterally from the longitudinal axis of the coil to apply the second film to a portion of the outer surface of the coil; transferring a second roll of film to a third applicator arm; moving the second and third applicator arms away from each other to apply a second film to another portion of the exterior surface of the coil; moving the second and third applicator arms laterally until the second and third applicator arms are generally aligned with a longitudinal axis of the coil to apply the second film to a portion of the first side of the coil; moving second and third applicator arms into the eye of the coil and toward each other to apply a second film to a portion of the inner surface of the coil; transferring a second roll of film to a second applicator arm within the eye of the coil; moving the second and third applicator arms away from each other and out of the eye of the coil to apply a second film to another portion of the inner surface of the coil; The coil wrapping apparatus of claim 10 configured to move the second and third applicator arms laterally to apply the second film to a portion of the second side of the coil.

12. 2. The coil wrapping apparatus of claim 1, further comprising a coil rotator positioned within the coil wrapping region, the controller operatively connected to the coil rotator, the coil rotator configured to rotate the coil about its longitudinal axis.

13. 1. A method of wrapping a coil with a first film from a first roll of film and a second film from a second roll of film, the method comprising: rotating the coil about its longitudinal axis; simultaneously winding the first and second films onto the coil using first and second film rolls simultaneously while the coil is rotating about its longitudinal axis; moving a first roll of film through the eye of the coil and around an exterior surface of the coil in multiple loops to wrap the first film around the coil; The method includes moving a second roll of film through the eye of the coil and around the exterior surface of the coil in multiple loops to wrap the second film around the coil.

14. 14. The method of claim 13, wherein each loop of the first roll of film comprises a generally rectangular path and each loop of the second roll of film comprises a generally rectangular path.

15. A film roll changing system for a coil wrapping machine, comprising: a first replacement film roll holder; a first empty film roll holder; A first film roll supplier; a first empty film roll remover; a second replacement film roll holder; a second empty film roll holder; A second film roll supplier; a second empty film roll remover.

16. a first replacement film roll holder track, the first replacement film roll holder being movable on the first replacement film roll holder track; a first empty film roll holder track, the first empty film roll holder being movable on the first empty film roll holder track; a first replacement film roll holder track, the second replacement film roll holder being movable on the second replacement film roll holder track; 16. The film roll changing system of claim 15, further comprising: a second empty film roll holder track, the second empty film roll holder being movable on the second empty film roll holder track.

17. A mandrel having an inner mandrel assembly, the inner mandrel assembly comprising: an upper handle assembly graspable by the mandrel gripper; a lower handle assembly graspable by the mandrel gripper; a shaft coupled to the upper and lower handle assemblies; an inner rotating assembly including a fixed clutch disc; an outer mandrel assembly rotatable relative to the inner mandrel assembly, the outer mandrel assembly comprising: an outer mandrel body engageable with a film roll; a film roll holding assembly attached to the outer mandrel body to secure the film roll to the outer mandrel body; an outer rotating assembly having a rotating clutch disc engageable with the inner rotating assembly; and one or more bearings arranged to allow the outer mandrel assembly to rotate relative to the inner mandrel assembly.

18. The mandrel of claim 17 , wherein an upper handle assembly and a lower handle assembly are rotatably fixed relative to the shaft and relative to each other.

19. 20. The mandrel of claim 18, wherein the upper handle assembly includes an upper handle having (1) an outer handle cylinder, (2) an outer handle block, (3) an inner handle cylinder, and (4) an inner handle block.

20. 20. The mandrel of claim 19, wherein the outer handle block and the inner handle block of the upper handle are engageable by mandrel gripper fingers to prevent rotation of the upper handle assembly.

21. 18. The mandrel of claim 17, wherein the shaft comprises: (1) an upper portion having a first diameter; (2) a central portion having a second diameter; and (3) a lower portion having a third diameter, a first transition between the upper portion and the central portion defining an upper shelf engageable by the upper handle assembly, and a second transition between the central portion and the lower portion defining a lower shelf engageable by the lower handle assembly.

22. The mandrel of claim 17 , wherein the inner rotating assembly is rotatably fixed to the shaft, the upper handle assembly, and the lower handle assembly.

23. 20. The mandrel of claim 17, wherein the inner rotating assembly further comprises: (1) a disc abutment plate configured to engage the stationary clutch disc; and (2) a pair of disc springs configured to apply a force to the disc abutment plate.

24. The mandrel of claim 17 , wherein the outer mandrel assembly further comprises a plurality of leaf springs attached to the outer mandrel body and configured to engage the film roll.

25. 20. The mandrel of claim 17, wherein the film roll retaining assembly comprises a retaining core configured to pivot between a first position that allows a film roll to be added or removed from the mandrel and a second position that locks the film roll to the mandrel.

26. 18. The mandrel of claim 17, wherein the outer rotating assembly comprises: (1) the rotating clutch disk engaged to the inner rotating assembly; (2) a spring housing secured to the rotating clutch disk; (3) a rotation stop engaged to the outer mandrel body; and (4) a tension spring secured at a first end to the spring housing and at a second end to the rotation stop.

27. 27. The mandrel of claim 26, wherein the spring housing and tension spring allow the rotation stop to rotate approximately 90-100 degrees about the spring housing.

28. A mandrel gripping portion, a base attachable to the applicator arm; an actuator attached to the base and actuated by a controller; A mandrel gripper having a mandrel engager movable by the actuator and adapted to mate with upper and lower handles of the mandrel.

29. 30. The mandrel of claim 28, wherein the base includes an arm connecting bracket with a first side panel, a second side panel, and a center panel connected to the first side panel and the second side panel.

30. 30. The mandrel of claim 28, wherein the mandrel engagers comprise upper and lower mandrel claws.

31. 30. The mandrel of claim 28, wherein the center panel defines an upper mandrel jaw opening and a lower mandrel jaw opening.

32. 30. The mandrel of claim 28, wherein the center panel further comprises an upper mandrel claw track and a lower mandrel claw track.

33. 30. The mandrel of claim 28, wherein the upper and lower mandrel claws engage the upper and lower mandrel claw tracks.

34. 30. The mandrel of claim 28, wherein the actuator is configured to move both the upper mandrel jaw and the lower mandrel jaw simultaneously in opposite directions.

35. 30. The mandrel of claim 28, wherein the upper mandrel claw comprises an actuator engaging arm, a vertical support bracket, a track engaging support member, and a lateral mandrel engaging member.

36. 36. The mandrel of claim 35, wherein the lateral mandrel engagement members comprise: (1) a first finger, (2) a second finger, (3) a finger connecting bar connecting the first finger to the second finger, and (4) a U-shaped mandrel engager.

37. 37. The mandrel of claim 36, wherein the U-shaped mandrel engager comprises a mandrel facing surface, a first handle locking catch configured to engage a handle of the mandrel to prevent rotation of the handle, and a second handle locking catch configured to engage a handle of the mandrel to prevent rotation of the handle.

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