System and method for wrapping coils

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 Art

[0002] Many steel manufacturers produce relatively large coiled steel sheets or strips, which they use or ship to customers for further processing. FIG. 1 shows an example of such a coil C. The coil C has a cylindrical outer surface OS, a relatively flat annular first side surface SS1, a relatively flat annular second side surface SS2 opposite the first side surface SS1, and a cylindrical inner surface IS extending between the side surfaces SS1 and SS2. The cylindrical inner surface IS is herein referred to as the "eye" E of the coil C and defines a cylindrical central opening extending between the opposing side surfaces SS1 and SS2. The 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 around the outer surface OS of the coil C so as to engage the inner surface IS and the outer surface OS of the coil C through the eye E. These straps prevent the coil from unwinding, but they do not protect the coil from the elements or damage during transport. If the customer desires this additional protection, the manufacturer will typically wrap the coil in plastic stretch film. For this purpose, the manufacturer will usually install one of several known coil wrapping systems on the production line. All of these known systems use a single roll of plastic stretch film to wrap the coil. While each of these known systems differs, they typically involve passing the film roll through the eyes of the coil and repeatedly looping it around the outside of the coil while the coil rotates along its longitudinal axis. These wrapping processes are relatively slow, and sometimes an operator will need to replace the empty film roll with a replacement film roll during the coil wrapping process. [Overview of the project] [Means for solving the problem]

[0004] Various embodiments of this disclosure provide a coil wrapping system and method for simultaneously winding separate films (such as plastic films) onto a coil using multiple separate film rolls while rotating the coil around its longitudinal axis.

[0005] Various embodiments of this disclosure provide mandrels for film rolls that assist in maintaining tension on the film before, during, and after the wrapping process by a coil wrapping system.

[0006] Various embodiments of the present disclosure provide a mandrel and a mandrel gripping unit for receiving, holding, and releasing a film roll attached to the mandrel.

[0007] Various embodiments of this disclosure provide a film roll changing system and related methods for automatically replacing an empty film roll with a new film roll. [Brief explanation of the drawing]

[0008] [Figure 1] This is a perspective view of an example of a coil that can be wrapped by the coil wrapping system of this disclosure. [Figure 1A] This is a top perspective view of a coil wrapping system, including a coil wrapping device and a film replacement system, according to one embodiment of the present disclosure. [Figure 1B] Figure 1A shows the coil wrapping system and another top perspective view of the coil positioned with respect to the coil wrapping system. [Figure 1C] Figure 1A is an end perspective view of the coil wrapping system. [Figure 1D] Figure 1A is a perspective view of the top of the coil wrapping device. [Figure 1E] Figure 1A is a top perspective view of the coil wrapping device. [Figure 1F] Figure 1A is a bottom perspective view of the first wrapper of the coil wrapping system. [Figure 1G] Figure 1F is a top perspective view of the first applicator arm of the first wrapper. [Figure 1H] Figure 1A is a perspective view of the second wrapper, the cutting, clamping, and splicing system of the second wrapper, and the tip holder of the second wrapper of the coil wrapping apparatus. [Figure 1I] Figure 1H is a rear perspective view of the cutting, clamping, and joining system of the second wrapper. [Figure 1J] Figure 1A is a rear perspective view of the second wrapper of the coil wrapping device and the cutting, clamping, and joining system of the second wrapper that engages with the coil. [Figure 1K] Figure 1A is a rear perspective view of the cutting, clamping, and joining system of the second wrapper of the coil wrapping apparatus. [Figure 1L] Figure 1A is a block diagram showing specific components of the coil wrapping system. [Figure 1M]Figure 1A shows the positions of the coil and film roll, as well as a side view of the leading edge of the film roll, at the start of the coil wrapping process by the coil wrapping device of the coil wrapping system. [Figure 1NA] This figure shows the coil (cross-section) being wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping apparatus of the coil wrapping system shown in Figure 1A during the wrapping process. [Figure 1NB] This figure shows the coil (cross-section) being wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping apparatus of the coil wrapping system shown in Figure 1A during the wrapping process. [Figure 1NC] This figure shows the coil (cross-section) being wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping apparatus of the coil wrapping system shown in Figure 1A during the wrapping process. [Figure 1ND] This figure shows the coil (cross-section) being wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping apparatus of the coil wrapping system shown in Figure 1A during the wrapping process. [Figure 1NE] This figure shows the coil (cross-section) being wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping apparatus of the coil wrapping system shown in Figure 1A during the wrapping process. [Figure 1NF] This figure shows the coil (cross-section) being wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping apparatus of the coil wrapping system shown in Figure 1A during the wrapping process. [Figure 1NG]During the wrapping process, it is a diagram showing a coil (cross-section) wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping device of the coil wrapping system of FIG. 1A. [Figure 1NH] During the wrapping process, it is a diagram showing a coil (cross-section) wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping device of the coil wrapping system of FIG. 1A. [Figure 1NI] During the wrapping process, it is a diagram showing a coil (cross-section) wound by a film roll (shown in a simplified form) conveyed by an applicator arm (shown in a simplified form) in the coil wrapping device of the coil wrapping system of FIG. 1A. [Figure 1NJ] It is a diagram showing a completely wrapped coil. [Figure 10] It is an upper perspective view of the first wrapper and the second wrapper of the coil wrapping device of the coil wrapping system of FIG. 1A, showing the state before starting to wrap the coil located between the first wrapper and the second wrapper. [Figure 1P] It is an upper perspective view of the first wrapper and the second wrapper of the coil wrapping device 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 at their respective first film roll transfer positions. [Figure 1Q] It is an upper perspective view of the first wrapper and the second wrapper of the coil wrapping device 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 at their respective second film roll transfer positions. [Figure 2A] It is a perspective view of the first replacement film roll holder of the film replacement system of the coil wrapping system of FIG. 1A, with no replacement film roll. [Figure 2B] FIG. 2A is a perspective view of one of the exchange film roll supports of the first exchange film roll holder, without the exchange film roll. [Figure 2C] FIG. 2A is a perspective view of the first exchange film roll holder, holding the exchange film roll. [Figure 2D] FIG. 2A is an enlarged perspective view of one of the supports of the exchange film roll of the first exchange film roll holder, holding the exchange film roll. [Figure 3A] FIG. 1A is a perspective view of the first film roll feeder of the film exchange system of the coil wrapping system. [Figure 3B] FIG. 3A is a perspective view of the main part of the first film roll supply body, showing its film roll moving body. [Figure 3C] FIG. 3A is a perspective view of the main part of the first exchange film roll holder and the first film roll feeder of the film exchange system, showing the film roll moving body arranged to remove the exchange coil from the support of the first exchange film roll holder. [Figure 3D] FIG. 3A is an enlarged partial perspective view of the first exchange film roll holder and the first film roll feeder of the film exchange system, showing the film roll moving body at the initial point of the process of removing the exchange coil from the support of the first exchange film roll holder. [Figure 3E] FIG. 3A is a perspective view of the first exchange film roll holder and the first film roll feeder of the film exchange system, showing the film roll moving body at the initial point of the process of removing the exchange coil from the support of the first exchange film roll holder. [Figure 3F] FIG. 3A is an enlarged perspective view of the first exchange film roll holder and the first film roll supply body of the film exchange system, showing the film roll moving body after removing the exchange coil from the support of the first exchange film roll holder. [Figure 4A]This is a top perspective view of an example of a mandrel of the present disclosure that functions as a mounting section for a film roll. [Figure 4B] Figure 4A is a perspective view of the mandrel from below. [Figure 4C] Figure 4A is a perspective view of the top of the mandrel. [Figure 4D] Figure 4A is a perspective view of the bottom of the mandrel. [Figure 4E] Figure 4A is a partially exploded view of the mandrel. [Figure 4F] This is a cross-sectional perspective view of the mandrel in Figure 4A, cut along the line 4F-4F in Figure 4B. [Figure 4G] Figure 4A is a cross-sectional side view of the lower part of the mandrel. [Figure 4H] Figure 4A is a cross-sectional plan view of the spring housing of the mandrel at various stages of film coating. [Figure 4I] Figure 4A is a cross-sectional plan view of the spring housing of the mandrel at various stages of film coating. [Figure 4J] Figure 4A is a cross-sectional plan view of the spring housing of the mandrel at various stages of film coating. [Figure 4K] Figure 4A is a cross-sectional plan view of the spring housing of the mandrel at various stages of film coating. [Figure 4L] Figure 4A is a cross-sectional plan view of the spring housing of the mandrel at various stages of film coating. [Figure 5A] Figure 1A is an enlarged perspective view of the mandrel gripping section of the coil wrapping system. [Figure 5C] Figure 5A is a cross-sectional perspective view of a portion of the upper mandrel claw of the mandrel gripping section, which holds the film roll attached to the mandrel shown in Figure 4A, partially taken along line 5C-5C in Figure 5D. [Figure 5D] Figure 5A is a partial view of a part of the upper mandrel claw of the mandrel gripping section, which holds the film roll mounted on the mandrel in Figure 4A. [Figure 6]Figure 1 is a diagram of the two mandrel gripping sections of the coil wrapping system, showing a film roll mounted on a mandrel being transferred from one mandrel gripping section to the other. [Modes for carrying out the invention]

[0009] The systems, apparatus and methods described herein may be implemented in various forms, but the drawings illustrate specific exemplary and non-limiting embodiments. Not all components shown in the drawings and described in the specification are required, and a particular implementation may include additional, different, or fewer components. Modifications to the arrangement and type of components, the shape, size, and material of components, and the manner of connection of components may be made without departing from the spirit or scope of the claims. Unless otherwise indicated, any orientation referred to herein reflects the orientation of the components shown in the corresponding drawings and does not limit the scope of this disclosure. Furthermore, terms referring to mounting methods, such as mounting, connection, etc., should be interpreted broadly to include indirect and operable mounting, connection, and similar mounting methods, not limited to direct mounting methods. This specification is intended to be interpreted as a whole and understood by those skilled in the art in accordance with the principles of this disclosure.

[0010] Coil wrapping system Various embodiments of the present disclosure provide a coil wrapping system that wraps a coil (such as the above-mentioned coil C) with film by moving a plurality of film rolls simultaneously through an eye E around the outer surface OS of the coil C, while rotating the coil C around its longitudinal axis LA. Figures 1A, 1B, 1C, and 1L show an example of a coil wrapping system 20 and its components. The coil wrapping system 20 includes a coil wrapping device 30 for winding a coil such as coil C (described above), a supply and delivery coil moving body (not shown) for moving the coils to the coil wrapping device 30 for winding and then moving the coils out of the coil wrapping device 30, a coil rotating body 500 for supporting and rotating each coil around its longitudinal axis during winding, a film roll exchange system 50 for receiving empty film rolls from the coil wrapping device 30 and supplying new film rolls to the coil wrapping device 30, a plurality of sensors S, an operator interface OI, and a control device CR. For the purposes of this disclosure, an empty film roll can be a completely empty film roll (no film remaining) or an approximately empty film roll (such as a film roll with an insufficient amount of film to wrap the next coil).

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

[0012] Coil wrapping device Figures 1A, 1B, 1C, 1D, 1E, and 1L show a coil wrapping device 30 and its components configured to simultaneously wrap each coil C with multiple film rolls (film rolls FR1 and FR2, etc.). The coil wrapping device 30 includes a mechanical frame 60, a first wrapper 100 slidably mounted on 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 on 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 rotating body, feeding and discharging coil moving body The mechanical frame 60, as best shown in Figures 1D and 1E, is formed from a number of tubular and / or solid members and other elements (not individually referenced) that support certain elements of the coil wrapping device 30, particularly the movably supported first wrapper 100 and second wrapper 300. The mechanical frame 60 includes four spaced-apart upright legs 62, 64, 66, and 68 and four crossbars 72, 74, 76, and 78. Crossbar 72 connects leg 62 to leg 64, crossbar 74 connects leg 64 to leg 66, crossbar 76 connects leg 66 to leg 68, and crossbar 78 connects leg 68 to leg 62. The legs 62 and 64 and crossbar 72 support the first wrapper 100, including its actuator 110 and its drive system 111. Specifically, opposing vertically extending rails (not indicated) are connected to legs 62 and 64 and slidably support the opposite end of the first wrapper 100. Similarly, legs 66, 68 and the crossbar 76 support the second wrapper 300, which includes its actuator 310 and its drive system 311. Specifically, opposing vertically extending rails (not indicated) are connected to legs 66 and 68 and slidably support the second wrapper 300.

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

[0015] The illustrated mechanical frame 60 is merely an example configuration, and any suitable configuration of the mechanical frame can be adopted in accordance with this disclosure.

[0016] As best shown in Figures 1A, 1B, 1C, and 1J, the coil rotator 500 includes a coil rotator frame 510 (partially shown), two cylindrical coil engages 520 and 530 supported by the coil rotator frame 510, and one or more coil engage actuators 540 supported by the coil rotator frame 510 and operably coupled to one or both of the coil engages 520 and 530. Under the control of the control device CR, the coil rotator 500 causes the coil engage actuators 540 to rotate the coil C, positioned on the cylindrical coil engages 520 and 530, around the longitudinal axis LA of the coil C at a desired speed during the winding of the coil C.

[0017] The coil wrapping device 30 includes, or operates with, an associated coil feeder 550, which, under the control of the control device CR, moves each standby coil (such as coil CA) that requires wrapping from the outer coil feeder area below the first wrapper 100 into the inner coil wrapping area when the first wrapper 100 is in the raised position (not shown, described below), and moves onto the coil engagers 520 and 530 of the coil rotor 500, so that it is wrapped by the first and second wrappers 100 and 300. The coil wrapping device 30 also includes, or operates with, an associated delivery coil moving body 560, which, under the control of the control device CR, moves the wrapped coil from the coil rotating body 500 in the coil wrapping region below the second wrapper 300 to the outer coil delivery region when the second wrapper 300 is in a raised position (not shown, but described later) after the coil C has been wrapped. After that, the wrapped coils (such as coil CW) are transported.

[0018] The first wrapper 100 and the second wrapper 300 are supported by the mechanical frame 60, so that the first wrapper 100 and the second wrapper 300 can move vertically upward independently to their respective raised positions, and each coil can move under the wrapper (as described above) and vertically downward to its respective wrapping position. More specifically, the first wrapper 100 is slidably mounted to the mechanical frame 60 and vertically movable between a raised position adjacent to the crossbar 72 (not shown), a coil-wrapping position below the raised position (shown in Figures 1A to 1E), and a film exchange 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 rotatable body 500. When the second wrapper 300 is in the coil-wrapping position, the first wrapper 100, together with the second wrapper 300 under the control of the control device CR, is operable to wrap the coil C in the coil-wrapping region (as described later). When the first wrapper 100 is in the film exchange position, the first wrapper 100 is operable to transport an empty (or nearly empty) film roll to the film exchange device 50.

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

[0020] First carriage actuator for the first wrapper, first drive system The first carriage actuator 110 and the first drive system 111 are operably connected to the first wrapper 100, as best shown in Figures 1E and 1F, and are configured to move the first wrapper 100 relative to the mechanical frame 60 between its raised position, coil-wrapping position, and film-changing position. The first carriage actuator 110 includes an electric motor in this exemplary embodiment, but in other embodiments it may include any other suitable actuator. The first drive system 111 includes drive shafts 112a and 112b, each having one end connected to the first carriage actuator 110; spaced drive wheels 116a and 116b, each connected to the other ends of the drive shafts 112a and 112b and rotatably supported by the mechanical frame 60; spaced driven wheels 118a and 118b, each connected to the mechanical frame 60 and rotatably supported; and a drive belt 12, which is wrapped around the wheels 116a and 118a and extends between the wheels 116a and 118a. The system includes 0a, a drive belt 120b wrapped around wheels 116b and 118b and extending between wheels 116b and 118b, first carriage connectors 122a and 124a (numbered but not shown for clarity) connecting the drive belt 120a to the first end of carriage 102 of the first wrapper 100, and carriage connectors 122b and 124b (not shown for clarity) connecting the drive belt 120b to the second end of carriage 102 of the first wrapper 100. During operation, in order to raise the first wrapper 100, the first carriage actuator 110, under the control of the control device CR, simultaneously rotates the drive shafts 112a and 112b, causing the spaced upper wheels 116a and 116b to rotate, thereby causing the drive belts 120a and 120b to rotate. The rotation of the drive belts 120a and 120b causes the first carriage connectors 122a and 124a to move upward, and the carriage connectors 122b and 124b cause the first carriage 102 of the first wrapper 100 to move upward. This process is reversed to move the first carriage 102 of the first wrapper 100 downward.

[0021] First rapper The first wrapper 100, as best illustrated in Figures 1D, 1E, 1F, and 1G, comprises a first carriage 102, a first applicator arm 130 slidably mounted on the first carriage 102, and a first longitudinal and lateral arm supported by the first carriage 102, operably connected to the first applicator arm 130 via a drive system (described later), and configured to move the first applicator arm 130 longitudinally and laterally relative to the coil C on the coil rotating body 500. The system includes applicator arm actuators 150a and 150b, a second applicator arm 180 slidably mounted on a 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 later), and configured to move the second applicator arm 180 longitudinally and laterally with respect to the coil C on the coil rotating body 500.

[0022] The first rapper's first carriage As best illustrated in Figure 1F, the first carriage 102 of the wrapper 100 has a carriage frame 104 having a first end 103a, a second end 103b on the opposite side, an inner side 103c, and an outer side 103d. The carriage 102 extends laterally (with respect to the longitudinal axis LA of the coil C on the coil rotating body 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. The carriage 102 includes two spaced-apart, laterally extending tracks 106 and 108 connected to the bottom of the carriage frame 104. The first applicator arm 130 and the second applicator arm 180 are slidably connected to tracks 106 and 108, respectively, and are independently laterally movable along tracks 106 and 108, as described below.

[0023] First rapper's first applicator arm The first applicator arm 130 includes an elongated frame 132, an elongated track 134 connected to the top of the elongated frame 132, and a gripping portion 5000 (described in detail below) connected to the inner end of the elongated frame 132. The first applicator arm 130 is slidably mounted to the carriage 102 via a trolley 160. Specifically, the trolley 160 is slidably mounted to tracks 106 and 108 so that the trolley 160 can slide laterally relative to the carriage frame 104. The trolley 160 is slidably mounted to track 134, thereby allowing the first applicator arm 130 to slide longitudinally relative to 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. Under the control of the control device CR, the lateral first applicator arm actuator 150b moves the first applicator arm 130 on tracks 106 and 108 laterally (relative 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, under the control of the control device CR, the lateral first applicator arm actuator 150b moves the first applicator arm 130 laterally relative 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 central axis of the coil.

[0025] Although not shown, the first lateral applicator arm actuator 150b is similar to the second lateral applicator arm actuator 200b, which is shown in more detail in Figure 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 rotating body 500, thereby 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 in between.

[0027] More specifically, as best shown in Figure 1G, the longitudinal first applicator arm actuator 150a includes an actuator 152a controlled by a control device CR and operably connected to a trolley 160 which is slidably connected to a carriage 102, a drive pulley 154a controlled by actuator 152a, two control pulleys 155a and 156a, and a belt 158a connected to the frame 132 of the applicator arm 130. During operation, in order to move the applicator arm 130 longitudinally, the actuator 152a rotates the drive pulley 154a under the control of the control device CR to engage with the belt 158a, thereby moving the first applicator arm 130 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 the 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 the top of the elongated frame 182, and a gripping portion 5000 connected to the inner end of the elongated frame 182. The second applicator arm 180 is slidably mounted to the carriage 102 via a trolley (not shown) slidably mounted on the track (not shown), so that the trolley can slide laterally relative to the carriage frame 104. The trolley is slidably mounted on the track 184, so 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 fixed and connected to the bottom of the carriage frame 104 and supported by the carriage frame 104 of the carriage 102. Under the control of the control device CR, the lateral applicator arm actuator 200b moves the second applicator arm 180 on tracks 106 and 108 laterally relative to the coil on the coil rotating body 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 axis of rotation of the coil. In other words, under the control of the control device CR, the lateral second applicator arm actuator 200b moves the second applicator arm 180 laterally relative to the longitudinal axis of the coil and laterally relative to 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 central axis of the coil.

[0030] More specifically, as best shown in Figure 1F, the lateral second applicator arm actuator 200b includes an actuator 202b connected to the carriage frame 104 and controlled by a control device CR, a first pulley 204b connected to actuator 202b, a second pulley 206b connected to the carriage frame 104, a drive belt 208b wrapped between the pulleys 204b and 206b and extending between them, and a trolley 210 connected to the drive belt 208a and coupled to the track 184 of the second applicator arm 180. In this way, the trolley 210 movably supports the applicator arm 180 for lateral movement while facilitating independent longitudinal movement of the second applicator arm 180. During operation, in order to move the applicator arm 180 laterally, the actuator 202b, under the control of the control device CR, rotates the pulley 204b, which in turn rotates the drive belt 208b, moving the trolley 210 laterally, and thus moving the second applicator arm 180 laterally. This rotation of the pulley 204b and the drive belt 208b is reversed, moving 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 control device CR, moves the second applicator arm 180 longitudinally relative to the carriage 102 between a transport position relative to the inner side surface 103c of the carriage 102 and a retracted position relative to the inner side surface 103c of the carriage 102. In other words, the longitudinal second applicator arm actuator 200a, under the control of the control device, moves the arm 180 perpendicular to the carriage 102 (and therefore longitudinally) between the transport position and the retracted position at the outer position, the eye position, and the positions in between.

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

[0033] Second wrapper, second carriage of the second wrapper, and 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 (unsigned), an opposite second end (unsigned), an inner (unsigned), and an outer (unsigned) end, 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, which supports a third applicator arm 330 and longitudinal and transverse third applicator arm actuators 350a and 350b, as well as a fourth applicator arm 380 and longitudinal and transverse fourth applicator arm actuators 400a and 400b. The carriage 302 includes two spaced-apart, laterally extending tracks 306 and 308 connected to the bottom of the frame 304. A third applicator arm 330 and a fourth applicator arm 380 are movably connected to tracks 306 and 308, respectively, and are independently laterally movable 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 an elevated position above the coil-wrapping position. Similar to what has been described above for the first wrapper 100 and the first carriage actuator 110, the second carriage actuator 310 moves the second wrapper 300 upward and downward to these respective positions under the operation of the control device CR.

[0035] Similar to the first carriage actuator 110, the second carriage actuator 310 and the second drive system 311 are operably connected to the second wrapper 300, as best shown in Figures 1E and 1F, and are configured to move the second wrapper 300 relative to the mechanical frame 60 between a raised coil winding position and a film exchange position. In this exemplary embodiment, the second carriage actuator 310 includes an electric motor, but in other embodiments, it may include any other suitable actuator. The second drive system 311 includes drive shafts 312a and 312b connected to the crossbar 76 of the frame 60 and having inner ends connected to the second carriage actuator 310, respectively; spaced upper drive wheels 316a and 316b connected to the opposite ends of the drive shafts 312a and 312b and connected to the crossbar 76 and rotatably supported; spaced lower driven wheels 318a and 318b connected to be rotatably supported by legs 68 and 66, respectively; and a wheel wrapped around the wheels 316a and 318a. The system 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) connecting the drive belt 320a to the first end of the carriage 302 of the second wrapper 300, and carriage connectors 322b and 324b (referenced but not shown) connecting the drive belt 320b to the 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 control device CR, simultaneously rotates the drive shafts 312a and 312b that rotate the spaced upper wheels 316a and 316b, thereby rotating 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 upward, thereby causing the second carriage 302 of the second wrapper 300 to move upward. The process is reversed to move the second carriage 302 of the second wrapper 300 downward.

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

[0037] The second rapper's third applicator arm 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 the top of the elongated frame 332, and a gripping portion 5000 (described in detail below) connected to the 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) so that the trolley can slide laterally relative to the carriage frame 304. The trolley is slidably mounted to the track 334 so that the third applicator arm 330 can slide longitudinally relative to the track.

[0038] A lateral third applicator arm actuator 350b is connected to the bottom of the carriage 302 and operably coupled to the third applicator arm 130. Under the control of the control device CR, the lateral third applicator arm actuator 350b moves the third applicator arm 330 laterally (with respect to the coil being wound) 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, under the control of the control device CR, the lateral third applicator arm actuator 350b moves the third applicator arm 330 laterally to the coil C on the coil rotating body 500 between an outer position adjacent to the first end of the carriage 302 and an eye position adjacent to the longitudinal central axis of the coil C.

[0039] The longitudinal third applicator arm actuator 350a, under the control of the control device CR, moves the third applicator arm 330 longitudinally relative to the longitudinal axis of the coil C on the coil rotating body 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, under the control of the control device, moves the arm 330 longitudinally relative to the coil and carriage 302 between a transport position and a retracted position at the outer position, the eye position, and the positions in between.

[0040] Second rapper's fourth applicator arm Similarly, the movable fourth applicator arm 380 includes an elongated frame 382, ​​an elongated track 384 connected to the top of the elongated frame 382, ​​and a gripping section 5000 connected to the 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) so 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, supported by its carriage frame (not shown or indicated). Under the control of the control device CR, the lateral applicator arm actuator 400b moves the fourth applicator arm 380 laterally relative to the coil C on the coil rotating body 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 axis of rotation of the coil C. In other words, under the control of the control device CR, the lateral fourth applicator arm actuator 400b moves the fourth applicator arm 380 laterally relative to the longitudinal axis of the coil C and laterally relative to the carriage 302, 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 transport position relative to the inner side of the carriage 302 and a retracted position relative to the inner side of the carriage 302. In other words, the longitudinal fourth applicator arm actuator 400a moves the arm 380 perpendicular to the carriage 302 (and therefore longitudinally) between the transport position and the retracted position, under the control of the control device, at the outer position, the eye position, and the positions in between.

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

[0044] Second wrapper cutting, clamping, and seam system The second wrapper 300 further includes a cutting, clamping and splicing system 420 (and associated cutting, clamping and splicing system actuators, not shown) operably connected to a second carriage 302. The cutting, clamping and splicing 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 control device CR, clamps, seals, and cuts the film of the film roll at the end of the coil winding process. The cutting, clamping and joining system 420 includes (i) a sealer / cutter frame 422 connected to and supported by a 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 the 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 the 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 the film rolls FR1 and FR2, respectively, are ready to be clamped, sealed, and cut, the first and second actuators of the cutting, clamping, and splicing system 420 move the first sealer / cutter 430 and the second sealer / cutter 440 under the control of the control device CR, engaging them with the first and second films F1 and F2 adjacent to the side surface SS1 of the coil C, respectively. The films are then wound around the first coil engager 434 and the second coil engager 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 the second sealer / cutter hand 446 to engage with the first film F1 and the second film F2, respectively, which are wound around the first coil engager 434 and the second coil engager 444 adjacent to the side surface SS1 of the coil C, thereby sealing and cutting the 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)) attached to the second carriage 302. As best shown in Figure 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 rolls received from the film roll feeders 900 and 1900 for subsequent coil winding.

[0047] The first film end holder 450a comprises (i) a first track mounting portion 452a slidably mounted on a track 305 extending laterally on 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 rotatably 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, under the control of the control device CR, moves the first film end holder arm 454a laterally on the track 452a, and (vi) a first film engaging portion actuator (not shown) operably connected to the outer film engaging portion 458a, and under the control of the control device CR, the first outer film engaging portion 458a is swung to open the first outer film engaging portion 458a and release the leading edge of the film. In this embodiment, the first outer film engaging portion 458a is configured to pivot and engage with 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 pull the first outer film engaging portion 458a towards the first inner film engaging portion 456a and maintain these engaging portions together to hold the leading edge of the film. In such an embodiment, the first film end holder 450a is therefore a magnetic holder for the leading edge of the film on the film roll.

[0048] Similarly, the second film end holder 450b includes (i) a second track mounting portion 452b slidably mounted on a 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 engaging portion 458b pivotably connected to the second film end holder arm 454b, and (v) a second arm operably connected to the second film end holder arm 454b. The system comprises (vi) a second arm actuator (not shown) which, under the control of a control device CR, moves a second film end holder arm 454b longitudinally on a track 452b, and a second film engagement actuator (not shown) operably connected to a second outer film engagement portion 458b, the second film engagement actuator which, under the control of the control device CR, pivots the second outer film engagement portion 458b between a film engagement position and a film release position. In this embodiment, the second outer film engagement portion 458b is configured to pivot and engage with a second inner film engagement portion 456b to hold the leading edge of the film. In an alternative embodiment, one or both of the second inner film engagement portion 456b and the second outer film engagement portion 458b include one or more magnets (not shown) that pull the second outer film engagement portion 458b towards the second inner film engagement portion 456b and maintain these engagement portions together to hold the leading edge of the film. In these embodiments, the second film end holder 450b is therefore a magnetic holder for the leading end of the film in the film roll.

[0049] Coil wrapping method and wrapping operation of a coil wrapping system The coil wrappers 100 and 300 of the coil wrapping device 30 of the coil wrapping system 20 cooperate to wrap a single coil C simultaneously using two separate film rolls FR1 and FR2 at the same time, when the coil C is rotated around its longitudinal axis LA by the coil rotating body 500 under the control of the control device CR. During the wrapping process, as generally shown in Figures 1NA to 1NI, the coil wrapping device 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. The coil wrapping system 50, under the control of the control device CR, repeats this process alternately, conveying film rolls FR1 and FR2 longitudinally through the eye E of coil C, while the respective films F1 and F2 from each film roll FR1 and FR2 are wrapped around the outer, side and inner surfaces of coil C, respectively, so that each of the first and second film rolls FR1 and FR2 is used to wrap approximately half of coil C. This simultaneous wrapping of coil C by the two film rolls FR1 and FR2 substantially reduces the amount of time required to wrap each coil C, reduces the amount of film used by each roll to wrap each coil, and as a result, each roll lasts longer before replacement is required.

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

[0051] Coil positioning in the coil wrapping region The steps for positioning coil C within the coil wrapping area and positioning the first and second wrappers 100 and 300 in order to wrap coil C include (a) raising the first wrapper 100 to its raised position, and (b) moving the unwrapped coil C longitudinally from the coil feeding area below the first wrapper 100 onto the coil rotating body 500, (and thus positioning the unwrapped coil within the coil wrapping area on the coil rotating body 500) The process includes (c) determining the coil wrapping position and (if not performed beforehand, lowering the first wrapper 100 to its coil wrapping position (and, if not performed beforehand, lowering the second wrapper 300 to its coil wrapping position). At this position, the applicator arms 130, 180, 330, and 380 are each at a vertical height, and the gripping portions 5000 of the arms 130, 180, 330, and 380 are aligned perpendicular to the longitudinal axis of the coil C on the coil rotating body 500 within the coil wrapping area.

[0052] Positioning of the film roll and positioning of the leading edge of the film on the film roll. Each positioning step of the applicator arms 130, 180, 330, and 380 of the first and second wrappers 100 and 300, as described below, includes longitudinal movement of each applicator arm by the respective longitudinal applicator arm actuator for that applicator arm, and lateral movement of each applicator arm by the respective lateral applicator arm actuator for that applicator arm. All of these movements are controlled by the control unit CR based on specific points in the coil wrapping process. Furthermore, one or more of these movements can be monitored by one or more sensors S, and one or more of these movements are brought about by the control unit CR based on feedback from one or more sensors S.

[0053] The following describes the wrapping process after the film roll has been replaced (as described below). The process of positioning the leading edges LE1 and LE2 of the films F1 and F2 of the film rolls FR1 and FR2, held by the third and fourth applicator arms 330 and 380 of the second wrapper 300, onto the coil C is best shown in Figures 1M, 1NA and 1O, by (a) positioning the fourth applicator arm 380 longitudinally and transversely at the first wrapping start position, and the leading edge of the film F1 of the film roll FR1 held by the fourth applicator arm 380 (b) Positioning the end portion LE1 on one side of the eye E of the coil C, substantially adjacent to a first region FA1 on the side surface SS1 of the coil C (i.e., the side of the coil facing the second wrapper 300); (c) Positioning the third applicator arm 330 longitudinally and laterally to a second wrapping start position, so that the leading end portion LE2 of the film F2 of the film roll FR2 held by the third applicator arm 330 is substantially adjacent to the second region FA2 on the side surface SS1 of the coil opposite to the eye E of the coil C. This process includes (c) positioning the leading end portion LE2 of the film F2 of the film roll FR2 in the first region FA2 adjacent to the side surface SS1 of the coil C by the first film end holder 450a; and (d) positioning the leading end portion LE1 of the film F1 of the film roll FR1 adjacent to the second region FA1 on the side surface 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 Figures 1NA and 1O, (e) positioning the first applicator arm 130 longitudinally and transversely adjacent to the side SS2 of the coil C (i.e., the side of the coil facing the first wrapper 100) (without holding any film rolls at this point), and aligning it transversely with the third applicator arm 330 of the second wrapper 300; and (f) positioning the second applicator arm 180 longitudinally and transversely adjacent to the side SS2 of the coil C (without holding any film rolls at this point), and aligning it transversely 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 the coil with film from a film roll. The process of simultaneously wrapping coil C with films F1 and F2 from both film rolls FR1 and FR2 includes the following series of steps:

[0056] The first series of steps includes (a) starting to rotate the coil rotating body 500 around its longitudinal axis LA (if it has not been started previously), (b) moving the film roll FR1 held by the fourth applicator arm 380 and its gripping portion longitudinally inward in a region adjacent to the coil C so that the film F1 of the film roll FR1 is applied to the region of the outer surface OS of the coil C, (c) moving the film roll FR2 held by the third applicator arm 330 and its gripping portion longitudinally inward into the eye E of the coil C so that the film F2 of the film roll FR2 is applied to the region of the inner surface IS of the coil C, (d) moving the second applicator arm 180 (which is not holding a film roll at this point) longitudinally inward in a region adjacent to the outer surface OS of the coil C, and (e) moving the first applicator arm 130 (which is not holding a film roll at this point) longitudinally inward into the eye E of the coil C. In the illustrated embodiment, steps (b), (c), (d), and (e) are performed simultaneously.

[0057] As best illustrated in Figure 1NB, the following series of steps include: (f) continuing to move the film roll FR1, held by the fourth applicator arm 380 and its gripping portion, longitudinally inward to the film roll transfer position (while continuously applying the film F1 of film roll FR1 to the area of ​​the outer surface OS of coil C); (g) continuing to move the film roll FR2, held by the third applicator arm 330 and its gripping portion, longitudinally inward to the film roll transfer position of eye E of coil C (while continuously applying the film F2 of film roll FR2 to the area of ​​the inner surface IS of coil C); (h) continuing to move the second applicator arm 180 longitudinally inward to the film roll transfer position in the area adjacent to the outer surface OS of coil C; and (i) continuing to move the first applicator arm 130 (which is not holding the film roll at this point) longitudinally inward to the film roll transfer position at eye E of coil C. Figure 1P also shows these applicator arms and the film roll transfer position. Steps (f), (g), (h), and (i) can be carried out simultaneously in the illustrated exemplary embodiment.

[0058] As best illustrated in Figure 1NC, the following series of steps include (j) transferring the film roll FR1 held by the gripping portion of the fourth applicator arm 380 to the gripping portion of the second applicator arm 180 at a film roll transfer position located in the area of ​​the outer surface OS of the coil C, and (k) transferring the film roll FR2 held by the gripping portion of the third applicator arm 330 to the gripping portion of the first applicator arm 130 at a film roll transfer position within the eye E of the coil C. Steps (j) and (k) can be performed simultaneously in the illustrated embodiment.

[0059] As best illustrated in Figure 1ND, the following sequence of steps includes: (l) moving the second applicator arm 180 and the film roll FR1 held by its gripping portion longitudinally outward in a region adjacent to the coil C, so that the film F1 of the film roll FR1 is subsequently applied to the outer surface region of the coil C; (m) moving the first applicator arm 130 and the film roll FR2 held by its gripping portion longitudinally outward toward the eye E of the coil C, so that the film F2 of the film roll FR2 is subsequently applied to the inner surface IS region 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 toward the eye E of the coil C. Steps (l), (m), (n), and (o) are performed simultaneously in the illustrated embodiment.

[0060] As best illustrated in Figure 1NE, the following series of steps are: (p) moving the second applicator arm 180 and the film roll FR1 held by its gripping part laterally adjacent to the side surface SS2 of the coil C, and stopping such lateral movement when the film roll FR1 held by the gripping part is in a plane aligned longitudinally with the eye E of the coil C; and (q) moving the first applicator arm 130 and the film roll FR2 held by its gripping part laterally adjacent to the side surface SS2 of the coil C, so that the film F2 of the film roll FR2 is applied to the area of ​​the side surface SS2 of the coil C. The process includes (p), (q), (r), and (s) stopping such lateral movement when the film roll FR2 held by the gripping part is in a plane longitudinally adjacent to the outer surface OS of the coil C; (r) moving the fourth applicator arm 380 laterally adjacent to the side surface SS1 of the coil C, and stopping such lateral movement when its gripping part is in a plane longitudinally aligned with the eye E of the coil C; and (s) moving the third applicator arm 330 laterally adjacent to the side surface SS1 of the coil C, and stopping such lateral movement when its gripping part is in a plane longitudinally adjacent to the outer surface OS of the coil C. Steps (p), (q), (r), and (s) can be performed simultaneously in the illustrated embodiment.

[0061] As best illustrated in Figure 1NF, the following series of steps include: (t) moving the first applicator arm 130 and the film roll FR2 held in its gripping portion longitudinally inward to the film roll transfer position, while applying the film F2 of the film roll FR2 to the region 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 gripping portion longitudinally inward to the film roll transfer position of the eye E of the coil C, while applying the film F1 of the film roll FR1 to the region of the inner surface IS of the coil C; (v) moving the fourth applicator arm 380 (which does not hold the film roll at this point) longitudinally inward to the film roll transfer position within the eye E of the coil C; and (w) moving the third applicator arm 330 (which does not hold the film roll at this point) longitudinally inward to the film roll transfer position in the region adjacent to the outer surface OS of the coil C. These applicator arms and film roll transfer positions are also shown in Figure 1Q. Steps (t), (u), (v), and (w) can be performed simultaneously in the illustrated exemplary embodiment.

[0062] As best illustrated in Figure 1NG, the following series of steps include (x) transferring the film roll FR2 held by 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 adjacent to the outer surface OS of the coil C, and (y) transferring the film roll FR1 held by 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, and these steps (x) and (y) can be performed simultaneously in the illustrated embodiment.

[0063] As best illustrated in Figure 1NH, the following sequence of steps includes (z) moving the film roll FR2, held by the gripping portion and the third applicator arm 330, longitudinally outward in the region outside the eye E of the coil C, so that the film F2 of the film roll FR2 is subsequently applied to the region of the outer surface of the coil C; (aa) moving the film roll FR1, held by the gripping portion and the fourth applicator arm 380, longitudinally outward in the region outside the eye E of the coil C, so that the film F1 of the film roll FR1 is subsequently applied to the region of the inner surface IS of the coil C; (bb) moving the first applicator arm 130 longitudinally outward in the region adjacent to the outer surface OS of the coil C; and (cc) moving the second applicator arm 180 longitudinally outward in the region outside the eye E of the coil C. Steps (z), (aa), (bb), and (cc) can be performed simultaneously in the illustrated embodiment.

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

[0065] Next, each of the steps from (b) to (gg) is repeated while the coil C continues to rotate around its longitudinal axis until approximately half of the coil C is wrapped with film F1 and approximately half of the coil is wrapped with film F2. After repeating steps (b) to (gg) two or three times, or an appropriate number of times, the films F1 and F2 are held at their respective leading ends LE1 and LE2, and the film end holders 450a and 450b can release the leading ends LE1 and LE2 of the films F1 and F2.

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

[0067] More specifically, this includes (i) positioning the first coil engager 434 in a first seal / cut position, and engaging the first coil engager 434 with the film F2 of a film roll FR2 located in a first region of the side surface SS1 of coil C adjacent to the eye E of 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 in a second seal / cut position, and engaging the second coil engager 444 with the film F1 of a film roll FR1 located in a second region of the side surface SS1 of coil C adjacent to the eye E of 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 (iii) rotating a first sealer / cutter 436 inward to engage and seal, cutting the film F2 of a film roll FR2 located in a first region of the side surface SS1 of coil C adjacent to the eye E of coil C; (iv) rotating a second sealer / cutter 446 inward to engage and seal, cutting the film F1 of a film roll FR1 located in a first region of the side surface SS1 of coil C adjacent to the eye E of coil C; (v) holding the leading edge of the film F2 of film roll FR2; and (vi) holding the leading edge of the film F1 of 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) pulling the first coil engage 434 from the first seal / cut position and (viii) pulling the second coil engage 444 from the second seal / cut 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 attachment to the next coil.

[0070] Figure 1NJ shows the state after the coil has been completely wrapped.

[0071] Removal of the wrapped coil from the coil wrapping area. A method for removing a wrapped coil from the wrapping area of ​​a coil includes (a) stopping the rotation of coil C on the coil rotating body 500 (if not previously done), (b) raising the second wrapper 300 to a raised position, (c) moving the fully wrapped coil longitudinally onto the coil rotating body 500 within the wrapping area of ​​the coil, under the second wrapper 300, and into the coil delivery area (and thereafter enabling 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 preparation method for wrapping the next coil, an exemplary mandrel 4000, and an exemplary mandrel gripping section 5000 of this exemplary embodiment of the present disclosure will be described.

[0073] Film roll replacement system The film roll replacement system 50 removes empty or nearly empty film rolls from the coil wrapping device 30 and supplies new film rolls to the coil wrapping device 30. As shown in Figures 1A, 1B, 1C, 2A, 2D, 3A, and 3F, 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 track 800, a first empty film roll holder track 810, a first film roll supply unit 900, a first empty film roll removal unit 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 unit 1900, and a second empty film roll removal unit 2000.

[0074] The first replacement film roll holder track 610 and the first empty film roll holder track 810 are positioned adjacent to the first outer region of the mechanical frame 60 and each extends laterally relative to the coil rotating body 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 the supply position (Figure 1A) to the reload position (Figure 1B). Figure 1B shows the state after a replacement roll has been loaded into the first replacement film roll holder 600 and before the first replacement film roll holder 600 is returned to the supply position shown in Figure 1A. The first empty film roll holder 800 is slidably mounted on the first empty film roll holder track 810 and is movable laterally from an empty film roll receiving position (Figure 1A) to an empty film roll unloaded position (Figure 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 external region on the opposite side of the mechanical frame 60 and each extends laterally relative to the coil rotating body 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 therefrom from a supply position (Figure 1A) to a reload position (Figure 1B). The second empty film roll holder 1800 is slidably mounted on the second empty film roll holder track 1810 and is laterally movable therefrom from an empty film roll receiving position (Figure 1A) to an empty film roll unloaded position (Figure 1B).

[0076] To restrict human access to the work area of ​​the coil wrapping system 20, appropriate protective structures, such as fences (not shown), can be used around the components of the coil wrapping system 20 to create protective barriers around the various components. The loading and unloading positions described above are outside such protective structures, and workers can load replacement film rolls onto the respective replacement film roll holders 600 and 1600, and unload empty film rolls from the respective empty film roll holders 800 and 1800, without entering such a protected work 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 their respective tracks 610, 810, 1610, and 1810 so as to be toward and away from the respective wrappers 100 and 300 and protective structures, or (ii) automatically movable and lockable on their respective tracks 610, 810, 1610, and 1810 by their respective actuators, such as the exemplary actuators described below, so as to be toward and away from the respective wrappers 100 and 300 and protective structures, under the control of the control device CR. 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 in 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 their respective actuators, such as the illustrative actuators described below.

[0078] The first film roll feeder 900 and the first empty film roll remover 1000 are positioned adjacent to the first external region of the mechanical frame 60, and each extends laterally with respect to the coil rotating body 500. The first film roll feeder 900 and the first empty film roll remover 1000 are positioned between the first replacement film roll holder track 610 and the first empty film roll holder track 810, and thus, when these holders are positioned in their respective feeding and empty film roll receiving positions as shown in Figures 1A and 1C, they are positioned between the first replacement film roll holder 600 and the first empty film roll holder 800. The first film roll feeder 900 is also aligned with the first replacement film roll holder 600 (when the holder is in the film roll feeding position), and under the control of the control device CR, the first film roll feeder 900 can obtain a replacement film roll (on the mandrel 4000) from the first replacement film roll holder 600 and feed the replacement film roll (on the mandrel 4000) to the third applicator arm 330 of the second wrapper 300. Furthermore, the first empty film roll removal unit 1000 is aligned with the first empty film roll holder 800 (when the holder is in a position to receive an empty film roll), and under the control of the control device CR, the first empty film roll removal unit 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. Since the first empty film roll removal unit 1000 obtains an empty film roll from the first applicator arm 130 of the first wrapper 100, in response to the control device CR's determination that the film roll held by the third applicator arm 330 is empty, the control device 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 feeder 1900 and the second empty film roll remover 2000 are positioned adjacent to the second external region of the mechanical frame 60, each extending laterally with respect to the coil rotating body 500. The second film roll feeder 1900 and the second empty film roll remover 2000 are positioned between the second replacement film roll holder track 1610 and the second empty film roll holder track 1810, and thus, when these holders are positioned in their respective feeding and empty film roll receiving positions as shown in Figures 1A and 1C, they are positioned between the second replacement film roll holder 1600 and the second empty film roll holder 1800. The second film roll feeder 1900 is also aligned with the second replacement film roll holder 1600 (when the holder is in the film roll feeding position), and under the control of the control device CR, the second film roll feeder 1900 can obtain a replacement film roll (on the mandrel 4000) from the second replacement film roll holder 1600 and feed the replacement film roll (on the mandrel 4000) to the fourth applicator arm 380 of the second wrapper 300. Furthermore, the second empty film roll removal unit 2000 is aligned with the second empty film roll holder 1800 (when the holder is in the empty film roll receiving position), and under the control of the control device CR, the second empty film roll removal unit 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. Since the second empty film roll removal unit 2000 obtains an empty film roll from the second applicator arm 180 of the first wrapper 100, in response to the control device CR's determination that the film roll held by the fourth applicator arm 380 is empty, the control device 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] First 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, which can be individually and separately provided to the third applicator arm 330 of the second wrapper 300 by the first film roll feeder 900 when the control device CR determines that each empty film roll held by the third applicator arm 330 of the second wrapper 300 (transferred to the first applicator arm 130 of the first wrapper 100 for removal) is to be replaced. The first replacement film roll holder 600 includes a replacement film roll holder frame 620 which is movably coupled to the track 610. The replacement film roll holder frame 620 includes a lower section 630 and an upper section 640. The lower section 630 includes a number of legs (not referenced) which are coupled to the track 610 and are slidable on the track 610. The upper section 640 includes a plurality of upright, longitudinal frame members (not indicated) that support a plurality of film roll holders 700, as described below. The track 610 is fixed in place on a support surface (such as the floor) and extends laterally outward in a first region adjacent to the mechanical frame 60, as described above, and is laterally aligned with the second wrapper 300. 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 the supply position shown in Figure 1A to the reloading position shown in Figure 1B, outside the supply position. In the supply position, the replacement film roll holder 600 is configured to supply replacement film rolls on a mandrel to the third applicator arm 330 of the second wrapper 300 via the first film roll feeder 900, if necessary. In the reloading position, the replacement film roll holder 600 is configured to reload additional replacement film rolls 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 moves the replacement film roll holder frame 620 on a track 610 between a supply position and a reload position under the control of the control device CR.This exemplary embodiment further includes a replacement film roll holder lock actuator 660 connected to a replacement film roll holder frame 620. The replacement film roll holder lock actuator 660 is configured, under the control of a control device CR, to move a locking pin 665 to lock it into a track 610, thereby locking the replacement film roll holder frame 620 in the supply position or reload position.

[0081] Figure 2A shows 12 film roll holders 700 that do not hold film rolls. Figure 2C shows a film roll holder 700 that holds 12 replacement film rolls (each mounted on a mandrel 4000). In this exemplary embodiment, the 12 film roll holders 700 are arranged in two rows of 6 film roll holders. Thus, the first replacement film roll holder 600 holds 12 replacement film rolls before additional replacement film rolls are reloaded, as shown in Figure 2C. The number and arrangement of film roll holders 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 of a shape and size such as to receive, hold, and release the upper handle 4116 of the upper handle assembly 4110 of the mandrel 4000 (described later). The lower mandrel holder 740 is connected to the upper portion 640 of the frame 620 below the upper mandrel holder 710, aligned with the upper mandrel holder 710 and spaced apart from it. The lower mandrel holder 740 includes a bracket of a shape and size such as 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 indicated) for holding 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 the upper mandrel holder 710, aligned with the upper mandrel holder 710, and spaced apart from the upper mandrel holder 710. The film end holder 780 includes a first film engager 782 connected to the frame 600 and a second film engager 790 pivotably connected to the first film engager 782. The second film engager 790 is rotatable between a film holding position shown in Figures 2A, 2B, 2C, and 2D and a film open position (not shown). The second film engager 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 engager 790 in the closed position. As shown in Figures 2C and 2D, the film end holder 780 holds the leading edge 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 edge 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 unit 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 here for simplicity. Generally, as best illustrated in Figures 1A, 1B, and 1C, the second replacement film roll holder 1600 is configured to hold replacement film rolls supplied individually to the fourth applicator arm 380 of the second wrapper 300 by the second film roll supply unit 1900 when the control device CR determines to replace an empty film roll held by the fourth applicator arm 380 (which is then transferred to the second applicator arm 180 of the first wrapper 100 for removal). Similarly, 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 a supply position (shown in Figure 1A) and a reload position (shown in Figure 1B) under the control of a control device 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, under the control of a control device CR, to move a lock pin (not shown) to engage with the track 1610 and lock the replacement film-roll holder frame in the supply position or the reload position.

[0084] First empty film roll holder The first empty film roll holder 800 is configured, as best illustrated in Figures 1A, 1B, and 1C, to hold the empty film rolls (on the mandrel 4000) obtained individually from the first applicator arm 130 of the first wrapper 100 by the first empty film roll removal body 1000 when the control device CR determines to replace the empty film roll held by the third applicator arm 330 or the first applicator arm 130. The first empty film roll holder 800 is substantially a mirror image of the empty first replacement film roll holder 600 (however, it does not initially hold any replacement film rolls on the mandrel). Therefore, for brevity, the first empty film roll holder 800 will not be described in detail here. 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), but is not required, since the first empty film roll holder 800 does not need to hold the leading edge of the film of such an empty film roll. 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 along the track 810 between an empty film roll receiving position (shown in Figure 1A) and an unloaded position (shown in Figure 1B) under the control of the control device CR. 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) under the control of the control device CR to engage with the track 810, thereby locking the empty film roll holder frame in the empty film roll receiving position or the unloaded 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 for brevity, will not be described herein. The second empty film roll holder 1800 is configured, as best illustrated in Figures 1A, 1B, and 1C, to hold the empty film rolls obtained individually by the second empty film roll removal body 2000 from the second applicator arm 180 of the first wrapper 100 when the control device CR determines to replace the empty film rolls held by the fourth applicator arm 380 and transferred to the second applicator arm 180 for removal. 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 the track 1810 between the empty film roll receiving position and the unloaded position under the control of the control device CR. This exemplary embodiment further includes an empty film roll holder lock actuator (not shown) connected to an empty film roll holder frame. The empty film roll holder lock actuator is configured, under the control of the control device CR, to move a lock pin (not shown) to engage with track 1810, thereby locking the empty film roll holder frame in an empty film roll receiving position or an empty loading position.

[0086] First film roll feeder The first film roll feeder 900 is positioned between the first replaceable film roll holder 600 and the first empty film roll removal body 1000, as best shown in Figures 3A to 3E, and extends partially laterally within the internal region of the mechanical frame 60. The first film roll feeder 900 includes a feeder frame 920 and a film roll mover 950 supported by the feeder frame 920.

[0087] The feed frame 920 is fixed and includes a lower section 922 and a track 924 mounted on the upper part of the lower section 922. The feed frame 920 is longitudinally aligned with the first replaceable film roll holder 600 so that the film roll mover 950 can reach each replaceable film roll holder support position of the first replaceable film roll holder 600. The feed frame 920 also extends laterally into a region within the mechanical frame 60, longitudinally aligning the film roll mover 950 with the third applicator arm 330 of the second wrapper 300 so that a replaceable film roll can be transferred to the third applicator arm 330.

[0088] The film roll mover 950 includes an upright support arm 952 movably connected to a track 924 mounted on a feed frame 920, and a support arm actuator 956 operably connected 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 control device CR. This allows the film roll mover 950 to interact with a first replaceable film roll holder 600 and with a third applicator arm 330. Thus, under the control of the control device CR, the support arm actuator 956 moves the entire support arm 952 and film roll moving body 950 along the track 924 to longitudinally align the first replaceable film roll holder 600 with different film holder support positions, and when the third applicator arm 330 is in the film roll receiving position as shown in Figure 1A, it aligns the support arm actuator 956 longitudinally with the third applicator arm 330.

[0089] The film roll moving body 950 further includes a longitudinally extending film roll transfer arm 960 that is longitudinally movably connected to a support arm 952, and a transfer arm actuator 966 that is 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 longitudinally inward and outward relative to the support arm 952 under the control of the control device CR. The film roll moving body 950 further includes a gripping portion 5000 (described later) connected to the end of the film roll transfer arm 960. The film roll moving body 950 further comprises a film roll tip holder 980 and a film roll moving body actuator 986 configured to rotate the fingers 984 of the holder 980. The film roll moving body 950 further comprises a film roll tip holder 980 fixedly connected to a film roll transport arm 960. The film roll moving body 950 further comprises the film roll tip holder 980 and the film roll moving body actuator 986, which are fixedly connected to the arm 960 by a bracket 981 and are therefore longitudinally movable together with the arm 960. The film roll tip holder 980 is otherwise similar to the film roll tip holder 450a described above and is therefore not described herein for brevity. The film roll moving body 950 includes an actuator 976 configured to move the film roll transport arm 960 and the film roll tip holder 980 upward and downward along a track 958 attached to a support arm 952.

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

[0091] Second film roll dispenser The second film roll feeder 1900 is positioned between the second replacement film roll holder 1600 and the second empty film roll removal body 2000, and extends partially laterally within the internal region of the mechanical frame 60. The second film roll feeder 1900 is a mirror image of the first film roll feeder 900 and is therefore not described here for simplicity.

[0092] The second film roll feeder 1900 is configured to, in response to a control device 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 under the control of the control device CR after the empty film roll has been transferred to the second applicator arm 180 by the fourth applicator arm 380 for removal, and then move the replacement film roll to the fourth applicator arm 380 of the second wrapper 300.

[0093] First empty film roll removal unit The first empty film roll removal unit 1000 is substantially the same as the first film roll supply unit 900, and therefore, for the sake of brevity, will only be briefly described herein.

[0094] The first empty film roll removal unit 1000 includes a removal unit frame 1020 and a film roll mover 1050 (shown in Figures 1B and 1C) supported by the removal unit frame 1020. The removal unit frame 1020 is stationary and similar to the supply unit frame 920. The removal unit frame 1020 is longitudinally aligned with the first empty film roll holder 800 so that the film roll mover 1050 can reach the support position of each empty film roll holder of the first empty film roll holder 800. The removal unit frame 1020 also extends laterally within a region of the mechanical frame 60 so that the film roll mover 1050 is longitudinally aligned with the first applicator arm 130 of the first wrapper 100 so that the first applicator arm 130 can transfer empty film rolls to the film roll mover 1050. The film roll moving body 1050 is substantially the same as the film roll moving body 950, except that its longitudinally extending film roll transport arm is longitudinally movable and, under the control of the control device CR, can move in opposite directions longitudinally inward and outward, and does not require a film roll tip holder.

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

[0096] The second empty film roll removal unit 2000 comprises a removal unit frame 2020 and a film roll mover 2050 (shown in Figure 1C) supported by the removal unit frame 2020. The removal unit frame 2010 is fixed and similar to the removal unit frame 1010. The removal unit frame 2020 is longitudinally aligned with the second empty film roll holder 1800 so that the film roll mover 2050 can reach each empty film roll holder support position of the second empty film roll holder 1800. The removal unit frame 2020 also extends laterally within a region of the mechanical frame 60 so that the film roll mover 2050 is longitudinally aligned with the second applicator arm 180 of the first wrapper 100 so that the second applicator arm 180 can transfer an empty film roll to the film roll mover 2050. The film roll transporter 2050 is substantially the same as the film roll transporter 950, except that its longitudinally extending film roll transport arm is longitudinally movable and, under the control of the control device CR, can move in opposite directions longitudinally inward and outward, and does not require a film roll tip holder.

[0097] Coil wrapping preparation and film roll replacement method Here, we will describe in more detail the preparation for wrapping the coil and the method for replacing an empty film roll with a replacement film roll using the film roll exchange system 50.

[0098] The method for preparing the wrapping of the next coil (i.e., before the next coil wrapping process begins) includes a step in which the control device CR determines whether both film rolls FR1 and FR2, which will be used by the first and second wrappers 100 and 300 to wrap the next coil, have enough film to wrap that next coil. If either of these film rolls FR1 or FR2 does not have enough film to wrap the next coil, the control device CR replaces the insufficient film roll with a replacement film roll from each replacement film roll holder 600 or 1600. Such an insufficient film roll is considered or is deemed to be empty as described above.

[0099] These decisions can be made based on data received by the control unit 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 each film roll FR began to be used. In various embodiments, the control unit CR makes decisions based on signals received from sensors S mounted on the respective gripping portions 5000 of the respective applicator arms 330 and 380 of the second wrapper 300, where the signals indicate readings of the amount of film F remaining on the respective films F1 and F2 of the film rolls FR1 and FR2 (after the previous coil C has been wrapped). In other embodiments, the control unit CR makes these decisions based on usage data that the control unit CR tracks and maintains with respect to each of the currently used film rolls FR1 and FR2, and the quantity and size of coil C previously wrapped using the currently used film rolls FR1 and FR2 (and the amount or length of film on each film roll). In other embodiments, the control device CR makes these decisions based on signals received from the sensor S and on such usage data.

[0100] In response to a control device CR determining that the film roll FR2 held by the third applicator arm 330 is insufficient to wrap the next coil, the control device 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 removal unit 1000, (3) causes the first empty film roll removal unit 1000 to transfer the empty film roll FR2 to the first empty film roll holder 800, (4) causes the first film roll feed unit 900 to obtain a replacement film roll RFR from the first replacement film roll holder 600, and (5) causes the first film roll feed unit 900 to transfer the obtained replacement film roll RFR to the third applicator arm 330. Steps (2) and (3) can be performed 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 removal unit 2000, (C) causes the second empty film roll removal unit 2000 to transfer the empty film roll FR1 to the second empty film roll holder 1800, (D) causes the second film roll supply unit 1900 to obtain a replacement film roll RFR from the second replacement film roll holder 1600, and (E) causes the second film roll supply unit 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 film rolls FR1 and FR2 are substantially identical in this exemplary embodiment, only the method for replacing an empty film roll FR2 is described in more detail herein for brevity. The method for replacing an empty film roll FR2 described below includes the positioning 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 moving bodies 950 and 1050, respectively. This positioning may include any necessary vertical, longitudinal, and / or lateral movements of these components by the respective actuators described above. All of these movements are controlled by the control device CR based on specific points in the film roll replacement process. Furthermore, one or more of these movements may be monitored by one or more sensors S, and one or more of these movements may be triggered by the control device 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, if necessary, vertically moving each of the first wrapper 100 and the second wrapper 300 to their respective vertical film replacement positions. In these film replacement positions, the third applicator arm 330 is aligned vertically with the first applicator arm 130 (i.e., at the same vertical height), the third applicator arm 330 is aligned vertically with the film roll mover 950 (i.e., at the same vertical height), and the first applicator arm 130 is aligned vertically with the film roll mover 1050 (i.e., at the same vertical height).

[0104] This method then includes the step of transferring an empty film roll FR2 to the first applicator arm 130 via the third applicator arm 330, the step of (a) moving the third applicator arm 330 longitudinally inward to position its gripping portion 5000 and the film roll FR2 held by the gripping portion at the film roll transfer position, and (b) moving the first applicator arm 130 longitudinally inward to transfer its gripping portion 5000 (which at this point does not hold the film roll) The process includes (a) positioning the film roll transfer position, (c) transferring the film roll FR2 from the gripping portion 5000 of the third applicator arm 330 to the gripping portion 5000 of the first applicator arm 130 at the film roll transfer position, (d) moving the third applicator arm 330 longitudinally outward with its gripping portion 5000 empty, and (e) moving the first applicator arm 130 longitudinally outward with its gripping portion 5000 holding the film roll FR2. Steps (a) and (b) can be performed simultaneously, and in this embodiment, steps (d) and (e) can be performed simultaneously.

[0105] Next, this method includes the steps of the first applicator arm 130 transferring the empty film roll FR2 to the first empty film roll removal unit 1000, and the first empty film roll removal unit 1000 transferring the empty film roll FR2 to the first empty film roll holder 800. This process includes (f) moving the film roll moving body 1050 of the first empty film roll removal body 1000 laterally to align its gripping portion with the first applicator arm 130 in the longitudinal direction, (g) moving the gripping portion 5000 of the film roll moving body 1050 outward in the longitudinal direction to the film roll transfer position, (h) if necessary, moving the first applicator arm 130 inward in the longitudinal direction to position its gripping portion 5000 and the 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 moving body 1050, (j) moving the first applicator arm 130 outward in the longitudinal direction with the gripping portion 5000 empty, and (k) with the gripping portion 5000 currently holding the film roll FR2. The process includes: (l) moving the roll moving body 1050 inward in the longitudinal direction; (m) moving the film roll moving body 1050 laterally (and vertically if necessary) to one aligned position on the empty film roll support of the first empty film roll holder 800 while its gripping portion 5000 is currently holding the film roll FR2; (n) moving the film roll moving body 1050 outward in the longitudinal direction to position its gripping portion and transferring the empty film roll FR2 to the selected empty film roll support of the first empty film roll holder 800; (o) moving the film roll moving body 1050 inward in the longitudinal direction with the gripping portion now empty.

[0106] This method also includes the steps of having a first film roll feeder 900 retrieve a replacement film roll RFR from a first replacement film roll holder 600, and having the first film roll feeder 900 transfer the retrieved replacement film roll to a third applicator arm 330. This involves (q) moving the film roll transfer arm 960 of the film roll moving body 950 and its gripping portion 5000 (which does not hold the film roll at this point) to a position where it is longitudinally aligned with one of the film roll supports 700 of the replacement film roll holder 600 that holds the replacement film roll RFR (this also includes moving the film roll transfer arm 960 vertically), (r) moving the film roll transfer arm 960 longitudinally outward as shown in Figure 3D or Figure 3E, positioning its gripping portion 5000 to transfer (grasp in this case) the replacement film roll RFR from the film roll support of the first replacement film roll holder 600, and moving the film roll tip holder 980 attached to the film roll transfer arm 960 longitudinally to transport (grasp in this case) the tip of the replacement film roll from the first replacement film roll holder 600, and (s) as shown in Figure 3D or As shown in Figure 3E, the process involves transferring (grabbing) the replacement film roll RFR from the first replacement film roll holder 600 and transferring (grabbing) the tip of the replacement film roll RFR from the tip holder 780 of the first replacement film roll holder 800; (t) as shown in Figure 3F, the process involves moving the film roll transfer arm 960, which is equipped with a gripping portion 5000 that holds the replacement film roll RFR, inward in the longitudinal direction, and simultaneously moving the film roll tip holder 980, which holds the tip of the replacement film roll RFR, inward in the longitudinal direction; and (u) moving the film roll transfer arm 960 laterally together with the gripping portion 5000 that holds the replacement film roll RFR, and moving the film roll tip holder 980, which holds the tip of the replacement film roll RFR, laterally to a position where it is aligned longitudinally with the third applicator arm 330 and the first tip holder 450a, respectively (including moving these components vertically if necessary).(v) If necessary, move 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, move the first tip holder 450a inward in the longitudinal direction to the film tip transfer position; (x) Transfer the replacement film roll RFR from the gripping portion 5000 of the film roll transfer body 950 to the gripping portion 5000 of the third applicator arm 330; (y) Transfer the leading edge of the film of the replacement film roll RFR from the film roll tip holder 980 to the first tip holder 450a. The process includes (z) moving the third applicator arm 330, which has a gripping portion 5000 holding the replacement film roll RFR, outward in the longitudinal direction, and moving the first tip holder 450a, which holds 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 in the lateral direction.

[0107] Mandrel Figures 4A to 4L show a mandrel 4000 configured to support a film roll according to an exemplary embodiment of the present disclosure. As described above, a number of film rolls are used with the coil wrapping system 50. Each film roll is mounted on a mandrel such as the mandrel 4000. The 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 each other, the inner mandrel assembly 4100 is held in a fixed position by a mandrel grip, such as the mandrel grip 5000 described later. The film rolls mounted on the outer mandrel assembly 4200 are rotatable under tension (as described later) and release the film from the film roll onto the coil in the manner described above. The mandrel 4000 maintains the film under tension when the film is applied to the coil by each applicator arm. The mandrel 4000 is further held by the mandrel gripping portion of each applicator arm and is configured to be transferred from one applicator arm to another, as described above.

[0108] Internal 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] Micro 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 lock nut 4126, and an upper handle lock washer 4128.

[0110] The upper handle retaining screw 4112 and the upper handle retaining washer 4114 secure the upper handle 4116 to the shaft 4130 so that the upper handle 4116 and the shaft 4130 are locked together in a rotatable manner.

[0111] The upper handle 4116 is dimensioned, shaped, positioned, oriented, and otherwise configured to be removablely engaged by the upper mandrel claws 5210 of the mandrel gripping portion 5000, as described below. The upper handle 4116 is fixed to the shaft 4130 by a key connection so 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 dimensioned, shaped, positioned, oriented, and otherwise configured to be engaged by the mandrel engaging body 5230 of the upper mandrel claws 5210. The outer handle block 4120 is rectangular in shape and includes an upper (unsigned) and a lower (unsigned) surface. The upper surface is dimensioned, shaped, positioned, oriented, and otherwise configured so as to engage with the fingers 5520 and 5520 of the upper mandrel claw 5210. The inner handle cylinder 4122 is cylindrical and may be similar to or identical to the outer handle cylinder 4118 in that it is coaxial with the central axis of the shaft 4130. The inner handle cylinder is also dimensioned, shaped, positioned, oriented, and otherwise configured so as to engage with the upper mandrel claw 5210. The inner handle block 4124 is square in shape and may be similar to or identical to the outer handle block 4120 in that it includes an upper (unsigned) and a lower (unsigned) surface. The upper surface is dimensioned, shaped, positioned, oriented, and otherwise configured so as to engage with the fingers 5520 and 5520 of the upper mandrel claw 5210.

[0112] The upper handle lock nut 4126 and the upper handle lock washer 4128 fix the upper handle 4116 to the shaft 4130 so that both the upper handle 4116 and the shaft 4130 are locked to rotate.

[0113] The upper handle assembly 4110 is rotationally locked to the fingers 5520 and 5520 of the upper mandrel claws 5210 of the mandrel grip 5000 when the mandrel 4000 is grasped by the mandrel grip 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 swivel assembly 4140, and the lower handle assembly 4140 are attached. The shaft 4130 is cylindrical. The shaft 4130 includes an upper section, a middle section, and a lower section having different diameters. The diameter of the upper section is smaller than the diameter of the middle section, such that the transition between the upper and middle sections of the shaft 4130 defines the upper shelf 4132. The upper shelf 4132 is configured to engage with the upper handle assembly 4110. Similarly, the diameter of the lower section is smaller than the diameter of the middle section, such that the transition between the lower and middle sections of the shaft 4130 defines the lower shelf 4134. The lower shelf 4134 is configured to engage with the lower handle assembly 4140. The shaft 4130 is fixed to the upper handle assembly 4110, the inner swivel assembly 4140, and the lower handle assembly 4140. The shaft 4130 is dimensioned, shaped, positioned, oriented, and otherwise configured to mesh with the various bearings of the outer mandrel assembly 4200, including the upper bearing 4240, the lower bearing 4242, and the swivel bearing 4244.

[0115] Internal Rotating Assembly The internal rotation assembly 4140 includes a fixed clutch disc 4142, a fixed disc contact plate 4144, and upper and lower disc springs 4146A and 4146B, respectively.

[0116] The fixed clutch discs 4142 are mounted on the shaft 4130 via keying, splinting, or other suitable couplings so that both of them are rotatably fixed to the upper handle assembly 4110. The fixed clutch discs 4142 include an upper surface (not indicated) and a lower surface (not indicated). The upper surface of the fixed clutch discs 4142 is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the lower surface of the rotating clutch disc 4238 of the outer mandrel assembly 4200 to provide a force that resists the rotation of the outer mandrel assembly 4200 relative to the inner mandrel assembly 4100 about the longitudinal axis 4130A.

[0117] The fixed disc contact plate 4144 provides support for the fixed clutch disc 4142 and is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the lower surface of the fixed clutch disc 4142. The fixed disc contact plate 4144 is mounted on the shaft 4130 so as to be rotatably fixed to the upper handle assembly 4110. The fixed disc contact plate 4144 includes an upper surface (not indicated) that engages with the fixed clutch disc 4142 and a lower surface (not indicated) that engages with the upper disc spring member 4146A.

[0118] The upper and lower disc springs 4146A and 4146B each comprise two spring components. The upper disc spring 4146A is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the lower surface of the fixed disc contact plate 4144, while the lower disc spring 4146B is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the lower handle lock washer 4152.

[0119] During the 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 with the outer mandrel assembly 4200 through contact between the fixed clutch disc 4142 of the inner rotating assembly 4140 and the rotating clutch disc 4238 of the outer mandrel assembly 4200, and is dimensioned, shaped, positioned, oriented, and otherwise configured to provide a desired amount of resistance to the 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 lock washer 4152, a lower handle lock nut 4154, a lower handle 4156, a lower handle retaining washer 4158, and a lower handle retaining screw 4160.

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

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

[0123] The lower handle retaining washer 4158 and the lower handle retaining screw 4160 secure the lower handle 4156 to the shaft 4130, thereby rotatably securing the lower handle 4156 and the 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 tightened or loosened to increase or decrease the force on the disc springs 4146A and 4146B. This allows for increasing or decreasing 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 rotation assembly 4230, and a plurality of bearings and support structures (not indicated).

[0125] Outer mandrel body The outer mandrel body 4220 includes an upper surface 4222 and a lower lip 4224, and defines a rotation stopper slot 4226.

[0126] The upper surface 4222 is the surface of the outer mandrel body 4220 to which the retaining core 4216 is fixed. The lower lip 4224 extends from the bottom of the outer mandrel body 4220 and provides a surface on which the bottom of the film roll rests. The lower lip 4224 prevents the film roll from sliding off the bottom of the mandrel 4000.

[0127] The rotation stopper slot 4226 is an opening defined by the outer mandrel housing 4220 that receives the rotation stopper 4232 of the outer rotation assembly 4230, as will be described later.

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

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

[0130] A retaining core screw 4212 rotatably secures the retaining core 4216 to the outer mandrel body 4220, particularly to the upper surface (not indicated) of the outer mandrel body 4220. A spring retaining pin 4214 is dimensioned, shaped, positioned, oriented and otherwise configured to engage with 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 screw 4212 and is biased by a spring (not shown) to a first position extending radially outward from the outer mandrel body 4220.

[0131] During 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 the film roll is positioned on the mandrel 4000, the underside of the retaining core 4216 prevents the film roll from sliding upward. To remove the film roll from the mandrel 4000 or to add a film roll to the mandrel 4000, the retaining core 4216 is swung to a second position, in which 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, not preventing the roll from sliding into or off the mandrel 4000.

[0132] External Rotating Assembly The external rotation assembly 4230 includes a rotation stopper 4232, a tension spring 4234, a spring housing 4236, and a rotation clutch disc 4238.

[0133] The rotation stopper 4232 is attached to the first end of the tension spring 4234 and is positioned in the rotation stopper slot 4226 of the outer mandrel body 4220. The positioning of the rotation stopper 4232 within the rotation stopper slot 4226 causes the rotation stopper 4232 to rotate along the outer mandrel body 4220.

[0134] The tension spring 4234 is attached to the rotation stopper 4232 at its first end, extends into the spring housing 4236, and is attached to the spring housing 4236 at its second end. The tension spring 4234 provides a biasing force between the rotation stopper 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 (not indicated) that is dimensioned, shaped, positioned, oriented and otherwise configured to engage with the slewing shaft bearing 4244, and a lower surface (not indicated) that is dimensioned, shaped, positioned, oriented and otherwise configured to engage with the rotating clutch disc 4238.

[0136] The rotating clutch disc 4238 is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the fixed clutch disc 4142. The rotating clutch disc 4238 includes an upper surface (not indicated) and a lower surface (not indicated). The upper surface of the rotating clutch disc 4238 is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the spring housing 4236. The lower surface of the rotating clutch disc 4236 is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the fixed clutch disc 4142 to provide a force that resists the rotation of the outer mandrel assembly 4200 relative to the inner mandrel assembly 4100 about the longitudinal axis 4130A.

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

[0138] The upper bearing 4240 and the lower bearing 4242 each include a ball bearing positioned between the shaft 4130 and the outer mandrel body 4220. The upper bearing 4240 and the lower bearing 4242 enable the rotation of the outer mandrel assembly 4200 relative to the inner mandrel assembly 4100.

[0139] The swivel bearing 4244 is positioned between the shaft 4130 and the outer mandrel body 4220. The swivel bearing 4244 allows the outer mandrel assembly 4200 to rotate relative to the inner mandrel assembly 4100. The swivel bearing 4244 also provides perpendicular support to the outer mandrel body 4220 relative to the shaft 4130.

[0140] The leaf springs 4246A to 4246H are each attached to the outer surface of the outer mandrel body 4220. The leaf springs 4246A to 4246H are arranged in pairs, perpendicularly, and spaced apart around the circumference of the outer mandrel body 4220. This exemplary embodiment includes eight leaf springs, but more or fewer leaf springs may be used. In addition, other types of springs may be used. The leaf springs 4246A to 4246H push the film roll outward against the inner surface of the film roll, rotatably securing the film roll to the outer mandrel body 4220.

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

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

[0143] The spring housing 4236 is rotatably fixed to the rotating clutch disc 4238, which ensures that the spring housing 4236 (and the second end of the tension spring 4234 attached thereto) rotates with the rotating clutch disc 4238. The first end of the tension spring 4234 is fixed to a rotation stopper 4232, which is positioned in a rotation stopper slot 4226 of the outer mandrel housing 4220, so that the first end of the tension spring 4234, the rotation stopper 4232, and the outer mandrel housing 4220 are rotatably fixed to each other.

[0144] Therefore, there are three distinct groups of components that are rotatably fixed to the other components within each group, which are (1) the inner mandrel assembly 4100, rotatably held by the upper mandrel claws 5210 and lower mandrel claws 5250 of the mandrel gripping section 5000, (2) the rotating clutch disc 4238 and spring housing 4236, and (3) the remaining components of the outer mandrel assembly 4200. There are also three bearings connected to two of these three groups, respectively, which include (1) the upper bearing 4240 located between the shaft 4130 of the inner mandrel assembly 4100 and the outer mandrel body 4220, (2) the lower bearing 4242 located between the shaft 4130 of the inner mandrel assembly 4100 and the outer mandrel body 4220, and (3) the swivel shaft bearing 4244 located between the spring housing 4236 and the outer mandrel body 4210.

[0145] Figures 4H, 4I, 4J, 4K, and 4L show cross-sections of the rotation stopper 4232, tension spring 4234, and spring housing 4236. Figures 4H, 4I, 4J, 4K, and 4L show the positions of these components when stationary and during the process of wrapping the film around the coil.

[0146] Figure 4H illustrates the stationary rotation stopper 4232, tension spring 4234, and spring housing 4236. The film roll can be mounted on the mandrel in this stationary state. No external rotational force is 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 stopper 4232 into the stationary position, as shown in Figure 4H.

[0147] Figure 4I shows the position of the rotation stopper 4232 after it has rotated counterclockwise. The counterclockwise rotation of the rotation stopper 4232 occurs when the film is 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 the rotation stopper 4232 stretch and move counterclockwise in response to the external torque.

[0148] Figure 4J shows the position of the rotation stopper 4232 when an external torque is continuously applied. The rotation stopper 4232 reaches the end of the spring housing 4236, stopping its movement. The spring housing 4236 is still held stationary by the rotation clutch disc 4238.

[0149] Figure 4K illustrates the positions of the rotation stopper 4232, the tension spring 4234, and the spring housing 4236 when an external torque continues to be applied after the rotation stopper 4232 has reached the end of the spring housing 4236. The spring housing 4236 begins to rotate counterclockwise. The rotation stopper 4232 remains in contact with the end of the spring housing 4236, and the tension spring 4234 remains fully stretched. Rather than continuing to pull the rotation stopper 4232 and the tension spring 4234, the external torque causes the spring housing 4236, the tension spring 4234, and the rotation stopper 4232 to rotate counterclockwise all simultaneously.

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

[0151] Figure 4L shows the positions of the rotation stopper 4232, tension spring 4234, and spring housing 4236 after the external torque is reduced and the film has slackened. The spring housing 4236 remains in the same position as shown in Figure 4K, held in place by the rotating clutch disc 4238. The tension spring 4234 pulls the rotation stopper 4232 clockwise. The clockwise rotation of the rotation stopper 4232 also rotates the outer mandrel body 4220 clockwise, thereby rewinding the slackened film onto the film roll.

[0152] In this example, the tension spring 4234 has a spring constant that provides a threshold force that must be overcome to stretch 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 generated by the film being pulled away from the film roll first overcomes the spring force and stretches 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 distance traveled by the tension spring 4234 is approximately 90 to 100 degrees of rotation around the spring housing 4236. This rotation allows for approximately 90 to 100 degrees of clockwise rotation (i.e., a 90 to 100-degree rewind returns the slack film to the film roll).

[0154] Mandrel gripping section Each mandrel gripping section 5000 is connected to the respective frame of each applicator arm (such as the frame 132 of the applicator arm 130) and is configured to hold and release a mandrel such as the mandrel 4000 described above, on which a film roll is mounted. The gripping sections can alternatively be configured according to the present disclosure.

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

[0156] The mandrel gripping section 5000 includes a base 5100, an actuator 5130 mounted on the base 5100, and a mandrel engaging body 5200. The base 5100 is dimensioned, shaped, positioned, oriented, and otherwise configured so that the applicator arms can be connected to the respective frames of each applicator arm and move the mandrel gripping section 5000 as needed to perform the various functions described herein. The mandrel engaging body 5200 includes an upper mandrel claw 5210 and a lower mandrel claw 5250, which, under the control of the control device, cooperate to grip a mandrel such as the mandrel 4000 described above.

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

[0158] The arm connection 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 respectively dimensioned, shaped, positioned, oriented, and otherwise configured to connect to the respective frames of the respective applicator arms that move the mandrel gripping section 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 and 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 elongated openings that extend in the direction of movement of the upper mandrel claw 5210 and the lower mandrel claw 5250 during operation. The upper mandrel claw opening 5118 and the lower mandrel claw opening 5120 allow portions of the upper mandrel claw 5210 and the lower mandrel claw 5250 to pass through, respectively, to operably connect to the actuator 5130, as described below. The upper mandrel claw track 5122 and the lower mandrel claw track 5124 are positioned above and below the upper mandrel claw opening 5118 and the lower mandrel claw opening 5120, respectively, as best shown in Figure 5A. The upper mandrel claw track 5122 is sized, shaped, positioned, oriented, and otherwise configured to engage with the track engagement support member 5216 of the upper mandrel claw 5210. Similarly, the lower mandrel claw track 5124 is sized, shaped, positioned, oriented, and otherwise configured to engage with the track engagement support member of the lower mandrel claw 5250.

[0160] In the diagram shown, the actuator 5130 is mounted on the base 5100 and positioned between the first side panel 5112 and the second side panel 5114 on the side opposite the mandrel engager 5200 of the center panel 5116. Alternatively, the actuator 5130 may be mounted on an applicator arm or another component. The actuator 5130 engages operablely and allows movement of the upper mandrel claw 5210 and the lower mandrel claw 5250. The actuator 5130 allows the upper mandrel claw 5210 and the lower mandrel claw 5250 to maintain central positioning in the upright direction, and the vertical center point between the upper mandrel claw 5210 and the lower mandrel claw 5250 remains constant. The actuator 5130 allows mirrored movement of the upper mandrel claw 5210 and the lower mandrel claw 5250, resulting in the claws moving away from or toward each other.

[0161] The upper mandrel claw 5210 and the lower mandrel claw 5250 are similar or identical mirror images of each other. Therefore, only the upper mandrel claw 5210 is 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 extends through the upper mandrel claw opening 5118 and is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the actuator 5130 at its first end. The second end of the actuator engagement arm 5212 is connected to a vertical support bracket 5214. The vertical support bracket 5214 is connected to the actuator engagement arm 5212 at its first end. The vertical support bracket 5214 extends upward and is connected to a track engagement support member 5216 at its second end.

[0164] The track engagement support member 5216 is dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the upper mandrel claw track 5122, and together provides lateral support to the upper mandrel claw 5210. The track engagement support member 5216 and the upper mandrel claw track 5122 also enable smooth vertical movement of the upper mandrel claw 5210. The track engagement support member 5216 is also connected to a lateral mandrel engagement member 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 engaging body 5230. The first finger 5220 and the second finger 5222 are shaped and sized to engage with one of the outer handle block 4120 or the inner handle block 5124 of the mandrel 4000. The finger connecting bar 5224 extends between the first finger 220 and the second finger 5222, connecting the two fingers.

[0166] The U-shaped mandrel engager 5230 extends inward 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-shape is oriented 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 dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the outer handle cylinder 4118 or the inner handle cylinder 4122 of the mandrel 4000. The first handle lock catch 5234 and the second handle lock catch 5236 are located below the U-shaped mandrel engaging body 5230, adjacent to the first finger 5220 and the second finger 5222, respectively. Both the first handle lock catch 5234 and the second handle lock catch 5236 are dimensioned, shaped, positioned, oriented, and otherwise configured to engage / receive with either the outer handle block 4120 or the inner handle block 4124 when the mandrel 4000 is positioned to be held by the grip 5000.

[0167] To move the upper mandrel claw 5210 and the lower mandrel claw 5250, the actuator 5130 acts both claws simultaneously and in opposite directions. To separate the claws, the actuator acts in a first direction, moving the upper mandrel claw 5210 upward and simultaneously moving the lower mandrel claw 5250 downward. To move the claws together, the actuator acts in a second direction opposite to the first direction, moving the upper mandrel claw 5210 downward and simultaneously moving the lower mandrel claw 5250 upward. The actuator may include a piston or other mechanism configured to move the claws as described herein.

[0168] Operation of the mandrel gripping part When the gripping section 5000 is operated, the upper mandrel claw 5210 and the lower mandrel claw 5250 are dimensioned, shaped, positioned, oriented, and otherwise configured to engage with the upper handle 4116 and the bottom handle 4156 of the mandrel 4000, respectively. As described above, the upper handle 4116 and the lower handle 4156 each include an inner handle block and an outer handle block. Each mandrel claw can engage with one of the two handle blocks at a time (i.e., either the inner handle block or the outer handle block). Therefore, there are several combinations of engagements between the upper mandrel claw 5210 and the lower mandrel claw 5250 and 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 the 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 the 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] Therefore, the mandrel gripping unit 5000 is capable of performing several operations, including receiving the mandrel 4000 and the film roll attached thereto, transferring the mandrel and the film roll thereto to another mandrel gripping unit 5000, and removing the mandrel and film roll from the mandrel gripping unit 5000.

[0170] More specifically, each combination of engagements 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 is possible, but for the sake of brevity, only the engagements between the upper mandrel claws 5210 and the lower mandrel claws 5250 and the respective outer handle blocks of the mandrel 4000 will be described below.

[0171] As an initial step, the actuator 5130 is activated by the control device, thereby separating the upper mandrel claw 5210 and the lower mandrel claw 5250 in opposite directions.

[0172] The mandrel gripping section 5000 moves to a position relative to the mandrel 4000, so that the upper handle 4116 and lower handle 4156 of the mandrel 4000 are positioned between the first and second fingers of the upper mandrel claw 5210 and lower mandrel claw 5250, respectively.

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

[0174] The actuator 5130 is activated again by the control device, moving the upper mandrel claw 5210 and the lower mandrel claw 5250 toward each other. The movement of the upper and lower mandrel claws 5210 and 5250 continues until the first handle lock catch 5234 and the second handle lock catch 5236 of the upper mandrel claw 5210 accept and engage with 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 claw 5250 and the outer handle block of the lower handle 4156.

[0175] Next, the mandrel 4000 is locked into the mandrel grip 5000. The first handle lock catch 5234 and the second handle lock catch 5236 engage with the outer surface of the outer handle block 4120 (for example, the surface facing away from the grip 5000), thereby preventing the mandrel 4000 and the film roll on it from coming off the mandrel grip 5000 without the claws separating from each other. The tolerances and geometric shapes of the first handle lock catch 5234, the second handle lock catch 5236 and the handle of the mandrel 4000 placed between them prevent the rotation of the handle of the mandrel 4000, (by preventing the rotation of the handle) prevent the rotation of the inner mandrel assembly 4100 of the mandrel 4000, and prevent the mandrel 4000 from pivoting or tilting during operation.

[0176] Each combination of engagements between the upper mandrel claws 5210 and the lower mandrel claws 5250 and the outer and inner handle blocks of the mandrel is possible. However, for simplicity, only the movement of the mandrel from the first mandrel gripping portion engaged with the respective outer handle block to the second mandrel gripping portion engaged with the respective inner handle block will be described with reference to Figure 6.

[0177] In the initial state, the first mandrel gripping section 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 gripping section 5000 has sole control over the mandrel 4000.

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

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

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

[0181] Next, the actuator of the second mandrel gripping section 5000S is activated by the control device CR, causing the upper and lower mandrel claws of the second mandrel gripping section 5000S to move toward each other. This movement continues until both the first and second handle lock catches of the upper mandrel claws of the second mandrel gripping section 5000S engage with the inner handle block 4120 of the upper handle 4116, and the first handle lock catch and the second handle lock catch of the lower mandrel claw of the second mandrel gripping section 5000S engage with the inner handle block 4156. The first handle lock catch and the second handle lock catch of the gripping section then engage with the inner handle block 4120, locking the mandrel in place on the second mandrel gripping section 5000S.

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

[0183] sensor The coil wrapping system 20 includes a plurality of sensors S configured to sense various states of the coil wrapping system 20, the positions of the components of the coil wrapping system 20, and the amount of remaining film on each film roll held by the gripping portion of the applicator arm. The sensors S are communicably connected to the control device CR. The sensors S can be any suitable sensors.

[0184] Worker Interface The coil wrapping system 20 includes a worker interface OI configured to receive input from an operator and, in certain embodiments, output information to the operator. The worker interface OI includes one or more input devices configured to receive input from the operator. In various embodiments, 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 worker 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 the settings of the coil wrapping system 200. The worker 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 worker interface is formed as part of the coil wrapping system 20 and is mounted, for example, on a mechanical frame 60. In other embodiments, the worker interface is separate from the mechanical frame 60.

[0185] control device The coil wrapping system 20 includes a control device CR which includes a processing device communicatively connected to a memory device. The processing device may include, but is not limited to, any suitable processing device such as a general-purpose processor, a dedicated 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, but is not limited to, any suitable memory device such as 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 removable memory, a magneto-optical medium, and / or an optical medium. The memory device stores instructions that can be executed by the processing device and controls the operation of the coil wrapping system 10 (for example, performing a coil moving process, a coil rotating process, a carriage moving process, a film supply roll loading process, a coil wrapping process, and film roll unloading as described herein). The control device CR is communicatively and operationally connected to the operator interface OI, a plurality of sensors S, actuators that move the first wrapping carriage 100 and its components, the second wrapping carriage 300 and its components, the coil rotating body 500, the first replacement film roll holder 600, the first empty film roll holder 800, the components of the first replacement film roll supply unit 900, the components of the first empty film roll removal unit 1000, the second replacement film roll holder 1600, the second empty film roll holder 1800, the components of the second film roll supply unit 1900, the components of the second empty film roll removal unit 2000, and the feeding and delivery coil moving bodies 550 and 560.

Claims

1. A coil wrapping device, Mechanical frame and A first wrapper supported by a mechanical frame and equipped with first and second applicator arms, A second wrapper supported by a mechanical frame, facing a first wrapper, and comprising third and fourth applicator arms, wherein a coil wrapping region is defined between the second wrapper and the first wrapper, The system comprises control devices operably connected to the first and second wrappers, configured to simultaneously use the first and second wrappers to wrap the first and second films from the first and second film rolls onto coils positioned within the coil wrapping area while the coils rotate around their longitudinal axes, and which are operably connected to the first, second, third, and fourth applicator arms, The control device is The second and fourth applicator arms rotate the coil around its longitudinal axis, passing the first film roll through the coil's eye and moving it in multiple loops around the outer surface of the coil, winding the first film onto the coil, and simultaneously, A coil wrapping device characterized in that first and third applicator arms rotate the coil about its longitudinal axis, pass a second film roll through the eye of the coil, move it around the outer surface of the coil in multiple loops, and wrap the second film around the coil.

2. The coil wrapping apparatus according to claim 1, wherein the first wrapper is movable vertically to a raised position relative to the mechanical frame, and the coil is movable within the coil wrapping area beneath the first wrapper.

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

4. The coil wrapping apparatus according to claim 1, wherein each loop of the first film roll has a substantially rectangular path, and each loop of the second film roll has a substantially rectangular path.

5. The coil wrapping apparatus according to claim 4, 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.

6. The coil wrapping apparatus according to claim 1, wherein the control device is configured to move the first and second wrappers together longitudinally during wrapping.

7. The coil wrapping apparatus according to claim 1, wherein the control device is configured such that the first and second wrappers move the first and second film rolls during wrapping, so that the lateral spacing between the two film rolls is substantially the same.

8. The coil wrapping apparatus according to claim 7, wherein the control device is configured to move the first and second wrappers together in the longitudinal direction during wrapping.

9. The control device moves the second and fourth applicator arms between one of the loops of the first film roll. The second applicator arm holds the first film roll, and while the second and fourth applicator arms are aligned approximately in line with the longitudinal axis of the coil, the second and fourth applicator arms are moved into the eye of the coil, bringing them closer together to apply the first film to a portion of the inner surface of the coil. The first film roll is transferred to the fourth applicator arm within the eye of the coil. Move the second and fourth applicator arms away from each other and out of the coil eye to apply the first film to another part of the inner surface of the coil. The second and fourth applicator arms are moved laterally to apply the first film to a portion of the first side surface of the coil. The second and fourth applicator arms are moved toward each other to apply the first film to a portion of the outer surface of the coil. The first film roll is transferred to the second applicator arm. The coil wrapping apparatus according to claim 1, configured to move the second and fourth applicator arms away from each other to apply the first film to another portion of the outer surface of the coil, and to move the second and fourth applicator arms laterally to align them approximately in line with the longitudinal axis of the coil to apply the first film to a portion of the second side surface of the coil.

10. The control device moves the first and third applicator arms during one loop of the second film roll. The first applicator arm holds the second film roll, and while the first and third applicator arms are spaced laterally apart from the longitudinal axis of the coil, the first and third applicator arms are moved toward each other to apply the second film to a portion of the outer surface of the coil. The second film roll is transferred to the third applicator arm. Move the first and third applicator arms away from each other to apply the second film to another portion of the outer surface of the coil. The first and third applicator arms are moved laterally until they are roughly aligned with the longitudinal axis of the coil, thereby applying the second film to a portion of the first side surface of the coil. The first and third applicator arms are moved into the coil eye and toward each other to apply the second film to a portion of the inner surface of the coil. The second film roll is transferred to the first applicator arm in the coil eye, Move the first and third applicator arms away from each other, and move them out of the coil eye, to apply the second film to another part of the inner surface of the coil. The coil wrapping apparatus according to claim 9, configured to move first and third applicator arms laterally to apply a second film to a portion of the second side surface of the coil.

11. The coil wrapping device according to claim 1, further comprising a coil rotating body positioned within the coil wrapping region, wherein the control device is operably connected to the coil rotating body and configured to cause the coil rotating body to rotate the coil about its longitudinal axis.

Images