Double spooler
The double-coil winder automates the transfer and positioning of the free wire end, addressing the productivity disruption caused by manual handling, ensuring efficient coil changes without machine stoppages.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- MASCHINENFABRIK NIEHOFF GMBH & CO KG
- Filing Date
- 2025-12-15
- Publication Date
- 2026-06-25
Smart Images
Figure EP2025087065_25062026_PF_FP_ABST
Abstract
Description
[0001] - 1 - December 16, 2025
[0002] 120590P22PC
[0003] Twin spooler
[0004] Description
[0005] The entire content of priority application DE 10 2024 137 913.8 is hereby incorporated by reference into the present application.
[0006] The present invention relates to a double-coil winder for winding a wire onto one of two coils. The wire is preferably made of an electrically conductive material and further preferably of a metallic material, in particular copper, aluminum, iron or nickel, or of an alloy containing at least one of these metals.
[0007] A double spooler is used in particular downstream of a wire drawing plant in order to wind the wire produced in the wire drawing plant onto spools and to transport, store and process it further in this form.
[0008] Once a coil is completely wound with wire, the wire, which is preferably produced continuously by the wire drawing machine and thus as a virtually endless strand, must be cut off and wound onto a new, empty coil.
[0009] The term "fully wound" can mean that the maximum permissible winding diameter on the coil has been reached, but also that the coil is sufficiently wound with wire due to other restrictions, for example, due to a maximum permissible weight of the coil or because the quantity of wire ordered by a customer has been reached. The term "fully wound" is therefore not to be understood as technically restrictive, but simply describes a degree to which the coil is filled with wire, at which the winding of the coil with wire is completed.
[0010] Since the wire drawing machine should ideally not be stopped during the required change from a fully wound to an empty spool, which would impair its productivity, a double spooler of the type considered here can be used, which can accommodate two spools. The removal of the fully wound spool and the feeding of an empty spool, the removal of the full spool from the double spooler and the insertion of the empty spool into the double spooler, as well as the cutting of the wire and the transfer of the wire from the fully wound to the empty spool, can be carried out largely or even fully automatically.
[0011] The wire is cut and transferred from the fully wound to the empty spool while both are simultaneously loaded into the double spooler. This can be done at full or reduced wire feed speed without stopping the upstream wire drawing machine, thus minimizing disruption to its productivity and the overall operational process.
[0012] The twin-coil winder underlying the present invention is generally known from the prior art and is offered, for example, by the applicant under the designations SND 631 and SND 801.
[0013] The coils generally consist of a cylindrical or conical core onto which the wire is wound, and two flanges that secure the core at both ends to prevent the wire from slipping off. - 3 - December 16, 2025
[0014] For example, the double-coil winders offered by the applicant have a maximum coil flange diameter of 630 or 800 mm, a minimum coil core diameter of 250 or 280 mm, and a total length of 475 or 600 mm. A coil fully wound with wire can then have a maximum coil weight of 600 or 1,350 kg.
[0015] Cutting the wire during the transfer from the fully wound to the empty spool leaves the cut, free wire end loose on the fully wound spool, hindering further transport. Therefore, after the fully wound spool is removed from the double-winder, an operator manually secures this free wire end to or on the spool. The position of the free wire end once the spool's rotation has stopped after winding is random. Consequently, the spool must first be manually rotated into a position that allows the operator to perform this securing. Due to the spool's dimensions, and especially the considerable weight of a fully wound spool, this is a laborious, time-consuming, and physically demanding process.
[0016] The invention is therefore based on the objective of improving the handling of the fully wound coil and in particular the free wire end when extending the fully wound coil from the double coiler.
[0017] This problem is solved by a double-coiler according to claim 1 and by a method for winding a wire onto each of two coils with such a double-coiler according to claim 6. Preferred embodiments of the invention are the subject of the dependent claims. - 4 - December 16, 2025
[0018] The double coiler considered here for winding a wire onto one of two coils has the following components: for each of the two coils (4a, 4b) a clamping device which is designed to receive the respective coil for winding from the coil with the wire in such a way that the two coil axes are essentially parallel to each other, and to set them into rotation independently of each other about the respective coil axis.
[0019] The two clamping devices are preferably rotatably mounted on a stationary machine part, in particular a frame, chassis, or housing, of the twin-coil winder and are driven independently of each other by a separate motor. Each of the two coils is preferably clamped axially by being received in a clamping device and tensioned by an axially movable quill. Depending on the design of the twin-coil winder, the coil axes of the two coils can run horizontally, vertically, or in another direction. A separate winding device is provided for each coil, or a common winding device is provided for both coils. This device is movable in the direction of the respective coil axis or the two coil axes and is designed to guide the wire in such a way that it runs onto the coil being wound, or onto a winding already formed on the coil, at various axial positions.
[0020] During the winding of each coil, the laying device moves back and forth along the coil axis between the two coil flanges, thus ensuring that the winding is built up evenly over the axial length of the coil core. For this purpose, the wire preferably runs over a deflecting roller that moves parallel to the coil axis, the axis of which is also aligned parallel to the coil axis - 5 - December 16, 2025, and from which the wire is guided, preferably at a short distance, onto the winding on the coil. Each coil has a catch disc, which is arranged concentrically to the respective coil axis and is rotationally fixed to the respective clamping device (24a, 24b), with a catcher that is rotationally fixed to the respective catch disc at a specific position on the circumference of the drive shaft and is designed to detachably fix the wire to the catcher, in particular to clamp it.
[0021] The catcher disc is preferably arranged concentrically to the coil axis directly behind the coil flange facing the catcher disc and is rotationally fixed to the clamping device of the associated coil. The catcher is preferably a mechanical clamping device that can clamp a wire lying tangentially against the catcher disc or passing a short distance in front of it, thus "catching" it and carrying it along when the catcher disc rotates, so that the wire can be wound onto the associated coil. The catcher is preferably attached to the outer circumference of the catcher disc. For each catcher disc, a capping device is provided, which is fixedly arranged adjacent to the respective catcher disc and is designed to cut the wire when the wire is fixed to the catcher on the catcher disc and the catcher passes the position of the capping device during rotation of the catcher disc.
[0022] The term "stationary" is used here and in the following to refer to a fixed position relative to a stationary part of the twin-coil amplifier, in particular to a frame, chassis, or housing of the twin-coil amplifier. - 6 - December 16, 2025
[0023] The capping device preferably has a cutting edge that cuts the wire when the wire is pulled past the capping device by the catcher on the rotating catcher disc and is under sufficient tension. The capping device is thus a passive device without moving parts and therefore requires little maintenance. For each catcher disc, an opening device is provided, which is fixedly arranged adjacent to the respective catcher disc at a specific position on the circumference of the catcher disc and is controllable such that the wire is released from its fixation in the catcher of the catcher disc when the wire is fixed in the catcher and the catcher passes the position of the opening device during a rotation of the catcher disc.
[0024] The opening device works, preferably through mechanical contact with the catcher as it passes over the rotating catcher disc, to release the wire from its fixation within the catcher. Unlike, for example, the capping device, the opening device is preferably not designed as a passive device without moving parts, since otherwise it would release the wire's fixation every time the catcher passes the opening device's position during a rotation of the catcher disc.
[0025] This should only occur, however, when the fully wound coil is to be removed from the double coiler, and as a prerequisite for this, the wire must be released from its fixation in the catcher. For this reason, the opening device is controllable with regard to its effect; that is, it can be switched on and off and only releases the wire's fixation when it passes the catcher if it is switched on. This control can be achieved, for example, by one or more electromechanical actuators controlled by a central control unit of the double coiler. - 7 - 16 December 2025 a transfer device which is configured to pivot the wire, while it is being wound onto one of the two coils, in such a way that, viewed in the direction of the two coil axes, it overlaps with the catcher disc belonging to the other of the two coils (4a, 4b).
[0026] The transfer device preferably has a deflection roller which is movable on a rail arranged next to the two catch discs between each position adjacent to the respective catch disc and thereby “carries” the wire in the direction of one of the two catch discs and pivots it in the manner mentioned.
[0027] This describes all the essential components for the function of the double coiler, in particular for the automatic transfer of the wire from a fully wound coil to an empty coil.
[0028] According to the invention, the double spooler further comprises for each of the two catching discs sensing means for sensing the capping rotation position of the respective catching disc, i.e. the rotation position of the catching disc with respect to a first reference position on the circumference of the catching disc, in particular the position of the catcher, relative to a second, stationary reference position, in particular the position of the opening device, at a time when the capping device on the other catching disc cuts the wire.
[0029] Note that the wire is not cut at the fully wound spool, but at the other, empty spool, to whose catcher the wire was previously secured. By detecting the cutting position, information is available that is necessary for precisely rotating the spool, ensuring that the free (cut) wire end lies in a specific position. For example, using this information, the spool can be rotated until, as the spool is extended from the double spooler, the free wire end is pointing towards the operator, allowing the operator to secure the free wire end without having to manually rotate the spool any further.
[0030] The first reference position on the circumference of the catch disc and the second, fixed reference position are, in principle, arbitrary. If the catch disc already has a specific marking on its circumference and / or a specific fixed marking, which, for example, are used to calibrate the rotational position of the drive shaft, these markings can preferably also be used as the first and second reference positions, respectively. However, it is particularly preferred to use the angular position of the catcher on the catch disc as the first reference position and / or the angular position of the fixed opening device as the second reference position, since the catcher passes the opening device when the wire is released, meaning that the catch disc already has a defined rotational position at that point.
[0031] By detecting the cap rotation position, the handling of the fully wound coil and especially the free wire end is improved when extending the fully wound coil from the double coiler, thus solving the underlying problem.
[0032] Preferred further developments of the invention are described below.
[0033] In a preferred embodiment of the invention, each capping device on one of the two catching discs has a cutting device made of an electrically conductive material, which is in contact with the wire during the cutting process. The detection means are configured to detect the electrical contact between the cutting device and the wire. The detection means further comprise a - 9 - December 16, 2025
[0034] Rotation angle detection device for the other capture disc and are designed to detect and store the cutting rotation position of the other capture disc using a time from the beginning to the end of the electrical contact between the cutting device and the wire during the cutting process.
[0035] This design takes advantage of the fact that wire, which is generally metallic, is also electrically conductive. This allows the moment of the cutting process to be detected simply and reliably. A particularly advantageous feature is that the cutting device is electrically insulated from the rest of the capping mechanism (for example, the cutting device is a metallic blade in a plastic housing), and the cutting device is connected to a cable. This cable completes a circuit through the cutting device and the wire, thereby detecting the electrical contact between the cutting device and the wire.
[0036] Since the cutting process occurs very quickly in practice, the beginning and end of the electrical contact between the cutting device and the wire are very close together in time. Therefore, to detect the cutting rotation position of the other drive shaft, either the beginning or end time, or an intermediate point in time, can be selected.
[0037] In a further preferred embodiment of the invention, the double reel further comprises control means which are configured to rotate one and / or the other of the two capture discs into a specific rotational position relative to the first and second reference positions, depending on the cap rotation position of the respective capture disc detected by the detection means.
[0038] The control means make it possible, in particular, to rotate the catch disc and the clamping device connected to it in a rotationally fixed manner, and thus the spool - as described above - IQ - December 16, 2025 - into a rotational position favorable for further handling before it is extended from the double spooler.
[0039] In a preferred embodiment of the invention described above, the double-coil winder further comprises a pressing device for each of the two clamping devices, which is arranged such that it always has essentially the same position relative to the respective coil. The pressing device is configured to press the wire wound onto the coil against the winding from the radial outside.The control means are designed to rotate the respective coil, after the wire has been cut, depending on the detected cutting position, into a rotational position in which the length of the free wire end, measured from the point where the pressure device last presses the wire against the winding in the direction of the wire's endpoint, to the wire's endpoint, is at most one tenth, preferably at most one twentieth, and more preferably at most one fortieth of the length of the last complete turn of the wire on the coil.
[0040] The pressure device prevents the winding on the spool from loosening after the wire is cut and prevents the last turns of wire from falling off the spool. It preferably has the form of a flap, which is pressed against the winding on the spool from the radial outside to the inside, particularly by spring force. The pressure device can press the wire against the winding along its entire axial length or only in the area of the last wound turns, as this is where the risk of loosening and slippage is greatest.
[0041] That the pressing device always has essentially the same position relative to a given coil preferably means that this position is essentially the same not only when the coil is held in the clamping device, but also when the coil is extended from the double coiler. In this way, it is ensured that the free wire end remains pressed against the winding even when the coil is extended from the double coiler and does not hinder further handling of the coil, for example by getting caught or snagged.
[0042] The fact that the free wire end does not hinder further handling of the coil is ensured in particular by the short length of the free wire end, which can be achieved according to this embodiment of the invention.
[0043] In a further preferred embodiment of the invention described above, the double-coil winder further comprises a transport device for each of the two clamping devices, which is configured to transport the respective coil into a position in which the coil can be received in the respective clamping device, and / or to transport the coil away from this position. The respective pressing device is attached to the transport device in such a way that it always maintains essentially the same position relative to the transported coil during the transport of the coil.
[0044] This ensures that the pressure device always has essentially the same position relative to the respective coil, even during the insertion of the coil into or during the removal of the coil from the twin coiler, the latter being the more relevant case, as the coil is then fully wound.
[0045] The transport device is preferably a chain conveyor onto which the spool can be placed or laid and to which the pressing device is also attached.
[0046] The invention further relates to a method for winding a wire onto one of two coils using a double coiler according to the invention. (December 16, 2025)
[0047] The procedure comprises the following steps, which further illustrate the functionality of the double coiler as explained above:
[0048] - Picking up a first, empty coil by one of the first of the two clamping devices,
[0049] - Fixing one wire end to the catcher of the first catching disc,
[0050] - Winding the wire onto the first coil,
[0051] - before or during winding the wire onto the first coil: taking a second, empty coil through the second of the two clamping devices,
[0052] - as soon as the first coil is completely wound: pivoting the wire by the transfer device in such a way that the wire, viewed in the direction of the two coil axes, overlaps with the second catch disc,
[0053] - Rotating the second capture disc until the catcher of the second capture disc contacts the wire,
[0054] - Securing the wire to the catcher of the second capture disc,
[0055] - Rotating the second capture disc until the catcher of the second capture disc passes the position of the cap device on the second capture disc,
[0056] - Cutting the wire by the cap device on the second capture disc,
[0057] - Capturing and storing the capping rotation position of the first capture disc at a time when the capping device on the second capture disc cuts the wire,
[0058] - Determining a first angular difference between the angular position of the catcher on the first catching disc and an imaginary angular position of the end of the cut wire on the winding on the first coil, if the free wire end were completely wound onto the first coil, from the angular difference between the position of the catcher and the first reference position, the capping rotation position of the first catching disc, the position of the point where the wire runs onto the winding on the first coil when the wire is cut, and the length distance between this point of entry and the capping device on the second catching disc, - 13 - 16 December 2025
[0059] - Rotating the first capture disc until the catcher of the first capture disc passes the position of the opening device on the first capture disc,
[0060] - Controlling the opening device on the first trap disc in such a way that the fixation of the wire on the trap of the first trap disc is released,
[0061] - Rotating the first capture disc by an angle dependent on the first angle difference, so that the position of the imaginary end of the cut wire corresponds to a specific fixed position,
[0062] - Removing the first coil from the first clamping device.
[0063] Preferably, the second catching disc rotates until the catcher contacts the wire, the wire is fixed to the catcher, the second catching disc rotates until the catcher passes the position of the capping device, and the wire is cut by the capping device at a high to very high speed of the second catching disc or the second coil, particularly continuing at nearly the same winding speed as the first coil. The subsequent rotation of the first catching disc until the catcher passes the position of the opening device, the release of the wire's fixation to the catcher, and the rotation of the first catching disc by an angle dependent on the first angular difference, preferably occur at a significantly reduced speed of the first catching disc or the first coil. Preferably, the two coils are operated at different speeds for this purpose.In particular, the first coil can run out of power and then continue to rotate at a low speed, while the second coil is already being wound at the high winding speed.
[0064] The procedure defined above describes the initial winding of a coil with wire after switching on the double-coil winder and thus assumes that no coil has yet been inserted into either of the two clamping devices. For winding the second and all subsequent coils, all steps except the first two are to be repeated, with the first and second steps being repeated on December 16, 2025.
[0065] The catch disc, the first and second clamping devices, and the first and second coils exchange their roles. The first two steps (the first clamping device picking up the first, empty coil and fixing the wire end to the catch of the first catch disc) are omitted, since after the last step, one coil (now the second) is already held in one of the clamping devices and the wire is already fixed to its catch. Otherwise, the process can, of course, be repeated any number of times to wind any number of coils alternately.
[0066] In a preferred embodiment of the inventive method with a double-coiler, which further comprises a pressing device, a second angular difference is additionally determined between the position of the opening device on the first catching disc and the position of the pressing device on the first catching disc. The angle dependent on the first angular difference is then calculated using the second angular difference such that, after rotating the first catching disc by this angle in the penultimate step of the method, the length of the free wire end is at most one-tenth, preferably at most one-twentieth, and more preferably at most one-fortieth of the length of the last complete turn of the wire on the first coil.
[0067] The advantages of this embodiment of the method correspond to the advantages already explained above for the corresponding embodiment of the twin spooler according to the invention.
[0068] Further advantages, features and applications of the present invention will become apparent from the following description in conjunction with the figures. These show:
[0069] Fig. 1 shows a twin-coil winder according to the invention in a side view.
[0070] Direction of the coil axes during the wire transfer from one - 15 - 16 December 2025
[0071] Spool onto the other, just before catching and cutting the wire;
[0072] Fig. 2 shows the same view as in Fig. 1, but shortly after the wire has been cut;
[0073] Fig. 3 shows a section of the double coiler according to Figs. 1 and 2 in a cross-section through the coil axis of one of the coils;
[0074] Fig. 4 shows a section of the double coiler according to Figs. 1 and 2 in a side view parallel to the coil axes during the winding of one of the coils;
[0075] Fig. 5 shows the same view as in Fig. 4, after the wire has been guided to the coil's capture disc;
[0076] Fig. 6 is a close-up of Fig. 1 showing the first capture disc and the first fully wound coil.
[0077] The double coiler 1 according to the invention and the method for winding a wire 2 with the double coiler 1 will now be explained with reference to an embodiment according to the figures 1 to 6.
[0078] The double spooler 1 has a frame 19, which is stationary and therefore fixed in place. Furthermore, the double spooler 1 has a first and a second clamping device 24a, 24b for holding a first and a second spool 4a, 4b, respectively. The clamping devices 24a, 24b are shown in Fig. 3 and are described in detail below. On one side of each clamping device 24a, 24b, a catch disc 14a, 14b is arranged concentrically to the respective spool axis 7a, 7b and non-rotatably connected to the respective clamping device 24a, 24b. Each catch disc 14a, 14b is located directly adjacent to a flange 5a, 5b of the respective spool 4a, 4b when the spool is held in the respective clamping device 24a, 24b. The two catch discs 14a, 14b are rotatably mounted on the frame 19. The axes of the two clamping devices 24a, 24b and 24b respectivelyThe two coil axes 7a, 7b are parallel to each other, and the two catch discs 14a, 14b lie in the same plane. - 16 - December 16, 2025.
[0079] The coils 4a, 4b to be wound are fed by chain conveyors 13a, 13b from outside the double coiler 1 to the respective clamping device 24a, 24b for insertion as empty coils. After winding, the coils are conveyed as full coils from the respective clamping device 24a, 24b to the outside of the double coiler 1 by the same chain conveyors 13a, 13b. For this purpose, the two chain conveyors 13a, 13b are arranged parallel to each other and parallel to the axes of the clamping devices 24a, 24b on opposite sides of the double coiler 1. The conveying direction of the chain conveyors 13a, 13b is therefore to the left and right, respectively, in Figures 1, 2, and 6, and into and out of the plane of the image, respectively, in Figures 3, 4, and 5. Furthermore, the chain conveyors 13a, 13b have a suitable device (not shown) upstream of the respective tensioning device 24a, 24b for feeding the coils 4a, 4b into the respective.to remove coils 4a, 4b from the double coiler 1.
[0080] Each chain conveyor 13a, 13b is further equipped with a pressure flap 12a, 12b, which presses the winding 6a, 6b of a fully wound coil 4a, 4b against the coil core, both when the coil 4a, 4b is held in the clamping device 24a, 24b and when the coil 4a, 4b is transported out of the double coiler 1 on the chain conveyor 13a, 13b. The pressure flap 12a, 12b prevents the wire 2 from loosening on the winding 6a, 6b and from partially falling off the winding 6a, 6b.
[0081] Each coil 4a, 4b has a core, which can be conical or, as in the illustrated embodiment, cylindrical, and onto which a winding 6a, 6b of the wire 2 can be applied. The axis of symmetry of the core simultaneously forms the coil axis 7a, 7b and thus also the axis of rotation of the coil 4a, 4b when it is held in the respective clamping device 24. In Figures 1 and 2, only one winding 6a is shown on the first coil 4a, since the coil 4a is fully wound in the situation shown, whereas the second coil 4b is empty. The core of each coil 4a, 4b is bounded at its axial ends by two coil flanges, which secure the winding 6a, 6b against slipping off the core in the axial direction. In each figure only the coil flange 5a, 5b, which is directed towards the catch disc 14a, 14b, is shown.
[0082] In the double-coil winder 1 according to the exemplary embodiment, the axes of the catch discs 14a, 14b, and thus also the coil axes 7a, 7b, are horizontally aligned during the winding of the coils 4a, 4b. However, this is not to be considered a limitation for the invention. The coil axes 7a, 7b could just as well be vertically aligned or aligned in another direction during the winding process.
[0083] The coils 4a, 4b are inserted into the clamping devices 24a, 24b from both axial ends. Each coil 4a, 4b is pressed against a hydraulically movable quill 21a, 21b (see Fig. 3) from the axial side opposite the corresponding catch disc 14a, 14b, thus clamping it axially and centering it by the quill 21a, 21b and, on the other side facing the catch disc 14a, 14b, by coil holding elements 23a, 23b. In this state, the two coils 4a, 4b can be rotated independently of each other by the drive shafts 22a, 22b. Specifically, the two coils 4a, 4b rotate in opposite directions and on their facing inner sides with the direction in which the wire 2 enters (as indicated by the two arrows in Fig. 2), so that they can pull the wire 2 onto the respective winding 6a, 6b on these inner sides and thereby wind it up.The two coils 4a, 4b, and thus also the two catch discs 14a, 14b, always rotate only in their respective directions during operation of the double coiler 1, since a reversal of direction would pose a risk of uncontrolled unwinding of the windings 6a, 6b on the coils 4a, 4b. - 18 - December 16, 2025.
[0084] To distribute the wire 2 evenly on the windings 6a, 6b in the axial direction of the coils 4a, 4b, the double coiler 1 has a laying device 25. This guides the wire 2 over a deflecting roller, the axis of which is aligned parallel to the coil axes 7a, 7b and which can move back and forth in the axial direction, onto the respective winding 6a, 6b.
[0085] The wire 2 is preferably produced in an upstream drawing machine (not shown). The wire 2 runs from above over a deflecting roller 20 into the double spooler 1 and is to be wound onto one of the spools 4a, 4b. For this purpose, the rotational speed of the spools 4a, 4b is regulated synchronously with the drawing machine such that the exit velocity of the wire 2 from the drawing machine is equal to the speed of the wire when wound onto the spool. The speed of the wire is always to be considered the linear feed rate of the wire.
[0086] Which of the two coils 4a, 4b is wound depends on which coil 4a, 4b (or the winding 6a, 6b built on it) the wire 2 is connected to. As soon as one of the two coils is completely wound—in this embodiment, this is the first coil 4a—the wire must be cut from the winding 6a on the first coil 4a and transferred to the other coil—here, the second coil 4b—which is still empty, and connected to it. This happens fully automatically in the double coiler 1 without human intervention. During the transfer of the wire 2, the second coil 4b is brought to the same rotational speed as the first coil 4a. During the transfer process, only the speed of the wire 2 in the upstream drawing machine, and consequently also in the double coiler 1, can be temporarily reduced.
[0087] The process of cutting and transferring wire 2 from the first coil 4a to the second coil 4b is described in detail below: - 19 - December 16, 2025
[0088] As soon as the winding 6a built up on the coil 4a has reached its maximum permissible diameter, or the winding of the coil 4a is to be terminated for any other reason, the laying device 25 is controlled such that the wire 2 is wound onto the axial end of the coil 4a facing the catch disc 14a, i.e., near the coil flange 5a, or the device waits until it reaches this axial position anyway during the winding of the coil 4a. Since the two coils 4a, 4b – corresponding to the catch discs 14a, 14b – are arranged with axes 7a, 7b parallel to each other and at the same height, i.e., with flanges 5a, 5b in one plane, the axial position of the wire 2 is thus also near the coil flange 5b of the second coil 4b.
[0089] Above the two catch discs 14a, 14b, a guide rail 17 is arranged, on which a deflecting roller 18 can move back and forth between a position above the first catch disc 14a and a position above the second catch disc 14b. The guide rail 17 can also be tilted horizontally to bring the deflecting roller 18 closer to the respective catch disc 14a, 14b. The deflecting roller 18 is also positioned axially close to the coil flanges 5a, 5b and thus at the same axial position as the wire 2 in the situation just described. If the deflecting roller 18 is now moved from a position above the first catch disc 14a, i.e. from the left in Figs. 1 and 2, on the guide rail 17 to the second catch disc 14b, i.e. to the right in Figs. 1 and 2, it pushes the wire 2 - which continues to run onto the winding 6a on the first coil 4a - in the form of a triangular bulge in the direction of the second catch disc 14b.
[0090] This situation is also shown in Fig. 4, which shows the double spooler 1 in the area of the second capture disc 14b and the second spool 4b from the side.
[0091] Then, two crossbars 15b, 16b, which are mounted near the coil 4b and between whose open ends the wire 2 runs, move axially towards each other. The crossbars 15b, 16b guide the wire 2 in such a way that it is pressed axially outwards over the coil flange 15b in the direction of the catch disc 14b.
[0092] This situation is illustrated in Fig. 5.
[0093] The catch disc 14b is coaxially connected to the coil 4b between the coil flange 5b and a flange 3b, and is rotationally fixed to the drive shaft 22. It has a slightly larger diameter than the coil flange 5b. A catcher 8b is also mounted on the outer circumference of the catch disc 14b. This catcher is capable of clamping and thus mechanically fixing (or "catching") the wire 2 as soon as it first touches the circumference of the catch disc 14b at the location of the catcher 8b or comes close to it.
[0094] The catcher 8b then pulls the wire 2 along the circumference of the catcher disc 14b until it reaches the position of the cutting bar 9b, which is fixed in a position located between the two coils 4a, 4b, near the circumference of the catcher disc 14b and also at the axial position of the catcher disc 14b. The cutting bar 9b has a metallic cutting edge and is arranged such that when the catcher 8b passes its position on the catcher disc 14b, it cuts the wire 2.
[0095] This situation is shown in Fig. 2, which otherwise shows the double spooler 1 in the same view as Fig. 1.
[0096] The catching disc 14b therefore rotates a maximum of approximately 30° between the "catching" and the cutting of the wire 2,
[0097] Now the guide roller 18 moves on the guide rail 17 into a "neutral" position between the first and second coils 4a, 4b, so that it no longer touches the wire 2 and therefore no longer guides it. - 21 - December 16, 2025
[0098] The traversing rods 15b, 16b remain in their positions after the wire 2 has been cut and are only moved back to their axial starting positions after a new coil 4b has been inserted, namely the traversing rod 15b towards the center of the coil and the traversing rod 16b behind the catch disc 14b.
[0099] Thus, the wire 2, guided by the laying device 25, can now be wound onto the second coil 4b and forms a winding 6b there. The end of the wire 2 remains fixed to the catcher 8b, which prevents the wire 2 from "slipping" onto the second coil 4b.
[0100] The first coil 4a, on the other hand, is now completely wound and is to be removed from the clamping device 24a. To do this, the end of the wire 2, which was fixed to the catch disc 14a by the catcher 8a at the beginning of the winding of the first coil 4a – by a corresponding process as just described for the second coil 4b – must first be released. For this purpose, an opening device 10a is fixedly mounted in the area of the outer circumference of the catch disc 14a. The opening device 10a can be switched on and off and, when switched on, releases the fixation of the wire 2 to the catcher 8a as soon as it passes the position of the opening device 10a. The opening device 10a remains switched off during the winding of the coil 4a. After the coil 4a is completely wound, the drive of the drive shaft 22a is switched off, so that the catch disc 14a with the coil 4a can come to a standstill.Then the opening device 10a is activated, and the catch disc 14a continues to rotate at a low speed until the catcher 8a on the catch disc 14a passes the position of the opening device 10a, thus releasing the wire 2 from the catcher 8a. This eliminates the connection between the wire 2 on the winding 6a on the first coil 4a and parts of the double coiler 1. The coil 4a can then be removed from the double coiler 1 by the chain conveyor 13a. - 22 - December 16, 2025.
[0101] As can be seen in Fig. 2, cutting the wire 2 by the cutting bar 9b creates a free wire end 11, which hangs loosely from the winding 6a on the first coil 4a. With each revolution of the coil 4a, the free wire end 11 is pulled under the pressure plate 12a. Its length, measured from the point where the wire 2 is last pressed against the winding 6a by the pressure plate 12a to the end of the wire 2, can therefore be at most the length of a complete wire turn with the maximum diameter on the winding 6a. Since the diameter of the coil flange 5a in a double-coil winder 1 of the type considered – as stated above – can be, for example, up to 800 mm, and the winding 6a can approximate the diameter of the coil flange 5a, the length of the free wire end 11 can thus be up to approximately 2.5 m.The actual length of the free wire end 11 depends on the angular difference between the endpoint of the wire 2 and the position of the pressure flap 12a once the rotation of the coil 4a has come to a standstill after it has been fully wound and is therefore random.
[0102] It is obvious that a free wire end 11 of this length can cause problems during the further processing of the fully wound coil 4a, for example, by the free wire end 11 getting caught in the double coiler 1 or in the chain conveyor 13a and breaking off during the further transport of the coil 4a, or by further turns of the wire 2 coming loose from the winding 6a in an uncontrolled manner and falling off.
[0103] According to the invention, it is therefore provided that the angular position of the free wire end 11 on the coil 4a can be determined. The angular position of the free wire end 11 is understood to be the angular position of the endpoint of the wire 2 on the coil 4a, assuming that the wire 2 is completely in contact with the winding 6a up to this endpoint.
[0104] The coil 4a can then be selectively rotated into a position such that the free wire end 11 is very short, in particular only a few centimeters long. This avoids the aforementioned problems with the free wire end 11, and the coil 4a can be easily processed further after being removed from the double coiler 1, for example, by a human operator attaching the free wire end 11 to the coil 4a or by packaging the entire coil 4a, preferably in a film. Even independently of the pressure flap 12a, the coil 4a can be selectively rotated in this way into a position that allows the operator to attach the free wire end 11 to the coil 4a without having to manually rotate the coil 4a again. The same applies if the attachment of the free wire end 11 to the coil 4a and / or the packaging of the coil 4a is automated.
[0105] The detection of the angular position of the free wire end 11 is now explained with reference to Fig. 6, which shows a close-up of Fig. 1 of the first catch disc 14a and the first coil 4a. In Fig. 1 and Fig. 6, the wire 2 also runs over the cutting steel 9b in the side view and thus has the same path as at the time shortly thereafter when it is cut.
[0106] The endpoint of the wire 2, where it is cut by the cutting steel 9b, is designated D. The point where the free wire end 11 meets the winding 6a is designated D'. Since the geometric dimensions of the double spooler 1 and the catch disc 14a are constant, and the wire path at the time of cutting the wire 2 is always the same, both the angular position of point D' (in the exemplary embodiment approximately at the four o'clock position) and the distance between points D and D' are constant. If one imagines the free wire end 11 completely wound onto the winding 6a, the endpoint of the wire 2 lies at a point D" on the winding 6a, which in the exemplary embodiment is approximately 104 degrees away from point D' (measured counterclockwise). This angular distance on the winding 6a is also constant if one assumes the maximum diameter of the winding 6a to be constant as well.Point D” thus always has the same angular position relative to the surroundings of the catching disc 14a at the time the wire 2 is cut. In the exemplary embodiment, point D” is located approximately at the one o'clock position. In a specific implementation of the method according to the invention, the diameter of the winding 6a can additionally be measured by a suitable sensor and taken into account when determining point D”.
[0107] The cutting tool 9a has a cutting edge (not shown) which is electrically insulated from the housing of the cutting tool 9a. The contact between the wire 2 and the cutting edge can thus be easily detected electrically if the cutting edge and the wire 2 are in a common circuit. Such a circuit is preferably formed with the power supply, in particular by a frequency converter, of the drive of the first drive shaft 22a. The point in time at which the wire 2 is cut can be considered to be, in particular, the point in time of the last contact between the cutting edge and the wire 2.
[0108] At the moment the wire 2 is cut, the angular difference between a first reference position on the catch disc 14a and a second, stationary reference position is simultaneously determined by a rotary encoder (not shown). For simplicity, the first reference position is position F of the catch 8a, since the catch disc 14a and the drive shaft 22a are rotationally fixed to each other, and the second, stationary reference position is position O of the opening device 10a. In the exemplary embodiment, the angular difference between points F and O at the moment the wire 2 is cut is approximately 178 degrees.
[0109] The calibration of the angular position of the catch disc 14a, i.e., the determination of a zero position, is carried out by an initiator (not shown) permanently installed on the drive shaft 14a when the double coiler is switched on. 1. - 25 - 16. December 2025
[0110] The angle difference between points D" and O is also constant; in this example, it is approximately 20 degrees. The angle difference between points F and D" is therefore approximately 158 degrees.
[0111] Additionally, the angular difference between points O and A is determined, where point A denotes the position on the circumference of the catch disc 14a at which the pressure flap 12a last presses the wire 2 against the winding 6a. Since the opening device 10a is fixed in place and the pressure flap 12a can also be considered fixed in place, at least when the coil 4a is held in the clamping device 24a, this angular difference is constant. In the exemplary embodiment, it is approximately 115 degrees.
[0112] Knowing these angular differences, the rotation of the capture disc 14a can now be controlled as desired:
[0113] First, as described above, the capture disc 14a, after its rotation has come to a standstill, is rotated at low speed until the catcher 8a passes the opening device 10a and the fixation of the wire 2 to the catcher 8a is released.
[0114] At this moment, the angular positions of point F on the catch disk 14a and the stationary point O coincide. Thus, the angular difference between points O and D" is approximately 158 degrees, and between points O and A approximately 115 degrees. Consequently, the catch disk 14a must be rotated approximately 43 degrees counterclockwise so that points D" and A coincide. This corresponds to the theoretically optimal position in which the endpoint of the wire 2 lies exactly where the pressure flap 12a last presses the wire 2 against the winding 6a, and thus the free wire end 11 has a length of zero. However, since the catch disk 14a can only be rotated clockwise in the exemplary embodiment due to the orientation of the winding 6a, the catch disk 14a is instead rotated counterclockwise. - 26 - December 16, 2025
[0115] 360 degrees - 43 degrees = 317 degrees further rotated clockwise to reach the stated position.
[0116] In practice, the theoretically optimal position of the wire 2 endpoint described above will not be chosen, as this creates the risk of the free wire end 11 slipping under the pressure flap 12a, resulting in a free wire end 11 with the length of a complete turn of wire 2. Instead, the position of the retaining disc 14a will be adjusted so that the free wire end 11 is only a few centimeters long. This prevents the risk of it slipping under the pressure flap 12a and ensures the free wire end 11 is short enough not to interfere with transport and further processing of the coil 4a.
[0117] - 27 - December 16, 2025
[0118] Reference symbol list
[0119] 1 twin spooler
[0120] 2 wires
[0121] 3a, 3b flange
[0122] 4a, 4b coil
[0123] 5a, 5b Coil flange
[0124] 6a, 6b winding
[0125] 7a, 7b Coil shaft
[0126] 8a, 8b Catcher
[0127] 9a, 9b Cut-off steel
[0128] 10a, 10b Opening device
[0129] 11 Free wire end
[0130] 12a, 12b Pressure flap
[0131] 13a, 13b Chain conveyor
[0132] 14a, 14b Catching disc
[0133] 15b Traversing bar
[0134] 16b Traversing bar
[0135] 17 Running rail
[0136] 18 Shift roller
[0137] 19 frame
[0138] 20 pulley
[0139] 21a, 21b Pinole
[0140] 22a, 22b Drive shaft
[0141] 23a, 23b Coil mounting parts
[0142] 24a, 24b Clamping device
[0143] 25 Laying equipment
[0144] D Endpoint of the wire
[0145] D' Point where the free wire end meets the winding
[0146] D“ Imaginary endpoint of the wire on the winding
[0147] F Position of the catcher -28- December 16, 2025
[0148] O Position of the opening device
[0149] A Position of the pressure flap
Claims
- 29 - December 16, 2025 Patent claims 1. Double coiler (1) for winding a wire (2) onto each of two coils (4a, 4b), comprising - for each of the two coils (4a, 4b) a clamping device (24a, 24b) which is designed to hold the respective coil (4a, 4b) for winding the coil (4a, 4b) with the wire (2) in such a way that the two coil axes (7a, 7b) are essentially parallel to each other, and to rotate them independently of each other about the respective coil axis (7a, 7b), - for each of the two coils (4a, 4b) or for both coils (4a, 4b) a common laying device (25), which is movable in the direction of the respective coil axis (7a, 7b) or the two coil axes (7a, 7b) and is designed to guide the wire (2) in such a way that it runs onto the coil (4a, 4b) or onto a winding (6a, 6b) already formed on the coil (4a, 4b) at different axial positions of the coil (4a, 4b) to be wound, - for each of the two coils (4a, 4b) a catch disc (14a, 14b) which is arranged concentrically to the respective coil axis (7a, 7b) and is connected to the respective clamping device (24a, 24b) in a rotationally fixed manner, with a catcher (8a, 8b) which is connected to the respective catch disc (14a, 14b) at a specific position (F) on the circumference of the catch disc (14a, 14b) in a rotationally fixed manner and is designed to detachably fix the wire (2) to the catcher (8a, 8b), in particular to clamp it firmly, - for each of the two capture discs (14a, 14b) a capping device (9a, 9b) which is fixedly arranged adjacent to the respective capture disc (14a, 14b) and is configured to cut the wire (2) when the wire (2) is fixed to the catcher (8a, 8b) on the capture disc (14a, 14b) and the catcher (8a, 8b) is in a - 30 - December 16, 2025 Rotation of the capture disc (14a, 14b) passes the position of the cap device (9a, 9b), - for each of the two capture discs (14a, 14b) an opening device (10a, 10b) which is fixedly arranged adjacent to the respective capture disc (14a, 14b) at a specific position (O) on the circumference of the capture disc (14a, 14b) and is controllable in such a way that the fixation of the wire (2) to the catcher (8a, 8b) of the capture disc (14a, 14b) is released when the wire (2) is fixed to the catcher (8a, 8b) and the catcher (8a, 8b) passes the position (O) of the opening device (10a, 10b) when the capture disc (14a, 14b) rotates, - a transfer device (17, 18) which is configured to pivot the wire (2) while it is being wound onto one of the two coils (4a, 4b) such that, viewed in the direction of the two coil axes (7a, 7b), it overlaps with the catch disc (14a, 14b) belonging to the other of the two coils (4a, 4b), characterized in that the double coiler (1) further comprises for each of the two catch discs (14a, 14b) sensing means for sensing the cap rotation position of the respective catch disc (14a, 14b), i.e. the rotation position of the catch disc (14a, 14b) with respect to a first reference position on the circumference of the catch disc (14a, 14b), in particular the position (F) of the catcher (8a, 8b), relative to a second, stationary reference position, in particular the position (O) of the opening device (10a, 10b), at a time when the cap device (9a, 9b) cuts the wire (2) on the other capture disc (14a, 14b).
2. Double spooler (1) according to claim 1, characterized in that each cap device (9a, 9b) is attached to one of the two catch discs (14a, - 31 - December 16, 2025 14b) each has a cutting device made of an electrically conductive material which is in contact with the wire (2) during the cutting process, the detection means being configured to detect the electrical contact between the cutting device and the wire (2), and the detection means further comprising a rotation angle detection device for the other capture disc (14a, 14b) and being configured to detect and store the cutting rotation position of the other capture disc (14a, 14b) using a time point from the beginning to the end of the electrical contact between the cutting device and the wire (2) during the cutting process.
3. Double spooler (1 ) according to one of the preceding claims, characterized in that the double spooler (1) further comprises control means which are configured to rotate one and / or the other of the two capture discs (14a, 14b) into a specific rotational position relative to the first and second reference positions depending on the cap rotation position of the respective capture disc (14a, 14b) detected by the detection means.
4. Double coiler (1) according to claim 3, characterized in that the double coiler (1) further comprises a pressing device (12a, 12b) for each of the two clamping devices (24a, 24b), which is arranged such that it always has essentially the same position (A) relative to the respective coil (4a, 4b), and which is configured to press the wire (2) wound onto the coil (4a, 4b) radially outwards against the winding (6a, 6b), wherein the control means are configured to rotate the respective coil (4a, 4b) after the wire (2) has been cut, depending on the detected cutting rotation position, into a rotation position in which the length of the free wire end (11), measured from the point (D') at which the pressing device (12a, 12b) presses the wire (2), in the direction of the - 32 - December 16, 2025 Looking towards the endpoint (D) of the wire (2), the wire (2) is pressed against the winding (6a, 6b) for the last time until the endpoint (D) of the wire (2) is at most one tenth, preferably at most one twentieth, further preferably at most one fortieth of the length of the last complete turn of the wire (2) on the coil (4a, 4b).
5. Twin spooler (1) according to claim 4, characterized in that the twin spooler (1) further comprises a transport device (13a, 13b) for each of the two clamping devices (24a, 24b), which is configured to transport the respective spool (4a, 4b) into a position in which the spool (4a, 4b) can be received in the respective clamping device (24a, 24b), and / or to transport the spool (4a, 4b) away from this position, wherein the respective pressing device (12a, 12b) is attached to the transport device (13a, 13b) in such a way that it always has essentially the same position relative to the transported spool (4a, 4b) during the transport of the spool (4a, 4b).
6. Method for winding a wire (2) onto each of two coils (4a, 4b) using a double coiler (1) according to one of the preceding claims, comprising the steps: -Receiving a first, empty coil (4a) by a first of the two clamping devices (24a), -Fixing one wire end to the catcher (8a) of the first catching disc (14a), -Winding the wire (2) onto the first coil (4a), -before or during the winding of the wire (2) onto the first coil (4a): taking a second, empty coil (4b) through the second of the two clamping devices (24b), - as soon as the first coil (4a) is completely wound: pivoting the wire (2) by the transfer device (17, 18) such that - 33 - 16 December 2025 the wire (2), viewed in the direction of the two coil axes (7a, 7b), overlaps with the second capture disc (14b), -Rotating the second capture disc (14b) until the catcher (8b) of the second capture disc (14b) contacts the wire (2), -Fixing the wire (2) to the catcher (8b) of the second catching disc (14b), -Rotating the second capture disc (14b) until the catcher (8b) of the second capture disc (14b) passes the position of the cap device on the second capture disc (14b), -Cutting of the wire (2) by the cap device (9b) at the second capture disc (14b), -Detecting and storing the capping rotation position of the first capture disc (14a) at a time when the capping device (9b) on the second capture disc (14b) cuts the wire (2), -Determining a first angular difference between the angular position (F) of the catcher (8a) on the first catching disc (14a) and an imaginary angular position (D") of the end of the cut wire (2) on the winding (6a) on the first coil (4a), if the free wire end (11) were completely wound onto the first coil (4a), from the angular difference between the position (F) of the catcher (8a) and the first reference position, the capping rotation position of the first catching disc (14a), the position of the run-up point (D') of the wire (2) onto the winding (6a) on the first coil (4a) when the wire (2) is cut, and the length distance between this run-up point (D') and the capping device (9b) on the second catching disc (14b), - Rotating the first capture disc (14a) until the catcher (8a) of the first capture disc (14a) passes the position (O) of the opening device (10a) on the first capture disc (14a), -Controlling the opening device (10a) on the first catch disc (14a) such that the fixation of the wire (2) on the catcher (8a) of the first catch disc (14a) is released, - 34 - December 16, 2025 -Rotating the first capture disc (14a) by an angle dependent on the first angle difference, such that the position (D") of the imaginary end of the cut wire (2) corresponds to a specific fixed position, -Removing the first coil (4a) from the first clamping device (24a).
7. Method according to claim 6 for winding a wire (2) onto one of two coils (4a, 4b) with a double coiler (1) according to claim 4 or 5, wherein a second angular difference between the position (O) of the opening device (10a) on the first catching disc (14a) and the position (A) of the pressing device (12a) on the first catching disc (14a) is additionally determined and the angle dependent on the first angular difference is calculated using the second angular difference such that, after rotating the first catching disc (14a) by this angle, the length of the free wire end (11) is at most one tenth, preferably at most one twentieth, further preferably at most one fortieth of the length of the last complete turn of the wire (2) on the first coil (4a).