APPARATUS FOR COILING FILAMENT ONTO A CIRCULAR CORE

Abstract

Disclosed is an apparatus for coiling a filament onto a circular core. The apparatus comprises a support structure with a pair of tightening clamps intersecting with guide rollers to adjust filament tension. A spring-loaded tensioner assembly is in communication with the clamps to facilitate uniform tensioning of the filament during coiling onto the circular core.

Specification

Description:Field of the Invention


The present disclosure generally relates to filament handling systems. Further, the present disclosure particularly relates to an apparatus for coiling a filament onto a circular core.
Background
The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
Coiling filaments onto circular cores is a process that is widely employed in various industrial sectors such as electronics, textiles, and material processing. Filament coiling involves the application of tension to the filament while it is being wound around the core. Proper tension adjustment during this process is crucial to avoid damage to the filament or the core, as well as to maintain the integrity of the final coiled product. The traditional systems and techniques for coiling a filament onto a circular core have evolved over time; however, such systems still present challenges, particularly in relation to uniform tension application and control during the coiling process.
One conventional system for coiling a filament employs a manual or semi-automated method, where an operator manually adjusts the tension by using simple mechanical structures, such as pulleys or weight-based systems. This approach is prone to inaccuracies in tension control, which can result in inconsistencies in the coiled filament. Uneven coiling may cause irregularities in the final product, leading to potential mechanical failures or inefficiencies in later applications. Additionally, the reliance on manual intervention reduces the reliability and precision of the coiling process, and the labour-intensive nature of such techniques adds to operational inefficiencies and costs.
Another known technique involves the use of automated coiling systems where the tension is controlled through basic motorized assemblies. Such systems often utilize electric motors to apply tension to the filament as it is being wound onto the core. While this approach reduces the need for manual intervention, the primary limitation is the lack of dynamic tension control. Motorized systems are typically unable to respond in real-time to changes in filament tension during the coiling process, particularly when fluctuations occur due to variations in the filament properties or the speed of coiling. The absence of responsive control mechanisms can result in over-tensioning or under-tensioning, leading to damaged filaments or improperly coiled products.
Moreover, existing systems that incorporate spring-based or weight-based tension control mechanisms face several challenges in maintaining consistent filament tension throughout the coiling process. Spring-based systems tend to suffer from wear over time, reducing their effectiveness in providing the required level of tension control. Weight-based systems, on the other hand, are bulky and difficult to calibrate accurately, often requiring frequent manual adjustments to compensate for changes in the filament or operational conditions. Both approaches, while effective in certain contexts, fail to provide a robust solution for ensuring uniform tension across a wide range of operational conditions, leading to variations in coiling quality and product reliability.
In addition, some state-of-the-art coiling systems incorporate tensioners that are actuated via pneumatic or hydraulic mechanisms. While such systems provide a more automated and efficient method for tension control, they are associated with drawbacks such as complexity, high maintenance costs, and the requirement for continuous external power or compressed air supply. The intricate nature of such systems makes them unsuitable for smaller-scale operations or applications where cost-effectiveness is a significant factor. Additionally, the pneumatic or hydraulic systems may not provide the fine control necessary for maintaining optimal tension levels, especially during changes in the coiling speed or the mechanical properties of the filament.
Other techniques also exist that integrate sensors for monitoring the tension of the filament during coiling. Sensor-based systems often rely on feedback loops where tension readings are taken periodically, and adjustments are made to the tensioning mechanism based on such readings. While this approach allows for more precise tension control, it also introduces a level of complexity that increases the cost and maintenance requirements of the system. Additionally, sensor-based systems are often vulnerable to inaccuracies caused by environmental factors such as temperature fluctuations or mechanical vibrations, which can result in erroneous tension readings and improper tension adjustments.
Furthermore, conventional systems that incorporate guide rollers for tension adjustment often encounter issues related to friction and wear. Over time, the friction between the filament and the guide rollers can lead to gradual degradation of the filament's surface, affecting the overall strength and quality of the coiled product. The wear on the guide rollers themselves may also result in inconsistencies in tension control, requiring frequent maintenance and replacement of components. Such limitations reduce the operational lifespan of coiling systems and lead to higher operational costs due to the need for frequent repairs and component replacements.
In light of the above discussion, there exists an urgent need for solutions that overcome the problems associated with conventional systems and/or techniques for coiling a filament onto a circular core, particularly in relation to achieving uniform tension control, reducing manual intervention, and minimizing the complexity and maintenance requirements of the coiling apparatus.
Summary
The following presents a simplified summary of various aspects of this disclosure in order to provide a basic understanding of such aspects. This summary is not an extensive overview of all contemplated aspects, and is intended to neither identify key or critical elements nor delineate the scope of such aspects. Its purpose is to present some concepts of this disclosure in a simplified form as a prelude to the more detailed description that is presented later.
The following paragraphs provide additional support for the claims of the subject application.
An objective of the present disclosure is to provide an apparatus for coiling a filament onto a circular core with improved control of filament tension, stability, and alignment during the coiling process. The apparatus of the present disclosure aims to ensure uniform tensioning and smooth coiling operations.
In an aspect, the present disclosure provides an apparatus for coiling a filament onto a circular core. The apparatus comprises a support structure with a pair of tightening clamps intersecting with guide rollers to adjust filament tension. The apparatus further comprises a spring-loaded tensioner assembly in communication with the tightening clamps, facilitating uniform tensioning of the filament during coiling onto the circular core.
Furthermore, the apparatus provides a mounting base extending longitudinally with the guide rollers, offering a stable foundation to maintain the alignment of the tightening clamps during the coiling operation. The apparatus enables modification of clamping force applied on the filament through an adjustment screw intersecting the axis of the guide rollers. Moreover, the guide rollers incorporate spring-loaded bearings in rolling contact with the filament to facilitate smooth movement and maintain consistent contact pressure.
The apparatus further includes a damping element in communication with a tension adjustment knob to reduce vibrations during the coiling process. The apparatus enables maintaining the preset tension level through a compression spring providing an adjustable counterforce. Additionally, the apparatus offers a pivot arm extending from the mounting base, enabling angular adjustments of the tightening clamps to accommodate different winding patterns.
The apparatus also incorporates a pressure sensor in communication with a control system to detect variations in filament tension and adjust it dynamically. Moreover, the guide rollers are equipped with an adjustable spacing unit to vary the distance between the rollers based on the filament's diameter. A retractable arm coupled with the pivot arm enables repositioning of the tightening clamps to facilitate the initiation and completion of the coiling process on the circular core.

Brief Description of the Drawings


The features and advantages of the present disclosure would be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 illustrates an apparatus (100) for coiling a filament onto a circular core, in accordance with the embodiments of the present disclosure.
FIG. 2 illustrates an apparatus (100) for coiling a filament onto a circular core, detailing the interaction between various components, in accordance with the embodiments of the present disclosure.
Detailed Description
In the following detailed description of the invention, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to claim those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims and equivalents thereof.
The use of the terms "a" and "an" and "the" and "at least one" and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The use of the term "at least one" followed by a list of one or more items (for example, "at least one of A and B") is to be construed to mean one item selected from the listed items (A or B) or any combination of two or more of the listed items (A and B), unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Pursuant to the "Detailed Description" section herein, whenever an element is explicitly associated with a specific numeral for the first time, such association shall be deemed consistent and applicable throughout the entirety of the "Detailed Description" section, unless otherwise expressly stated or contradicted by the context.
As used herein, the term "apparatus" refers to a mechanical or electrical system consisting of interconnected parts or devices used for a specific task. The term includes any equipment, machinery, or device composed of various components designed to perform an intended operation. In the context of the present disclosure, the apparatus relates to a system involving multiple elements that interact to coil a filament onto a circular core. The apparatus may include various sub-elements, such as support structures, clamps, rollers, and a tensioner assembly, all of which work together to achieve the objective of coiling the filament. Additionally, the apparatus encompasses systems that ensure the uniformity and precision of the coiling process by enabling adjustment of the filament tension. The apparatus, therefore, relates to a system where each component plays a specific role in facilitating the coiling of the filament onto the circular core with appropriate tension.
As used herein, the term "support structure" refers to a foundational framework or base that provides mechanical stability and alignment to other components of a system. The support structure may consist of a rigid or semi-rigid material capable of holding and positioning elements, such as clamps and rollers, to ensure proper functioning of the apparatus. In the current context, the support structure includes a pair of tightening clamps and guide rollers that intersect for adjusting the tension of the filament. Said support structure enables proper placement and alignment of the filament during the coiling process. Furthermore, such a support structure may vary in size or material depending on the type of filament and circular core being utilized but serves the primary purpose of maintaining the operational integrity of the apparatus.
As used herein, the term "tightening clamps" refers to mechanical devices that apply force to secure or fasten components in place. The tightening clamps are used to hold or compress objects, such as filaments, ensuring that said filaments remain stable and properly aligned during operation. In the present disclosure, the tightening clamps are part of the apparatus and interact with the guide rollers to adjust the filament tension while the filament is coiled onto the circular core. Such tightening clamps provide a mechanism for precise tensioning, allowing for controlled coiling. Additionally, the tightening clamps can be made of various materials based on the type of filament and the operational requirements of the apparatus. Said clamps are crucial to ensuring the filament is properly tensioned during the coiling process.
As used herein, the term "guide rollers" refers to cylindrical mechanical components that facilitate the smooth movement of an object, such as a filament, along a specific path. Guide rollers are positioned strategically to support and direct the filament, ensuring that it moves in a controlled and uniform manner. In the present context, the guide rollers are intersecting components that work in conjunction with the tightening clamps to adjust the tension of the filament as it coils onto the circular core. The guide rollers may be made of various materials, such as metal or plastic, depending on the nature of the filament and the required operational conditions. Said guide rollers ensure that the filament is properly directed and tensioned during the coiling process, contributing to the overall functionality of the apparatus.
As used herein, the term "spring-loaded tensioner assembly" refers to a mechanical device that uses a spring mechanism to apply continuous force to maintain tension on an object. The spring-loaded tensioner assembly is designed to ensure uniform tensioning of a filament during the coiling process. In the apparatus described, the tensioner assembly works in communication with the tightening clamps, enabling uniform application of tension to the filament as it is coiled onto the circular core. Said assembly may vary in design, including compression springs or extension springs, to suit specific tensioning requirements. Such a tensioner assembly is essential for ensuring that the filament maintains consistent tension throughout the coiling process, preventing slack or over-tensioning. The spring mechanism within the tensioner allows for smooth and continuous adjustment of the tension, thereby enabling proper coiling onto the circular core.
FIG. 1 illustrates an apparatus (100) for coiling a filament onto a circular core, in accordance with the embodiments of the present disclosure. In an embodiment, a support structure (102) forms the base of the apparatus (100) for coiling a filament onto a circular core. The support structure (102) is constructed to provide stability and alignment for the components of the apparatus (100) during operation. Said support structure (102) may be made of rigid materials such as metal or reinforced plastic, ensuring adequate durability to withstand operational loads. The support structure (102) includes a pair of tightening clamps (104) and guide rollers (106), which are positioned to intersect, allowing for precise adjustment of the filament tension as the filament is coiled onto the circular core. The tightening clamps (104) are mounted on the support structure (102) in such a manner that said clamps (104) can be adjusted vertically or horizontally depending on the filament's size or tension requirements. The guide rollers (106) are mounted adjacent to the clamps (104) to guide the filament through the system, maintaining a consistent path and allowing for smooth tension adjustment. The support structure (102) thus holds and aligns the necessary components in a stable configuration, allowing for efficient coiling of the filament onto the circular core while maintaining appropriate tension throughout the process.
In an embodiment, the tightening clamps (104) are mechanical devices that grip the filament securely and apply the necessary force to adjust the filament tension during the coiling process. Said tightening clamps (104) are arranged in pairs and are mounted on the support structure (102) in such a way that each clamp (104) intersects with the guide rollers (106) to provide optimal tensioning control. The tightening clamps (104) are capable of exerting varying amounts of pressure depending on the filament's material and the required tension. Each clamp (104) may include an adjustable mechanism, such as a screw or lever, that allows for precise control over the force applied to the filament. The intersecting arrangement of the clamps (104) with the guide rollers (106) enables the filament to pass through a controlled path where the tension can be fine-tuned to prevent over-tightening or slack during the coiling process. Such clamps (104) interact directly with the filament and the guide rollers (106) to facilitate smooth and consistent coiling onto the circular core.
In an embodiment, the guide rollers (106) are cylindrical components that assist in controlling the movement of the filament during the coiling process. Said guide rollers (106) are positioned on the support structure (102) in an intersecting arrangement with the tightening clamps (104). The guide rollers (106) are typically made of durable materials, such as metal or polymer, that provide smooth surfaces for the filament to move over while ensuring minimal friction and wear on the filament. Each roller (106) is rotatably mounted on the support structure (102), allowing the filament to be guided through the apparatus (100) in a controlled manner. The intersecting placement of the guide rollers (106) and the tightening clamps (104) ensures that the filament's tension is adjusted appropriately while being coiled onto the circular core. The guide rollers (106) facilitate smooth movement and prevent tangling or excessive friction, ensuring that the filament follows a defined path throughout the coiling process. Additionally, the guide rollers (106) may vary in size and material based on the type of filament being used.
In an embodiment, a spring-loaded tensioner assembly (108) is integrated into the apparatus (100) to assist with maintaining consistent tension on the filament as it is coiled onto the circular core. Said spring-loaded tensioner assembly (108) is in communication with the tightening clamps (104), which are responsible for applying force to the filament to maintain the desired tension. The spring-loaded tensioner assembly (108) includes a spring mechanism that provides a constant force to counterbalance fluctuations in filament tension during the coiling process. The spring within said tensioner assembly (108) compresses or extends in response to changes in the filament's tension, allowing the apparatus (100) to adapt dynamically to varying conditions. The tensioner assembly (108) is designed to ensure that the filament remains taut and uniform throughout the entire coiling process. The communication between the spring-loaded tensioner assembly (108) and the tightening clamps (104) enables coordinated tension control, thereby preventing slack or over-tensioning of the filament during the coiling operation. Said tensioner assembly (108) is particularly important in applications where precise control over filament tension is necessary to achieve optimal coiling results.
In an embodiment, the support structure (102) further comprises a mounting base extending longitudinally with the guide rollers (106). The mounting base provides a stable foundation to maintain the alignment of the tightening clamps (104) during the coiling operation. Said mounting base is typically constructed from durable materials such as metal or rigid composites, providing structural integrity to the apparatus (100). The mounting base is aligned along the length of the guide rollers (106) to ensure that the filament follows a precise path during the coiling process. This alignment helps in controlling the filament's tension and movement, preventing deviations that could otherwise affect the uniformity of the coiling. Additionally, the mounting base serves as a platform upon which various components of the apparatus (100) are securely attached. This includes not only the tightening clamps (104) but also any auxiliary parts necessary for stabilizing the filament during operation. The longitudinal extension of the mounting base allows the apparatus (100) to handle a variety of filament sizes and core dimensions, making it adaptable to different coiling requirements.
In an embodiment, the tightening clamps (104) are in operative alignment with an adjustment screw that intersects the axis of the guide rollers (106). Such an adjustment screw is designed to modify the clamping force applied by the clamps (104) on the filament during the coiling process. The adjustment screw is typically a threaded component, enabling precise adjustments by rotating the screw to either increase or decrease the pressure exerted by the clamps (104). The interaction between the adjustment screw and the clamps (104) ensures that the filament is held firmly without causing damage or distortion. The alignment of the adjustment screw along the axis of the guide rollers (106) ensures that the filament remains properly positioned as it passes through the apparatus (100). This configuration allows the operator to control the tension on the filament, ensuring that the coiling process proceeds smoothly without interruptions or inconsistencies. Furthermore, the adjustment screw may be made of materials such as stainless steel, ensuring longevity and resistance to wear during repeated usage.
In an embodiment, the guide rollers (106) comprise a set of spring-loaded bearings in rolling contact with the filament. These spring-loaded bearings facilitate smooth movement and maintain consistent contact pressure along the filament during the coiling process. The bearings are typically housed within the rollers (106) and are designed to rotate freely as the filament moves, reducing friction and preventing excessive wear on the filament. The spring mechanism within the bearings applies a constant pressure that adjusts dynamically as the filament moves, ensuring that the tension remains uniform throughout the process. The rolling contact provided by the spring-loaded bearings ensures that the filament follows a controlled path, avoiding slippage or misalignment. Additionally, the use of spring-loaded bearings allows the apparatus (100) to accommodate filaments of varying diameters, as the springs can compress or expand to adjust to the filament's thickness. The bearings themselves are generally made of durable materials such as steel or ceramic to provide longevity and smooth operation over extended periods.
In an embodiment, the tensioner assembly (108) comprises a damping element that intersects with a tension adjustment knob (118). Such a damping element reduces vibrations during the coiling process, providing a more stable operation. The damping element is typically a material or structure that absorbs and dissipates mechanical vibrations that may arise as the filament is coiled onto the circular core. Said damping element can be made from materials such as rubber or elastomers, which are known for their vibration-dampening properties. The intersection between the damping element and the tension adjustment knob (118) allows for precise control of the tension applied to the filament while minimizing unwanted vibrations that could cause fluctuations in the coiling process. The tension adjustment knob (118) allows the operator to fine-tune the tensioner assembly (108) based on the specific requirements of the filament and core. The damping element thus plays a critical role in maintaining the overall stability of the apparatus (100) during high-speed or continuous coiling operations.
In an embodiment, the adjustment knob is in operative engagement with a compression spring nested within the tensioner assembly (108). The compression spring provides an adjustable counterforce to maintain the preset tension level during coiling onto the circular core. Said compression spring is typically housed inside the tensioner assembly (108) and works in conjunction with the adjustment knob to regulate the amount of force applied to the filament. The operator can manipulate the adjustment knob to compress or decompress the spring, thereby changing the level of tension applied to the filament as it is wound around the core. The spring is made from high-tensile materials such as steel, ensuring durability and consistent performance under repetitive use. The compression spring ensures that the filament remains taut during the entire coiling process, preventing slack or excessive tension that could negatively impact the uniformity of the winding. Additionally, the adjustable nature of the compression spring allows the apparatus (100) to accommodate filaments of varying thicknesses and material properties, providing flexibility for different coiling applications.
In an embodiment, the support structure (102) further comprises a pivot arm extending from the mounting base. Such a pivot arm enables angular adjustments of the tightening clamps (104) to accommodate different winding patterns on the circular core. The pivot arm is connected to the mounting base through a rotational joint, allowing for movement in one or more axes. This movement allows the tightening clamps (104) to be positioned at various angles relative to the core, which is particularly useful when coiling filaments in non-uniform or complex patterns. The pivot arm is generally constructed from a rigid material such as metal to provide the necessary support for the tightening clamps (104) while allowing for smooth and controlled adjustments. The ability to adjust the angle of the tightening clamps (104) increases the versatility of the apparatus (100), enabling it to be used for different types of coiling operations. Furthermore, the pivot arm may include locking mechanisms to secure the clamps (104) in the desired position once the appropriate angle has been set, ensuring stability throughout the coiling process.
In an embodiment, the spring-loaded tensioner assembly (108) comprises a pressure sensor in communication with a control module. Said pressure sensor detects variations in filament tension and sends feedback to the control module to adjust the tension dynamically. The pressure sensor is typically located within the tensioner assembly (108) and continuously monitors the force applied to the filament. When the sensor detects deviations from the preset tension level, it communicates this information to the control module, which then adjusts the tensioner assembly (108) accordingly. This real-time feedback mechanism allows the apparatus (100) to maintain consistent tension throughout the coiling process, compensating for any irregularities that may occur. The pressure sensor may use various sensing technologies, such as strain gauges or piezoelectric materials, to accurately measure the tension applied to the filament. The integration of the pressure sensor and control module provides an automated solution for maintaining optimal tension, reducing the need for manual adjustments and increasing the overall efficiency of the coiling process.
In an embodiment, the guide rollers (106) are arranged with an adjustable spacing unit. Such a spacing unit is configured to vary the distance between the rollers (106) based on the diameter of the filament. The spacing unit consists of mechanical components, such as sliders or gears, that allow the rollers (106) to be moved closer together or further apart, depending on the requirements of the filament being used. The adjustable nature of the spacing unit enables the apparatus (100) to accommodate a wide range of filament diameters, ensuring that the filament is properly guided and tensioned throughout the coiling process. The operator can manually adjust the spacing unit to set the appropriate distance between the rollers (106), or the unit can be configured to automatically adjust based on sensor inputs. The spacing unit itself is typically made from durable materials such as metal, providing long-lasting performance and precise control over the roller positioning.
In an embodiment, the support structure (102) comprises a retractable arm coupled with the pivot arm. Said retractable arm allows for the repositioning of the tightening clamps (104) to facilitate the initiation and completion of the coiling process on the circular core. The retractable arm is extendable and retractable, enabling the operator to move the clamps (104) into position at the start of the coiling process and then retract them once the coiling is complete. This movement is especially beneficial in situations where the clamps (104) need to be repositioned without disturbing the filament or the core. The retractable arm is typically connected to the pivot arm through a sliding mechanism or telescoping joint, allowing for smooth and controlled movement. The retractable arm is constructed from materials such as aluminum or steel to provide the necessary strength and durability while ensuring ease of use for the operator. This feature enhances the flexibility and convenience of the apparatus (100), allowing for efficient handling of the filament during both the start and end of the coiling operation.
FIG. 2 illustrates an apparatus (100) for coiling a filament onto a circular core, detailing the interaction between various components, in accordance with the embodiments of the present disclosure. The process begins with the operator initializing the coiling process by engaging the support structure (102). The support structure (102) positions the filament using tightening clamps (104), which intersect with guide rollers (106) to adjust the filament tension. The tightening clamps (104) communicate tension needs to the spring-loaded tensioner assembly (108). The tensioner assembly (108) applies uniform tension to the filament while the guide rollers (106) guide the filament onto the circular core. The coiling process proceeds as the filament is wound around the core in a controlled manner. The operator monitors the tension during the process and adjusts the system as necessary. The interaction between the tightening clamps (104), guide rollers (106), and the tensioner assembly (108) ensures precise control over the filament tension and movement during the entire coiling operation.
In an embodiment, the support structure (102) with a pair of tightening clamps (104) intersecting with guide rollers (106) allows for precise tension adjustment of the filament during coiling onto the circular core. The mechanical interaction between the tightening clamps (104) and guide rollers (106) establishes a controlled pathway for the filament, ensuring that the filament is maintained under appropriate tension as it is coiled. The intersection of the clamps (104) with the rollers (106) provides a dual-function system where the filament is both guided and tensioned simultaneously, reducing the likelihood of slippage or uneven winding. The alignment ensures smooth and consistent filament handling, improving the overall coiling accuracy. The design promotes a balanced distribution of forces across the filament, minimizing potential stress points that could lead to filament breakage or deformation during operation. The support structure (102) provides the necessary foundation for holding these elements in alignment, ensuring consistent performance during repetitive coiling operations.
In an embodiment, the support structure (102) further comprises a longitudinally extending mounting base that provides a stable foundation for the tightening clamps (104) and guide rollers (106). This longitudinal extension ensures that all components remain aligned along a fixed axis, which is essential for maintaining filament tension throughout the coiling process. By providing a stable platform, the mounting base reduces any lateral movement of the clamps (104) or rollers (106), which could otherwise cause misalignment of the filament during coiling. The longitudinal design also facilitates the handling of longer or more flexible filaments, allowing the apparatus (100) to support a variety of coiling operations. Additionally, the extended mounting base helps in distributing the operational loads evenly, reducing localized stress and wear on specific components. This stable foundation is crucial for ensuring that the tightening clamps (104) and guide rollers (106) perform consistently, even under varying load conditions.
In an embodiment, the tightening clamps (104) are aligned with an adjustment screw that intersects the axis of the guide rollers (106), allowing for precise control over the clamping force applied to the filament. The adjustment screw provides a mechanical means to finely tune the pressure exerted by the clamps (104), enabling operators to adapt the clamping force based on the material properties of the filament, such as its diameter or elasticity. By intersecting the guide roller (106) axis, the adjustment screw maintains a consistent tension across the length of the filament, preventing any variation in pressure that could affect the uniformity of the coiling process. The mechanical relationship between the screw, clamps (104), and rollers (106) ensures that adjustments to filament tension are made without introducing lateral stresses or misalignments. This precise control helps in avoiding damage to delicate filaments and improves the overall durability of the coiling system during extended use.
In an embodiment, the guide rollers (106) include a set of spring-loaded bearings that remain in rolling contact with the filament, providing continuous smooth movement and maintaining consistent pressure. These spring-loaded bearings dynamically adjust to changes in filament thickness or tension, ensuring uninterrupted rolling contact as the filament is guided through the apparatus (100). The spring mechanism within the bearings automatically compensates for minor variations in filament thickness, ensuring that the filament remains securely within the rollers' path without creating excessive friction. This consistent pressure distribution reduces wear on both the filament and the rollers (106) while facilitating a uniform winding process. Furthermore, the rolling contact provided by the spring-loaded bearings minimizes resistance, enabling higher-speed coiling operations while maintaining precise control over the filament's movement. The use of spring-loaded bearings is particularly beneficial for filaments that require sensitive handling, as it reduces the risk of deformation or damage during coiling.
In an embodiment, the tensioner assembly (108) includes a damping element that intersects with the tension adjustment knob (118), reducing vibrations during the coiling process. Vibrations introduced by mechanical movements or external disturbances can negatively impact the uniformity of the filament winding. The damping element absorbs and dissipates these vibrations before they can propagate through the system, ensuring that the filament maintains consistent tension without oscillations that could lead to uneven coiling. By positioning the damping element in direct communication with the tension adjustment knob (118), the system provides immediate and responsive vibration control, stabilizing the entire tensioner assembly (108). This reduction in vibrations enhances the precision of the coiling process, particularly in high-speed or continuous operations where even minor disturbances can affect the final product. The integration of the damping element with the tension adjustment system allows for smoother, more controlled filament handling, significantly improving the quality and consistency of the wound filament.
In an embodiment, the adjustment knob (118) is operatively engaged with a compression spring nested within the tensioner assembly (108), providing an adjustable counterforce that maintains the preset tension level during the coiling process. The compression spring is designed to resist variations in filament tension, allowing the operator to set and maintain a desired level of tension consistently throughout the operation. The engagement of the adjustment knob (118) with the compression spring allows for fine-tuning of the spring's force, giving the operator control over how much counterforce is applied to the filament. As the filament is coiled, the compression spring automatically compensates for any fluctuations in tension, preventing slack or over-tightening. This adjustable counterforce improves the system's adaptability to different filament types, ensuring consistent winding performance regardless of changes in filament properties or coiling speed. The compression spring's adjustable nature also extends the system's flexibility, allowing for easy customization based on specific operational requirements.
In an embodiment, the support structure (102) includes a pivot arm extending from the mounting base, which enables angular adjustments of the tightening clamps (104) to accommodate different winding patterns on the circular core. The pivot arm is mounted to allow rotational movement of the clamps (104), enabling the apparatus (100) to handle various coiling geometries and filament paths. By allowing the clamps (104) to be positioned at different angles, the pivot arm ensures that the filament is evenly distributed along the surface of the circular core, regardless of the complexity of the winding pattern. This adjustable feature also makes the system versatile for different coiling applications, from simple uniform windings to more intricate patterns requiring precise angular adjustments. The pivot arm's flexibility helps avoid filament overlap or gaps during the coiling process, ensuring a smooth, uniform final product. This adjustability also enhances the system's capability to handle cores of different shapes and sizes, broadening its application range.
In an embodiment, the spring-loaded tensioner assembly (108) is integrated with a pressure sensor that communicates with a control module, allowing real-time detection of variations in filament tension. The pressure sensor continuously monitors the tension applied to the filament as it is coiled onto the circular core, sending feedback to the control module to dynamically adjust the tensioner assembly (108) as needed. This automated tension adjustment system ensures that the filament remains at a consistent tension throughout the coiling process, even as external conditions change, such as variations in filament diameter or material elasticity. The real-time feedback mechanism allows the system to immediately compensate for any deviations, reducing the likelihood of filament slack or excessive tension. This dynamic control over filament tension significantly improves the accuracy and quality of the coiling process, particularly in high-precision applications where consistent tension is essential for achieving uniform results.
In an embodiment, the guide rollers (106) are arranged with an adjustable spacing unit that allows the distance between the rollers to be varied based on the filament's d












I/We Claims


An apparatus (100) for coiling a filament onto a circular core, comprising:
a support structure (102) with a pair of tightening clamps (104) intersecting with guide rollers (106) for adjusting filament tension; and
a spring-loaded tensioner assembly (108) in communication with said clamps (104), facilitating uniform tensioning of said filament during coiling onto said circular core.
The apparatus (100) of claim 1, wherein said support structure (102) further comprises a mounting base extending longitudinally with said guide rollers (106), such mounting base providing a stable foundation to maintain the alignment of said tightening clamps (104) during the coiling operation.
The apparatus (100) of claim 1, wherein said tightening clamps (104) are in operative alignment with an adjustment screw intersecting the axis of said guide rollers (106), such adjustment screw being configured to modify the clamping force applied by said clamps (104) on the filament.
The apparatus (100) of claim 2, wherein said guide rollers (106) comprise a set of spring-loaded bearings in rolling contact with said filament, said spring-loaded bearings facilitating smooth movement and maintaining consistent contact pressure along said filament.
The apparatus (100) of claim 1, wherein said tensioner assembly (108) comprises a damping element intersecting with a tension adjustment knob (118), such damping element reducing vibrations during the coiling process.
The apparatus (100) of claim 4, wherein said adjustment knob is in operative engagement with a compression spring nested within said tensioner assembly (108), said compression spring providing an adjustable counterforce to maintain the preset tension level during coiling onto said circular core.
The apparatus (100) of claim 1, wherein said support structure (102) further comprises a pivot arm extending from said mounting base, such pivot arm enabling angular adjustments of said tightening clamps (104) to accommodate different winding patterns on said circular core.
The apparatus (100) of claim 1, wherein said spring-loaded tensioner assembly (108) comprises a pressure sensor in communication with a control module, said pressure sensor detecting variations in filament tension and sending feedback to said control module to adjust the tension dynamically.
The apparatus (100) of claim 1, wherein said guide rollers (106) are arranged with an adjustable spacing unit, such spacing unit being configured to vary the distance between said rollers (106) based on the diameter of the filament.
The apparatus (100) of claim 1, wherein said support structure (102) comprises a retractable arm coupled with said pivot arm, such retractable arm allowing for the repositioning of said tightening clamps (104) to facilitate the initiation and completion of the coiling process on said circular core.




Disclosed is an apparatus for coiling a filament onto a circular core. The apparatus comprises a support structure with a pair of tightening clamps intersecting with guide rollers to adjust filament tension. A spring-loaded tensioner assembly is in communication with the clamps to facilitate uniform tensioning of the filament during coiling onto the circular core.

 , Claims:I/We Claims


An apparatus (100) for coiling a filament onto a circular core, comprising:
a support structure (102) with a pair of tightening clamps (104) intersecting with guide rollers (106) for adjusting filament tension; and
a spring-loaded tensioner assembly (108) in communication with said clamps (104), facilitating uniform tensioning of said filament during coiling onto said circular core.
The apparatus (100) of claim 1, wherein said support structure (102) further comprises a mounting base extending longitudinally with said guide rollers (106), such mounting base providing a stable foundation to maintain the alignment of said tightening clamps (104) during the coiling operation.
The apparatus (100) of claim 1, wherein said tightening clamps (104) are in operative alignment with an adjustment screw intersecting the axis of said guide rollers (106), such adjustment screw being configured to modify the clamping force applied by said clamps (104) on the filament.
The apparatus (100) of claim 2, wherein said guide rollers (106) comprise a set of spring-loaded bearings in rolling contact with said filament, said spring-loaded bearings facilitating smooth movement and maintaining consistent contact pressure along said filament.
The apparatus (100) of claim 1, wherein said tensioner assembly (108) comprises a damping element intersecting with a tension adjustment knob (118), such damping element reducing vibrations during the coiling process.
The apparatus (100) of claim 4, wherein said adjustment knob is in operative engagement with a compression spring nested within said tensioner assembly (108), said compression spring providing an adjustable counterforce to maintain the preset tension level during coiling onto said circular core.
The apparatus (100) of claim 1, wherein said support structure (102) further comprises a pivot arm extending from said mounting base, such pivot arm enabling angular adjustments of said tightening clamps (104) to accommodate different winding patterns on said circular core.
The apparatus (100) of claim 1, wherein said spring-loaded tensioner assembly (108) comprises a pressure sensor in communication with a control module, said pressure sensor detecting variations in filament tension and sending feedback to said control module to adjust the tension dynamically.
The apparatus (100) of claim 1, wherein said guide rollers (106) are arranged with an adjustable spacing unit, such spacing unit being configured to vary the distance between said rollers (106) based on the diameter of the filament.
The apparatus (100) of claim 1, wherein said support structure (102) comprises a retractable arm coupled with said pivot arm, such retractable arm allowing for the repositioning of said tightening clamps (104) to facilitate the initiation and completion of the coiling process on said circular core.

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