Decoiler for wire and rod

Abstract

A decoiler for delivery of wire or rod feed stock to a downstream production machine from a pre-formed coil. The decoiler includes an extended length rotatable mandrel adapted to extend along the interior of the coil such that the mandrel supports loops of the coil in hanging and slidable relation along the mandrel. At least a first feed head is disposed adjacent to the proximal end of the mandrel. The first feed head is adapted to feed the wire or rod feed stock from a rear loop of the coil outwardly in a curved path to form a spiral feed loop having a diameter greater than the coil. A variable height guide element is disposed at a position below the first feed head. The variable height guide element engages and follows an interior of the spiral feed loop to change height with a change in diameter of the spiral feed loop and to provide an output signal for speed control of the first feed head to maintain the diameter of the spiral feed loop within predefined limits.

1 . A decoiler for delivery of wire or rod to a downstream production machine from a pre-formed coil having a plurality of loops in interconnected helical relation, the decoiler comprising:
 an extended length mandrel having a proximal end and a distal end, the mandrel being adapted to extend along the interior of the coil such that the mandrel supports loops of the coil in hanging and slidable relation along the mandrel;   a first feed head disposed adjacent to the proximal end of the mandrel, the first feed head adapted to feed the wire or rod from a rear loop of the coil outwardly in a curved path to form a spiral feed loop having a diameter greater than the coil, the first feed head having adjustable speed control;   a variable height guide disposed at a position below the first feed head, the variable height guide adapted to engage an interior of the spiral feed loop and to change height with a change in diameter of the spiral feed loop, wherein the speed of the first feed head is adjusted in response to the position of the variable height guide such that the diameter of the spiral feed loop is maintained within a predefined range.   
     
     
         2 . The decoiler as recited in  claim 1 , wherein the extended length mandrel is rotatably supported on a cantilever frame adapted to extend longitudinally through the interior of the coil. 
     
     
         3 . The decoiler as recited in  claim 2 , further including a sensor bar extending longitudinally through the interior of the coil, the sensor bar adapted to activate shut-down of the decoiler upon cinching of the coil. 
     
     
         4 . The decoiler as recited in  claim 3 , wherein the sensor bar extends from a distal end of the cantilever frame towards the rear loop of the coil. 
     
     
         5 . The decoiler as recited in  claim 1 , wherein the first feed head includes a roller having a channel adapted to grip the wire or rod. 
     
     
         6 . The decoiler as recited in  claim 1 , further including a feed guide comprising a curved transition shoe adapted to collect the wire or rod exiting the spiral feed loop and to deliver the wire or rod along a substantially linear travel path transverse to a longitudinal axis of the coil. 
     
     
         7 . The decoiler as recited in  claim 6 , wherein the curved transition shoe is disposed behind the first feed head. 
     
     
         8 . The decoiler as recited in  claim 1 , wherein the variable height guide comprises a dancer pulley. 
     
     
         9 . The decoiler as recited in  claim 8 , wherein the variable height guide is adapted to provide a position output signal. 
     
     
         10 . A decoiler for delivery of wire or rod to a downstream production machine from a pre-formed coil having a plurality of loops in interconnected helical relation, the decoiler comprising:
 an extended length mandrel having a proximal end and a distal end, the mandrel being adapted to extend along the interior of the coil such that the mandrel supports loops of the coil in hanging and slidable relation along the mandrel;   a first feed head disposed adjacent to the proximal end of the mandrel, the first feed head adapted to feed the wire or rod from a rear loop of the coil outwardly in a curved path to form a spiral feed loop having a diameter greater than the coil, the first feed head having adjustable speed control;   a variable height guide disposed at a position below the first feed head, the variable height guide adapted to engage an interior of the spiral feed loop and to change height with a change in diameter of the spiral feed loop, wherein the speed of the first feed head is adjusted in response to the position of the variable height guide such that the diameter of the spiral feed loop is maintained within a predefined range;   a feed guide adapted to collect the wire or rod exiting the spiral feed loop and to deliver the wire or rod along a substantially linear outbound travel path transverse to a longitudinal axis of the coil;   at least a second feed head disposed downstream from the feed guide along the outbound travel path, the second feed head adapted to selectively engage the wire or rod in torque applying relation to assist in conveyance of the wire or rod, each of the first feed head, the second feed head and the mandrel being rotatable in both clockwise and counterclockwise directions.   
     
     
         11 . The decoiler as recited in  claim 10 , wherein the feed guide comprises a curved transition shoe adapted to collect the wire or rod exiting the spiral feed loop and to deliver the wire or rod along a substantially linear travel path transverse to a longitudinal axis of the coil. 
     
     
         12 . The decoiler as recited in  claim 11 , wherein the curved transition shoe is disposed behind the first feed head. 
     
     
         13 . The decoiler as recited in  claim 10 , wherein the variable height guide comprises a dancer pulley. 
     
     
         14 . The decoiler as recited in  claim 13 , wherein the variable height guide is adapted to provide a position output signal. 
     
     
         15 . A decoiler for delivery of wire or rod to a downstream production machine from a pre-formed coil having a plurality of loops in interconnected helical relation, the decoiler comprising:
 an extended length mandrel having a proximal end and a distal end, the mandrel being adapted to extend along the interior of the coil such that the mandrel supports loops of the coil in hanging and slidable relation along the mandrel;   a first feed head disposed adjacent to the proximal end of the mandrel, the first feed head adapted to feed the wire or rod from a rear loop of the coil outwardly in a curved path to form a spiral feed loop having a diameter greater than the coil, the first feed head having adjustable speed control;   a variable height guide disposed at a position below the first feed head, the variable height guide adapted to engage an interior of the spiral feed loop and to change height with a change in diameter of the spiral feed loop, wherein the speed of the first feed head is adjusted in response to the position of the variable height guide such that the diameter of the spiral feed loop is maintained within a predefined range;   a feed guide adapted to collect the wire or rod exiting the spiral feed loop and to deliver the wire or rod along a substantially linear outbound travel path transverse to a longitudinal axis of the coil;   a selectively engaged curvature adjustment unit disposed downstream of the feed guide along the outbound travel path, the curvature adjustment unit comprising a pair of force application rollers, the force application rollers held in fixed, spaced relation to one another on opposing sides of the outbound travel path, the force application rollers being moveable along a line in transverse relation to the outbound travel path to selectively apply inward or outward bending force to the wire or rod.   
     
     
         16 . The decoiler as recited in  claim 15 , wherein the force application rollers are supported on a moveable sleeve mounted on a guidepost. 
     
     
         17 . The decoiler as recited in  claim 16 , further including at least a second feed head disposed downstream from the curvature adjustment unit along the outbound travel path, the second feed head adapted to selectively engage the wire or rod in torque applying relation to assist in conveyance of the wire or rod, each of the first feed head, the second feed head and the mandrel being rotatable in both clockwise and counterclockwise directions. 
     
     
         18 . The decoiler as recited in  claim 17 , wherein the variable height guide comprises a dancer pulley. 
     
     
         19 . The decoiler as recited in  claim 18 , wherein the variable height guide is adapted to provide a position output signal.