Wire Barrel Packing System and Method of Use

Abstract

A wire barrel packing system that ensures wire is loaded evenly within the barrel and methods of using the same are disclosed herein. The wire barrel backing system may comprise a turntable on which the barrel is placed and a capstan configured to pull the wire from a feeder and feed the wire into the barrel. The turntable may be configured to rotate the barrel as wire is fed into the barrel. The capstan may be configured to raise or lower vertically with respect to the barrel as wire is fed into the barrel. The capstan may also be configured to move horizontally, both inwardly and outwardly, to cause the wire to be laid evenly within the barrel in a helical manner.

What is claimed is: 
     
         1 . A wire barrel packing system for loading wire into a barrel that ensures wire is loaded evenly within the barrel, the system comprising:
 a frame within which a barrel is positioned for receiving a wire;   a turntable on which the barrel is placed, wherein the turntable is configured to rotate the barrel as wire is fed into the barrel; and   a capstan configured to pull the wire from a feeder and feed the wire into the barrel, wherein the capstan is configured to move relative to the frame and the turntable as wire is fed into the barrel.   
     
     
         2 . The wire barrel packing system of  claim 1 , wherein the capstan comprises a belt wrap capstan. 
     
     
         3 . The wire barrel packing system of  claim 1 , wherein the system further comprises a wire landing guide configured to guide the wire as the wire is fed from the capstan into the barrel. 
     
     
         4 . The wire barrel packing system of  claim 3 , wherein the wire landing guide is positioned perpendicular to a bottom surface of the barrel. 
     
     
         5 . The wire barrel packing system of  claim 1 , wherein the capstan is configured to move vertically with respect to the frame and the turntable. 
     
     
         6 . The wire barrel packing system of  claim 5 , wherein the capstan is raised vertically with respect to the frame and the turntable as wire is fed into a barrel, and wherein the capstan is lowered vertically with respect to the frame and the turntable prior to loading a new barrel. 
     
     
         7 . The wire barrel packing system of  claim 5 , wherein the capstan is configured to move vertically with respect to the frame and the turntable to position a wire landing guide within a pre-determined distance from a bottom of the barrel or a top of the wire loaded into the barrel. 
     
     
         8 . The wire barrel packing system of  claim 1 , wherein the capstan is configured to move horizontally with respect to the frame and the turntable. 
     
     
         9 . The wire barrel packing system of  claim 8 , wherein the capstan is moved inwardly and outwardly horizontally to cause the wire to be laid evenly within the barrel in a helical manner. 
     
     
         10 . The wire barrel packing system of  claim 1 , wherein the system further comprises a motor and a set of rails attached to the frame, wherein the motor is configured to cause movement of the capstan along the set of rails. 
     
     
         11 . The wire barrel packing system of  claim 1 , wherein the system further comprises one or more devices or sensors configured to monitor the loading of the wire into the barrel. 
     
     
         12 . A method of loading wire into a barrel using a wire barrel packing system that prevents gaps and an uneven laying of the wire, the method comprising:
 positioning a capstan over a barrel;   feeding a wire into the barrel using the capstan, wherein a turntable on which the barrel is positioned is rotated as wire is fed into the barrel;   monitoring the wire being fed into the barrel via the capstan; and   adjusting the loading of the wire into the barrel based on the monitoring of the wire being fed into the barrel via the capstan.   
     
     
         13 . The method of  claim 12 , the method further comprising rolling the barrel onto the turntable positioned beneath the capstan. 
     
     
         14 . The method of  claim 12 , wherein positioning the capstan over the barrel comprises raising or lowering the capstan to a pre-determined distance from a bottom of the barrel or wire loaded into the barrel. 
     
     
         15 . The method of  claim 14 , wherein the pre-determined distance comprises a distance between a bottom of a wire landing guide associated with the capstan and the bottom of the barrel or a top of the wire loaded into the barrel. 
     
     
         16 . The method of  claim 12 , wherein adjusting the loading of the wire into the barrel comprises adjusting a rotational speed of the turntable. 
     
     
         17 . The method of  claim 12 , wherein adjusting the loading of the wire into the barrel comprises moving the capstan inwardly and outwardly horizontally relative to the barrel to cause the wire to be laid evenly within the barrel in a helical manner.