Apparatus, methods, and systems for winding coils of flexible material

Abstract

Apparatus and methods for winding flexible material include a rotatable plate assembly rotatably driven by a first rotary shaft, the assembly supporting second and third rotary shafts with corresponding first and second mandrel parts mounted thereon. The first and second mandrel parts each form at least part of a winding spool. The second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, the rotational axis of the first rotary shaft. The rotation of the plate assembly is coordinated with counter rotation of the first and second mandrel parts. In embodiments, such coordinated rotation occurs during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other. The flexible material can be cable, wire, tubing, hose, rope, or other filamentary material. Other aspects are described and claimed.

What is claimed is: 
     
         1 . An apparatus for winding flexible material, comprising:
 a rotatable plate assembly whose rotation is driven by a first rotary shaft, the plate assembly supporting second and third rotary shafts with first and second mandrel parts mounted thereon, wherein the first and second mandrel parts each form at least part of a winding spool for winding a coil of the material thereon, wherein the second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, a rotational axis of the first rotary shaft; and   means for coordinating rotation of the plate assembly about the first rotational axis with counter rotation of the first and second mandrel parts about the second and third rotational axes, respectively.   
     
     
         2 . An apparatus according to  claim 1 , wherein:
 the means for coordinating the rotation of the plate assembly with the counter rotation of the first and second mandrel parts is configured to operate during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other.   
     
     
         3 . An apparatus according to  claim 2 , wherein:
 the transition operations are also performed between packaging operations that employ the first and second mandrel parts in an opposite ordered sequence one after the other.   
     
     
         4 . An apparatus according to  claim 1 , wherein:
 the means for coordinating the rotation of the plate assembly with the counter rotation of the first and second mandrel parts comprise a gear mechanism.   
     
     
         5 . An apparatus according to  claim 1 , wherein:
 the means for coordinating the rotation of the plate assembly with the counter rotation of the first and second mandrel parts comprises at least one electronic controller that controls the rotation of the plate assembly and the counter rotation of the first and second mandrel parts.   
     
     
         6 . An apparatus according to  claim 1 , wherein:
 the second rotary shaft and the first mandrel part mounted thereon as well as the third rotary shaft and the second mandrel part mounted thereon are further configured to rotate independently from the first rotary shaft and the plate assembly with the plate assembly in one or more fixed rotational positions.   
     
     
         7 . An apparatus according to  claim 1 , further comprising:
 a cutter system mounted on the plate assembly and centrally disposed between the first and second mandrel parts.   
     
     
         8 . An apparatus according to  claim 7 , wherein:
 the cutter mechanism comprises first and second slots and corresponding cutting elements, wherein the first slot and corresponding cutting element are configured to cut material that is wound onto the first mandrel part while material is captured by the second mandrel part, and wherein the second slot and corresponding cutting element are configured to cut material that is wound onto the second mandrel part while material is captured by the first mandrel part.   
     
     
         9 . An apparatus according to  claim 1 , wherein:
 the first rotary shaft is operably coupled to a first drive mechanism that is operated to drive rotation of the first rotary shaft and the plate assembly.   
     
     
         10 . An apparatus according to  claim 1 , further comprising:
 a second drive mechanism coupled to a winding mandrel interface, wherein the winding mandrel interface is configured to be selectively engaged and coupled to either one of the first and second mandrel parts.   
     
     
         11 . An apparatus according to  claim 10 , wherein:
 the winding mandrel interface and the first mandrel part or the second mandrel part coupled thereto form the winding spool for winding operations.   
     
     
         12 . An apparatus according to  claim 11 , wherein:
 the second drive mechanism and the winding mandrel interface are operated to selectively engage and couple to one of the first and second mandrel parts and then rotate the winding spool as part of the winding operations.   
     
     
         13 . An apparatus according to  claim 12 , wherein:
 the winding operations are carried out in a controlled manner that employs the first and second mandrel parts in an ordered sequence one after the other with the first and second mandrel parts disposed at a predefined first position, which is set by rotational position of the plate assembly.   
     
     
         14 . An apparatus according to  claim 13 , further comprising:
 a traverse mechanism configured to guide material onto the winding spool at the predefined first position during the winding operations.   
     
     
         15 . An apparatus according to  claim 13 , further comprising:
 a movable plastic film applicator configured to apply plastic film onto material wound onto the winding spool at the predefined first position during the winding operations.   
     
     
         16 . An apparatus according to  claim 1 , wherein:
 the first and second mandrel parts each have a plurality of mandrel segments that move radially relative to a central axis between a collapsed configuration and an expanded configuration.   
     
     
         17 . An apparatus according to  claim 16 , wherein:
 the first and second mandrel parts each have a locking mechanism that retains the plurality of mandrel segments in the expanded configuration.   
     
     
         18 . An apparatus according to  claim 17 , wherein:
 the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the mandrel segments in a predefined rotational position of the hub with the plurality of mandrel segments in the expanded configuration.   
     
     
         19 . An apparatus according to  claim 18 , wherein:
 the rotatable hub has a lever that is configured to return the rotatable hub to the predefined rotational position of the hub during rotation of the plate assembly.   
     
     
         20 . An apparatus according to  claim 17 , wherein:
 the first and second mandrel parts each have an unlocking mechanism that releases the lock mechanism that retains the plurality of mandrel segments in the expanded configuration and permits the plurality of mandrel segments to move to the collapsed configuration.   
     
     
         21 . An apparatus according to  claim 20 , wherein:
 the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the plurality of mandrel segments in a predefined rotational position of the hub; and   the unlocking mechanism comprises a spring-biased pusher rod that engages a ramp surface of the hub to rotate the hub out of the predefined rotational position of the hub.   
     
     
         22 . An apparatus according to  claim 1 , wherein:
 the first and second mandrel parts each have a grabber mechanism that is configured to catch and grab material, wherein the grabber mechanism is configured to catch and grab material during the coordinated rotation of the plate assembly and the counter rotation of the first and second mandrel parts.   
     
     
         23 . An apparatus according to  claim 1 , wherein:
 the first and second mandrel parts each comprise a winding spool for winding a coil of the material thereon that is detachably mountable on the second and third rotary shafts.   
     
     
         24 . An apparatus according to  claim 1 , wherein:
 the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material.   
     
     
         25 . A method for winding flexible material, comprising:
 providing a rotatable plate assembly whose rotation is driven by a first rotary shaft, the plate assembly supporting second and third rotary shafts with first and second mandrel parts mounted thereon, wherein the first and second mandrel parts each form at least part of a winding spool for winding a coil of the material thereon, wherein the second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, a rotational axis of the first rotary shaft; and   coordinating rotation of the plate assembly about the first rotational axis with counter rotation of the first and second mandrel parts about the second and third rotational axes, respectively.   
     
     
         26 . A method according to  claim 25 , wherein:
 the coordinating of the rotation of the plate assembly with the counter rotation of the first and second mandrel parts occurs during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other.   
     
     
         27 . A method according to  claim 26 , wherein:
 the transition operations are also performed between packaging operations that employ the first and second mandrel parts in an opposite ordered sequence one after the other.   
     
     
         28 . A method according to  claim 25 , wherein:
 the coordinating of the rotation of the plate assembly with the counter rotation of the first and second mandrel parts employs a gear mechanism.   
     
     
         29 . A method according to  claim 25 , wherein:
 the coordinating of the rotation of the plate assembly with the counter rotation of the first and second mandrel parts employs at least one electronic controller that controls the rotation of the plate assembly and the counter rotation of the first and second mandrel parts.   
     
     
         30 . A method according to  claim 25 , further comprising:
 configuring the second rotary shaft and the first mandrel part mounted thereon to rotate independently from the first rotary shaft and the plate assembly with the plate assembly in one or more fixed rotational positions.   
     
     
         31 . A method according to  claim 25 , further comprising:
 configuring the third rotary shaft and the second mandrel part mounted thereon to rotate independently from the first rotary shaft and the plate assembly with the plate assembly in one or more fixed rotational positions.   
     
     
         32 . A method according to  claim 25 , further comprising:
 providing a cutter system mounted on the plate assembly and centrally disposed between the first and second mandrel parts, wherein the cutter mechanism comprises first and second slots and corresponding cutting elements;   configuring the first slot and corresponding cutting element to cut material that is wound onto the first mandrel part while material is captured by the second mandrel part; and   configuring the second slot and corresponding cutting element to cut material that is wound onto the second mandrel part while material is captured by the first mandrel part.   
     
     
         33 . A method according to  claim 25 , further comprising:
 operably coupling the first rotary shaft to a first drive mechanism that is operated to drive rotation of the first rotary shaft and the plate assembly.   
     
     
         34 . A method according to  claim 33 , further comprising:
 providing a second drive mechanism coupled to a winding mandrel interface; and   configuring the winding mandrel interface to be selectively engaged and coupled to either one of the first and second mandrel parts.   
     
     
         35 . A method according to  claim 34 , wherein:
 the winding mandrel interface and the first mandrel part or the second mandrel part coupled thereto form the winding spool for winding operations.   
     
     
         36 . A method according to  claim 35 , wherein:
 the second drive mechanism and the winding mandrel interface are operated to selectively engage and couple to one of the first and second mandrel parts and then rotate the winding spool as part of the winding operations.   
     
     
         37 . A method according to  claim 36 , wherein:
 the winding operations are carried out in a controlled manner that employs the first and second mandrel parts in an ordered sequence one after the other with the first and second mandrel parts disposed at a predefined first position, which is set by rotational position of the plate assembly.   
     
     
         38 . A method according to  claim 37 , further comprising:
 providing a traverse mechanism; and   configuring the traverse mechanism to guide material onto the winding spool at the predefined first position during the winding operations.   
     
     
         39 . A method according to  claim 37 , further comprising:
 providing a movable plastic film applicator; and   configuring the plastic film applicator to apply plastic film onto material wound onto the winding spool at the predefined first position during the winding operations.   
     
     
         40 . A method according to  claim 25 , wherein:
 the first and second mandrel parts each have a plurality of mandrel segments that move radially relative to a central axis between a collapsed configuration and an expanded configuration.   
     
     
         41 . A method according to  claim 25 , wherein:
 the first and second mandrel parts each have a locking mechanism that retains the plurality of mandrel segments in the expanded configuration.   
     
     
         42 . A method according to  claim 41 , wherein:
 the locking mechanism operates to retain the plurality of mandrel segments in the expanded configuration automatically by engagement of a mandrel interface with one of the first and second mandrel parts.   
     
     
         43 . A method according to  claim 41 , wherein:
 the first and second mandrel parts each have an unlocking mechanism that releases the lock mechanism that retains the plurality of mandrel segments in the expanded configuration and permits the plurality of mandrel segments to move to the collapsed configuration.   
     
     
         44 . A method according to  claim 43 , wherein:
 the unlocking mechanism operates to release the locking mechanism automatically by engagement of a mandrel interface with one of the first and second mandrel parts.   
     
     
         45 . A method according to  claim 25 , wherein:
 the first and second mandrel parts each have a grabber mechanism that is configured to catch and grab material, wherein the grabber mechanism is configured to catch and grab material during the coordinated rotation of the plate assembly and the counter rotation of the first and second mandrel parts.   
     
     
         46 . A method according to  claim 25 , wherein:
 the first and second mandrel parts each comprise a winding spool for winding a coil of the material thereon that is detachably mountable on the second and third rotary shafts.   
     
     
         47 . A method according to  claim 24 , wherein:
 the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material.