Snap-On, Wire Pay-Off Cap Assembly

U.S. Pat. No. 3,425,647, issued Feb. 4, 1969 to Joseph J. Kovaleski, and entitled "WIRE TAKE-OFF DEVICE."

Co-pending application of Joseph J. Kovaleski, U.S. Ser. No. 563,792, filed Mar. 31, 1975, and entitled "SPOOL HANDLING DOLLY," now U.S. Pat. No. 3,995,758 dated Dec. 7, 1976.

Co-pending application of Joseph J. Kovaleski, U.S. Ser. No. 725,095, filed Sept. 17, 1976, and entitled "WIRE PAY-OFF CAP ASSEMBLY FOR WIRE SPOOLS."

Co-pending application of Joseph J. Kovaleski, U.S. Ser. No. 578,364, filed May 16, 1975, and entitled "TENSION BRUSH WITH ADJUSTABLE BRAKE," now U.S. Pat. No. 3,972,489 dated Aug. 3, 1976.

Co-pending application of Joseph J. Kovaleski, U.S. Ser. No. 620,319 filed Oct. 7, 1975, and entitled "SUPPORTING FIXTURE FOR WIRE CARRYING SPOOLS" now U.S. Pat. No. 3,998,403 dated Dec. 21, 1976.

Co-pending application of Joseph J. Kovaleski, U.S. Ser. No. 563,787, filed Mar. 31, 1975, and entitled "TENSION BRUSH FOR WIRE SPOOL AND METHOD FOR MAKING SAME," now U.S. Pat. No. 3,998,403 dated Dec. 21, 1976.

Co-pending application of Joseph J. Kovaleski, U.S. Ser. No. 622,025 filed Oct. 14, 1975, and entitled "QUICK-CONNECT WIRE PAY-OFF CAP ASSEMBLY," now U.S. Pat. No. 3,997,127 dated Dec. 14, 1976.

This invention relates generally to wire spooling equipment, and more particularly to devices for facilitating the de-reeling of wire from a spool.

In U.S. Pat. No. 3,425,647, issued to Joseph J. Kovaleski on Feb. 4, 1969 there is shown a pay-out cap assembly comprising a freely rotatable wheel and stationary tension brush for de-reeling wire off the free end of the spool. In order to install the cap assembly at one end of the spool it is necessary to raise the spool end by lifting or tilting the spool, after which the assembly can be secured in place. In the past, special hubs or fixtures of one sort or another have been employed to retain such an assembly in its operative position. However, these items were generally cumbersome, and time-consuming to install. Also, problems associated with slightly differing spool bore diameters often made high speed operation of pay-out equipment difficult or impossible to realize.

The above drawbacks and disadvantages of prior cap assemblies for wire spools are obviated by the present invention, which has for an object the provision of a novel and improved quick-connect snap-on cap assembly which is simple in construction, reliable in operation, and which features especially quick installation on and removal from existing spools. A related object of the invention is the provision of a cap assembly as above, wherein no special tools are required for installation, and wherein few separate parts are involved whereby the fabrication cost is kept low.

The above objects are accomplished by a wire pay-off cap assembly for use with flanged, wire-filled spools to control the unreeling of wire past the ends thereof, comprising a support member, a flanged wheel carried on said support member, a circular tension brush disposed broadside to the wheel and having a plurality of radially disposed tines extending past the wheel periphery, and a unique clamping means connected with the support member and engageable with the rim of one flange of the spool for releasably securing the member, wheel and brush at one end of the spool with the wheel broadside to the spool end. The arrangement is such that it enables an especially quick snap-on installation of the cap assembly to a particular spool to be had, all without the need for special tools or equipment. Removal of the cap assembly is also readily accomplished.

Features of the invention reside in the provision of a cap assembly as above characterized, which is sturdy and rugged in construction, and which employs few moving parts, thus being economical to fabricate and assemble.

Other features and advantages will hereinafter appear.

In the drawings, illustrating several embodiments of the invention:

FIG. 1 is a vertical sectional view of the snap-on cap assembly of the present invention, shown installed on a flanged, wire-filled spool from which pay-out is ready to commence.

FIG. 2 is an enlarged fragmentary view of one of the arms of the cap assembly of FIG. 1.

FIG. 3 is a section taken on line 3--3 of FIG. 2.

FIG. 4 is a section taken on line 4--4 of FIG. 1.

FIG. 5 is a view like FIG. 1 of a somewhat modified snap-on cap assembly, constituting another embodiment of the invention.

FIG. 6 is a section taken on line 6--6 of FIG. 5.

Referring first to FIG. 1, and in accordance with the present invention there is illstrated the novel and improved snap-on wire pay-off cap assembly for use with flanged spools, to control the unreeling of wire past the ends thereof.

The spool 10 is supported on a horizontal member 11 with the cap assembly installed on one of the spool flanges 12, for effecting pay-off of wire to an idler or take-up mechanism (not shown). The spool is shown partially filled with wire 16.

The improved snap-on cap assembly of the present invention includes a support member comprising a shaft 20 on which there is rotatably carried a take-off wheel 22 having a peripheral flange 24 extending past the periphery of the spool flange 16. The wheel may be constituted as two pieces, as illustrated and described in my co-pending application U.S. Ser. No. 725,095 identified above. Alternately, it can be constituted as a single sheet metal part. The wheel 22 is carried on a molded plastic sleeve 26 which in turn rides on a ball bearing 28 carried on the shaft 20. Also carried by the latter is a circular brush 32 having radially extending tines 34 embedded in a conical disk 31 glued to the body, the tines being disposed adjacent the periphery of the wheel 22 and adapted to be brushed by the wire as it is being paid out past the wheel flange 24. The brush 32 has a body 33 including multiple, radially extending stiffening ribs 35, and a hub 36 secured by a set screw 42 on a flattened portion 40 of the member 20. A spacer 43, metal washer 44 and felt washer 45 are between the hub 36 and wheel 22.

The bearing 28 is held against axial movement by a ring 47 received in a circumferential groove in the shaft 20. In this way, the stationary felt washer 45 bears against the sleeve 26 of the wheel and applies a braking force thereto for improved control over the unreeling operation under conditions of variable speed pay-out. Adjustment of the drag or braking force applied to the wheel can be effected by loosening the set screw 42 and sliding the brush 32 toward the wheel 22 just slightly, thereby compressing the felt washer 45 and increasing the drag on the sleeve 26. The wheel 22 can optionally include a plurality of radially extending stiffening ribs 23 for added stiffness, as shown in FIG. 4. A knob 21 facilitates grasping the assembly during installation or handling.

At the inner end of the support member 20 there is carried a hub in the form of a washer 49 to which three radially disposed arms 46, 48 and 50 are welded, these being particularly illustated in dotted outline FIG. 4. The washer 49 is welded to the shaft 20, and the latter has three radially extending recesses to receive the ends of the arms. The arm 46 is constituted as a pair of inner and outer telescoping members 52, 54 respectively. Similarly, the arm 48 includes telescoping members 56, 58, and the arm 50 includes members 60, 62. As shown, the three large-diameter members 54, 58 and 62 are tubular; the members 54 and 58 carry mounting blocks 64 having threaded apertures to receive set screws 66 which clamp against the respective inner telescoping member 52 or 56 to hold them in predetermined positions with respect to their outer members. Adjustment in the overall length of the arms 46 or 48 is accordingly effected by loosening the set screws 66 and sliding the inner member 52, 56 to its desired position, to accommodate a particular spool size being employed. In FIG. 2 the member 60 carries a pin 68 near its inner end, and one end of a tensile spring 70 is secured thereto. The spring 70 is completely encased in and concealed by the outer telescoping member 62, and has its other end secured to a cross pin 72 carried by the member 62. A block 64 is provided in the member 62, secured by screws 66 and constituting a guide for the member 60 to minimize binding thereof, and to prevent turning of the member 60 with respect to the member 62. The members 52, 56 and 60 constitute hook portions of the arms 46, 48 and 50 respectively, having hooked ends 80, 82 and 84 respectively, which are adapted to be latched over the rim of the spool flange 12 as shown in FIG. 1 when the cap assembly is installed; the members 52, 56 and 60 are preferably constituted or hardened steel or spring steel such that they will retain their shape even after prolonged periods of use.

In FIG. 4, during the installation on a spool, of a typical snap-on pay-off cap assembly constructed in accordance with the present invention, the members 52, 56 are initially positioned to the approximate locations with respect to their outer telescoping members 54, 58 to accomodate the particular spool size being employed. To install the cap assembly, the operator merely grasps the wheel 22 with both hands, latches the hook 84 over the spool flange, pulls upwardly to stretch the spring 70 and enable the hooks 80, 82 to first by-pass and then latch over the opposite side of the flange 16. Upon release of the assembly, the spring 70 maintains the engagement of all three hooks with the flange. Removal of the cap assembly is accomplished as readily.

The above construction is seen to have the advantage of extreme simplicity, yet it provides a very satisfactory solution to the problem of quickly and easily securing a cap assembly to one end of a spool. The construction is capable of use with any flanged spool, regardless of whether the latter is positioned horizontally as shown in FIG. 1, such as on a spindle attached to a spool-supporting rack, or inclined to the horizontal, on a tilting fixture such as that shown and described in the application of Joseph J. Kovaleski, U.S. Ser. No. 620,319 filed Oct. 7, 1975 and entitled "SUPPORTING FIXTURE FOR WIRE CARRYING SPOOLS." Accordingly, great flexibility is realized, with high speed pay-out of wire being readily accomplished.

Another embodiment of the invention is illustrated in FIGS. 5 and 6, showing a modified spool 10a constituted of sheet metal, and a modified pay-out cap assembly for use therewith. The cap assembly includes a stationary brush 32a comprising a body 33a and a hub 36a, with a plurality of radially extending tines 34 embedded in the body 33a. The hub is secured on the shaft 20a by means of a set screw 42a, as in the previous embodiment. A knob 21a facilitates grasping and handling of the cap assembly. Also carried on the shaft 20a is a rotatable wheel 22a having multiple stiffening ribs 23a and a somewhat flattened peripheral flange 24a. The wheel 22a is carried on a molded bushing 26a and a ball bearing 28a. A bronze bearing 29 is also carried by the bushing 26a, and turnably engages the shaft 20a. A retainer washer 47a bears against the inner race of the bearing 28a and positions the wheel 22a axially. Welded to the shaft 20a is a solid block 49a constituting a hub, and including three radially extending recesses which receive three arms 46a, 48a and 50a. As shown in FIG. 6, the arms welded in place on the hub 49a.

As in the previous embodiment, the arm 48a is constituted of a tubular outer portion 58a and a telescoping inner portion or hook portion 56a and including a hooked end 82a. A guide block 64a is carried by the portion 58a and multiple screws 66a provided for locking the portion 56a in a fixed radial position. Similarly, the arm 46a includes a tubular portion 54a and a hook portion 52a having a hook 80a, and including a guide block 64a. The arm 50a is spring-biased, comprising a tubular portion 62a and a hook portion 60a having a hooked end 84a. A tensile spring 70 extends between pins 68 and 72 carried respectively by the member 60a and 62a, for biasing the hook portion 60a radially inward. The tubular portion 62a also includes a small guide block 67 having a single screw 66b securing it in place, for minimizing binding of the hook portion 60a during its sliding movement, and for preventing turning thereof with respect to the tubular portion 62a.

The operation of this embodiment is substantially the same as that of the first embodiment, in that during installation, the hook 84a is first latched over the flange 12a, and the cap assembly pulled downwardly in FIG. 6, until the hooks 80a and 82a bypass the flange, after which the cap assembly is urged toward the spool 10a, and the hooks 80a, 82a latched in position.

With the hook portions 60a, 52a and 56a being constituted of spring steel, the likelihood of permanent deformation or damage thereto is greatly minimized. Moreover, the improved cap assembly of the present invention can be readily installed by one person, even where relatively heavy steel wheels are employed. This is important where high speed operation involving multiple spools is desired.

From the above it can be seen that I have provided novel and improved, snap-on pay-off assemblies employing few moving parts, the assemblies being especially adaptable to a wide variety of spooling installations. The devices can be readily installed on and removed from existing spools without the use of special equipment or tools, and are thus seen to represent a distinct advance and improvement in the technology of wire de-reeling equipment.

Variations and modifications are possible without departing from the spirit of the invention.