Apparatus and method for holding and tacking material
This is a continuation, of Ser. No. 102,192, filed Oct. 29, 1979 now abandoned which matured from PCT/US79/00917, Oct. 29, 1979, Publication No. WO81/01119, Apr. 30, 1981, 102(e) date Oct. 29, 1979, abandoned. 
    
    
     DESCRIPTION 
     1. Technical Field 
     This invention relates to material-tacking apparatus and, more particularly, to an apparatus and a method for holding and tacking an elongate material under tension to a body. 
     2. Background Art 
     Many articles are formed in part by wrapping or winding a material helically about the body of the article. One such article is in the tire manufacturing area wherein an annular body has a layer of elongate material helically wound thereon substantially radially about the body of the tire. The elongate material is applied under tension, which tension is preferably kept uniform, not only at the start up of the winding or wrapping operation, but also continuously throughout the application of the elongate material and remains so at the conclusion of the winding step. 
     Heretofore, the tensioned cable was manually held against the body by means of a tacking strip. The strip was then tacked or stitched by hand onto the body member. A shuttle, which rotates in a plane substantially transverse to the plane of rotation of the body, is rotated about the body as the body is rotated in the plane of the body. An operator remained with the apparatus to visually observe the application of the elongate material to the body and when the wrapping was completed, the operator manually shuts off the shuttle drive mechanism and the body rotating mechanism and manually tacks or stitches the elongate material to the body prior to severing the elongate material connected to the supply. If, during the application of the elongate material to the body, the elongate material broke, the operator would shut down the equipment and attempt to catch the loose end of the elongate material so as to tack the end to the body before the elongate material became unraveled. 
     The manual tacking steps added labor costs to the end product and made it extremely difficult to quality control the tension on the elongate material at start up and at shutdown of winding on each body, as well as maintaining uniformity of tacking or stitching both at start up and at shutdown. 
     DISCLOSURE OF INVENTION 
     The present invention is directed to overcoming one or more of the problems as set forth above. 
     In one aspect of the present invention, there is provided an elongate material clamping and tacking apparatus adapted to be associated in relatively close proximity to a shuttle that is used for winding the elongate material on the body. The apparatus includes means for advancing, pivoting and retracting a tacker arm relative to the area where elongate material is being applied to the body. Means are provided on the tacker arm for clamping the material to the arm. Signaling means are provided on the body for activating the arm to initially tack the cable to the body as the shuttle starts to rotate relative to the advancing body. The advancing body moves the tacker arm to a position whereby the elongate material is released from the clamping means on the arm. The arm is then pivoted away from the body prior to the full retraction of the arm to a non-operational position. The signaling means carried by the body will signal completion of the winding operation to stop both the rotation of the body and the shuttle, whereupon the arm advances and pivots against the body to tack the elongate material thereto. The elongate material is then stitched to the body and severed from the supply. The tacker arm is then pivoted away from the body and is activated to clamp the end of the severed elongate material to the tacker arm prior to tacking and winding the elongate material on a second body. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is a perspective view of the elongate material holding and tacking apparatus in operative position with respect to a body of a toroidal member and to a material-winding shuttle; 
     FIG. 2 is an elevational view of the end of the tacker arm and the material-clamping mechanism with the tacker arm bearing against a body to be wrapped; 
     FIG. 3 is a partial cross-sectional view taken along the line 3--3 of FIG. 2; 
     FIG. 4 is a top plan view of the holding and tacking apparatus initially tacking a strand of elongate material to a body; 
     FIG. 5 is a top plan view, similar to FIG. 4, only showing the fully retracted position of the apparatus and with the tacker arm shown in phantom at two intermediate positions between the body and the retracted position; 
     FIG. 6 is an elevational view of the apparatus of FIG. 1 with the elongate material clamped to the distal end portion of the tacker arm; and 
     FIG. 7 is an enlarged, partial elevational view of the distal end portion of the tacker arm of FIG. 6 showing the clamping apparatus in the unclamped position. 
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     Referring broadly to FIG. 1, a winding or wrapping apparatus 10 is illustrated for applying elongate material 12, such as cable or the like, in a pattern to the outer surface of a body, such as a toroidal member, 14. The body or toroidal member 14, in the illustrated embodiment, is a torus tube carcass comprised of a disintegratable core 16 upon which is disposed one or more layers of rubber material 18. The body 14 is positioned on a side wall 20 and is rotated in the plane of the side wall 20 transverse to the normal axis of rotation of the body 14. A shuttle 22 is rotatably driven in a plane substantially transverse to the plane of the side wall 20 about the body 14 so that as the body 14 is rotated relative to the rotation of the shuttle 22, the elongate material 12, such as cable or the like, is continuously wound on the body 14 in a helical or spiral pattern. Although the drawing illustrates the body 14 rotating in a horizontal plane with the shuttle 22 rotating in a vertical plane transverse thereto, it is to be understood that the body 14 could be vertical and could rotate in a vertical plane with the shuttle 22 being in a horizontal plane transverse thereto without departing from the invention. The shuttle 22 carries a spool 24 of elongate material 12 and has a braking apparatus 26 for applying a drag to the spool 24 so that the elongate material 12 drawn from the spool 24 will be drawn under a substantially uniform tension. Mounted on the shuttle 22 is a series of guides 25 and pulleys 27 which permit the elongate material 12 to be drawn off from the spool 24 and to be applied to the surface of the body 14 under a substantially uniform tension. The body 14 has a pair of diametrically disposed, radially inwardly projecting flag or signaling members 28 and 29 carried by the body 14 as is illustrated somewhat schematically in FIG. 5. 
     To tack the elongated material or cable 12 against the body 14 at the start of the winding operation and to tack the last one or more passes of the elongate material or cable 12 to the body 14 at the completion of the winding or wrapping operation, an elongate material holding and tacking apparatus 30 is provided. The apparatus 30, as best shown in FIGS. 4-6, is mounted on a frame 32 fastened to the floor or to a base 34. Frame 32 has a deck 36 upon which is bolted a bracket 38 for supporting one end of an actuator 40. The actuator 40, as well as those actuators hereinafter introduced, is preferrably an air actuator and includes a cylinder 44 in which is reciprocably mounted a piston, not shown, connected to an outwardly extending rod 42. Air from a source of pressurized air is admitted to and is exhausted from the opposite ends of the cylinder 44 through valves 46 and 48 connected to the head and rod ends, respectively, of the actuator 40. Although an air actuator 40 is described, it is to be understood that the actuator could be fluid, hydraulic, mechanical or the like. A bracket 50 is mounted on one end of the cylinder 44 and has a proximity switch 52 thereon with a sensing end 53 facing away from the cylinder 44 in the direction of the rod 42. A member 54 extends transverse to the rod 42 at the outer end thereof and has a ferrous portion in alignment with the proximity switch 52. 
     The valves 46,48, as well as those valves hereinafter introduced, are conventional solenoid-actuated valves which are spring biased to a first position at which the respective air chambers of the associated actuator is exhausted to atmosphere, and are moved in response to an electrical signal to a position at which pressurized air is admitted to the respective air chamber. The proximity switch 52, as well as those hereinafter introduced, is of the type which is actuated by the presence of a ferrous material, such as the ferrous portion of member 54, in close proximity thereto. 
     A clevis bracket 56 is fastened to a carriage 58 and extends sidewardly therefrom. The outer end of the rod 42 is fastened to the clevis bracket 56 by means of a pin 60 and a spring clip 62. The carriage 58 has a pair of guides 64 slidably engaging a pair of tracks 66 mounted on the deck 36 by a pair of spaced apart blocks 68,69. The carriage 58 has a pair of vertically spaced apart brackets 70 (FIG. 6) sidewardly extending therefrom between which extends a pivot 72 for securing the proximal end 74 of a tacker arm 76 thereto. Admitting air to the valve 46 of the actuator 40 will move the rod 42, carriage 58 and tacker arm 76 back and forth along an axis substantially parallel to the axis of the rod 42, the carriage 58 being guided on the tracks 66 for producing the linear reciprocating motion of the tacker arm 76. 
     Mounted on the carriage 58 is a bracket 77 to which one end of a cylinder 80 of an actuator 78 is connected. A rod 82 is axially extendible and retractable from the cylinder by pressurized air, or the like, admitted to or exhausted from the opposite ends of the cylinder 80 through solenoid-actuated valve members 83 and 84. A bracket 86 is mounted on the one end of the cylinder 80 and has a proximity switch 88 thereon with a sensing end 89 facing away from the cylinder 80 in the direction of the rod 82. The distal end of the rod 82 has a member 90 extending transverse to the rod 82 with a ferrous portion thereof aligned with the sensing end 89 of the proximity switch 88. The proximity switch 88 is actuated by the close presence of the ferrous portion 89 of the member 90 as described above with respect to proximity switch 52. The outer end of the rod 82 is connected to a clevis 92 carried by the tacker arm 76 by means of a pin 94 and spring clip 95. The base of the clevis 92 is rigidly secured to the proximal end 74 of the tacker arm 76 and, not only projects transverse to the axial length of the tacker arm 76, but also projects away from the axis of the pivot 72 of said arm. The axis of the pin 94 is parallel to the axis of the pin 72 so that admitting pressurized air to appropriate valve 83,84 of the actuator 78 will extend or retract the rod 82 from the cylinder 80 which will pivot the tacker arm 76 a few degrees clockwise or counterclockwise about the axis of the pin 72. Since the actuator 78 is mounted on the carriage 58, the tacker arm 76 can be pivoted about the pivot 72 and can be moved axially parallel to the tracks 66 simultaneously or independently as desired. A bracket 97 is bolted to the deck 36 and supports a proximity switch 98 with a sensing end 99 pointing inward toward the carriage guides 64. The carriage 58 has a vertically extending ferrous portion 96 (see FIGS. 4,5) at the corner thereof which is positioned to pass in front of and in close proximity to the sensing end 99 of the proximity switch 98. The right-hand block 69 on the deck 36, as viewed in FIGS. 4 and 5, supports a proximity switch 100 with a sensing end 101 pointing toward the carriage 58, which carriage 58 has a ferrous portion 102 in alignment with the proximity switch 100 so that the proximity switch 100 senses the presence of the carriage 58 when the carriage is in the right-hand position on the guides 64. 
     The apparatus just described provides the operating structure for moving the tacker arm 76 forward and backward, and for pivoting the tacker arm 76 toward and away from the body 14. 
     Referring to FIGS. 2, 3, 6 and 7, an apparatus 104 is shown for clamping and unclamping the loose end of the elongate material 12 to the tacker arm 76. That is, the tacker arm 76 has a tacking head 105 on the distal end portion 106 thereof, which head 105 is spring-urged transverse to the axis of the tacker arm 76 by a compression spring 108 (FIG. 2). Guide pins 110 extend in opposite directions from a shank of the tacker head 105 and engage in elongate slots 112 in the top and bottom surfaces of the tacker arm 76 so as to be guided for spring-urged, limited transverse movement relative to the axis of the tacker arm 76. 
     The tacking head 105 has a plurality of vertically oriented grooves 114 on the face 116 projecting transverse to the axis of the tacker arm 76. Mounted on the lower side of the tacker arm 76 and carried by the distal end portion 106 of said tacker arm 76 is a bracket 107 supporting one end of an air actuator 118 which includes a cylinder 119 and an axially extendible rod 120. Pressurized air is supplied to the opposite sides of the cylinder 119 through solenoid-actuated valves 121 and 122. A support 124 is secured to the forward end of the cylinder 119 and has a portion projecting outward from the cylinder, which portion receives and mounts a proximity switch 126 having a sensing end 127 facing away from the cylinder 119 in the direction of the rod 120. A member 128 extends transverse to the rod 120 at the outer end thereof and has a ferrous portion 129 in alignment with the sensing end 127 of the proximity switch 126. A bifurcated bracket 130 is secured to the underside of the tacker arm 76 and has a bellcrank lever 132 pivotally mounted thereto by means of a pivot 134 extending through the elbow of the crank. A spring clip 135 secures the pivot 134 to the bracket 130. A short leg 136 of the bellcrank 132 is pivotally connected by a pin 137 and spring clip 138 to the distal end of the rod 120 so that axial movement of the rod 120 will pivot the bellcrank 132 about the pivot 134 to raise and lower a long leg 140 of the bellcrank 132 toward and away from the undersurface 142 of the tacker arm 76. The leg 140 of the bellcrank 132 has a gripping pad 144 on the outer portion thereof which aligns with a notch 146 formed transverse to the axis of the tacker arm 76 in the undersurface 142 thereof. 
     A strip of elongate material 12 is pulled from the pulley 27 on the shuttle 22 and is laid in one groove 114 of the face 116 of the tacking head 105 (FIG. 3) and is drawn around and under the end portion 106 of the tacker arm 76 to somewhat compress the spring 108 and is then laid in the notch 146 whereupon actuation of a switch, as by tripping a foot pedal, will cause an electrical signal to be directed to and actuate the solenoid valve 121 to admit pressurized air to the head end of the cylinder 119 of the actuator 118 to extend the rod 120 thereby pivoting the bellcrank 132 and clamping the end portion of the elongate material 12 in the notch 146 by contact of the pad 144 on the bellcrank 132 thereagainst. The gripping force of the bellcrank 132 on the elongate material 12 is such that the elongate material 12 has no, or minimal, slack as it extends from the shuttle 22 to the tacker arm 76 prior to starting the winding or wrapping of the elongate material 12 on the body 14. A short strip of tacking tape 148 is threaded between the elongate material 12 and the face 116 of the tacking head 105 (FIGS. 2 and 3) with one end portion 149 of the tape 148 stuck against the projections between the grooves 114 and the other end portion 150 of the tape 148 extending freely, axially outward from the tacker arm 76. 
     Although, in one embodiment of the invention, one or all of the actuators can be manually controlled without the use of the proximity switches, the preferred embodiment has the proximity switches (52,88,98,100,126) and control valves (46,48,83,84,121,122) connected to an Allen Bradley 1750, Programmable Control. The proximity switches (52,88,98,100,126) each direct an input signal to the computer in response to being actuated while the control valves (46,48,83,84,121,122) each receive an output signal from the computer in response to one or more input signals being fed to the computer. 
     INDUSTRIAL APPLICABILITY 
     At the time the elongate material 12 is clamped to the tacker arm 76 and the tacking tape 148 is secured to the tacking head 105, the tacker arm 76 is extended and the axis of the tacker arm 76 lies at an acute angle to the axis of the rod 42, dotted line position &#34;A&#34; of FIG. 4, so that the tacking head 105 is spaced from the body 14 with the elongate material 12 lying generally along a centerline 152 passing, at one end, through the rotational axis of the body 14 and, at the other end, through the outer extremity of the tacker arm 76. The mechanism for rotating the body 14 in the plane of the side wall 20 is actuated, such as by a manual switch, not shown, so that the body 14 commences rotating in a clockwise direction as viewed in FIGS. 4 and 5. At a predetermined point, one of the flags 28 or 29 (FIG. 5) will pass in close proximity to and actuate a proximity switch, not shown, which sends an electrical signal to the computer which directs an output signal to the control valve 83. The control valve 83, in turn, directs pressurized air into the head end of the actuator 78 to pivot the tacker arm 76 toward the body 14 to forcibly engage the tacking head 105 with the elongate material 12 and tacking tape 148 against the outside wall of the body 14. The pivoting of the tacker arm 76 will open the proximity switch 88 which will signal the computer to deactivate the valve 46 to vent the cylinder 44 so that the rod 42, tacker arm 76 and carriage 58 will be free to move to the left as viewed in FIGS. 4 and 5. After a predetermined time delay, the shuttle 22 will commence rotating about the body 14 to lay the first course of the winding on the body 14. 
     The body 14 will continue to advance in the clockwise direction so that as the first complete wrap of elongate material 12 approaches the initial position of the tacker arm 76, the outer end of the tacker arm 76, which is forcibly urged against the body 14, will have been moved toward the tacker apparatus 30 whereby the elongate material 12 will clear the outer end of the tacker arm 76 or, under unusual circumstances, will engage with the tapered corner 154 of the tacker arm 76 which will guide the elongate material 12 into position on the body 14 adjacent the first complete wrap of the elongate material. The second pass of the elongate material 12 will lay over part of the end portion 150 of the tacking tape 148 so as to trap the tape 148 between the second pass of the elongate material 12 and the body 14. The shuttle 22 will lay continuous spiral passes of elongate material 12 around the body 14 with the first couple of passes overlapping the end portion 150 of the tape 148. As the body 14 rotates, the carriage 58 and the tacker arm 76, which is forcibly urged against the body 14, will be moved axially to the left, as viewed in FIGS. 4 and 5, along the guides 64. 
     After a few passes of the shuttle 22 and, at about the time the shuttle 22 reaches full speed, the tacker arm 76 will have been moved to the dotted line position &#34;B&#34; of FIG. 5 and the ferrous portion 96 of the carriage 58 will pass in close proximity to and actuate the proximity switch 98 which sends an electrical signal to the computer, which directs an output signal to the control valve 122 which directs pressurized air to the rod end of the actuator 118 to retract the rod 120 and pivot the bellcrank 132 to unclamp the pad 144 from the elongate material 12. When the bellcrank 132 is fully pivoted, the ferrous portion 129 on the rod 120 will actuate the proximity switch 126 which sends an electrical signal to the computer which directs an output signal to the control valve 84 which directs pressurized air into the rod end of the actuator 78 to retract the rod 82, thereby pivoting the tacker arm 76 about the pivot 72 to move the tacker head 105 to the dotted line position &#34;C&#34; of FIG. 5. When the tacker arm 76 has pivoted fully to the position &#34;C,&#34; the ferrous member 89 will actuate the proximity switch 88 which sends an electrical signal to the computer which directs an output signal to the control valve 48 which directs pressurized air into the rod end of the actuator 40 to retract the rod 42, carriage 58 and tacker arm 76 to the fully retracted position &#34;D&#34; shown in solid lines in FIG. 5, whereupon the ferrous member 54 will actuate the proximity switch 52 which sends an electrical signal to the computer to place the apparatus at rest. 
     The shuttle 22 will continue to spirally wind the elongate material 12 on the body 14 until the second flag 28 or 29 passes the initial proximity switch, which was passed by the first flag 28 or 29 to start the cycle, to arm the apparatus for completion of the cycle. The body 14 will continue to rotate until the next flag 28 or 29, which will be the same flag that initially activated the apparatus, passes and actuates the initial proximity switch which sends an electrical input signal to the computer to shut down the shuttle 22 and to arrest further rotation of the body 14 about its axis. The computer also sends an electrical output signal to valve 46 to direct pressurized air to the head end of the actuator 40 to move the rod 42, carriage 58 and tacker arm 76 forward to a position roughly equivalent to the dotted line position &#34;A&#34; of FIG. 4, where the tacker head 105 aligns with the starting and stopping passes of the elongate material 12. The ferrous portion 102 of the carriage 58 will be in a position to close the proximity switch 100 which will signal the controls to activate the valve 83 to admit pressurized air to the actuator 78 to drive the rod 82 forward to pivot the tacker arm 76 in a counterclockwise direction to forcibly engage the tacker head 105 against the initial and final passes of the elongate material 12 on the body 14. The tacker head 105 of the tacker arm 76 will hold the elongate material 12 under tension against the body 14 until the last pass of the elongate material 12 is hand stitched to the body 14, whereupon the elongate material 12 is severed near the body 14. A manual switch is activated to signal the valve 84 to direct pressurized air to the head end of the actuator 78 to pivot the tacker arm 76 about the pivot 72 to the dotted line position &#34;A&#34; of FIG. 4 with the ferrous portion 90 engaging the proximity switch 88 to signal the controls that the apparatus is ready for the next winding. 
     The loose end of the elongate material 12 can be grasped and pulled around the tacker head 105 with the elongate material 12 laid in a groove 114 on the face 116. The elongate material 12 is then drawn underneath the tacker arm 76 and into the notch 146 whereupon the actuator 118 is manually activated to pivot the bellcrank 132 so that long leg 140 is in the clamping position against the undersurface 142 of the tacker arm 76. The tacking tape 148 is inserted between the elongate material 12 and the head 105. The apparatus is now armed, ready for use in tacking the elongate material 12 against the next body 14 placed on the body-rotating apparatus as described hereinabove. 
     During the running of the shuttle 22 for winding the elongate material 12 on the body 14, if the elongate material 12 breaks, a switch will be tripped to actuate the forward motion of the tacker arm 76 and then the pivoting motion of the tacker arm to engage the tacker head 105 against the elongate material 12 and the body 14 until the break is repaired. 
     Other aspects, objects and advantages of this invention can be obtained from a study of the drawings, the disclosure and the appended claims.