TECHNICAL FIELD
The present invention relates to a machine for aluminium wire coil flipping.
BACKGROUND AND PRIOR ART
Aluminium wire coil flipping machine serves the main function of flipping the
aluminium coils. It is essential to decrease the size of the bigger coils into smaller coils
and then separating the wires layer by layer. These separated wires are fed in to the steel
ladles undergoing treatment.
Flipping of the coil is an essential task, which is carried out manually at steel plants. The
manual operation makes it an abnormally high labour intensive and costly operation.
Thus, there is need of a machine for flipping the coils quickly and economically.
Addition of aluminium bars into steel ladles adopted during ladle treatment results in
very poor recovery of aluminium. Feeding of wire directly fi-om the coils, which weigh
from 2 to 3 tonnes, is also problematic. Aluminium addition to the steel leidle through
wire feeding machine during rinsing or treatment in ladle heating fiimace is
comparatively a new technique adopted for desired level of aluminium and its better
recovery.
EP 0803310 discloses a reeling machine for an aluminiimi wire comprising a motor
reduction gear for a drive mechanism, which rotates the coil, plurality of inlet gates, an
upper wall, two lateral walls and a bottom extending to a bottom wall opposite the inlet
face where the wire emerges after having followed a given path. The machine further
comprises means that allows the positioning of the bottom in one of two positions
corresponding to a position for charging the coil and a working position. The machine
further comprises a means for regulating the speed of defilement of the wire.
OBJECTS OF THE INVENTION
It is thus an object of the present invention to provide a machine for aluminium wire coil
flipping which supplies uninterrupted wires in the steel ladle undergoing ladle treatment.
Yet another object of the present invention is to provide an aluminium wire coil-flipping
machine which is quick and economical.
Yet another object of the invention is to increase the recovery of aluminium during the
ladle treatment.
Another object of the invention is to provide aluminium wire coil flipping machine,
which occupies less space.
SUMMARY OF THE INVENTION
The present invention provides a machine provided for aluminium wire coil flipping
comprising:
revolving table comprising a thrust bearing and guide cone in the middle and brakes for
checking unwanted rotation;
wire tensioning means for increasing friction in the wire movement comprising rope
pulleys for passing the wire in'S' shape through pulleys;
wire guiding means consisting of geared motor drive, cross travel facility through lead
screw, guide head and limit switches for travel control and reversal of the guide head;
drive unit for driving the spool comprising geared motor coupled with driving centre;
spool; and
revolving centre with axial movement for loading, unloading facility of spool on the
machine.
DETAILED DESCRIPTION
The present invention relates to a machine for aluminium wire coil flipping comprising:
The revolving table comprising a circular plate provided with a guide cone in the middle
and its mounting on a thrust bearing for free rotation during uncoiling. The revolving
table further comprises brakes to regulate the speed of rotation and to avoid the
slackening of wire. The said brakes essentially comprise wooden blocks fitted in metallic
casing and screw for tightening or loosening to regulate the friction on the revolving
table.
The wire tensioning means comprising a set of guide rollers prior to the entry to the
tensioning pulleys provided for 'S' shape movement of wire. The grooved pulleys are
mounted on a post, fixed with the main frame. Wire alignment guides are also provided.
The wire guiding means comprises of a drive, a lead screw mounted over plummer
blocks for cross travel of the guide head carrying the wire. The guide head with female
thread for movement on lead screw and wire guide slit may be equipped with guide
rollers mounted on anti-friction bearings. The guide head itself comprises of guide
passage provided with guide rollers fitted with ball bearings and a guide nose. For
reversal of the movement a plurality of limit siwtches, preferably two on either sides are
also provided. The wire guide system is located adjacent to the spool. The drive
comprises geared motor wherein the drive center of the conical head with the driving key
is to be engaged with spool for rotation. The geared motor is preferably of 5.5kW and 25
rpm output.
The spool meant for rewinding the wire is equipped with the side plates with coil
strapping grooves and collapsible mandrel. The spool has one side detachable and other
side remains fixed to pullout from the coil. Preferably, the spool comprises a guide plate
and collapsible mandrel in three segments with one side plate welded to inner moimting
pipe and the other side plate is detachable.
The drive unit comprises a geared motor coupled with driving center with the spool
engaging cone and mounted on plummer blocks with antifrction bearings.
The center with engaging cone is free to rotate on bearing housed in a housing mounted
on guide blocks fixed with the frame and comprises a conical head with key to be
engaged with spool and adapted to move axially. The axial movement unit comprises of a
lead screw and sleeve nut fixed with the housing. The lead screw is rotated with a lever at
end. This axial movement is required for loading and unloading of the spool over the
machine. Alternatively, the said revolving center may be mounted on taper roller bearing
housed in a housing capable of moving axially in guiding blocks welded to said base
frame. The axial movement of the revolving center is achieved through lead screw rotated
by handle for locking and unlocking of the spool.
A sturdy frame used for mounting the revolving table, tensioning pulleys, guide pulleys,
wire guide and spool drive comprises of channel structure and an attending platform
before the spool for its loading and unloading.
In an embodiment of the present invention, the feeding of aluminium wires into the steel
ladles is done through machine. The machine is built near the steel ladles where the
purification of aluminium is carried out.
BRIEF DESCRIPTION OF PREFERRED EMBODIMENT
The scope of the invention is not Umited to the exemplary embodiments described herein.
Figure 1 shows the assembly of the machine;
Figure 2 shows the drive head including spool; and
Figure 3 shows the wire guide system.
DETAILED DESCRIPTION OF PREFERED EMBODIMENTS
Figure 1 shows the assembly of the machine where the revolving table (1) is mounted on
a thrust bearing (3) and with a guide cone (2). The guide cone is provided in the middle
of the revolving table and this facilitates rotation of the mother coil during unwinding to
flipped coil. The revolving table is provided with brakes (4) which check the firee rotation
of revolving table. Tensioning pulleys (5) are functionally adapted to be connected to the
wires to create tension in wire due to friction. The rope pulleys (6) and the roller guide
(7) are mounted on post (8) which along with the guide roller (9), provided prior to entry
to the tensioning pulleys, ensure the "S" shaped movement of the wire. The wire guide
system (10) comprises a gear motor, a lead screw, a guide head, a limit switch and a
coupling and is mounted on a frame for travel of the wire. The frame (11) is used for
mounting the revolving table, tensioning pulleys, guide pulleys, wire guide and spool
drive and comprises of channel structure and an attending platform before the spool for
its loading and unloading. A collapsible spool (12) is provided for rewinding the wire.
Figure 2 shows the drive head including spool, for rewinding the wire, where a geared
motor (21), a coupling (22) and a drive centre (24) are engaged with a spool (12) to rotate
at 25 rpm. The spool with a collapsible mandrel (16) is mounted between a drive centre
and a revolving centre (25) and comprises of two side plates, one of which is fixed (14)
and another is detachable (15) towards free revolving centre (25). The spool is capable of
winding a coil of diameter 900 mm and weighing around 1000 kg. The coiling mandrel
(16) comprises of 3 segments, which are 120 degrees apart. After winding, the spool is
taken out and kept on the wooden planks vertically to retrieve the collapsible mandrel
(16) with fixed plate (14) out. The revolving centre (25) comprises of conical head
mandrel (26) mounted on anti-friction bearings (28) and (36) in housing (29) capable of
axial movement by 150 mm by lead screw (33) and sleeve nut (34) actuated by a handle
bar (35). The axial movement is required for loading and unloading of the spool over the
machine.
Figure 3 shows the wire guide system where the drive motor (37) for cross travel upto
900 mm through lead screw (38) and guide head (39) comprises of guide passage
provided with guide rollers fitted with ball bearings and a guide nose. Further limit
switches (40) are provided for cross limit and guide head (39) reversal. The ratio of spool
rotation and wire guide lead screw is 1:2.
The machine, provided for in the present invention, offers the following advantages
among others:
1. This machine requires less space for operation.
2. It gives uninterrupted supply of aluminium wires into the steel ladles.
3. It is economic and faster.
4. It allows good recovery of aluminium during the ladle treatment.
WE CLAIM
1. A machine for aluminium wire coil flipping comprising:
a revolving table comprising of thrust bearing and guide cone in the middle and brakes
for checking unwanted rotation;
a wire tensioning means for increasing friction in the wire movement comprising of
rope pulleys for passing the wire in 'S' shape through pulleys;
a wire guiding means comprising geared motor drive, cross travel facility through lead
screw, guide head and limit switches for travel control and reversal of the guide head;
a drive unit for driving the spool comprising geared motor coupled with driving center;
a spool; and
a revolving centre with axial movement for loading, unloading facility of spool on the
machine.
2. A machine as claimed in claim 1, wherein the said revolving-table comprises of a
guide cone in the center and a thrust bearing.
3. A machine as claimed in claim 1 or 2, wherein said brakes comprise of wooden blocks
fitted in metallic casing and screw for tightening or loosening to regulate the friction on
the revolving table.
4. A machine as claimed in claim 1, 2 or 3, wherein the said wire tension is activated
through tension pulleys mounted over each other to guide the wire in'S ' shape.
5. A machine as claimed in any of the preceding claims, wherein the said wire guiding
means comprises a cross travel lead screw and a drive-geared motor.
6. A machine as claimed in any of the preceding claims, wherein the said guide head with
female thread for movement on lead screw and wire guide slit is equipped with guide
rollers mounted on anti-friction bearings.
7. A machine as claimed in claim 6, wherein the said side guide additionally comprises a
plurality of limit switches on either side to control the cross travel and its reversal.
8. A machine as claimed in claim 7, comprising two limit switches, one on either side to
control the cross travel and its reversal.
9. A machine as claimed in any of the preceding claims, wherein said spool comprises a
guide plate and collapsible mandrel in three segments with one side plate welded to
inner mounting pipe and the other side plate being detachable.
10. A machine as claimed in any of the preceding claims, wherein the said drive comprises
of geared motor wherein the drive centre of conical head and driving key is to be
engaged with spool for rotation.
11. A machine as claimed in any of the preceding claims, wherein the said geared motor is
of 5.5 kW and 25 rpm output.
12. A machine as claimed in any of the preceding claims, wherein the said revolving centre
comprises of a conical head with key to be engaged with spool, and axial movement
facility.
13. A machine as claimed in any of the preceding claims, wherein the said revolving centre
is mounted on taper roller bearing housed in a housing capable of moving axially in
guiding blocks welded to the base frame.
14. A machine as claimed in any of the preceding claims, wherein the said axial movement
of revolving centre is achieved through lead screw rotated by handle for locking and
unlocking of the spool.
15. A machine as claimed in any of the preceding claims, additionally comprising a sturdy
frame for mounting the revolving table, wire tensioning means, guide pulleys, wire
guiding means and spool drive, the said frame comprising a channel structure and an
attending platform before the spool for its loading and unloading
16. A machine for aluminium wire coil flipping substantially as described herein and
illustrated with reference to the accompanying figures.

The invention relates to a machine for faster and economic flipping of an aluminium wire
coil. The machine of the present invention essentially comprises a revolving table, a wire
tensioning system, a wire guiding system, a spool drive and a revolving centre mounted
on a sturdy frame.