WIRE SPOOLER AND TWISTER
FIELD OF INVENTION
The present invention relates to wire spooler and twister.
More particularly, the present invention relates to making loosely twisted wire spool from
plurality of wires.
BACKGROUND OF THE INVENTION
Present invention is to draw wires from multiple wire bobbins, loosely twist them and
spool them to make bobbin with bunch of wires. This invention relates to making of wire
bunch to be used in the winding robot (patent application number 201631019543A) for
winding of bunch of wires on to a plate for the manufacturing of brush seals. The wires
are loosely twisted so that the twisting does not create a hard spot when the wire bunch
is layed on to a plate for which this invention is particularly developed but not limited to
this application alone.
In a patent US1855491, an apparatus is described for winding and twisting the yarns
having uniform number of twists per unit length.
In a patent US1858528 & US2593984, an invention is described for manufacturing a cable
or rope from plurality of wires.

In a patent US7500345B2, authors presented an invention to manufacture a conductor
with a central core having multiple wires twisted around the core in axial direction.
The objective of the present invention is to draw wire from multiple bobbins, twist them
together and wind the bunch of wires on to another bobbin. The bunch of wires from this
wire spool wound on to a plate (2-3 inch width) and released at one end by holding
together at other end as illustrated in Fig.1. Therefore twisting should be loose such that
the bunch of wires should not have any hard spot.
The present invention is another apparatus for loosely twisting the multiple wires together
and spooling them to avoid hard spot after winding the bunch of wires on to a plate.
OBJECTS OF THE INVENTION
The object of the invention is to propose an apparatus to loosely twist the multiple wires
drawn from wire bobbins and spool the wire bunch on to another bobbin.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig.1: (a) Shows a plate wound with bunch of wires; (b) Shows the wires released at end
of plate
Fig.2: Shows the isometric view of present invention wire spooler and twister
Fig.3: Shows details of twisting unit

Fig.4: Shows wire tensioner arrangement
Fig.5: Shows axial shifting mechanism
Fig.6: Shows Spooler unit
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
The wire spooler and twister described here is a four bobbin system and is illustrated from
Fig.2 to Fig.6.
The apparatus consists of a rotary harness (1) which supports the wire spool bobbins (2)
and is driven by a motor (3). The motor (3) is connected to rotary harness (1) through a
belt drive (4). The wires (5) from each bobbin (2) are routed through the levers of
twisting fork (6). Twisting fork (6) is positively fastened to rotary harness (1) and rotates
along with it. The wires (5) from twisting fork (6) are routed to guide post-1 (7). The
individual wires (5) from bobbins (2) are bunched at guide post-1 (7). The individual wires
gets twisted at guide post-1 (7) by the rotation of rotary harness (1) along with bobbins
(2) and twisting fork (6). The pitch of the twisting is decided by the angular speed of
rotary harness (1). The twisting is due to mere friction between the wires (5). The bunch
of wires from guide post-1 (7) are routed to guide post-2 (8) via wire tensioner (9). The
wire tensioner (9) is required to avoid slackness in the winding. The required tension by
wire tensioner (9) is created by a spring (10) connecting to wire tensioner lever (11). The

bunch of wires from guide post-2 (8) are routed to target bobbin (12) via axial shift
arrangement (13). The purpose of axial shift arrangement (13) is to wind the present
turn of wire bunch adjacent to previous turn of winding.
Axial shift arrangement consists of a motor (14) whose shaft is connected to a threaded
shaft (15). Shifting element (16) is screwed on to a threaded shaft (15) and constrained
to rotate and allowed to translate on the threaded shaft (15) by its (15) rotation. The
rotation of the motor (14) is controlled such that the shifting element (16) moves by a
distance equal to diameter of wire bunch after the completion of every turn of winding on
the target bobbin (12). The winding of bunch of wires on to the target bobbin (12) is
achieved by rotating the target bobbin (12), which in-turn pulls the wire bunch from guide
post-2 (8). The rotation of the target bobbin (12) is achieved through a motor (17) and
belt drive (18).
After completing one layer of winding on to the target bobbin, the direction of winding has
to be reversed which is achieved by reversing the direction of rotation of motor (14) of the
axial shift arrangement (13). The speed of the motors (3, 14, and 17) and direction of
rotation of motor (14) is controlled by a controller. The communication to reverse the
direction of motor (14) by the controller is achieved thru a sensor (19) and known width
of target bobbin (12). Controller synchronise the motors for continuous winding of
individual wires from wire spool bobbins to wind as a bunch of wires with twisting on to a
target bobbin.

WE CLAIM
1. Wire spooler and twister for loosely twisting multiple wires drawing from bobbins
and spooling as loosely twisted bunch of wires on another bobbin comprising:-
- a rotary harness (1), over which a plurality of wire spool bobbins (2) are
mounted;
- the rotary harness being connected to a motor (3) through a belt drive (4);
- a twisting fork (6) having levers fixedly connected to the rotary harness (1);
- the levers of the fork (6) having holes for passing wires (5);
- a guide post (7) placed adjacent to the proximate side of twisting fork (6) for
allowing entry of the twisted wires through the holes provided on it, wherein
when the motor (4) is rotated, it transfer the rotary movement to the rotary
harness (1) along with bobbins (2) filled with wires (5) which in turn also
transfer the rotation to the twisting fork (6) allowing the wires (5) to be loosely
twisted due to mere friction between the wires (5) at guide post (7) and
subsequently passing through the holes at the top of the guide post (7) and
finally being wound on a bobbin.
2. The wire spooler and twister as claimed in claim 1, further comprising a target
bobbin (12) mounted on a bracket along with a motor (17) for winding the finally
twisted wires (5).

3. The wire spooler and twister as claimed in claim 2, wherein the target bobbin (12)
receives rotation from the motor (17) through belt drive (18).
4. The wire spooler and twister as claimed in claim 1, wherein a wire tensioner (9) is
placed next to guide post (7) for avoiding slackness in the winding of twisted wires.
5. The wire spooler and twister as claimed in claim 4, wherein the wire tensioner (9) is
equipped with a spring (10) for imparting tension to the twisted wires (5).
6. The wire spooler and twister as claimed in claim 1, wherein the set up is equipped
with a axial shift arrangement (13) to wind the present turn of wires (5) adjacent to
previous turn of winding.
7. The wire spooler and twister as claimed in claim 6, wherein the axial shift
arrangement (13) further comprising a motor (14), a threaded shaft (5) and a
shifting element (16).
8. The wire spooler and twister as claimed in claim 7, wherein the threaded shaft (15)
receives the rotary movement from the motor (14).

9. The wire spooler and twister as claimed in claim 8, wherein the rotary movement of
the threaded shaft (15) is converted to linear movement by a shifting element (16)
having internal threads and mounted on threaded shaft (15).
10.The wire spooler and twister as claimed in claim 9, further comprising a sensor (19)
for reversing the rotational direction of the motor (14).
11.The wire spooler and twister as claimed in claim 1, loosely twists the multiple wires
(5) leaving no hard spot at the location of twist.