Device and method for automatically twisting metal wires, in particular for connecting adjacent, preferably mutually intersecting structure elements

Abstract

The invention concerns an apparatus, a method and a use of the apparatus for automatically twisting metal wires. The invention concerns in particular such an apparatus for connecting adjacent, preferably mutually crossing structural elements, comprising a wire feed means for feeding wire, preferably endless wire, into the apparatus, an arcuate wire guide which has a selectively openable and closable opening and which is adapted to guide the fed wire in the closed position along the arcuate wire guide from a first side of the arcuate wire guide to a second side of the arcuate wire guide, that is in opposite relationship with respect to the opening, a pulling slider adapted to engage the fed wire on the first side of the arcuate wire guide and to pull it towards the second side of the arcuate wire guide, and a twisting unit adapted to engage the fed wire on both sides of the arcuate wire guide and to twist it by means of a rotational movement.

Claims

1. An apparatus for twisting metal wires for connecting adjacent or mutually crossing structural elements, the apparatus comprising: a wire feed means for feeding wire into the apparatus, an arcuate wire guide that has a selectively openable and closable opening and is adapted to guide the fed wire when in the closed position along the arcuate wire guide from a first side of the arcuate wire guide to a second side of the arcuate wire guide, wherein the first and second sides of the arcuate wire guide are in opposite relationship with respect to the opening, a pulling slider adapted to engage the fed wire on the first side of the arcuate wire guide and to pull the fed wire towards the second side of the arcuate wire guide, and a twisting unit adapted to engage the fed wire on both the first and second sides of the arcuate wire guide and to twist the fed wire by a rotational movement.

2. An apparatus according to claim 1 wherein the first and second sides of the arcuate wire guide separate from each other to open the opening and come together to close the opening, and wherein the opening is arranged at a proximal end of the apparatus.

3. An apparatus according to claim 1 wherein the twisting unit has a first wire guide passage hole and a second wire guide passage hole and wherein the wire feed means is adapted to pass the fed wire through the first wire guide passage hole.

4. An apparatus according to claim 3 wherein the pulling slider is adapted to pass the wire pulled to the second side of the arcuate wire guide through the second wire guide passage hole in such a way that the wire forms a loop from the first wire guide passage hole to the second wire guide passage hole.

5. An apparatus according to claim 3 comprising a clamping device arranged on the first or the second side of the arcuate wire guide and adapted to hold the wire passed through the first wire guide passage hole or to hold the wire passed through the second wire guide passage hole.

6. An apparatus according to claim 5 comprising a drive means for conveying the wire, wherein the drive means is adapted to convey the wire passed through the second wire guide passage hole and held by the clamping device to shorten a loop that has formed to a predetermined size.

7. An apparatus according to claim 6 wherein the drive means is associated with the wire feed means and is adapted to convey the wire selectively into the apparatus in a feed direction or in an opposite direction.

8. An apparatus according to claim 6 wherein the drive means includes a drive member that is motor-drivable and is coupled to the pulling slider in such a way that the pulling slider is displaceable selectively from the first side of the arcuate wire guide towards the second side of the arcuate wire guide and from the second side of the arcuate wire guide towards the first side of the arcuate wire guide.

9. An apparatus according to claim 1 wherein the twisting unit has two coaxially arranged gears through which first and second wire guide passage holes completely extend, and wherein the two coaxially arranged gears are drivable both in opposite directions and in a same direction.

10. An apparatus according to claim 1 comprising a cutting body configured to sever the wire within the apparatus and adapted to sever the wire on at least one of the first side of the arcuate wire guide and on the second side of the arcuate wire guide.

11. A method of twisting a metal wire for connecting two or more adjacent or mutually crossing structural elements, the method comprising the steps: providing two adjacent or mutually crossing structural elements, feeding the wire into an apparatus according to claim 1, passing a crossing region of the structural elements through the opened opening of the arcuate wire guide of the apparatus, closing the opening of the arcuate wire guide so that the crossing region of the structural elements is enclosed by the arcuate wire guide, engaging the fed wire by the pulling slider, while the arcuate wire guide is in the closed position, pulling the fed wire by the pulling slider along the arcuate wire guide from the first side of the arcuate wire guide to the second side of the arcuate wire guide, engaging the fed wire on both the first and second sides of the arcuate wire guide by a twisting unit, and twisting the engaged wire by a rotational movement of the twisting unit.

12. A method according to claim 11 wherein the step of engaging the fed wire by a twisting unit includes at least one of the following steps: passing the fed wire through a first wire guide passage hole, and passing the wire that has been pulled to the second side of the arcuate wire guide in such a way that the wire forms a loop from the first wire guide passage hole to a second wire guide passage hole around the structural elements.

13. A method according to claim 12 including: holding the wire passed through the first wire guide passage hole or the wire passed through the second wire guide passage hole.

14. A method according to claim 13 including: conveying the wire passed through the second wire guide passage hole and held by a clamping device in such a way that the formed loop is reduced to a predetermined size.

15. The method according to claim 12, wherein passing the fed wire through the first wire guide passage hole comprises using the wire feed means of the apparatus to pass the fed wire through the first wire guide passage hole.

16. A method according to claim 11 wherein the step of engaging the fed wire on both sides of the arcuate wire guide by the twisting unit includes: driving in opposite directions two coaxially arranged gears, both of the gears including first and second wire guide passage holes such that the wire is passed through the first and second wire guide passage holes and is clamped, and wherein the step of twisting the engaged wire by rotational movement of the twisting unit includes: driving the two gears in a same direction with the clamped wire.

17. A method according to claim 11 including the step: prior to the twisting step, severing the wire on at least one of the first and second sides of the arcuate wire guide by a cutting body within the apparatus.

18. A method of using an apparatus for automatically twisting metal wires for connecting adjacent or mutually crossing structural elements for the production of a reinforcing cage for a pylon element of a wind power installation, wherein the apparatus is an apparatus in accordance to claim 1, the method comprising: feeding wire into the wire feed means, placing the opening of the arcuate wire guide in an open position, placing the adjacent structural elements or the mutually crossing structural elements in the opening, placing the opening in a closed position to surround the structural elements or the mutually crossing structural elements, engaging the fed wire by the pulling slider at the first side of the arcuate wire guide, using the pulling slider, pulling the fed wire towards the second side of the arcuate wire guide, and twisting the wire fed on both sides of the arcuate wire guide by rotational movement of the twisting unit, and wherein the reinforcing cage has first structural elements that includes a plurality of first and second prestressing cables arranged in mutually crossing relationship.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) The invention is described in greater detail hereinafter by means of an embodiment by way of example and with reference to the accompanying Figures in which:

(2) FIG. 1 shows a perspective view of an apparatus according to one embodiment of the invention for twisting metal wires,

(3) FIG. 2 shows a side view of the apparatus of FIG. 1 in another operating condition,

(4) FIG. 3 shows a partly sectional side view of the apparatus of FIG. 1, and

(5) FIG. 4 shows a partly transparent perspective view of a portion of the apparatus of FIG. 1.

DETAILED DESCRIPTION

(6) FIG. 1 shows an apparatus 1 for automatically twisting metal wires. The apparatus 1 has a main body 3. Arranged on the main body 3 at a proximal end of the apparatus 1 is an arcuate wire guide 5. The arcuate wire guide 5 has a closable and openable opening 7 arranged substantially centrally between a first side 9 of the arcuate wire guide 5 and a second side 11 of the arcuate wire guide 5.

(7) In the illustrated embodiment the first side 9 of the arcuate wire guide is arranged fixedly relative to the main body 3 while the second side 11 of the arcuate wire guide 5 can be deflected by means of a lever mechanism 15 in such a way that the opening 7 is moved from the closed position shown in FIG. 1 into an open position (FIG. 2). In the illustrated embodiment the lever mechanism 15 is driven by means of a pneumatic cylinder 17.

(8) The arcuate wire guide 5 is of a substantially tongs-like configuration and in the interior of the two sides 9, 11 of the arcuate wire guide has a region 27 for receiving adjacent, preferably mutually crossing structural elements.

(9) The arcuate wire guide 5 has a slot 13 extending substantially along the entire arc thereof. The slot 13 subdivides the first side 9 of the arcuate wire guide into two arc portions 9a, 9b. Similarly the slot 13 subdivides the second side 11 of the arcuate wire guide 5 into two arc portions 11a, 11b.

(10) The slot 13 is adapted to receive a pulling slider 23 which is movable along the arcuate wire guide and which is guided by a guide groove 29 arranged internally in the arcuate wire guide.

(11) A twisting unit 25 is arranged at an end of the region 27, that is opposite to the arcuate wire guide 5. The twisting unit 25 is adapted to receive and engage the wire guided along the arcuate wire guide 5, and is further adapted to twist it by rotation about an axis of rotation X.

(12) Arranged at a distal end of the main body 3, that is opposite to the arcuate wire guide 5, is a drive chain 19 which extends partially out of the housing or main body 3 of the apparatus 1. The drive chain has a plurality of guide pins 21 adapted to stabilize and guide the drive chain 19 under a thrust loading.

(13) In regard to the further Figures the same references are used for similar or identical elements. Accordingly, in regard to the description of those elements, in relation to each Figure reference is also directed to the other Figures. In the condition shown in FIG. 2 the arcuate wire guide 5 is moved by lateral pivotal movement of the second side 11 of the arcuate wire guide, into a position in which the opening 7 of the arcuate wire guide 5 is opened. The opening makes it possible to embrace two or more adjacent, preferably mutually crossing structural elements, for example two or more prestressing cables, in order to twist them.

(14) In addition, in the operating condition shown in FIG. 2, the pulling slider 23 is a distance further along the first side 9 of the arcuate wire guide 5 in a direction towards the second side 11 of the arcuate wire guide 5.

(15) FIG. 3 permits a view on to the interior of the apparatus 1. The wire to be twisted is fed in a plurality of feed passages 31a, 31b by means of a drive means 49 in the direction of the arcuate wire guide 5. The drive means 49 has a piston 50 which deflects a first coupling member 52 and a second coupling member 53 in such a way that a clamping member 51, through which the wire is also passed, clamps the wire fast at the drive means 49. That makes it possible for the wire to be conveyed in the feed direction and in opposite relationship thereto.

(16) The pulling slider 23 is coupled to the drive chain 19. The movement of the drive chain 19 in both drive directions is ensured by means of a drive pinion 33 arranged drivably on the main body 3 of the apparatus. By suitable driving of the drive chain 19, the pulling slider 23 is guided by means of the groove 29 and moved out of the position shown in FIG. 3 along the arcuate wire guide 5 on to the opposite second side 11 of the arcuate wire guide 5. That is preferably effected when the pulling slider 23 has engaged the fed wire in a clamping device 41 and has clamped it fast.

(17) The twisting unit 25 (FIGS. 3 and 4) has two gears 37, 39 which are arranged coaxially with each other and directly adjacent to each other and through each of which a first wire guide passage hole 43 and a second wire guide passage hole 45 respectively completely extend. The first and second wire guide passage holes 43, 45 are preferably arranged in diametrally opposite relationship with respect to the axis of rotation of the two gears 37, 39 and are adapted to receive the wire. In the course of being fed by means of the drive means 49 the wire is passed through the first wire guide passage hole 43 on the first side of the arcuate wire guide 5 and passed by means of the pulling slider 23 on the second side 11 of the arcuate wire guide 5 through the second wire guide passage hole 45. In the passed-through condition (passed through the second wire guide passage hold 45) a second clamping device 46 is adapted to clamp the wire fast so that a reduction in the size of the loop can be effected by means of rearward conveying movement of the wire by the drive means 49, upon a movement back from the second side 11 of the arcuate wire guide 5 in the direction of the first side 9. The drive and further details of the twisting unit 25 are also shown in FIG. 4.

(18) The clamping device 41 of the pulling slider 23 is preferably of such a configuration that a first slider member 36, for engagement and clamping of the wire by the pulling slider 23, upon deflection out of an open position, deflects a second slider member 38 which causes clamping of the wire. Coupling of the first slider member 36 to the second slider member is preferably implemented by means of two mutually adapted inclined planes which make it possible for the slider members 36, 38 to slide against each other and which define the direction of movement of the slider members.

(19) The first slider member 36 is preferably arranged on the pulling slider and oriented in such a way that it is moved towards a step 40 upon movement of the pulling slider 23 from the first side towards the second side. The step 40 and the slider member 36 are firstly brought into contact with each other upon the approach of the pulling slider 23 to its end position on the second side. When the pulling slider 23 further approaches its end position on the second side the step 40 pushes against the slider member and displaces it from its relative position on the pulling slider 23 in the direction of its open position (shown in FIG. 3). That permits the wire to be transferred to the second clamping device and permits a return conveying movement of the pulling slider 23 without entraining wire. FIG. 4 shows the arrangement of the two gears 37, 39 relative to the pulling slider and the arcuate wire guide 9 as a perspective view. The first gear 37 of the twisting unit 25 is driven by means of a first gear 47. The second gear 39 of the twisting unit 25 is driven by means of a second gear 48. The gears 47 and 48 are connected by means of torsion shafts 55, 57 to a respective servo motor. The first gear 37 and the second gear 39 are drivable selectively in opposite directions or in the same direction by means of the gears 47, 48. The respective portions of the wire guide passage holes 43, 45 are slightly turned relative to each other by the gears 37, 39 being driven in opposite directions, and that leads to the wire which is passed through the wire guide passage holes 43, 45 being clamped fast. In the clamped-fast condition the motors are preferably actuated in such a way that the gears 37, 38 are driven in the same direction, in such a way that clamping of the wire is maintained.

(20) Preferably the wire guide passage holes 43, 45 are in the form of slots, the slots extending along curved paths. Preferably the curved paths in the first gear 37 are not in coincident relationship with those in the second gear 47. Particularly preferably the curved paths are in the form of circular arcuate portions wherein the center points of the circles, that are associated with the arcuate portions, are arranged eccentrically in relation to the respective gears. That provides that the clamping is particularly gently built up upon relative movement of the gears with respect to each other as the wire guide passage holes in the form of slots are only gradually moved out of their coincident position with the portion of the wire guide passage hole, that is respectively associated with the other gear.

(21) In a preferred embodiment the gears 37, 47 each have a plurality of sets of the wire guide passage holes. It is to be assumed that, in the course of time, wear occurs at the edges of the holes as a result of being acted upon by the clamping force. Gears with a plurality of sets of holes then have the advantage that there is no need for a complete change, but it is only necessary to “advance” the gears to the next set of holes.

(22) FIG. 4 also shows a possible configuration of a clamping device 41 within the pulling slider 23. This is implemented as shown in Figure 4 by a rotatable pin which can narrow or close the through-passage for the fed wire.

(23) With reference to FIGS. 1 to 4, set out hereinafter is a brief outline of the mode of operation of the apparatus 1 according to an embodiment of the invention. After two or more structural elements, for example prestressing cables, have been prepared, and arranged in mutually adjoining relationship, preferably in mutually crossing relationship, then, if fixing of the two structural elements in wanted in the region of the adjoining or mutually crossing relationship (hereinafter referred to as the twisting region), the apparatus 1 is moved closer to the twisting region. To embrace the twisting region of the two structural elements the second side 11 of the arcuate wire guide 5 is opened by actuation of the lever mechanism 15 so that the opening 7 is opened. The adjacent, preferably mutually crossing structural elements are introduced into the inner region 27 of the arcuate wire guide or the latter is passed tongs-like around them.

(24) To prepare for a loop-forming operation the wire is fed in the direction of the pulling slider 23 either manually or by means of a drive device like for example the drive means 49. The wire is engaged by the pulling slider 23 by means of a clamping device 41 and passed from the first side 9 of the arcuate wire guide 5 in the direction of the second side 11 thereof. Optionally, the pulling slider 23 is already partially displaced along the first side 9 of the arcuate wire guide 5 before the arcuate wire guide 5 has become placed completely around the structural elements and the opening 7 is closed again. With the opening 7 closed, the pulling slider 23 is moved completely on to the second side 11 of the arcuate wire guide, where the wire engaged by the pulling slider 23 is transferred to the second wire guide passage hole 45 of the twisting unit 25. In the operation of feeding the wire, the wire has already also been previously passed through the first wire guide passage hole 43 of the twisting unit 25.

(25) Then the wire which forms a loop is clamped fast by means of a wire clamp 46. The pulling slider 23 is released from the wire and moves partly or completely back into its original position again on the first side of the arcuate wire guide 5 (for example as shown in FIG. 1).

(26) Before the twisting unit 25 twists the wire by rotation of the two wire guide passage holes 43, 45 around each other, the length of the wire loop formed is preferably shortened to a predetermined dimension dependent on the spacing of the two wire guide passage holes 43, 45 and the required minimum loop length which in turn depends on the thickness of the structural elements.

(27) Shortening of the loop is preferably effected by means of the drive means 49 or by means of again engaging the wire by the pulling slider 23 when the latter has not yet moved completely back into its position on the first side 9 of the arcuate wire guide 5 (FIG. 1), followed by subsequent return movement by means of the pulling slider.

(28) When the loop has reached its predetermined length the gears 37, 39 are firstly driven in opposite directions by means of the gears 47, 48 and the motors connected thereto until sufficient clamping is achieved within the twisting unit 25. In that clamped condition the gears 37, 39 are then driven in the same direction and the wire is severed within the apparatus 1, preferably by means of a cutting body, for example by means of one or more cutting edges on the gears. The twisting unit 25 performs a twisting movement about the axis X subsequently to the severing operation. After the desired number of revolutions the opening 7 is opened again and the apparatus 1 is removed from the twisting region in order for example to perform a subsequent twisting operation.

(29) As will be apparent from the foregoing description the entire procedure in forming the loop and twisting the structural elements is effected in fully automated fashion, which represents significantly easier work for operators.