APPARATUS, METHODS, AND SYSTEMS FOR WINDING COILS OF FLEXIBLE MATERIAL

Abstract

Apparatus and methods for winding flexible material include a rotatable plate assembly rotatably driven by a first rotary shaft, the assembly supporting second and third rotary shafts with corresponding first and second mandrel parts mounted thereon. The first and second mandrel parts each form at least part of a winding spool. The second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, the rotational axis of the first rotary shaft. The rotation of the plate assembly is coordinated with counter rotation of the first and second mandrel parts. In embodiments, such coordinated rotation occurs during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other. The flexible material can be cable, wire, tubing, hose, rope, or other filamentary material. Other aspects are described and claimed.

Claims

1. An apparatus for winding flexible material, comprising: a rotatable plate assembly whose rotation is driven by a first rotary shaft, the plate assembly supporting second and third rotary shafts with first and second mandrel parts mounted thereon, wherein the first and second mandrel parts each form at least part of a winding spool for winding a coil of the material thereon, wherein the second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, a rotational axis of the first rotary shaft; and means for coordinating rotation of the plate assembly about the first rotational axis with counter rotation of the first and second mandrel parts about the second and third rotational axes, respectively.

2. An apparatus according to claim 1, wherein: the means for coordinating the rotation of the plate assembly with the counter rotation of the first and second mandrel parts is configured to operate during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other.

3. An apparatus according to claim 2, wherein: the transition operations are also performed between packaging operations that employ the first and second mandrel parts in an opposite ordered sequence one after the other.

4. An apparatus according to claim 1, wherein: the means for coordinating the rotation of the plate assembly with the counter rotation of the first and second mandrel parts comprise a gear mechanism.

5. An apparatus according to claim 1, wherein: the means for coordinating the rotation of the plate assembly with the counter rotation of the first and second mandrel parts comprises at least one electronic controller that controls the rotation of the plate assembly and the counter rotation of the first and second mandrel parts.

6. An apparatus according to claim 1, wherein: the second rotary shaft and the first mandrel part mounted thereon as well as the third rotary shaft and the second mandrel part mounted thereon are further configured to rotate independently from the first rotary shaft and the plate assembly with the plate assembly in one or more fixed rotational positions.

7. An apparatus according to claim 1, further comprising: a cutter system mounted on the plate assembly and centrally disposed between the first and second mandrel parts.

8. An apparatus according to claim 7, wherein: the cutter mechanism comprises first and second slots and corresponding cutting elements, wherein the first slot and corresponding cutting element are configured to cut material that is wound onto the first mandrel part while material is captured by the second mandrel part, and wherein the second slot and corresponding cutting element are configured to cut material that is wound onto the second mandrel part while material is captured by the first mandrel part.

9. An apparatus according to claim 1, wherein: the first rotary shaft is operably coupled to a first drive mechanism that is operated to drive rotation of the first rotary shaft and the plate assembly.

10. An apparatus according to claim 1, further comprising: a second drive mechanism coupled to a winding mandrel interface, wherein the winding mandrel interface is configured to be selectively engaged and coupled to either one of the first and second mandrel parts.

11. An apparatus according to claim 10, wherein: the winding mandrel interface and the first mandrel part or the second mandrel part coupled thereto form the winding spool for winding operations.

12. An apparatus according to claim 11, wherein: the second drive mechanism and the winding mandrel interface are operated to selectively engage and couple to one of the first and second mandrel parts and then rotate the winding spool as part of the winding operations.

13. An apparatus according to claim 12, wherein: the winding operations are carried out in a controlled manner that employs the first and second mandrel parts in an ordered sequence one after the other with the first and second mandrel parts disposed at a predefined first position, which is set by rotational position of the plate assembly.

14. An apparatus according to claim 13, further comprising: a traverse mechanism configured to guide material onto the winding spool at the predefined first position during the winding operations.

15. An apparatus according to claim 13, further comprising: a movable plastic film applicator configured to apply plastic film onto material wound onto the winding spool at the predefined first position during the winding operations.

16. An apparatus according to claim 1, wherein: the first and second mandrel parts each have a plurality of mandrel segments that move radially relative to a central axis between a collapsed configuration and an expanded configuration.

17. An apparatus according to claim 16, wherein: the first and second mandrel parts each have a locking mechanism that retains the plurality of mandrel segments in the expanded configuration.

18. An apparatus according to claim 17, wherein: the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the mandrel segments in a predefined rotational position of the hub with the plurality of mandrel segments in the expanded configuration.

19. An apparatus according to claim 18, wherein: the rotatable hub has a lever that is configured to return the rotatable hub to the predefined rotational position of the hub during rotation of the plate assembly.

20. An apparatus according to claim 17, wherein: the first and second mandrel parts each have an unlocking mechanism that releases the lock mechanism that retains the plurality of mandrel segments in the expanded configuration and permits the plurality of mandrel segments to move to the collapsed configuration.

21. An apparatus according to claim 20, wherein: the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the plurality of mandrel segments in a predefined rotational position of the hub; and the unlocking mechanism comprises a spring-biased pusher rod that engages a ramp surface of the hub to rotate the hub out of the predefined rotational position of the hub.

22. An apparatus according to claim 1, wherein: the first and second mandrel parts each have a grabber mechanism that is configured to catch and grab material, wherein the grabber mechanism is configured to catch and grab material during the coordinated rotation of the plate assembly and the counter rotation of the first and second mandrel parts.

23. An apparatus according to claim 1, wherein: the first and second mandrel parts each comprise a winding spool for winding a coil of the material thereon that is detachably mountable on the second and third rotary shafts.

24. An apparatus according to claim 1, wherein: the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material.

25. A method for winding flexible material, comprising: providing a rotatable plate assembly whose rotation is driven by a first rotary shaft, the plate assembly supporting second and third rotary shafts with first and second mandrel parts mounted thereon, wherein the first and second mandrel parts each form at least part of a winding spool for winding a coil of the material thereon, wherein the second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, a rotational axis of the first rotary shaft; and coordinating rotation of the plate assembly about the first rotational axis with counter rotation of the first and second mandrel parts about the second and third rotational axes, respectively.

26. A method according to claim 25, wherein: the coordinating of the rotation of the plate assembly with the counter rotation of the first and second mandrel parts occurs during transition operations performed between winding operations that employ the first and second mandrel parts in an ordered sequence one after the other.

27. A method according to claim 26, wherein: the transition operations are also performed between packaging operations that employ the first and second mandrel parts in an opposite ordered sequence one after the other.

28. A method according to claim 25, wherein: the coordinating of the rotation of the plate assembly with the counter rotation of the first and second mandrel parts employs a gear mechanism.

29. A method according to claim 25, wherein: the coordinating of the rotation of the plate assembly with the counter rotation of the first and second mandrel parts employs at least one electronic controller that controls the rotation of the plate assembly and the counter rotation of the first and second mandrel parts.

30. A method according to claim 25, further comprising: configuring the second rotary shaft and the first mandrel part mounted thereon to rotate independently from the first rotary shaft and the plate assembly with the plate assembly in one or more fixed rotational positions.

31. A method according to claim 25, further comprising: configuring the third rotary shaft and the second mandrel part mounted thereon to rotate independently from the first rotary shaft and the plate assembly with the plate assembly in one or more fixed rotational positions.

32. A method according to claim 25, further comprising: providing a cutter system mounted on the plate assembly and centrally disposed between the first and second mandrel parts, wherein the cutter mechanism comprises first and second slots and corresponding cutting elements; configuring the first slot and corresponding cutting element to cut material that is wound onto the first mandrel part while material is captured by the second mandrel part; and configuring the second slot and corresponding cutting element to cut material that is wound onto the second mandrel part while material is captured by the first mandrel part.

33. A method according to claim 25, further comprising: operably coupling the first rotary shaft to a first drive mechanism that is operated to drive rotation of the first rotary shaft and the plate assembly.

34. A method according to claim 33, further comprising: providing a second drive mechanism coupled to a winding mandrel interface; and configuring the winding mandrel interface to be selectively engaged and coupled to either one of the first and second mandrel parts.

35. A method according to claim 34, wherein: the winding mandrel interface and the first mandrel part or the second mandrel part coupled thereto form the winding spool for winding operations.

36. A method according to claim 35, wherein: the second drive mechanism and the winding mandrel interface are operated to selectively engage and couple to one of the first and second mandrel parts and then rotate the winding spool as part of the winding operations.

37. A method according to claim 36, wherein: the winding operations are carried out in a controlled manner that employs the first and second mandrel parts in an ordered sequence one after the other with the first and second mandrel parts disposed at a predefined first position, which is set by rotational position of the plate assembly.

38. A method according to claim 37, further comprising: providing a traverse mechanism; and configuring the traverse mechanism to guide material onto the winding spool at the predefined first position during the winding operations.

39. A method according to claim 37, further comprising: providing a movable plastic film applicator; and configuring the plastic film applicator to apply plastic film onto material wound onto the winding spool at the predefined first position during the winding operations.

40. A method according to claim 25, wherein: the first and second mandrel parts each have a plurality of mandrel segments that move radially relative to a central axis between a collapsed configuration and an expanded configuration.

41. A method according to claim 25, wherein: the first and second mandrel parts each have a locking mechanism that retains the plurality of mandrel segments in the expanded configuration.

42. A method according to claim 41, wherein: the locking mechanism operates to retain the plurality of mandrel segments in the expanded configuration automatically by engagement of a mandrel interface with one of the first and second mandrel parts.

43. A method according to claim 41, wherein: the first and second mandrel parts each have an unlocking mechanism that releases the lock mechanism that retains the plurality of mandrel segments in the expanded configuration and permits the plurality of mandrel segments to move to the collapsed configuration.

44. A method according to claim 43, wherein: the unlocking mechanism operates to release the locking mechanism automatically by engagement of a mandrel interface with one of the first and second mandrel parts.

45. A method according to claim 25, wherein: the first and second mandrel parts each have a grabber mechanism that is configured to catch and grab material, wherein the grabber mechanism is configured to catch and grab material during the coordinated rotation of the plate assembly and the counter rotation of the first and second mandrel parts.

46. A method according to claim 25, wherein: the first and second mandrel parts each comprise a winding spool for winding a coil of the material thereon that is detachably mountable on the second and third rotary shafts.

47. A method according to claim 24, wherein: the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In order to describe the manner in which the above-recited and other features of the disclosure can be obtained, a more particular description will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. For better understanding, the like elements have been designated by like reference numbers throughout the various accompanying figures. While some of the drawings may be schematic or exaggerated representations of concepts, at least some of the drawings may be drawn to scale. Understanding that the drawings depict some example embodiments, the embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:

[0045] FIGS. 1 to 4 are perspective views of an exemplary embodiment of a system for winding coils of flexible material according to the present disclosure.

[0046] FIGS. 5 and 6 are perspective views of a portion of the system of FIGS. 1 to 4, including a rotatable plate assembly supporting two mandrel parts with a cutter system disposed therebetween according to the present disclosure; the window 101a shown in FIGS. 5 and 6 can be coupled to the support frame 101 as shown in FIGS. 1 to 4; the other portions of the system shown in FIGS. 5 and 6 can be coupled to other parts of the system as shown in FIGS. 1 to 4.

[0047] FIG. 7 is a side view illustrating a mandrel part and a winding mandrel interface according to the present disclosure; the segments of the mandrel part and the winding mandrel interface are configured in corresponding collapsed configurations according to the present disclosure; the mandrel part and the winding mandrel interface shown in FIG. 7 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0048] FIG. 8 is a side view illustrating the winding mandrel interface coupled to a mandrel part with the segments of the mandrel part and the winding mandrel interface configured in corresponding expanded configurations according to the present disclosure; the mandrel part and the winding mandrel interface shown in FIG. 8 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0049] FIGS. 9 and 10 are cross-sectional views illustrating the winding mandrel interface coupled to a mandrel part with the mandrel segments of the mandrel part and the coupling segments of the winding mandrel interface configured in corresponding expanded configurations according to the present disclosure; the mandrel part and the winding mandrel interface shown in FIGS. 9 and 10 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0050] FIG. 11 is a cross-sectional view of a mandrel part with the mandrel segments of the mandrel part configured in their expanded configuration according to the present disclosure; the mandrel part shown in FIG. 11 can be coupled to the other parts of the system as shown in FIGS. 1 to 6.

[0051] FIG. 12 is a side view illustrating a mandrel part and a packaging mandrel interface according to the present disclosure; the mandrel segments of the mandrel part are configured in an expanded configuration according to the present disclosure; the mandrel part and the packaging mandrel interface shown in FIG. 12 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0052] FIG. 13 is a side view illustrating the packaging mandrel interface coupled to a mandrel part with the mandrel segments of the mandrel part configured in their expanded configuration according to the present disclosure; the mandrel part and the packaging mandrel interface shown in FIG. 13 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0053] FIG. 14 is a cross-sectional view illustrating the packaging mandrel interface coupled to a mandrel part with the mandrel segments of the mandrel part in their expanded configuration according to the present disclosure; the mandrel part and the packaging mandrel interface shown in FIG. 14 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0054] FIG. 15 is a cross-sectional view illustrating the packaging mandrel interface coupled to a mandrel part with the mandrel segments of the mandrel part in their collapsed configuration according to the present disclosure; the mandrel part and the packaging mandrel interface shown in FIG. 15 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0055] FIG. 16 is a cross-sectional view of a mandrel part with the mandrel segments of the mandrel part configured in their collapsed configuration according to the present disclosure; the mandrel part shown in FIG. 16 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0056] FIGS. 17 to 21 are perspective views that illustrate automated coordinated movement and operation of the mandrel parts together with other parts of the system during transition operations according to the present disclosure; the parts of the system shown in FIGS. 17 to 21 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0057] FIGS. 22 and 23 are perspective views that illustrate a plastic film applicator according to the present disclosure; the plastic film applicator is mounted to a belt that extends through a channel formed by a track, which can be disposed about the rotating platform of the system as shown in FIGS. 17 to 21; the belt and plastic film applicator are configured to move along the track by operation of a servo-motor; the parts of the plastic film applicator shown in FIGS. 22 and 23 can be coupled to the front side of the window of the support frame of the system as shown in FIGS. 1 to 6.

[0058] FIGS. 24A and 24B are views of an exemplary mandrel segment locking mechanism that can be part of a mandrel part as described herein.

[0059] FIGS. 25 and 26 are views of an exemplary mandrel segment unlocking mechanism as described herein; FIG. 25 is a partial cut-away view illustrating a spring-biased moveable pusher rod part of the mandrel segment unlocking mechanism and a corresponding fixed pusher rod part of the packaging mandrel interface; the fixed pusher rod part is configured to engage and move the spring-biased moveable pusher rod part such that it rotates the hub of the mandrel locking mechanism and releases the mandrel locking mechanism; FIG. 26 is a cross-sectional view of the packaging mandrel interface coupled to a mandrel part, which shows the mandrel segment unlocking mechanism of the mandrel part in detail; the mandrel part and the packaging mandrel interface shown in FIGS. 25 and 26 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0060] FIG. 27 is a perspective view of a system that employs coordinated movement and operation of winding spools together with other parts of the system according to the present disclosure; the parts of the system shown in FIG. 27 can be coupled to other parts of the system as shown in FIGS. 1 to 6.

[0061] FIG. 28 is a perspective view of an exemplary winding spool.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0062] FIGS. 1 to 4 illustrate an exemplary embodiment of a system 100 for winding coils of flexible material, which includes a support frame 101 secured to a horizontal support surface 103 (e.g., concrete floor of a building). The support frame 103 includes a vertical window 101a. A vertical plate assembly (or platform) 105 is mounted to the window 101a and configured to rotate relative to the window 101a/support frame 101. A first rotary shaft 107 is mechanically coupled or fixed to the plate assembly 105 and extends away from the back side of the window 101a and plate assembly 105 as best shown in FIGS. 3 and 4. The first rotary shaft 107 is configured to drive rotation of the plate assembly 105 relative to the window 101a/support frame 101. Two mandrel parts 109a, 109b are mounted on respective second and third rotary shafts 111a, 11b that are mounted to the plate assembly 105 and extend away from the front side of the window 101a and plate assembly 105 as best shown in FIGS. 1 and 2. The rotational axis of the first rotary shaft 107 is referred to as the first rotational axis, while the rotational axes of the second and third rotary shafts 111a, 111b are referred to the second and third rotational axes, respectively. The second and third rotational axes are parallel to one another and parallel to, but laterally offset from, the first rotational axis as is evident from the figures. The two mandrel parts 109a, 109b each define portions of respective winding spools.

[0063] The first rotary shaft 107 can be operably coupled to a bearing support 113 and a first drive mechanism 115 (e.g., motor/gear box) that are disposed on the back side of the window 101a and plate assembly 105 as best shown in FIGS. 3 and 4. The first drive mechanism 113 can be operated to drive rotation of the first rotary shaft 107 and the plate assembly 105 relative to the window 101a/support frame 101. The bearing support 113 can be mounted to the window 101a/support frame 101 and configured to constrain the rotation of the first rotary shaft 107 with minimal friction.

[0064] In embodiments, the plate assembly 105 can include a circular plate 105a with two elongated support elements 105b, 105c mounted on opposite sides of the plate 105a as best shown in FIGS. 5 and 6. The support element 105b can be mounted directly to the front side of plate as shown. The support element 105c can be mounted to the back side of plate 105a via spacers (one shown as 105d). The plate 105a includes a central coupler 105e that rigidly couples the plate 105a to the first rotary shaft 107 such that the plate assembly 105 rotates with the rotary shaft 107 as described herein. The plate 105a and the two elongated support elements 105b, 105c include bearings that are offset laterally from the central coupler 105e and receive the second and third rotary shafts 111a, 111b and support rotation of the second and third rotary shafts 111a, 111b relative to the window 101a/support frame 101 as described herein. The two mandrel parts 109a, 109b (and the second and third rotary shafts 111a, 111b) can be configured to rotate together with the plate assembly 105 (and the first rotary shaft 107) by a planetary gear mechanism mounted on the plate assembly 105. The two mandrel parts 109a, 109b (and the second and third rotary shafts 111a, 111b) can also be configured to rotate independently from the plate assembly 105 (and the first rotary shaft 107).

[0065] In embodiments, the planetary gear mechanism includes two planet gears 115a, 115b that mesh with a fixed ring gear 115c that is rigidly mounted to the window 101a as best shown in FIG. 6. The planet gear 115a is mounted to the second rotary shaft 111a on the back side of the support element 105c adjacent or near the end of the second rotary shaft 111a. A clutch 117a is mounted at the end of the second rotary shaft 111a. The clutch 117a can move axially with the second rotary shaft 111a relative to the planet gear 115a between a disengaged configuration and an engaged configuration. In the disengaged configuration, the clutch 117a is spaced from the planet gear 115a and permits the second rotary shaft 111a to rotate relative to the window 101a/frame 101 with the platform assembly 105 in a fixed rotational position. In the engaged configuration, the clutch 117a contacts and engages the planet gear 115a such that rotation of the planet gear 115a relative to the fixed ring gear 115c as imparted by rotation of the platform assembly 105 drives counter rotation of the second rotary shaft 111a. The planet gear 115b is mounted to the third rotary shaft 111b on the back side of the support element 105c adjacent or near the end of the third rotary shaft 111b. A clutch 117b is mounted at the end of the third rotary shaft 111b. The clutch 117b can move axially with the third rotary shaft 111b relative to the planet gear 115b between a disengaged configuration and an engaged configuration. In the disengaged configuration, the clutch 117b is spaced from the planet gear 115b and permits the third rotary shaft 111b to rotate relative to the window 101a/frame 101 with the platform assembly 105 in a fixed rotational position. In the engaged configuration, the clutch 117b contacts and engages the planet gear 115b such that rotation of the planet gear 115b relative to the fixed ring gear 115c as imparted by rotation of the platform assembly 105 drives counter rotation of the third rotary shaft 111b.

[0066] In embodiments, the clutch 117a can be configured in its disengaged configuration such that the mandrel part 109a and the second rotary shaft 111a can rotate independently from the plate assembly 105 (and the first rotary shaft 107) with the platform assembly 105 in a fixed rotational position. Similarly, the clutch 117b can be configured in its disengaged configuration such that the mandrel part 105b and the third rotary shaft 111b can rotate independently from the plate assembly 105 (and the first rotary shaft 107) with the platform assembly 105 in the fixed rotational position. Furthermore, the clutch 117a and the clutch 117b can be configured concurrently in their engaged configuration while the first drive mechanism 115 drives rotation of the first rotary shaft 107 and the plate assembly 105 in a particular rotational direction (e.g., counter-clockwise when viewed from the back side of the plate assembly and clockwise when viewed from the front side of the plate assembly) relative to the window 101a/frame 101. The rotation of the plate assembly 105 relative to the window 101a/frame 101 drives counter rotation of the planetary gears 115a, 115b relative to the fixed ringed gear 115c together with the corresponding rotary shafts 111a, 111b and the mandrel parts 109a, 109b in the rotational direction opposite that of the first rotary shaft 107 and the plate assembly 105 (e.g., clockwise when viewed from the back side of the plate assembly and counter-clockwise when viewed from the front side of the plate assembly).

[0067] A cutter system 118 can be mounted on the plate assembly 105 (i.e., on the support element 105b) in a position centrally disposed between the two mandrel parts 109a, 109b as best shown in FIG. 5. In embodiments, the cutter system 118 can be formed as a rectangular plate that generally extends away from the front side of the plate assembly 105 coaxial to the rotational axis of the first rotating shaft 107 and the plate assembly 105. The rectangular plate has two opposed edges that include two slots or grooves 118a, 118b that guide material therethrough during rotation of the plate assembly 105 in the transition operations as described herein. The two slots or grooves 118a, 118b are diametrically spaced apart from one another and offset from the central portion of the plate (and offset from the rotational axis of the first rotating shaft 107 and the plate assembly 105). In embodiments, the two slots or grooves 118a, 118b can extend in a linear direction parallel to the rotational axes of the first, second and third rotary shafts 107, 111a, 111b. The cutter system 118 also supports cutting elements that are configured to cut through the material that is guided by and passes through the two slots or grooves 118a, 118b. In embodiments, the cutting elements can be configured as ram-type cutting elements actuated to move linearly in a direction corresponding to the linear direction of the respective slots or grooves 118a, 118b to cut through material that is guided by and passes through the respective slots or grooves. In other embodiments, the cutting elements can be configured as scissor type cutting elements or another configuration. The actuation of the cutting elements can be provided by pneumatic means, hydraulic means, or an electric motor. The slot or groove 118a and the corresponding cutting element can be configured to support cutting of material that is wound onto the winding spool formed by mandrel part 109a (and captured and grabbed by the grabber mechanism of mandrel part 109b) as show in FIG. 21. The slot or groove 118b and the corresponding cutting element can be configured to support cutting of material that is wound onto the winding spool formed by mandrel part 109b (and captured and grabbed by the grabber mechanism of mandrel part 109a).

[0068] A second drive mechanism (e.g., motor/gear box) 119 can be coupled to a winding mandrel interface 121 as best shown in FIGS. 1 and 2. The winding mandrel interface 121 can be configured to be selectively engaged and coupled to either one of the two mandrel parts 109a, 109b as best shown in FIGS. 7 and 8. When the winding mandrel interface 121 is engaged and coupled to the respective mandrel part, both the winding mandrel interface and the mandrel part form a winding spool as best shown in FIG. 8, which can be used for winding operations as described herein. Furthermore, when the winding mandrel interface 121 is engaged and coupled to the respective mandrel part (109a or 109b), the winding mandrel interface 121 is adapted to automatically configure the respective winding mandrel part/winding mandrel to rotate independently from the plate assembly 105 (and the first rotary shaft 107) with the plate assembly 105 in a fixed rotational position. In this configuration, the second drive mechanism 119 can be operated to drive rotation of the winding mandrel interface 121 and the mandrel part (109a or 109b) during the winding operations. In embodiments, the engagement and coupling of the winding mandrel interface 121 to the respective mandrel part (109a or 109b) can involve linear motion toward the plate assembly 105. Similarly, the disengagement and decoupling of the winding mandrel interface 121 from the respective mandrel part (109a or 109b) can involve linear motion away from the plate assembly 105. For example, for engagement and disengagement of the winding mandrel interface 121 relative to the respective mandrel part (109a or 109b), the second drive mechanism (e.g., motor/gear box) 119 and the winding mandrel interface 121 can be configured to move linearly along a track 123 that mounted to the frame 101 as shown in FIGS. 1 and 2.

[0069] In embodiments, the second drive mechanism 119 and the winding mandrel interface 121 can be operated to selectively engage and couple to the two mandrel parts (109a, 109b), and then rotate the resulting winding spools formed by the two mandrel parts in an alternating manner. These alternating operations can be carried out in a controlled manner when the respective mandrel parts (109a or 109b) are disposed at a predefined first position (or winding station). In embodiments, the first position (winding station) can be set by the rotational position of the plate assembly 105 during the winding operation. In embodiments, the winding station corresponds to the 3 o'clock rotational position of the plate assembly 105 in the frame window 101a.

[0070] The apparatus can also include a traverse mechanism 125 supported by the frame 101 as best shown in FIG. 1. The traverse mechanism 125 can be configured to guide material onto the winding spool at the first position (winding station) during the winding operations. In embodiments, the traverse mechanism 125 can be configured to guide the material laterally relative to winding spool to form layers having a figure-eight pattern provided with aligned holes (cumulatively a payout hole) such that the inner end of the flexible material (wire) may be drawn out through the payout hole. The resulting wound coil forms the shape of a short hollow cylinder. When a package of flexible material (wire) is wound in this manner, the flexible material (wire) may be unwound through the payout hole without rotating the package, without imparting a rotation in the flexible material (wire) around its axis (i.e., twisting), and without kinking. This can provide a major advantage to the users of the flexible material (wire). The apparatus can include a material feeder (not shown) that is operative to supply material to the traverse mechanism 125 during the winding operations. For example, the material feeder can include a rotating spool-based system well-known in the packaging arts.

[0071] The apparatus can also include a movable plastic film applicator 127 supported by the frame 101 and configured to apply plastic film onto material wound onto the winding spool at the first position (winding station) during the winding operation as best shown in FIGS. 17-20. In embodiments, the vertical window 101a of the support frame 101 can support track 129 at a fixed position below the two mandrel parts 109a, 109b (and the corresponding second and third rotary shafts 111a, 111b) on the front side of the plate assembly 105 (partially shown). In one embodiment, the track 129 can define an arcuate path for guided movement of the applicator 127 mounted thereto. In another embodiment, the track 129 can define a linear path for guided movement of the applicator 127 mounted thereto. In still other embodiments, the track 129 can define a piecewise linear or piecewise curvilinear path or other path for guided movement of the applicator 127 mounted thereto. The movement of the applicator 127 along the track 129 can be controlled by a servo-motor, whose operation is controlled by one or more system controllers. Details of an exemplary blower-type design for applicator 127 is described in U.S. Pat. No. 8,191,337, issued Jun. 5, 2012, commonly assigned to assignee of the present application and herein incorporated by reference in its entirety.

[0072] In embodiments shown in FIGS. 22 and 23, the applicator 127 can be coupled to a belt 181 (such as toothed belt) that moves through a channel 183 in the track 129. The belt 181 can be configured to run over a series of pulleys or sprockets 185, which can be mounted to the window 101a of the support frame 101 (FIGS. 1 and 2). A servo-motor 187 can be coupled to the belt 181 by a drive pulley or sprocket 188. Tensioner pulleys or sprocket 189a, 189b can be configured to apply tension to the belt 181. The servo-motor 187 and drive pulley or sprocket 188 as well as the tensioner pulleys or sprockets 189a, 189b can be mounted to the vertical window 101a of the support frame 101 (FIGS. 1 and 2). The servo-motor 187 can be configured to drive movement of the belt 181 and the applicator 127 coupled thereto along the track 129 (in both directions away from and toward the servo-motor 187).

[0073] In other embodiments, the servo-motor 187 can be mounted directly on the applicator 127 and configured to drive movement of servo-motor 187 together with applicator 127 along the track 129. For example, the servo-motor 187 could be connected to track 129 by one or more cogged wheels that engage with corresponding geometry of the track 129.

[0074] Turning back to FIGS. 7 to 12, each mandrel part 109a, 109b can include a support collar 131 mounted on a hollow spline shaft 133 as best shown in FIGS. 9 and 10. The support collar 131 can be adapted to support a plurality of displaceable mandrel segments 135 that move axially and radially relative to the support collar 131 to define a collapsed configuration and an expanded configuration. In the collapsed configuration, portions of the mandrel segments 135 extend generally parallel to one another with relatively smaller lateral offset therebetween and are offset radially from the central axis of the collar 131 at a first diameter D1 (FIGS. 7, 10). In the expanded configuration, the same portions of the mandrel segments extend generally parallel to one another with relatively larger lateral offset therebetween and are offset radially from the central axis of the collar at a second diameter D2 where the second diameter D2 is larger than the first diameter D1 (FIGS. 8, 9, 11, 12). The mandrel segments 135 can move axially and radially relative to the support collar 131 from the collapsed configuration to the expanded configuration, or vice versa. In embodiments, the support collar 131 can support an annular flange 137 that extends radially outward away from the support collar 131 and surrounds the mandrel segments 135. The spline shaft 133 can be mounted to the plate assembly 105 (including the circular plate 105a and the support elements 105b, 105c) and forms the second and third rotary shafts 111a, 111b of the system. The spline shaft 133 includes or supports a plate interface 139 at one end and a keyed interface 141 at the opposite end. The plate interface 139 interfaces to a respective clutch (117a, 117b) for coupling to the planetary gear 115a, 115b as described herein. The keyed interface 141 can be configured to interface to the winding mandrel interface 121 or the packaging mandrel interface 171, respectively.

[0075] In embodiments, the support collar 131 can include a first part that extends beyond the annular flange 137 toward the keyed interface 141 and a second part that extends beyond the annular flange 137 toward the plate interface 139 (and back cover 132b). The first part can have a tapered frustoconical outer surface with slots 143 that are aligned with internal bores 145 formed by the second part of the support collar 131 and an outer casing 132a as best shown in FIGS. 9 to 14. The outer casing 132a extends between the annular flange 137 and the back cover 132b as shown. The slots 143 and the bores 145 are adapted to receive corresponding sections of the mandrel segments 135 for sliding movement therein. The slots 143 and bores 145 extend at a fixed angle relative to the central axis of the spline shaft 133 and the support collar 131 to guide the axial and radial movement of the mandrel segments 135 relative to the support collar 131 to define the collapsed configuration and the expanded configuration. In embodiments, the mandrel segments 135 can be biased by springs or other resilient elements into the collapsed configuration. For example, springs 147 (or other resilient elements) can be anchored by the back cover 132b and disposed within the internal bores 145 defined by the support collar 131 and the outer casing 132a.

[0076] In embodiments, each mandrel part 109a, 109b can employ a segment locking system that retains the mandrel segments 135 of the respective mandrel part in the radially expanded configuration until the locking system is released. The expanded configuration of the mandrel segments is best shown in FIG. 11. In the expanded configuration, the coil of material wound on the mandrel segments (and with plastic film applied thereto) can be supported and held in position by the mandrel segments 135 such that the coil cannot be easily removed from the mandrel segments 135. The keyed interface 141 of the respective mandrel parts (109a or 109b) can be configured to engage and mate to corresponding keyed interfaces of the winding mandrel interface 121 and the packaging mandrel interface 171. When the keyed interface 141 of the respective mandrel part engages and mates to the corresponding keyed interfaces of the winding mandrel interface 121 and the packaging mandrel interface 171, the matching keyed interfaces can automatically configure the spline shaft 133 of the respective mandrel part such that i) it rotates independently from the plate assembly 105, for example by pushing a rod 133a that extends through the spline shaft 133 to disengage the corresponding clutch (117a or 117b) from the corresponding planetary gear (115a or 115b), and ii) it is rotational driven by the winding mandrel interface 121 or the packaging mandrel interface 171. Furthermore, the respective mandrel parts (109a or 109b) can include features or parts that cooperate with features or parts of the packaging mandrel interface 171 to release the segment locking system of the respective mandrel parts.

[0077] In embodiments, the segment locking system of the respective mandrel parts (109a or 109b) can include a rotating hub 191 internal to the respective mandrel part (109a or 109b) with a set of ball detents 191a mounted thereon as shown in FIGS. 24A and 24B. The mandrel segments 135 can each include a catch or cutout feature 135a that is configured to receive and engage a corresponding ball detent 191a in a certain position of the rotating hub 191 to lock the mandrel segments 135 in their expanded configuration. In this locked expanded configuration, the engagement between the ball detents 191a and the corresponding cutout features 135a of the mandrel segments 135 prohibits movement of the mandrel segments 135 radially inward toward their collapsed configuration and locks the mandrel segments 135 in their expanded configuration.

[0078] In embodiments, the parallel portions of two or more mandrel segments 135 of the respective mandrel parts 109a, 109b can be shorter in length (cutoff) relative to the parallel portions of the other mandrel segments 135 as best shown in FIGS. 7 and 9. The shorter-length mandrel segments can be configured to expose a material capture mechanism that is adapted to capture material therein. In embodiments, the material capture mechanism can be adapted to i) automatically capture material during the transition operations (and while cutting the material during the transition operations) and ii) retain the free end of material formed by the cutting operations during the remainder of transition operations following the cut and subsequent winding operations. In embodiments, the material capture mechanism can include two cone-shaped elements and hook member (collectively labeled 148) as best shown in FIGS. 7 and 9. The two cone-shaped elements pivot relative to one another with a spring-biased configuration that captures material between the two cone-shaped elements. The hook member can pivot into a spring-biased configuration that captures material. The two cone-shaped elements and the hook are aligned with grooves/cut-outs defined by the longer mandrel segments on opposite sides of mechanism 148 as shown. Such grooves/cut-outs can receive material and guide the material into mechanism 148 during the transition operations as described herein.

[0079] In embodiments, the winding mandrel interface 121 can include a support collar 151 mounted on a solid spline shaft 153 as best shown in FIGS. 7 to 10. The spline shaft 153 can be rotationally driven by the second drive mechanism 119. The support collar 151 can be adapted to support two or more displaceable coupling segments 155 that move axially and radially relative to the support collar 151 to define a collapsed configuration and an expanded configuration. In the collapsed configuration, portions of the coupling segments 155 extend generally parallel to one another with relatively smaller lateral offset therebetween and are offset radially from the central axis of the collar 151 at the diameter D3 (which corresponds to the first diameter D1 of the collapsed configuration of the mandrel segments 135 of the respective mandrel parts) (FIGS. 7, 10). In the expanded configuration, the same portions of the coupling segments 155 extend generally parallel to one another with relatively larger lateral offset therebetween and are offset radially from the central axis of the collar 151 at the diameter D4 where the diameter D4 is larger than the diameter D3 (and D4 corresponds to the second diameter D2 of the expanded configuration of the mandrel segments 135 of the respective mandrel parts) (FIGS. 8, 9). The coupling segments 155 can move axially and radially relative to the support collar 151 from the collapsed configuration to the expanded configuration, or vice versa. The support collar 151 can also be adapted to support an annular flange 157 that extends radially outward away from the support collar 151 and surrounds the coupling segments 155. The spline shaft 153 is mechanically coupled to a keyed interface 159 at one end opposite a drive coupling end 161. The keyed interface 159 is adapted to mate to and engage the keyed interface 141 of the respective mandrel parts 109a, 109b. The drive coupling end 161 is adapted to mate to and engage the second drive mechanism 119.

[0080] In embodiments, the support collar 151 can include a first part that extends beyond the annular flange 157 toward the keyed interface 159 and a second part that extends beyond the annular flange 157 toward the drive coupling end 161 (and cover 162b). The first part has a tapered frustoconical outer surface with slots 163 that are aligned with internal bores 165 formed by the second part of the support collar 151 and an outer casing 162a as best shown in FIGS. 9 and 10. The outer casing 162a extends between the annular flange 157 and the cover 162b as shown. The slots 163 and bores 165 are adapted to receive corresponding sections of the coupling segments 155 for sliding movement therein. The slots 163 and bores 165 extend at a fixed angle relative to the central axis of the spline shaft 153 and the support collar 151 to guide the axial and radial movement of the coupling segments 155 relative to the support collar 151 to define the collapsed configuration and the expanded configuration. In embodiments, the coupling segments 155 can be biased by springs or other resilient elements into the collapsed configuration. For example, springs 167 (or other resilient elements) can be anchored by the cover 162b and disposed within the internal bores 165 defined by the support collar 151 and the outer casing 162a.

[0081] When the winding mandrel interface 121 is initially engaged and coupled to the respective mandrel part (109a or 109b), both the mandrel segments 135 of the respective mandrel part and the coupling segments 155 of the winding mandrel interface 121 can be configured in their corresponding collapsed configurations, and the coupling segments 135 of the winding mandrel interface 121 contact and mate to the shorter (or cut-off) parallel mandrel segments 135 of the respective mandrel part (for example, through contact via a pin-hole mating interface) with the collar 151 of the winding mandrel interface 121 contacting the longer parallel mandrel segments 135 of the respective mandrel part. In this configuration, further axial movement of the winding mandrel interface 121 toward the respective mandrel part (109a or 109b) and the resulting further engagement of the winding mandrel interface 121 and the respective mandrel part (109a or 109b) imparts axial and radial movement of the mandrel segments 135 into their expanded configuration together with axial and radial movement of the coupling segments 155 into their corresponding expanded configuration. When the mandrel segments 135 are moved into their expanded configuration, the segment locking system of the respective mandrel part (109a or 109b) can be automatically activated to lock the mandrel segments 135 in their expanded configuration (until being unlocked, for example, by the operation of the packaging mandrel interface 171). In this engaged configuration, the keyed interface 141 of the respective mandrel part (109a or 109b) and the keyed interface 159 of the winding mandrel interface 121 can cooperate to configure the spline shaft 133 of the respective mandrel part (109a or 109b) such that it rotates independently from the plate assembly 105 and drives the rotation of the spline shaft 133 of the respective mandrel part (109a or 109b) (for example, for winding of material onto the coil). In the expanded configuration of the mandrel segments 135, the coil of material that is wound on the mandrel segments 135 is supported and held in position on by the mandrel segments 135 such that the coil cannot be easily removed from the mandrel segments 135.

[0082] In embodiments, with the winding mandrel interface 121 mated to the respective mandrel part (109a or 109b), these two components together form a winding spool. The mandrel segments 125 of the mandrel part (109a or 109b) and the coupling segments of the winding mandrel interface 121 define a central mandrel of the winding spool. The flange 137 of the mandrel part (109a or 109b) and the flange 157 of the winding mandrel interface 121 define opposed end forms of the winding spool. The second drive mechanism 119 can be adapted to drive rotation of the winding mandrel interface 121 and the respective mandrel part (109a or 109b) that form the winding spool relative to plate assembly 105 while the plate assembly 105 is held in a fixed position. This configuration allows material to be wound onto the winding spool in a pattern controlled by the operation of the traverse mechanism 125 during the winding operations. After the winding operations are complete, the winding mandrel interface 121 (and the second drive mechanism 119 coupled thereto) can be disengaged and decoupled from the respective mandrel part (109a or 109b). In embodiments, the disengagement and decoupling of the winding mandrel interface 121 from the respective mandrel part involves linear motion away from the plate assembly 105.

[0083] During transition operations, the first drive mechanism 115 can be operated to rotate the first rotary shaft 107 and the plate assembly 105 together with second and third rotary shafts 111a, 111b and the two mandrel parts 109a, 109b mounted thereon about the first rotational axis. In embodiments, this rotation is configured to rotate the two mandrel parts (109a or 109b) one hundred and eighty degrees about the first rotational axis such that two mandrel parts exchange rotational position with one another. This rotates the mandrel part located at the first position (winding station) to a predefined second position (or packaging station) dictated by the one hundred and eighty degree rotation of the plate assembly 105, and simultaneously rotates the mandrel part located at the second position (packaging station) to the first position (winding station). In embodiments, if one considers the ring gear 115c as a clock face, the first position (winding station) can be defined at the 3 o'clock rotational position, and the second position (packaging station) can be defined at the 9 o'clock rotational position. Alternatively, other suitable rotational positions of the plate assembly 105 can be used for the winding station and packaging station, respectively.

[0084] In embodiments, during the transition operations, the plastic film applicator 127 can be configured to move along a curved track 129 and apply plastic film (e.g., stretch wrap) to material wound on the respective mandrel part (109a or 109b) as the mandrel part rotates from the first location to the second location.

[0085] A third drive mechanism (e.g., robot system) 180 can be coupled to a packaging mandrel interface 171 as shown in FIGS. 1 and 2. The packaging mandrel interface 171 is configured to selectively engage and couple to either one of the two mandrel parts 109a, 109b. The packaging mandrel interface 171 can be configured to engage and couple to a respective mandrel part (with mandrel segments in their locked expanded configuration) that holds a wound coil of material wrapped with plastic film at the second position (packaging station). In embodiments, the engagement and coupling of the packaging mandrel interface 171 to the respective mandrel part (109a or 109b) involves linear motion toward the plate assembly 105.

[0086] In embodiments illustrated in FIGS. 12 to 15, the packaging mandrel interface 171 can include a spline shaft 173 mechanically coupled to a drive collar assembly 173a. The drive collar assembly 173a is mechanically coupled to an annular flange 177 that extends radially outward away from the spline shaft 173. The drive collar assembly 173a and the annular flange 177 can support a plurality of grabber elements 175 that pivot radially relative to the spline shaft 173 to define an expanded configuration and a collapsed configuration. In the expanded configuration (FIGS. 12-14), the ends of the grabber elements 175 are offset radially from the central axis of the spline shaft 173 at a diameter D5 that is equal to or greater than the second diameter D2 (where D2 corresponds to the expanded configuration of the mandrel segments 135 of the respective mandrel parts). In the collapsed configuration (FIG. 15), the ends of the grabber elements 175 are offset radially from the central axis of the spline shaft 173 at diameter D6 (where D6 is less than D6 and can but need not correspond to the first diameter D1 of the collapsed configuration of the mandrel segments of the respective mandrel parts). The grabber elements 175 can pivot relative to the spline shaft 173 from the expanded configuration to the collapsed configuration, or vice versa. The annular flange 177 has slots 179 that receive portions of the grabber elements 175 and accommodate the pivoting movement of the grabber elements 175. The grabber elements 175 can be configured to extend radially relative to the spline shift 173 through alternating void spaces between the mandrel segments 135 of the respective mandrel part in their collapsed configuration (e.g., to engage the inside surface of a wound coil). The spline shaft 173 can be mechanically coupled to the drive collar assembly 173a at one end, and the spline shaft 173 can include a keyed interface 173b at the opposite end. The keyed interface 173b is adapted to mate to and engage the keyed interface 141 of the respective mandrel parts 109a, 109b. The drive collar assembly 173a is adapted to mate to and engage the third drive mechanism 180.

[0087] When the keyed interface 173b of the packaging mandrel interface 171 is initially engaged and coupled to the keyed interface 141 of a respective mandrel part (109a or 109b), the mandrel segments 135 of the respective mandrel part can be configured in their locked expanded configuration In this configuration, the coil of material wound on the mandrel segments 135 (and with plastic film applied thereto) is supported and held in position by the mandrel segments 135 of the mandrel part. Furthermore, when the keyed interface 173b of the packaging mandrel interface 171 is engaged and coupled to the keyed interface 141 of the respective mandrel part (109a or 109b), the keyed interfaces 141, 173b can cooperate to automatically configure the spline shaft 133 of the respective mandrel part such that it rotates independently from the plate assembly 105 and drives the rotation of the spline shaft 133 of the respective mandrel part (e.g., for setting the orientation of the payout hole of the wound coil).

[0088] The packaging mandrel interface 171 can further include a payout tube support 199, which is configured to support a payout tube that is positioned within a payout hole of a coil wound on a respective mandrel part (109a or 109b) coupled thereto. Such support can be configured to limit movement of the payout tube when material is grabbed and pulled through the payout tube by an external robotic system as described herein.

[0089] Furthermore, the respective mandrel parts (109a, 109b) and the packaging mandrel interface 171 can include cooperating features or parts that are adapted to release the segment locking system of the respective mandrel parts when the keyed interface 173b of the packaging mandrel interface 171 is engaged and coupled to the keyed interface 141 of the respective mandrel part (109a or 109b). The release of the segment locking system of the mandrel part permits the mandrel segments 135 of the mandrel part to automatically move from the expanded configuration to the collapsed configuration as shown in FIG. 16.

[0090] In embodiments where the segment locking system of the respective mandrel parts includes a rotating hub 191 with a set of ball detents 191a as shown in FIGS. 24A and 24B, the segmented locking system can be released by linear actuation of a two-part pusher rod shown in FIGS. 25 and 26. In this embodiment, the support collar 131 of the respective mandrel parts (109a, 109b) can support spring-biased linear movement of a pusher rod part 195 having end 195a opposite a wedge-shaped end 195b, and the drive collar assembly 173a of the packaging mandrel interface 171 can support a fixed pusher rod part 196 having end 196a opposite end 196b. The moveable pusher rod part 195 is biased by a spring into a position where the wedge-shaped end 195b is offset from the hub 191. The end 196a of the fixed pusher rod part 196 of the packaging mandrel interface 171 can be configured to connect and mate to the end 195a of moveable pusher rod part 195 of the respective mandrel part when the packaging mandrel interface 171 is mated to the respective mandrel part (109a or 109b). In this configuration, linear movement of the packaging mandrel interface 171 together with the fixed pusher rod part 196 toward the mandrel part imparts linear motion of the pusher rod part 195 toward the hub 191. Such linear motion can cause the wedge-shaped end 195b of the movable pusher rod part 195 to contact the ramp surface 191b of the rotating hub 191, which drives rotation of the hub 191. The rotation of the hub 191 causes the detents 191a of the rotating hub 191 to move out of position within the corresponding catches/cutouts 135a in the spring-loaded mandrel segments 135, which permits radial movement of the mandrel segments 135 to their collapsed configuration (driven by spring action). A trip lever 193 can be mounted on the hub 191 as shown in FIGS. 24A and 24B. The trip lever 193 can be configured to contact and engage with a stay 194 fixed to the support frame (FIG. 2) during the rotation of the plate assembly 105 as part of the transition operations. The contact and engagement of the trip lever 193 and the stay 194 during such rotation can impart rotation of the hub 191 into a predefined position/orientation where the detents 191a of the hub 191 are positioned in alignment with the spring-loaded mandrel segments 135 of the mandrel part. In this predefined position/orientation, the detents 191a of the hub 191 are positioned to engage the catches/cutouts 135a of the spring-loaded mandrel segments 135 when the spring-loaded mandrel segments 135 are moved into their expanded configuration by the coupling of the winding mandrel interface 121 to the mandrel part as described herein.

[0091] Before, after or during the movement of the mandrel segments 135 into their collapsed configuration (FIG. 15), the grabber elements 175 can be pivoted into their expanded configuration (FIGS. 12 to 14) to extend radially through alternating void spaces between the mandrel segments 135 of the coupled mandrel part and contact the inner surface of the wound coil. With the mandrel segments 135 of the coupled mandrel part in their collapsed configuration and the grabber elements 175 in their expanded configuration, the wound coil of material (wrapped with plastic film) is supported solely by the grabber elements 175. The packaging mandrel interface 171 can then be disengaged and decoupled from the respective mandrel part. In embodiments, the disengagement and decoupling of the packaging mandrel interface 121 from the respective mandrel part involves linear motion away from the plate assembly 105. The wound coil of material (wrapped with plastic film) supported by the grabber elements 175 of the packaging mandrel interface 171 can be moved or transported by the third drive mechanism 180 coupled thereto, and can be released and removed from the packaging mandrel interface 171 by pivoting motion of the grabber elements 175 into their collapsed configuration.

[0092] In embodiments, the wound coil of material (wrapped with plastic film) on the respective mandrel part has a payout hole between the windings of the wound material. The third drive mechanism 180 and the packaging mandrel interface 171 can be adapted to rotate or otherwise orient the wound coil of material (wrapped with plastic film) on the coupled mandrel part at the second location (packaging station) into an orientation where the payout hole is positioned in an upright (or other known) configuration for receiving a payout tube. In embodiments, the payout tube can be placed in the payout hole by a robotic payout tube handling system 201 as shown in FIGS. 1 and 2.

[0093] The packaging mandrel interface 171 can further include a payout tube support 199, which is configured to support the payout tube placed om the payout hole of a coil wound on a respective mandrel part (109a or 109b) coupled thereto. Such support can be configured to limit movement of the payout tube when material is grabbed and pulled through the payout tube by the robotic payout tube handling system 201.

[0094] In embodiments, the robotic payout tube handling system 201 receives payout tubes from a supply of payout tubes. The system may include a payout tube supply station 203 including a storage hopper 205 for receiving payout tubes, a conveyor 207 that transfers payout tubes from the storage hopper 205 to a feed bowl or small hopper 209, and a linearizing feed path 211 from the bowl or hopper 209 to a pickup station 211. The bowl or hopper 209 can be configured to position the payout tubes in a predefined orientation on the linearizing feed path 211 for delivery to the pickup station in the predefined orientation. The robotic payout tube handling system 201 can be configured to acquire a payout tube from the pickup station 211 and install the payout tube into the payout hole in the wound coil at the second location (packaging station). The robotic payout tube handling system 201 can be further configured to engage and draw a free end of material from the wound coil through the installed payout tube, and support the payout tube against the wound coil while the material is drawn out through the payout tube at the second location (packaging station).

[0095] One or more controllers can be coupled to the various drive mechanisms (115, 119), the cutter system 118, the robotic system(s) 180, 201, the components of the payout tube supply station 203, and various position sensors (such as shaft encoders, contact sensors, proximity sensors, etc.). A user interface (such as a touch screen display) can be operably coupled to the controller(s) to control and coordinate the execution of the operations performed by the system.

[0096] In an embodiment, the system may be operated in a repetitive 4-part cycle of winding operations concurrent with packaging operations, with transition operations between the cycles of concurrent winding and packaging operations as summarized in Table 1 below:

TABLE-US-00001 TABLE 1 Repetitive 4-Part Cycle Part 1 Part 2 Part 3 Part 4 winding winding operations with operations with mandrel part mandrel part 109a at winding 10ba at winding station station concurrent with transition concurrent with transition operations operations move mandrel move mandrel part 109a to part 109b to packaging station packaging station and mandrel part and mandrel part 109b to winding 109a to winding station station packaging packaging operations with operations mandrel part with mandrel 109b at part 109a at packaging packaging station station

[0097] The winding operations of parts 1 and 3 are performed with a respective mandrel part (109a or 109b) positioned in the first position (winding station). The packaging operations of parts 1 and 3 are performed with a respective mandrel part (109a or 109b) positioned in the second position (packaging station). The transition operations of parts 2 and 4 rotate the two mandrel parts 109a, 109b one-hundred and eighty degrees about the first rotational axis of the first rotary shaft 107 and the plate assembly 105 such that two mandrel parts 109a, 109b exchange rotational position with one another. This rotates the mandrel part located at the first position (winding station) to the second position (packaging station), and simultaneously rotates the mandrel part located at the second position (packaging station) to the first position (winding station).

[0098] In embodiments, the second drive mechanism 119 can be configured to drive rotation of the second rotary shaft 111a and the mandrel part 109a in a first rotational direction (counter-clockwise) about the corresponding second rotational axis during the winding operations when the second drive mechanism 119 is operably coupled to the mandrel part 109a. Similarly, the second drive mechanism 119 can be configured to drive rotation of the third rotary shaft 111b and the mandrel part 109b in the first rotational direction (counter-clockwise) about the corresponding third rotational axis during the winding operations when the second drive mechanism 119 is operably coupled to the mandrel part 109b.

[0099] During the transition operations, the first drive mechanism 115 can be configured to rotate the first rotary shaft 107 and the plate assembly 105 in a second rotational direction (clockwise direction), and the planetary gear arrangement (gears 115a, 115b, 115c) can be configured to drive counter rotation of the second rotary shaft 111a and the mandrel part 109a mounted thereon as well as counter rotation of the third rotary shaft 111b and the mandrel part 109b mounted thereon in a coordinated manner (e.g., both in the first (counter-clockwise) rotational direction opposite the second (clockwise) rotational direction of the plate assembly) during the rotation of the first rotary shaft 107 and the plate assembly 105.

[0100] In other embodiments, during the transition operations, the rotation of the second rotary shaft 111a and the mandrel part 109a mounted thereon can be coordinated with the rotation of the third rotary shaft 111b and the mandrel part 109b mounted thereon (e.g., both in a first (counter-clockwise) rotational direction opposite the second (clockwise) during rotation of the first rotary shaft 107 and the plate assembly 105 by electronic control of the motors that drive rotation of first rotary shaft 107 and the plate assembly 105 and the counter rotation of the second rotary shaft 111a/mandrel 109a and the third rotary shaft 111b/mandrel 109b.

[0101] In the winding operations, the winding mandrel interface 121 engages and couples to the respective mandrel part (109a or 109b) located at the first position (winding station), and the winding spool formed by the winding mandrel interface and the mandrel part at the first position (winding station) is rotated by operation of the second drive mechanism 119 with the plate assembly 105 in a fixed position corresponding to the first position (winding station). This rotation winds a coil of material onto the winding spool with the material guided onto the winding spool by the traverse mechanism 125 as shown in FIG. 17. The second drive mechanism 119 (not shown) operates to rotate the winding spool formed on the first rotary shaft 111a to form a coil of material of a defined length of wire. The defined length can be set by user input on the user interface. After winding is complete, the winding mandrel interface 121 disengages and decouples from the mandrel part. For purposes of explanation, the initial winding can be performed with the first rotary shaft 111a and corresponding mandrel part 109a engaged and coupled to the winding mandrel interface 121 and the second drive mechanism 119, and the second rotation drive shaft 111b and corresponding mandrel part 109b located at the second position (packaging station). However, it should be appreciated that each of the first and second rotary shafts and corresponding mandrel parts are the same and either may be a starting point for the operations described.

[0102] In the transition operations, the first drive mechanism 115 rotates the first rotary shaft 107 to rotate the plate assembly 105 and the mandrel parts 109a, 109b mounted thereon by one-hundred and eight degrees and exchange the positions of the two mandrel parts (and the first and second rotary shafts) between the winding station and packaging station as shown in FIGS. 17-21. During this rotation, the plastic film applicator 127 moves on its track 129 to apply a plastic film onto the wound coil as the plate assembly 105 is rotated and the wound coil is moved and rotated on the plate assembly 105. Furthermore, during this rotation, material attached to the wound coil at the winding station and supplied by the traverse mechanism 125 is pulled or otherwise placed into the path of the cutter system 118 and also pulled or otherwise placed into the path of the material capture mechanism of the other mandrel part (which is moving from the packaging station) as best shown in FIGS. 20 and 21. The material in the path of the material capture mechanism of the other mandrel part is automatically captured by the mechanism during the rotation, and then the material in the path of the cutter system 118 is cut during the rotation. The cutting of the material releases the wound coil from the supply of material provided by the traverse mechanism 125, and leaves a free end of material captured by the other mandrel part (which is moving to the winding station). The winding operations of the next coil employs the winding spool formed from the other mandrel part at the winding station. The winding operations occur simultaneously with the packaging operations.

[0103] In the packaging operations, the packaging mandrel interface 171 engages and couples to the respective mandrel part (109a or 109b) located at the second position (packaging station). The third drive mechanism 180 is operated to rotate the wound coil (with plastic film) such that the payout hole of the coil is in a known orientation. With the payout hole positioned at the known orientation, the payout tube handling system 201 inserts the payout tube in the payout hole and pulls out an inner end of material through the payout tube. The payout tube support 199 of the packaging mandrel interface 171 can be configured to support the payout tube in the payout hole when material is grabbed and pulled through the payout tube by the payout tube handling system 201. The packaging mandrel interface 171 can include grabber elements 175 that engages the interior of the wound coil and supports the resultant wound coil with plastic film and payout tube. The packaging mandrel interface 171 then disengages and decouples from the mandrel part at the packaging station, removing the resultant wound coil of material (wrapped with plastic film with payout tube) from the mandrel part and leaving behind the empty mandrel part (in its collapsed configuration). The resultant wound coil of material (wrapped with plastic film with payout tube) supported by the grabber elements 175 of the packaging mandrel interface 171 can be moved or transported by the third drive mechanism 180 coupled thereto. For example, the resultant wound coil of material can be transported to another location for storage or further packaging. The packaging operations of the next coil employs the winding spool formed from the other mandrel part at the packaging station. The packaging operations (or portions thereof) can occur simultaneously with the winding operations.

[0104] In other embodiments, the system can be used to wind a coil of material without a payout tube. In this embodiment, the packaging operations performed at the second location (packaging station) can involve configuring the grabber elements of the packaging mandrel interface to engage the interior of the wound coil and support the resultant wound coil with plastic film. The packaging mandrel interface then disengages and decouples from the mandrel part at the packaging station, removing the resultant wound coil of material (wrapped with plastic film) from the mandrel part and leaving behind the empty mandrel part (in its collapsed configuration). The resultant wound coil of material (wrapped with plastic film) supported by the grabber elements of the packaging mandrel interface can be moved or transported by the third drive mechanism coupled thereto. For example, the resultant wound coil of material can be transported to another location for storage or further packaging. The packaging operations of the next coil employs the winding spool formed from the other mandrel part at the packaging station. The packaging operations (or portions thereof) can occur simultaneously with the winding operations as described herein.

[0105] In yet other embodiments, the mandrel parts of the system can be winding spools (two shown as 109a, 109b) that are detachably mounted on (and dismounted from) the rotary shafts 111a, 111b of the system as shown in FIG. 27. An example winding spool is shown FIG. 28, which includes a central mandrel 301 with opposed end forms 303A and 303B. The central mandrel 301 can surround a keyed axial passageway 305 that is configured to receive and engage the rotary shaft 111a or 111b for mounting thereon. Other winding spools with different mandrel designs and/or end form designs can be employed if desired. Cycles of concurrent winding and packaging operations with transition operations therebetween can be performed with the winding spools as follows. During packaging operations at the packaging station, a winding spool with a coil of material wound thereon (possibly with a plastic film applied thereto and optional payout tube) can be dismounted from one of the rotary shafts (111a or 111b) and replaced with an empty winding spool mounted thereon. These packaging operations can be performed manually by a human operator or by a robotic system. Concurrent with these packaging operations at the packaging station, an empty winding spool mounted on the other rotary shaft (in the previous packaging operations) can be operated to wind a coil of material thereon at the winding station. During the transition operations, the plate assembly 105 rotates and the winding spool with a coil of wound material thereon at the winding station moves from the winding station to the packaging station and the empty winding spool at the packaging station moves from the packaging station to the winding station. During this rotation, the plastic film applicator 127 can move on its track 129 to apply a plastic film onto the wound coil as the plate assembly 105 is rotated and the wound coil is moved and rotated on the plate assembly 105. Furthermore, during this rotation, material attached to the wound coil at the winding station and supplied by the traverse mechanism 125 can be pulled or otherwise placed into the path of the cutter system 118 and also pulled or otherwise placed into the path of a material capture mechanism of the empty winding spool (which is moving from the packaging station). The material in the path of the material capture mechanism of the empty winding spool can be automatically captured by the mechanism during the rotation, and then the material in the path of the cutter system 118 is cut during the rotation. The cutting of the material releases the wound coil from the supply of material provided by the traverse mechanism 125, and leaves a free end of material captured by the empty winding spool (which is moving to the winding station).

[0106] During the transition operations, the rotation of the first rotary shaft and the plate assembly mounted thereon can be coordinated with counter rotation of the second and third rotary shafts and the winding spools mounted thereon.

[0107] In embodiments, the means for coordinating rotation of the first rotary shaft and the plate assembly with counter rotation of the second and third rotary shafts and the winding spools mounted thereon can include a gear mechanism. The gear mechanism can be configured to rotate the second rotary shaft and the winding spool mounted thereon as well as rotate the third rotary shaft and the winding spool mounted thereon in a coordinated manner (e.g., in a common rotational direction opposite the rotational direction of the plate assembly) with respect to rotation of the first rotary shaft and the plate assembly.

[0108] In other embodiments, the means for coordinating rotation of the first rotary shaft and the plate assembly mounted thereon with counter rotation of the second and third rotary shafts and the winding spools mounted thereon can employ electronic controller that control motors that drive the rotation of the first rotary shaft and plate assembly and the counter rotation of the second and third rotary shafts and the winding spools.

[0109] The cycles of concurrent winding and packaging operations with transition operations therebetween as described herein can be performed continuously and autonomously repeated. The packaging operations may be timed to occur in the same or reduced amount of time as the winding operations such that the winding operations can occur substantially continuously without waiting for the packaging operations to complete. The apparatus can provide for cycles of concurrent winding and packing operations with minimal downtime, which can provide significant advantages and efficiencies for winding coils, and particularly for REELEX-type systems, though not limited thereto.

[0110] In embodiments, the flexible material wound into the coil can be cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material.

Enumerated Clauses:

[0111] Enumerated clauses are now provided for the purpose of illustrative some possible embodiments that may be provided in accordance with the disclosure. The clause sets provided below are for illustration and not to be construed as limiting, exclusive or exhaustive. Features recited in one clause set may be utilized and incorporated into one or more of the other clause sets.

Clause Set 1:

[0112] Embodiments disclosed herein may provide an apparatus for winding flexible material that includes: [0113] 1.1. A rotatable plate assembly whose rotation is driven by a first rotary shaft, wherein the plate assembly supports second and third rotary shafts that drive rotation of corresponding first and second mandrel parts, wherein the first and second mandrel parts each form at least part of a winding spool for winding a coil of the material thereon; and [0114] a cutter mechanism for cutting the material, wherein the cutter mechanism is mounted to the rotatable plate assembly and disposed between the first and second mandrel parts. [0115] 1.2. An apparatus according to clause 1.1, wherein the cutter mechanism has first and second slots and corresponding cutting elements, wherein the first slot and corresponding cutting element is configured to cut material that is wound by the first mandrel part while being captured by the second mandrel part, and wherein the second slot and corresponding cutting element is configured to cut material that is wound by the second mandrel part while being captured by the first mandrel part. [0116] 1.3. An apparatus according to clause 1.1, wherein the second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, a rotational axis of the first rotary shaft. [0117] 1.4. An apparatus according to clause 1.1, wherein the first and second mandrel parts each have a plurality of mandrel segments that move radially relative to a central axis between a collapsed configuration and an expanded configuration. [0118] 1.5. An apparatus according to clause 1.4, wherein the first and second mandrel parts each have a locking mechanism that retains the plurality of mandrel segments in the expanded configuration. [0119] 1.6. An apparatus according to clause 1.5, wherein the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the mandrel segments in a predefined rotational position of the hub with the plurality of mandrel segments in the expanded configuration. [0120] 1.7. An apparatus according to clause 1.6, wherein the rotatable hub has a lever that is configured to return the rotatable hub to the predefined rotational position of the hub during rotation of the plate assembly. [0121] 1.8. An apparatus according to clause 1.5, wherein the first and second mandrel parts each have an unlocking mechanism that releases the lock mechanism that retains the plurality of mandrel segments in the expanded configuration and permits the plurality of mandrel segments to move to the collapsed configuration. [0122] 1.9. An apparatus according to clause 1.8, wherein the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the plurality of mandrel segments in a predefined rotational position of the hub; and the unlocking mechanism comprises a spring-biased pusher rod that engages a ramp surface of the hub to rotate the hub out of the predefined rotational position of the hub. [0123] 1.10. An apparatus according to clause 1.1, wherein the first and second mandrel parts each have a grabber mechanism that is configured to catch and grab material, wherein the grabber mechanism is configured to catch and grab material during the coordinated rotation of the plate assembly and the counter rotation of the first and second mandrel parts. [0124] 1.11. An apparatus according to clause 1.1, further comprising a traverse mechanism configured to guide material onto the winding spool. [0125] 1.12. An apparatus according to clause 1.1, further comprising a movable plastic film applicator configured to apply plastic film onto material wound onto the winding spool. [0126] 1.13. An apparatus according to clause 1.1, wherein the first and second mandrel parts each comprise a winding spool for winding a coil of the material thereon that is detachably mountable on the second and third rotary shafts. [0127] 1.14. An apparatus according to clause 1.1, wherein the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material. [0128] 1.15 An apparatus according to clause 1.1, which is combined with one or more of the features of clauses 1.2 to 1.14.

Clause Set 2:

[0129] Embodiments disclosed herein may provide an apparatus for winding flexible material that includes: [0130] 2.1 At least one mandrel part having a plurality of mandrel segments that move radially relative to a central axis between a collapsed configuration and an expanded configuration; and [0131] a winding mandrel interface configured to mate to the at least one mandrel part, wherein the winding mandrel interface has a plurality of coupling segments that move radially relative to a central axis between a collapsed configuration and an expanded configuration; [0132] wherein the mating of the winding mandrel interface to the mandrel part forms a winding spool for winding a coil of the material thereon. [0133] 2.2. An apparatus according to clause 2.1, wherein the plurality of coupling segments of the winding mandrel interface is configured to directly couple to the plurality of the plurality of mandrel segments of the mandrel part when the winding mandrel interface is mated to the mandrel part. [0134] 2.3 An apparatus according to clause 2.1, wherein linear motion of the winding mandrel interface toward the mandrel part causes radial movement of the plurality of mandrel segments into their expanded configuration together with radial movement of the plurality of coupling segments in their expanded configuration to form the winding spool. [0135] 2.4 An apparatus according to clause 2.1, wherein the mandrel part has a locking mechanism that retains the plurality of mandrel segments in the expanded configuration. [0136] 2.5 An apparatus according to clause 2.4, wherein the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the mandrel segments in a predefined rotational position of the hub with the plurality of mandrel segments in the expanded configuration. [0137] 2.6 An apparatus according to clause 2.5, wherein the rotatable hub has a lever that is configured to return the rotatable hub to the predefined rotational position of the hub. [0138] 2.7 An apparatus according to clause 2.4, wherein the mandrel part has an unlocking mechanism that releases the lock mechanism that retains the plurality of mandrel segments in the expanded configuration and permits the plurality of mandrel segments to move to the collapsed configuration. [0139] 2.8 An apparatus according to clause 2.7, wherein the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the plurality of mandrel segments in a predefined rotational position of the hub; and the unlocking mechanism comprises a spring-biased pusher rod that engages a ramp surface of the hub to rotate the hub out of the predefined rotational position of the hub. [0140] 2.9 An apparatus according to clause 2.1, wherein the winding mandrel interface has a spline shaft with a keyed interface configured to drive rotation of the mandrel part when the winding mandrel interface is mated to the mandrel part. [0141] 2.10 An apparatus according to clause 2.1, wherein the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material. [0142] 2.11 An apparatus according to clause 2.1, which is combined with one or more of the features of clauses 2.2 to 2.10.

Clause Set 3:

[0143] Embodiments disclosed herein may provide an apparatus for winding flexible material that includes: [0144] 3.1 At least one mandrel part having a plurality of mandrel segments that move radially relative to a central axis between a collapsed configuration and an expanded configuration; and [0145] a packaging mandrel interface configured to mate to the at least one mandrel part, wherein the packaging mandrel interface has a plurality of grabber elements that extend through alternating void spaces between the mandrel segments of the mandrel part in their collapsed configuration. [0146] 3.2 An apparatus according to clause 3.1, wherein the plurality of grabber elements is configured to engage an inside surface of a wound coil of the material disposed on the mandrel part when mated to the packaging mandrel interface to support the wound coil of material and release the wound coil of material from the mandrel part. [0147] 3.3 An apparatus according to clause 3.1, wherein the packaging mandrel interface has a spline shaft, and the grabber elements are configured pivot radially relative to the spline shaft. [0148] 3.4 An apparatus according to clause 3.1, wherein the mandrel part has a locking mechanism that retains the plurality of mandrel segments in the expanded configuration and an unlocking mechanism that releases the lock mechanism that retains the plurality of mandrel segments in the expanded configuration and permits the plurality of mandrel segments to move to the collapsed configuration; and the packaging mandrel interface includes at least one part that cooperates with the unlocking mechanism to automatically activate the unlocking mechanism when the packaging mandrel interface is mated to the mandrel part. [0149] 3.5 An apparatus according to clause 3.4, wherein the locking mechanism comprises a rotatable hub with ball detents that are configured to engage cutouts defined by the mandrel segments in a predefined rotational position of the hub with the plurality of mandrel segments in the expanded configuration; the unlocking mechanism comprises a spring-biased pusher rod configured to engages a ramp surface of the hub to rotate the hub out of the predefined rotational position of the hub; and the at least one part of the packaging mandrel interface includes a pusher rod part configured to engage the spring-biased pusher rod of the unlocking mechanism and move the spring-biased pusher rod into engagement with the ramp surface of the hub when the packaging mandrel interface is mated to the mandrel part. [0150] 3.6 An apparatus according to clause 3.1, wherein the packaging mandrel interface has a spline shaft with a keyed interface configured to drive rotation of the mandrel part when packaging mandrel interface is mated to the mandrel part. [0151] 3.6 An apparatus according to clause 3.1, wherein the packaging mandrel interface further includes a payout tube support. [0152] 3.7 An apparatus according to clause 3.6, wherein the packaging mandrel interface is configured to rotate the mandrel part to orient a payout hole of a wound coil of material on the mandrel part for insertion of a payout tube in the payout hole; and the payout tube support is configured to support the payout tube in the payout hole when material is grabbed and pulled through the payout tube by an external robotic system. [0153] 3.8 An apparatus according to clause 3.1, wherein the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material. [0154] 3.9 An apparatus according to clause 3.1, which is combined with one or more of the features of clauses 3.2 to 3.8.

Clause Set 4:

[0155] Embodiments disclosed herein may provide an apparatus for winding flexible material that includes: [0156] 4.1 A rotatable plate assembly whose rotation is driven by a first rotary shaft, wherein the plate assembly supports second and third rotary shafts that drive rotation of corresponding first and second mandrel parts, wherein the first and second mandrel parts each form at least part of a winding spool for winding a coil of the material thereon; and [0157] a movable plastic film applicator configured to move along a track and apply plastic film onto material wound onto the winding spool. [0158] 4.2 An apparatus according to clause 4.1, wherein the track follows an arcuate or linear path disposed about the plate assembly. [0159] 4.3 An apparatus according to clause 4.1, wherein the plastic film applicator is mounted to a belt that moves through a channel in the track, and the belt is driven by a servo-motor. [0160] 4.4 An apparatus according to clause 4.1, wherein a servo-motor is mounted to the plastic film applicator, wherein the servo-motor is configured to move with the plastic film applicator along the track. [0161] 4.5 An apparatus according to clause 4.1, further comprising a controller for controlling movement of the plastic film applicator along the track in a coordinated manner with rotational movement of the plate assembly. [0162] 4.6 An apparatus according to clause 4.1, further comprising a traverse mechanism configured to guide material onto the winding spool. [0163] 4.7 An apparatus according to clause 4.1, further comprising a cutter mechanism for cutting the material, wherein the cutter mechanism is mounted to the rotatable plate assembly and disposed between the first and second mandrel parts. [0164] 4.8 An apparatus according to clause 4.1, wherein the first and second mandrel parts each comprise a winding spool for winding a coil of the material thereon that is detachably mountable on the second and third rotary shafts. [0165] 4.9 An apparatus according to clause 4.1, wherein the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material. [0166] 4.10 An apparatus according to clause 4.1, which is combined with one or more of the features of clauses 4.2 to 4.9.

Clause Set 5:

[0167] Embodiments disclosed herein may provide a method for winding flexible material that includes: [0168] 5.1 Providing a rotatable plate assembly whose rotation is driven by a first rotary shaft, the plate assembly supporting second and third rotary shafts with first and second mandrel parts mounted thereon, wherein the first and second mandrel parts each form at least part of a winding spool for winding a coil of the material thereon, wherein the second and third rotary shafts have rotational axes that are parallel to one another and parallel to, but laterally offset from, a rotational axis of the first rotary shaft; and [0169] controlling rotational movement of the plate assembly about the first rotational axis between a first station and a second station, wherein the first station is used to wind coils of the material using the first and second mandrel parts, and wherein the second station is used to remove wound coils of the material from the rotational plate assembly. [0170] 5.2 A method according to clause 5.1, wherein: [0171] the first station is used to wind coils of the material using the first and second mandrel parts in an ordered sequence one after the other, and the second station is used to remove wounds coils of material from the first and second mandrel parts in an opposite ordered sequence one after the other. [0172] 5.3 A method according to clause 5.1, wherein the second station is used to orient payout holes of the wound coils, place payout tubes in the payout holes of the wound coils and pull material through the payout tubes. [0173] 5.4 A method according to clause 5.1, wherein the rotation of the movement of the plate assembly about the first rotational axis is configured to rotate the first and second mandrel parts one-hundred and eighty degrees about the first rotational axis such that first and second mandrel parts exchange rotational position with one another. [0174] 5.5 A method according to clause 5.1, further comprising coordinating rotation of the plate assembly about the first rotational axis with counter rotation of the first and second mandrel parts about the second and third rotational axes, respectively. [0175] 5.6 A method according to clause 5.1, further comprising cutting the material during rotation of the plate assembly. [0176] 5.7 A method according to clause 5.1, further comprising automatic capturing and grabbing material by one of the first and second mandrel parts during the rotation of the plate assembly. [0177] 5.8 A method according to clause 5.1, further comprising applying a plastic film onto wound coils during the rotation of the plate assembly. [0178] 5.9 A method according to clause 5.1, wherein the first and second mandrel parts each comprise a winding spool for winding a coil of the material thereon that is detachably mountable on the second and third rotary shafts. [0179] 5.10 A method according to clause 5.1, wherein the flexible material is selected from the group consisting of cable (including network cable and fiber optic cable), wire (including THHN wire, NM-B wire, grounding wire, UF-B wire), tubing, hose, rope, or other filamentary material. [0180] 5.11 A method according to clause 5.1, which is combined with one or more of the features of clauses 5.2 to 5.10.

[0181] There have been described and illustrated herein several embodiments of apparatus, systems, and methods of winding coils of flexible material. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereto, as it is intended that the invention be as broad in scope as the art will allow and that the specification be read likewise. It will therefore be appreciated by those skilled in the art that yet other modifications could be made to the provided invention without deviating from its spirit and scope as claimed.