WIRE TIE SYSTEMS AND METHODS

Description

RELATED APPLICATIONS

This application claims benefit of and priority to U.S. Patent Application No. 63/571,153 filed on Mar. 28, 2024 and titled “WIRE TIE SYSTEMS AND METHODS,” which is hereby incorporated by reference in its entirety.

FIELD

Embodiments relate generally to wire production and more particularly to wire tie systems and methods.

BACKGROUND

Wire ties are often employed in baling processes to secure bales of loose material. In the recycling industry, for example, materials like cardboard, paper, plastic, metal, or textiles are often compressed and compacted into individual bales that are wrapped using wire ties. Wire ties used for baling are sometimes referred to as “bale ties” or “bale wire ties.” Wire ties are often made of galvanized steel, high-strength plastic, or similarly strong materials to enable tight wrapping and securing of bales of material. By securely bundling bales with wire ties, the risk of material spillage, shifting, or damage during handling and transport is minimized, promoting safety and efficiency. Additionally, wire ties can improve overall organization and management of materials by helping to maintain bale size and shape, which facilitates handling and storage. As such, wire ties can play a crucial role in material baling, storage, transportation, and handling.

SUMMARY

Wire ties (or “bale ties” or “bale wire ties”) are typically secured (or “wrapped”) about bales manually or with the help of automated wire tying machines, depending on the scale of operations. Manual application often involves workers using hand tools to wrap and secure wire ties around bales. Automated wire tying typically employs one or more special purpose machines that wrap and secure wire ties around bales, which can be especially helpful to streamline the baling process for larger volumes.

A wire tie is typically formed with a looped end that facilitates securing the wire tie ends. A single loop wire tie refers to a wire tie having one looped end. For example, a single loop wire tie may have one of its ends folded back on itself and twisted to generate a preformed opening (or “end loop”). During a baling process, the other end of the wire tie can be passed through the end loop and be folded back on itself and twisted to secure the ends together and, in turn, secure the wire tie about a bale. A double loop wire tie refers to a wire tie having two looped ends. For example, a double loop wire tie may have each of its two ends folded back on itself and twisted to generate preformed openings (or “end loops”). During a bailing process, a wire tie can be passed through the end loops and be folded back on itself and twisted to secure the ends together and, in turn, secure the wire tie about a bale.

Manufacturing wire ties typically involves several steps to generate a finished wire tie. For example, manufacturing single-loop wire ties may involve some or all of the following series of steps: (1) sourcing wire of an appropriate size and material (e.g., galvanized steel wire or high-strength plastic) based on factors such as desired cost strength, durability, and corrosion resistance; (2) shaping the wire (e.g., drawing the sourced wire through a series of dies to reduce its diameter to a desired size and ensure that the wire has a uniform diameter and smooth surface finish); (3) finishing the wire (e.g., galvanizing or coating shaped steel wire to enhance corrosion resistance or heat-treating or additive-treating shaped plastic wires for improved strength and durability); (4) cutting the wire (e.g., cutting a long strand of wire into individual wires of relatively shorter lengths); (5) looping the wire (e.g., forming a loop at one or both ends of the wire by bending the wire back on itself and twisting the bent wire to form a looped end on each individual wire); (6) quality checking (e.g., conducting visual inspections, dimensional measurements, strength and durability testing, or the like at one or more stages of the process); and (7) packaging and distribution (e.g., packaging generated looped wire ties into bundles for shipment to customers for use in securing bales of material).

Provided in some embodiments is a loop wire tie manufacturing technique that provides for efficient and effective forming of looped wire ties. In some embodiments, a looping system is operable to receive individual lengths wire, and bend and twist the ends of each of the lengths of wire to form respective looped wires. In certain embodiments, the looping system includes a twist cylinder having a looping member (or “pin” or “peg”) protruding radially therefrom, and a bend cylinder having a bending member (or “pin” or “peg”) that is operable to engage and bend an end of a wire about the looping member (e.g., to generate a bend that includes a distal end of the wire looped back to a position proximate an adjacent portion of the wire), where the twist cylinder is operable to rotate, with the length of wire bent about the looping member, to twist the distal end about the adjacent portion of the wire to form a looped end on the length of wire. The looped wires may, for example, be subsequently discharged from the looping system as they are formed and then be gathered into bundles of looped wires for packaging and distribution.

In some embodiments, the twist cylinder includes a semicylindrical member, having an exterior surface defined by a semicircular face and a planar face, with the looping member (or “peg”) extending from the planar face, and the looping system further includes a proximity sensor that is disposed proximate the twist cylinder and operable to sense proximity of an edge formed by the intersection of the semicircular portion and the planar face portion of the exterior surface of the twist cylinder. During operation, the proximity sensor may generate a signal indicative of the edge being located at or near the proximity sensor, and a rotational position of the twist cylinder (e.g., an angular position of the twist cylinder about its longitudinal axis) may be correlated to the location of the proximity sensor. Such locating may be used to determine and calibrate the angular position of the twist cylinder which can, for example, be used for determining and coordinating positioning of the twist cylinder during a wire tie looping operation. For example, in response to receiving a signal from the proximity sensor indicating that the edge located at the intersection of the semicircular portion and the planar face portion of the exterior surface of the twist cylinder is at or near the proximity sensor (e.g., a spike or drop-off in a proximity sensor signal), it may be determined that the twist cylinder is located at a “home” angular position, where the edge is aligned with the proximity sensor, and this home angular position may be used as a reference (or “home”) point for conducting subsequent movement of the twist cylinder. For example, where it is desirable to rotate the twist cylinder to an angular position that is angularly offset by 15 degrees clockwise from the home angular position, in response to receiving a proximity sensor signal indicating that the edge is at or near the proximity sensor, the looping system may control a motor controller to operate a twist motor to rotate the twist cylinder clockwise by 15 degrees. This may provide a “homing” routine that includes determining an angular position for use as a reference for subsequent movements, and applying an angular offset that rotates the twist cylinder into a desired position based on the determined angular position.

In some embodiments, the twist cylinder is positioned to bend lengths of wire in a given plane (e.g., a vertical plane) and the proximity sensor is angularly offset from the plane to enable bending of the wire without physical interference by the proximity sensor. For example, where the bending of the wire about the peg involves maintaining the twist cylinder in a vertical orientation (e.g., an angular position that includes the planar face oriented vertically), the proximity sensor may be angularly offset from vertical (e.g., by a given distance or angle, such as 45 degrees) to enable loading or bending of the wire in the vertical plane without physical contact of the end of the wire with the proximity sensor. In such an embodiment, a homing routine may be conducted (e.g., prior to looping of each wire tie) that includes rotating the twist cylinder to a “home” defined by an angular position (e.g., 15 degrees counter clock-wise from vertical) at which the proximity sensor provides a signal indicating that the edge at the transition from the semicircular face to the planar face is at or near the sensor (e.g., a spike or drop off in a sensing signal), determining that the twist cylinder is located at the “home” angular position (e.g., 15 degrees counter clock-wise from vertical), and controlling the twist cylinder to rotate it by an offset (e.g., clockwise 15 degrees) to position the planar face vertical for subsequent, receipt, bending or twisting of a length of wire to form a looped wire tie.

Provided in some embodiments is a wire tie looping system, including: a twist cylinder including: an elongated semicylindrical member including: a cylindrical face portion; and a planar face portion; and a looping peg extending transverse from the planar face portion, the twist cylinder adapted to rotate about a twist axis defined by a longitudinal axis of the elongated semicylindrical member; a bend cylinder including: a bending peg extending therefrom, the bend cylinder adapted to: rotate about a bend axis that is oriented transverse to the twist axis; and translate along the bend axis; an edge sensor adapted to sense proximity of an edge defined by an intersection of the cylindrical face portion and the planar face portion, the edge sensor laterally offset from the twist axis to enable a length of wire to pass vertically into a looping position including the length of wire adjacent the planar face portion oriented vertically; an index wheel adapted to rotate about an index axis to guide lengths of wire into and out of a looping position, the index axis oriented parallel to the twist axis; a twist motor adapted to drive rotation of the twist cylinder about the twist axis; a bend motor adapted to drive rotation of the bend cylinder about the bend axis; a bend slide motor adapted to drive translation of the bend cylinder along the bend axis; an index motor adapted to drive rotation of the index wheel about the index axis; a wire tie control system adapted to: drive rotation of the twist motor to drive rotation of the twist cylinder about the twist axis; monitor, during rotation of the twist cylinder, a proximity signal output by the edge sensor; determine, based on the monitoring of the proximity signal, that the twist cylinder is at a first angular position including the planar face portion oriented at an angle relative to vertical; drive, in response to determining that the twist cylinder is in the first angular position, rotation of the twist motor to drive rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to a second angular position including the planar face portion oriented vertically; drive, in response to rotation of the twist cylinder to the second angular position, rotation of the index motor to drive rotation of the index wheel about the index axis to deposit a length of wire into a looping position, the looping position including the length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the length of wire extends to a first side of the looping peg and a central portion of the length of wire extends to a second side of the looping peg; drive, in response to depositing the length of wire into the looping position, the bend slide motor to drive translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the length of wire; drive, in response to moving the bending peg proximate the length of wire, rotation of the bend motor to drive rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the length of wire about the looping peg of the twist cylinder such that the end of the length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the length of wire; drive, in response to bending of the end of the length of wire about the looping peg, rotation of the twist motor to drive rotation of the twist cylinder about the twist axis to cause twisting of the end of the length of wire about the central portion of the length of wire to form a looped end on the length of wire; and drive, in response to forming of the looped end on the length of wire, rotation of the index motor to drive rotation of the index wheel about the index axis to eject the length of wire out of the looping position.

In some embodiments, the wire tie control system further adapted to: in response to ejection of the length of wire out of the looping position: drive rotation of the twist motor to drive rotation of the twist cylinder about the twist axis; monitor, during rotation of the twist cylinder, the proximity signal output by the edge sensor; determine, based on the monitoring of the proximity signal, that the twist cylinder is at the first angular position including the planar face portion oriented at an angle relative to vertical; drive, in response to determining that the twist cylinder is in the first angular position, rotation of the twist motor to drive rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to the second angular position including the planar face portion oriented vertically; drive, in response to rotation of the twist cylinder to the second angular position, rotation of the index motor to drive rotation of the index wheel about the index axis to deposit a second length of wire into the looping position, the looping position including the second length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the second length of wire extends to the first side of the looping peg and the central portion of the second length of wire extends to the second side of the looping peg; drive, in response to depositing the second length of wire into the looping position, the bend slide motor to drive translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the second length of wire; drive, in response to moving the bending peg proximate the second length of wire, rotation of the bend motor to drive rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the second length of wire about the looping peg of the twist cylinder such that the end of the second length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the second length of wire; drive, in response to bending of the end of the second length of wire about the looping peg, rotation of the twist motor to drive rotation of the twist cylinder about the twist axis to cause twisting of the end of the second length of wire about the central portion of the second length of wire to form a looped end on the second length of wire; and drive, in response to forming of the looped end on the second length of wire, rotation of the index motor to drive rotation of the index wheel about the index axis to eject the second length of wire out of the looping position.

Provided in some embodiments is a wire tie looping system, including: a twist cylinder including: an elongated semicylindrical member including: a cylindrical face portion; and a planar face portion; and a looping peg extending transverse from the planar face portion, the twist cylinder adapted to rotate about a twist axis defined by a longitudinal axis of the elongated semicylindrical member; a bend cylinder including: a bending peg extending therefrom, the bend cylinder adapted to: rotate about a bend axis that is oriented transverse to the twist axis; and translate along the bend axis; an edge sensor adapted to sense proximity of an edge defined by an intersection of the cylindrical face portion and the planar face portion, the edge sensor laterally offset from the twist axis to enable a length of wire to pass vertically into a looping position including the length of wire adjacent the planar face portion oriented vertically; an index wheel adapted to rotate about an index axis to guide lengths of wire into and out of a looping position, the index axis oriented parallel to the twist axis; a wire tie control system adapted to: drive rotation of the twist cylinder about the twist axis; monitor, during rotation of the twist cylinder, a proximity signal output by the edge sensor; determine, based on the monitoring of the proximity signal, that the twist cylinder is at a first angular position; drive, in response to determining that the twist cylinder is in the first angular position, rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to a second angular position; drive, in response to rotation of the twist cylinder to the second angular position, rotation of the index wheel about the index axis to deposit a length of wire into a looping position, the looping position including the length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the length of wire extends to a first side of the looping peg and a central portion of the length of wire extends to a second side of the looping peg; drive, in response to depositing the length of wire into the looping position, translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the length of wire; drive, in response to moving the bending peg proximate the length of wire, rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the length of wire about the looping peg of the twist cylinder such that the end of the length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the length of wire; drive, in response to bending of the end of the length of wire about the looping peg, rotation of the twist cylinder about the twist axis to cause twisting of the end of the length of wire about the central portion of the length of wire to form a looped end on the length of wire; and drive, in response to forming of the looped end on the length of wire, rotation of the index wheel about the index axis to eject the length of wire out of the looping position.

In some embodiments, the wire tie control system further adapted to: in response to ejection of the length of wire out of the looping position: drive rotation of the twist cylinder about the twist axis; monitor, during rotation of the twist cylinder, the proximity signal output by the edge sensor; determine, based on the monitoring of the proximity signal, that the twist cylinder is at the first angular position; drive, in response to determining that the twist cylinder is in the first angular position, rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to the second angular position; drive, in response to rotation of the twist cylinder to the second angular position, rotation of the index wheel about the index axis to deposit a second length of wire into the looping position, the looping position including the second length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the second length of wire extends to the first side of the looping peg and the central portion of the second length of wire extends to the second side of the looping peg; drive, in response to depositing the second length of wire into the looping position, translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the second length of wire; drive, in response to moving the bending peg proximate the second length of wire, rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the second length of wire about the looping peg of the twist cylinder such that the end of the second length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the second length of wire; drive, in response to bending of the end of the second length of wire about the looping peg, rotation of the twist cylinder about the twist axis to cause twisting of the end of the second length of wire about the central portion of the second length of wire to form a looped end on the second length of wire; and drive, in response to forming of the looped end on the second length of wire, rotation of the index wheel about the index axis to eject the second length of wire out of the looping position. In certain embodiments, further including: a twist motor adapted to drive rotation of the twist cylinder about the twist axis; a bend motor adapted to drive rotation of the bend cylinder about the bend axis; a bend slide motor adapted to drive translation of the bend cylinder along the bend axis; and an index motor adapted to drive rotation of the index wheel about the index axis, the wire tie control system further adapted to: drive rotation of the twist motor to drive rotation of the twist cylinder about the twist axis; drive rotation of the bend motor to drive rotation of the bend cylinder about the bend axis; drive rotation of the index motor to drive rotation of the index wheel about the index axis; drive the bend slide motor to drive translation of the bend cylinder along the bend axis. In some embodiments, the first angular position includes the planar face portion oriented at an angle relative to vertical. In certain embodiments, the second angular position includes the planar face portion oriented vertically. In some embodiments, the length of wire is sized, heat-treated, and coated wire. In certain embodiments, the controller is adapted to operate a cutter to cut the length of wire from a strand of wire. In some embodiments, including a bale of material secured by way of the length of wire having the looped end.

Provided in some embodiments is a method of producing looped wire ties, including: driving rotation of a twist cylinder about a twist axis, the twist cylinder including: an elongated semicylindrical member including: a cylindrical face portion; and a planar face portion; and a looping peg extending transverse from the planar face portion, the twist cylinder adapted to rotate about the twist axis defined by a longitudinal axis of the elongated semicylindrical member; monitoring, during rotation of the twist cylinder, a proximity signal output by an edge sensor, the edge sensor adapted to sense proximity of an edge defined by an intersection of the cylindrical face portion and the planar face portion, the edge sensor laterally offset from the twist axis to enable a length of wire to pass vertically into a looping position including the length of wire adjacent the planar face portion in a vertical orientation; determining, based on the monitoring of the proximity signal, that the twist cylinder is at a first angular position; driving, in response to determining that the twist cylinder is in the first angular position, rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to a second angular position; driving, in response to rotation of the twist cylinder to the second angular position, rotation of an index wheel about an index axis to deposit a length of wire into a looping position, the looping position including the length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the length of wire extends to a first side of the looping peg and a central portion of the length of wire extends to a second side of the looping peg, the index wheel adapted to rotate about the index axis to guide lengths of wire into and out of the looping position, the index axis oriented parallel to the twist axis; driving, in response to depositing the length of wire into the looping position, translation of a bend cylinder along a bend axis toward the planar face portion of the twist cylinder to move a bending peg proximate the length of wire, a bend cylinder including: the bending peg extending therefrom, the bend cylinder adapted to: rotate about the bend axis, the bend axis oriented transverse to the twist axis; and translate along the bend axis; driving, in response to moving the bending peg proximate the length of wire, rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the length of wire about the looping peg of the twist cylinder such that the end of the length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the length of wire; driving, in response to bending of the end of the length of wire about the looping peg, rotation of the twist cylinder about the twist axis to cause twisting of the end of the length of wire about the central portion of the length of wire to form a looped end on the length of wire; and driving, in response to forming of the looped end on the length of wire, rotation of the index wheel about the index axis to eject the length of wire out of the looping position.

In some embodiments, the method further including: in response to ejection of the length of wire out of the looping position: driving rotation of the twist cylinder about the twist axis; monitoring, during rotation of the twist cylinder, the proximity signal output by the edge sensor; determining, based on the monitoring of the proximity signal, that the twist cylinder is at the first angular position; driving, in response to determining that the twist cylinder is in the first angular position, rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to the second angular position; driving, in response to rotation of the twist cylinder to the second angular position, rotation of the index wheel about the index axis to deposit a second length of wire into the looping position, the looping position including the second length of wire oriented parallel to the twist axis, adjacent the planar face portion of the twist cylinder, and adjacent the looping peg of the twist cylinder such that an end of the second length of wire extends to the first side of the looping peg and the central portion of the second length of wire extends to the second side of the looping peg; driving, in response to depositing the second length of wire into the looping position, translation of the bend cylinder along the bend axis toward the planar face portion of the twist cylinder to move the bending peg proximate the second length of wire; driving, in response to moving the bending peg proximate the second length of wire, rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the second length of wire about the looping peg of the twist cylinder such that the end of the second length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the second length of wire; driving, in response to bending of the end of the second length of wire about the looping peg, rotation of the twist cylinder about the twist axis to cause twisting of the end of the second length of wire about the central portion of the second length of wire to form a looped end on the second length of wire; and driving, in response to forming of the looped end on the second length of wire, rotation of the index wheel about the index axis to eject the second length of wire out of the looping position. In certain embodiments, the method further including: driving rotation of a twist motor to drive rotation of the twist cylinder about the twist axis; driving rotation of a bend motor to drive rotation of the bend cylinder about the twist axis; driving rotation of the index motor to drive rotation of the index wheel about the index axis; driving the bend slide motor to drive translation of the bend cylinder along the bend axis. In some embodiments, the first angular position includes the planar face portion oriented at an angle relative to vertical. In certain embodiments, the second angular position includes the planar face portion oriented vertically. In some embodiments, the method further including sizing, heat treating, and coating the length of wire. In certain embodiments, the method further including operating a cutter to cut the length of wire from a strand of wire. In some embodiments, the method further including securing a bale of material using the length of wire having the looped end. In certain embodiments, the method further including transporting the bale of material secured using the length of wire having the looped end.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a wire tie environment in accordance with one or more embodiments.

FIGS. 2A-4D illustrate various views of components of a wire tie looping system in accordance with one or more embodiments.

FIG. 5 illustrates aspects of a bend and twist system of the wire tie looping system in accordance with one or more embodiments.

FIG. 6A-6G illustrate operational aspects of the bend and twist system of the wire tie looping system in accordance with one or more embodiments.

FIG. 7 is a flowchart diagram that illustrates a method of producing wire ties in accordance with one or more embodiments.

FIG. 8 is a diagram that illustrates an example computer system in accordance with one or more embodiments.

While this disclosure is susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are described in detail. The drawings may not be to scale. It should be understood that the drawings and the detailed descriptions are not intended to limit the disclosure to the particular form disclosed, but rather to disclose modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the claims.

DETAILED DESCRIPTION

Provided in some embodiments is a loop wire tie manufacturing technique that provides for efficient and effective forming of looped wire ties. In some embodiments, a looping system is operable to receive individual lengths wire, and bend and twist the ends of each of the lengths of wire to form respective looped wires. In certain embodiments, the looping system includes a twist cylinder having a looping member (or “pin” or “peg”) protruding radially therefrom, and a bend cylinder having a bending member (or “pin” or “peg”) that is that operable to engage and bend an end of a wire about the looping member (e.g., to generate a bend that includes a distal end of the wire looped back to a position proximate an adjacent portion of the wire), where the twist cylinder is operable to rotate, with the length of wire bent about the looping member, to twist the distal end about the adjacent portion of the wire to form a looped end on the length of wire. The looped wires may, for example, be subsequently discharged from the looping system as they are formed and the be gathered into bundles of looped wires for packaging and distribution.

In some embodiments, the twist cylinder includes a semicylindrical member, having an exterior surface defined by a semicircular face and a planar face, with the looping member (or “peg”) extending from the planar face, and the looping system further includes a proximity sensor that is disposed proximate the twist cylinder and operable to sense proximity of an edge formed by the intersection of the semicircular portion and the planar face portion of the exterior surface of the twist cylinder. During operation, the proximity sensor may generate a signal indicative of the edge being located at or near the proximity sensor, and a rotational position of the twist cylinder (e.g., an angular position of the twist cylinder about its longitudinal axis) may be correlated to the location of the proximity sensor. Such locating may be used to determine and calibrate the angular position of the twist cylinder which can, for example, be used for determining and coordinating positioning of the twist cylinder during a wire tie looping operation. For example, in response to receiving a signal from the proximity sensor indicating that the edge located at the intersection of the semicircular portion and the planar face portion of the exterior surface of the twist cylinder is at or near the proximity sensor (e.g., a spike or drop-off in a proximity sensor signal), it may be determined that the twist cylinder is located at a “home” angular position, where the edge is aligned with the proximity sensor and this home angular position may be used as a reference (or “home”) point for conducting subsequent movement of the twist cylinder. For example, where is desirable to rotate the twist cylinder to an angular position that is angularly offset by 15 degrees clockwise from the home angular position, in response to receiving a proximity sensor signal indicating that the edge is at or near the proximity sensor, the looping system may control a motor controller to operate a twist motor to rotate the twist cylinder clockwise by 15 degrees. This may provide a “homing” routine that includes determining an angular position for use as a reference for subsequent movements, and applying an angular offset that rotates the twist cylinder into a desired position based on the determined angular position.

In some embodiments, the twist cylinder is positioned to bend lengths of wire in a given plane (e.g., a vertical plane) and the proximity sensor is angularly offset from the plane to enable bending of the wire without physical interference by the proximity sensor. For example, where the bending of the wire about the peg involves maintaining the twist cylinder in a vertical orientation (e.g., an angular position that includes the planar face oriented vertically), the proximity sensor may be angularly offset from vertical (e.g., by a given distance or angle, such as 45 degrees) to enable loading or bending of the wire in the vertical plane without physical contact of the end of the wire with the proximity sensor. In such an embodiment, a homing routine may be conducted (e.g., prior to looping of each wire tie) that includes rotating the twist cylinder to a “home” defined by an angular position (e.g., 15 degrees counter clock-wise from vertical) at which the proximity sensor provides a signal indicating that the edge at the transition from the semicircular face to the planar face is at or near the sensor (e.g., a spike or drop off in a sensing signal), determining that the twist cylinder is located at the “home” angular position (e.g., 15 degrees counter clock-wise from vertical), and controlling the twist cylinder to rotate it by an offset (e.g., clockwise 15 degrees) to position the planar face vertical for subsequent, receipt, bending or twisting of a length of wire to form a looped wire tie.

FIG. 1 is a diagram that illustrates a wire tie environment 100 in accordance with one or more embodiments. In the illustrated embodiment, wire tie environment 100 includes a wire tie looping system 102 operable to receive one or more incoming wires 104, cut the incoming wire(s) 104 into respective lengths of wire 106, and conduct wire tie looping to loop ends of the lengths of wire 106 to generate looped wire ties (or “looped bale ties”) 108.

In some embodiments, wire tie looping system 102 includes a wire intake system 110, a wire cutting system 112, a wire looping system 114, and a wire tie collection system 116.

In the illustrated embodiment, wire intake system 110 includes wire intake racks 120 that each have wire alignment holes 122 arranged to support and align a respective incoming wire 104. Wire tie cutting system 112 includes a wire cutter 124 operable to cut incoming wires 104 into lengths of wire 106. Wire tie looping system 114 includes a wire guide 126, a wire indexer system 128, and a wire bend and twist system 130. Wire tie collection system 116 includes a bundling tray 132 operable to collect looped wire ties 108.

In some embodiments, wire intake system 110 is operable to receive one or more incoming wires 104 and provide (or “feed”) the one or more incoming wires 104 for cutting by wire cutting system 112. For example, in the illustrated embodiment, each of the four illustrated incoming wires 104 (e.g., wires 104a, 104b, 104c and 104d) may be provided (or “threaded” or “fed”) (e.g., in the direction of arrow 134) through a respective set of wire alignment holes 122 (e.g., wire alignment holes 122a, 122b, 122c, and 122d) that arrange the wires 104 in a feeding position 136, where the wires 104 are aligned in parallel on a first side of wire cutter 124 (with spacing corresponding to spacing of wire alignment holes 122). The four illustrated incoming wires 104 may, for example, be strands of wire that are fed from respective spools of wire. As described, the strands may, for example, be pre-sized, treated, coated or the like. The four illustrated incoming wires 104 may be further advanced (e.g., pushed or pulled by a roller or the like in the direction of arrow 134), from feeding position 136 to a cutting position 138 where the far right ends of the wires 104 extend to a second side of wire cutter 124. With the incoming wires 104 advanced into cutting position 138, wire cutter 124 may cut the incoming wires 104 to produce four corresponding straight (or “un-looped”) lengths of wire 106 (e.g., lengths of wire 106a, 106b, 106c and 106d). Wire cutter 124 may, for example, include a guillotine-style blade that is advanced to cut through incoming wires 104. The length of wire 104 advanced into the cutting position 138 may correspond to a desired length of produced looped wire ties (or “looped bale ties”) 108. For example, where a 20 foot looped wire tie 108 is desired and approximately 1 foot of wire is required to form a looped end, the wire 104 advanced into the cutting position 138 may extend approximately 21 feet to the right of wire cutter 124. Once cut, the resulting lengths of wire 106 may drop (e.g., by gravity) (as illustrated by arrow 142) into wire guide 126, which operates to catch and direct the falling lengths of wire 106 to a queuing position 140, just above wire indexer system 128. The lengths of wire 106 may remain in queuing position 140 until they are individually advanced into wire bend and twist system 144, for example, by wire indexer system 128 (as illustrated by arrow 145). Wire guide 126 may, for example, include a y-shaped funnel that directs the falling lengths of wire 106 to queuing position 140. Once a length of wire 106 is advanced by wire indexer system 128 (as illustrated by arrow 145) into a looping position 146, wire bend and twist system 130 may operate to bend and twist the length of wire 106 to form a loop at one end, forming a corresponding looped wire tie 108. Once looped, the resulting looped wire tie 108 may be advanced (or “ejected”), for example, by wire indexer system 128 (as illustrated by arrow 148), into bundling tray 132 of wire tie collection system 116. Here, the looped wire ties 108 may be collected and packaged for transport.

Although, certain embodiments illustrate and describe simultaneous intake and processing of four lengths of wire 106 for the purpose of explanation, embodiments may employ any suitable number of wires 104 to generate a corresponding number of lengths of wire 106 (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or the like). Such lengths of wire 106 may be produced at regular intervals by way of wire advancement and cutting. For example, where 600 looped wire ties 108 are produced per hour (e.g., a looped wire tie 108 every 6 seconds) and four lengths of wire 106 are generated simultaneously, four lengths of wire 106 may be advanced and cut about every 24 seconds. Continuing with the above example, each incoming wire 104 may be advanced at a rate of about 21 feet per 24 seconds (e.g., at about 0.88 feet/second) to synchronize with the desired rate of generation of lengths of wire 106 and looped wire ties 108. As described here, incoming wires 104 may be pre-sized, treated, and coated.

In some embodiments, wire indexer system 128 includes an indexer wheel 150 that is operable to capture a length of wire 106, feed the length of wire 106 to the bend and twist system 144 for looping to create a looped wire tie 108 therefrom, and advance the looped wire tie 108 to wire tie collection system 116. For example, indexer wheel 150 may include a disc-shaped member oriented in a vertical plane and having four index notches disposed evenly about its perimeter (e.g., a disc with notches at a 90 degree spacing about its perimeter). During the wire tie looping process, the indexer wheel 150 may be rotated about an index axis 154 oriented generally parallel to the lengths of wire 106, to capture, advance, and eject lengths of wire 106 and corresponding looped wire ties 108. For example, indexer wheel 150 may be oriented vertically, with its four notches oriented at 12, 3, 6 and 9 o'clock positions, respectively. One of the lengths of wire 106 held in queuing position 140 may be directed by wire guide 126 and gravity, for example, into the first notch oriented at 12 o'clock (or “top” or “load”) position. With the length of wire 106 captured within the first notch, an index motor 152 may drive rotation of indexer wheel 150 by 90 degrees about index axis 154 (e.g., in the direction of arrow 156), to rotate the first notch, and the length of wire 106 captured within the first notch, to the 9 o'clock (or “side” “or “loop”) position. With the indexer wheel 150 in the side position, the length of wire 106 may be manipulated by wire bend and twist system 130 to form a corresponding looped wire tie 108. The length of wire 106 may, for example, be bent and twisted by wire bend and twist system 130 (as described here) to form a loop in the end of the length of wire 106 (a looped end 160) to form a corresponding looped wire tie 108. With the newly formed looped wire tie 108 engaged with the first notch of indexer wheel 150, index motor 152 may drive rotation of indexer wheel 150 by an additional 90 degrees (e.g., 90 degrees counter-clockwise, in the direction of arrow 156 about an index axis 154) to rotate the first notch, and the looped wire tie 108 captured within the first notch, to the 6 o'clock (or “down” or “eject”) position, where, for example, gravity causes the looped wire tie 108 to fall downward (in the direction of arrow 148) into wire tie collection system 116 (e.g., bundling tray 132 that collects and holds multiple looped wire ties 108). In some instances, multiple looped wire ties 108 are bundled for packaging and transport. For example, where it is desirable to generate wire tie bundles that include sets of 25 looped wire ties 108, after 25 looped wire ties 108 are collected in wire tie collection system 116, the 25 looped wire ties 108 collected may be bundled (e.g., wrapped in cellophane or the like) and the bundled set of 25 looped wire ties 108 further bent/coiled along their length into a large circular loop that is deposited in a container for transport.

In some embodiments, wire indexer system 128 operates to capture, advance, and eject lengths of wire 106 and generated looped wire ties 108 sequentially and simultaneously. For example, while the first notch of indexer wheel 150 oriented in the 9 o'clock (or “side” or “loop”) position, a second notch is oriented at the 12 o'clock (or “top” or “load”) position to receive a second length of wire 106 therein. As indexer wheel 150 is rotated to move the first notch to the 6 o'clock (or “down” or “eject”) position to eject the first looped wire tie 108, the second notch rotates into the 9 o'clock (or “side” “or “loop”) position, to deliver the second length of wire 106 to wire bend and twist system 130 for bending and twisting to form a corresponding second looped wire tie 108, while a third length of wire 106 is received in a third notch oriented at the 12 o'clock (or “top” or “load”) position. Subsequent rotation of indexer wheel 150 moves the second notch to the 6 o'clock (or “down” or “eject”) position to eject the second looped wire tie 108, the third notch rotates into the 9 o'clock (or “side” “or “loop”) position to feed the length of wire 106 to wire bend and twist system 130 for bending and twisting to form a corresponding third looped wire tie 108. Such a process may continue iteratively to form any number of looped wire ties 108.

In some embodiments, bend and twist system 144 is operable to generate a looped end 160 on a length of wire 106 to form a looped wire tie 108. For example, bend and twist system 144 may bend (or “fold”) an end of a length of wire 106 back on itself, and subsequently twist the bent end about a body portion proximate the bend in the length of wire 106 to form a looped end on the length of wire 106 to form a looped wire tie 108.

FIGS. 2A-4D illustrate various views of components of wire tie looping system 102, including components of bend and twist system 144, in accordance with one or more embodiments. FIGS. 2A-2C illustrate perspective and end views of the relative positioning of a twist cylinder 200, a bend cylinder 202, and a twist cylinder position sensing system 204, including an edge position sensor (or “edge sensor”) 206 and an edge position sensor mount 208 operable to fix a position of edge position sensor 206 relative to twist cylinder 200. FIGS. 3A-3D illustrate perspective, end and top views of components of wire tie looping system 102, similar to those of FIGS. 2A-2C, but with edge position sensor mount 208 not shown for purpose of enhanced visualization of components. FIGS. 4A-4D illustrate perspective and end views of bend cylinder 202 (and a twist peg of twist cylinder 200) to illustrate aspects of bending of a length of wire 106 by bend cylinder 202 (about the twist peg of twist cylinder 200).

Referring to FIGS. 2A-3D, twist cylinder 200 includes an elongated cylindrical body 210 having a cylindrical portion 212 and a semicylindrical portion 214 defined by a cylindrical face portion 216 and a planar face portion 218. Twist cylinder 200 is operable to rotate about a twist axis 220 that is, for example, coincident with the longitudinal axis of elongated cylindrical body 210. During a bend and twist operation, twist axis 220 may, for example, be generally parallel to a length of wire 106 fed to bend and twist system 144 for end looping. Twist cylinder 200 further includes a cylindrical twist member (or “peg” or “looping peg”) 222 extending from and transverse to planar face portion 218. Further, during a bend and twist operation, a length of wire 106 may be bent about twist member 222 by rotation of bend cylinder 202 about a bend axis 224 that is coincident with a longitudinal axis of twist member 222 and transverse to twist axis 220. With the length of wire 106 bent about twist member 222, twist cylinder 200 may be rotated about twist axis 220 to twist the bent end of the length of wire 106 to form a looped end on the length of wire 106 and, thereby, form a corresponding looped wire tie 108.

Referring to FIGS. 2A-2C and 4A-D, bend cylinder 202 includes an elongated cylindrical body 230 having an end defined by a planar face portion 232. Bend cylinder 202 is operable to rotate about bend axis 224 that is, for example, coincident with the longitudinal axis of twist member 222. During a bend and twist operation, bend axis 224 may, for example, be generally perpendicular to a length of wire 106 fed to bend and twist system 144 for end looping. Bend cylinder 202 further includes a cylindrical bend member (or “peg” or “bending peg”) 234 extending from and transverse to planar face portion 232. During a bend and twist operation, bend cylinder 202 may be rotated about bend axis 224 to cause bend member 234 to engage and bend a length of wire 106 about twist member 222. For example, referring to FIGS. 4A and 4B, a length of wire 106 may be lowered into position (in the direction of arrow 236) to be disposed atop twist member 222 (e.g., adjacent planar face portion 218), bend cylinder 202 may be advanced along bend axis 224 toward planar face portion 218 of twist cylinder 200 (in the direction of arrow 238) to capture length of wire 106 between planar face portion 232 of bend cylinder 202 and planar face portion 218 of twist cylinder 200 (e.g., with a distal end of twist member 222 disposed in a recess of planar face portion 232 of bend cylinder 202). Bend cylinder 202 may be rotated about bend axis 224 (as illustrated by arrows 240 and 242 of FIGS. 4A-4D) to cause bend member 234 to engage and bend of a length of wire 106 about the twist member 222, such that a first (“end”) portion 244 of length of wire 106 initially disposed on a first side of twist member 222 is wrapped around twist member 222 such that it is disposed adjacent a second (“body”) portion 246 of length of wire 106 disposed on a second/opposite side of twist member 222. As described, with the length of wire 106 bent about twist member 222, twist cylinder 200 may be rotated about twist axis 220 to twist the bent end portion 244 of the length of wire 106 about the second (“body”) portion 246 of the length of wire 106 to form a looped end on the length of wire 106 and, thereby, form a corresponding looped wire tie 108.

In some embodiments, a bend and twist (or “looping”) operation includes advancing planar face portion 218 of twist cylinder 200 into a desired orientation to facilitate bending of a length of wire 106 about twist member 222. For example, it may be desirable to have planar face portion 218 oriented transverse (e.g., perpendicular) to bend axis 224 to facilitate a smooth and complete bend of a length of wire 106 about twist member 222. If, for example, planar face portion 218 is not oriented transverse to bend axis 224, then, as bend cylinder 202 rotates about bend axis 224, the distance between the tip of twist member 222 and planar face portion 218 may vary, which, if too small, may lead to physical contact therebetween, or, if too large, may create a large enough gap between the tip of twist member 222 and planar face portion 218 to allow the length of wire 106 to slip off of twist member 222. Thus, for example, where bend axis 224 is oriented horizontally, it may be desirable to orient planar face portion 218 of twist cylinder 200 in a vertical orientation, at least during a bend portion of a bend and twist (or “looping”) operation.

In some embodiments, twist cylinder position sensing system 204 is operable to detect the orientation of twist cylinder 200. This may, for example, enable accurate determination of the orientation of twist cylinder 200, which can, in turn, be used as a basis for precise movement of twist cylinder 200, such as movements to orient planar face portion 218 of twist cylinder 200 vertically. Referring to FIGS. 2A-3D, twist cylinder position sensing system 204 includes an edge position sensor 206 suspended relative to twist cylinder 200 by way of an edge position sensor mount 208. In FIGS. 2C and 3C, twist cylinder 200 is positioned in a desired orientation, with planar face portion 218 oriented vertically (as illustrated by plane 250). Further, edge position sensor 206 is laterally and angularly offset from vertical plane 250. Such an angular and lateral offset may provide for detection of the location of an edge 252 defined by an intersection of the cylindrical face portion 216 and the planar face portion 218, while allowing a length of wire 106 to pass vertically (e.g., as illustrated by arrow 236) into a looping position comprising the length of wire 106 adjacent vertically oriented planar face portion 218. As described, in some embodiments, during rotation of twist cylinder 200, a proximity signal output by edge sensor 206 is monitored to determine when twist cylinder 200 is at a first angular position (e.g., “home” angular position where edge 252 is aligned with edge sensor 206), and where the first angular position is offset by a given angle from the desired orientation (e.g., with planar face portion 218 oriented 15 degrees counter-clockwise from vertical), rotate twist cylinder 200 about twist axis 220 by the first angular offset (e.g., 15 degrees clockwise) to orient twist cylinder 200 to the desired orientation (e.g., with planar face portion 218 oriented vertical). Such a homing routine may be conducted regularly (e.g., after each looping operation or after a given number of looping operations, such as every second, third, fourth, or fifth looping operation or the like), to provide accurate and precise orienting of twist cylinder 200 and its planar face portion 218 for the associated bend and twist operations. In the illustrated embodiment, position sensor mount 208 includes a vertically oriented face 253 that is generally aligned with vertical plane 250 and the vertically oriented planar face portion 218. Face 253 may, for example, be aligned with a guide element of wire guide 126. Such a face 253 may serve as a guide that helps to direct length of wire 106 into queuing position 140 and to looping position 146.

In some embodiments, edge sensor 206 is a proximity sensor capable of detecting the presence of nearby objects without physical contact between them. For example, edge sensor 206 may be an inductive-type proximity sensor that is operable to detect the presence of nearby metals, and output a signal (e.g., a direct current (DC) voltage) that is indicative of the presence of nearby metals. The voltage of the signal may, for example, be relatively high when metals are nearby and relatively low when metals are farther away. In some embodiments, as edge 252 passes by edge sensor 206, a change in the voltage of the signal may indicate that edge 252 is nearby (or “aligned”) with edge sensor 206, and it can be determined that twist cylinder 200 is oriented with its edge 252 aligned with edge sensor 206. For example, where twist cylinder 200 is rotating clockwise, as edge 252 passes in front of edge sensor 206 there may be a sharp, detectable increase in the voltage of the signal (e.g., to a level above a threshold voltage), and it may be determined that that twist cylinder 200 is oriented with its edge 252 aligned with by edge sensor 206 at the moment of the increase in the voltage (e.g., to a level above the threshold voltage). Similarly, where twist cylinder 200 is rotating counterclockwise, as edge 252 passes in front of edge sensor 206 there may be a sharp, detectable decrease in the voltage of the signal (e.g., to a level below a threshold voltage), and it may be determined that that twist cylinder 200 is oriented with its edge 252 aligned with by edge sensor 206 at the at the moment of the decrease in the voltage (e.g., to a level below the threshold voltage). This orientation may be used as a “home” position and subsequent movements may be based on angular offsets from the home position.

FIG. 5 illustrates aspects of bend and twist system 144 of wire tie looping system 102, including positioning of edge position sensor 206 relative to twist cylinder 20, in accordance with one or more embodiments. In the illustrated embodiment, edge sensor 206 is oriented at an angle (θ) (e.g., 45 degrees) relative to vertical, laterally offset by a distance (D) (e.g., 1-25 mm) from the vertically oriented face portion 218 (or twist axis 220), and vertically offset a distance (H) (e.g., 25-75 mm) from the vertically oriented face portion 218 (or twist axis 220), such that edge sensor 206 is positioned at a sensing distance (S) (e.g., 1-25 mm) from cylindrical portion 212 when present. In some embodiments, sensing distance (S) may be a minimal distance that places edge position sensor 206 as close as reasonably possible to the path of cylindrical face portion 216 without causing a significant risk of collision between edge position sensor 206 and cylindrical face portion 216, or another portion of twist cylinder 200. The location and orientation of edge sensor 206 may be defined by orientation and location of the center of tip 256 of a sensing elements of edge sensor 206. In the illustrated embodiment, edge sensor 206 is positioned such that detection beam 262 of edge sensor 206 is directed toward a point on cylindrical face portion 216 slightly counterclockwise from vertical (e.g., where it intersects cylindrical face portion 216 just to the left of the vertical plane passing through twist axis 220 and a vertically oriented planar face portion 218) and does not pass through twist axis 220. Embodiments may employ any suitable positioning of edge sensor 206. For example, edge sensor 206 may be positioned such that detection beam 262 of edge sensor 206 is directed to pass through twist axis 220. Referring to the illustrated embodiment, edge sensor 206 may, for example, be positioned to left and down/lower from its illustrated position, such that detection beam 262 of edge sensor 206 is directed to pass through twist axis 220.

FIGS. 6A-6G illustrate operational aspects of bend and twist system 144 of wire tie looping system 102, including rotation and orientation of twist cylinder 200, in accordance with one or more embodiments. Referring to FIG. 6A, during a homing operation, twist cylinder 200 may be rotated clockwise (as indicated by arrow 260) while a proximity sensor signal (e.g., a voltage) generated by edge sensor 206 and the corresponding orientation of twist cylinder 200 are monitored. The voltage may, for example, be relatively low as a detection beam 262 of edge sensor 206 is generally directed to a location where the cylindrical face portion 216 is not yet present. Referring to FIG. 6B, as a result of continued clockwise rotation (as indicated by arrow 264) edge 252 may align with detection beam 262 of edge sensor 206 and, as a result, the voltage of proximity sensor signal may, for example, increase from below to above a threshold voltage, and the orientation of twist cylinder 200 at the time of the sensed transition may be determined as the home orientation associated with a given angle (α) relative to vertical. The angle (α) may for example be determined based on prior testing that includes measuring the angle (α) of planar face portion 218 relative to vertical when the voltage of the proximity sensor signal increases past the threshold voltage. For example, where prior testing and measurement reveals that planar face portion 218 is oriented at angle (α) of 15 degrees counterclockwise when the voltage of the proximity sensor signal increases from below, to above the threshold voltage, in response to detecting the voltage of the proximity sensor signal increases from below, to above the threshold voltage the associated orientation of twist cylinder 200 may be determined to be 15 degrees counterclockwise (or at an angular position of-15 degrees). With the current orientation determined based on the proximity sensor signal, twist cylinder 200 may be moved relative to the determined orientation, into a desired orientation. For example, in response to determining that twist cylinder 200 is oriented 15 degrees counterclockwise (or-15 degrees) and that it is desired for twist cylinder 200 to be oriented at 0 degrees (e.g., where planar face portion 218 is oriented vertically), twist cylinder 200 may be rotated clockwise by 15 degrees (as indicated by arrow 266 and angle (α)), to orient twist cylinder 200 at 0 degrees (e.g., with planar face portion 218 oriented vertically). Such a homing routine may ensure the accuracy and precision of the orientation of twist cylinder 200 and planar face portion 218. Continuing with the example and referring to FIG. 6D, with twist cylinder 200 at 0 degrees (e.g., with planar face portion 218 oriented vertically), a length of wire 106 may be lowered into position (in the direction of arrow 268) and be disposed atop twist member 222 (e.g., adjacent planar face portion 218). Referring to FIG. 6E, bend cylinder 202 may be advanced along bend axis 224 toward planar face portion 218 of twist cylinder 200 (in the direction of arrow 270) to capture length of wire 106 between planar face portion 232 of bend cylinder 202 and planar face portion 218 of twist cylinder 200 (e.g., with a distal end of twist member 222 disposed in a recess of planar face portion 232 of bend cylinder 202), and bend cylinder 202 may then be rotated about bend axis 224 to cause bend member 234 to engage and bend a length of wire 106 about the twist member 222 (as illustrated by arrow 272), such that a first (“end”) portion 244 of length of wire 106 initially disposed on a first side of twist member 222 is wrapped around twist member 222 such that it is disposed adjacent a second (“body”) portion 246 of length of wire 106, which is disposed on a second/opposite side of twist member 222 (e.g., as illustrated and described with regard to FIGS. 4A-4D). Referring to FIG. 6F, with the length of wire 106 bent around twist member 222, bend cylinder 202 may be retracted along bend axis 224 away from planar face portion 218 of twist cylinder 200 (in a direction opposite that of arrow 270), and twist cylinder 200 may be rotated about twist axis 220 (as illustrated by arrows 274) to twist the bent end portion 244 of the length of wire 106 around the second (“body”) portion 246 of the length of wire 106 to form a looped end on the length of wire 106 and, thereby, form a corresponding looped wire tie 108. Referring to FIG. 6G, the looped wire tie 108 may be subsequently ejected (e.g., by way of indexer system 128) (as illustrated by arrows 276) and, for example, be collected by way of wire tie collection system 116. In such an embodiment, a subsequent looping operation may be conducted, for example, repeating the homing, bending, and twisting operations described with regard to FIGS. 6A-6G, to produce a next looped wire tie 108, and so forth.

Referring to FIG. 1, in some embodiments rotation of twist cylinder 200 is driven by a twist motor 190, rotation of bend cylinder 202 is driven by a bend motor 192, translation of bend cylinder 202 is driven by a bend slide motor 194, rotation of indexer wheel 150 is driven by an index motor 152, and advancement of wire cutter 124 is driven by a cutter motor 196. In some embodiments, wire tie looping system 102 includes a controller 188 (or other wire tie control system) operable to control operation of various components of wire tie looping system 102. For example, controller 188 may provide twist, bend, slide, index and cut control (or “drive”) signals that are operable to drive movement (e.g., rotation or translation) of respective ones of twist motor 190, bend motor 192, bend slide motor 194, index motor 152, and cutter motor 196. Controller 188 may include a computer system that is the same or similar to computer system 1000 described with regard to FIG. 8.

In the illustrated embodiment, twist axis 220 intersects and is transverse to bend axis 224, twist axis 220 is parallel to index axis 154, twist axis 220 is laterally offset from index axis 154. Additionally, index axis 154 is transverse to bend axis 224, and twist axis 220, bend axis 224 and index axis 154 are co-planar, being located in the same horizontal plane.

FIG. 7 is a flowchart diagram that illustrates a method of producing wire ties 700 in accordance with one or more embodiments. Some or all of the procedural elements of method 700 may be performed, for example, by wire tie looping system 102 or by another entity or person.

Method 700 may include orienting a twist member (block 702). In some embodiments, orienting a twist member includes positioning a twist cylinder into a desired angular position for executing a bend operation. This may include driving rotation of a twist motor to drive rotation of a twist cylinder about a twist axis, monitoring (during rotation of the twist cylinder) a proximity signal output by an edge sensor, determining (based on the monitoring of the proximity signal) that the twist cylinder is at a first angular position, and driving (in response to determining that the twist cylinder is in the first angular position) rotation of the twist motor to drive rotation of the twist cylinder about the twist axis by a given angular offset to rotate the twist cylinder to a second, desired angular position. Such orienting a twist member may, for example, be the same or similar to that described with regard to FIGS. 6A-6C. For example, orienting a twist member may include controller 188 conducting a twist cylinder homing operation that includes, while monitoring the voltage of the proximity sensor signal provided by edge sensor 206, providing a drive signal to twist motor 192 to drive rotation of twist cylinder 200 about twist axis 220 and, in response to detecting the proximity sensor signal rising above (or falling below) a threshold level, determining that twist cylinder 200 is in a home position that includes edge 252 of twist cylinder 200 aligned with by edge sensor 206 (e.g., with planar face portion 218 is oriented at angle (α) of 15 degrees counterclockwise). Where the home position is known to be angularly offset counterclockwise by the given angle (α) from a desired orientation that includes planar face portion 218 oriented vertically, the orienting further includes providing a drive signal to twist motor 190 to drive further rotation of twist cylinder 200 by 15 degrees clockwise about twist axis 220, to rotate twist cylinder 200 into the desired vertical orientation.

Method 700 may include loading a length of wire (block 704). In some embodiments, loading a length of wire includes positioning a length of wire proximate a twist member of a twist cylinder oriented in a desired angular position for executing a bend operation. This may include driving, in response to rotation of the twist cylinder to the second angular position, rotation of an index motor to drive rotation of an index wheel about an index axis to deposit a length of wire into a looping position that includes the length of wire oriented parallel to the twist axis, adjacent a planar face portion of the twist cylinder and a looping peg of the twist cylinder such that an end of the length of wire extends to a first side of the looping peg and a central portion of the length of wire extends to a second side of the looping peg. Such loading of a length of wire may, for example, be the same or similar to that described with regard to advancement of a length of wire (in the direction of arrow 268) as described with regard to FIG. 6D. For example, loading a length of wire may include controller 188 conducting a load operation that includes providing a drive signal to index motor 152 to drive rotation of indexer wheel 150 about the index axis 154 to deposit a length of wire 106 into a looping position where the length of wire 106 is oriented parallel to the twist axis 220, adjacent planar face portion 218 of twist cylinder 200, and adjacent the twist member 222 of twist cylinder 200 such that such that a first (“end”) portion of 244 of the length of wire 106 extends on a first side of twist member 222 and a second (“body”) portion 246 of the length of wire 106 extends on a second/opposite side of twist member 222.

Method 700 may include bending a length of wire (block 706). In some embodiments, bending a length of wire includes bending a length of wire positioned proximate a twist member. This may include driving, in response to depositing the length of wire into the looping position, a bend slide motor to drive translation of a bend cylinder along a bend axis toward a planar face portion of the twist cylinder to move a bending peg proximate the length of wire, and driving, in response to moving the bending peg proximate the length of wire, a bend motor to drive rotation of the bend cylinder about the bend axis to cause the bending peg of the bend cylinder to bend an end of the length of wire about the looping peg of the twist cylinder such that the end of the length of wire wraps around the looping peg to extend to the second side of the looping peg and is positioned proximate the central portion of the length of wire. Such bending of a length of wire may, for example, be the same or similar to that described with regard to bending of a length of wire (in the direction of arrow 272) as described with regard to FIG. 6E. For example, bending a length of wire may include controller 188 conducting a bend operation that includes providing a drive signal to bend slide motor 194 to drive, in response to depositing the length of wire 106 into the looping position, translation of the bend cylinder 202 along bend axis 224 toward the planar face portion 218 of twist cylinder 202 to move bend member 234 proximate the length of wire 106, and providing a drive signal to bend motor 192, in response to moving bend member 234 proximate length of wire 106, to drive rotation of bend cylinder 202 about bend axis 224 to cause bend member 234 of bend cylinder 202 to bend first (“end”) portion of 244 of length of wire 106 about twist member 222 of twist cylinder 202 such that the first (“end”) portion of 244 of length of wire 106 wraps around twist member 222 to extend to the second side of twist member 222 and is positioned proximate the second (“body”) portion 246 of the length of wire 106.

Method 700 may include twisting a length of wire (block 708). In some embodiments, twisting a length of wire includes twisting a bent length of wire to form a looped end on the length of wire. This may include driving, in response to bending of the end of the length of wire about the looping peg, the twist motor to drive rotation of the twist cylinder about the twist axis to cause twisting of the end of the length of wire about the central portion of the length of wire to form a looped end on the length of wire. Such twisting a length of wire may, for example, be the same or similar to that described with regard to twisting of a length of wire (in the direction of arrows 274) as described with regard to FIG. 6F. For example, twisting a length of wire may include controller 188 conducting a twist operation that includes providing a drive signal to twist motor 190 to drive, in response to bending of end of the length of wire 106 about the looping peg 222, rotation of twist cylinder 200 about twist axis 220 to cause twisting of the first (“end”) portion of 244 of length of wire 106 about the second (“body”) portion 246 of the length of wire 106 to form a looped end 160 on the length of wire 106, to form a looped wire tie 108.

Method 700 may include ejecting a length of wire (block 710). In some embodiments, ejecting a length of wire includes ejecting a looped wire tie that is a length of wire having a looped end. This may include driving, in response to forming of the looped end on the length of wire, rotation of the index motor to drive rotation of the index wheel about the index axis to eject the length of wire out of the looping position. Such ejection of a length of wire may, for example, be the same or similar to that described with regard to ejection of a length of wire (in the direction of arrows 274) as described with regard to FIG. 6G. For example, ejecting a length of wire may include controller 188 conducting an eject operation that includes providing a drive signal to index motor 152 to drive, in response to forming of the looped end 160 on the length of wire 106, rotation of indexer wheel 150 about the index axis 154 to eject the length of wire 106 (looped wire tie 108) out of the looping position and into a bundling tray 132 of wire tie collection system 116 that is operable to collect looped wire ties 108.

In some embodiments, some or all of the operations of method 700 are repeated to produce multiple looped wire ties 108. For example, method 700 may further include, after ejecting a length of wire (block 710), returning to orienting a twist member (block 702) (as illustrated by the dashed line) to repeat the above-described processes to produce a next looped wire tie 108, and so forth.

In some embodiments, the described wire tie looping process is one of multiple operations. For example, a wire production process may be performed to produce incoming wire 104, and the described wire tie looping process may be performed on incoming wire 104 to produce lopped wire ties 108, which may then be packaged and transported, for example, to a distributor or customer. In some embodiments, the wire production process includes providing multiple rolls of raw wire (e.g., four rolls of wire rod), sizing the raw wire to generate gauged wire (e.g., drawing four elements of wire rod from the four rolls of wire rod and passing the four elements of wire rod through a respective roller to generate four wire elements of a desired gauge), annealing the gauged wire to generate annealed wire (e.g., passing the four wire elements of a desired gauge through a furnace to generate four annealed wire elements), quenching the annealed wire to generate quenched wire (e.g., passing the four annealed wire elements through a quenching bath to generate four quenched wire elements), and coating the quenched wire to generate coated wire (e.g., passing the four quenched wire elements through a cleaning and painting process to generate coated wire). In some embodiments, the wire production process is conducted on continuous strands of wire pulled from multiple rolls of raw wire, with the resulting strands of heat-treated and coated wire provided as incoming wire 104 for the described wire tie looping process.

FIG. 8 is a diagram that illustrates an example computer system (or “system”) 1000 in accordance with one or more embodiments. System 1000 may include a memory 1004, a processor 1006 and an input/output (I/O) interface 1008. Memory 1004 may include non-volatile memory (e.g., flash memory, read-only memory (ROM), programmable read-only memory (PROM), erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM)), volatile memory (e.g., random access memory (RAM), static random access memory (SRAM), synchronous dynamic RAM (SDRAM)), or bulk storage memory (e.g., CD-ROM or DVD-ROM, hard drives). Memory 1004 may include a non-transitory computer-readable storage medium having program instructions 1010 stored on the medium. Program instructions 1010 may include, for example, program modules 1012 that are executable by a computer processor (e.g., processor 1006) to cause the functional operations described, such as those described with regard to controller 188 or method 700.

Processor 1006 may be any suitable processor capable of executing program instructions. Processor 1006 may include one or more processors that carry out program instructions (e.g., the program instructions of program modules 1012) to perform the arithmetical, logical, or input/output operations described. Processor 1006 may include multiple processors that can be grouped into one or more processing cores that each include a group of one or more processors that are used for executing the processing described here, such as the independent parallel processing of partitions (or “sectors”) by different processing cores to generate a simulation of a reservoir. I/O interface 1008 may provide an interface for communication with one or more I/O devices 1014, such as a joystick, a computer mouse, a keyboard, or a display screen (e.g., an electronic display for displaying a graphical user interface (GUI)). I/O devices 1014 may include one or more of the user input devices. I/O devices 1014 may be connected to I/O interface 1008 by way of a wired connection (e.g., an Industrial Ethernet connection) or a wireless connection (e.g., a Wi-Fi connection). I/O interface 1008 may provide an interface for communication with one or more external devices 1016, computer systems, servers or electronic communication networks. In some embodiments, I/O interface 1008 includes an antenna or a transceiver.

Further modifications and alternative embodiments of various aspects of the disclosure will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the embodiments. It is to be understood that the forms of the embodiments shown and described here are to be taken as examples of embodiments. Elements and materials may be substituted for those illustrated and described here, parts and processes may be reversed or omitted, and certain features of the embodiments may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of this description of the embodiments. Changes may be made in the elements described here without departing from the spirit and scope of the embodiments as described in the following claims. Headings used here are for organizational purposes only and are not meant to be used to limit the scope of the description.

It will be appreciated that the processes and methods described here are example embodiments of processes and methods that may be employed in accordance with the techniques described here. The processes and methods may be modified to facilitate variations of their implementation and use. The order of the processes and methods and the operations provided may be changed, and various elements may be added, reordered, combined, omitted, modified, and so forth. Portions of the processes and methods may be implemented in software, hardware, or a combination thereof. Some or all of the portions of the processes and methods may be implemented by one or more of the processors/modules/applications described here.

As used throughout this application, the word “may” is used in a permissive sense (meaning having the potential to), rather than the mandatory sense (meaning must). The words “include,” “including,” and “includes” mean including, but not limited to. As used throughout this application, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly indicates otherwise. Thus, for example, reference to “an element” may include a combination of two or more elements. As used throughout this application, the term “or” is used in an inclusive sense, unless indicated otherwise. That is, a description of an element including A or B may refer to the element including one or both of A and B. As used throughout this application, the phrase “based on” does not limit the associated operation to being solely based on a particular item. Thus, for example, processing “based on” data A may include processing based at least in part on data A and based at least in part on data B, unless the content clearly indicates otherwise. As used throughout this application, the term “from” does not limit the associated operation to being directly from. Thus, for example, receiving an item “from” an entity may include receiving an item directly from the entity or indirectly from the entity (e.g., by way of an intermediary entity). Unless specifically stated otherwise, as apparent from the discussion, it is appreciated that throughout this specification discussions utilizing terms such as “processing,” “computing,” “calculating,” “determining,” or the like refer to actions or processes of a specific apparatus, such as a special purpose computer or a similar special purpose electronic processing/computing device. In the context of this specification, a special purpose computer or a similar special purpose electronic processing/computing device is capable of manipulating or transforming signals, typically represented as physical, electronic or magnetic quantities within memories, registers, or other information storage devices, transmission devices, or display devices of the special purpose computer or similar special purpose electronic processing/computing device.

In this patent, to the extent any U.S. patents, U.S. patent applications, or other materials (e.g., articles) have been incorporated by reference, the text of such materials is only incorporated by reference to the extent that no conflict exists between such material and the statements and drawings set forth herein. In the event of such conflict, the text of the present document governs, and terms in this document should not be given a narrower reading in virtue of the way in which those terms are used in other materials incorporated by reference.