VACUUM BASED TENSIONING SYSTEM FOR TUBING IN AN AUTOMATED ASSEMBLY PROCESS

Abstract

 A tensioning system (100) for tubing (102, 206) comprises a vertically arranged vacuum box (106, 216) with a vacuum applied at a bottom section of the vacuum box. Tubing enters and exits the vacuum box at a top section and forms a loop (220) of tubing with in the vacuum box. The vacuum on the tubing provides a consistent tension to tubing exiting the tensioner. The payout speed of the tubing can be controlled based at least in part on the location of the loop of the tubing within the vacuum box. If the loop is too high, the payout speed can be increased and if the loop of tubing is too low the payout speed can be reduced.

Description

RELATED APPLICATIONS

[0001] The current application claims priority to US Provisional Application 63/615,604 filed December 28, 2023 and entitled "Vacuum Based Tensioning System for Tubing in an Automated Assembly Process," the entire contents of which are incorporated herein by reference in their entirety for all purposes.

TECHNICAL FIELD

[0002] The current disclosure relates to a tensioning system for paying out tubing and in particular to a vacuum based tensioning system.

BACKGROUND

[0003] When tubing is used in assembling parts or components, the tubing may be payed out from a roll. In an automated assembly system, a length of tubing may be pulled and subsequently cut from the roll of tubing. The cut piece of tubing may be the desired part or component or may be formed or assembled into the desired part or component. Regardless of the particular assembly process, it is desirable to be able to reliably pull the desired length of tubing.

[0004] Reliably pulling the desired length of tubing can depend upon maintaining a consistent tension on the tubing while pulling and cutting the tube lengths. Tubing typically has some amount of elasticity and as such if the tension is not consistent, the length of the tube can vary.

[0005] Tensioning systems exist that attempt to maintain a consistent tension on the tubing. A dancer arm between the tube roll and the pulling location can help provide a consistent tension to the tubing. However, while existing tensioning systems can provide a consistent tension to tubing, they may be relatively slow in their response. As the operating speeds of the assembly systems increase, existing tensioning systems may not be able to provide a consistent tension required.

[0006] An additional, alternative and / or improved tensioning system is desirable.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

FIG. 1 depicts a vacuum tensioning system;

FIG. 2 depicts a tubing assembly system using a vacuum tensioning system;

FIG. 3 depicts components of the vacuum tensioning system of FIG. 2;

FIG. 4 depicts an implementation of multiple tensioning systems;

FIG. 5 is a method of operating a vacuum tensioning system;

FIG. 6A and 6B depict an assembly of a tubing-based part;

FIG. 7 depicts an tubing assembly portion of the tubing assembly system of FIG. 2;

FIGs. 8-10 depicts details of the tubing assembly portion of FIG. 6; and

FIG. 11 is a method of assembling a tubing product.

DETAILED DESCRIPTION

[0008] In accordance with the present disclosure there is provided a tensioning system for use with tubing, the tensioning system comprising: a payout motor for paying out tubing from a roll of tubing; a vertical vacuum box having a top section and bottom section, the top section of the box having at least one opening through which the tubing can enter and exit the vacuum box, the bottom section of the box having an opening for coupling the vacuum box to a vacuum pump, vacuum pressure in the vacuum box providing a tensioning force to a loop of tubing entering and exiting the vacuum box from the top section of the vacuum box during use; at least one sensor for determining a position of the loop of tubing within the vacuum box; and a controller configured to control a speed of the payout motor based on the position of the loop determined from the at least one sensor.

[0009] In a further embodiment of the tensioning system, the at least one sensor for determining the position of the loop of tubing comprises: an upper sensor arranged towards the top of the vacuum box; and a lower sensor arranged towards the bottom of the vacuum box, wherein the controller is further configured to speed up the payout motor if the position of the loop of tubing is above the upper sensor, and slow down the payout motor if the position of the loop of tubing is below the lower sensor.

[0010] In a further embodiment of the tensioning system, the tensioning system further comprises: an output bearing for directing the tubing exiting the vacuum box towards an assembly process.

[0011] In a further embodiment of the tensioning system, the tensioning system further comprises a pre-tensioning system arranged between the roll of tubing and the vacuum box.

[0012] In a further embodiment of the tensioning system, the pre-tensioning system comprises a dancer arm.

[0013] In a further embodiment of the tensioning system, the pre-tensioning system further comprises a pre-tensioning roller arranged between the dancer arm and the vacuum box, the pre-tensioning roller applying a force to the tubing.

[0014] In a further embodiment of the tensioning system, the pre-tensioning roller is coupled a pre-tensioning motor and wherein the controller is further configured to control a speed of the pre-tensioning motor.

[0015] In accordance with the present disclosure there is further provided a method for tensioning a tubing comprising: applying a vacuum to a bottom section of a vacuum box, a loop of tubing entering and exiting the vacuum box at a top section of the vacuum box, the tubing payed out from a payout roll; determining if a position of the loop of tubing within the vacuum box is above an upper limit, and when it is determined that the position of the loop is above the upper limit increasing a payout speed of the tubing from the payout roll; and; determining if the position of the loop of tubing within the vacuum box is below a lower limit, and when it is determined that the position of the loop is below the lower limit decreasing a payout speed of the tubing from the payout roll.

[0016] In a further embodiment of the method, the method further comprises controlling a speed of a pre-tensioning motor that applies a pre-tensioning force to the tubing before entering the vacuum box.

[0017] In accordance with the present disclosure there is further provided a method of assembling a component comprising a section of tubing, the method comprising: controlling a tension of tubing according to any of the methods above; capturing an end of the tubing from a holding positioning; rotating the captured end of the tubing around a winding spindle; lowering the would tubing on to a holding pallet having a first end holder and a second end holder, wherein: the captured end of the tubing is received in the first end holder; and tubing at the holding position is received in the second end holder; and cutting the tubing at the holding position.

[0018] In a further embodiment of the method, the method further comprises: coupling a component to the tubing end at at least one of the first end holder and the second end holder.

[0019] In accordance with the present disclosure there is further provided an assembly system comprising: a vacuum tensioning system according to any of the above vacuum tensioning systems; and assembly equipment for consuming a portion of the tubing from the vacuum tensioning system.

[0020] In a further embodiment of the assembly system, the assembly system further comprises: one or more additional tensioning systems according to any of the above vacuum tensioning systems.

[0021] In a further embodiment of the assembly system, the assembly equipment comprises equipment for assembling a component comprising a section of tubing comprising: a pull-out gripper for pulling a length of tubing from a holding position; a rotary gripper for capturing an end of tubing from the pull-out gripper and rotating the tubing around a coiling surface to provide a coil of tubing; an actuator for cutting the tubing at the holding position; and a moveable support surface for receiving the coil of tubing, the support surface including a first end support and a second end support for supporting respective first and second ends of the coil of tubing.

[0022] In a further embodiment of the assembly system, the assembly system further comprises: a tube gripper arranged at an insertion location for gripping an end of tubing on a moveable support surface at the insertion location, the tube gripper arranged to move the end of tubing relative to a component being coupled to the tubing.

[0023] A tensioning system is described further herein that uses a vacuum to provide consistent tension to a length of tubing as it is being consumed in a manufacturing process. A loop of tubing hangs in a vacuum box, with the tubing entering from the roll of tubing and exiting towards the manufacturing process. A vacuum is applied towards a bottom of the vacuum box and applies tension to the loop of tubing, and so the tubing exiting towards the manufacturing process. In manufacturing processes, a length of tube may be pulled from a roll of tubing and cut from the roll. Tubing typically has some elasticity and as such the stick-out or positioning of the tubing end after cutting can depend upon the tension on the tube when it was cut. By providing consistent tension on the tube as it is being pulled by the manufacturing process, the end of the cut tubing may be more consistently located. Such consistent locating of the cut ends of the tubing can allow for simpler manufacturing process which may operate at greater speed. Further, as described further herein, the tensioner system relies upon the vacuum to provide the tension and as such does not rely upon moving parts to provide the consistent tension and as such can respond faster to changing loads on the tubing, which can result from uneven pulling, wrapping or cutting.

[0024] The vacuum tensioning system allows accurate and precise locating of tubing ends after cutting in a manufacturing process. Such precise and accurate end locating can enable an efficient manufacturing process. An illustrative manufacturing process enabled by the vacuum tensioner is described further below in which lengths of tubing are cut, coiled and at least one end placed on the cut tubing. With the accurate and precise locating of the tubing provided in part by the vacuum tensioner, the manufacturing process is able to reliably operate at high speed.

[0025] FIG. 1 depicts a vacuum tensioning system. The vacuum tensioning system 100 may be used in various manufacturing process in which tubing is payed out from a roll. The tubing 102 is received on a roll 104. The tubing can be controllably payed out from the roll. For example, a motor (not visible in FIG. 1) may be arranged to control the speed at which the roll 102 rotates. The tubing 102 enters a vacuum box 106. The vacuum box 106 is generally vertically arranged and has an interior volume in which a loop of the tubing can hang. The tubing enters and exits the vacuum box from a top of the vacuum box, while a vacuum is applied at a bottom of the box. The vacuum may be provided by a port 108 or other connection to a vacuum source. The vacuum applies tension to the loop of tubing in the vacuum box. An output bearing, depicted in FIG. 1 as an output roller bearing 110 directs the tubing 112 exiting the vacuum box towards the manufacturing process that is consuming the tubing.

[0026] As the manufacturing process consumes the tubing, a location of the loop of tubing within the vacuum box may change. In particular, if the rate of consumption by the manufacturing process is greater than the rate of payout the location of the loop will move upwards towards the top of the vacuum box. If the consumption rate is less than the payout rate, the location of the tubing will move lower towards the bottom of the vacuum box. In order to provide consistent tension on the tubing as it is payed out, the loop of tubing should remain within an operating window within the vacuum box. That is, the loop should not be too close to the top as the vacuum may not provide sufficient tension to the tubing, and may allow the loop of tubing to exit the vacuum box completely. Similarly, the loop should not be too close to the bottom as the vacuum may provide too much tension to the tubing and possibly suck the tubing towards the vacuum source.

[0027] In order to maintain the loop of tubing within the operating window of the vacuum box, the tensioning system 100 includes at least one sensor to monitor the location of the loop of tubing within the vacuum box. FIG. 1 depicts two sensors 114 and 116 that can detect the presence or absence of the tubing at their respective locations. It will be appreciated that other sensors may be used. For example an imaging sensor may capture the location of the loop within the box if the vacuum box had a transparent portion. Regardless of the specific sensors used, a payout controller 118 uses the sensor information to control a payout speed of the tubing from the roll. For example, if the upper sensor 114 does not detect the presence of the tubing, the payout controller 118 may increase the payout rate of the tubing from the roll. Similarly, if the lower sensor 116 detects the presence of the tubing, the payout controller 118 may decrease the payout rate of the tubing from the roll.

[0028] The tensioning system 100 can maintain the loop of tubing within the operating window of the vacuum box 106 and as such maintain a consistent tension on the tubing as it is consumed by the manufacturing process.

[0029] FIG. 2 depicts a tubing assembly system using a vacuum tensioning system. FIG. 3 depicts components of the vacuum tensioning system of FIG. 2 in isolation. The tubing assembly system 200 comprises automated manufacturing equipment 202 for assembling a part or component using tubing. The particular automated manufacturing equipment 202 depicted in FIG. 2 is described in further detail below with particular reference to FIGs. 6-9. Although specific automated manufacturing equipment 202 is depicted, it will be appreciated that the vacuum tensioner for tubing can be used with various manufacturing processes, whether fully automated, semi-automated, or manual, that consume tubing.

[0030] The tubing for the automated manufacturing equipment 202 is fed by a vacuum tensioner 204. The vacuum tensioner 204 pays out tubing 206 from a roll 208 that is mounted to a support structure 210. A main payout motor 308 of FIG. 3 is coupled to the roll 208 and can be operated by a controller (not depicted in FIG. 2) in order to control the payout rate of the tubing from the roll. The vacuum tensioner includes a pre-tensioning system comprising a dancer arm 212 and a pre-tensioning roller 214. The dancer arm 212 may have a weight on one end opposite a roller that the tubing passes over. The dancer arm can pivot up or down in order to take-up or let out slack in the tubing. The pre-tensioning roller 214 may apply a constant force to the tubing, for example the roller 214 may have some amount of friction that provides tension to the tubing, or the roller 214 may be coupled to a pre-tensioning motor, 314 of FIG. 3, that can control the rotation of the pre-tension roller.

[0031] Although not required, the pre-tensioning system can help smooth the payout of the tubing into a vacuum box 216, which includes a port 218 towards the bottom for applying vacuum pressure to the interior of the vacuum box. The vacuum box is generally vertical and has an interior volume that allows a loop of tubing to hang within it. The depth, which is in to and out of the page of FIG. 2, of the box is based on the size of the tubing and is sufficient to allow the tubing to move freely within the interior of the vacuum box while providing a small gap between the tubing and the walls in order to allow the vacuum to generate a pressure differential sufficient to provide consistent tension on the tubing. The particular depth of the vacuum box may be based on a number of factors including the amount of vacuum applied, the size of the tubing, the elasticity of the tubing, the desired tension on the tubing, etc. The width of the vacuum box is sufficient to allow a loop of the tubing to form within the vacuum box and the height of the vacuum box is sufficient to provide an operating window for the loop location the provides enough slack in the loop to allow differences between the consumption rate of the manufacturing process and the payout rate of the tubing to be smoothed by the excess tubing in the vacuum box.

[0032] In operation a roll of tubing is secured to the payout motor 308 of FIG. 3 and fed around the dancer arm 212 and pre-tensioning roller 214 of the pre-tensioning system and a loop of the tubing 220 is formed within the vacuum box 216. The tubing is depicted as entering exiting the top of the vacuum box, however it is possible that the tubing could enter and/or exit the vacuum box through sides of the vacuum box. Holes, slots or other openings can be arranged on the top and/or sides to allow the tubing to enter and exit the vacuum box. The loop of tubing exits the vacuum box and passes over, around, through, etc. an output bearing depicted as an output roller 222 that directs the tensioned tubing 224 to the manufacturing process 202.

[0033] The tensioning system 204 includes one or more sensors that allow the location of the loop within the vacuum box to be determined. It is not necessary to determine the exact location of the loop tubing within the vacuum box, rather it is only necessary to determine if the loop has passed above an upper location in the vacuum box or passed below a lower location in the vacuum box. Accordingly, while a sensor, such as an imager or range finder, may be used that can determine the height of the loop of tubing within the vacuum box, it is possible to use an upper sensor 226 and a lower sensor 228 as depicted. Each sensor 226, 228 can detect the presence, or absence, of tubing at the sensor. The sensors 226, 228 may each comprise a transmitter and a receiver arranged on opposite sides of the vacuum box as depicted, although other sensor arrangements are possible.

[0034] The loop sensor is, or sensors 226, 228 are, communicatively coupled to a controller, not shown, that uses the sensor information in order to control the rate at which the tubing is payed out from the roll. The controller may use additional information such as information about the manufacturing process including consumption rates of the process, current payout speeds, etc. If the sensor or sensors indicate that the loop of tubing is too close to the top of the box, or the operating window, the controller can increase the payout speed from the roll. The controller may control the speed of both the payout motor 308 and the pre-tensioning motor 314. As the payout rate increases, the location of the loop within the vacuum box will lower. The controller can cause the payout roll to turn a specific amount to provide enough excess tubing to lower the loop of tubing to a desired location within the vacuum box. Additionally or alternatively, the controller may increase the speed at which the motor 208 turns in order to lower the loop. Similarly, if the loop of tubing is too low in the vacuum box, for example the loop of tubing is detected by the lower sensor, the controller can control the main payout motor 308 and/or the pre-tensioner motor 314 in order to slow the payout rate until the location of the loop of tubing is raised within the vacuum box. The controller may stop the payout motor and/or the pre-tensioning motor or possibly reverse either of the motors in order to more quickly increase the height of the loop of tubing within the vacuum box.

[0035] The controller can use the sensor information in order to control the payout motor and/or the pre-tensioning motor, in order to maintain the location of the loop of tubing within an operating window of the vacuum box in which the vacuum provides consistent tension to the tubing exiting the vacuum box. It will be appreciated that the vacuum box is not sealed and air is able to enter the box towards the top of the box. The flow of air and/or the pressure differential across the tubing between the top of the vacuum box and the bottom of the vacuum box can provide enough force to the loop of tubing in order to consistently tension the tubing exiting the vacuum box, even when there are non-consistent forces acting on the tubing as a result of the manufacturing processes.

[0036] FIG. 4 depicts an implementation of multiple tensioning systems. The above has described a vacuum tensioning system for use with tubing. The tensioning system uses a vertically aligned box in order to allow a loop of tubing to fall within the box. In addition to providing tensioning system for tubing that can be used with high-speed manufacturing processes, the tensioning system also advantageously provides a relatively compact foot print.

[0037] Ad depicted in FIG. 4, the compact footprint of the tensioning system can allow multiple tensioning systems to be arranged in the same location. As depicted a support structure, depicted as a vertical plate or wall 402 can mount the components of multiple tensioning systems. A first tensioning system 404 and a second tensioning system 406, depicted in broken lines, can be mounted on the same support structure 402, or possibly separate support structures. The compact footprint can allow the use of multiple tensioning systems to be arranged in a small area. The multiple tensioning systems may be used for various purposes including for example feeding separate manufacturing equipment, feeding the same manufacturing equipment that requires more than one tubing source, using different tubing in the same manufacturing process, providing redundancy, and/or providing a stand-by tensioning system to allow quick changes when a roll of tubing runs out.

[0038] FIG. 5 is a method of operating a vacuum tensioning system. The method 500 assumes that the roll of tubing is already mounted to the tensioning system and a loop of the tubing arranged to pass into and out of the vacuum box. A vacuum is applied to the vacuum box (502). Applying the vacuum may simply comprise turning on a vacuum system that operates at a constant speed, or the vacuum may be controlled in order to provide a variable amount of vacuum pressure and / or airflow at the vacuum box. The control of the vacuum source may be performed by a controller or may be a manual process. The tubing is payed out from the roll into the vacuum box (504) and exits from the vacuum box to a manufacturing process. Depending upon the rate at which the tubing is consumed by the manufacturing process and the rate at which it is payed out from the roll, a location of the loop of tubing within the vacuum box will vary. One or more sensors can be used to determine the approximate loop location within the vacuum box. The controller determines if the loop of tubing is above a high point location (506) and if it is (Yes at 506) the payout rate of the tubing is increased (508). As the payout of tubing increases, the location of the loop of the tubing within the vacuum box will descend within the box. If the tubing is not above the high point location (No at 508), the tubing location can be checked to determine if it is below a low point location (510) and if it is (Yes at 510) the payout rate of the tube can be decreased (512). As the payout rate is decreased, and the tubing is consumed by the manufacturing process, the location of the loop within the vacuum box will raise. If the tubing is below the low point location, and so is considered within the operating window, the payout of the tubing (504) can continue, and the tubing from the vacuum box can be consumed by an assembly process (514). It will be appreciated that the payout rate can be further controlled based on other information. For example if the rate of consumption by the assembly process varies in a known and/or consistent manner, the payout rate can be controlled to attempt to more closely match the payout rate to the consumption rate.

[0039] The method 500 depicts the process of checking the location of the loop of tubing as being a sequential process with the high point location being checked first and then the low point location being checked in a looping manner. It will be appreciated that the order may be switched, or they may be checked in parallel to each other. Furthermore, different techniques can be used to implement the method 500 including for example interrupting a normal operation mode if or when the sensor or sensors indicate that the loop location is out of the operating window.

[0040] Other techniques may be used in order to control the tubing payout rate in addition to, or as an alternative to, the use of the upper and lower detections described above. For example, a closed loop style controller, such as a PID (proportional, Integral, and Derivative) controller, may be used to maintain a setpoint of the loop location in the vacuum box. Deviations of the loop location, which may be determined from one or more sensors, from the setpoint may be used as an error value and fed back into the closed loop controller in order to adjust the tubing payout rate to bring the loop location back to the target setpoint.

[0041] The above has described a tensioning system for tubing that can be used with a variety of assembly processes. The vacuum tensioning system can provide consistent tension on tubing in with quickly changing forces applied to the tubing by the manufacturing process. While the consistent tension on the tubing provided by the vacuum tensioner can be useful in a wide variety of applications, one such application is described in further detail below.

[0042] FIG. 6A and 6B depict an assembly of a tubing-based part. A part 604 may be assembled from tubing by wrapping, winding, or coiling a length of the tube 602 and the securing an end 604 to the tubing. In order to the insert the end 604 onto the coil of tubing, the end of the tubing must be located precisely in order to locate the end of the tube and ensure enough of the tubing has been inserted into the end. Previous solutions which did not include a vacuum tensioner as described above often relied upon additional steps in order to successfully locate the location of the end of the tubing since the tension on the tubing was not consistent when cut. Without the consistent tension on the tubing when cut, or otherwise processed, the amount of stick-out can vary enough to require additional processing to arrange the tubing for subsequent assembly steps. By providing consistent tension to the tubing, the amount of stick-out is more tightly controlled and the end of the cut tubing can more reliably be located. As described further below with reference to FIGs. 7 - 10, the vacuum tensioning system enables a high throughput assembly process that can assemble the tubing product 604.

[0043] FIG. 7 depicts a tubing assembly portion of the tubing assembly system of FIG. 2. FIGs. 8 - 10 depicts details of the tubing assembly portion of FIG. 7. The assembly equipment 202 consumes tubing from a vacuum tensioner in order to assembly the product 604 depicted in FIG. 6B. Broadly, the assembly equipment performs two separate operations. The first, depicted generally at 702 is a coiling operation in which a length of tubing from the vacuum tensioner is wound into a coil and placed on a transport pallet. The transport pallet moves the coiled tubing to the next assembly step, depicted generally at 704, which inserts the end on to the coil of tubing. The pallet can move the complete part onto other assembly and/or packaging steps. The pallet may move on a conveyor system, such as a linear motor conveyor. Advantageously, a linear motor conveyor can reliably locate the pallet, and so the coiled tube on the track and as such the transport system can position the coiled tube precisely to insert the ending without requiring repositioning of the coil on the pallet.

[0044] FIG 8 depicts portions of the coiling section of the assembly process and FIG. 9 depicts main components of the coiling process in isolation. The assembly equipment for coiling the tube pulls a length of tubing from the vacuum tensioner and coils the tubing and placing the coil on a transportation pallet. The tubing may enter the equipment from the vacuum tension at a cutting location where each length of tubing is cut by an actuator such as a knife 918, most clearly seen in FIG. 9. The remaining tube 920 sticks out a certain amount, which is generally consistent across multiple operations since the tension on the tubing is consistent as a result of the vacuum tensioner. The tubing sticking out 920 is grabbed by an actuator depicted as gripper 802 which may retract or pull the tubing by moving the gripper which may be attached to a movable platform 804. Since the amount of stick-out of the cut tubing 920 is relative consistent, the gripper can consistently grip and pull the same length of tubing. Once the length of tubing has been pulled, a second rotary gripper 806 can grip the tubing and the pull-out gripper 802 can release the tubing. The rotary gripper806 may rotate the captured end of the tubing around a coiling surface 808. The coiling surface is depicted as four separate portions of a circle around which the tube can be coiled. The four sections can be expanded and retracted relative to each other. In the expanded state, the tubing can be wound about the coiling surface. Once the appropriate length of tubing has been coiled, the wound tubing can be deposited onto a pallet carrier. The coiling surface 808 can be mounted on a vertical actuator 810 that allows the rotating coiling surface to be raised and lowered relative to a pallet. The coiled tubing can be lowered on to a supporting structure of the transportation pallet. The coiling surfaces 808 can then retract relative to each other in order to reduce the overall circumference of the coiling surface 808 and deposit the coiled tubing 812 onto the pallet support 814. When depositing the coiled tubing onto the pallet support the cut end may be placed on a first end support and the second end of the coil can be placed on a second end support and the tubing cut. Once the tubing is cut, the pallet with the coiled tubing with both ends supported by respective end supports can be moved to the next operation on the linear motor track 816and an empty pallet can be moved in to position in order to receive another coiled section of tubing.

[0045] FIG. 10 depicts details of the end insertion of the assembly process. The coiled tube on the pallet can be positioned into a second processing location where one or more grippers 1002 can rotate downward to grip the end of the tubing. With the end of the tubing gripped, the end 1010 can be pressed onto the cut end. The end may be held on a slidable mount that forces the end onto the cut end of the tubing. In order to facilitate sliding of the end on to the tubing, a lubricant can be added to the cut end of the tubing by a dispenser 1014 prior to sliding the end 1010 onto the tubing. Once the end is inserted, the grippers 1002 can release the tubing and the assemble tube coil and end can be moved on the pallet to the next processing step.

[0046] As depicted most clearly in FIG. 10, the pallet supports the two ends of the cut tubing by respective end holders 1012a, 1012b. With the precise movement of the pallet and the reliable positioning of the tubing resulting from the consistent tension from the vacuum tensioner, the ends of the tubing are in a reliable location to allow the end to be effectively inserted onto the tube ends without requiring additional steps or equipment for repositioning the cut tubing ends to a particular location. Accordingly, the assembly equipment depicted in FIGs. 7 - 10 can operate at higher speeds with fewer operations since repositioning of the tubing may not be necessary.

[0047] FIG. 11 is a method of assembling a tubing product. The method 1100 assumes the assembly process is for forming a tubing product depicted in FIG. 6B. The tension on the tubing is controlled using a vacuum tensioner (1102) as described above. An end of the tubing is captured by an actuator at a holding position (1104) and pulled in order to allow the end to be captured and rotated around a winding spindle (1106). Once the tube is coiled it can be lowered onto a holding pallet with the captured end supported in a first end holder and the tubing at the holding position in a second end holder on the pallet (1108). With the coil of tubing in place on the pallet, the end of the tubing at the holding position can be cut (1110) and the pallet moved to a position for inserting an end. The tubing at one of the holding supports can be coupled to a component at an end of the tubing by an actuator. The component may be slid onto or into the end of the tubing by providing relative movement between the component and the end of the tubing. The inserted into, or on to, the tubing (1112). It will be appreciated that additional processing steps may be performed.

[0048] It will be appreciated by one of ordinary skill in the art that the system and components shown in FIGs. 1-11 may include components and/or steps not shown in the drawings. For simplicity and clarity of the illustration, elements in the figures are not necessarily to scale, are only schematic and are non-limiting of the elements structures. It will be apparent to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as defined in the claims.

[0049] Although certain components and steps have been described, it is contemplated that individually described components, as well as steps, may be combined together into fewer components or steps or the steps may be performed sequentially, non-sequentially or concurrently. Further, although described above as occurring in a particular order, one of ordinary skill in the art having regard to the current teachings will appreciate that the particular order of certain steps relative to other steps may be changed. Similarly, individual components or steps may be provided by a plurality of components or steps. One of ordinary skill in the art having regard to the current teachings will appreciate that the components and processes described herein may be provided by various combinations of software, firmware and/or hardware, other than the specific implementations described herein as illustrative examples.

[0050] The techniques of various embodiments may be implemented using software, hardware and/or a combination of software and hardware. Various embodiments are directed to apparatus, e.g. a node which may be used in a communications system or data storage system. Various embodiments are also directed to non-transitory machine, e.g., computer, readable medium, e.g., ROM, RAM, CDs, hard discs, etc., which include machine readable instructions for controlling a machine, e.g., processor to implement one, more or all of the steps of the described method or methods.

[0051] Some embodiments are directed to a computer program product comprising a computer-readable medium comprising code for causing a computer, or multiple computers, to implement various functions, steps, acts and/or operations, e.g. one or more or all of the steps described above. Depending on the embodiment, the computer program product can, and sometimes does, include different code for each step to be performed. Thus, the computer program product may, and sometimes does, include code for each individual step of a method, e.g., a method of operating a communications device, e.g., a wireless terminal or node. The code may be in the form of machine, e.g., computer, executable instructions stored on a computer-readable medium such as a RAM (Random Access Memory), ROM (Read Only Memory) or other type of storage device. In addition to being directed to a computer program product, some embodiments are directed to a processor configured to implement one or more of the various functions, steps, acts and/or operations of one or more methods described above. Accordingly, some embodiments are directed to a processor, e.g., CPU, configured to implement some or all of the steps of the method(s) described herein. The processor may be for use in, e.g., a communications device or other device described in the present application.

[0052] Numerous additional variations on the methods and apparatus of the various embodiments described above will be apparent to those skilled in the art in view of the above description. Such variations are to be considered within the scope of the current disclosure.

Claims

1. A tensioning system (100) for use with tubing, the tensioning system comprising:

a payout motor for paying out tubing (102) from a roll of tubing (104);

a vertical vacuum box (106) having a top section and bottom section, the top section of the box having at least one opening through which the tubing can enter and exit the vacuum box, the bottom section of the box having an opening for coupling the vacuum box to a vacuum pump (108), vacuum pressure in the vacuum box providing a tensioning force to a loop of tubing entering and exiting the vacuum box from the top section of the vacuum box during use;

at least one sensor (114, 116) for determining a position of the loop of tubing within the vacuum box; and

a controller (118) configured to control a speed of the payout motor based on the position of the loop determined from the at least one sensor.

2. The tensioning system of claim 1, wherein the at least one sensor for determining the position of the loop of tubing comprises:

an upper sensor (114) arranged towards the top of the vacuum box; and

a lower sensor (116) arranged towards the bottom of the vacuum box,

wherein the controller is further configured to speed up the payout motor if the position of the loop of tubing is above the upper sensor, and slow down the payout motor if the position of the loop of tubing is below the lower sensor.

3. The tensioning system of claim 1 or 2, further comprising:
an output bearing (110) for directing the tubing exiting the vacuum box towards an assembly process.

4. The tensioning system of any one of claims 1 to 3, further comprising a pre-tensioning system arranged between the roll of tubing and the vacuum box.

5. The tensioning system of claim 4, wherein the pre-tensioning system comprises a dancer arm (212).

6. The tensioning system of claim 5, wherein the pre-tensioning system further comprises a pre-tensioning roller (214) arranged between the dancer arm and the vacuum box, the pre-tensioning roller applying a force to the tubing.

7. The tensioning system of claim 6, wherein the pre-tensioning roller is coupled a pre-tensioning motor (314) and wherein the controller is further configured to control a speed of the pre-tensioning motor.

8. A method (500) for tensioning a tubing comprising:

applying a vacuum (502) to a bottom section of a vacuum box, a loop of tubing entering and exiting the vacuum box at a top section of the vacuum box, the tubing payed out from a payout roll;

determining if a position of the loop of tubing within the vacuum box is above an upper limit (506), and when it is determined that the position of the loop is above the upper limit increasing a payout speed of the tubing from the payout roll (508); and;

determining if the position of the loop of tubing within the vacuum box is below a lower limit (510), and when it is determined that the position of the loop is below the lower limit decreasing a payout speed of the tubing from the payout roll (512).

9. The method of claim 8, further comprising controlling a speed of a pre-tensioning motor that applies a pre-tensioning force to the tubing before entering the vacuum box.

10. A method (1100) of assembling a component comprising a section of tubing, the method comprising:

controlling a tension of tubing (1102) according to a method of claim 8 or 9;

capturing an end of the tubing from a holding positioning (1104);

rotating the captured end of the tubing around a winding spindle (1106);

lowering the would tubing on to a holding pallet (1108) having a first end holder and a second end holder, wherein:

the captured end of the tubing is received in the first end holder; and

tubing at the holding position is received in the second end holder; and

cutting the tubing at the holding position (1110).

11. The method of claim 10, further comprising: coupling a component to the tubing end at at least one of the first end holder and the second end holder (1112).

12. An assembly system (200) comprising:

a vacuum tensioning system (100, 204, 404) according to any one of claims 1 to 7; and

assembly equipment (202) for consuming a portion of the tubing from the vacuum tensioning system.

13. The assembly system of claim 10, further comprising:
one or more additional tensioning systems (100, 204, 404) according to any one of claims 1 to 7.

14. Th assembly system of claim 12 or 13, wherein the assembly equipment comprises equipment (202) for assembling a component comprising a section of tubing comprising:

a pull-out gripper (804) for pulling a length of tubing from a holding position;

a rotary gripper (806) for capturing an end of tubing from the pull-out gripper and rotating the tubing around a coiling surface (808) to provide a coil of tubing (812);

an actuator (918) for cutting the tubing at the holding position; and

a moveable support surface (814) for receiving the coil of tubing, the support surface including a first end support and a second end support for supporting respective first and second ends of the coil of tubing.

15. The assembly system of claim 14, further comprising:
a tube gripper (1002) arranged at an insertion location for gripping an end of tubing on a moveable support surface at the insertion location, the tube gripper arranged to move the end of tubing relative to a component being coupled to the tubing.

Drawing