Digital Creel System

This application claims priority and the benefit of U.S. patent application Ser. No. 17/754,913, filed Apr. 15, 2022, which claims priority to International Patent Application PCT/US2020/056331, International File Date Oct. 19, 2020, which claims priority to U.S. Provisional Application No. 62/916,375, filed Oct. 17, 2019, all of which are incorporated by reference herein in their entirety.

Filamentary materials are commonly utilized as reinforcements for plastic or elastomeric compounds or may themselves be fabricated into integral arrangements as utilized in the textile, hose, and tire industries. These filamentary materials, often referred to as wires, are stored on (wrapped around) spools. In addition, these wires may include, without limitation, fibers in single and multiple strands, flat bands, or tubing produced in long lengths and wound on spools. The various wires may be either natural or synthetic fibers, glass or metal.

Creel systems are utilized to pull the wires from its spools and manipulate them into final form. Creel systems include a plurality of tension controller systems that each have a spindle that permit the spools to rotate as the wire is withdrawn therefrom. These tension controller systems have control arms and rollers that are utilized to provide tension to the wire and may be adjusted via compressed air. Creel systems may further comprise a front organizing stand into which wires are fed from the spools. Front organizing stands often include sub-systems, including a broken/loose wire detector sensor, direction change roller, and a front roller or eyelet board.

Conventional creel systems, however, are not able to measure and automatically adjust wire tension. Rather, conventional creel systems will sound an alarm if a wire is broken/loose wire contacts the conductive sensor rod on the front organizing stand and, if enough broken/loose wires are detected, production will be shut down and the suspect wires addressed. Moreover, conventional creel systems provide little feedback or operational feedback to the operator in real time.

In view of the shortcomings of the conventional creel systems, there is a need for a creel system that measures operating characteristics and displays the same to a user in real time so that the operator may take corrective action, and there is a need for a creel system that automatically controls and optimizes wire tension based on those measured operating characteristics.

Embodiments herein are directed towards a creel system. The creel system may comprise a frame having a plurality of tension controller apparatuses for paying out a wire under tension, each of the tension controller apparatuses having a brake shoe that is engageable with a spindle and a control arm that that is rotatable towards the spindle to move the brake shoe away from the spindle and rotatable away from the spindle to move the brake shoe towards the spindle, an air pressure control system operatively connected to each of the tension controller apparatuses and actuatable to move the brake shoe towards the spindle, the tension control apparatus in communication with at least one apparatus sensor disposed on at least one of the control arms, and a central control system in communication with the air pressure control system, wherein the central control system ascertains a wire tension based on data from the apparatus sensor and the air pressure control system, and wherein the central control system is configured to actuate the air pressure control system in response to the wire tension. In a further embodiment, the creel system further comprises a loose wire detection system in communication with the central control system, the loose wire detection system comprising a wire tree positioned downstream from the frame and including a plurality of vertically spaced sensor bars configured to generate a loose wire detection signal upon contact between a wire and at least one sensor bar. In a further embodiment, the creel system further comprises a tension monitoring system in communication with the central control system, the tension monitoring system comprising a tension monitoring stand positioned downstream from the frame, the tension monitoring stand including at least one tension sensor that receives a wire from the frame, wherein the at least one tension sensor measures the tension of the received wire and generates a tension output signal that is sent to the central control system, wherein the central control system changes the air pressure of the air pressure control system based on the tension output signal. In another further embodiment, the tension monitoring stand comprises a left tension sensor, a center tension sensor, and a right tension sensor, each configured to receive a wire from a left portion of a plane of wires, a wire from a central portion of the plane of wires, and a wire from a right portion of the plane of wires. In a further embodiment, the creel system further comprises a plurality of platforms, wherein a frame having a plurality of tension controller apparatuses for paying out a wire under tension is mounted to each platform, each platform includes a set of wheels that are driven by a motor, the motor of each platform is in communication with the central control system which directs the motor to drive the associated platform to a target position. In another further embodiment, each platform includes a proximity sensor configured to generate a position signal in response to reading at least one feature plate located at a predetermined position on the creel room floor. In another further embodiment, the feature plate comprises a plate body having a plurality of pockets, each pocket is configured to receive one of a steel and nylon pad, an order of steel and nylon pads creating a unique code read by the proximity sensor relating to the position of the platform within the creel room. In another further embodiment, each platform includes at least one photo eye sensor configured to measure a distance between adjacent platforms, wherein the central control system generates a stop motion signal based on a predetermined threshold distance measured by the at least one photo eye sensor. In a further embodiment, the creel system further comprises at least one mechanical travel limit switch in communication with the central control system configured to prevent over-travel of a platform beyond a predetermined location. In a further embodiment, the creel system further comprises at least one pull switch comprising a rope mounted at a front end of a creel row, the pull switch generates a stop signal when the rope is pulled, the stop signal readable by the central control system to cease operation of the creel system. In another further embodiment, the central control system is configured to shut down the creel system based on a stop signal generated from a creel row based and determined position of the creel row in the creel room. In a further embodiment, the creel system further comprises a data storage in communication with the central control system, the data storage configured to storage a log file.

Embodiments herein are directed towards a method of operating a creel system, comprising: with a APC module, controlling the tension of at least one wire by directing an air pressure to at least one tension control apparatus having a brake shoe that is engageable with a spindle and a control arm that that is rotatable towards the spindle to move the brake shoe away from the spindle and rotatable away from the spindle to move the brake shoe towards the spindle; with LWD module, receiving sensor bar data from a plurality of sensor bars disposed on a wire tree a and determining a location on the wire tree where at least one wire contracts a sensor bar of the plurality of sensor bars; and with a Position module, tracking a position of a creel row with respect to a creel room based on location data received from at least one proximity sensor or other sensing technology device associated with each creel row and controlling a motor associated with each creel row to move a creel row to a target position. In a further embodiment, the method further comprises positioning a plurality of feature plates, each plate comprising a plate body having a plurality of pockets, each pocket is configured to receive one of a steel and nylon pad, wherein an order of steel and nylon pads creates a unique code readable by the proximity sensor and used by the position module to determine a location of the creel row. In a further embodiment, the method further comprises with an environment module, receiving environment data from at least one environment sensor and controlling the operation of the creel system based on data received by the at least one environment sensor. In a further embodiment, the method further comprises with a TMS module, receiving wire tension data from at least one tension sensor located between a creel row and a calender and/or; adjusting the air pressure delivered to at least one tension control apparatus based on a measured tension. In a further embodiment, the method further comprises with at least one mechanical travel limit switch in communication with the central control system, generate a limit switch signal and stop the motion of an associated creel row based on the generated limit switch signal. In a further embodiment, the method further comprises with a CAS module, receiving collision data from at least one eye sensor associated with each creel row and determining a distance between a creel row in motion and adjacent creel row, and controlling the motion of a moving creel row based on the determined distance between the creel row in motion and adjacent creel row. In a further embodiment, the method further comprises with at least one pull switch comprising a rope mounted at a front end of a creel row, generating a stop signal when the rope is pulled, and shutting down the operation of the creel system based on the pull switch signal. In another further embodiment, shutting down the creel system is based on both the stop signal generated from a creel row based on a determined position of the associated creel row in the creel room.

The present disclosure is related to creel systems and, more particularly, to digital creel systems that provide real-time optimized feedback, automatic control and increased efficiency.

The embodiments described herein provide a control system for a creel system. The control system is a digital control system integrating multiple creel room processes, which previously functioned independently of each other. In some embodiments, the digital control system integrates together one or more of the following separate functions: (i) servo valve operated air pressure control console (i.e., an APC), (ii) a loose wire detection system (i.e., an LWD), (iii) a shifting platform control (i.e., SPC), (iv) a tension monitoring system (a TMS), and (v) one or more shifting platform safety devices. The digital control system may include one or more sensors for monitoring various parameters of the creel system, such as ambient temperature and/or humidity within the creel room. The digital control system integrates signals associated with the foregoing functions and/or parameters and system controls into a common Industrial Personal Computer (IPC), which may include a touch screen user interface. The digital control system may also allow for user input parameters which are not required for creel room function, but may be desirable for the end user, for example, the size of wire currently being run on the creel system. The IPC may be programmed to include a series of data display screens and control screens navigable by the operator. The IPC may communicate wirelessly or over cables/wires (e.g., Ethernet) and the IPC may include an internal Programmable Logic Controller (PLC) accessible by other customer PLCs. For example, the IPC PLC may be accessible by a calender PLC which sends signals commands to adjust air pressure modifying wire tension in the creel room in addition to monitoring other creel room data. Accordingly, the digital control system permits real-time monitoring of wire characteristics as the wire is un-spooled and fed from the creel system. Other embodiments described herein provide tension control systems utilizable in a creel system that include a sensor that measures the tension in a wire, which the tension control system utilizes to control the rotation of a spool of wire, and thus eliminate or minimize strain or breaking of the wire unspooled therefrom. The digital control system may also be configured to self-adjust based on measured data taken during a creel run, for example, logic may be programmed (e.g., on the IPC) such that a user-specified target tension is maintained throughout the creel run by measuring tension via the TMS, and adjusting the air pressure as required to maintain that tension.

Creel systems provide the mechanism for delivery to a calender or conveyor of cords, typically fabric or steel. The creel system is the first step in the manufacture of textiles or tires because it is important to the quality of the product that the cords be organized and brought together with even tension.

is a side view of an example creel systemthat may incorporate the principles of the present disclosure. The depicted creel systemis just one example creel system that can suitably incorporate the principles of the present disclosure. Indeed, many alternative designs and configurations of the creel systemmay be employed, without departing from the scope of this disclosure.

The creel systemmay be utilized to deliver a plurality of cords, filaments, or wires W, for example, to a calender or conveyor machine (not illustrated). The wires W may comprise various materials, such as, for example, fabric or steel. As illustrated, the creel systemmay include a creel frame, a front organizing stand (FOS), and a main organizing stand (MOS), which are secured on a factory floor or ground G. In some embodiments, the creel frame, the FOS, and the MOSare installed in a dedicated room commonly referred to as a creel room (not illustrated). The creel systemdelivers wire W in direction D towards a calendering operation/process (not illustrated) which processes the wire W into a form utilizable in the final product (i.e., tires). In some applications, the frameis comprised of multiple frame segments, side by side, that each operate (one after the other, or in unison) to deliver the wire downstream to the same calendering process, and in such application each side by side frameis referred to as a creel row.illustrates the creel systemcomprising a single creel row, however, one or more additional creel rows (with the same and/or different configuration than the first creel row) may be implanted in the system. Each of the FOSand MOSprovide organization for wires W in a system. Eventually, each layer of wires W may be oriented in one flat plane for entry into the calender. The FOSand MOSare utilizable to gradually move the wires W into this position before they leave the creel room.

In some embodiments, the creel framesare mounted on one or more platforms P that are movable and carry the creel framesmounted thereon as they are moved relative to the ground G (i.e., of a creel room). The platforms P may have wheels (e.g., that ride along rails embedded in the ground G of the creel room. The platforms P may be motor driven and controllable, for example, by a shifting platform control (SPC) drive system. With multiple creel rows in one system, one creel row can be positioned on the calender centerline while running, and the other creel row (or creel rows) may be positioned off to the side out of the way while being loaded with spools of wire W, such that, when the first creel row completes its run, it may be moved to the side and the next creel row takes its place minimizing calender downtime, and then, the creels rows may be switched again when the second row has finished (and so on). In some embodiments, multiple rows (for example, 2 rows) are positioned in a run position symmetric to the calender center line, in close lateral proximity to one another and, in this example, both creel rows would pay off wire W to the calender in unison; though, in some embodiments a single row is run from a position offset from the calender centerline.

The wires W are provided on reels or spools. The creel framecarries the spoolsand may group or organize them in a series of rows that are vertically spaced (relative to the ground G) from each other. Thus, the wires W are payed-out from the spoolsin a series of rows, where each such row comprises a bundle wires W. The wire W may be fed downstream in direction D to the FOSand the MOS, and then further downstream for calendering.illustrates an example where the FOSincludes a wire tree, which may be configured detect loose wires in each row of wires W as they are fed further downstream. The wire treeincludes a plurality of detector rods or sensors arranged as branches that each correspond (or align) with a respective one of the rows of wires W, and the detector rods/sensors may be integrated within of a loose wire detection system (LWD System) and placed on either or both sides of the creel framefor detecting the presence of a loose or sagging wire W in the wire rows. Also in the illustrated example, the FOSincludes a direction change apparatusfor receiving each row of wire W as they pass through the wire tree. The direction change apparatusmay include a plurality of rollers configured to facilitate change of vertical direction of the wire W and facilitate its downstream delivery to the MOSand any other downstream operations, for example, a downstream calendering operation. In addition, the illustrated example illustrates the FOSincludes an organizing board apparatus, which may be either an “Eyelet Board” consisting of individual ceramic eyelets arranged in a steel plate, and/or a “Roller Board” comprised of a plurality of vertical and horizontal rollers, which define “Openings” through which the individual (or bundles) of wire W may be directed, and which further facilitates directing the wire W downstream in a particular vector depending on the end use application. Together, the direction change apparatusand roller board apparatusre-direct each row of wires W so that they may be received by the MOS. In some examples, the wire tree, the direction change apparatus, and/or the roller board apparatusare separate (stand-alone) components and/or any one of them may be integral with either the creel frame. However, as described below with reference to, the wire tree, the direction change apparatus, and the organizing board apparatusmay be integrated together as a single structure, such as the FOS.

In some examples, elementofmay be a LWD Upright, elementofmay be the Eyelet Board Upright, and elementofmay be the DCR Upright. In some examples, elementofmay be the LWD upright, but elementofmay be the DCR Upright, and elementofmay be the Roller Board Upright. In some examples, the LWD Upright, the Eyelet Board Upright, and the DCR Upright may be positioned in that order, rear to front (i.e., DCR being closest to calender). In other examples, for example, where utilizing rollers for the organizing, the LWD Upright, the-DCR upright, and the roller may be positioned in that order, rear to front (i.e., Roller being closest to calender).

In the illustrated embodiments, the creel frameis a structure comprising a plurality of horizontal members H and vertical members V configured to array the spoolsin a rectangular grid. In other embodiments, however, the creel framemay be differently configured without departing from the present disclosure. Thus, the creel framemay carry the spoolsin various arrangements or organizations, rectangular or otherwise.

Here, for example, the creel framecarries six rows and sixty-seven columns of spools. It will be appreciated, however, that the creel framemay include more or less rows and/or columns of spoolswithout departing from the present disclosure. For example, the creel framemay be taller and include one or more additional rows of spools, or may be shorter and include fewer rows of spools.

Similarly, the creel framemay be longer or shorter and include more or less columns of spools. In embodiments comprising a multitude of columns of spools, the creel framemay include discrete frame sections or segments F. As will be appreciated, providing the creel framein discrete frame sections facilitates shipping and installation of creel framesand provides the end-user the ability to scale creel operations up or down as needed. Here, for example, the creel frameincludes eight frame segments F-Fthat together define an individual creel row, with frame segments Fand Fhaving six rows and six columns of spools, frame segment Fhaving six rows and five columns of spools, and frame segments F-Fhaving six rows and ten columns of spools. Accordingly, the exemplary creel systemofincludes a single creel row of multiple frames supporting a total of four-hundred and two spools. However, the creel systemmay have various other set-ups without departing from the present disclosure.

is a close up view of the front portion of the creel system, according to one or more embodiments of the present disclosure. In particular,illustrates the FOSwhen installed proximate to a front portion (or flanged end pad)′ of the creel frame, such as a mating flanged end pads.illustrates the FOSwithout the creel frame. Here, the FOSincludes a baseon which the wire tree, the direction change apparatus, and the organizing board apparatusare mounted such that they together define an individual unit.

The wire treemay include a plurality of detector rodsextending from the wire treeand configured detect the presence of a loose or sagging wire W. Here, the detector rodsare organized to correspond to each row of wire W output from the creel frame, and are utilizable with a loose wire detection (LWD) system. A sleeve may be provided on any one or more of the detector rodsto thereby cover or insulate at least a portion of each particular detector rod. For example, insulator sleeves may be provided around a portion (or length) of the detector rodsat which they may interact or engage (or be engaged by) the wire W.

The direction change apparatusmay include a plurality of direction changing roller assembliesand the organizing board apparatusmay include a roller board assembly. With this arrangement, the FOSfacilitates re-directing (or re-direction of) the rows of wires W into a new (vertical and/or horizontal) direction. In the illustrated example, the FOSalso includes a frame extensionconfigured to mount or attach to the creel frame, such that the FOSmay be secured to the creel frame. In some examples, a mounting padmay be included on the top of the FOSframe, which may be utilized in some embodiments to support additional overhead structure. This mounting padmay be provided in multiple sizes and configurations.

The creel systemmay further include a control systemfor controlling operation of the various sub-systems of the creel system. The control systemmay comprise a IPC that may be installed at various locations proximate to the creel system, for example, in the creel room, or may instead be provided at another location segregated or spaced away therefrom (e.g., outside of the creel room and/or in a separate control room). As mentioned below, the creel system may further include an air pressure control (APC) systemthat, in the illustrated embodiment, supplies pneumatic power to the creel framevia one or more conduits or hoses; however, other types of power may be utilized instead or in combination with pneumatic power, such as hydraulic power. The APC systemmay be provided at various locations relative to the creel systemand, in one embodiment, is disposed in the creel room, proximate to the creel frame.

The central control systemmay communicate with various sub-systems, sensors, or devices. For example, the central control systemmay monitor and control the APC system, the SPC drive system, the LWD system, a tension monitoring system (TMS), and/or various other systems or sensors and aggregate data about overall operation. The central control systemmay be variously embodied without delineating from the scope of the present disclosure, for example, as an internal Programmable Logic Controller (PLC), personal computer, tablet, smartphone, etc., The central control systemmay include a processorthat may be any of various commercially available processors including, without limitation, a single-core processor, a dual-core processor (or more generally by a multiple-core processor), a digital processor and cooperating math coprocessor, a digital controller, or the like. The central control systemmay include at least one user interfaceand/or display configured to present data related to the operation of creel systemto a user. The user interfacemay also allow a user to input commands into the central control systemfor the monitoring and controlling the various components. In some embodiments, the central control systemmay be located in a creel room and/or at locations proximate to other control equipment (e.g., calender equipment control interfaces). In other embodiments, the central control systemmay be mounted on a portion of the creel systemitself, such as a portion of the frame. In even other embodiments, the central control systemis a remote device capable of operating the creel system from a distance, e.g., the central control systemis a device located in a room other than the creel room, or is a device held by an operator at a facility where the digital creel is installed or remotely.

The central control systemmay also include a data storage. Implementation of the associated data storageis capable of occurring on any mass storage device(s), for example, magnetic storage drives, a hard disk drive, optical storage devices, flash memory devices, or a suitable combination thereof. The associated data storagemay be implemented as a component of the central control system, e.g., resident in memory, or the like. The central control systemmay then save data obtained during operation in a database or log file (event log) within the data storagewhich may be utilized by operators, for example, to ensure efficient operation of the creel system and/or address logged errors, creating reports, etc.

illustrates an alternate MOSthat is utilizable with the creel system, according to one or more embodiments of the present disclosure. In the illustrated example, the MOSis provided on a trackto be movable in a path defined by the track. Here, the MOSincludes a frameand a plurality of wheels. The wheelsare provided on the frameto ride along the track, and thereby constrain movement of the MOSto a pathdefined by the track. Here, the trackextends in a direction that is substantially perpendicular to the direction D, such that the pathtraveled on by the MOSis also substantially perpendicular to direction D as indicated by the arrowheads of the path. It will be appreciated, however, that the trackmay have different geometries for positioning the MOSas may be needed or beneficial in a particular creel setup. For example, the trackmay be at least partially arcuate. Also, a drive system may be provided for moving the MOSalong the track. For example, the MOSmay include an onboard motor assembly configured to drive one or more of the wheels. Thus, the MOSis movable such that it may be selectively aligned with various creel rows. When the MOSis provided as a movable MOS, multiple such MOSsmay be utilized and each provided on the tracks, so that while one MOSis running on center with the calender, another one or more MOSis off to the side being loaded in front of another creel row that is not actively running; then, when the run is complete, the loaded MOScan slide over to the center and be ready to run.

The MOSincludes a pair of guide roller assemblies,. In some embodiments, the guide roller assemblies,include flattening rollers. The guide roller assemblies,are arranged to take the grid pattern of wires coming through the main roller board, and level them into a flat plane when it exits the stand such that a flat plane of wires is provided as input to the calendering process. Thus, at some point, the wires W may be guided to a flat sheet/plane, either by rollers assemblies,integrated in the exemplary MOSof, and/or as a separate roller prior to the calender intake. In some examples, the calender may include a guide roller at the intake to accomplish this. In some examples, the MOSmay include one or more additional roller assemblies in addition to the rollers,, or the MOSmay include a single roller assembly.

The MOS also includes a main organizing board assembly. The main organizing board assemblymay be either a “Main Eyelet Board” comprised of ceramic eyelets in a steel plate, or a “Main Roller Board” comprised of a plurality of vertically oriented rollers and a plurality of horizontally oriented rollers. Accordingly, the wire W may be routed through the main organizing board assembly, under (or over) the first guide roller assembliesand over (or under) the second guide roller assemblies, and then routed out therefrom for further downstream processing (i.e., to the calendar). Depending on which corresponding opening in the front organizing board a given wire W comes from before passing through the main organizing board assembly, the wire W may be re-directed downward by a roller in the main organizing board toward the guide rollersand, or may be re-directed upward by a roller in the main organizing board toward the guide rollersand, or the wire may pass substantially horizontally through the main organizing board toward the guide rollersand(e.g., without being re-directed).

are perspective views of the creel systemof, according to one or more embodiments of the present disclosure. More specifically,is a partial perspective view of a rear end of the creel systemof, whereasis a partial perspective view of a front or output end of the creel systemof. Furthermore,illustrates a partial perspective view of a front or output end of the creel systemwhen partially assembled utilizing an alternate creel frame, according to one or more embodiments.

As illustrated, the creel systemfurther includes a plurality of tension controller apparatusesthat are actuated by the APC system.illustrate the framesupporting a plurality of tension controllers, whereasillustrates just two tension controllersinstalled on the frame(and without spoolsthereon) to illustrate remaining locations at which tension controllers may be installed/mounted and how input air may be supplied to the tension controllers. The tension controller apparatusesare mounted on the creel frameand carry (or hold) the spoolssuch that the wire W may be unwound therefrom for downstream operations and/or processing. The APC systemintegrates with the tension controller apparatusesand may be used to adjust (i.e., increase or decrease) the tension (or speed) on the wires as the spoolsunwind (or rotate). Thus, the APC systemmay cause the tension controller apparatusesto increase friction applied to the spoolsas they unwind, which provides greater resistance to rotation of the spoolsand adds tension to the wire W as it is unwound therefrom. A plurality of intermediate support rollersmay be provided for helping support and/or direct the wire W.

The APC systemmay be provided at various locations about the creel system. For example, the APC systemmay be provided in a console that is mounted to a part of the creel system, such as the creel frame, or, the APC systemmay be differently provided, such as a stand-alone console that is positionable at various locations.

The APCmay be supplied with air regulated to a desired pressure, for example and without limitation, about 10 pounds per square inch (psi) to about 30 psi, including about 30 psi, and including about 25 psi. One or more input linesmay be provided for supplying the input air. In some embodiments, a single input lineis utilized to feed all tension controller apparatusesin the creel system. In other embodiments, a plurality of input linesare utilized, with each such input linesupplying input air to a group of tension controller apparatuses. In some examples, a network of hoses and lines may be routed throughout the frame to supply the various tension controller apparatuses(or groups of tension controllers). For example, the input linemay be connected to (and supply input air to) a plurality of manifolds, where each of the manifoldsis connected to a group of tension controllers. Here, each of the manifoldsis oriented vertically to supply columns of tension controllerson opposing sides of the manifold, where each tension controllerin a particular column is fed with supply air through an individual input lineextending from the manifold.

The APCmay include at least one electronically operated valve (servo valve) associated/controlling at least one tension controller apparatus. In some embodiments, an electrical signal for actuating each servo valve originates from the calender. In some embodiments, the central control systemis configured to actuate each servo valve. In some embodiments, a servo valve is associated/controls a single row of tension controller apparatus, e.g., rowor columnof. By adjusting the output air pressure to each row, the central control systemcan change the tension output of the tension controller apparatus, thereby setting the desired tension of the wires W. In some embodiments, the valves are located in a pneumatic panel enclosure that may be positioned adjacent to the main electrical enclosure.

In some embodiments, the central control systemreceives signals from the calender to set the target air pressure for at least one tension controller apparatus. For example, the calender may send an input signal to the control systemto govern a pilot-operated regulator, in and, based on the value of that input signal, the control systemmay then send an appropriate 4-20 mA signal to the servo valve driving the pilot regulator to a target pressure (e.g., determinable via a pressure to tension curve). Thus, the central control systemreceives and analyzes input signals from the calender and then sends an appropriate electrical signal to the servo valves based on the input signals from the calender.

The central control systemmay also be configured to send a digital signal back to the calender. The digital signal sent back to the calender may be indicative of a plurality of different parameters, such as, for example the set pressure point received, and/or the actual pressure reading from the servo valve. In some embodiments, the digital signal to the calender also includes the actual pressure reading at each creel row, which may be accomplished through the installation of a sensor and a slave PLC at each creel row to send the data to the central control system. The additional data points provide the calender a more accurate representation of the actual realized pressure output based on the input target permitting the calender to be programmed to adjust target pressure based on this downstream feedback. Thus, the control systemis beneficial in that, compared to other systems that utilize just one-way communication between the calender and the air pressure control, the control systemis able to provide digital signal feedback to the calender as well as providing visual feedback to an operator via the user interface.

The control systemmay display information (e.g., the target pressure, actual valve pressure, and actual creel frame pressure) on the user interface. The user interfacemay comprise one or more touchscreen displays that may be provided at various locations, for example, in a creel room. Upper and lower pressure thresholds may be set/stored in the control systemto trigger an alarm state if the pressure deviates outside the acceptable operating limit. The control systemmay be configured to maintain an event log, accessible to the creel room operator via the IPC touchscreen display, and which log may include a record of air pressure alarm state and activity.

are perspective views of an exemplary tension controller apparatusutilizable with the creel systemof, according to one or more embodiments of the present disclosure. As illustrated, the tension controller apparatusincludes a spindlethat carries the spool(), a brake drum, a brake shoe, a diaphragm actuator, a control arm, and a control arm roller. The control armis connected to a pivot shaftand configured to pivot towards and away from the spindle. The control armis also connected to the brake shoesuch that the brake shoeis urged into contact with the brake drumas the control armpivots away from the spindle.

The control arm rolleris connected to the control armand thus pivotable toward and away from the spindle. The control arm rollerextends substantially perpendicular to the control armand substantially parallel with the spindleand the spoolmounted thereon. Here, the control arm rolleris configured as a smooth cylindrical drum over which the wire W may pass, and is dimensioned to be at least as long as an axial length of the spoolto insure the smooth and uniform withdrawal of the wire W from the spoolwithout fouling or substantial deflection. As the wire W is payed out from the spooland passes over the control arm roller, the wire W may be maintained thereon by a pair of lateral flanges,

The diaphragm actuatoris connected to the APC systemand is configured for pneumatic operation as hereinafter described. A pistonextends from a lower end of the diaphragm actuator. The pistonis pivotally fixed to a brake arm, and the brake armis fixed to the pivot shaftsuch that rotation of the brake armrotates the pivot shaftand the control armattached thereto. The diaphragm actuatoris supplied with fluid (e.g., air) at its upper end via a portthat may receive a hose (not illustrated) or other conduit leading from the APC system. As will be appreciated, the portmay be interconnected to a manifold (not illustrated) which services a plurality of tension controller apparatus, and application of the fluid via the APC systemcauses actuation of the pistonrelative to the diaphragm actuator.

In operation, the spoolof wire W is mounted on the spindle, and an end of the wire W is led from the top of the spool, under and around the control arm rollerin a clockwise direction (in) and to a downstream take-up mechanism (not illustrated). Prior to actuating the downstream take-up mechanism, the control armand the control arm rollerwill repose, displaced from the spool. At this time, the brake shoeis urged into engagement with the braking surface of the brake drum, thereby arresting rotation of the brake drumand the spindleconnected thereto, so that the wire W cannot be payed-out from the spoolthat is mounted on the spindle.

As the wire W is taken up, the control armand control arm rollerwill rotate toward the spooland, in so doing, will move the brake shoeaway from the brake drum. Such movement of the brake shoerelative to the brake drumwill reduce the friction force between the brake shoeand the braking surface of the brake drum, thereby permitting rotation of the brake drum, the spindle, and the spoolmounted on the spindle. The force exerted on the control armby the wire W (when engaging the control arm roller) is balanced against the friction between the brake shoeand the braking surface of the brake drumto maintain a constant tension in the wire W. The tension from this force-balance system is, within normal operating limits, independent of the coefficient of friction between the braking surfaces of the brake drumand the brake shoe. In the event the take-up decreases in rate or ceases, the requisite amount of braking is immediately applied so there is never any undesirable slack created in the wire W. Likewise, upon an increase in the rate of take-up, the balance between the braking force and the force applied by the diaphragm actuator, permits a smooth and uniform rate of payout without stretching or jerking of the wire W.

Application of air pressure to the diaphragm actuatorvia the APC systemactuates the pistonextending therefrom, thereby urging the brake armto rotate (counter-clockwise inand clockwise in). Such rotation of the brake armproduces a torsional force about the pivot shaftthat in turn urges the brake shoeinto engagement with the braking surface of the brake drum, thereby producing a desired tension force in the wire W. Since this torsional force must be overcome by the force exerted on the control armby the control arm roller, as produced by the tension in wire W, before the control armrotates (clockwise inand counter-clockwise in), it constitutes a biasing force substantially proportional to the tension in the wire W.

Thus, the tension in the wire W may be adjusted by controlling the air pressure in the diaphragm actuator.is a curve showing the relationship between air pressure and wire tension (i.e., tension of a wire W) in an exemplary tension controller apparatus, according to one or more embodiments. More specifically,is an air pressure verses wire tension operating curve that may be utilized to control the tension in a wire W by adjusting the air pressure supplied to the diaphragm actuator. The operating curve of, however, may vary depending on a number of factors, including but not limited to, the amount of wire W on the spool(i.e., whether the spoolis full or empty), the weight of the spool, the operating speed, and the tension controller apparatusutilized.

The creel systemmay include various sensors and/or detection systems that monitor the wires W and the environmental conditions present in the creel room during operation. For example, the creel systemmay include a wire W detection system that detects broken or loose wires W encountered in each row of wires W (i.e., the “LWD System”). In addition, the creel systemmay include a tension monitoring system (“TMS”)for detecting and measuring tension in the wire W. The creel systemmay include one or more additional sensors for measuring various other aspects of the creel system, including environmental parameters and/or operational parameters associated with the creel system. For example, the creel systemmay include an environmental monitoring system (not illustrated) that includes one or more sensors for measuring conditions of the creel room such as temperature, humidity or moisture, and/or atmospheric pressure. As hereinafter discussed, the control systemmay include software that permits the operator thereof to modify or control various operating parameters of the creel systemin response to the information gathered via the foregoing sensors and/or detection systems. Thus, the operator may fine-tune the tension of the wire W and/or fine-tune the environmental conditions experienced within the creel room.

is a close-up view of the tension controller apparatusofconfigured with limit switches, according to one or more embodiments of the present disclosure. The depicted arrangement of switches is just one example arrangement that can suitably incorporate the principles of the present disclosure. Indeed, many alternative designs and configurations of switches may be employed, without departing from the scope of this disclosure.

Here, a pair of limit switches,is provided on the tension controller apparatus, and a switch bladethat is connected to the brake armof the tension controller apparatus. The limit switches,may comprise various types of limit switch, such as the MICROSWITCH V3-1101-D8 or V7-2B17D8. As the brake armrotates (with the control arm) about the pivot shaft() in response to a change in the tension imparted by the wire W on the control arm roller(), the switch blademay reciprocate between the limit switches,. When the brake armrotates a sufficient degree clockwise or counter-counter-clockwise to the bounds of the normal operating range (e.g., to either the lower or upper bound of the range 0-35°), the switch bladeengages one of the limit switches,thereby indicating that either tension in the wire W is too high or tension in the wire W is too low indicating that the wire W is loose or broken. In other embodiments, a single limit switch (not illustrated) may be utilized to measure whether the tension is too high or whether the wire W is loose or broken. The single limit switch, for example, could be engaged by the brake armas the brake armrotates within normal operating limits (e.g., between the range 0-35°), but become disengaged when the brake armrotates in either direction outside of the normal operating limits. These embodiments, however, do not provide wire W tension measurements between the limits defined by the limit switches,(e.g., between the upper and lower bounds of the range 0-35°).

The limit switches,(or the single limit switch) may comprise various types of switches or sensors, as known in the art. Regardless of type, however, they may be configured to communicate with the user interface() as hereinafter described. When engaged, for example, the limit switches,may supply a signal to actuate a transmitter (not illustrated) provided on the creel frame. The transmitter communicates with a remote receiver (not illustrated) disposed in the user interface, which may in turn produce an audio or video indication (or both) to remotely indicate that the tension in the wire W is too great or that the wire W is too loose or broken. The signal transmitted from the transmitter to the remote receiver may be coded to uniquely identify signals from a plurality of tension controller apparatuses.

Various other devices or tension sensors may be utilized to monitor tension in the wire W instead of, or in addition to, the limit switches,. For example, one or more additional tension sensors may be utilized, such as a TE-24 Check-Line® heavy-duty tension sensor manufactured by Electromatic Equipment Company, Inc. (each, a “TE-24 sensor”). In one such embodiment, one TE-24 sensor is utilized for each of the tension controller apparatuses. In other embodiments, however, one or more TE-24 sensors are utilized to monitor the tension of wires W of a group of tension controller apparatuses(e.g., a row of tension controller apparatuses). Thus, the TE-24 sensor may be utilized to measure a group of wires W, though the TE-24 sensors may locally influence the wire W tension as they are routed through its wheeled measurement mechanism. The TE-24 sensor, or any of them, may be provided at various locations about the creel system, for example, at the front of the creel frameand/or proximate to the FOS. As mentioned above, the TE-24 sensor(s) may be utilized in addition to, or instead of, the limit switches detailed above. Also, it will be appreciated that tension sensors other than the TE-24 sensor may be utilized without departing from the present disclosure.

In another example, one or more tension sensing rollers may be utilized, such as the TSR-3 or TSR-4 Tension Sensing Roller manufactured by The Montalvo Corporation (each, a “tension-sensing roller”). In one such embodiment, a single tension-sensing roller is utilized for each row of tension controller apparatuses. In this manner, each tension-sensing roller would provide an average reading of the tension of all wires W in the row rather than providing unique tension readings of the individual wires W in the particular row, and thus might not provide feedback of a variance in tension that would necessitate a shutdown (e.g., where 1 to 3 wires W are loose). As mentioned above, the tension-sensing roller(s) may be utilized in addition to, or instead of, the TE-24 sensor(s) and/or the limit switches detailed above. Also, it will be appreciated that tension-sensing rollers other than the TSR-3 or TSR-4 Tension Sensing Rollers may be utilized without departing from the present disclosure. For example, a tension-sensing roller that may measure each individual wire passing there over may be utilized.

In even other embodiments, tension of a wire W may be determined based on the position of the control arm(or control arm roller) associated with that wire W via a position sensor (the “Position Sensor”). In some of these embodiments, the Position Sensor is an instrument that measures angles of slope and inclination with respect to gravity. Accordingly, the Position Sensor may comprise various types of instruments, including but not limited to inclinometers, tilt sensors, accelerometers, gyroscopes, and combinations thereof, and may take measurements in one, two, or three axes. In one example, the Position Sensor is an inclinometer that is mounted to the control arm(or the control arm roller) and configured to determine the angular position thereof within its full range of motion (e.g., 0-35°). In even other embodiments, the Position Sensor is an inductive sensor that may determine the distance that the control arm(or the control arm roller) has traveled relative to a stationary reference point (e.g., on the tension controller apparatus) to determine its angular position within the full range of motion. Moreover, a rotational encoder/sensor or similar device may be provided on any or each of the tension controller apparatuses, in addition to or instead of any of the above, to carry out the same measurements.

After determining the position of the control arm(or control arm roller) via the Position Sensor, that information may be utilized to extrapolate a corresponding wire W tension from an operating curve such as that provided in. For example, knowing the full range of motion of the control arm(e.g., 0-35°), it may be determined that the wire W is broken when the control armis fully forward or that the wire W is overly tight when the control armis fully rearward, and intermediate wire W tension conditions may be determined by correlating an intermediate angular position there-between (i.e., when the control armis between the fully forward and fully rearward positions) with a tension obtained from an operating curve (e.g.,) based on air pressure. With this information (i.e., feedback), the creel systemmay automatically adjust the air pressure provided to any individual or groups of tension controller apparatusesas needed via the APC systemto optimize operation. In other embodiments, an operator of the creel systemmay utilize this information to manually adjust the air pressure provided to any individual or groups of tension controller apparatusesas needed via the APC system.