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Publication numberUS20040021031 A1
Publication typeApplication
Application numberUS 10/613,821
Publication dateFeb 5, 2004
Filing dateJul 7, 2003
Priority dateNov 16, 1998
Publication number10613821, 613821, US 2004/0021031 A1, US 2004/021031 A1, US 20040021031 A1, US 20040021031A1, US 2004021031 A1, US 2004021031A1, US-A1-20040021031, US-A1-2004021031, US2004/0021031A1, US2004/021031A1, US20040021031 A1, US20040021031A1, US2004021031 A1, US2004021031A1
InventorsDan Klaus
Original AssigneeDan Klaus
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Device for traversing a flexible linear product for spooling
US 20040021031 A1
A linear traverse mechanism for guiding the spooling of a flexible linear product at high speed, made possible by reducing the inertial load of the mechanism while reducing the angular deflection of the filament. The mechanism includes a pivotally mounted traverse arm controlled by an electric motor having precision indexing ratio characteristics to compensate for linear error. In one embodiment, the linear product is fed through a guiding means carried by said traverse arm to be discharged adjacent a receiving spool. Control of movement of the traverse arm depends upon manually controlled programming means, which compares a desired position of the traverse arm with an actually attained position of the arm.
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I claim:
1. In a device for traversing a linear flexible product for winding upon a spool or core, said device including a pivotally mounted traverse arm, a rotating motor, and a link interconnecting a point on a rotating part of said motor with a point on said traverse arm for imparting arcuate motion thereto over a predetermined arcuate path, the improvement comprising: means for controlling rotation of said motor through arcuate sectors of 180 degrees and less, such that a free end of said traverse arm moves at a substantially uniform rate of traverse over said predetermined path; said means for controlling rotation comprising motor means for driving said spool at a predetermined uniform angular velocity, an electronic controller feedback means driven by rotation of said spool for generating a digital position reference signal to said controller, said controller including a program to rotate said motor to a desired position corresponding to said reference signal required to move said traverse arm disregarding any non-uniform motion created by linkage deviations, and a process control device for selecting ratio and position criteria, and communicating said criteria to said controller feedback means.
2. The improvement set forth in claim 1, in which said controller is manually adjusted.
3. The improvement set forth in claim 1, in which the linear flexible product is fed coaxially with respect to a pivot axis of said traverse arm, and parallel to said arm to be discharged from said arm adjacent a free end of said traverse arm.
4. The improvement in accordance with claim 3, said traverse arm including tubular guiding means adjacent said free end thereof.
5. In a device for traversing a linear flexible product for winding upon a spool or core, said device including a pivotally mounted traverse arm, a rotating motor, and a link interconnecting a rotating part of said motor with a point on said traverse arm, the improvement comprising means on said arm for receiving said product along a path of motion coaxial with respect to a pivot axis of said arm, and guiding means on said arm for guiding said product to a point of discharge adjacent said spool.
6. In a linear traverse mechanism where guiding the spooling of a flexible linear product including a pivotally mounted traverse arm dispensing said product at a pre end thereof, and motion means where imparting arcuate motion to said arm the improvement comprising; means for sensing the instantaneous location of a free end of said arms in terms of digital data; a master control block controlling the angular direction, velocity and position of said traverse motor; means for transmitting said digital data to said control block on a continuous basis; logic blocks for determining the direction of rotation of said motor means; and a logic processor having a manually entered program relative to a traverse width, and starting and finishing locations on a given spool; where by control of said motor means is dependent on the instantaneous position of said linkage arm relative to the instantaneous position indicated by said processor.
7. The improvement in accordance with claim 6, further comprising a winding means, a motor driving said winding means, a digital feedback encoder sending a digital count signal to said control means, motion of said traverse arm being reversed upon the attainment of a predetermined count.
8. The improvement in accordance with claim 7, including means or momentarily halting movement of said traverse arm at one end of a traverse path of movement during a partial revolution of said winding means.
  • [0001]
    This application is a continuation-in-part of my co pending application; Ser. No. 09/342,826 filed Apr. 27, 2001, which is a continuation in part of application Ser. No. 09/427,443 filed Oct. 27, 1999, now abandoned.
  • [0002]
    This invention relates generally to the field of spooling a delicate flexible linear product such as thread, wire, cable, hose, and the like. It also relates an improved guiding means, which moves in a plane parallel to that of the spool/coil, which forms progressive layers of product as the spool/coil rotates, while minimizing the stresses and tension fluctuations that are created by product misalignment and radial bends.
  • [0003]
    The invention also relates to the process by which the traversing guide is synchronized with the winding member to form the desired level wind package.
  • [0004]
    These objectives are accomplished by employing a pivotally mounted guide with the capabilities of digitally addressing the desired position of the guide by calculating the rotational value of the winding member and commanding the traversing guide to the precise location to form the layering desired without the use of high wear cams or slide blocks.
  • [0005]
    Traverse guiding means are well known in the art, and have included a pivotally mounted guide having an orificed free end through which the product passes, as well as mechanical driving means, including a driven crank and linkage communicating with a point on the guide.
  • [0006]
    Previous pendulum type devices have been employed to move a flexible product in a linear motion while the product is being wound onto a package, such as a spool or coil. Some of these mechanisms have not been concerned with linear motion synchronized with the rotation of the winding members. Others include a mechanical cam device to compensate for the inconsistent motion of the guide. These mechanical linkages add considerable inertia to the device, thereby slowing the spooling process. In addition, these compensating components are of high frictional wear that reduces the life of said components. Previous devices have not performed direction reversal of the pivotally mounted guide, other than end of stroke mechanical linkage adjustments. Where the guide is driven at high speeds, the heavy inertial load of the mechanisms impedes any instant reversal of the path of movement. Previous means of reversal have included mechanical cams, slides, complicated mechanical linkages, and gears of both arcuate and oval configuration. Previous traversing components, for the most part, have not addressed the tension fluctuations and product abuse that are common to traversing.
  • [0007]
    U.S. Pat. No. 4,015,798: Discloses a guide arm that moves in a radial arc from a common axis. The lateral traverse motion is provided by the rotation of a “double diamond lead screw” (barrel cam). The cable is fed essentially coaxial with respect to the guiding arm and sheaves are provided to guide the product to the winding drum.
  • [0008]
    U.S. Pat. No. 2,848,173: Relates to an apparatus for traversing a yam to a specific profile that is accomplished by driving a pivotal guide through a complex gear/cam assembly.
  • [0009]
    U.S. Pat. No. 5,678,778: Relates to a reciprocating slide block guide that is driven by a cam box that compensates for the non-uniform motion due to angular losses.
  • [0010]
    In order to understand how the present invention differs from prior art, the criteria for the ideal traversing mechanism must be explored. When traversing a delicate filament at high speed, it is desirable to guide the filament only in a lateral plane. Any deviation or bending of the filament from its relaxed alignment is detrimental. The tension, while winding, should be as consistent as feasible. The mechanism should possess the capability to change direction instantly with no lag in its synchronization to its defined path. The device should be capable of varying the full stroke, at will, thereby altering the width of the layer. The device should allow for pitch (lead) variation at will. The motion of the apparatus must be dependable and not alter due to wear. Any angular disparities that are created by linkages should be compensated for without high wear, high inertia cams.
  • [0011]
    U.S. Pat. No. 4,015,798: This apparatus varies from the present invention in that it is not an axial driven device. The driving member is a double diamond lead screw, which has no capabilities to change pitch (lay) or stroke. The driving source of the cam is mechanically linked to the winding member and incorporates no capabilities for ratio change or reversal, other than drive train modifications. Although the invention may seem to feed the flexible product coaxial with respect to the to the pivot axis it shows that the product is being rotated above the axis. This may seem to be a minor variation, but in high speed traversing, the tension fluctuations produced by this deviant path are detrimental. The primary reason for the feeding of the product coaxial with respect to the axis is to reduce tension fluctuations that are common to linear traversing devices at high speed. By moving the feed closer to the axis as the disclosed device teaches, these fluctuations are reduced, but they are still present. An additional difficulty with the disclosed device is the multiple radial bends that are employed to route the cable to its final destination. In winding a delicate flexible product at high speed, it is desirable to minimize any radial bends or distortion to the elements natural path, that is, to endeavor to maintain as straight a path as possible. The second turn around sheave guiding the element to the winding member introduces an additional radial bend to the element. Thus this device was clearly not designed for high-speed delicate winding, as can be easily seen by the mass of the structure.
  • [0012]
    U.S. Pat. No. 2,848,173: The traversing motion of this apparatus is one of profiled traverse (non linear). The motion of the traverse guide in this mechanism is totally dependant on the cam, gearbox and linkages to form the desired layering and to compensate for the motion loss/gain of the angular differences of the linkages. This traversing mechanism winds a predetermined path and lacks the capabilities to change lay or traverse width other than mechanical retooling.
  • [0013]
    U.S. Pat. No. 5,678,778: This apparatus employs a known master/follower scheme in the regulation of the traverse guide. The follower circuitry of the traverse position controller differs significantly from the present invention by the means by which the synchronization of the traverse guide with the winding arbor is attained. The device is primarily a velocity follower (speed), which follows the winding member (master). The reporting of the speed and location of the guide is reliant on a feedback device that is positioned before the driving linkage. Any change or wear in the cam box or linkages will produce erroneous guide position feedback. Although this mechanism discloses a master/follower arrangement that is electronically controlled, the stroke of the traverse guide is reliant on the linkage. Variable stroke adjustment is not addressed. In order to compensate for non-uniform motion of the linkage, a cam box is employed. The filament guide is housed in a flat self-lubricating slide block. The eventual wear of both the cam box and the slide block are not desirable Another detrimental quality of the sliding block traverse is the filament misalignment while winding. In any lateral traversing mechanism the filament is exposed to angular displacement that accumulates product, causing fluctuations in tension. These tension fluctuations have to be compensated for. The most common means of compensation is a multiple pass accumulator. This introduces additional undesirable radial bends to the filament.
  • [0014]
    Prior traversing art utilizes numerous means to transform rotary motion to lateral motion. The most common of these mechanisms is illustrated in FIG. 8. The driving means as represented by (75) can be either separately derived or common to the winding member (80). The reciprocating motion of the filament guide (79) is accomplished by the rotation of a crank (78). This rotation may be either continuous or oscillating. The changing angles ((A), (B)) between the crank (78), the linkage arm (77) and the filament guide (79) produces a stroke, that if uncorrected, would form a non uniform layering of the filament (F). This distortion is compensated for by introducing a device that compensates for these disparities. Most of these devices include cam mechanisms (76). Prior art includes feedback devices to communicate the position of the filament guide (74). Prior art has contained the filament guide by the use of linear slides and pivotal mounts. These devices exhibit various difficulties that are detrimental to the high speed processing of delicate products. The first of these is one of mass. As more components are added to the device to compensate for non-uniform motion, the inertial load is increased, hindering the speed or directional changes of the guide. If stroke adjustments are desired, the linkage must be adjusted or changed or the rotation of the driving member reverse& The surface-to-surface frictional wear of both the slides and cam devices add to the problematic characteristics. If position feedback (74) is employed at the driving means (75), the position of the guide is dependant on mechanical constants that change due to wear and maladjustment. The means by which the traverse guide is synchronized with the winding member is either direct drive or speed following. Ratio changes in direct driven devices are accomplished through mechanical components that add to the mass of the device. Speed following devices are prone to accumulating error. The final drawback that is inherent to these devices is one of product misalignment. When traversing delicate product at high speeds it is essential to try to maintain an undisturbed alignment to the winding member. The oscillation of the guide creates angular deflection of this alignment (C), (D). This deflection causes two problems. The additional linear accumulation causes tension fluctuations. In addition, the misalignment of the product to the guide creates a bend at the contact point (E).
  • [0015]
    Briefly stated, one aspect of the invention contemplates an improved guiding means by which a continuous segment of the product is moved in a plane parallel to the axis of the spool or core of the winding device, while reducing the inertial load of the traversing mechanism and minimizing the angular deflection of the product, thereby increasing the speed by which the product can be traversed in a precise manner. A second aspect is the precise locating of the traverse guide, which is accomplished by employing a novel digital addressing strategy that utilizes a digital feedback device that is located after the linkages that produce non-uniform motion of the guide. By implementing this method, compensating cams that are required to counteract mechanical deficiencies are eliminated. It is also the intention of the invention to reduce the self-destruction of the members by eliminating surface-to-surface wear due to friction. It is an object of the invention to electronically interface the motion of the traversing guide with the winding member, so that the positioning of traverse motion may be programmed for required traverse profiles and reversals of the guide. Thus, it is possible to utilize less than the entire arcuate path of motion of the free end of the guide, where use of the entire path is not required, whereby the same mechanism may be employed for winding spools or coils of varying axial length.
  • [0016]
    [0016]FIG. 1 is a perspective view showing the general process by which the product is layered onto a rotating arbor or spool, and the relationship of the guiding mechanism to the rotating member.
  • [0017]
    [0017]FIG. 2 is a view in elevation showing a traversing mechanism forming a part of the embodiment of the invention.
  • [0018]
    [0018]FIG. 2a is a side view in elevation thereof
  • [0019]
    [0019]FIG. 3 is a-block diagram showing the components used to synchronize the traverse assembly to the winding member.
  • [0020]
    [0020]FIG. 4 is a schematic drawing showing longitudinal motion of the traverse assembly as a function of O and radius.
  • [0021]
    [0021]FIG. 5 is a program flow of a logic processor (LP) and operator interface.
  • [0022]
    [0022]FIGS. 6 and 7 are diagrams that show the program flow of a traverse motor controller (MC).
  • [0023]
    [0023]FIG. 8 is a block diagram showing prior art traversing mechanisms.
  • [0024]
    C1 Accumulative counter for the winding member
  • [0025]
    Cp Pulse Per Revolution (PPR) of the winding member
  • [0026]
    Cr The accumulated rotational count of the winding member expressed in revolutions.
  • [0027]
    Cs The total accumulated count of counter C1
  • [0028]
    Da The digital address of any linear position along the winding plane (P)
  • [0029]
    Dir Direction of the Traverse Motor
  • [0030]
    Dti Desired traverse position along the winding plane (P) in inches
  • [0031]
    Dts Desired rotational traverse position in encoder steps
  • [0032]
    Fsi Front stop expressed in inches
  • [0033]
    Goto Programming command to the motor control processor
  • [0034]
    Hs Homing switch
  • [0035]
    L Traverse Lead expressed in inches
  • [0036]
    O Traverse origin, an angular position of 90 degs, with reference to the winding plane.
  • [0037]
    Rsi Rear stop expressed in inches
  • [0038]
    Rss Rear stop position expressed in encoder steps
  • [0039]
    Run Run signal
  • [0040]
    Te Traverse encoder
  • [0041]
    Tp Pulses per revolution of the traverse encoder
  • [0042]
    Tw Traverse width expressed in inches
  • [0043]
    Equations Used:
  • Cr=Cs/Cp
  • Fsi=Rsi+Tw
  • Rss=(asin(Rsi/r))(Tp/2π)
  • Da=(a sin(Y/r))(Tp/2π)
  • Fss=(a sin(Fsi/r))(Tp/2π)
  • Dts=(a sin(Dti/r))(Tp/2π)
  • Dti=Fsi−(LCr) or Dti=Rsi+(LCr).
  • t=a sin(Y/r)
  • [0044]
    Referring to FIG. 1, there is illustrated a longitudinally mounted guide (1), an orificed free end of which moves in a plane parallel to a winding surface (2) following the speed of a winding apparatus (3) to a set ratio to result in layering of the wound product.
  • [0045]
    If the ratio of the guide (1) to the winding apparatus (3) is changed, the space between the layering may be increased or decreased at will. If the reversal at the end of the longitudinal stroke is changed, the layer width (4) may be increased or decreased as required.
  • [0046]
    One problem that exists is in the movement of the guide (1). The mechanism required to move the guide to and fro to the position required, and to perform quick reversals of the direction at the end of a stroke, is of high inertia. A secondary disadvantage of this configuration is, at high speed; the motion of the guide in its path, causes tension fluctuations in the product due to the deviation of the guide from its aligned position. Additionally, the accurate positioning of the guide is complicated by the angular losses of the linkages that are common to traversing mechanisms.
  • [0047]
    Referring to FIGS. 2 and 2a, when the arm (8) and product guide (9) are attached at a pivot (7) and allowed to swing about this pivot in an arc (10) that is parallel to the winding plane (P), the inertia of the assembly is significantly reduced. By driving the pivotally mounted guide from a driven rotating crank (5), the rotational reversal of the crank is used to limit the stroke of the product guide (9). The flexible product is fed through entry hole (12) around sheave (13) through product guide (9) to the winding member (14). The rotating crank (5) converts rotary motion to linear motion through arm (6). This causes the entire assembly to oscillate around pivot (7). Due to the product path through the axis of the mechanism, tension fluctuations that are caused by the side-to-side motion of longitudinal traversing are greatly reduced. The product guide (9) is so constructed as to guide the product only in the desired parallel winding plane. As the product leaves the sheave (13), it is free to form a natural angle to the varying diameter of the core. This path eliminates the sharp bends that are detrimental to many filament products. The ultimate goal of the invention is to position the product guide (9) in the precise desired location along the winding plane (P) with respect to the rotational position of the winding member (14). It is also the intention to accomplish this by disregarding any non-uniform motion that is generated by angular inconsistencies created by the members (5), (6) and (8).
  • [0048]
    [0048]FIG. 3 schematically illustrates the disclosed embodiment. Winding shaft (15) is driven by either a constant or variable speed motor (16), which may be manually controlled by a separate speed controller. Element (17) is a digital feedback encoder driven from shaft (15) which sends a digital count signal to a logic controller (18). Logic controller (18) contains the necessary logic for the synchronization of the two drives, and interface from the operator input. Component (19) is the traverse motor controller that commands the traverse motor (20) to the desired position for accurate positioning. The rotary position of the traverse is communicated to the motor controller (19) by encoder (22). This positioning is accomplished by utilizing a motion controller and motor that incorporates the capabilities of both speed (velocity) and position control. It is not the intention of this disclosure to detail the process by which the controller accomplishes the positioning of the motor, as there are numerous devices existing, that are well known by those experienced in the art of motion control. Operator interface is accomplished by means of a process control device (21) with the capabilities of setting selectively any of a plurality of ratio and position criteria.
  • [0049]
    Prior to the start of the winding cycle, a “homing” routine is initiated. This routine rotates the traverse drive motor (20) in the clockwise rotation until switch (24) is activated. This switch is positioned to activate when the traverse arm (8) is at right angle to the winding axis. At this point, the origin of the traverse arm (O) is set.
  • [0050]
    [0050]FIG. 4 illustrates that the primary objective of the invention to locate the product at a desired, precise, location along the winding plane (P) with reference to the accumulated rotation of winding shaft (Cr). To accomplish this task the first value that is ascertained is (Cr). Digital feedback encoder (17) is driven from shaft (15), which sends a digital count signal to counter (C1). This counter is a component of the logic processor (LP FIG. 5) and is capable of storing the accumulated count that sums the rotation of the winding shaft (Cr) from the time of reset. The next value ascertained is the desired location along winding plane (P). The linear position along winding plane (P) is defined as a linear measurement from the origin (O). Any position to the right of (O) is a positive value. Any position to the left of (O) is a negative value. The process begins by placing the product at position (Fsi). The desired linear position (Dti) is now found by subtracting the product of (L)(Cr) from (Fsi). (L) Is the desired lead of the product across the winding plane (P) as the process advances. Once the product reaches the desired rear stop position (Rsi), the accumulated count of (Cr) is reset to zero and the guide motion is reversed by adding the product of [(L)(Cr)] to (Rsi). This process continues until the required length is achieved. Therefore (Dti) is the desired traverse position, expressed in inches, along the product on winding plane (P) at any time in the winding cycle. (Dti) is found by adding to (Rsi), or subtracting from (Fsi), the product of (L)(Cr).
  • Dti=Fsi−(LCr)
  • [0051]
  • Dti=Rsi+(LCr).
  • [0052]
    (Rsi) is the end of the desired backward motion expressed in inches, which is manually measured from origin and entered into the operator interface ((21) FIG. 5). ((Rsi) is a negative quantity). (Tw) represents the total traverse width, expressed in inches, and is operator entered. (Fsi) is the end of the desired forward motion, expressed in inches. (Fsi) is the sum of (Rsi) and (Tw).
  • Fsi=Rsi+Tw
  • [0053]
    These linear values must now be converted to a digital position of the traverse arm that the processors can comprehend. This is achieved by applying polar coordinates to the guide position. To convert the three variables defined as linear positions, (Dti), (Fsi) and (Rsi), into a value that can be used by the processors, the desired angular position of the traverse arm (8) for each of these variables first must be found. Encoder (22) is a bi-directional device that is configured to add or subtract pulses dependent on the direction of its rotation. Counter clockwise rotation adds, clockwise rotation subtracts. By summing theses pulses the processor is made aware of the position of the arm at any point in the process. In order to calculate any of the angular values with reference to the linear position along plane (P), each of these values are substituted for Y in the following equation.
  • t=a sin(Y/r)
  • [0054]
    In order to ascertain the digital address of the encoder for these angular values the equation
  • Da=tTp/
  • [0055]
    is used
  • [0056]
  • [0057]
    Da=Digital address of encoder (22) for any position along the plane (P) referenced from the origin (O).
  • [0058]
    Tp=Steps per revolution of encoder (22)
  • [0059]
    r=length of the traverse arm in inches
  • [0060]
    Y=any linear point on the (P) plane referenced from the origin (O)
  • [0061]
    2π=Radians for one revolution (360)
  • [0062]
  • Da=(a sin(Y/r))(Tp/2π)
  • [0063]
    This equation assigns the digital encoder address for any linear position.
  • [0064]
  • Rsi=−4 inches
  • Tw−8 inches r=10.75 Tp=1800
  • [0065]
  • Fsi=Rsi+Tw . . . Fsi=4
  • Fss=(a sin(Fsi/r))(Tp/2π) . . . Fss=109
  • Rss=(a sin(Rsi/r))(Tp/2π) . . . Rss=−109
  • [0066]
  • [0067]
    (Fss)=Front stop in steps (digital address);
  • [0068]
    (Rss)=Rear stop in steps (digital address)
  • [0069]
    In order to create a symmetrical package and for operator ease, it is required that the beginning layer start at point (Fsi) and end at (Rsi). As the process starts, the position of the traverse is at (Fsi). The logic continuously commands the motor to a position that satisfies the equation Dti=Fsi−(LCr). To convert the linear position of Dti to a digital value of encoder (22) the equation
  • Dts=(a sin(Dti/r))(Tp/2π)
  • [0070]
    is employed.
  • [0071]
  • Cs=640
  • Cp=480
  • L=0.2
  • [0072]
  • Cr=Cs/Cp
  • Cr=1.33 (revs)
  • Dti=4−(0.21.33)
  • Dti=3.73
  • Dts=(a sin(3.73/10.75)(1800/2π)
  • Dts=101.6
  • [0073]
    When the product reaches (Rss) the accumulative count of (C1) is set to zero, the rotation of the traverse motor is reversed and the equation Dti=Rsi+(LCr) is applied. This process continues, alternating between the two calculated values, as subsequent layers of filament are wound
  • [0074]
    The process of layer winding requires that when the product reaches the end of the traverse stroke at either (Rsi) or (Fsi), lateral motion must cease for a partial rotation of the winding arbor. This is accomplished by ignoring the count from encoder (17) for a predetermined period and will be explained in detail hereinafter.
  • [0075]
    Simply stated this process calculates the desired position of the traverse and commands the motor to go to this desired digital address.
  • [0076]
    Sequence of Operation
  • [0077]
    [0077]FIG. 5 shows the program flow of the logic processor LP. (30), (31), (32), (34) are the values entered by the operator through the operator interface (21). The values are utilized to determine the values of (L) (Lead), (Tw ) (Traverse width), (Rsi) (Rear stop in Inches)and lead dwell. These values are stored in the processor's memory. Value (31) and (32) are also applied to math block (33) for calculating (Fsi). Values (30) and (32) are also directed to the motor control data bus (47) for later control of the traverse motor positioning (39) is a discrete input to start or stop the run sequence. The logic of the run trigger is well within the talents of one skilled in the winding art. Neither is it necessary to specify in detail the type of switches, encoders, etc. as this is also within the capabilities of one skilled in the art.
  • [0078]
    Internal Relay (R1) is a latching relay that changes either state by applying a single pulse to the latch or unlatch inputs (40). (17) Is an encoder that sends a digital signal from the winding arbor which is passed through internal relay contacts (R1) to either accumulative counters (C1) or (C2) (Acc). (C1) is an accumulating counter that stores the value of (Cs), which is conveyed to math block (37) that evaluates the value of (Cr).
  • [0079]
    The function of counter (C2) is to accumulate counts from the winding arbor in place of (C1) to allow for lead dwell at the end of each traverse stroke. The accumulated count of (C1) is reset to zero by the internal relay (R1) at the end of each traverse stroke. This latching of (R1) also redirects the count (17) from (C1) to (C2). When the encoder count is routed to (C2),it is not incrementing (C1). (Cs) now remains at zero until the count (17) is directed back to (C1) through the unlatching of (R1). The preset (Pre) value of (C2) is manually set in the operator interface and con eyed to (C2) by (34). When the accumulated value (ACC) of (C2) reaches the (Pre) value, the done bit (Dn) is set. (R1) is unlatched (40) and the Acc value of (C2) is reset to zero. This process, in effect, halts the traverse motion by negating (Cr) for a predetermined period.
  • [0080]
    The sequence of operation starts with block (43). On startup and at the end of each cycle a “homing routine” (43) is initiated in the processor and a discrete signal is sent to the motor control com data bus (47). The processor waits for a “homing complete” signal to be received from the data bus (47) before allowing the run sequence to engage. Once the “homing complete” signal is received, the run sequence (45) is activated by the operator, which starts the winding member motor (46).
  • [0081]
    During the cycle, math block (37) is constantly calculating the rotational count (Cr) of the winding arbor by dividing (Cs) by (Cp). The result, (Cr) is a varying value of the rotational count of the arbor. Math block (33) calculates the value of (Fsi) by subtracting (Rsi) from (Tw). The values of (Cr), (L), (Fsi) and (Rsi) are directed to the motor controller MC through the corn bus (47).
  • [0082]
    The Motor controller logic can be seen by referring to FIGS. 6 and 7. Data from the processor is communicated to the MC by the communication data bus (47). Math blocks (52) and (53) convert the linear values (Fsi) and (Rsi) into the digital global variables (Fss) and (Rss) that are used in the positioning process. (55) is a discrete input from the home switch (24) signifying that the traverse arm is at the origin position.
  • [0083]
    The numeric position of the traverse arm is derived in summing block (56) that sums the count from encoder (22), which is attached to the pivot of the traverse arm. Encoder (22) sends digital pulses to the block (56). Clockwise “CW” rotation of the encoder decreases the value; counterclockwise “CCW” rotation increases the value. This position value (Pos) is a global variable that is directed to the positioning segment of the motion controller as well as being available for calculation in blocks (68) and (72). The accumulative value of the position is reset to zero on homing (62).
  • [0084]
    When the LP initiates a “homing routine” (58), block (59) communicates a CW rotation to the motion controller setting the velocity (Ve11) required for-the precise positioning of the traverse arm origin (O). When block (60) is evaluated as true (switch (55) closed) the motor is commanded to stop motion (61) and the position value (Pos) is set to zero (62). This establishes the origin (O) position of the traverse. This origin places the traverse arm at a right angle to the winding plane. The processor then commands the motor “Goto” position Fss (63). The arm is now placed at the precise location of the front stop (Fss) and the homing routine is complete. Block (64) signifies that the “homing routine” is complete after motion has ceased, which is reported back to LP through (47).
  • [0085]
    Referring to FIG. 7, (54) is the input from the LP defining the values of (Cr) and (L) for use in math blocks (66) and (70). When the run command is received from the LP, block (65) sets the motor to the CW rotation (Dir). Math block (66) calculates (Dti) and (Dts). (Dts) is defined as a global variable, which can be referenced throughout the processor. Block (67) commands the controller to “Goto” the numeric position of (Dts) at a velocity (Ve12). This speed is sufficient to increment the traverse motor to its predetermined position at all winding speed ranges. As the winding arbor count (Cr) increases, (Dts) is incrementally decreased from the front stop (Fsi) by the value of (LCr). This process continues until the position of the arm reaches the numeric value of the (Rss).
  • [0086]
    When block (68) is evaluated as true ((Pos)=(Rss)):
  • [0087]
    (R1) is latched resetting the value of (Cr) (73) to zero.
  • [0088]
    Block (69) reverses the direction (Dir) of the motor.
  • [0089]
    The value of (Dti) is recalculated in block (70), in doing so block (71) commands the controller to “Goto” the numeric position of (Dts) at a velocity (Ve12). As (Cr) increases, (Dts) is incrementally increased from the rear stop (Rsi) by the value of (LCr). This process continues until (Pos) is equal to (Fss).
  • [0090]
    When block (72) is evaluated as true:
  • [0091]
    (R1) is once again latched resetting the value of (Cr) to zero.
  • [0092]
    The processor loops back to block (65) starting the process over again. This loop continues until the run sequence is interrupted by the LP.
  • [0093]
    The motion control block (57) of the MC controls the direction, velocity and position of the traverse motor (20). The control of this motor (20) is primarily that of position. This position is controlled by means of comparing the traverse arm position feedback from (56) to the commanded “Goto” position from blocks (63), (67) or (71) and accelerating the motor until the positions equate. The direction of the motor rotation (Dir) is controlled by the commands from the logic blocks (59), (65) or (69). The velocity of the motor is set by means of the values conveyed from blocks (63), (67) and (71). The process by which the controller accomplishes the precise positioning of the motor is well known in the art.
  • [0094]
    It is now apparent that the positioning of the product across the winding plane is accomplished by commanding the traverse motor to “Goto” a desired linear position that ignores the non-uniform motion created by linkage deviations. The continuous looping of the process evaluates the desired position and commands the motor to “Goto” this position, in doing so, any prior errors are compensated for and are not accumulative. It may appear that this incremental motion of the traverse would cause the arm to pulse to its commanded position, but this stepping motion is dampened by acceleration/deceleration settings in the motion controller.
  • [0095]
    It may thus be seen that I have invented new and highly useful improvements in flexible product spooling devices in which many of the disadvantages of prior art constructions have been eliminated or substantially ameliorated. A principle advantage of the present invention is the ability to instantaneously sense the precise position of the traverse arm independently of the mechanical means which move the traverse arm, thus effectively eliminating the effect of wear on mechanical parts. By simplifying the construction of the traverse arm so that the product is fed as directly as possible, undesirable stresses on the product are significantly reduced.
  • [0096]
    A manually adjustable digital processor is employed which uses a homing routine for initiating a cycle of movement which simplifies initial location of the traverse arm and the control over each successive traverse of the arm to its final stop when the spooling has been completed. The invention may be installed into many existing spooling devices with minimal modification.
  • [0097]
    I wish it to be understood that I do not consider the invention to be limited to the precise details of structure shown and described in the specification, for obvious modifications will occur to those skilled in the art to which the invention pertains.
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Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US6983927 *Oct 7, 2003Jan 10, 2006Camoplast Industrial Inc.Level wind apparatus for use on a snow grooming vehicle
US7137586Jan 10, 2005Nov 21, 2006National-Oilwell, L.P.Hydraulic spooler
US20040069981 *Oct 7, 2003Apr 15, 2004Bombardier Inc.Level wind apparatus for use on a snow grooming vehicle
US20060151653 *Jan 10, 2005Jul 13, 2006National-Oilwell, L.P.Hydraulic spooler
CN103287917A *Jun 6, 2013Sep 11, 2013金红叶纸业集团有限公司Cable coiling device
CN103420198A *Aug 30, 2013Dec 4, 2013洛阳市明伟机械科技有限公司Swinging-arm-type flexible belt bundle winding machine
U.S. Classification242/483.8, 242/397.3
International ClassificationB65H54/28
Cooperative ClassificationB65H54/2848, B65H54/2827, B65H54/2884
European ClassificationB65H54/28E, B65H54/28L, B65H54/28P