BR112020020026A2 - METHOD FOR POSITIONING A SPINDLE WITH PRECISION IN AN AUTOMATIC TOWER WINDER - Google Patents

Abstract

method for accurately positioning a spindle on an automatic tower winder. the invention relates to an automatic tower winding device. the invention provides a device and a method for accurately positioning a spindle on the automatic tower winder when changing the bobbin. it involves, during the process of changing the coil, the step of turning the turret in at least two distinct rotational movements performed at controlled speeds, where the empty coil assumes its precise winding position. in an important inventive aspect of the invention, the rotation of the tower is controlled by detecting the current in the motors that control the spindles. the present invention also describes a system for controlling turret and spindle movements. it comprises a primary control system (10) to control the rotation movement of the tower and a secondary control system (11) to control the rotation movement of the spindle. it also comprises a main control system (12) that controls the two systems (10, 11) and receives signals / information and sends commands to the two control systems (10, 11).

Description

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DESCRIPTIVE REPORT METHOD FOR PRECISIONING A SPINDLE IN A WINDER

TOWER TYPE AUTOMATIC Field of invention

[001] The invention relates to an automatic winding tower type device that can safely position a winding spindle after a coil change. History of the invention

[002] The automatic winder of the tower type is used to wind tapes, wires or bands that arrive continuously in a coil. In general, in the tower type winder, a pair of coil supports - also known as spindles - are mounted at the opposite ends of a rotating tower mounted on the appropriate machine frame. Each spindle is alternately moved from the normal winding position to the unloading position every half turn of the tower. The tower continues to rotate in the same direction at required time intervals or when the spindle in operation reaches its maximum conveyor length for winding tapes. Each spindle needs a precisely controlled rotation around its own axis and can be independently driven by an electric motor through a suitable mechanism, such as a belt and pulley arrangement or with an independent direct drive electric motor system. Conventionally, encoders or other suitable devices are mounted on the engine to monitor engine speed, and the signal is communicated to an electronic controller with the help of a suitable cable. The controller then sends the electrical signals to the inverter / drive of the active motor, determining the power to be given to the motor that drives the spindle.

[003] Conventional winders of the above type are disclosed in the Patents

2/15 US No. 5228630 and 4765552, in European Patent 861800A2 and WO 2017/093950.

[004] Automatic tower winders have been introduced to provide coils of polyolefin flat / fibrillated yarns and to improve efficiency while reducing waste. The automatic exchange process replaces the wire transport coil with empty spindles.

[005] In these conventional automatic winders, the turret is rotated using a clutch and pulley in synchronicity. The turret rotation is performed by releasing the clutch and transferring the driving force to the pulley for rotation. After the turret rotation, the empty coil is correctly positioned by sliding the coil in the reverse direction, towards the pressure roller of the CAM box. Preferably, the spindle is positioned so that the pressure roller exerts uniform pressure on the spindle present in the winding. The reverse movement of the tower's transport spindle is controlled according to the time and speed parameters preset in the control system. Practically, in conventional systems, the movement of the tower is not uniform and, therefore, the position of the spindle after the change is not accurate and the movement is not as smooth as necessary, due to changes in mechanical conditions. Machines of the type discussed here are generally not operated in a completely dust-free environment. Therefore, as time progresses, the accumulation of foreign particles in the mechanical components of the machinery increases even after taking abundant precautions to clean and maintain the machine. The accumulation of particulate matter hinders the smooth movement of the moving elements over a period of time. In other words, the resistance of the system to the smooth movement of the components increases due to general wear and accumulation of particulate matter.

[006] For example, the tower may be blocked due to the accumulation of particles of

3/15 dust can either be tightened or loosened during the maintenance cycle - any of which can affect the tower's rotation, making it fast / slow and / or irregular in nature. This irregular behavior is generally known as ‘Mechanical failures’. It is known that conventional winders inevitably suffer from incorrect positioning of the spindle in relation to the pressure roller CAM due to the referred mechanical failures.

[007] The improper positioning of the spindle causes a space between the spindle coil that is ready to be wound and the pressure roller which, in turn, produces uneven winding tension and, therefore, uneven packing density. In addition, some of the existing systems lead to inaccurate spindle positioning when the turret movement pushes the extra CAM roller in the reverse direction. This is due to the lower sensitivity achieved in these spindle positioning methods, for example, as mentioned in WO 2017/093950.

[008] Therefore, it is necessary to provide a method for positioning the spindle accurately and with greater precision than the conventional methods of the automatic method of the automatic winder of the tower type, in particular, a method that identifies the correct position of positioning of the tower and the spindle after reverse movement, after removal.

[009] It is also necessary to provide a system that reduces the possibility of the tower being positioned in an intermediate location, leaving a space between the spindle and the pressure roller or positioning itself beyond the desired location, exerting extra pressure on the roller. Objects of the Invention

[010] Therefore, it is the aim of the present invention to provide an improved automated method that can identify the correct positioning of the spindle more accurately and in a shorter response time.

4/15 of the spindle motor motor chain, as the spindle touches the pressure roller.

[011] Another objective of the present invention is to provide a system with greater precision to achieve the correct position of the tower, which reduces the possibility of pressing the pressure roller more due to the lower sensitivity in the previous positioning methods. - Parts List: o Tower (1) o Spindle (2A) o Spindle (2B) o Tape / wire (3) o CAM Box (4) o Pressure roller (5) o Tape guide (6) o Primary reels and secondary (7, 7A) o Tensioning arc (8) o Positional winding line (9) o Close positional line (9 ') o Primary control system (10) o Secondary control system (11) o Control system main (12) Summary of the Invention

[012] The invention relates to an automatic tower winding device. The automatic bobbin change process involves winding the cut film / wire onto a bobbin, followed by rotating the tower to place an empty bobbin in the winding position. Pressure rollers are provided to ensure consistent and accurate winding. The precise relative positioning of the coils and pressure rollers is

5/15 important. Wear and particulate dust can cause winder systems to malfunction, which can affect the accuracy of turret speeds and the relative positioning of coils and pressure rollers, especially when turret rotation during the coil exchange stage is done in a single rotation. The invention provides a system and method for positioning the spindle more precisely in the automatic tower winder, especially for identifying the correct positioning position of the spindle of the tower after the reverse movement after withdrawal. This involves, during the process of changing the coil, the turret turning step in at least two distinct rotational movements performed at controlled speeds, in which the empty coil assumes its precise winding position. In an important inventive aspect of the invention, the rotation of the tower is controlled by detecting the current in the motors that control the spindles. Description of the figures

[013] The objects and advantages of the invention can be understood with reference to the following description, taken in conjunction with the attached drawings:

[014] Figure 1 shows a schematic of a tower with two spindles;

[015] Figure 2 shows a scheme in which the predefined tape length is reached;

[016] Figure 3 shows a diagram of the tower under the process of changing the coil;

[017] Figure 4 shows a diagram representing the completion of the automatic exchange process and the deviation of the spindle in relation to the pressure roller;

[018] Figure 5 shows a diagram of positioning the tower and spindle in the correct position;

[019] Figure 6 shows the comparative change in the spindle and tower motor currents as a percentage of the nominal values;

[020] Figure 7 shows the relationship between the control systems of the invention.

6/15 Detailed description of the invention

[021] The present invention describes an improved procedure for precise positioning of the tower after changing the coil. The terms 'precise', 'precisely' or 'exact' used in this specification, in the context of positioning, spindle or tower, are intended to express that a good or considerably good position of the tower or spindle is achieved, for example through which the best possible quality coil is produced.

[022] Figure 1 shows the present invention in an operational state. It shows a spindle tower, with a spindle in position to start winding. Each spindle is driven by an associated spindle motor. There is also a motor that drives the tower. The engines are not shown in the figure.

[023] Figure 1 shows the present invention in an operational state. It shows a tower (1) at the beginning of a winding operation. It has empty primary and secondary coils (7, 7A) mounted on two spindles (2A, 2B), with their centers designated respectively as points A, A ', which fit into what is called the positional winding line (9) or an axis / positional line of the coil and where one of the two spindles (2A) is in the winding position to start winding. The position of the positional winding line (9), which is an imaginary axis, is a position which is suitable for winding the wire and will be known to a person skilled in the art. When the tower (1) is in this position, the centers (A, A ') of both coils (7, 7A) (currently empty) fall on the positional winding line (9) and one of the empty winding coils (7 or 7A), mounted on the spindles (2A or 2B), ideally touches the pressure roller (5). In this position, the pressure exerted by the primary coil (7), which is in the winding position, and the pressure roller (5), one on top of the other, is the ideal pressure for a given wire (3), something that a specialist in the technique it would readily know.

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[024] The wire / ribbon (3) is delivered after cutting and conditioning the ribbon line machine from the 'a' direction (as shown in Fig. 1) after passing through a dancing arm that regulates the ribbon tension. The speed of the tape line in the unloaded tapes varies from 200 to 800 meters per minute; the density of the tape material ranges from 400 to 3000 denier.

[025] Each spindle is driven by an associated spindle motor. There is a motor that drives the tower.

[026] The winding of a wire / ribbon (3) begins on the first currently empty coil (7) after a CAM box (4) curves at an angle 'θ' (measured from the vertical) in the 'b' direction (indicated by an anti-clockwise arrow in Figure 1). The magnitude of the angle is dependent on the geometry / design of the tower and would be known to a person skilled in the art. As the winding of the tape (3) progresses, the package diameter of the first reel (7) increases to a predetermined value. At this stage, a coil change is expected when the common winder head controller instructs the turret drive system motor (not shown in the figures) to turn to change coils, so that the secondary coil (7A) now empty, assume the winding position.

[027] Figure 2 shows a position of the CAM box (4), where the predefined diameter of the primary coil (7) after the winding of the wire has been reached. As part of the coil change process, the CAM box now rotates clockwise (i.e., in a direction opposite to b) and the pressure roller (5) is retracted from the wound primary coil (7). A device that performs the aforementioned rotation of the CAM box (4) can be an electromechanical, pneumatic or hydraulic system. After the retractable rotation of the CAM box, the tower (1) starts to rotate in the direction indicated by the arrow 'c' in Figure 3, which shows the tower in a state of transition movement.

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[028] At the end of the transition movement, according to the invention, the tower reaches a position such that the secondary coil (7A) now empty that is mounted on the spindle (2B) reaches a position close to the winding position (Figure 4 ). In the actual winding position, the center (A ') of the secondary coil (7A) must be precisely in the position previously occupied by the center (A) of the primary coil, now filled (7) at the beginning of its winding. However, according to the present invention, at the end of the transition movement, the line joining the coil centers (A-A ') reached at the end of the transition movement does not coincide with the final winding position represented by the line winding positional (9); the actual position of the line joining the centers of the two coils (A-A ') at the end of the transition is deliberately offset by an angle' ϕ '(see Figure 4), called the displacement angle, in relation to the positional line of necessary winding (9). In one aspect of the invention, the displacement angle (ϕ) can be up to 45 °. The actual positional line joining the centers (A, A ') of two coils (7, 7A) at the end of the first rotational movement is referred to as a close positional line (9'). If, as in conventional mode, after the winding of the primary operational coil (7) is completed, the turret (1) at the end of its transition movement is rotated from its original winding position to its final position (so that the coil empty secondary (7A) is in the winding position) in a single continuous movement (as indicated by the direction of rotation arrow 'c'), there will then be a strong possibility that the spindle that needs to be wound will stop before or after pressure roller location - but not at the exact desired location.

[029] The final position of the secondary coil (7A) is reached as a result of at least two distinct rotational movements. In the case where there are only two distinct rotational movements, the total rotational movement will comprise

9/15 a first and a second rotational movement. At the end of the transition movement, also called the first rotation movement (indicated by the arrow c in Figure 3), for the purposes of this description, the empty secondary coil (7A) is intentionally stopped in the next position (9 '). In the desired final winding position (9), the pressure roller rests on the empty secondary coil (7A) and exerts gentle pressure on it before winding can begin. The rotation speed of the first rotation movement depends on several parameters, such as yarn and denier type, line speed, winder designs in general, and would be known to a person skilled in the art.

[030] The first rotation movement is followed by a second rotation movement (indicated by the direction d in Figure 4) in the direction necessary for the secondary coil (7A) to reach the desired end position, which occurs at a slower speed than the first rotational speed. As the second rotation movement continues, the secondary coil (7A) approaches its final winding position, and at some point touches the pressure roller (5), which may already have reached its predetermined location or is in process to achieve it. At that moment, the current in the shaft motor starts to rise. The second rotation movement is interrupted when the current in the spindle motor reaches a predetermined value, indicating that the pressure roller (5) and the secondary coil (7A) are in the necessary final relative positions where the winding can start. In some winding systems, the winding of the secondary coil (7A) may have already started before the pressure roller (5) and the second coil (7A) assume their necessary final relative positions.

[031] The rotation speed (measured in RPM) of the second rotation movement can be up to 25% of the first rotation speed. This is done because controlling the movement at low speed to obtain a

10/15 precise final positioning of the secondary coil (7A) is much more feasible or possible than trying to do it at high speed, performed in a single rotational movement. It is preferable, but not necessary, that the position of the secondary coil (7A) at the end of the first rotation movement is beyond the desired end position, so that directions c and d can be opposite each other.

[032] The position reached by the secondary coil (7A) at the end of the first rotation movement can optionally be before its desired end position. In this situation, the second rotation movement occurs in the same direction as the first rotation movement, that is, the directions c and d can be the same (that is, both can be clockwise).

[033] The final position of the secondary coil winding (7A) (see Figure 5) is such that the secondary coil (7A) touches the pressure roller (5) in a position where the tape tension does not vary much during the winding process. In the preferred application, the secondary coil (7A) reaches the required position by turning slightly in the reverse direction 'd' (see Figure 4). Normally, this reverse movement (d) is controlled by defined parameters, however, sometimes, due to problems related to the mechanical adjustment of the parts that facilitate the movement, the spindle does not reach the correct position. Therefore, it is necessary to provide a procedure that identifies the exact position of the spindle.

[034] The present invention also describes a system for controlling turret and spindle movements (see Figure 7). It comprises a primary control system (10) for controlling the rotation movement of the tower and a secondary control system (11) for controlling the rotation movement of the spindle. It also comprises a main control system (12) that controls the two systems (10, 11) and receives signals / information and sends commands to the two control systems (10, 11). In other words, at the beginning of the

11/15 winding, the main control system (12) sends a command to the primary control system (10) to start the first rotation movement and stop it when meeting the criteria described in this disclosure. Likewise, the main control also sends a command to the primary control system (10) to initiate the second rotation movement at the appropriate time. In a main aspect of the present invention, the main control system (12) receives information from the secondary control system (11) about the increase in the spindle current, and after that spindle current reaches its defined limit value, the main control (12) instructs the primary control system (10) to stop the second movement of rotation of the tower and lock it, so that the secondary coil (7A) remains in the ideal position.

[035] The development of oscillation in the currents in the tower and spindle motors is illustrated in the comparative graph shown in Figure 6, characterized by the data points 'X' and 'Y' representing, respectively, the points where the motor current spindle speed and the turret motor current start to increase as a result of the spindle touching the pressure roller (5) while positioning the turret.

[036] After critical observation, the inventor noticed that the spindle motor current reaches its limit value much earlier than the tower current reaches its own limit value. This is a very important discovery that allows control of the movement of the tower based on the detection of the spindle current. The time difference between data points 'X' and 'Y' clearly shows a delay of approximately 400 ms in one of the captured instances for the tower motor current to change significantly compared to the spindle motor current in increasing load due to the resistance applied by the pressure roller (5) to the movement of the tower. In a conventional device where the tower current controls the movement of the tower, this

12/15 additional time would mean that the turret would continue to rotate for an extra period, even after the spindle touched the pressure roller. This can have a detrimental effect on the operation of the device and, consequently, affect the quality of the wound coil (ie the final product).

[037] A key aspect of the present invention is that the current in the motor that drives the spindle is used to control the stop of the rotational movement of the tower, once the spindle touches the pressure roller.

[038] A key aspect of the present invention is that the current in the motor that drives the spindle is used to control the stop of the rotational movement of the tower, once the spindle touches the pressure roller.

[039] The present invention further improves the accuracy and responsiveness of the turret movement in relation to the specified position when detecting the spindle motor current, so that when the spindle touches the pressure roller (5), the motor current of the active spindle increases to a more precisely defined value and in a short period to a limit value. The limit value can be predefined below, above or equal to the motor nominal value to release the command when the current reaches the defined level during the specified time; when the spindle motor current trip value reaches a specific value, the main control system (12) sends a command to the primary control system (10) to stop at the initial winding position.

[040] It is evident that the invention has several applications.

[041] In the first application, a method is disclosed to position the spindle accurately in the automatic winder of the tower type, said winder incorporating a rotating tower (1) driven by a tower motor, said motor being controlled by a system of tower drive and said spindle being driven by a spindle motor controlled by a spindle drive system, said tower (1) having at least primary and

Secondary 13/15 (7, 7A) that are mounted on the respective spindles (2A, 2B) in a diametrically opposite position along a positional winding line (9), and characterized by the primary coil (7) being positioned in one position for winding a ribbon / yarn (3) on it, wherein, at the beginning of the ribbon winding process, said primary coil (7) touches a pressure roller (5) provided on said winder, said method comprising the step of, in said primary coil (7), reaching its predetermined packaging size by rotating the tower (1) in at least two distinct rotational movements performed at controlled speeds, preferably two distinct rotational movements, in which a first rotation movement is carried out at a first controlled speed of rotation until a point at which the centers (A, A ') of said coils (7, 7A) fall on a nearby positional line (9'), where said nearby positional line (9 ' ) and said line p winding (9) are at a finite displacement angle (ϕ) from one another, followed by the rotation of said tower in a direction necessary for a second controlled rotation speed to perform a second rotation movement, up to a point in that said secondary coil (7A) touches said pressure roller (5), followed by a stop and lock action to interrupt the rotation of said tower (1), wherein said second controlled speed is less than or equal to the first controlled speed and in which said action of stopping and braking comprises the steps of: - monitoring the change current in said spindle motor up to the predetermined / predefined limit value; - sending a command through a secondary control system (11) that controls said spindle rotation to a main control system (12) that controls said secondary control system (11),

14/15 informing that the said spindle current has reached its limit value; - send a command through said main control system (12) to a primary control system (10) that controls the rotation of the tower, instructing said primary control system (10) to stop the second rotation movement of said tower (1) and then lock said tower (1) in the position reached at the end of said second rotation movement.

[042] In a next application, the first movement is carried out so that said center (A ') of said secondary coil (7A) crosses over said positional winding line (9).

[043] In an additional application, the direction of rotation of said second rotation movement is opposite to the direction of rotation of said first rotation movement.

[044] In yet another application, the direction of rotation of said second movement of rotation is the same as the direction of rotation of said first movement of rotation.

[045] The invention also describes a system for positioning the spindle accurately in the automatic winder of the tower type, using the method disclosed in previous applications. The system (see Figure 7) comprises: - a primary control system (10) to perform said two distinct rotational movements of said tower; - a secondary control system (11) for performing said rotation of said spindles; - a main control system (12) for receiving information and sending instructions to one or both said primary and secondary control systems (10, 11), characterized by said main control system (12), when receiving information from said system of control control

15/15 secondary (11) that the increase in said spindle current has reached its predefined limit, send a command to said primary control system (10) to stop said second rotation movement of said tower and lock said tower in that position.

[046] Although the description above contains a number of specificities, they should not be interpreted as a limitation in the scope of the invention, but rather as an example of the respective preferred applications. It should be noted that modifications and variations are possible based on the above disclosure, without departing from the spirit and scope of the invention. Therefore, the scope of the invention must be determined not by the illustrated applications, but by the attached claims and their legal equivalents.

Claims (7)

CLAIMS 1) A method for accurately positioning a spindle on the automatic tower winder, said winder incorporating a rotating tower (1) driven by a tower motor, said motor being controlled by a tower drive system and said spindle being driven by a spindle motor controlled by a spindle drive system, said tower (1) having at least primary and secondary coils (7, 7A) that are mounted on the respective spindles (2A, 2B) in a position diametrically opposite along a positional winding line (9), and in which the primary spool (7) is positioned in a position for winding a tape on it, where, at the beginning of the tape winding process, said primary spool (7) touches a pressure roller (5) provided in said winder, said method comprising the step of, in said primary coil (7), reaching its predetermined packaging size by rotating the tower (1) in at least two rotational movements distinct movements performed at controlled speeds, preferably two distinct rotational movements, in which the first rotation movement is carried out at a first controlled rotation speed to a point where the centers (A, A ') of said coils (7, 7A) fall into a close positional line (9 '), where said close positional line (9') and said positional winding line (9) meet at a finite displacement angle (ϕ) from each other, followed by the rotation of the said tower in a direction necessary for a second controlled rotation speed to perform a second rotation movement, to a point where said empty secondary coil (7A) touches said pressure roller (5), followed by a stop action and locking to interrupt the rotation of said tower (1), wherein said second controlled speed is less than or equal to the first controlled speed, characterized by said stopping and locking action comprising follow the steps of: - monitoring the increase in current in said spindle motor until the predetermined limit value, said increase in current occurring when the empty coil touches said pressure roller (5); - send a command through a secondary control system (11) provided to control said spindle rotation to a main control system (12) provided to control said secondary control system (11), informing that said spindle current has reached its limit value; - sending a command through said main control system (12) to a primary control system (10) provided to control the rotation of the tower, instructing said primary control system (10) to stop the second rotation movement of said tower (1) and then lock said tower (1) in the position reached at the end of said second rotation movement. 2) A method according to claim 1, characterized in that said first movement is carried out so that said center (A ') of said secondary coil (7A) crosses over said winding position line (9). A method according to claim 2, characterized in that the rotation direction of said second rotation movement is opposite to the direction of rotation of said first rotation movement. A method according to claim 3, characterized in that the direction of rotation of said second movement of rotation is the same as the direction of rotation of said first movement of rotation. 5) A method according to claim 4, characterized in that the limit value of said spindle current is predefined below or above the nominal value of said spindle motor. 6) A system for positioning a spindle accurately in the automatic winder of the tower type, using the method according to claim 1, characterized by the said system comprising: - a primary control system (10) to perform said two distinct rotational movements said tower; - a secondary control system (11) for performing said rotation of said spindles; - a primary control system (12) for receiving information and sending instructions to one or both said primary and secondary control systems (10, 11), wherein said primary control system (12), upon receiving information from said system secondary control (11) that the increase in said spindle current has reached its predefined limit, sends a command to said primary control system (10) to stop said second rotation movement of said tower (1) and lock said tower in that position. 7) The system according to claim 6, characterized in that the spindle current limit value is set below or above the nominal value of said spindle motor.