EP1053366A1

EP1053366A1 - Monitoring control device with real time data sampling for machine used in the cable industry

Info

Publication number: EP1053366A1
Application number: EP98902045A
Authority: EP
Inventors: Yves Michnik
Original assignee: Individual
Current assignee: Innocable SA
Priority date: 1998-01-08
Filing date: 1998-01-08
Publication date: 2000-11-22
Anticipated expiration: 2018-01-08
Also published as: KR20010033937A; DE69814472D1; CN1090699C; RU2194817C2; DE69814472T2; CN1285886A; ATE239818T1; MXPA00006615A; CA2317497A1; US6330787B1; JP2002500291A; WO1999035329A1; AU5869598A; AU742355B2; EP1053366B1

Abstract

The monitoring and control device with real time data sampling comprises an optical measuring apparatus, a processing circuit with microprocessor, and an external control means. The microprocessor receives and samples data coming from the optical measuring apparatus to know the position of the wire element and its mechanical vibration behavior in real time before it is wound onto the main cable. An EPROM memory is programmed to generate a self-correction function should a drift of the position and vibration data of the wire element occur. The first motor, the second motor, and the mechanical tensioning means are controlled to re-establish optimum operation of the assembly machine.

Description

CONTROLLED CONTROL DEVICE WITH REAL-TIME INFORMATION PICKUP FOR A MACHI NEVER USED IN THE CABLING INDUSTRY

Technical field of the invention

The invention relates to a command and control device for an assembly machine intended to perform a winding operation of at least one wired element on a main cable to form a coiled cable, said assembly machine being equipped with '' actuators comprising:

- a rusting head which guides said wire element wound on at least one supply coil,

- a first head motor for driving the winding head in rotation, - a second motor for driving in rotation a take-up reel on which said wound cable is wound,

- And means for mechanical tensioning of the wire element during the winding phase, said control device comprising: - an optical measuring device containing at least one light emitter for the projection of a light beam on the wire element, and a receiver for capturing the reflected light beam with production of a measurement signal,

a microprocessor processing circuit intended to receive said measurement signal, and to send control and / or adjustment signals to said actuators,

- And an external control means comprising in particular a microcomputer for the input of the automatic operating parameters of the assembly machine according to a predetermined program of the processing circuit. The present invention relates generally to an assembly machine intended to perform a winding operation of at least one wire element.

More specifically, the invention relates to a control command device with real-time information acquisition for such an assembly machine.

The invention can be applied for example to an assembly machine intended to wind together wired elements one on the other or with each other, and it can also be applied to an assembly machine intended to wind one or more peripheral wire elements on a central cable. These elements can be metallic or composed of other materials.

In the remainder of the text, a wire element will be called any object in the form of a cable or wire, the cross section of which may be any (the wire element may be, for example, a thin strip), but is more often in general shape substantially circular and constant over its entire length. Such a wired element can constitute a simple filiform object fulfilling an essentially mechanical function (for example a reinforcing wire or an insulating or protective strip), or can constitute a cable including one or more wires ensuring the transport of energy. or a signal in electrical, magnetic, optical or other form.

In the remainder of the text, a central cable will be called any wired element as defined above, but the stiffness or the tension force of which is generally relatively large to allow another wired element to be wound around this wired element. central.

In the rest of the text, any peripheral wire element as defined above will be called "peripheral wire element", but the stiffness of which is generally lower than that of the central wire element, so that it is possible to d '' wrap the peripheral wire element around the central cable. However, it could also be envisaged, without departing from the scope of the present invention, a central cable of a stiffness less than that of the peripheral wire element, and in which the central cable is maintained with a sufficiently large tension so that it is however possible to wind the peripheral wire element around the central cable.

In the rest of the text, the term “winding operation” will mean any operation carried out by the device according to the present invention intended to cause winding of at least one wired element on or with at least one other wired element or on a central cable.

Among such possible winding operations, the following examples may be cited:

- a covering, that is to say a winding of a wire element according to contiguous turns or not in general on a central cable.

- stranding, that is to say a winding of several wire elements while respecting a previously defined winding pitch (distance measured on the central cable between the start of the winding and the end thereof, having at the start winding and at the end of winding the same reference on the circumference of the cable).

- a wrapping for wrapping a central cable with one or more ribbons,

- An operation consisting in creating a braiding around a central cable, this braiding being constituted by several spindles (a spindle being made up of several wire elements or individual wire elements wound around the central cable alternating with each other to the others so as to constitute one or more layers of braiding around the central cable, in particular to constitute a coaxial cable. The braiding can constitute a mesh of several spindles or layers made up of several wire elements. Such braiding can be used for example for constitute a shield for the central cable, or any other protection for the central cable.

- braiding performed on itself, that is to say without being applied around a central cable, so as to constitute a full braid or a hollow braid. In the remainder of the text, the term “assembly machine” will be used to mean any machine making it possible to carry out such possible winding operations, even if these machines perform, instead of an assembly proper, braiding, ribboning, wrapping, stranding, quartering or the like.

Description of the Prior Art

The document WO 93/07303 and the document FR-A 2739701 describe devices for carrying out a winding operation of at least one wire element comprising an optical means making it possible to carry out the following measurements during the winding operation:

- measurement on the wire element stretched between the winding head and the same place of winding, of the intensity of reflection of an incident light beam; - measurement on the wire element stretched between the winding head and the place of winding, of the amplitude of the oscillation of the specular reflection angle of an incident light beam, this amplitude of oscillation being representative of the tension of the wire element during winding;

- implementation, on the wire element stretched between the winding head and the actual place of winding, of one of the measures mentioned above only during a time window defined by a continuous means of the angular position of the winding head, in order to select a single determined wire element which is subject to this measurement;

- measurement, on the wire element stretched between the winding head and the place of winding, of the presence / absence of the reflection intensity of an incident light beam for continuous measurement of the angular position of the winding head.

In this prior art, use is made of an optical assembly intended to send a light beam onto the wired element, and to carry out the corresponding optical measurements on the reflected light, and of electronic means which receives signals from the optical assembly and auxiliary signals from other measuring elements to deliver the desired information on the operation of the machine, or to automatically make adjustments to the operating parameters of the machine. A problem posed for this type of assembly machines of the prior art in the event of automatic operation requires the following operations:

- select and adapt on the machine a specific type of optical measuring device whose characteristics are compatible with the type of wire element used,

- select and adapt on the machine a specific type of a power communication component whose characteristics are compatible with the type of functional device which it is intended to control automatically,

- And select and adapt on the machine a specific device allowing, during the operation of the machine, to make operational the power communication component, while deactivating the initial manual control of the functional device of the assembly machine that this component must control automatically, and to deactivate this component while making operational the initial manual control when the user wishes to carry out a manual control of this functional device in place of his automatic control.

The conditions of a treatment can vary considerably for the following reasons:

- the existing assembly machines represent a relatively large fleet of machines overall, but in which there is a great diversity of types of machines (for example machines with vertical or horizontal axis, machines for single strand to be wound, or for a large number of strands to be wound, machines with automatic or manual control);

- for a machine of a particular type, it is possible to carry out winding operations of different types (for example quartering, banding, braiding or wrapping);

- for a particular winding operation, wire elements of very different natures can be treated (for example certain wires are very reflective and others are very little, certain wires are large and others are very thin, for example a few micrometers). The ambient lighting conditions of the machine can vary considerably during the day (for example when the machine goes from normal artificial lighting at night to direct sunlight during the day through a window), and can vary in significant proportions instantly (for example when the artificial lighting of the workshop is on or off).

It follows from these observations a need to produce a command control device with taking information in real time, which can be adapted to an assembly machine with any operating cycle.

Subject of the invention

An object of the present invention is to provide a real-time control device for a universal assembly machine, usable with several types of operation, and different winding modes.

The command-control device according to the invention is characterized in that:

- the microprocessor of the processing circuit receives and samples information from the optical measuring device to know in real time the position of the wire element and its behavior in mechanical vibration before it is wound on the main cable, - means memorization, in particular an EPROM memory, are programmed to develop an autocorrection function in the event of a drift in the position and vibration data of the wire element,

- And electrical means for controlling the first motor, the second motor, and mechanical tensioning means are arranged to restore optimum operation of the assembly machine.

According to a preferred embodiment, the electrical control means are controlled in real time by the microprocessor to adjust the synchronism between the first motor of the winding head and the second motor of the take-up spool of the main cable, and establish a predetermined mechanical tension on the wire element by means of at least one electromagnetic brake. The processing circuit memorizes after sampling the maximum, minimum and average vibration values of the wired element to observe in real time the vibratory behavior and the positioning of said wired element on the screen page of the microcomputer, the resident program of the EPROM memory making it possible to control the assembly machine on the position and vibration of the wire element relative to the main cable.

According to a characteristic of the invention, auxiliary sensors of ambient temperature and / or of hydrometry are connected to the processing circuit to know a possible drift of the wired element linked to a fluctuating environment.

According to another characteristic of the invention, the transmitter and the receiver of the optical measuring device are provided with tilt adjustment means for adjusting the field of emission and reception of the light beam cooperating with the wire element. .

Brief description of the drawings

Other advantages and characteristics will emerge more clearly from the description which follows of an embodiment of the invention, given by way of nonlimiting example and represented in the appended drawings in which:

- Figure 1 is a schematic plan view of an assembly machine equipped with a control device with real-time information acquisition according to the invention;

- Figure 2 is a sectional view of an optical measurement sensor constituting one of the elements of the device of Figure 1;

- Figure 3 shows on an enlarged scale the area for monitoring the wrapping process;

- Figure 4 shows a block diagram of the electronic processing circuit of the control command device;

- Figures 5 and 6 respectively illustrate the diagrams for measuring maximum and minimum vibrations of the wire element for different values of mechanical tension; - Figure 7 shows two curves 1 and 2 representative of the average values of maximum and minimum vibrations as a function of the mechanical tension applied to the wire element.

Description of a preferred embodiment

In FIG. 1, the assembly machine 15 comprises a winding head 50 provided with an eccentric pulley 51 which guides a wire element 4 or 4A wound on a first supply reel 52 or a second supply reel 52A, each braked by an electromagnetic brake, respectively 53F and 53A. A third supply reel 54 supports a wound main cable 6, a free end strand 6A of which extends from the reel 54 to a take-up reel 55, which is driven by a motor 56M passing tautly through the winding head 50 coaxially. A free end strand 4B of the wire element 4 or 4A extends from the pulley 51 to a zone 8 of the cable strand 6A, this zone being situated between the winding head 50 and the take-up reel 55. A head motor 57M rotates the winding head 50 via an appropriate transmission 58. Such a machine is described in detail in document FR-A 2739701.

A speed and angular position encoder 59 measures the speed and the angular position of the winding head 50. In operation, the wire element (s) 4 or 4A are wound on the central cable 6 to form a wound cable, assembled , twisted 6B which is then wound on the take-up reel 55. The control device with real-time information acquisition 15 (surrounded by dotted lines) comprises:

an optical measuring device 16 placed opposite the end strand 4B, and intended to deliver optical measuring signals,

a data processing circuit 17 which receives measurement signals from the optical device 16 via a cable 18,

- And an external control means 20, for example a microcomputer, which allows a user to control at least one automatic operating parameter of the assembly machine, by controlling a programmed operation of the data processing circuit 17 via a cable 21. An output of circuit 17 is connected to the variator 56V of the motor 56M via a branch cable 64A, and an input of circuit 17 is connected to a corresponding control 63 via a branch cable 64B.

Another output of the circuit 17 is connected to the power supply 53C of the brake 53F, via a branch cable 66A, and an input is connected to the control unit 65 via a cable 66B to couple the motor 53G of the first supply coil 52.

Another output of circuit 17 is connected to the drive 57V of the motor 57M via a branch cable 62A, and an input is connected to the corresponding control 61 via a branch cable 62B.

An input of circuit 17 is connected to encoder 59 via a branch cable 68A, and an output is connected to the corresponding display 67 via a branch cable

68B.

The computer 20 then serves as a general control:

- to control 56M and 57M motors via 56V and 57V drives,

- to control the brakes 53A, 53F, or the motor 53G which works in torque,

- to check the speed and the angular position of the winding head 50 via the encoder 59,

- to display the value of the optical measuring device 16,

- and / or for any other information, calculation or display processing.

In FIG. 2, the optical measuring device 16 comprises an optical box 25 containing a means of projecting a light beam by infrared 26A and 37A, an ambient light sensor 28, and a receiver

35 of light.

The projection means comprises a first infrared emitter 26A and a second infrared emitter 37A which project two light beams 36 and 38 having a precise angular departure origin _* and "1, creating an intersection 41 at a certain distance.

The infrared light receiver 35 is placed inside a tube 35A, and measures the light reflected by the wire element 4B. The receiver 35 makes it possible to measure a light reflected in a non-specular way, and it can therefore be used:

- wire presence / absence detector, - continuous analog measurement of a reflection characteristic of the wire (for example the evolution of the brightness of the wire or the evolution of the color of the wire) in order to continuously control the quality of the wire,

- high sensitivity sensors with very rapid response in the case where the wire is extremely thin or very dark, in order to detect the precise manner in time of the appearance of the wire element 4B in the field of the infrared beams 36 and 38.

In the sheath of the cable 18 are grouped together the wires 32, 40 connected inside the housing 25 to the transmitters 26A, 37A, the wire 39 connected to the receiver 35, and the wire 34 connected to the sensor 28.

The light emitters 26A, 37A 10 of the optical measuring apparatus 16 can have different emission wavelengths, as well as different emission powers. The angle o, “1 of inclination of the emitters 26A, 37A can be adjusted in order to increase or decrease the distance from the intersection zone 41. The inclination angle c 2 of the light receiver 35 is also adjustable to modify the reception area.

The choice of the type of emitters 26A, 37A and the light receiver 35 depends on the reflectivity characteristics of the wire element 4, and on the type of measurement to be carried out.

Figure 3 shows on a larger scale the real-time monitoring area of the wrapping process. The optical measuring device 16 makes it possible to check the degree of vibration 73 of the ribbon of the wire element 4B before it is wound on the strand 6A of the main cable 6. Analysis of the vibration by the data processing circuit 17 allows regulate the mechanical tension exerted on the tape by the brake 53F. The wrapping point is also monitored by the optical measuring device 16 in zone 8, so as to obtain optimum laying precision at the level of the overlap and of the pitch of the turns of the ribbon, and to detect any crease or reversal of the ribbon.

In FIG. 4, the electronic processing circuit 17 comprises a microprocessor 75 capable of receiving information in real time from the sensor 16, and cooperating with the microcomputer of the external control means 20 for entering data and parameters as a function of the desired operating conditions. The microprocessor 75 is also connected to a ROM memory 77, a RAM memory 78, and to an EPROM memory 80, which has a resident program which develops a self-correction function for a observed drift (position and vibration of the wired element ) by acting on active components (brakes 53A of the wire element 4A, synchronism of the motors 56M, 57M, etc.).

The taking of information in real time by the sensor 16 makes it possible to know the position of the wire element 4, as well as its behavior relative to its maximum vibration.

In the diagrams of FIGS. 5 and 6, the behavior of the wire element 4 is displayed as a function of the value of the mechanical tension determined by the brake 53F.

The designation SV-22G in diagram A corresponds to a voltage of 22 grams applied to the wire element 4. FIG. 5 shows the maximum value of the vibration, while FIG. 6 illustrates the minimum value, after sampling carried out by the circuit treatment 17.

The other diagrams B, CD, E, and F correspond to higher mechanical tensions, in particular 52 grams for the designation SV-52G, 11 1 grams for the designation SV-111G, 148 grams for the designation SV-148G, 157 grams for the designation SV-157-G, and 209 grams for the designation SV-209G.

In FIG. 7, the average of the vibration observed on the wire element 4 subjected to a tension of 22 grams (SV-22G), is 260 points. The difference between the maximum and the minimum decreases after increasing the tension, to become almost constant between 148 grams and 209 grams.

This observation in real time of the behavior of the wire element 4, makes it possible to very quickly correct the operation of the assembly machine. The position of the wire element 4 relative to the strand of the main cable 6 is also known at all times. The operation of the assembly machine can be carried out in two distinct modes:

1 Manual mode: It makes it possible to adjust the assembly machine to deposit at a precise location the wire element 4 on the main cable support 6. The settings are made on:

- the synchronism between the winding head 50 of the wire element 4, and the rotation of the take-up reel 55 which pulls the main cable 6, - the voltage applied to the wire element 4 via the electromagnetic brake 53A .

After this manual adjustment of the control control device 15 on the assembly machine, the behavior of the wire element can be observed on the screen page of the microcomputer 20, namely:

- the vibration of the wire element (Average figure 7, Maximum figure 5, Minimum figure 6),

- the position of the wire element (Average of the vibration, figure 7).

The user can intervene at any time on the previously mentioned settings, as well as on the settings of the assembly machine. For example, when using fragile materials (PTFE for example), the ambient temperature or the relative humidity directly influences the behavior of the wire element 4. The path taken by the wire element (guide wheel, guide, ...) can suddenly or gradually cause a difficulty (blocked guide wheel, dirty guide, ...) consequently increasing the tension of the wire element 4, and disturbing the positioning of the wire element 4 relative to main cable 6 previously adjusted. Other parameters can influence the removal of the wire element 4, in particular in the event of a dimensional defect (width or diameter).

2 Automatic use mode

When switching from manual to automatic mode, the vibration values of the wire element 4 are memorized after sampling, as well as the average positioning value of the wire element 4. These values therefore serve as reference values for the operation of the machine in automatic mode.

The resident program of the EPROM memory 80 provides for slaving the assembly machine to the position and the vibration of the wire element 4 relative to the main cable 6A. The resident program makes it possible to control active components of the device 15 to make up for the observed drift (position of the wired element, vibration of the wired element) by orders of priority previously programmed in the EPROM memory 80.

In the event of a drift of the wire element 4 at its initial stored position, the program makes it possible to act on the setpoint for rotation of the winding head 50, by accelerating or decelerating the head d winding 50, or on the drawing setpoint of the receiving coil 55 by accelerating or decelerating the drawing of the cable 6B, or by acting on the setpoint of the mechanical tension applied to the wire element which also influences its position.

The order of priority for intervention on the active components can be modified at any time by the user of the assembly machine to contribute to optimum positioning of the wire element 4 relative to the main cable 6, and / or to minimize or increase the vibration of the wire element 4.

If the observed drifts are too great for self-correction, the resident program of the EPROM 80 memory is designed to stop the assembly machine.

Real-time monitoring of the installation of the wire element 4 and of its vibration is associated with traceability, which makes it possible to inform the user of the drifts observed, in order to know the resulting quality level on a given manufacture, and to know the manufacturing process concerning a particular product by associating the manufacturing times, the manufacturing speeds (rotation of the winding head, ...) and possible stops (change of the wire element for example). This monitoring of the wired element also makes it possible to know the possible drift. consecutive to parameters external to the assembly machine (ambient temperature, hygrometry, ...). Auxiliary sensors 82 transmit the temperature and humidity measurements to the microprocessor 75 for this purpose.

Claims

1. Control-command device for an assembly machine intended to carry out a winding operation of at least one wire element (4, 4A) on a main cable (6, 6A) to form a coiled cable (6B), said assembly machine being equipped with actuators comprising: - a winding head (50) which guides said wire element (4, 4A) wound on at least one supply reel (52, 52A),

- a first head motor (57M) for driving the winding head (50) in rotation,

a second motor (56M) for driving in rotation a take-up reel (55) on which said wound cable is wound (6B),

- And means for mechanical tensioning of the wire element (4, 4A) during the winding phase, said control device comprising:

- an optical measuring device (16) containing at least one light emitter (26A, 37A) for projecting a light beam onto the wire element (4A), and a receiver (35) for capturing the light beam reflected with production of a measurement signal,

a microprocessor processing circuit (17) intended to receive said measurement signal, and to send control and / or adjustment signals to said actuators,

- And an external control means (20) comprising in particular a microcomputer for the input of the automatic operating parameters of the assembly machine according to a predetermined program of the processing circuit (17), characterized in that:

- the microprocessor (75) of the processing circuit (17) receives and samples information from the optical measuring device (16) to know in real time the position of the wire element (4, 4A) and its behavior in mechanical vibration (73) before it is wound on the main cable (6, 6A),

- storage means, in particular an EPROM memory (80), are programmed to develop a self-correction function in the event of appearance a drift of the position and vibration data of the wire element (4A),

- And electrical means for controlling the first motor (57M), the second motor (56M), and mechanical tensioning means are arranged to restore optimum operation of the assembly machine.

2. Control control device according to claim 1, characterized in that the electrical control means are controlled in real time by the microprocessor (75) to adjust the synchronism between the first motor (57M) of the winding head (50 ) and the second motor (56M) of the take-up spool (55) for drawing the main cable (6A), and establishing a predetermined mechanical tension on the wire element (4, 4A) by means of at least one electromagnetic brake ( 53A, 53F).

3. Command control device according to claim 1, characterized in that the processing circuit (17) stores after sampling the maximum, minimum and average vibration values of the wire element (4) to observe in real time the vibrational behavior and positioning of said wired element on the screen page of the microcomputer, the resident program of the EPROM memory (80) making it possible to control the assembly machine on the position and the vibration of the wired element (4) to the main cable (6A).

4. Command control device according to claim 3, characterized in that auxiliary sensors (82) of ambient temperature and / or of hydrometry are connected to the processing circuit (17) to know a possible drift of the wired element (4) linked to a fluctuating environment.

5. Command control device according to claim 1, characterized in that the transmitter (26A, 37A) and the receiver (35) of the optical measuring device (16) are provided with tilt adjustment means for adjusting the emission and reception field of the light beam cooperating with the wire element (4).

6. Command control device according to claim 1, characterized in that the first motor (57M) is equipped with an encoder (59) of speed and angular position connected to the processing circuit (17) to check the data of speed and angular position of the winding head (50), said data being displayed on a display (67).

7. Control control device according to claim 5, characterized in that the optical measuring device (16) is provided with a sensor (28) of ambient light, and two emitters (26A, 37A) of light at infrared surrounding the central receiver (35), the assembly being arranged inside a box (25) disposed in the vicinity of the wire element (4B).