WO2023126948A1 - Strand feeder and method of operating same - Google Patents

Abstract

A continuous solid material feeder is disclosed. The continuous solid material feeder comprises: an entrance conduit; an advancing assembly configured to advance a continuous solid material; a motor axially connected to at least one gear in the advancing assembly; a continuous solid material exit unit; and a sensor configured to measure one or more parameters indicative of the force applied on the continuous solid material by at least one of: an exit conduit connected to the continuous solid material exit unit and the entrance conduit.

Description

STRAND FEEDER AND METHOD OF OPERATING SAME

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a PCT Patent Application which claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63/295,902, filed January 2, 2022, entitled “STRAND FEEDER AND METHOD OF OPERATING SAME”. The content of the above application is all incorporated by reference as if fully set forth herein in its entirety.

FIELD OF THE INVENTION

[0002] The present invention relates generally to industrial wire feeders. More specifically, the present invention relates to industrial strand wire feeders.

BACKGROUND OF THE INVENTION

[0003] Strand feeders are used in the industry to feed strands for various industrial applications. In most cases, the strand feeder is controlled to provide the strand or wire at a known rate and/or known tension.

[0004] In complex systems that require maneuvering the strand along a path that includes a plurality of bends, the traditional dancer tension-controlling method is insufficient and too large at times.

[0005] Therefore, there is a need for an alternative to the traditional dancer mechanism for feeding strands along a path that includes a plurality of bends and a plurality of feeders on the same line, that provides better control of the final tension and velocity of the strand feed into the industrial production system.

SUMMARY OF THE INVENTION

[0006] Some aspects of the invention are directed to a continuous solid material feeder, comprising: an entrance conduit; an advancing assembly configured to advance a continuous solid material; a motor axially connected to at least one gear in the advancing assembly; a continuous solid material exit unit; and a sensor configured to measure one or more parameters indicative of the force applied on the continuous solid material by at least one of an exit conduit connected to the continuous solid material exit unit and the entrance conduit. [0007] In some embodiments, the continuous solid material feeder further comprising: a body for holding the entrance conduit, the advancing assembly, and the motor; a slider at which the body is configured to slide thereon; and a slider base connected to the slider. In some embodiments, the sensor is a load cell attached to the slider top.

[0008] In some embodiments, a continuous solid material feeder further comprising: a body for holding the orientating entrance, the advancing assembly, and the motor; wherein the sensor is a proximity sensor connected to the body; and wherein the continuous solid material exit unit comprises: a spring having known spring parameters; a tubular slider configured to slide on the exit conduit, connected to a first end of the spring; and a disc connected to a second end of the spring; and wherein the proximity sensor is configured to measure a distance between the disc and the body.

[0009] In some embodiments, the continuous solid material exit unit comprises a continuous solid material director; and an encoder. In some embodiments, the advancing assembly comprises a plurality of gears; a plurality of vulcanized wheels for advancing the continuous solid material, wherein at least some of the vulcanized wheels are axially connected to gears; and a main gear axially connected to the motor providing a rotational movement to the plurality of gears.

[0010] In some embodiments, the advancing assembly comprises: a plurality of gears; and

[0011] a main gear axially connected to the motor providing a rotational movement to the plurality of gears. In some embodiments, the continuous solid material feeder further comprising: one or more electric power inputs.

[0012] In some embodiments, the continuous solid material feeder further comprising one or more communication inputs in communication with at least one of: the motor, the orientation motor, the force/tension sensor, and the encoder.

[0013] Some aspects of the invention may be directed to a system for controllably advancing a continuous solid material, comprising: one or more spools for providing the continuous solid material; a plurality of continuous solid material feeders according to any one of the embodiments discloses herein; a plurality of conduits configured to direct continuous solid materials, threaded therein, between continuous solid material feeders; and a head continuous solid material feeder, comprising an orientating entrance comprising a continuous solid material orientation guide; an advancing assembly configured to advance a continuous solid material; a motor axially connected to at least one gear in the advancing assembly; and a continuous solid material exit unit.

[0014] In some embodiments, the system further comprising a controller configured to: control each motor in each continuous solid material feeder to advance the continuous solid material based on received parameters indicative of the force applied on the continuous solid material by at least one of: an exit conduit connected to the continuous solid material exit unit and the entrance conduit.

[0015] Some aspects of the invention may be directed to a method of controllably advancing a continuous solid material, comprising: receiving, form a first sensor included in a first a continuous solid material feeder, a parameter indicative of the force applied on the continuous solid material by at least one of: a first exit conduit feeder and an entrance conduit included in the first continuous solid material feeder; receiving, form a second continuous solid material feeder, a velocity of the continuous solid material in a second exit conduit of the second continuous solid material feeder; and controlling a motor included in the first continuous solid material feeder to advance the continuous solid material based on the parameter and the velocity.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The subject matter regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of operation, together with objects, features, and advantages thereof, may best be understood by reference to the following detailed description when read with the accompanying drawings in which:

[0017] Fig. 1 A and IB are illustrations of the front view and back view of a strand feeder according to some embodiments of the invention;

[0018] Figs. 2A and 2B, are illustrations of another strand feeder according to some embodiments of the invention;

[0019] Fig. 3 is a block diagram of a system for feeding strands according to some embodiments of the invention; and

[0020] Figs. 4A and 4B are block diagrams of control loops for controlling a strand feeder according to some embodiments of the invention.

[0021 ] It will be appreciated that for simplicity and clarity of illustration, elements shown in the figures have not necessarily been drawn to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0022] One skilled in the art will realize the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The foregoing embodiments are therefore to be considered in all respects illustrative rather than limiting of the invention described herein. The scope of the invention is thus indicated by the appended claims, rather than by the foregoing description, and all changes that come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

[0023] Some aspects of the invention may be directed to a continuous solid material feeder and a system comprising several continuous solid material feeders for controllably feeding continuous solid material, such as, strands, sheets, wires, etc., to any industrial system. Such a feeder and a system may feed continuous solid material (e.g., as a raw material) to an additive manufacturing system, printing system, electrical wires industry, welding machines (Such as MIG), and more. A system of continuous solid material feeders according to embodiments of the invention may allow providing the continuous solid material to the industrial system at an accurate speed and tension, even if the continuous solid material must travel along a bent path (e.g., through two or more 90-180 degree turns over several meters).

[0024] As used herein a continuous solid material may be defined as any elongated material, provided, for spools, rolls, and the like, to an industrial system. For example, the continuous solid material may include, strands, wires, sheets, and the like.

[0025] In some embodiments, the continuous solid material may be any type of continuous solid material made from any suitable material, for example, a polymeric continuous solid material, metallic continuous solid material, etc. In a nonlimiting example, the continuous solid material may be a polymeric strand made from polyethylene, polyester, or polypropylene. In some embodiments, the continuous solid material may have any cross-section, for example, rectangular, round, triangular, hexagonal etc.

[0026] In some embodiments, the continuous solid material may be provided to the feeder from a spool. In some embodiments, the stand may travel inside a delivering conduit between one feeder to the other. In some embodiments, the conduit may be a full tube, a tubular net, a semi-open conduit, and the like. In some embodiments, while traveling inside the conduit, the conduit may apply force on the continuous solid material (e.g., due to friction). The applied force may affect and alter the tension and speed of the continuous solid material at the entrance to the industrial system. Since each industrial system requires the provision of a continuous solid material at specific tension and speed, it is required to control the feeding process to provide the continuous solid material at the required tension and speed.

[0027] Reference is now made to Figs. 1 A and IB which are illustrations of the front view and back view of a continuous solid material feeder 100 according to some embodiments of the invention. Continuous solid material feeder 100 may include an entrance conduit 110, an advancing assembly 120 configured to advance a continuous solid material 10, and a motor 130. In some embodiments, motor 130 may be axially connected to at least one gear 126, 122 in advancing assembly 120. In some embodiments, system 100 may further include a continuous solid material exit unit 140, and a sensor 150 configured to measure one or more parameters indicative of the force applied on continuous solid material 10 by at least one of an exit conduit 105B connected to the continuous solid material exit unit and entrance conduit 110.

[0028] In some embodiments, continuous solid material feeder 100 may further include a body 160 for holding entrance conduit 110, advancing assembly 120, and motor 130. System 100 may further include a slider 170 at which body 160 is configured to slide thereon and a slider base 176 connected to the slider.

[0029] In a nonlimiting example, sensor 150 may be a load cell attached to slider base 176. In some embodiments, load cell sensor 150 may be attached to slider base near exit 105B, as illustrated or near entrance 105A. Another nonlimiting example, of a sensor, is illustrated and discussed with respect to Figs. 2 A and 2B.

In some embodiments, continuous solid material entrance or exit unit 140 may include a continuous solid material director 142 and an/or encoder 144. Encoder 144 may be configured to directly measure the movement of the continuous solid material using a rolling wheel of known perimeter thus removing any system backlash or slippages from being measured. The encoder allows for more direct and precise measurement of the continuous solid material movement but is not mandatory for the tension control to work according to the invention stated above.

[0030] In some embodiments, entrance conduit 110 may be a full tube, a tubular net, a semi-closed conduit, and the like. Entrance conduit 110 may be connected to a delivering conduit, encompassing stand 10. In some embodiments, sensor 150 (e.g., a load cell) may be connected near entrance conduit 110 for measuring one or more parameters indicative of the force applied on continuous solid material 10 by entrance conduit 110. For example, a load cell may be connected to slider base 176 near entrance 105A measuring the force applied on slider base 176 by entrance tube 110 when continuous solid material 10 is traveling in entrance conduit 110.

[0031] In some embodiments, motor 130 may be any electrical, hydraulic or pneumatic motor known in the art.

[0032] Advancing assembly 120, may be or may include any mechanical and/or electrotechnical components that may allow advancing stand 10 in a required direction, from entrance 110 to exit 140.

[0033] In the nonlimiting example illustrated in Figs. 1A and IB, advancing assembly 120 may include a plurality of gears 122 for providing rotational movement to a plurality of vulcanized wheels 124. Volcanized wheels 124 may advance the continuous solid material. In some embodiments, at least some of the vulcanized wheels may be axially connected to gears 122. Advancing assembly 120 may further include a main gear 126 axially connected to motor 130 for providing a rotational movement to the plurality of gears 122. Another nonlimiting example is illustrated and discussed with respect to Figs. 2A and 2B.

[0034] As should be understood by one skilled in the art other advancing mechanisms, like belt feeders, metallic wheels, chain movement, the screw may be enplanement as well. [0035] Reference is now made to Figs. 2A and 2B are illustrations of another continuous solid material feeder according to some embodiments of the invention. Continuous solid material feeder 200 may include substantially the same main components as continuous solid material feeder 100. Continuous solid material feeder 200 may include an entrance conduit 110, an advancing assembly 220 configured to advance a continuous solid material 10, and a motor 130. In some embodiments, motor 130 may be axially connected to at least one gear 222, in advancing assembly 220. In some embodiments, system 200 may further include a continuous solid material exit unit 140, and a sensor 250 configured to measure one or more parameters indicative of the force applied on continuous solid material 10 by at least one of an exit conduit 105B connected to the continuous solid material exit unit and entrance conduit 110.

[0036] In some embodiments, continuous solid material feeder 200 may further include a body 160 for holding entrance conduit 110, advancing assembly 220, and motor 130. System 100 may further include a slider 170 at which body 160 is configured to slide thereon and a slider base 176 connected to the slider.

[0037] Advancing assembly may include a plurality of gears 222, assembled such that continuous solid material 10 may pass between several pairs of gears 222, advancing continuous solid material 10 forward. In some embodiments, advancing assembly 220 may further include a main gear (not illustrated) axially connected to motor 130 for providing a rotational movement to the plurality of gears 222.

[0038] In some embodiments, continuous solid material feeder 200 may further include a sensor 250 (e.g., a proximity sensor) connected to body 160. In some embodiments, continuous solid material exit unit 140 may include: a spring 141 having a known spring parameter, a tubular slider 143 configured to slide on the exit conduit, connected to a first end of the spring; and a disc 145 connected to a second end of the spring. In some embodiments, proximity sensor 250 may be configured to measure a distance between the disc and the body. In some embodiments, one or more measured distances may be the one or more parameters indicative of the force applied on continuous solid material 10 by the exit conduit.

[0039] In some embodiments, continuous solid material feeders 100 or 200 may further include one or more electric power inputs. In some embodiments, continuous solid material feeders 100 or 200 may further include one or more communication inputs 190 in communication with at least one of: motor 130, sensor 150, and the encoder 144. One or more communication inputs 190 may be configured to provide instructions received from a main controller to motor 130, sensor 150/250 and the encoder 144. In some embodiments, continuous solid material feeders 100 or 200 may further include one or more communication outputs 192, configured to send data to the main controller, for example, the measured one or more parameters indicative of the force applied on the continuous solid material by at least one of: exit conduit 105B connected to the continuous solid material exit unit and the entrance conduit 110. [0040] Reference is now made to Fig. 3 which is a block-diagram of a system 1000 for feeding continuous solid materials according to some embodiments of the invention. System 1000 may include one or more spools 50 for providing the continuous solid material and a plurality of continuous solid material feeders 100 or 200 according to embodiments of the invention. System 1000 may further include a plurality of conduits 105 configured to direct continuous solid materials, threaded therein, between the continuous solid material feeders; and head continuous solid material feeder 300.

[0041 ] Head continuous solid material feeder 300 may include, an entrance, for example, entrance 110 comprising a continuous solid material orientation guide, an advancing assembly, for example, advancing assemblies 120/220 configured to advance a continuous solid material and a motor, for example, motor 130, axially connected to at least one gear in the advancing assembly and a continuous solid material exit unit, for example, exit unit 140. In some embodiments, head continuous solid material feeder 300 does not include a sensor configured to measure one or more parameters indicative of the force applied on the continuous solid material.

[0042] In some embodiment, system 1000 may include two or more spools in order to ensure a continuous provision of continuous solid materials to system 1000, once a first spool is running out of continuous solid material. In some embodiments, system 1000 may include an automatic switching unit for switching between the first spool to the second spool and vice versa. In some embodiments, each one of spools 50 may provide a continuous solid material to a first continuous solid material feeder 100/200. In some embodiments, system 1000 may further include a Y junction 400 for directing one continuous solid material provided by the first or the second spools to a first conduit 105. Conduit 105 may be a full conduit, a tubular net, a semi-open conduit, and the like. At least one conduit 105 (e.g., a first conduit 105) may be at least 500 mm long and may further include at least one bend or turn. The turn may be between 20 degrees to 180 degrees turn, for example, the turn may be a 30 degrees turn, a 45 degrees turn, a 60 degrees turn, a 75 degrees turn, a 90 degrees turn or more.

[0043] In some embodiments, first conduit 105 may direct the continuous solid material to a second continuous solid material feeder 100/200. Form second continuous solid material feeder 100/200 the continuous solid material may be directed to a third conduit 105, which may be similar or different from first conduit 105. [0044] In some embodiments, from the second conduit 105 the continuous solid material may be directed to the head feeder 300 to be provided to the industrial system. Alternatively, additional continuous solid material feeders 100/200 and conduits 105 may be added to system 1000 dependent on the distance between spools 50 and the industrial system.

[0045] In some embodiments, system 1000 may further include a main controller (not illustrated). The main controller may include any computing device configured to execute instructions stored in a memory associate with the controller. The instructions may include any method of controlling system 1000 disclosed herein.

[0046] Reference is now made to Figs. 4A and 4B which are block diagrams of control loops for controlling each continuous solid material feeder in a system of continuous solid material feeders, such as, system 1000. In each system, the forward continuous solid material feeder is defined as the master continuous solid material feeder for the continuous solid material feeder placed before, which is defined as the slave feeder. In some embodiments, system 1000 needs to provide continuous solid material 10 to the industrial system at a required tension and speed, therefore, the tension speed is determined by head continuous solid material feeder 300. Accordingly, head continuous solid material feeder 300 is the master for the continuous solid material feeder 100A/200A with is the master for the continuous solid material feeder 100B/200B (e.g., in system comprising two continuous solid material feeders 100/200). Therefore, continuous solid material feeder 100B/200B is the slave of second continuous solid material feeder 100A/200A which is the slave of head continuous solid material feeder 300.

[0047] In some embodiments, the control of each continuous solid material feeder 100/200 may be conducted in the forward direction, by measuring one or more parameters indicative of the force applied on the continuous solid material by exit conduit 105B connected to the continuous solid material exit unit 140, for example, by a load cell. Such a control loop is diagrammatically illustrated in Fig. 4A, wherein the control is conducted on the “salve” continuous solid material feeder.

[0048] In the control loop Fig. 4A, the first continuous solid material feeder is the slave continuous solid material feeder, and the second continuous solid material feeder is the master continuous solid material feeder.

[0049] In block 410, a parameter indicative of the force applied on the continuous solid material by exit conduit 105B may be received from the first continuous solid material feeder. For example, force/load measurements from sensor 150 (e.g., a load cell) connected to slider base 176 near exit 105B may include measuring the force applied on slider base 176 by exit conduit 105B when continuous solid material 10 is traveling in exit conduit 105B.

[0050] In block 420, a reference parameter indicative of the force applied on the continuous solid material in the salve continuous solid material feeder (e.g., the first continuous solid material feeder) may be received, as an input, for example, from a main controller/database.

[0051] In block 430, the measured parameter and the reference parameter may be provided and compared in a dynamic proportional integral derivative (PID) controller.

[0052] In block 440, a velocity of the master continuous solid material feeder (e.g., the second continuous solid material feeder) may be received (e.g., from head continuous solid material feeder 300 or from the continuous solid material feeder 200A/100A located ahead in the progression direction of the continuous solid material).

[0053] In block 450, the velocity of the slave (e.g., the first continuous solid material feeder) may be calculated based on the received measured parameter, the received reference parameter, and the received master continuous solid material feeder velocity.

[0054] In block 460, a motor (e.g., motor 130) may be controlled to advance the continuous solid material, inside the salve continuous solid material feeder (e.g., the first continuous solid material feeder) at the calculated velocity.

[0055] In some embodiments, the control of each continuous solid material feeder 100/200 may be conducted in the backward direction, by measuring one or more parameters indicative of the force applied on the continuous solid material by entrance conduit 110, for example, by a load cell. Such a control loop is diagrammatically illustrated in Fig. 4B.

[0056] In the control loop Fig. 4A, the first continuous solid material feeder is the master continuous solid material feeder and the second continuous solid material feeder is the slave continuous solid material feeder.

[0057] In block 415, a parameter indicative of the force applied on the continuous solid material by entrance conduit 110 may be received from the first continuous solid material feeder. For example, force/load measurements from sensor 150 (e.g., a load cell) connected to slider base 176 near entrance conduit 110 may include measuring the force applied on slider base 176 by entrance conduit 110 when continuous solid material 10 is traveling in entrance conduit 110. Alternatively, the parameter indicative of the force applied on the continuous solid material by entrance conduit 110 may be received from proximity sensor 250 thus may include the distance between disc 145 and body 160.

[0058] In block 425, a reference parameter indicative of the force applied on the continuous solid material in the master (e.g., the first continuous solid material feeder) may be received, as an input, for example, from the main controller.

[0059] In block 435, the measured parameter and the reference parameter may be provided and compared in a dynamic proportional integral derivative (PID) controller.

[0060] In block 440, a velocity of the slave continuous solid material feeder (e.g., the second continuous solid material feeder) may be received (e.g., from continuous solid material feeder 200B/100B located backwards from the progression direction of the continuous solid material).

[0061] In block 455, the velocity of the master (e.g., the first continuous solid material feeder) may be calculated based on the received measured parameter, the received reference parameter, and the received master continuous solid material feeder velocity.

[0062] In block 465, a motor (e.g., motor 130) may be controlled to advance the continuous solid material, in the master (e.g., the first continuous solid material feeder), at the calculated velocity.

[0063] Unless explicitly stated, the method embodiments described herein are not constrained to a particular order or sequence. Furthermore, all formulas described herein are intended as examples only and other or different formulas may be used. Additionally, some of the described method embodiments or elements thereof may occur or be performed at the same point in time.

[0064] While certain features of the invention have been illustrated and described herein, many modifications, substitutions, changes, and equivalents may occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.

[0065] Various embodiments have been presented. Each of these embodiments may of course include features from other embodiments presented, and embodiments not specifically described may include various features described herein.

Claims

1. A continuous solid material feeder, comprising: an entrance conduit; an advancing assembly configured to advance a continuous solid material; a motor axially connected to at least one gear in the advancing assembly; a continuous solid material exit unit; (and a sensor configured to measure one or more parameters indicative of the force applied on the continuous solid material by at least one of: an exit conduit connected to the continuous solid material exit unit and the entrance conduit.

2. The continuous solid material feeder of claim 1, further comprising: a body for holding the entrance conduit, the advancing assembly, and the motor; a slider at which the body is configured to slid thereon; and a slider base connected to the slider.

3. The continuous solid material feeder of claim 2, wherein the sensor is a load cell attached to the slider top.

4. The continuous solid material feeder of claim 1, further comprising: a body for holding the orientating entrance, the advancing assembly, and the motor; wherein the sensor is a proximity sensor connected to the body; and wherein the continuous solid material exit unit comprises: a spring having known spring parameters; a tubular slider configured to slide on the exit conduit, connected to a first end of the spring; and a disc connected to a second end of the spring; and wherein the proximity sensor is configured to measure a distance between the disc and the body.

5. The continuous solid material feeder according to any one of the preceding claims, wherein the continuous solid material exit unit comprises: a continuous solid material director; and an encoder.

6. The continuous solid material feeder according to any one of the preceding claims, wherein the advancing assembly comprises: a plurality of gears; a plurality of vulcanized wheels for advancing the continuous solid material, wherein at least some of the vulcanized wheels are axially connected to gears; and a main gear axially connected to the motor providing a rotational movement to the plurality of gears.

7. The continuous solid material feeder according to any one of claims 1 to 5, wherein the advancing assembly comprises: a plurality of gears; and a main gear axially connected to the motor providing a rotational movement to the plurality of gears.

8. The continuous solid material feeder according to any one of the preceding claims, further comprising: one or more electric power inputs.

9. The continuous solid material feeder according to any one of the preceding claims, further comprising one or more communication inputs in communication with at least one of: the motor, the orientation motor, the force/tension sensor and the encoder.

10. A system for controllably advancing a continuous solid material, comprising: one or more spools for providing the continuous solid material; a plurality of continuous solid material feeders according to any one of the preceding claims; a plurality of conduits configured to direct continuous solid materials, threaded therein, between continuous solid material feeders; and a head continuous solid material feeder, comprising an orientating entrance comprising a continuous solid material orientation guide; an advancing assembly configured to advance a continuous solid material; a motor axially connected to at least one gear in the advancing assembly; and a continuous solid material exit unit.

11. The system of claim 10, further comprising a controller configured to: control each motor in each continuous solid material feeder to advance the continuous solid material based on received parameters indicative of the force applied on the continuous solid material by at least one of: an exit conduit connected to the continuous solid material exit unit and the entrance conduit.

12. A method of controllably advancing a continuous solid material, comprising: receiving, form a first sensor included in a first a continuous solid material feeder, a parameter indicative of the force applied on the continuous solid material by at least one of: a first exit conduit feeder and an entrance conduit included in the first continuous solid material feeder; receiving, form a second continuous solid material feeder, a velocity of the continuous solid material in a second exit conduit of the second continuous solid material feeder; and controlling a motor included in the first continuous solid material feeder to advance the continuous solid material based on the parameter and the velocity.

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