Automatic line roll reading apparatus with RFID tags, related systems and tracking methods

Abstract

An automatic reading device (100) for tracking spools (1) of wire having a tube (3) provided with an RFID tag (5), comprising a reader (102) adapted to exchange information with the RFID tag (5) through an antenna (101) and an electronic system (103) comprising a central processing unit. The device according to the invention is characterized in that it comprises a spool handling support (2) having a tip (21) on which a plurality of spools (1) of wire having a tube (3) provided with an RFID tag (5) can be sequentially inserted and in that the tip (21) is the antenna (101).

Description

TECHNICAL FIELD

[0001] The subject of the present invention is an automatic system for tracing a reel of textile thread, and a related method for automatically tracing a reel of thread using said system. BACKGROUND

[0002] Due to the increasing demand for quality on the market, there has been a long-standing need, even in the textile industry, to be able to provide a full traceability of the product, i.e. to be able to reconstruct the history of a textile finished product (whatever the sector it relates to: clothing, home, automotive, etc.) up to the origin of all the threads that made it. The threads used are the result of various steps and processes that together determine the quality characteristics of the finished product.

[0003] In industrial production, the threads are wound on tubes to form reels using machines called winding machines. In industrial systems, the automation of the process of moving the reels from the winding machines to the subsequent stages (for example, a sorting production line, a warehouse or a palletizing) is essential. To perform these tasks, the automatic handling system comprises a machine called "doffer" which is suitable for picking up the ready reels from the winding machines and transporting them to the next work station. For technical reasons, the reels must be able to be traced and distinguished according to the production machine, the production batch and other quality-related parameters.

[0004] At present, this tracing is done manually. The tubes inside the reels are usually made of cardboard, which offers many advantages, such as low cost, good temperature resistance, the possibility of marking with symbols and colors, and the ease of sticking labels in them.

[0005] To trace the path of the reels, the most commonly used technique at present involves the use of identification codes with graphic elements, such as QR codes or bar codes, which are applied to the inside of the tubes either by marking the codes directly or by sticking labels containing them.

[0006] However, this system still has some drawbacks: not only is it necessary to add a labeling station, but it also forces the operator to use identification tools for the codes, which are sometimes difficult to access inside the tube. For the same reason, the automatic recognition of these labels is complex.

[0007] In order to have more and more automation and central control devices, it is necessary to be able to automatically trace the reels from the beginning, i.e. from the moment the reel leaves the winding machine. SUMMARY

[0008] The aim of the present invention is to solve the problems related to the traditional reel tracing system.

[0009] In particular, it is an object of the present application to provide a system able to automatically track a coil of wire as soon as it is unwound from a winding machine.

[0010] This object is achieved by the automatic reading device for tracking a coil of wire according to the present disclosure, by the coil handling machine according to the present disclosure, by the automatic coil tracking system according to the present disclosure, by the automatic coil tracking method according to the present disclosure, by the computer according to the present disclosure and by the computer program for implementing the automatic tracking method according to the present disclosure. Preferred embodiments are described in the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0011] The features and advantages of the device according to the present application will become more apparent from the following description, given by way of indicative and non-limiting example, with reference to the enclosed drawings, in which:

[0012] - Figure 1 A perspective view of a coil of wire 1 is shown;

[0013] - Figure 2 A perspective view of the automatic reading device 100 according to the present application is shown, in particular an exploded view of the antenna 101 connected to the electronic device 104 by means of a connection cable 105;

[0014] - Figure 3 An automatic reading device 100 of Figure 2 is shown, in which the casing of the electronic device 104 has been partially removed;

[0015] - Figure 4 A side view of the components of the automatic coil tracking machine according to the present application is shown, in particular a side view of the coil handling support or reel handling support 2 having an end head with the automatic reading device 100;

[0016] - Figure 5 An exploded view of the end head of the coil handling support in Figure 4 is shown;

[0017] - Figure 6 A longitudinal sectional view of the end head of the coil handling support in Figure 4 is shown;

[0018] - Figure 7 A perspective view of the end head of the coil handling support in Figure 4 is shown, after removal of the outer cover;

[0019] - Figure 8 A work diagram of the automated cycle for automatically tracking a coil of wire loaded onto the coil handling support is shown. DETAILED DESCRIPTION

[0020] With reference to the above figures, and in particular to Figure 1 Some definitions useful for understanding the present application are given below.

[0021] Tube 3: cylindrical body for winding the thread forming the thread roll 1; the cylindrical body is usually made of plastic or cardboard.

[0022] Thread roll 1: the thread roll is obtained by winding the thread so that it adheres to the tube 3, thus maintaining the cylindrical symmetry. The thread roll 1 can have different profiles depending on the physico-chemical properties of the thread collected for mechanical textile reasons.

[0023] Radio Frequency Identification (RFID): RFID is an automatic identification technology based on the propagation of electromagnetic waves in the air, which allows the explicit, automatic (hands-free), mass and remote detection of objects, animals and people, both stationary and in motion.

[0024] RFID tag 5: the tag is also known as transponder or smart tag; the main component of the tag is a small silicon piece surrounded by an antenna, usually made of copper, which is connected to the antenna and which, when the tag is hit by an electromagnetic field of the appropriate frequency, receives from the antenna the energy necessary for its operation.

[0025] Therefore, in general, as Figure 1 shown, the thread roll 1 comprises a tube 3 inside which a tag 5 with RFID is fixed, which allows the unique identification of the tube 3, and therefore of the thread roll 1.

[0026] In one example embodiment, the tag 5 (RFID tag) is of the unidirectional type, i.e. it can be read / written depending on a specific orientation of the tag plane with respect to the antenna. The optimal position of the tag 5 is in the central band of the tube, so that it is as far as possible from the tags 5 on the adjacent tubes. However, this is not essential; the system is designed so that it can work anyway. If the tag 5 is unidirectional, the orientation must be defined; if the tag 5 is omnidirectional, the orientation does not affect the reading / writing of the tag.

[0027] In another example embodiment, the tag 5 (RFID tag) is of the omnidirectional type, i.e. it can be read / written regardless of the orientation of the tag plane with respect to the antenna. Advantageously, this solution allows the RFID tag 5 to be attached in any orientation and in any position inside the tube 3.

[0028] The subject of the present application is an automatic tracking system comprising Figure 2 and Figure 4 an automatic reading device 100 as shown in Figure 1 and a plurality of tubes 3 with RFID tags 5.

[0029] The automatic reading device 100 comprises an antenna 101 connected by a connection cable 105 to a reader 102 connected to an electronic system 103.

[0030] The antenna 101 communicates with the antenna of the RFID tag 5 through radio waves.

[0031] Preferably, the antenna 101 is of the coaxial type, i.e. it is able to receive and emit signals in a plane of 360°. Advantageously, this solution, combined with the use of omnidirectional RFID tags 5, ensures the certainty of reading the RFID tags 5 inside the tube 3 and therefore the certainty of tracing the coil 1.

[0032] The reader 102 is adapted, on the one hand, to exchange information with the RFID tag 5 through the antenna 101 and, on the other hand, to interact with the electronic system 103 to which it is connected.

[0033] The reader 102 therefore has the function of managing the antenna 101 for the emission and reception of radiofrequency signals.

[0034] The electronic system 103 comprises a central processing unit (CPU) adapted to manage the sending of the data read by the reader 102 to at least one programmable logic controller (PLC) and / or at least one computer through an industrial serial protocol.

[0035] The reader 102 and the electronic system 103 connected to it are housed in an electronic device 104 provided with a casing 106 which can be easily positioned in the workstations of the textile mill, for example on the "doffer" machine, which is adapted to pick up the coils 1 from the winding machines and convey them to the next work station.

[0036] In particular, the antenna 101 is shown in Figure 2 and Figure 3

[0037] The antenna 101 comprises a head 110 in which a seat 116 is made in which the antenna body 111 is housed, which is adapted to read / write the RFID tag 5 through radio waves.

[0038] Preferably, the seat 116 in which the antenna body 111 is housed merges into the front opening 119.

[0039] Preferably, the head 110 is made of a non-shielding material, i.e. a material that does not interfere with the electromagnetic field, for example a plastic material. ​

[0040] Preferably, the head 110 has a truncated-cone shape, with a smaller diameter the closer to the tip.

[0041] The head 110 is closed at the rear by a bushing 117, which also closes a seat 116 in which the antenna body 111 is housed.

[0042] A screen 114 is arranged at the rear of the bushing 117. Preferably, the screen 114 is made of a shielding material, such as metal.

[0043] The antenna body 111 is connected at the rear to an attenuator 112, which is connected to an adapter 113 for the connection cable 105. Both the attenuator 112 and the adapter 113 are arranged inside the bushing 117, which is closed at the rear by the screen 114.

[0044] Note that the adapter 113 protrudes from the screen 114.

[0045] The connection cable 105, which makes the data connection between the antenna 101 and the electronic device 104, which comprises the reader 102 and the electronic system 103, comprises a connector 115, which is connectable to the adapter 113 of the antenna 101.

[0046] The automatic reading apparatus 100 is characterized in that it comprises a thread package handling support 2 having a tip 21, into which a plurality of thread packages 1 are sequentially inserted, and in particular the tip 21 is an antenna 101.

[0047] The thread package handling support 2 is therefore provided, at the tip 21, with the antenna 101.

[0048] Advantageously, the antenna 101 is designed to replace the tip of the thread package handling support 2, without affecting the correct operation of other standard electronic devices already on the support 2.

[0049] As Figure 4 shown, the thread package handling support 2 comprises a thread package handling support body 22, which terminates at one end in the tip 21 (through which the thread packages 1 are loaded) and at the opposite end in a connection end 23 to the machine.

[0050] The hollow, circular thread package handling support body 22 comprises, at the tip 21, an antenna seat 24, into which the antenna 101 is at least partially inserted. For example, as Figure 6 shown, the end portion of the antenna 101 (i.e. the bushing 117, followed by the screen 114) is inserted into the antenna seat 24.

[0051] Preferably, the wire coil handling support body 22 also houses inside it, at the end 21, a spacer 25 in which an end portion of a connection cable 105 is housed, the connection cable 105 having a connector 115 that is connectable to an adapter 113 of the antenna 101.

[0052] Preferably, the connection cable 105 extends inside the wire coil handling support body 22 and comes out from the connection end 23 thereof. Thus, the electronic device 104 of the automatic reading apparatus 100 is arranged at the connection end 23 of the wire coil handling support 2.

[0053] Preferably, the connection cable 105 extends inside a shielded tube, for example a metal tube, arranged inside the wire coil handling support body 22.

[0054] Preferably, the wire coil handling support body 22 further houses inside it a wire coil pushing device 26, for example in the form of a pneumatic cylinder.

[0055] One subject of the present application is also a machine for handling wire coils 1, at least partially shown in Figure 4 to Figure 7 . Said machine comprises a plurality of wire coil handling supports 2, on which a succession of wire coils 1 is loaded in sequence starting from the end 21, the wire coils having an RFID tag 5 inserted inside the tube 3. In particular, each wire coil handling support 2 is provided with an antenna 101 at the end 21.

[0056] In one example embodiment, the machine is a "doffer" machine for picking up wire coils 1 from a winding machine and transporting them to the next work station.

[0057] Advantageously, the automatic reading apparatus 100 according to the present application is sized, positioned and arranged so as to read / write one RFID tag 5 at a time when the machine picks / releases a wire coil 1 equipped with a tube 3 with an RFID tag 5, all this happening in an environment where tens of wire coils 1 are found within a few meters.

[0058] One important step for the correct operation of the automatic reading apparatus 100 is the setting of the antenna 101. In fact, the tube 3 of the wire coil has a predetermined length and the emission power of the antenna signal is adjusted according to this predetermined length. In fact, the automatic reading apparatus 100 must read / write only one RFID tag 5 at a time and must do so only during the process of loading or unloading a wire coil onto / from a wire coil handling support 2.

[0059] One subject of the present application is also to provide a method for automatically tracking wire coils 1.

[0060] The method according to the present application comprises at least the following steps:

[0061] - providing at least one automatic reading device 100 as described above, i.e. having a wire coil handling support 2 with an antenna 101 at the end 21;

[0062] - using a tracking algorithm to track each wire coil 1 inserted on the wire coil handling support 2.

[0063] The tracking algorithm allows to identify the input order of the wire coils 1 when they are inserted on the wire coil handling support 2.

[0064] In particular, the tracking algorithm is executed by a computer and comprises at least the following AUTOMATION CYCLE steps:

[0065] 1. At the beginning of the loading of the wire coils 1 on the wire coil handling support 2, a counter that samples the clock pulses is started; the number of wire coils to be loaded is known (n = number of expected wire coils);

[0066] 2. When a wire coil 1 is loaded inserted on the wire coil handling support 2, the reading from each RFID tag 5 is sampled by the antenna 101;

[0067] 3. After the loading of the wire coil 1 on the wire coil handling support 2, the counter is closed;

[0068] 4. The counted clock is divided by the number of expected wire coils, thus defining a band corresponding to each wire coil 1 loaded:

[0069] a. first band -> first wire coil;

[0070] b. second band -> second wire coil;

[0071] ...

[0072] n. n-th band -> last expected wire coil.

[0073] OPTIMAL CONDITION: if the antenna 101 is correctly set, i.e. so that only one RFID tag 5 is read at a time, and if the RFID tags 5 are correctly positioned in the tube 3, so that they are read one at a time, there will be a unique match between:

[0074] a. first band -> first wire coil;

[0075] b. second band -> second wire coil;

[0076] ...

[0077] n. n-th band -> last expected wire coil.

[0078] IMPERFECT CONDITION: If the power of the antenna 101 is too high, or if two RFID tags 5 from two consecutive tubes 3 are placed close to each other, the antenna 101 will pick up signals from both consecutive RFID tags 5, even if these two consecutive RFID tags are different.

[0079] In this case, there are two correction logics intervention:

[0080] a. The order of acquisition of the RFID tags 5;

[0081] b. The clock interval of reading the RFID tags.

[0082] FAILED OR MISSING RFID CONDITION: If the number of RFID tags 5 detected is less than the expected number of spools, and thus one or more RFID tags are failed or missing, the software uses the clock interval as a correction logic to understand which one of the series a to n is the missing tube.

[0083] Another object of the present application is to provide a computer programmed to implement the method of automatic tracking of spools 1 as described above.

[0084] Another object of the present application is to provide a computer program comprising portions of code which, when the program is executed on a computer, implement the method of automatic tracking of spools 1 as described above.

[0085] Example ( Figure 8 ) :

[0086] The software expects five spools 1 and therefore five different RFID tag codes, which will be referred to as STRING1, STRING2, STRING3, STRING4 and STRING5, by way of example.

[0087] RFID tag code tube 1: "STRING1"

[0088] RFID tag code tube 2: "STRING2"

[0089] RFID tag code tube 3: "STRING3"

[0090] RFID tag code tube 4: "STRING4"

[0091] RFID tag code tube 5: "STRING5"

[0092] The software does not know in advance the code it is expecting, so it samples the RFID tag readings at a set frequency.

[0093]

[0094]

[0095] The sum of the clocks obtained at the end of the detection, and therefore at the end of the movement of loading the coil 1 onto the coil handling support 2, is divided by the expected number of tubes 3. In this way, virtual segments are obtained (in the example above, five segments with 10 clock values), in each of which the system waits for the detection of an RFID tag to be read.

[0096] The algorithm reconstructs the correct order of the RFID tag readings after the first reading of the unique code associated with the tag.

[0097] Having a counter allows imperfect or missing tube conditions or other inconsistencies to be identified; in the example table, the RFID tag associated with the fourth coil was not detected.

[0098] The tracking system according to the present application provides for the exchange of data with the automation system. The on-board electronic system is designed to exchange data with the outside through standard industrial protocols. In this way, it is possible to connect a personal computer (PC) and / or a PLC, thus connecting a database.

[0099] The tracking system according to the present application also provides for the possibility of writing on the RFID tags of the tubes 3. In this way, it is possible to track the path of the coils 1 in a more complete way, for example by recording the date and time of production, the machine and the origin location, the increase in production, etc.

[0100] Innovatively, the device 100 for automatically tracking the coils 1, the related machine, the related system and the related automatic tracking method make it possible to automatically track the path of the coils 1 in the factory and therefore make it objective and fast.

[0101] Advantageously, the system according to the present application allows the automation system to maintain high performance, since the "doffer" equipped with the coil handling support and the device 100 for tracking can:

[0102] - collect a plurality of coils 1 in succession at a time, without having to slow down;

[0103] - identify the RFID tags related to the coils 1 on the "doffer";

[0104] - identify the order in which the coils enter the "doffer";

[0105] - allow the exchange of data with the system;

[0106] - allowing data to be written to the RFID tag memory.

[0107] It will be appreciated that those skilled in the art can make modifications to the products described above, all of which are included within the scope of protection defined by the following claims.

Claims

1. An automatic reading device (100) for tracking bobbins (1) having tubes (3) provided with RFID tags (5), comprising: - an antenna (101); - a reader (102) connected to the antenna (101) by a connection cable (105), the reader being adapted to exchange information with the RFID tags (5) through the antenna (101); - an electronic system (103) connected to the reader (102), the electronic system comprising a central processing unit; - a bobbin handling support (2) provided with a head (21) on which a plurality of bobbins (1) having tubes (3) provided with RFID tags (5) can be sequentially inserted, and wherein the head (21) is the antenna (101); characterized in that the antenna (101) comprises a head (110) provided with an internal seat (116) in which an antenna body (111) is housed, the seat (116) being closed at the rear by a partition (114).

2. The automatic reading device (100) according to claim 1, wherein The antenna (101) is of the coaxial type, i.e. it is adapted to receive and emit signals in a plane of 360°.

3. The automatic reading device (100) according to claim 1 or 2, wherein The head (110) is made of a non-shielding material and the partition (114) is made of a shielding material.

4. The automatic reading device (100) according to claim 3, wherein The non-shielding material is a plastic material and the shielding material is a metal.

5. The automatic reading device (100) according to claim 1 or 2, wherein The bobbin handling support (2) comprises a cylindrical and hollow support body (22) and wherein the connection cable (105) extends inside a shielding tube arranged inside the support body (22) until the connection cable emerges from a connection end (23).

6. The automatic reading device (100) according to claim 5, wherein The shielding tube is a metal tube.

7. A machine for handling wire coils (1), comprising a plurality of automatic reading devices (100) according to any one of the preceding claims, wherein, The machine is a "doffer".

8. An automatic system for tracking bobbins (1) of textile thread, comprising: - an automatic reading device (100) according to any one of claims 1 to 6; - a series of tubes (3) for bobbins (1), each of the tubes (3) being provided with an RFID tag (5).

9. A method for automatically tracking bobbins (1) of thread having tubes (3) provided with RFID tags (5), comprising at least the following steps: - providing at least one automatic reading device (100) according to any one of claims 1 to 6; - tracking each bobbin (1) inserted on the bobbin handling support (2) by means of a tracking algorithm; wherein the tracking algorithm is run by a computer and comprises at least the following steps: a- starting a counter which samples the clock pulses at the beginning of the loading of the bobbins (1) on the bobbin handling support (2); b- sampling the readings of each RFID tag (5) through the antenna (101) while the bobbins (1) are being loaded on the bobbin handling support (2). c. At the end of the loading of the coils (1) on the coil handling supports (2), the counter is closed and the clock counted in step b is divided by the expected number of coils and a clock range is defined corresponding to each loaded coil (1).

10. The method for automatically tracking a wire spool (1) according to claim 9, wherein, The tracking algorithm further comprises the following steps associated with the perfect case in which the antenna (101) has read only one RFID tag (5) in a clock range: Based on the RFID tag (5) read, the corresponding coil (1) is associated with the clock range.

11. The method for automatically tracking a wire spool (1) according to claim 9 or 10, wherein The tracking algorithm further comprises the following steps associated with the imperfect case in which the antenna (101) has read two different RFID tags (5) simultaneously in the same clock range: By applying at least one of the following correction logics, the corresponding coil (1) is associated with the clock range: a. the acquisition order of the RFID tags (5); b. the clock interval in which the RFID tags (5) are read.

12. The method for automatically tracking a wire spool (1) according to claim 9 or 10, wherein, The tracking algorithm further comprises the following steps associated with the faulty or missing RFID case in which the antenna (101) has not read any RFID tag (5) in a clock range: By applying the following correction logic, the corresponding coil (1) is associated with the clock range: - the clock interval in which the RFID tag (5) is missing.

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