Digital creel system

Abstract

The creel system includes a plurality of tension control devices that hold the axis of the wire. The tension control devices apply tension to the wire and can be manipulated to fine tune or control the tension applied to the wire. The creel system can also include a plurality of sensors that measure the operation of the creel system as well as the condition of the wire. In such embodiments, the creel system can include a user interface that provides data to the operator in real time, and the operator can interact with the user interface to control the operation of the creel system.

Description

[0001] Cross-reference to related applications

[0002] This application is a divisional application of the international application PCT / US2020 / 056331, filed on October 19, 2020, and entered the Chinese national phase on June 8, 2022, with national application number 202080084900.2. The parent application of this divisional application claims priority and benefit to pending U.S. Provisional Application No. 62 / 916,375, filed on October 17, 2019, the entire contents of which are incorporated herein by reference. Technical Background

[0003] Typically, filament materials are used as reinforcements for plastic or elastomeric compounds, or they can be made into integral structures, such as those used in the textile, hose, and tire industries. These filament materials, commonly referred to as wires, are stored (wound) on spools. Furthermore, these wires can include, but are not limited to, single and multi-strand fibers, flat strips, or tubular materials produced in long lengths and wound on spools. Various wires can be natural or synthetic fibers, glass, or metal.

[0004] A yarn carrier system is used to pull yarn from its spools and manipulate them into their final form. The yarn carrier system comprises multiple tension controller systems, each with a mandrel that allows the spools to rotate as the yarn is drawn from them. These tension controller systems have control arms and rollers for applying tension to the yarn and can be adjusted using compressed air. The yarn carrier system may also include a front weave support into which the yarn is fed from the spools. The front weave support typically includes subsystems that include a break / loose yarn detection sensor, a reversing roller, and a front roller or eyelet plate.

[0005] However, traditional yarn regrowth systems cannot measure and automatically adjust yarn tension. Instead, if a broken / loose thread comes into contact with the conductive sensor strip on the front scaffold, a traditional yarn regrowth system will sound an alarm, and if enough broken / loose threads are detected, it will stop production and handle the suspected threads. Furthermore, traditional yarn regrowth systems provide almost no real-time or operational feedback to the operator.

[0006] Given the shortcomings of traditional yarn creel systems, there is a need for a yarn creel system that can measure operating characteristics and display them to the user in real time so that the operator can take corrective measures, and a yarn creel system that can automatically control and optimize the yarn tension based on the measured operating characteristics. Summary of the Invention

[0007] The embodiments described herein pertain to a yarn crease system. This yarn crease system may include a frame, a pneumatic control system, and a central control system in communication with the pneumatic control system. The frame has multiple tension control devices for releasing yarn under tension. Each tension control device has a brake shoe engageable with a mandrel and a control arm rotatable toward the mandrel to move the brake shoe away from the mandrel and rotatable away from the mandrel to move the brake shoe toward the mandrel. The pneumatic control system is operatively connected to each tension control device and actuable to move the brake shoe toward the mandrel. The tension control devices communicate with at least one device sensor disposed on at least one control arm. The central control system determines the yarn tension based on data from the device sensors and the pneumatic control system, and is configured to actuate the pneumatic control system in response to the yarn tension. In another embodiment, the yarn crease system further includes a slack detection system in communication with the central control system. The slack detection system includes a yarn tree positioned downstream of the frame and comprising multiple vertically spaced sensor strips configured to generate a slack detection signal based on contact between the yarn and at least one sensor strip. In another embodiment, the yarn truss system further includes a tension monitoring system in communication with a central control system. This tension monitoring system includes a tension monitoring bracket positioned downstream of the frame, comprising at least one tension sensor that receives yarn from the frame. The at least one tension sensor measures the tension of the received yarn and generates a tension output signal, which is sent to the central control system, which adjusts the air pressure of the air pressure control system based on the tension output signal. In yet another embodiment, the tension monitoring bracket includes a left tension sensor, a center tension sensor, and a right tension sensor, respectively configured to receive yarn from a left portion of the yarn plane, yarn from a center portion of the yarn plane, and yarn from a right portion of the yarn plane. In yet another embodiment, the yarn truss system further includes multiple platforms, each with a frame having multiple tension control devices for releasing yarn under tension. Each platform includes a set of wheels driven by a motor, the motor of each platform communicating with the central control system, which guides the motor to drive the relevant platform to a target position. In another embodiment, each platform includes a proximity sensor configured to generate a position signal in response to reading at least one feature plate located at a predetermined position on the floor of the yarn rack chamber. In yet another embodiment, the feature plate includes a plate body having a plurality of recesses, each recess configured to receive one of a steel and a nylon pad, the sequence of which generates a unique code read by the proximity sensor relating to the position of the platform within the yarn rack chamber. In yet another embodiment, each platform includes at least one photoelectric sensor configured to measure the distance between adjacent platforms, wherein a central control system generates a stop motion signal based on a predetermined threshold distance measured by the at least one photoelectric sensor.In another embodiment, the yarn truss system further includes at least one mechanical travel limit switch communicating with a central control system configured to prevent the platform from overtraveling beyond a predetermined position. In another embodiment, the yarn truss system further includes at least one pull-cord switch comprising a cord mounted at the front end of the yarn truss row, the pull-cord switch generating a stop signal when the cord is pulled, the stop signal being readable by the central control system to stop the operation of the yarn truss system. In yet another embodiment, the central control system is configured to shut down the yarn truss system based on a stop signal generated by the yarn truss row and based on a determined position of the yarn truss row within the yarn truss chamber. In another embodiment, the yarn truss system further includes a data storage device communicating with the central control system, the data storage device being configured to store log files.

[0008] The embodiments of this document pertain to a method for operating a yarn creel system, comprising: using an APC module to control the tension of at least one yarn by directing air pressure to at least one tension control device, the tension control device having a brake shoe and a control arm, the brake shoe being capable of engaging a mandrel, the control arm being capable of rotating toward the mandrel to move the brake shoe away from the mandrel and being capable of rotating away from the mandrel to move the brake shoe toward the mandrel; using an LWD module to receive sensor strip data from a plurality of sensor strips disposed on a yarn tree and determine the position of at least one yarn on the yarn tree that is in contact with a sensor strip among the plurality of sensor strips; and using a position module to track the position of the yarn creel rows relative to the yarn creel chamber based on position data received from at least one proximity sensor or other sensing technology device associated with each yarn creel row, and controlling a motor associated with each yarn creel row to move the yarn creel row to a target position. In another embodiment, the method further includes positioning a plurality of feature plates, each plate comprising a plate body having a plurality of recesses, each recess being configured to receive one of steel and nylon pads, wherein the order of the steel and nylon pads creates a unique code readable by a proximity sensor, and this unique code is used by a position module to determine the position of the yarn creel row. In another embodiment, the method further includes using an environment module to receive environmental data from at least one environmental sensor and controlling the operation of the yarn creel system based on the data received from the at least one environmental sensor. In another embodiment, the method further includes using a TMS module to receive wire tension data from at least one tension sensor located between the yarn creel row and the calender; and / or adjusting the air pressure delivered to at least one tension control device based on the measured tension. In another embodiment, the method further includes using at least one mechanical travel limit switch in communication with a central control system to generate a limit switch signal and stopping the movement of the associated yarn creel row based on the generated limit switch signal. In another embodiment, the method further includes using a CAS module to receive collision data from at least one eye sensor associated with each yarn rack row, determining the distance between the moving yarn rack row and adjacent yarn rack rows, and controlling the movement of the moving yarn rack row based on the determined distance between the moving yarn rack row and adjacent yarn rack rows. In another embodiment, the method further includes using at least one pull-cord switch comprising a cord mounted at the front end of the yarn rack row, generating a stop signal when the cord is pulled, and shutting off operation of the yarn rack system based on the pull-cord switch signal. In yet another embodiment, shutting off the yarn rack system is based on a stop signal generated from the yarn rack row and a determined position of the associated yarn rack row within the yarn rack chamber. Brief description of the attached figures

[0009] The following figures are included to illustrate certain aspects of this disclosure and should not be considered as exclusive embodiments. The disclosed subject matter can be modified, altered, combined, and equivalent in form and function without departing from the scope of this disclosure.

[0010] Figure 1A-1B This is a side view of an exemplary yarn truss system incorporating the principles of this disclosure, and Figure 1C-1D This is an isometric perspective view of an exemplary yarn rack system component.

[0011] Figure 2A-2D yes Figure 1A A perspective view of the yarn frame system.

[0012] Figures 3A-3B It can be used Figure 1A and Figure 2A-2D Front and rear perspective views of the tension control device in the image.

[0013] Figure 4 It means Figures 3A-3B The curve showing the relationship between air pressure and wire tension in a tension control device.

[0014] Figure 5 yes Figures 3A-3B A close-up view of the tension control device.

[0015] Figure 6 This is an exemplary frame for a yarn truss system, showing an example area of ​​tension control devices that can be controlled as a set.

[0016] Figure 7 This is a perspective view of an alternative exemplary yarn carrier system that can be incorporated into the principles of this disclosure.

[0017] Figures 8A-8D These are front, top, side and sectional views of the tension monitoring bracket according to this disclosure.

[0018] Figures 9A-9B Various exemplary user interfaces are shown, while Figure 9C It shows Figure 9B A close-up view on the right side of the console.

[0019] Figure 10A-10N yes Figure 9A A screenshot of the touchscreen display, which shows various aspects of the software platform that can be used to monitor and control the yarn rack system.

[0020] Figure 11 It is a plan view of a yarn rack system with multiple rows of yarn racks according to this disclosure.

[0021] Figure 12 This is a schematic diagram of multiple rows of yarn racks in a yarn rack chamber according to the present disclosure.

[0022] Figure 13A This is an exemplary floor according to this disclosure. Figure 13B This is an exemplary unit for detecting flooring according to the present disclosure.

[0023] Figure 14 This is an exemplary control system diagram of the yarn rack system according to the present disclosure.

[0024] Figures 15A-15C An alternative system for sensing or tracking the position of a moving yarn rack row, according to this disclosure, is shown. Detailed Implementation

[0025] This disclosure relates to yarn creel systems, and more specifically, to digital yarn creel systems that provide real-time optimization feedback, automatic control, and improved efficiency.

[0026] Embodiments herein provide a control system for a yarn truss system. This control system is a digital control system integrating multiple yarn truss chamber processes that previously operated independently of each other. In some embodiments, the digital control system integrates one or more of the following individual functions: (i) a servo-valve-operated pneumatic control (i.e., APC) console, (ii) a loose thread detection (i.e., LWD) system, (iii) a moving platform control (i.e., SPC), (iv) a tension monitoring system (TMS), and (v) one or more moving platform safety devices. The digital control system may include one or more sensors for monitoring various parameters of the yarn truss system, such as the ambient temperature and / or humidity within the yarn truss chamber. The digital control system integrates signals related to the foregoing functions and / or parameters and system control into a general-purpose industrial personal computer (IPC), which may include a touchscreen user interface. The digital control system may also allow the user to input parameters that are not necessary for the yarn truss chamber functions but may be desired by the end user, such as the size of the yarn currently running on the yarn truss system. The IPC may be programmed to include a series of data display screens and operator-navigable control screens. The IPC can communicate wirelessly or via cable / wire (e.g., Ethernet), and may include an internal programmable logic controller (PLC) accessible to other customer PLCs. For example, the IPC PLC may be accessible by a calender PLC that, in addition to monitoring other yarn creel chamber data, sends signal commands to adjust air pressure to modify the yarn tension in the yarn creel chamber. Therefore, the digital control system allows real-time monitoring of yarn characteristics as the yarn is unwound and fed from the yarn creel system. Other embodiments of this disclosure provide a tension control system for use with a yarn creel system, including a sensor that measures the tension in the yarn. The tension control system utilizes this sensor to control the rotation of the spool, thereby eliminating or minimizing strain or breakage of the yarn being drawn from the spool. The digital control system can also be configured to self-adjust based on measurement data acquired during yarn creel operation; for example, logic can be programmed (e.g., on the IPC) such that a user-specified target tension is maintained throughout yarn creel operation by measuring tension via a TMS, and the air pressure is adjusted as needed to maintain that tension.

[0027] A creel system provides the mechanism for feeding cords (usually fabric or steel) to a calender or conveyor. The creel system is the first step in textile or tire manufacturing because the organization and gathering of the cords at a uniform tension is crucial for product quality.

[0028] Figure 1A This is a side view of an exemplary yarn carrier system 100 that can be incorporated into the principles of this disclosure. The depicted yarn carrier system 100 is merely one exemplary yarn carrier system that can be suitably incorporated into the principles of this disclosure. In fact, various alternative designs and configurations of the yarn carrier system 100 can be employed without departing from the scope of this disclosure.

[0029] The yarn creel system 100 is used to convey multiple cords, filaments, or wires W to, for example, a calender or conveyor (not shown). The wire W may comprise various materials, such as fabric or steel. As shown, the yarn creel system 100 may include a yarn creel frame 102, a front weave support (FOS) 104, and a main weave support (MOS) 106 fixed to a factory floor or ground G. In some embodiments, the yarn creel frame 102, FOS 104, and MOS 106 are housed in a dedicated chamber, commonly referred to as a yarn creel chamber (not shown). The yarn creel system 100 conveys the wire W along direction D to a calendering operation / process (not shown) that processes the wire W into a form usable for the final product (i.e., tires). In some applications, the frame 102 consists of multiple frame segments arranged side-by-side, each frame segment operating (one after another, or concurrently) to convey the wire downstream to the same calendering process, and in such applications, the side-by-side frames 102 are referred to as yarn creel rows. Figure 1A A yarn frame system 100 comprising a single yarn frame row is shown; however, one or more additional yarn frame rows (with the same and / or different configurations as the first yarn frame row) may be incorporated into system 100. In system 100, each of FOS 104 and MOS 106 provides organization for the wire W. Ultimately, each layer of wire W can be oriented in a plane to enter the calender. FOS 104 and MOS 106 can be used to gradually move the wire W to that position before it leaves the yarn frame chamber.

[0030] In some embodiments, the yarn frame 102 is mounted on one or more movable platforms P, carrying the yarn frame 102 mounted thereon as the platform moves relative to the ground G (i.e., the yarn frame chamber). Platform P may have wheels (e.g., to travel along tracks embedded in the ground G of the yarn frame chamber). Platform P may be motor-driven and controllable, for example, via a mobile platform control (SPC) drive system 122. In a system with multiple yarn frames, one yarn frame can be positioned on the calender centerline during operation, while another one(s) yarn frames can be positioned on an unobstructed side while the axis of the yarn W is loaded, so that when the first yarn frame completes its operation, it can be moved aside and the next yarn frame takes its place, thereby minimizing calender downtime. Then, when the second yarn frame completes, the yarn frame can be switched again (and so on). In some embodiments, multiple yarn rows (e.g., two yarn rows) are positioned in operating positions symmetrical to the centerline of the calender, closely laterally close to each other, in which example, the two yarn rows will simultaneously place the yarn W onto the calender; however, in some embodiments, a single yarn row operates from a position offset from the centerline of the calender.

[0031] Wire W is mounted on a spool or bobbin 108. A yarn frame 102 carries the bobbins 108 and can combine or organize them into a series of rows perpendicularly spaced (relative to the ground G). Therefore, wire W is released from the bobbins 108 in a series of rows, each row comprising a bundle of wire W. Wire W can be fed downstream along direction D to FOS 104 and MOS 106, and then further downstream rolled. Figure 1AAn example of FOS 104 including a yarn tree 110 is shown, which can be configured to detect loose yarns as each row of yarn W is further fed downstream. The yarn tree 110 includes a plurality of detector rods or sensors arranged in a branching manner, each detector rod or sensor corresponding to (or aligned with) a corresponding row of yarn W, and the detector rods / sensors can be integrated within a loose yarn detection system (LWD system) and placed on either side of the yarn creel frame 102 for detecting the presence of loose or sagging yarn W in each row of yarn. Also in the illustrated example, FOS 104 includes a direction-changing device 112 for receiving each row of yarn W as it passes through the yarn tree 110. The direction-changing device 112 may include a plurality of rollers configured to facilitate changing the vertical orientation of the yarn W and facilitating its downstream delivery to MOS 106 and any other downstream operations, such as downstream calendering operations. Furthermore, the illustrated example shows that FOS104 includes a weaving plate device 114, which can be a “perforated plate” consisting of individual ceramic eyelets arranged in a steel plate and / or a “roller plate” consisting of multiple vertical and horizontal rollers defining an “opening” through which a single (or bundle) of wire W can be guided, and further facilitates guiding the wire W downstream in a specific vector according to the end-use application. The direction-changing device 112 and the roller plate device 114 together redirect each row of wire W so that they can be received by MOS106. In some examples, the wire tree 110, the direction-changing device 112, and / or the roller plate device 114 are separate (independent) components and / or any one of them can be integrated with any yarn creel frame 102. However, as combined... Figure 1B and 1C As shown, the line tree 110, the orientation changing device 112, and the organization plate device 114 can be integrated into a single structure, such as FOS 104.

[0032] In some examples, Figure 1A Component 110 can be an LWD post. Figure 1A Component 112 can be a perforated plate column. Figure 1A Component 114 can be a DCR post. In some examples, Figure 1B Component 110 can be an LWD post, but Figure 1B Component 112 can be a DCR column. Figure 1B Element 114 can be a roll column. In some examples, the LWD column, the perforated plate column, and the DCR column can be positioned in a back-to-front order (i.e., the DCR is closest to the calender). In other examples, such as when using rolls for fabrication, the LWD column, the DCR column, and the rolls can be positioned in a back-to-front order (i.e., the rolls are closest to the calender).

[0033] In the illustrated embodiment, the yarn frame 102 is a structure comprising a plurality of horizontal members H and vertical members V, configured to arrange the spools 108 in a rectangular grid. However, in other embodiments, the yarn frame 102 may be configured differently without departing from this disclosure. Thus, the yarn frame 102 may carry the spools 108 in various arrangements or organizations (rectangular or other ways).

[0034] Here, for example, the yarn frame 102 carries six rows and sixty-seven columns of bobbins 108. However, it should be understood that the yarn frame 102 may include more or fewer rows and / or columns of bobbins 108 without departing from this disclosure. For example, the yarn frame 102 may be taller and include one or more additional rows of bobbins 108, or it may be shorter and include fewer rows of bobbins 108.

[0035] Similarly, the yarn frame 102 can be longer or shorter and includes more or fewer columns of bobbins 108. In embodiments including multiple columns of bobbins 108, the yarn frame 102 may include discrete frame portions or segments F. It should be understood that providing the yarn frame 102 in discrete frame portions facilitates the transport and installation of the yarn frame 102 and provides the end user with the ability to scale the yarn frame operation up or down as needed. Here, for example, the yarn frame 102 includes eight frame segments F1-F8 that define separate rows of yarn, wherein frame segments F1 and F2 have six rows and six columns of bobbins 108, frame segment F3 has six rows and five columns of bobbins 108, and frame segments F4-F8 have six rows and ten columns of bobbins 108. Therefore, Figure 1A An exemplary yarn frame system 100 includes a single yarn frame row having multiple frames supporting a total of 402 spools 108. However, the yarn frame system 100 may have various other configurations without departing from this disclosure.

[0036] Figure 1B This is a close-up view of the front portion of a yarn carrier system 100 according to one or more embodiments of the present disclosure. In particular, Figure 1B The image shows the FOS104 when installed near the front (or flange end gasket) 102' of the yarn carrier frame 102, for example, with a mating flange end gasket. Figure 1C FOS 104 without yarn frame 102 is shown. Here, FOS 104 includes base 130, yarn tree 110, orientation changing device 112 and weaving plate device 114 mounted on base 130, so that they together define a separate unit.

[0037] The wire tree 110 may include a plurality of detector rods 132 extending from the wire tree 110 and configured to detect the presence of loose or sagging wires W. Here, the detector rods 132 are organized to correspond to each row of wires W exiting from the yarn frame 102 and are capable of being used with the loose wire detection (LWD) system 124. Sleeves may be provided on any one or more detector rods 132 to cover or insulate at least a portion 132 of each particular detector rod. For example, an insulating sleeve may be provided around a portion (or length) of the detector rod 132 where the insulating sleeve may interact with or engage (or be engaged with) the wires W.

[0038] The orientation-changing device 112 may include a plurality of orientation-changing roller assemblies 134, and the weaving plate device 114 may include a roller assembly 136. This arrangement facilitates the reorientation (or redirection) of rows of yarn W to a new (vertical and / or horizontal) direction. In the illustrated example, the FOS 104 also includes a frame extension 140 configured to mount or attach to the yarn carrier frame 102, thus securing the FOS 104 to the yarn carrier frame 102. In some examples, a mounting pad 142 may be included on top of the FOS 104 frame; in some embodiments, the mounting pad 142 may be used to support additional overhead structures. The mounting pad 142 may have various sizes and configurations.

[0039] The yarn truss system 100 may also include a control system 116 for controlling the operation of various subsystems of the yarn truss system 100. The control system 116 may include an IPC, which may be installed at various locations near the yarn truss system 100, for example, in the yarn truss chamber, or alternatively, provided at another location isolated from or separated from the yarn truss (e.g., outside the yarn truss chamber and / or in a separate control room). As described below, the yarn truss system may also include an air pressure control (APC) system 118, which, in the illustrated embodiment, provides pneumatic power to the yarn truss frame 102 via one or more conduits or hoses 120; however, other types of power may be used instead of or in combination with pneumatic power, such as hydraulic power. The APC system 118 may be located at different locations relative to the yarn truss system 100, and in one embodiment, it is located inside the yarn truss chamber, near the yarn truss frame 102.

[0040] The central control system 116 can communicate with various subsystems, sensors, or devices. For example, the central control system 116 can monitor and control the APC system 118, SPC drive system 122, LWD system 124, tension monitoring system (TMS) 126, and / or various other systems or sensors, as well as aggregated data related to overall operation. The central control system 116 can be implemented in various ways without departing from the scope of this disclosure, for example, as an internal programmable logic controller (PLC), personal computer, tablet computer, smartphone, etc. The central control system 116 may include a processor 115, which can be any of a variety of commercially available processors, including but not limited to single-core processors, dual-core processors (or more generally multi-core processors), digital processors and cooperative mathematical coprocessors, digital controllers, or similar processors. The central control system 116 may include at least one user interface 117 and / or display configured to present data related to the operation of the yarn truss system 100 to a user. The user interface 117 may also allow the user to input commands into the central control system 116 for monitoring and controlling various components. In some embodiments, the central control system 116 may be located in the yarn rack room and / or near other control devices (e.g., calendering equipment control interfaces). In other embodiments, the central control system 116 may be mounted on a portion of the yarn rack system 100 itself, such as a portion of the frame 102. Even in other embodiments, the central control system 116 is a remote device capable of operating the yarn rack; for example, the central control system 116 may be a device located in a room outside the yarn rack room, or a device held by an operator at a facility equipped with digital yarn racks, or remotely.

[0041] The central control system 116 may also include a data storage device 119. The associated data storage device 119 can be implemented on any high-capacity storage device, such as a magnetic storage drive, hard disk drive, optical storage device, flash memory device, or a suitable combination thereof. The associated data storage device 119 can be implemented as a component of the central control system 116, for example, residing in memory, etc. The central control system 116 can then store data acquired during operation in a database or log file (event log) within the data storage device 119, which the operator can use to, for example, ensure the effective operation of the scaffolding system and / or record address errors, create reports, etc.

[0042] Figure 1DAn alternative MOS 106 according to one or more embodiments of the present disclosure is shown, which can be used with a yarn crease system 100. In the illustrated example, the MOS 106 is mounted on a track 150 to enable movement within a path defined by the track 150. Here, the MOS 106 includes a frame 152 and a plurality of wheels 154. The wheels 152 are mounted on the frame 152 to travel along the track 150, thereby constraining the movement of the MOS 106 within a path 156 defined by the track 150. Here, the track 150 extends in a direction generally perpendicular to direction D, such that the path 156 of the MOS 106 is also generally perpendicular to direction D, as indicated by the arrow of path 156. However, it should be understood that the track 150 may have different geometries for positioning the MOS 106, which may be necessary or advantageous in a particular yarn crease setup. For example, the track 150 may be at least partially arcuate. Furthermore, a drive system may be provided to move the MOS 106 along the track 150. For example, the MOS 106 may include an onboard motor assembly configured to drive one or more wheels 154. Therefore, MOS 106 is movable, thus allowing selective alignment with each row of yarn joists. When MOS 106 is provided as a movable MOS, multiple such MOS 106 can be used, each positioned on a track, such that when one MOS 106 is running in the center of the calender, one or more other MOS 106 are offset to the side loaded in front of another non-running row of yarn joists; then, when the run is complete, the loaded MOS 106 can slide back to the center and be ready for run.

[0043] MOS106 includes a pair of guide roller assemblies 158a and 158b. In some embodiments, the guide roller assemblies 158a and 158b include leveling rollers. The guide roller assemblies 158a and 158b are arranged to employ a grid pattern of wire passing through the master roller plate and to flatten them into a plane as they leave the support, thereby providing planar wire as input to the calendering process. Therefore, at certain times, the wire W can be integrated into... Figure 1D The roller assemblies 158a, 158b in the exemplary MOS 106, and / or as separate rollers before the calender inlet, are guided to the flat plate / plane. In some examples, the calender may include guide rollers at the inlet to achieve this purpose. In some examples, in addition to rollers 158a, 158b, MOS 106 may include one or more additional roller assemblies, or MOS 106 may include a single roller assembly.

[0044] The MOS also includes a main fabrication plate assembly 160. The main fabrication plate assembly 160 can be a “master eye plate” consisting of ceramic eyelets in a steel sheet, or a “master roll plate” consisting of a plurality of vertically oriented rolls and a plurality of horizontally oriented rolls. Therefore, wire W can pass through the main fabrication plate assembly 160, below (or above) the first guide roll assembly 158a and above (or below) the second guide roll assembly 158b, and then be laid from there for further downstream processing (i.e., to a calender). Depending on which corresponding opening in the preceding fabrication plate a given wire W originates from before passing through the main fabrication plate assembly 160, wire W can be redirected downward toward guide rolls 158a and 18b by the rolls in the main fabrication plate, or it can be redirected upward toward guide rolls 158a and 18b by the rolls in the main fabrication plate, or the wire can pass substantially horizontally through the main fabrication plate toward guide rolls 158a and 18b (e.g., without being redirected).

[0045] Figure 2A-2D yes Figure 1A A perspective view of a yarn truss system 100, according to one or more embodiments of the present disclosure. More specifically, Figure 2B yes Figure 2A A partial perspective view of the rear end of the yarn truss system 100. Figure 2C yes Figure 2A A partial perspective view of the front or output end of the yarn carrier system 100. Furthermore, Figure 2D A partial perspective view of the front end or output end of the yarn frame system 100 when partially assembled using an alternative yarn frame 102 according to one or more embodiments is shown.

[0046] As shown in the figure, the yarn frame system 100 also includes multiple tension control devices 202 actuated by the APC system 118. Figure 2B and 2C A frame 102 supporting multiple tension controllers 202 is shown, while Figure 2C A frame 102 supporting multiple tension controllers 202 is shown. Figure 2DOnly two tension controllers 202 mounted on frame 102 (without the bobbin 108) are illustrated to illustrate the remaining locations where tension controllers can be mounted and how input air can be supplied to the tension controllers 202. The tension control device 202 is mounted on the yarn carrier frame 102 and carries (or holds) the bobbin 108, allowing the yarn W to be unwound for downstream operation and / or processing. An APC system 118 is integrated with the tension control device 202 and can be used to adjust (i.e., increase or decrease) the tension (or speed) on the yarn as the bobbin 108 is unwound (or rotated). Therefore, the APC system 118 can cause the tension control device 202 to increase the friction applied to the bobbin 108 as it is unwound, providing greater resistance to the rotation of the bobbin 108 and increasing the tension of the yarn W as it is unwound. Multiple intermediate support rollers 208 may be provided to help support and / or guide the yarn W.

[0047] The APC system 118 can be located at various locations around the yarn truss system 100. For example, the APC system 118 can be located in a control console that is mounted to a part of the yarn truss system 100 (e.g., the yarn truss frame 102), or the APC system 118 can be provided in different ways, such as in a separate control console that can be positioned in different locations.

[0048] Air regulated to the required pressure can be supplied to the APC 118, for example, but not limited to, approximately 10 pounds per square inch (psi) to approximately 30 psi, including approximately 30 psi and including approximately 25 psi. One or more input lines 204 can be provided for supplying input air. In some embodiments, a single input line 204 is used to supply all tension control devices 202 in the yarn frame system 100. In other embodiments, multiple input lines 204 are used, each such input line 204 supplying input air to a group of tension control devices 202. In some examples, a network of hoses and lines can be laid throughout the frame to supply various tension control devices 202 (or tension controller groups 202). For example, the input line 204 can be connected to (and supply input air to) multiple manifolds 206, where each manifold 206 is connected to a group of tension controllers 202. Here, each manifold 206 is vertically oriented to supply a column of tension controllers 202 on the opposite side of the manifold 206, wherein supply air is supplied to each tension controller 202 in a particular column via a separate input line 210 extending from the manifold 206.

[0049] APC 118 may include at least one electronically operated valve (servo valve) associated with / controlling at least one tension control device 202. In some embodiments, the electrical signal source for actuating each servo valve is a calender. In some embodiments, a central control system 116 is configured to actuate each servo valve. In some embodiments, the servo valve is associated with / controlling a single-row tension control device 202, for example... Figure 6 Row 604 or column 606. By adjusting the air pressure output to each row 604, the central control system 116 can change the tension output of the tension control device 202, thereby setting the desired tension of the wire W. In some embodiments, the valve is located within a pneumatic panel housing, which may be positioned near the main electrical housing.

[0050] In some embodiments, the central control system 116 receives signals from the calender to set a target gas pressure for at least one tension control device 202. For example, the calender may send an input signal to the control system 116 to control a pilot-operated regulator based on the value of the input signal. The control system 116 may then send an appropriate 4-20mA signal to a servo valve to drive the pilot regulator to the target pressure (e.g., determined by a pressure-tension curve). Thus, the central control system 116 receives and analyzes the input signal from the calender and then sends an appropriate electrical signal to the servo valve based on the input signal from the calender.

[0051] The central control system 116 can also be configured to send digital signals back to the calender. The digital signals sent back to the calender can indicate multiple different parameters, such as the received set pressure point and / or actual pressure readings from servo valves. In some embodiments, the digital signals to the calender also include actual pressure readings at each yarn bedding row, which can be achieved by installing sensors at each yarn bedding row and transmitting data from the PLC to the central control system 116. These additional data points provide the calender with a more accurate representation of the actual achieved pressure output based on the input target, thereby allowing the calender to be programmed to adjust the target pressure based on this downstream feedback. Therefore, the advantage of the control system 116 is that, compared to other systems that only utilize one-way communication between the calender and pneumatic control, the control system 116 is able to provide digital signal feedback to the calender and visual feedback to the operator via the user interface 117.

[0052] The control system 116 can display information (e.g., target pressure, actual valve pressure, and actual yarn rack frame pressure) on a user interface 117. The user interface 117 may include one or more touchscreen displays, which can be located in various locations, such as in the yarn rack room. Upper and lower pressure thresholds can be set / stored in the control system 116 to trigger alarm states when the pressure deviates from acceptable operating limits. The control system 116 can be configured to maintain an event log, accessible to the yarn rack room operator via an IPC touchscreen display, and this log may include records of pressure alarm states and activities.

[0053] Figure 3A and 3B It is possible to use one or more embodiments of this disclosure with Figure 1A and Figure 2A-2D A perspective view of an exemplary tension control device 202 used in conjunction with a yarn carrier system 100. As shown, the tension control device 202 includes a load-bearing bobbin 108 ( Figures 1A to 2D The system comprises a spindle 302, a brake drum 304, a brake shoe 306, a diaphragm actuator 308, a control arm 310, and a control arm roller 312. The control arm 310 is connected to a pivot 314 and configured to pivot toward and away from the spindle 302. The control arm 310 is also connected to the brake shoe 306 such that when the control arm 310 pivots away from the spindle 302, the brake shoe 306 is pushed into contact with the brake drum 304.

[0054] The control arm roller 312 is connected to the control arm 310 and is therefore pivotable toward and away from the spindle 302. The control arm roller 312 is generally perpendicular to the control arm 310 and generally parallel to the spindle 302 and the spool 108 mounted thereon. Here, the control arm roller 312 is configured as a smooth cylindrical roller through which the wire W can pass, and its dimensions are designed to be at least as long as the axial length of the spool 108 to ensure that the wire W is drawn smoothly and evenly from the spool 108 without fouling or significant deflection. As the wire W is released from the spool 108 and passes through the control arm roller 312, the wire W is held on the control arm roller 312 by a pair of transverse flanges 316a, 316b.

[0055] As described below, the diaphragm actuator 308 is connected to the APC system 118 and configured for pneumatic operation. A piston 318 extends from the lower end of the diaphragm actuator 308. The piston 318 is pivotally fixed to a brake arm 320, which is fixed to a pivot 314, such that rotation of the brake arm 320 causes rotation of the pivot 314 and control arm 310 attached thereto. Fluid (e.g., air) is supplied to the diaphragm actuator 308 at its upper end through a port 322, which may receive a hose (not shown) or other conduit leading from the APC system 118. It should be understood that the port 322 may be a manifold (not shown) connected to a plurality of tension control devices 202, and fluid application via the APC system 118 causes the piston 318 to be actuated relative to the diaphragm actuator 308.

[0056] During operation, the spool 108 of the wire W is mounted on the spindle 302, and one end of the wire W starts from the top of the spool 108 and rotates clockwise (in... Figure 3A The wire is guided to the lower and surrounding area of ​​the control arm roller 312, and then to the downstream take-up mechanism (not shown). Before the downstream take-up mechanism is actuated, the control arm 310 and control arm roller 312 will be stationary and displaced from the spool 108. At this time, the brake shoe 306 is pushed to engage with the brake surface of the brake drum 304, thereby preventing the rotation of the brake drum 304 and the mandrel 302 connected thereto, thus preventing the wire W from being released from the spool 108 mounted on the mandrel 302.

[0057] As the wire W is wound up, the control arm 310 and control arm roller 312 rotate toward the spool 108, and in doing so, move the brake shoe 306 away from the brake drum 304. This movement of the brake shoe 306 relative to the brake drum 304 reduces the friction between the brake shoe 306 and the brake drum 304, thereby allowing the brake drum 304, spindle 302, and spool 108 mounted on the spindle 302 to rotate. The force exerted on the control arm 310 by the wire W (when the control arm roller 312 is engaged) is balanced by the friction between the brake shoe 306 and the brake drum 304 to maintain a constant tension on the wire W. The tension from this force balancing system is independent of the coefficient of friction between the brake drum 304 and the brake shoe 306 within the normal operating range. In the event of a decrease or stop in the winding rate, the required braking amount is applied immediately, thus preventing any unwanted slack in the wire W. Similarly, as the winding rate increases, the balance between the braking force and the force applied by the diaphragm actuator 308 allows for a smooth and uniform unwinding rate without stretching or pulling the wire W.

[0058] The APC system 118 applies air pressure to the diaphragm actuator 308, actuating the piston 318 extending from it, thereby causing the brake arm 320 to rotate. Figure 3A The counterclockwise direction and Figure 3B(clockwise direction). This rotation of the brake arm 320 generates a torsional force about the pivot 314, which in turn causes the brake shoe 306 to engage with the brake surface of the brake drum 304, thereby generating the required tension on the wire W. Because before the control arm 310 rotates ( Figure 3A clockwise and Figure 3B (Counterclockwise), the torsional force must be overcome by the force applied to the control arm 310 by the control arm roller 312, as produced by the tension in the wire W, and thus the torsional force constitutes a bias force that is substantially proportional to the tension in the wire W.

[0059] Therefore, the tension in the wire W can be adjusted by controlling the air pressure in the diaphragm actuator 308. Figure 4 This is a curve illustrating the relationship between air pressure and wire tension (i.e., the tension of wire W) in an exemplary tension control device 202 according to one or more embodiments. More specifically, Figure 4 This is the working curve of air pressure versus wire tension, which can be used to control the tension in the wire W by adjusting the air pressure supplied to the diaphragm actuator 308. However, Figure 4 The embodiments may vary depending on a number of factors, including but not limited to the amount of wire W on the spool 108 (i.e., whether the spool 108 is full or empty), the weight of the spool 108, the operating speed, and the tension control device 202 used.

[0060] The yarn creel system 100 may include various sensors and / or detection systems that monitor the yarn W and the environmental conditions presented in the yarn creel chamber during operation. For example, the yarn creel system 100 may include a yarn W detection system that detects yarn W that has encountered breakage or loosening in each row of yarn W (i.e., a "LWD system"). Additionally, the yarn creel system 100 may include a tension monitoring system ("TMS") 126 for detecting and measuring tension in the yarn W. The yarn creel system 100 may include one or more additional sensors for measuring various other aspects of the yarn creel system 100, including environmental and / or operational parameters associated with the yarn creel system 100. For example, the yarn creel system 100 may include an environmental monitoring system (not shown) that includes one or more sensors for measuring conditions in the yarn creel chamber, such as temperature, humidity, and / or atmospheric pressure. As discussed below, the control system 116 may include software that allows its operator to modify or control various operational parameters of the yarn creel system 100 in response to information collected by the aforementioned sensors and / or detection systems. Therefore, the operator can fine-tune the tension of the wire W and / or fine-tune the environmental conditions experienced in the yarn rack room.

[0061] Figure 5 According to one or more embodiments of this disclosure Figures 3A-3BA close-up view of the tension control device 202 configured with limit switches. The depicted switch arrangement is merely one example arrangement that can be appropriately combined with the principles of this disclosure. In fact, many alternative designs and configurations of the switches can be employed without departing from the scope of this disclosure.

[0062] Here, a pair of limit switches 504a and 504b are provided on the tension control device 202, and a switch blade 506 is connected to the brake arm 320 of the tension control device 202. The limit switches 504a and 504b may include various types of limit switches, such as microswitches V3-1101-D8 or V7-2B17D8. As the brake arm 320 (together with the control arm 310) responds to the force applied by the wire W to the control arm roller 312 (… Figures 3A-3B The change in tension on the pivot 314 ( Figures 3A-3B The switch blade 506 can reciprocate between limit switches 504a and 504b when the brake arm 320 rotates clockwise or counterclockwise a sufficient degree to the limit of the normal operating range (e.g., to the lower or upper limit of the range 0-35°). This engages one of the limit switches 504a or 504b, thereby indicating that the tension in the wire W is too high or too low, indicating that the wire W is loose or broken. In other embodiments, a single limit switch (not shown) can be used to measure whether the tension is too high or whether the wire W is loose or broken. For example, a single limit switch can be engaged by the brake arm 320 when the brake arm 320 rotates within its normal operating range (e.g., within the range of 0-35°), but disengages when the brake arm 320 rotates out of its normal operating range in either direction. However, these embodiments do not provide for wire tension measurement between limits defined by limit switches 504a, 504b (e.g., between the upper and lower limits in the 0° 35° range).

[0063] Limit switches 504a, 504b (or a single limit switch) may include various types of switches or sensors known in the art. However, regardless of type, they can be configured to interact with user interface 117. Figure 1A Communication is provided as described below. For example, when engaged, limit switches 504a, 504b can provide a signal to activate a transmitter (not shown) disposed on the yarn frame 102. The transmitter communicates with a remote receiver (not shown) disposed in the user interface 117, which in turn can generate audio or video indications (or both) to remotely indicate that the tension in the yarn W is too high or that the yarn W is too loose or broken. The signals transmitted from the transmitter to the remote receiver can be encoded to uniquely identify signals from the plurality of tension control devices 202.

[0064] Instead of limit switches 504a and 504b, or any other devices or tension sensors besides limit switches 504a and 504b, various other devices or tension sensors can be used to monitor the tension in the wire W. For example, one or more additional tension sensors, such as the TE-24 manufactured by Electromatic Equipment Company, Inc., can be used. Heavy-duty tension sensors (each a "TE-24 sensor"). In one embodiment, one TE-24 sensor is used for each tension control device 202. However, in other embodiments, one or more TE-24 sensors are used to monitor the tension of the wire W of a group of tension control devices 202 (e.g., a row of tension control devices 202). Thus, the TE-24 sensor can be used to measure a group of wires W, although the TE-24 sensor may locally affect the tension of the wire W as the wire W is routed through its wheel-type measuring mechanism. The TE-24 sensor, or any of them, can be positioned at different locations around the yarn carrier system 100, for example, at the front of the yarn carrier frame 102 and / or near the FOS 104. As described above, the TE-24 sensor can be used in addition to or in place of the limit switches detailed above. Furthermore, it should be understood that tension sensors other than the TE-24 sensor can be used without departing from this disclosure.

[0065] In another example, one or more tension sensing rollers, such as the TSR-3 or TSR-4 tension sensing rollers manufactured by Montalvo Corporation (each is a "tension sensing roller"), can be used. In such an embodiment, a single tension sensing roller is used for each row of tension control device 202. In this way, each tension sensing roller will provide an average reading of the tension of all wires W in that row, rather than providing a tension reading of a single wire W in a unique row, and therefore may not be able to provide feedback on tension changes that require a stop (e.g., where 1 to 3 wires W are loose). As described above, tension sensing rollers can be used in addition to or in place of the TE-24 sensor and / or limit switch detailed above. Furthermore, it should be understood that tension sensing rollers other than the TSR-3 or TSR-4 tension sensing rollers can be used without departing from this disclosure. For example, a tension sensing roller capable of measuring the tension of each individual wire passing through there can be used.

[0066] In other embodiments, the tension of the wire W can be determined by a position sensor (“position sensor”) based on the position of the control arm 310 (or control arm roller 312) associated with the wire W. In some embodiments, the position sensor is an instrument that measures the slope and tilt angle relative to gravity. Thus, the position sensor can include various types of instruments, including but not limited to inclinometers, tilt sensors, accelerometers, gyroscopes, and combinations thereof, and can be measured on one, two, or three axes. In one example, the position sensor is an inclinometer mounted to the control arm 310 (or control arm roller 312) and configured to determine its angular position over its entire range of motion (e.g., 0–35°). In other embodiments, the position sensor is a sensing sensor that can determine the distance that the control arm 310 (or control arm roller 312) has traveled relative to a stationary reference point (e.g., on the tension control device 202) to determine its angular position over its entire range of motion. Furthermore, in addition to or instead of any of the above-described means, a rotary encoder / sensor or similar means can be provided on any or each tension control device 202 to perform the same measurement.

[0067] After determining the position of the control arm 310 (or control arm roller 312) via a position sensor, this information can be used to... Figure 4 The corresponding wire W tension can be inferred from the operating curves shown. For example, knowing the full range of motion of the control arm 310 (e.g., 0-35°), it can be determined whether the wire W breaks when the control arm 310 is fully forward or is overstretched when the control arm 310 is fully backward, and this can be determined by comparing the intermediate angle position between them (i.e., when the control arm 310 is in the fully forward and fully backward positions) with the pressure-based operating curve (e.g., ...). Figure 4 The obtained tension is correlated to determine the tension condition of the intermediate wire W. Using this information (i.e., feedback), the yarn creel system 100 can automatically adjust the air pressure supplied to any single or group of tension control devices 202 via the APC system 118 as needed to optimize operation. In other embodiments, the operator of the yarn creel system 100 can use this information to manually adjust the air pressure supplied to any single or group of tension control devices 202 via the APC system 118 as needed.

[0068] Furthermore, when paired with one or both of the tension sensing rollers and TE-24 sensors detailed above, the position sensor measurements can be correlated to independently obtain tension feedback from one or more tension control devices 202 (see [link to relevant documentation]). Figure 6 Then, a table containing appropriate values ​​for the set air pressure (e.g., for tension, wire type, spool packaging, feed rate, etc.) can be used to check the tension control device 202 separately in a predetermined area (e.g., row or column) or throughout the entire yarn rig system 100, as shown below. Figure 6As described.

[0069] Therefore, the yarn frame system 100 can be modified to automatically control any or all of the tension control devices 202, thereby fine-tuning the tension of the yarn W. Figure 6 The diagram illustrates individual frames F that can be incorporated into a yarn truss frame 102 and various regions of frames F that can be controlled independently, according to one or more embodiments. In some embodiments, for example, each tension control device 202 is disposed in a separate region 602, such that the yarn truss system 100 can automatically control each tension control device 202 individually. In other embodiments, each row of tension control devices 202 is organized into region 604, such that the yarn truss system 100 can automatically control each row of tension control devices 202 as a group. Similarly, each column of tension control devices 202 can be organized into region 606, such that the yarn truss system 100 can automatically control each column of tension control devices 202 as a group. In other embodiments, all tension control devices on the frame are organized into region 608, allowing the yarn truss system 100 to automatically control the tension control devices 202 on each frame F (e.g., frame F1) as a group, independently of the tension control devices 202 on other frames F (e.g., frames F2-F8); in other embodiments, all tension control devices 202 on the yarn truss frame 102 are organized into a single region (not shown), allowing the yarn truss system 100 to automatically control all tension control devices 202 on the yarn truss frame 102 as a group. As described above, in these or other embodiments, the yarn truss system 100 allows its operator to manually control the tension control devices 202 individually or in any number of groups.

[0070] LWD systems can be integrated into various types of yarn frame systems. As described herein, a yarn frame system may include one or more yarn frame rows, each of which has a frame structure and multiple rows of tension controllers (e.g., four to six) mounted on both sides of the frame structure (i.e., the left-hand and right-hand sides). All the yarns for a given row of tension controllers on a particular side of the frame pass through the weave plate at the front of the yarn frame row. During the operation of the yarn frame, all the yarns in each row and on each side flow along a similar path.

[0071] Figure 7 An alternative exemplary yarn truss system 700 incorporating an LWD system according to one or more embodiments is shown. It should be understood that, although... Figure 7 The FOS104 shown is different from the reference. Figure 1C The FOS104 is described. Figure 1C The FOS104 can be integrated into Figure 7 In systems, and vice versa, because the subject matter of this disclosure can be used with various types of FOS designs. LWD system integration in Figure 7In the illustrated yarn crease system 700, all the yarn W of the tension control device 202 for a given row on one side of frame 102 passes through a weave plate, such as a weave plate 702 mounted on a bracket 704 positioned between the yarn tree 110 and the direction-changing device 112 at the front of the yarn crease row. During operation of the yarn crease system 700, all the yarn in each row and on each side will flow through a similar path. Here, the LWD system utilizes multiple loose yarn sensor strips, such as detector rods 132, which are placed near the weave plate 702, a few inches below the flow path of the yarn W of the tension controller 202 for a particular row. The detector rods 132 may be insulated from the yarn tree 110 and / or frame 102 and are arranged such that (at least) the detector rods 132 are positioned to correspond to each row tension controller 202 on each side of frame 102. The detector rod 132 can be mounted at different locations around the yarn carrier system, where it is sufficiently close to the flow path of the yarn W in the tension controller 202 for a specific row of yarn. For example, the detector rod 132 can be positioned on or around the FOS 104 (see example...). Figure 1C and Figure 7 The loose wire detector bar 132 is located on or around the frame 102. It can detect when a single wire W has broken and come into contact with the detector bar 132. In some examples, the loose wire detector bar 132 can detect loose / broken wires by grounding via a wire closed circuit. However, in some embodiments, the detector bar 132 can be configured differently to detect when a predetermined number of wires have broken or come into contact with it. Also in the illustrated example, the LWD system includes an electrical enclosure / cabinet 706 connected to each detector bar 132, and the electrical enclosure / cabinet 706 includes an indicator panel 708 that alerts the operator when one of the wires W becomes loose enough to come into contact with one of the loose wire sensor bars 132.

[0072] During yarn rack operation, it is not uncommon for yarn W to break due to upstream obstacles or defects within the yarn W. In such cases, the tension control device 202 ceases to maintain tension at the end of the yarn W, allowing the yarn W to sag and contact the detector rod 132. This contact closes the circuit from the detector rod 132 to the electrical housing / cabinet 706, thereby providing an indication on the indicator panel 708, such as by activating a light and / or sounding a horn. Based on the light illuminating on the indicator panel 708, the yarn rack operator can determine which row and side of the frame 102 the broken yarn W is located in. Using this information, the operator can locate the broken yarn W and manually determine which spool has the broken yarn W and take appropriate action.

[0073] The control system 116 described herein can be integrated into various yarn truss systems, including but not limited to... Figure 7 The yarn rack system 700. The control system 116 can be used in conjunction with the electrical enclosure / cabinet 706, or the control system 116 can replace the electrical enclosure / cabinet 706. Figure 7 An exemplary housing 710 is also shown, which may, for example, accommodate aspects of the APC 118, the SPC drive system 122, or other control or safety features associated with the creel system. System air pressure is manually controlled via a pneumatic manifold system located in the APC housing panel, with the air pressure setpoint also derived from the calender chamber, which controls the servo-operated pressure valves. Three pressures are monitored: the calender chamber setpoint, the APC valve feedback, and the creel pressure.

[0074] Therefore, the LWD system can communicate with the central control system 116. For example, the LWD may include one or more slave PLCs, with each yarn creel frame 102 associated with a separate slave PLC (i.e., a slave PLC is provided for each yarn creel frame 102). Here, each slave PLC can send signal data to the central control system 116 for each detector bar 132 associated with the specific frame 102 associated with the slave PLC. Thus, when a loose or broken yarn W is detected (i.e., through contact with a detector bar 132), the LWD system sends a signal to the central control system 116, which then triggers an alarm / indication. That is, the user interface 117, or a display associated with the user interface display 117, can show a graphical representation of the stacked detector bars 132, highlighting the specific sensor bar 132 where a broken yarn W was detected. This information can also be logged to the storage device 119 in the form of an event log. Furthermore, the central control system 116 can send a signal to the calender indicating the status of each detector bar 132. In this way, the calender operator can choose to take action in response to a line break. Therefore, the control system 116 can provide signal feedback to the calender.

[0075] Figures 8A-8DExemplary aspects of a tension monitoring system (TMS) 126 according to one or more embodiments of the present disclosure are illustrated. In the illustrated embodiment, the TMS 126 includes a tension monitoring bracket 800. The tension monitoring bracket 800 can be positioned at various locations, for example, it can be positioned in the yarn rack chamber near where the yarn W leaves the yarn rack chamber and enters the calender (i.e., the calender window). Thus, the tension monitoring bracket 800 can be located after (i.e., downstream of) the MOS 106, such that at least one yarn W from the MOS 106 is guided or travels through the tension monitoring bracket 800. In some embodiments, the yarn W is fed through the top of the bracket 800. The TMS includes one or more individual tension measurement sensors 802, each measuring the tension of the yarn W by passing the yarn W through a plurality of grooved rollers 804. The tension monitoring bracket 800 can be positioned above a yarn layer that may include multiple individual yarns W, for example, 600-1200 individual yarns W. In some embodiments, three tension measurement sensors 802 are positioned along the TMS bracket 800 (e.g., ...). Figure 8B The width positioning (as shown) ensures that at least one wire W is positioned from the left side 810, center 811, and right side 812 of the wire layer respectively (as shown). Figure 8C (As shown) can be measured.

[0076] although Figures 8A-8D An exemplary design of a tension monitoring bracket 800 for measuring the tension on three discrete wires is shown. The tension monitoring bracket 800 can be configured in different ways to measure the tension on different numbers of discrete wires (i.e., more or less than three wires). For example, the tension monitoring bracket 800 can be configured to measure the total tension on all wires, for example, as the average tension of all wires, and such a tension monitoring bracket can be integrated with a MOS or provided as a standalone device.

[0077] The TMS communicates electronically with the central control system 116. For example, one or more tension measurement sensors 802 may include cable connectors 820 or output leads, allowing them to be hardwired to the central control system 116. In some examples, at least one of the tension measurement sensors 802 communicates wirelessly with the central control system 116, directly or indirectly. The tension measurement sensor 802 generates a tension output signal, which is sent to the central control system 116; for example, a tension output signal representing the tension of the wire, 4-20mA. The control system 116 makes the tension value, with a data address, measured by the tension measurement sensor 802 available for the calender to read at any time. The calender logic is capable of measuring the actual tension output of a specified air pressure input signal. This feedback loop allows the calender to make small adjustments to the air pressure input signal based on the measured tension output, thereby providing a more precise tension control method for the calender. The central control system 116 may, for example, output the tension measurement value on an IPC touchscreen display, and such an IPC touchscreen is available for use by the yarn rack operator to monitor the tension in the wire W.

[0078] The user interface 117 can have various configurations. In some embodiments, such as... Figure 7 As shown, the user interface 117 includes relay logic circuitry, each of whose outputs is controlled by a combination of input or output conditions, such as input switches and / or control relays. In other embodiments, such as those described above... Figure 9A and Figure 9B The embodiments described herein. User interface 117 includes controller 116 that receives signals from various sensors and / or detection systems (i.e., monitoring the yarn W and environmental conditions present in the yarn rack chamber during operation) to provide control signals, such as LWD systems and / or environmental monitoring systems. The controller and these various sensors and / or detection systems can communicate via any suitable wired or wireless means. Therefore, user interface 117 can be configured to enable an operator to control the operation of yarn rack system 100 during operation. For example, central control system 116 can be configured to provide visual and / or auditory performance information to the operator of yarn rack system 100 in real time, and then receive commands from the operator, enabling the operator to correct inputs and / or optimize performance.

[0079] The central control system 116 can be set in the console 900. Figure 9A and 9BExemplary console 900 according to various embodiments of the present disclosure is shown. In various embodiments, console 900 houses a central control system 116 and includes a user interface 917, such as in the form of an IPC touchscreen display. Console 900 includes a controller as detailed above and is configured to provide detailed system information to an operator and is also configured to receive operator input in response to such information, as described below. As shown, the controllable user interface 917 includes a touchscreen display through which the operator can input commands to control the yarn rapier system 100 and observe (monitor) system performance, since the yarn rapier system 100 can display any number of status alarms or notifications on the touchscreen display. Here, the user interface 917 includes a touchscreen display that includes multiple inputs 904 that the operator can manipulate, for example, to change information displayed on the touchscreen display. In some embodiments, console 900 may further include multiple LED indicators 906, which may correspond to inputs 904 and provide indication of which input 904 is selected. An emergency stop 908 may also be provided.

[0080] Therefore, the yarn rack system 100 can be controlled by a central control system 116 integrated into the console 900. The console 900 can send and receive information from the various yarn rack subsystems and / or devices described herein. Using the information received from these monitoring systems (or any of them), text or graphics describing the yarn condition (i.e., whether it is broken), yarn tension, and / or the environmental conditions inside the yarn rack room can be provided to the operator in real time on the display 917. The console 900 may also include (or be connected to) other displays or inputs (not shown). For example, when the yarn rack system 100 is installed in the yarn rack room of the facility, one or more other computers can be connected to the user interface via a LAN network or other means to provide other users with the ability to monitor and / or control the yarn rack system 100.

[0081] Figure 9B An alternative version of the console 900 according to one or more alternative embodiments is shown. Here, the console 900 is divided into separate sides 920, 922. The left side 920 includes an IPC 924, remote access control keys 926, a collapsible shelf 928, keyboard and / or mouse access points (connectors) 930, and an emergency stop 932. Here, the left side 920 includes a left-side door 934 that can be opened via a latch 936. The IPC 924 is programmable to include software for implementing one or more aspects of the central control system 116 described herein.

[0082] Figure 9C It shows Figure 9BA close-up view of the right side 922 of the console 900. As shown, the right side 922 may include a right-side door 938 that can be opened via a latch 936. Additionally, a power disconnector 940 and a sensor 942 for measuring temperature and / or humidity may be provided on the right side 922 of the console 900. Furthermore, multiple buttons, indicators, and / or switches may be provided to control or operate the system or sensor system in the event of an HMI display failure. It should be understood that this will allow the user to continue operating the system in the event of a screen malfunction.

[0083] The control system 116 may include a software platform that displays real-time measurements of the yarn rapier system 100 on a touchscreen display 917 or IPC 924 and allows the operator to control its operation in real time. Figure 10A-10I These are screenshots of a touchscreen display 917 or IPC 924 according to one or more embodiments of the present disclosure and illustrate various aspects of the platform. However, it should be understood that the software platform is fully customizable and can be modified for the specific applications of the end user, and the following screenshots are merely one exemplary embodiment of the software platform. Therefore, the software platform may include any number of other screenshots and / or functions without departing from the present disclosure.

[0084] Figure 10A An introductory screen 1002 of a platform according to one or more embodiments of the present disclosure is illustrated. Here, the platform includes language translation capabilities so that a user can select which language to display on a touchscreen display 917, and Figure 10B A translation selection screen 1004 of a platform according to one or more embodiments of the present disclosure is shown. In some embodiments, the language selection will also change the units displayed for the measurement values. For example, if the operator selects German translation, the units may be displayed in SI units, while if the operator selects English translation, the units may be displayed in U.S. Common Units (e.g., for U.S. users) or SI units (e.g., for UK users).

[0085] Figure 10C A system function selection screen 1006 of a platform according to one or more embodiments of the present disclosure is illustrated. Here, the operator's company logo can be displayed on the screen, and the operator can select a specific function he / she wishes to access. For example, the function selection screen 1006 may include various function selections for the operator, such as operation screen selection buttons 1008a, alarm screen selection buttons 1008b, system information screen selection buttons 1008c, and / or maintenance screen selection buttons 1008d. The screen 1006 may also include an option to return the operator to the main screen 1002.

[0086] Figure 10DAn operation screen 1010 according to one or more embodiments of the present disclosure is shown. The operation screen 1010 can be accessed by pressing an operation screen selection button 1008a. The operation screen 1010 may be a main production screen, including various indicators and / or selections, such as an operation mode indicator 1011, a temperature and / or humidity indicator 1013, a selected joist indicator (i.e., on or off), and may display mirrored joist lights, position status (i.e., whether the joist position is valid), selection status (i.e., whether the joist row selection is valid), machine status (i.e., whether the machine is ready), etc. This configuration may allow selection of a single joist operating position, may allow initiation of an automatic shift cycle, and may also include a "Ready for Production" button to signal to the calender that the joist is ready for production. Furthermore, a home button 1015a may be located on the operation screen 1010 to allow the operator to return to the home screen. In addition, the operation screen 1010 may include options that allow switching and navigation between screens of the system, such as APC screen button 1015b, LWD screen button 1015c and alarm screen button 1015d.

[0087] Figure 10E-10F Single-row creel operation or production screen 1014 and double-row creel operation or production screen 1016 are shown respectively according to one or more embodiments of the present disclosure. These screens display temperature and humidity data. Regarding the single-row creel operation or production screen 1014, APC activity is displayed, such as calender setpoint pressure in psi, APC solenoid valve pressure setpoint feedback on the selected creel in psi, and actual pressure of the selected creel frame in psi. Regarding the double-row creel operation or production screen 1016, the calender pressure setpoint in psi can be received from the calender via a network connection, and the information is displayed on screen 1016. Furthermore, the APC solenoid valve pressure setpoint feedback pressure of the selected creel is received from the APC (and generated by a pressure sensor located on the APC), and the pressure fed back to the servo air valve can be compared with the value sent from the calender. Additionally, the actual pressure of the selected creel can be monitored, and such data is transmitted back to the PLC to display any discrepancies with the setpoint, feedback, and actual creel pressure. The single-yarn stand and double-yarn stand operation or production screens 1014 and 1016 can also provide monitoring of the tension monitoring bracket 800, such as displaying tension readings from the sensor 802, and screen 1014 can display the average tension of the selected yarn at the tension monitoring bracket 800, and can provide navigation buttons for switching between screens, such as a function screen and a main screen.

[0088] Figure 10G-10J Various LWD-related screens 1018, 1020 according to one or more embodiments of this disclosure are shown. In particular, Figure 10G and Figure 10HThe performance of the LWD system during single yarn rig operation is shown, while Figure 10I and Figure 10J The performance of the LWD system during double-row operation is shown. These screens depict a wire tree with conductive sensors and can indicate the presence of loose or broken wire by highlighting specific conductive bars that have tripped or sensed loose or broken wire. For example, Figure 10G and Figure 10I This includes a graphical representation of a line tree with conductive bars when inactive (i.e., in a non-alarm state), while Figure 10H and Figure 10J This includes a graphical representation of a line tree with conductive bars when activated (i.e., in an alarm state). Figure 10H In the diagram, the screen displays that conductive rod R2 has been activated / tripped, where conductive rod R2 corresponds to the actual conductive rod located in the second row from the right at the top of the wire tree; however, a different naming convention can be provided, for example, such that R1 corresponds to the bottom right and R5 corresponds to the top right. This allows the operator to easily determine if there is a broken or loose wire in the operating yarn holder of the second row of wires from the right. Figure 10J In the middle, the screen displays that conductive rod L2 in the left yarn rack has been activated / tripped, where conductive rod L2 corresponds to the actual conductive rod located on the left and in the second row from the top of the yarn tree on the left yarn rack. In this way, the operator can easily determine whether a broken or loose thread has been detected in the left yarn rack of the second row of yarn from the left.

[0089] Figure 10K An alarm and history log screen 1022 according to one or more embodiments of the present disclosure is shown. The alarm and history log screen 1022 is accessible via an alarm screen button 1015d on any of the aforementioned screens. The alarm and history log screen 1022 includes an active alarm log and an alarm history log, and one or both of these can track various statistics associated with each event, including but not limited to date, time, description, associated system, status, and actions taken. The screen can be customizable and can record additional data. For example, an operator can customize one or both logs to list all or only certain events requiring immediate corrective action, and / or allow color coding of different events based on their status (e.g., events that have not yet been fixed might be highlighted in red, while fixed events are in green, and events that have been checked and / or are being checked are in yellow). Furthermore, an operator can assign an event to one of his or her colleagues so that the colleague receives an alarm notification (e.g., on his or her mobile device with a mobile application, as described below), and can then take corrective action while the operator monitors the status of the event, and his or her colleague addresses the same issue. The recorded data and information can be exported to a variety of different devices, including via USB download or other wireless transfers. Figure 10KThe alarms and history log screen 1022 shown does not include any recorded events. Figure 10L This is a list of example alarm messages that can be populated within the log on screen 1022. Additionally, the alarm and history log screen 1022 can provide navigation buttons for switching between screens such as function screens and the main screen.

[0090] Figure 10M A maintenance screen 1024 according to one or more embodiments of the present disclosure is shown. The maintenance screen 1024 can be accessed by pressing a maintenance screen selection button 1008d. The maintenance screen 1024 may provide real-time temperature and humidity readings (or other environmental information) and also provides access to information that may be helpful for maintenance and / or the operating system. For example, the operator can access electrical schematics of various devices, which he / she can export to another device or printer for later use. Furthermore, the operator can access manuals, frequently asked questions, and / or other warranty information. In some embodiments, the operator can communicate with maintenance personnel via software; for example, the operator can schedule maintenance appointments using functions accessible on the maintenance screen 1024. Additionally, the maintenance screen 1024 may provide navigation buttons for switching between screens, such as function screens and a main screen.

[0091] Figure 10N A system information screen 1026 according to one or more embodiments of the present disclosure is shown. The system information screen 1026 can be accessed by pressing the system information selection button 1008c. In addition, the system information screen 1026 can provide information and details about a particular ray system and the equipment used therewith, and may include navigation buttons for switching between screens such as function screens and main screens.

[0092] However, control of the yarn truss system 100 can also be achieved using remote devices, including through the use of yarn truss system control and / or visualization applications installed on computers, laptops, or mobile devices. For example, a mobile device or smartphone "app" can be installed to communicate with the control system 116. In this example, such a mobile device can communicate with the central control system 116 to provide remote monitoring of various yarn truss systems, functions, and devices, similar to the control device 900 described using console 900, allowing the operator to remotely monitor the operating parameters and / or environmental parameters of the yarn truss operation. This communication between the remote device and the control system 116 (or console 900) can occur via various wireless or wired communication methods, such as Bluetooth. TM or WiFi TMWireless transmission, via the Internet, wherein the controller of control system 116 (or console 900) is connected to the Internet via a hardwired connection (e.g., USB cable, Ethernet cable (e.g., CAT6 cable), etc.) or a combination thereof. The application can send and receive information to and from control system 116, or can directly send and receive information to and from one or more systems, sensors, or devices in the yarn rack system (e.g., LWD system and / or environmental monitoring system).

[0093] In alternative or supplementary embodiments, the application may include the same operator input options provided on the control system 116 to provide control commands to the controller (of the controllable user interface 917) to manually or automatically tension the wire W and / or monitor (and / or adjust) the environmental conditions of the yarn rack chamber. In further alternative or supplementary embodiments, security features may be provided by the application or built into the application. For example, the mobile phone may implement security controls (e.g., passwords, PINs, codes, patterns, biometric scanning, etc.), may prevent full access to the platform, allow monitoring but prevent remote control, transmit or receive data to or from the application, or other activities related to the yarn rack system (e.g., changing the environmental conditions of the yarn rack chamber) based on successful authorization through the security control.

[0094] Figure 11Aspects of a mobile platform control (SPC) 122 when implemented on a multi-row yarn purlin system 1100 according to one or more embodiments of the present disclosure are illustrated. While the multi-row yarn purlin system 1100 may be similar in some respects to the yarn purlin systems 100, 700 described above, the yarn purlin system 1100 is mounted on mobile platforms 1110a, 1110b and includes SPC 122. In this type of yarn purlin system 1100, individual yarn purlin rows 1111a, 1111b (typically 1111), each having its own yarn purlin frame 102 (and each including one or more frame segments F), a front weave support (FOS) 104, and a main weave support (MOS) 106, are attached to steel platforms 1110a, 1110b, each such platform P carrying an individual yarn purlin row 1111. Platforms 1110a, 1110b may include motors 1108 configured to drive wheels (not shown) along tracks 1106 embedded in the yarn purlin chamber floor. The motor 1108 can be controlled at the main housing of the system, which may include, for example, an emergency stop button and buttons for controlling the movement of each row to the right and left. The main housing may be located in the yarn rack chamber along with other system controls. In other embodiments, each row may have its own control panel directly mounted to the moving row. In a system 1100 having multiple yarn rack rows 1111a, 1111b, one yarn rack row 1111a may be positioned on the calender centerline 1104 during operation (in the "running position"), while the other yarn rack row 1111b may be positioned to the side (in the "loading position"). In other embodiments, two yarn rack rows may be symmetrically positioned, particularly about the calender centerline, so that they can operate together. In this way, the second yarn rack row 1111b does not obstruct the calender centerline 1104 and can be used to load bobbins. When the first yarn frame row 1111a completes its run, it can then be moved to one side, for example, onto the embedded track 1106, where the second yarn frame row 1111b occupies its position along the calender centerline 1104. This minimizes calender downtime between runs. When the second yarn frame row 1111b completes, the yarn frame rows 1111a and 1111b can be switched again.

[0095] The central control system 116 and the motor 1108 can communicate with each other. This allows the operator to manipulate the user interface 117, 917 to move each row of yarn racks 1111a, 1111b to a desired position on the yarn rack chamber floor. In some embodiments, the yarn rack rows 1111a, 1111b are configured to move sequentially to their new target positions. Although two rows of yarn racks 1111a, 1111b are shown, it should be understood that the number of yarn rack rows 1111 is not limited. Compared to using buttons in the main housing to control the platform, the central control system 116 provides the ability to automatically move all yarn rack rows to the desired position based on a single specified operator input. As a further example, Figure 12 A yarn rack room with eleven yarn rack row positions 1111 is shown.

[0096] In some embodiments, each platform 1110a, 1110b includes at least one proximity sensor 1105 configured to detect a feature 1109 on the floor G of the yarn rack room. This feature 1109 may be present in the floor in the form of a pad. In other embodiments, for example, as... Figures 15A-15C As shown, the proximity sensor is replaced by an RFID reader that senses an RFID tag mounted on the floor. In other embodiments, mechanical limit switches may be used to determine the position. This allows each platform 1110a, 1110b to move until it reaches a detectable feature 1109. For example, the detectable feature 1109 may be a pad that can be detected by proximity sensor 1105 and is located at the loading and running position of the yarn rack row. In some examples, limit switches may be used to prevent platform 1110 (e.g., an external platform) from overtraveling.

[0097] In some embodiments, reference Figure 12 The position of the yarn rack row 1111 is aided by placing an coded proximity plate 1209 at a predetermined location in the yarn rack chamber. That is, feature 1109 on the floor of the yarn rack chamber embodies the proximity plate 1209. In some embodiments, the plate 1209 is made of 0.5-inch nylon and has multiple machined recesses, each recess configured as a receiving pad (e.g., a steel or nylon pad) secured to the recess by fasteners, adhesives, etc. After the plate position is confirmed, the plate 1209 is secured to the yarn rack chamber floor G, for example, by screws. This design allows for later adjustment of the yarn rack row position compared to a design using an embedded plate. In other embodiments, the proximity sensor is replaced by an RFID reader that senses an RFID tag mounted on the floor. In other embodiments, a mechanical limit switch may be used to determine the position.

[0098] Figure 12 The overall layout of the proximity plates 1209 in the yarn rack chamber is shown. Each plate 1209 is coded by placing a nylon or metal pad in each recess, as described in more detail below. When the plate 1209 is correctly positioned below the proximity sensor 1105, the proximity sensor 1105 is able to read the code of the plate 1209. Figure 12As shown, multiple plates 1209, each with a unique code (i.e., the location of the metal and nylon pads on plate 1209), are fixed to the floor near FOS 104. Each yarn rack row 1111 runs on track 1106 to a desired position 1209 associated with the plate. Plates 1209 can be positioned such that multiple areas are defined within the yarn rack chamber. That is, plates 1209 can be positioned in front of FOS 104, defining a running area 1220. Plates can also be positioned away from FOS 104, for example, on its opposite side, defining an exclusion / loading area 1222. In other embodiments, the proximity sensor is replaced by an RFID reader that can sense RFID tags mounted on the floor. In other embodiments, mechanical limit switches can be used to determine the position.

[0099] The central control system 116 can use board 1209 to determine where each yarn rack row 1111 is located before the automatic function is executed. For alarm purposes, the central control system 116 can ignore yarn rack rows 1111 that are not in the operating area 1220, i.e., yarn rack rows 1111 located in the exclusion / loading area 1222. In other embodiments, proximity sensors are replaced by RFID readers that sense RFID tags mounted on the floor. In other embodiments, mechanical limit switches can be used to determine the location.

[0100] Figure 13A An exemplary plate 1209 for fixed attachment to a floor is shown according to one or more embodiments of the present disclosure. The plate 1209 is configured to be detected by a proximity plate detector, thereby providing the position of a yarn rack row 1111 for use in automated functions. The plate 1209 includes a generally planar body 1302 having a thickness that allows a plurality of recesses 1304 to be continuously aligned along the planar body. Each recess 1304 is configured to receive a metal or non-metallic shape-complementary pad (1305, 1306, respectively). The order and number of the metal pads 1305 and the non-metallic pads 1306 in the recesses 1304 provide a binary code that can be read by a proximity sensor 1105 located on a platform 1110. Figure 13AIn the illustrated embodiment, the body 1302 includes a total of six recesses 1304 configured to receive either a metal pad 1305 or a non-metal pad 1306. In some embodiments, the metal pad 1305 is a steel pad. In some embodiments, the non-metal pad 1306 is a nylon pad. Although six recesses are illustrated, it should be understood that the number of recesses is not limited, and the body may include more or fewer than six recesses. Furthermore, although the recesses 1304 and the inserted pads 1305, 1306 are illustrated as aligned in a spaced-apart sequence, the sequence position is not limiting. That is, any arrangement of pads that can be read by the corresponding proximity sensor 1105 can be used without departing from the scope of this disclosure, such as in circular patterns, block patterns, etc. In some embodiments, the plate 1209 may be mounted or positioned within the first or front rail 1106. In other embodiments, the proximity sensor is replaced by an RFID reader that senses an RFID tag mounted on the floor. In other embodiments, a mechanical limit switch may be used to determine the position.

[0101] Figure 13B A proximity pad detector unit 1320 according to one or more embodiments of the present disclosure is shown. The proximity pad detector unit 1320 includes a frame 1322 and at least one sensor or detector 1324 supported by the frame 1322. The frame 1322 may be connected to a yarn rack row 1111 such that it moves with the yarn rack row 1111 and provides indication as it passes over a detection plate 1209, thereby providing an indication of the position of the yarn rack row 1111, on which the detection plate 1209 is read. In some embodiments, the detector 1324 includes a plurality of individual detector indicators 1326 (e.g., LEDs) that will provide indication (e.g., be energized or illuminated) when powered. In some examples, the detector indicator 1326 corresponding to the steel pad 1305 in the plate 1209 will be activated / energized, while the detector indicator 1326 associated with the non-metallic pad 1306 will not be energized. Figure 13A and Figure 13BIn the example shown, plate 1209 includes six recesses 1304 for six pads, wherein the first and fifth recesses are each provided with metal pads 1305a and 1305e, respectively, and detector 1324 includes six individual detector indicators 1326, each corresponding to a recess 1304 on plate 1209. The first detector indicator 1326a is activated / energized when oriented over the first metal pad 1306a, and the fifth detector indicator 1326e is activated / energized when oriented over the fifth metal pad 1306a. In some examples, for instance, when the yarn row 1111 moves individually to the center row position, one or more plates 1209 may be provided to include metal pads 1305 in all their recesses 1304 to confirm the functionality of detector 1326. The proximity pad detector unit 1320 can communicate with the central control system 116, allowing the central control system 116 to access data from the detector 1324 to determine the position of the yarn rack row 1111. In other embodiments, the proximity sensor replaces the RFID reader, which can sense RFID tags mounted on the floor. In other embodiments, mechanical limit switches can be used to determine the position.

[0102] Figures 15A-15C An alternative system 1500 for sensing the position of a moving yarn rack row is illustrated according to one or more alternative embodiments. The sensing system 1500 may include one or more RFID tag readers 1502 configured to identify / sensor RFID tags 1504 mounted on the floor. Each yarn rack row may include at least one reader 1502. The RFID tags 1504 may be held on the floor by a plate 1506. While the sensing system 1500 can be used instead... Figures 13A-13B The system. In some examples, the sensing system 1500 can be integrated with... Figures 13A-13B The system is used in combination. For example, some yarn rack rows may include Figures 13A-13B The system, while other yarn rack rows may include Figures 15A-15C The sensing system 1500; and / or at least some yarn rack rows may simultaneously include Figures 13A-13B The system and sensing system 1500.

[0103] The yarn truss system described herein may therefore include one or more safety features or devices. Such safety features and / or devices can be controlled by the control system 116. That is, several devices within the yarn truss systems 100, 1100 generate information to enhance the safety of system operation. Safety features and devices may include, for example, safety cord pull switches, collision detection and avoidance systems, and platform drive photoelectric sensors for interrupting frequency converter drive motion.

[0104] Regarding the safety rope emergency stop switch (SRES), please refer again. Figure 1A-1DA pull switch 1140 may be provided to stop the operation of the yarn frame system 1100 and / or send a signal to stop production. The pull switch 1140 may be mounted along the side of the yarn frame row 1111. The switch 1140 may be mounted or secured to the frame 102 (or its frame segment F), for example, at the front end 1142 of each yarn frame row 1111. In other embodiments, the switch 1140 may be mounted to the frame of the FOS. A cord (not shown) may be connected to each pull switch 1140 to activate or deactivate the pull switch 1140. The cord may be routed from their associated pull switches 1140 along the yarn frame row 1111, for example, along the long side 1144 of the yarn frame row 1111b toward the rear end 146 of the yarn frame row 1111b. The cord may be positioned at different locations around the frame 102, for example, in a user-accessible location; in one example, the cord is positioned on the horizontal plane of the third row tension controller 202. However, the position and length of the cord are adjustable and can be arranged in various positions as needed for specific end-use applications. Switch 1140 is designed to send an SRES signal when the cord is pulled, which can be used by the calender operator to shut down production in an emergency. The pull switch 1140 can communicate electronically with the central control system 116, and in some embodiments, the safety SRES signal from the pull switch 1140 is routed to the central control system 116, making the data address available for the calender to read at any time. For example, the pull switch 1140 can be connected to the central control system 116 such that when the cord is pulled, a warning light on the user interface 117, 917 can illuminate and / or generate some other indication thereon, where the SRES signal is appropriately addressed so that the calender can read or retrieve it at any time. Thus, the generated SRES signal can be addressed for the calender to read at any time, and this information can be combined with other data required by the calender without additional wiring. In some embodiments, some pull switches 1140 are active while others are inactive. For example, during production operation, the yarn rack system 1100 can scan only the running yarn rack row 1111a in the calender centerline 1104 to activate the cord switch 1140, while the safety cord and pull switch 1140 are not monitored in inactive yarn rack rows (e.g., yarn rack row 1111b), thus allowing loading / unloading / maintenance of such inactive yarn rack rows without interrupting production operation in the event of a trip of switch 1140.

[0105] In some embodiments, the yarn truss system 1100 includes a collision avoidance system (CAS) for detecting adjacent yarn truss rows 1111 and preventing collisions during movement operations involving any yarn truss row 1111. The CAS includes collision avoidance photocells 1150 for detecting adjacent yarn truss rows 1111. The photocells 1150 may be positioned on the frame 102, for example, at a lower outward extension of the frame 102, wherein each yarn truss row 1111a, 1111b has two photocells, each yarn truss row 1111 having a first photocell 1150 for monitoring leftward movement of the associated yarn truss row 1111 and a second photocell 1150 for monitoring rightward movement of the associated yarn truss row 1111. The photocells 1150 may communicate with a central control system 116. Communication between the photocells 1150 and the central control system 116 may be wireless and / or via a wired connection. The anti-collision photocell 1150 prevents the yarn rack rows 1111a and 1111b from colliding with each other during any motor-driven event.

[0106] The CAS (Computer-Assisted Detection) can be used to detect yarn rack rows 1111b that are close to the moving yarn rack row 1111a. Once the adjacent yarn rack row 1111b is detected, it affects the drive of the moving row 1111a. For example, the CAS can be configured to send a stop signal that disables the drive command in that direction but does not affect the drive function in the opposite direction. In such an example, any disabled drive command or drive function can be reset or restored if the moving yarn rack row 1111a has moved to a position where the adjacent yarn rack row 1111b is no longer within the detection range or area of ​​the anti-collision photodetector 1150. In some examples, the CAS can be configured to send a stop signal to disable the drive command in that direction, and then send a run command to automatically enable the drive function in the opposite direction. The CAS can be activated by the movement of the yarn rack rows 1111a, 1111b (manual, automatic, or IPC mode). In this case, the CAS is in an inactive or dormant mode until it is activated or woken up by movement.

[0107] In some embodiments, photoeyes 1150 may include beam-type devices mounted around the movable yarn rack row 1111. In some embodiments, each photoeye 1150 projects a signal or beam of light (e.g., infrared) onto a receiver 1152 at the other end 1146 of the yarn rack row 1111, thereby creating a beam of light extending along the periphery of the yarn rack row 1111, for example, along the side of the yarn rack row 1111. Mounting them in opposite directions on one side with its transmitter facing rearward and the other side with its receiver 1152 facing rearward helps to prevent any signal leakage that could cause a false trip signal. When the beam on either side is interrupted, the corresponding yarn rack safety relay trips, sends a fault signal to the central control system 116, and shuts down the drive system, thereby stopping movement. Operating information about the photoeyes 1150 and any faults may be visually presented on user interfaces 117, 917 (e.g., indicator lights, screen alarms or messages and / or graphics) and / or audibly presented at and / or near the console 900, for example, a speaker, an alarm, etc. This operational information can be presented to the operator at the console 900 in a manner indicating the location where a beam interruption was detected (e.g., an indicator light associated with a specific row or column of the yarn rack). This system helps prevent personnel from being struck by moving frames and yarn rack rows, and avoids any obstructions on the floor that could impede the movement of the yarn rack rows. Furthermore, the system can be activated by moving yarn rack rows 1111a, 1111b (manual, automatic, or IPC mode), thus placing the system in an inactive or dormant mode until it is activated or awakened by movement. In some examples, when the system has tripped and the problem causing the trip has been resolved, the drive system can be resumed by pressing the reset button on the control system 116 (e.g., in the console 900).

[0108] In some embodiments, the central control system 116 is configured to prevent the yarn trellis line 1111 from overtraveling. For example, the outer sides of the first and last platforms 1110a, 1110b may be equipped with mechanical travel limit switches configured to prevent the platforms 1110a, 1110b from overtraveling beyond the range of track 1106. For example, when a moving platform actuates the limit switches, the limit switches generate limit switch signals readable by the central control system for controlling the movement of the moving yarn trellis line. For outward movement, these switches can directly disconnect the drive at the ends of the yarn trellis lines 1111a, 1111b. In some examples, such mechanical limit switches can be reset by manually reversing the movement of the yarn trellis line 1111 at console 900. In some embodiments, reaching the overtraveling limit position can restrict movement to allow the yarn trellis line to return only from the end of its travel.

[0109] In some embodiments, the yarn truss systems 100, 1100 include environmental sensors, including but not limited to temperature and humidity sensors. That is, if present, at least one of the environmental sensors communicates electronically with the central control system 116. The central control system 116 receives environmental data (temperature data, humidity data, etc.), and if the value of the environmental data exceeds a predetermined threshold, the central control system 116 issues an alarm to notify the operator at the user interface 117 of the environmental status. In some embodiments, the environmental data is recorded in a data storage device 119. In still other embodiments, the environmental data generated by the environmental sensors has a data address for the calender to read at any time.

[0110] In some embodiments, the control system 116 is configured to access a cloud network, enabling third parties to remotely access the control system 116. In yet other embodiments, the control system 116 is configured to allow direct, peer-to-peer communication with the system manufacturer via Internet Protocol. For example, production technicians can leverage this feature to remotely provide support and resolve any issues with systems 100 and 1100. In some examples, this feature allows the manufacturer to access software loaded onto the central computer system 116 via a customer network connection. The customer controls access to systems 100 and 1100 via keys on a physical console 900, thus ensuring the manufacturer can only access systems 100 and 1100 when explicitly granted access by the customer, thus maintaining the security of their network. Using this remote access capability, the manufacturer will be able to provide software updates and enhancements during development without physical access to the machines.

[0111] According to another aspect of this disclosure, reference is made to Figure 14 The system provides a digital yarn crease system 1400 with automated and efficient yarn crease functionality. It should be understood that... Figure 14 The various components shown are for illustrating aspects of exemplary embodiments, and other similar components implemented in hardware, software, or a combination thereof can be substituted therein. System 1400 is configured to control the power or operation of a yarn creel system, such as yarn creel systems 100, 1100, or similar material handling equipment, based on data received from various sensors and subsystems.

[0112] like Figure 14As shown, system 1400 includes a central control system, generally referred to as a central computer system 1416, capable of implementing the exemplary methods described herein and below. The central computer system 1416 may be implemented differently without departing from the scope of this disclosure, such as an industrial computer, a programmable logic controller (PLC), a personal computer, a tablet computer, a smartphone, or other known devices hosting software platforms and / or applications. The exemplary computer system 1416 includes a processor 1424 that performs the exemplary methods by executing processing instructions 1426 stored in memory 1428 connected to the processor 1424 and controlling the overall operation of the computer system 1416.

[0113] The control system 1416 may also include a user interface 117, 917 similar to that of the central computer system 116, for monitoring and controlling various components of the yarn crease system. The control system 1416 communicates electronically with the sensors and subsystems described in more detail herein and is configured (via wired and / or wireless connections) to receive data collected by the sensors and subsystems that is relevant to or indicates the operation of the yarn crease devices 100, 1100.

[0114] Instruction 1426 includes an air pressure control (APC) module 1430 configured to control the air pressure to the tension control device 202 via the APC system 118, as described above with respect to system 100. Thus, the APC module 1430 can increase or decrease the friction applied to the spool 108 by increasing / decreasing the air pressure, by controlling various servo valves based on the detected tension of the wire W, and / or by signals originating from the calender 1410 communicating with the central control system 1416. In other words, the central control system 1416 receives signals from the calender 1410 to set a target air pressure for at least one tension control device 202 (or at least one row of tension controllers 202). In some embodiments, the central control system 1416 is also configured to send signals back to the calender 1410, including received set pressure points and / or actual pressure readings from the servo valves of the APC system 118.

[0115] Instruction 1426 also includes an LWD module 1432, which, as described above, when implemented by processor 1424, controls the power and operation of the LWD system and receives data signals from it. That is, LWD module 1432 is configured to determine when wire W contacts sensor bar 704, which can indicate that wire W is loose or broken. Upon determination of a broken or loose wire W, central control system 1416 may issue an alarm. In some embodiments, this includes graphically displaying the position on a digital representation of the wire tree 110, the area where wire W has been contacted, for example, in IPC user interface 917. The indication and position of the broken / sag wire on the wire tree can be recorded to storage device 119 connected to system 1416. In some embodiments, central control system 1416 is configured to send data to calender 1410, including an indication of a broken or loose wire W and the relative position of the broken or loose wire W, depending on which sensor bar 704 is actuated by the loose / broken wire W.

[0116] Command 1426 also includes an environment module 1434, which controls the power and operation of the yarn creel systems 100 and 1100 in response to signals received from the environment sensor 1460 relating to the operating environment of the yarn creel room. In some embodiments, the environment sensor 1460 includes temperature and humidity sensors. When the central control system 1416 receives environmental data exceeding a predetermined threshold, such as a temperature above a threshold temperature, the central control system 1416 issues an alarm. In some embodiments, the environmental alarm includes shutting off the power to the yarn creel systems 100 and 1100. In other embodiments, the environmental data and alarm signals are provided to the calender 1410.

[0117] Instruction 1426 also includes a tension monitoring system (TMS) module 1436, configured to receive tension measurements from a tension monitoring system 1480, which may include, for example, a tension monitoring bracket 800, as described above in more detail with reference to Figure 8. Specifically, a tension measurement sensor 802 of the bracket 800 generates a tension output signal, which is sent to a central control system 1416. The tension value measured by the tension measurement sensor 802 is provided with a data address by the control system 1416 for the calender to read at any time. The calendering logic is capable of measuring the actual tension output of a specified air pressure input signal. This feedback loop allows the central control system 1416 or the calender to make minor adjustments to the air pressure input signal and / or APC 118 based on the measured tension output, thereby providing a more precise tension control method for the calender.

[0118] In some embodiments, the tension value measured by the tension measuring sensor 802 is displayed on the user interface 117, 917 for monitoring. This screen allows the yarn rack operator to monitor the tension of the yarn W.

[0119] Command 1426 also includes a position module 1438 configured to determine the position of the yarn rack rows 1111 and control the movement of each row. As described above, each yarn rack row 1111 can be placed on a movable platform 1110. The platform 1110 includes a motor 1108 connected to wheels that enable movement of the yarn rack rows 1111 fixed to the wheeled platform 1110. The movement 1110 of the platform is guided by a track 1106. The yarn rack chamber floor may also include at least one feature / marker read by a proximity sensor 1105 on the platform, allowing the position module 1438 to determine the position of a particular yarn rack row 1111. The control system 1416 communicates electronically with the motor 1108 such that, upon receiving a movement command from the user, the position module activates the motor 1108 and causes the platform 1110 to move along the track 1106 in the desired direction.

[0120] In some embodiments, the position module 1438 is configured to process signals obtained from proximity sensors 1105 that read features 1109 or plates 1209 mounted on platform 1110, and determine the position of each yarn rack row 1111 within the yarn rack chamber. The position module is also configured to control motors 1108 of each platform 1110 and initiate movement of the associated yarn rack row 1111 to a target position. For example, in a system with four yarn rack rows, the current state might be that the first yarn rack row is currently in the middle running position, while the second, third, and fourth yarn rack rows are in loading positions away from one side (e.g., the left). Here, if the operator commands the third yarn rack row to move to the running position, the position module 1438 will determine the position of each yarn rack row and instruct the first yarn rack row to move to the right to the loading position, for example, the first yarn rack row returns to its origin, while making room for the second yarn rack row to move to its loading position a second time; finally, the third yarn rack row will be instructed to move to its designated running position. In such an example, each movement coordinated by the position module 1438 can occur automatically after an operator-specified command. Therefore, system 1416 can provide the ability to automatically move all yarn rack rows to the desired position based on input from a single designated operator. In other embodiments, proximity sensors and plates are replaced by RFID tag readers, with the RFID tags mounted on the floor. In still other embodiments, mechanical limit switches may be used instead. In further embodiments, other sensor technologies may be used. Without departing from this disclosure, various types of sensing technologies can be utilized to determine the position of the yarn rack rows.

[0121] Instruction 1426 also includes a collision avoidance system (CAS) module 1440 configured to prevent the yarn rows 1111 from colliding with each other during any movement. That is, the CAS module 1440 can be configured to receive collision data from collision avoidance sensors 1150 mounted to the yarn rows 1111 or platform 1110, as described above. The CAS module 1440 can cooperate with the position module 1438 or its components to disable drive commands of the position module 1438 by generating a stop signal based on the collision data from the collision avoidance sensors 1150. In other words, the CAS module 1440 can receive collision data from at least one sensor 1150 associated with each yarn row 1111 and determine the distance between the moving yarn row 1111 and adjacent yarn rows. When the moving yarn frame row 1111 travels a certain threshold distance to the adjacent yarn frame row 1111, the CAS module 1440 sends a stop signal to the motor 1108 that drives the yarn frame row 1111 to avoid collisions between the moving yarn frame row and the adjacent yarn frame row.

[0122] Various components of computer system 1416 can be connected via data / control bus 1425. The processor 1424 of computer system 1416 communicates with associated data memory 119 via link 1442 and with various subsystems, such as APC system 118, LWD system, and environmental sensors 1460 and sensors, via link 1443. Suitable communication links 1442 and 1443 may include, for example, public switched telephone networks, proprietary communication networks, infrared, optical, or other suitable wired or wireless data communications.

[0123] Therefore, the disclosed systems and methods are well suited to achieving the stated purposes and advantages, as well as those inherent therein. The specific embodiments disclosed above are merely illustrative, as the teachings of this disclosure can be modified and practiced in different but equivalent ways. This will be apparent to those skilled in the art who benefit from the teachings herein. Furthermore, there are no limitations on the details of the constructions or designs shown herein, except as described in the following claims. Therefore, it will be apparent that the specific illustrative embodiments disclosed above can be changed, combined, or modified, and all such changes are considered to be within the scope of this disclosure. The exemplary systems and methods disclosed herein can be suitably practiced in the absence of any elements not specifically disclosed herein and / or any optional elements disclosed herein. While compositions and methods are described as “comprising,” “including,” or “comprises” various components or steps, compositions and methods may also be “generally composed of” or “of” various components and steps. All numbers and ranges disclosed above may vary. Whenever a numerical range with a lower and upper limit is disclosed, any number falling within that range and any range of inclusion is specifically disclosed. In particular, each numerical range disclosed herein (in the form of "from about a to about b" or equivalently "from about a to b" or equivalently "about ab") should be understood to list each number and range contained within a broader range of values. Furthermore, unless the patentee explicitly and clearly defines otherwise, the terms in the claims have their simple, ordinary meaning. Additionally, the indefinite articles "a" or "an" used in the claims are defined herein as referring to one or more elements introduced therein. If the use of words or terms in this specification conflicts with one or more patents or other documents that may be incorporated herein by reference, the definitions consistent with this specification shall prevail.

[0124] The directional terms used, such as above, below, upper part, lower part, above, below, left, right, etc., are related to the illustrative embodiments shown in the figures, with upward or upper direction pointing towards the top of the corresponding figure, and downward or lower direction pointing towards the bottom of the corresponding figure.

[0125] As used herein, the phrase "at least one" preceding a series of items, separated by the terms "and" or "or," modifies the list as a whole rather than as a list of each element (i.e., each item). The phrase "at least one" allows for the meaning of at least one of any given item, and / or at least one of any combination of these items, and / or at least one of each item. For example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" respectively refer to only A, only B, or only C; any combination of A, B, and C; and / or at least one of A, B, and C.

Claims

1. A creel system comprising: a frame having a plurality of tension control devices for paying out wire under tension, each of the tension control devices having a brake shoe engageable with a mandrel and a control arm rotatable toward the mandrel to move the brake shoe away from the mandrel and rotatable away from the mandrel to move the brake shoe toward the mandrel; at least one device sensor disposed on at least one of the control arms; and a central control system operable to determine wire tension based on data from the device sensor, and wherein the central control system is configured to track a position of the frame relative to a creel room based on position data associated with each of the frames and control a motor associated with the frame to move the frame to a target position.

2. The creel system of claim 1, further comprising a loose wire detection system in communication with the central control system, the loose wire detection system comprising a wire tree positioned downstream of the frame and including a plurality of vertically spaced sensor bars configured to generate a loose wire detection signal based on contact between wire and at least one of the sensor bars.

3. The creel system of claim 1, further comprising a tension monitoring system in communication with the central control system, the tension monitoring system comprising a tension monitoring bracket positioned downstream of the frame, the tension monitoring bracket including at least one tension sensor that receives wire from the frame, wherein the at least one tension sensor measuring a tension of the received wire and generating a tension output signal that is sent to the central control system, wherein the central control system changes an air pressure of an air pressure control system based on the tension output signal.

4. The creel system of claim 3, the tension monitoring bracket including a left tension sensor, a center tension sensor, and a right tension sensor configured to receive wire from a left side portion of a wire plane, wire from a center portion of the wire plane, and wire from a right side portion of the wire plane, respectively.

5. The creel system of claim 1, further comprising a plurality of platforms, wherein a frame having a plurality of tension control devices for paying out wire under tension is mounted to each platform, each platform including a set of wheels driven by a motor, the motor of each platform being in communication with the central control system, the central control system directing the motor of the associated platform to a target position.

6. The creel system of claim 5, wherein, each platform including a proximity sensor configured to generate a position signal in response to reading at least one feature plate located at a predetermined position on a floor of a creel room.

7. The creel system of claim 5, wherein, each platform including at least one light eye sensor configured to measure a distance between adjacent platforms, wherein the central control system generates a stop motion signal based on the at least one light eye sensor measuring a predetermined threshold distance.

8. The creel system of claim 5, further comprising at least one mechanical travel limit switch in communication with the central control system, the central control system configured to prevent platform over travel beyond a predetermined position.

9. The creel system of claim 1, further comprising at least one trip wire switch, the trip wire switch comprising a cord mounted at a front end of a creel row, the trip wire switch generating a stop signal when the cord is pulled, the stop signal readable by the central control system to stop operation of the creel system.

10. The creel system of claim 9, wherein, the central control system configured to shut down the creel system based on the stop signal generated by the creel row, and based on a determined position of the creel row in the creel chamber.

11. The creel system of claim 1, further comprising a data storage in communication with the central control system, the data storage configured to store measurement data to a log file.

12. The creel system of claim 1, further comprising an air pressure control system in communication with the central control system and operably connected to each of the tension control devices and actuatable to move the brake shoe toward the mandrel, the tension control device in communication with at least one device sensor disposed on at least one of the control arms.

13. The creel system of claim 1, wherein, the central control system configured to wirelessly communicate with a remote device, and the remote device programmed to allow remote monitoring and control of the creel system.

14. The creel system of claim 1, further comprising a user interface in communication with the central control system, wherein the user interface is operable to display real-time performance information of the creel system, and the user interface is operable to allow control of the creel system.

15. The creel system of claim 1, further comprising a temperature and humidity sensor to measure environmental conditions within the creel chamber, wherein the temperature and humidity sensor is in communication with the central control system such that the central control system receives data from the temperature and humidity sensor, wherein the data is indicative of environmental conditions within the creel chamber.

16. The creel system of claim 1, further comprising a plurality of platforms, wherein a frame having a plurality of tension control devices for paying out wire under tension is mounted to each platform, each platform comprising a set of wheels for moving the associated platform to a target position.

17. The creel system of claim 5, wherein, each platform comprising an RFID reader, wherein the RFID reader is programmed to read an RFID tag having a unique ID number, the RFID tag located at a known position on a floor of the creel chamber.

18. The creel system of claim 5, wherein, each platform comprising an encoder to determine a position of the platform.

19. The creel system of claim 12, wherein, the central control system configured to store a pressure threshold and trigger an alarm state when pressure deviates from the pressure threshold.

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