Method and apparatus for inserting coil

Abstract

To provide a coil insertion method for inserting a coil into a mandrel.SOLUTION: Before the coil mounted on a coil truck is inserted into a mandrel, the coil truck is stopped, and the distance to each position on the side face of the coil is measured by using a first sensor fixed opposite to the side face of the coil as a scanning laser range finder. The position of the center of the inner diameter portion of the coil is obtained from the obtained distance data, and the lifting amount of the coil required for alignment with the preset axial center of the mandrel is calculated. A second sensor fixed opposite to the coil is used as a scanning laser range finder to measure the distance to each position in the coil width direction. The position of the center of the width of the coil is obtained from the obtained distance data, and the moving amount of the coil carriage to a preset line reference position is calculated. As a result, the information required for insertion into the mandrel can be calculated in a space-saving manner without the need for movement of the sensor or movement of the coil carriage.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method and apparatus for inserting a coil into a mandrel of an unwinding device such as a payoff reel. [Background technology]

[0002] In the steel industry, many process lines operate in which steel strip coils (hereinafter simply referred to as coils) are unwound using a payoff reel or other unwinding device and processed. In such process lines, the coil is loaded onto a coil cart, and the coil outer diameter is measured using pulses from a pulse generator (PLG) obtained by raising and lowering the coil cart. The coil width is also measured using pulses from the PLG obtained by moving the coil cart. The measured coil outer diameter and coil width are then used to calculate the center positions of the coil width and coil outer diameter. After aligning the coil with the mandrel, the coil cart is moved axially around the mandrel to insert the coil onto the mandrel. However, this method of inserting the coil onto the payoff reel has the drawback of being unable to detect if the coil falls over during insertion.

[0003] To address this issue, for example, Patent Document 1 discloses a coil tip-over prevention device that includes a travel distance measuring means for measuring the deviation between the travel distance of the coil on the coil car and the travel distance of the coil car, and a conveyor movement stopping means for stopping the movement of the coil car. This ensures that the conveyor stops only when the side of the coil hits the mandrel, preventing the coil from tipping over. Note that, in the technology described in Patent Document 1, when inserting the coil into the mandrel, a solenoid valve raises and lowers the coil on the coil car, and a height alignment detector detects the coil center to align the coil axis with the center of the mandrel. Furthermore, the coil car travels in the direction of the mandrel, and a width alignment detector detects the center of the coil in the width direction to align the line center with the center of the coil in the width direction.

[0004] Furthermore, the coil insertion method described in Patent Document 2 uses a first sensor that is positioned facing the side of the coil and is movable in the vertical direction. The distance from the first sensor to the facing side of the coil, the distance to the end face of the mandrel, and the distance to the background are measured at each vertical position to obtain distance data. From the obtained distance data, a distance profile is obtained, which is a diagram showing the relative relationship between the inner diameter portion of the coil and the mandrel, and whether or not the coil can be inserted into the mandrel is determined.

[0005] Then, while the coil is being inserted into the mandrel, the second sensor measures the distance to the side of the moving coil and calculates the relationship between the coil movement distance and time. The obtained relationship between the coil movement distance and time determines whether the inserted coil has fallen over. The first and second sensors are preferably laser distance meters.

[0006] This prevents contact (collision) between the coil and the mandrel, and also enables early detection of coil tipping during insertion, significantly reducing or preventing a decrease in product yield and damage to the equipment. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 64-66017 [Patent Document 2] Japanese Patent Publication No. 2022-96122 Summary of the Invention [Problem to be solved by the invention]

[0008] However, the technology described in Patent Document 1 requires space for raising and lowering the coil mounted on a coil cart and for the coil cart to travel in order to calculate the center position of the coil outer diameter and coil width. Furthermore, the technology described in Patent Document 2 moves a first sensor facing the side of the coil up and down to obtain a distance profile, which is a diagram showing the relative relationship between the inner diameter portion of the coil and the mandrel, and determines whether or not insertion is possible. The technology described in Patent Document 2 also requires space for moving the sensor up and down.

[0009] Therefore, an object of the present invention is to provide a coil insertion method and device for inserting a coil mounted on a coil cart into a mandrel of a payoff reel, which saves space without moving the sensor. [Means for solving the problem]

[0010] To achieve the above-mentioned object, the inventor first carefully considered the placement of the sensors to be used. As a result, as shown in FIG. 2, the first sensor is fixedly disposed at a predetermined position facing the side of the coil, and the second sensor is fixedly disposed at a predetermined position above the coil facing the coil. The first sensor 41 is used to measure the distance to each position on the side of the coil, and the second sensor 42 is used to measure the distance to each position in the width direction of the coil. It is preferable to select a scanning laser rangefinder as the sensor to be used. This is because a scanning laser rangefinder can measure the distance to each position of an opposing object and the distance to an object on a uniaxial scanning plane, along with the laser scanning angle.

[0011] The position (coordinates) of each position on the side of the coil is calculated from distance data to each position on the side of the coil measured using the fixed first sensor 41, and the position of the center of the coil's inner diameter part is determined. Then, from the obtained position of the center of the coil's inner diameter part and the preset position of the axial center of the mandrel, the amount of coil lift in the vertical direction required to align the axial center of the mandrel with the center of the coil's inner diameter part is calculated.

[0012] The position of the coil width direction center is determined from distance data between the second sensor 42, which is measured using a fixed second sensor, and each position in the coil width direction. Then, the coil movement amount required to move the coil width direction center to the line reference position is calculated from the obtained coil width direction center position and a preset line reference position. Note that the "line reference position" here refers to a position preset on the mandrel that allows the coil to be inserted until the coil width direction center is at this line reference position.

[0013] This makes it possible to calculate the amount of coil lift and coil carriage movement required to insert the coil into the mandrel without the need for sensors or movement of the coil carriage.

[0014] The present invention was completed based on the above findings and further investigations. The gist of the present invention is as follows. [1] A coil insertion method in which a coil carriage carrying a coil is moved to insert the coil into a mandrel, Before inserting the coil into the mandrel, a coil inner diameter center position calculation step of determining the position of the center of the inner diameter portion of the coil using a first sensor fixed to face the side surface of the coil; and a coil lift amount calculation step of calculating the amount of lift of the coil required to align the obtained center of the inner diameter portion of the coil with a preset axial center of the mandrel. a coil width direction center position calculation step of determining the position of the width center of the coil by a second sensor fixedly provided opposite to the coil; and a coil carriage movement amount calculation step of calculating the movement amount of the coil carriage from the obtained coil width direction center position to a preset line reference position, a coil insertion method characterized by: raising and lowering the coil using a lifting means attached to the coil cart in accordance with the calculated lifting distance of the coil; aligning the axial center of the mandrel with the center of the inner diameter of the coil; and then moving the coil cart by the obtained coil cart movement distance to insert the coil into the mandrel. [2] The coil insertion method described in [1] is characterized by comprising a coil movement distance measuring step of measuring the movement distance of the moving coil using a third sensor fixed opposite the mandrel while the coil cart is moved to insert the coil into the mandrel, a coil movement distance vs. time relationship calculation step of calculating the relationship between the movement distance of the coil and time, and a coil tipping / contact determination step of determining whether the coil has fallen over or contacted something during insertion from the obtained relationship between the movement distance of the coil and time. [3] The coil insertion method described in [2] is characterized in that it includes a coil carriage travel control process that, if it is determined in the coil tipping / contact determination process that the coil has not tipped or contacted, continues the travel of the coil carriage, and, on the other hand, stops the travel of the coil carriage if it is determined that the coil has tipped or contacted. [4] The coil insertion method according to [1] or [2], wherein the first sensor and the second sensor are scanning laser range finders. [5] A coil insertion device for inserting a coil into a mandrel, a coil carriage having a lifting means for lifting the coil up and down, the coil carriage carrying the coil and traveling freely toward and away from the mandrel; a first sensor fixed to face the side of the coil and measuring the distance between each position on the side of the coil, a second sensor fixed to face the coil and measuring the distance between each position in the coil width direction, and a third sensor fixed to face the mandrel and measuring the moving distance of the moving coil, an analysis means for calculating the amount of lifting of the coil and the amount of movement of the coil carriage from the data of the distance measured by the first sensor and the data of the distance measured by the second sensor, and further for calculating the relationship between the distance of movement of the coil and time from the data of the distance of movement of the coil measured by the third sensor; a determining means for determining whether or not the coil has fallen over or come into contact with another coil during insertion based on the obtained relationship between the moving distance of the coil and time; A coil insertion device comprising: [6] The coil insertion device according to [5], wherein the first sensor and the second sensor are scanning laser range finders. [Effects of the Invention]

[0015] According to the present invention, the amount of coil lift and the amount of coil carriage movement required to insert the coil into the mandrel of the payoff reel can be achieved without actually lifting or moving the coil. Furthermore, according to the present invention, it is possible to save space and shorten the time required for coil insertion, which is a significant industrial effect. [Brief explanation of the drawings]

[0016] [Figure 1] FIG. 1 is an explanatory diagram schematically illustrating an example of the configuration of a coil insertion device used in the present invention. [Figure 2] FIG. 1 is an explanatory diagram showing a schematic overview of distance measurement using a scanning laser rangefinder. [Figure 3] 1A and 1B are explanatory diagrams schematically illustrating the amount of lifting and lowering of the coil and the amount of movement of the coil carriage, where (a) is a side view and (b) is a plan view. [Figure 4] FIG. 10 is an explanatory diagram schematically illustrating an example of an obtained distance profile. [Figure 5] 10 is a flowchart showing an outline of the procedure of a coil insertion method. DETAILED DESCRIPTION OF THE INVENTION

[0017] FIG. 1 shows an example of the configuration of a coil insertion device used in the present invention.

[0018] In the present invention, the coil 1 is loaded onto a coil cart 2, and the coil cart 2 is made to travel toward a mandrel 3 of a pay-off reel (not shown), and the coil 1 is inserted into the mandrel 3. The mandrel 3 is fixed, and the coil cart 2 travels on a rail (not shown) so as to be able to move forward and backward relative to the mandrel 3. The coil cart 2 is provided with an elevating means 21 that can be raised and lowered in the vertical direction in order to correct the position of the coil in the vertical direction. The elevating means 21 makes it possible to adjust (center) the vertical position of the coil.

[0019] The first sensor 41 is fixedly installed (anchored) facing the side surface 12 of the coil 1. From the viewpoint of measurement accuracy, it is preferable that the first sensor 41 be arranged so that it can scan a line passing through the vicinity of the center of the coil 1 or the mandrel 3 when the side surface 12 of the coil 1 is viewed from the front.

[0020] Furthermore, second sensor 42 is fixedly installed (anchored) facing coil 1. Second sensor 42 is preferably installed near the center position in the coil width direction at each position above, below, front, back, etc. around the periphery facing coil 1. First sensor 41 and second sensor 42 are scanning laser range finders.

[0021] In the present invention, before inserting the coil 1 into the mandrel 3, the coil carriage 2 is stopped, and the process includes a step of calculating the center position of the inner diameter portion of the coil, a step of calculating the amount of lifting of the coil, a step of calculating the center position of the coil in the width direction, and a step of calculating the amount of movement of the coil.

[0022] (Coil inner diameter center position calculation process) In the coil inner diameter portion center position calculation step, first, a first sensor 41 fixedly installed opposite the side surface 12 of the coil 1 is used to scan with a laser to measure the distance between the first sensor 41 and each position on the side surface 12 of the coil, as shown in Fig. 2. Then, the obtained distance data is input to an analysis means 51, which calculates the coordinates (positions) of each position on the side surface 12 of the coil 1, and determines the position of the center of the inner diameter portion 11 of the coil 1.

[0023] (Coil lift amount calculation process) From the obtained position of the center of the inner diameter of the coil and the preset position of the axial center of the mandrel, the amount of coil lift required to align the axial center of the mandrel 3 with the center of the inner diameter of the coil 1 is calculated, as shown in Figure 3(a). Note that the centering of the mandrel 3 and the coil carriage 2 is set within a predetermined accuracy range for the equipment.

[0024] It is also possible to create a distance profile as shown in Fig. 4(a) by continuously overlapping the distances between the first sensor 41 and each position on the side surface 12 of the coil obtained by the analysis means 51. The distance profile shown in Fig. 4(a) can be said to be a diagram in which the position of the inner diameter portion 11 of the coil 1 is accurately depicted.

[0025] (Coil width center position calculation process) In the coil width center position calculation step, a second sensor 42 fixedly installed (fixed) facing the coil 1 is used to scan with a laser to measure the distance between the second sensor 42 and each position in the coil width direction, as shown in FIG. 2. Note that in FIG. 2, the sensor 42 is fixedly installed above the coil 1, but this is not limited to this in the present invention. The sensor 42 can also be installed below the coil 1, in front of the coil 1, or behind the coil 1. The obtained distance data is then input into analysis means 51, and the position of the coil width center is determined.

[0026] (Coil carriage movement calculation process) From the obtained position of the center of the coil in the width direction and the preset line reference position, the amount of movement of the coil carriage required to align the center of the coil in the width direction with the line reference position is calculated.

[0027] It is also possible to create a distance profile as shown in FIG. 4(b) by continuously overlapping the distances between the second sensor 42 and each position in the width direction of the coil obtained by the analysis means 51.

[0028] The coil 1 is raised and lowered by the lifting means 21 attached to the coil cart 2 according to the calculated lifting distance of the coil, and the center of the inner diameter of the coil is aligned with the axial center of the mandrel.The coil cart is then moved the distance calculated to insert the coil 1 into the mandrel 3.

[0029] While the coil 1 is inserted into the mandrel 3 by moving the coil carriage 2, the present invention includes a coil movement distance measuring process, a coil movement distance vs. time relationship calculating process, a coil tipping (contact) determining process, and a coil carriage travel control process.

[0030] (Coil movement distance measurement process) The coil movement distance measuring step uses a third sensor 43 that is fixedly installed (fixed) facing the mandrel 3. It is preferable that the third sensor 43 is fixedly installed above the mandrel 3 and above the center line of the mandrel 3, but the present invention is not limited to this. Any position above, below, front, or back of the periphery facing the mandrel 3 is suitable.

[0031] It is preferable that the third sensor 43 be a spot-type laser rangefinder. For example, any sensor that can measure distance with a predetermined resolution, such as a TOF (Time of Flight) rangefinder, may be used, and the third sensor 43 is not limited to the spot-type laser rangefinder.

[0032] When the coil carriage 2 is moved to insert the coil 1 into the mandrel 3, the third sensor 43 continuously measures the distance from a fixed point on the coil 1 to the third sensor 43.

[0033] (Process for calculating the relationship between coil movement distance and time) The obtained distance data is input to the analysis means 51, the change in position (movement distance) of the moving coil 1 is determined, and the analysis means 51 calculates the relationship between the movement distance of the coil 1 and time.

[0034] (Coil fall contact detection process) The obtained relationship between the change in position (movement distance) of the coil 1 and time is input to the determination means 52. The determination means 52 determines that the coil has fallen over or made contact during insertion if the relationship between the movement distance of the coil 1 and time deviates by a predetermined value (threshold value) or more from the previously measured relationship between the travel distance of the coil cart 2 and time. If there is no deviation, it determines that the coil has not fallen over or made contact during insertion. Since the coil cart 2 travels at a constant speed, if the relationship between the movement distance of the moving coil 1 and time deviates by a predetermined threshold value or more (for example, 1% or more) from the relationship between the travel distance of the coil cart 2 and time, it is estimated that the coil has started to fall over or make contact during insertion.

[0035] In addition, if the first sensor 41 or the second sensor 42 is capable of measuring a fixed point of the coil 1, the moving distance of the coil 1 may be measured using the first sensor 41 or the second sensor 42, which is a scanning laser rangefinder, instead of the third sensor 43.

[0036] (Coil carriage travel control process) In the coil carriage travel control process, if the judgment means 52 determines in the coil tipping judgment process that there is no coil tipping or contact, the coil carriage continues to travel, but if it determines that there is coil tipping or contact, the coil carriage stops traveling. The resolving means and the determining means may also be provided with a recording means.

[0037] The present invention will be further described below with reference to examples. [Example]

[0038] Using the coil insertion device shown in Figure 1, a coil carriage 2 carrying a coil 1 (unit weight: 10 tons) was run on the rails, and the coil insertion work was carried out for three coils (A, B, C) by inserting the coil into the mandrel 3 (diameter: 600 mm) of the payoff reel.

[0039] Before inserting the coil 1 into the mandrel 3, the coil carriage 2 was stopped at a predetermined position (distance from the first sensor position to the coil side surface: 1.5 m, below the second sensor). Then, as shown in FIG. 2, a fixed first sensor 41 (scanning laser rangefinder: scanning angle 190°) was used to measure the distance between the first sensor 41 and each position on the coil side surface 12. The obtained distance data was input into analysis means 51, and the position (coordinates) of each position on the coil side surface 12 was calculated. Furthermore, the center position of the inner diameter portion 11 was determined from each calculated position on the coil side surface 12 (coil inner diameter portion center position calculation step). Then, as shown in FIG. 3(a), the amount of coil lift required to align the axial center of the mandrel with the center of the coil inner diameter portion was calculated (coil lift amount calculation step).

[0040] The distances between the first sensor 41 and each position on the side surface 12 of the coil obtained by the analysis means 51 were continuously overlapped to create a distance profile as shown in Fig. 4(a). The diameter of the inner diameter part of the coil was calculated from the obtained distance profile and compared with the diameter of the mandrel 3 to confirm that the coil could be inserted into the mandrel.

[0041] Next, a second sensor 42 fixedly installed (fixed) above the coil 1 facing the coil was used to measure the distance between the second sensor 41 and each position in the coil width direction, as shown in Fig. 2. The second sensor 42 was a scanning laser range finder (scan angle 190°).

[0042] The obtained distance data was input into the analysis means 51, and the position (coordinates) of the coil width direction center was calculated (coil width direction center position calculation step). From the obtained coil width direction center position and the position of the preset line reference position, the movement amount of the coil carriage 2 required to align the coil width direction center with the line reference position was calculated (coil carriage movement amount calculation step), as shown in Fig. 3(b).

[0043] In response to a command from the determination means 52, the coil 1 was raised and lowered by the lifting means 21 attached to the coil carriage 2 according to the calculated amount of lifting of the coil, and the center of the inner diameter portion 11 of the coil was aligned with the axial center of the mandrel 3. Then, the coil carriage 2 was moved at a predetermined speed by the calculated amount of coil carriage movement, and the coil was inserted into the mandrel.

[0044] While the coil carriage 2 was running and the coil 1 was being inserted into the mandrel 3, a third sensor 43 fixedly installed (secured) on the top of the mandrel 3 was used to continuously measure the distance between a fixed point on the side of the moving coil 1 and the third sensor 43 (coil moving distance measuring process). The third sensor 43 was a spot-type laser range finder.

[0045] The obtained distance data was input into the analysis means 51, and the relationship between the travel distance of the coil 1 and time was calculated (coil travel distance-time relationship calculation step). Then, the determination means 52 compared the relationship between the travel distance of the coil 1 and time with the previously calculated relationship between the travel distance of the coil carriage 2 and time, and determined whether the coil had fallen over or contact had started (coil fall-contact determination step). If the relationship between the travel distance of the coil 1 and time deviated from the relationship between the travel distance of the coil carriage 2 and time by more than a predetermined threshold, it was determined that the coil had fallen over or contact had started. If there was no deviation, it was determined that the coil had not fallen over or contact had not started.

[0046] In the coil carriage travel control step, when it is determined in the coil tipping / contact determination step that the coil has tipped or started to contact, the determination means 52 issues a command to stop the travel of the coil carriage.

[0047] In Coil A, the relationship between the travel distance of Coil 1 and time began to deviate from the relationship between the travel distance of Coil Carriage 2 and time, so it was determined that the coil had fallen over or started to come into contact, and the travel of Coil Carriage 2 was stopped.

[0048] For the other coils, there was no discrepancy between the relationship between the travel distance of coil 1 and the time and the relationship between the travel distance of coil cart 2 and the time, so the coil cart continued to travel and the insertion of the coil into the mandrel was completed. [Explanation of symbols]

[0049] 1 coil 11 Coil inner diameter 12 Coil side 2 Coil cart 21 Lifting means (coil lifting means) 3 mandrels 41 First Sensor 42 Second Sensor 43 Third Sensor 51 Analysis means 52 Judgment means

Claims

1. A coil insertion method for inserting a coil into a mandrel by running a coil carriage carrying the coil, Before inserting the coil into the mandrel, a coil inner diameter center position calculation step of determining the position of the center of the inner diameter portion of the coil using a first sensor fixed to face the side surface of the coil; and a coil lift amount calculation step of calculating the amount of lift of the coil required to align the obtained center of the inner diameter portion of the coil with a preset axial center of the mandrel. a coil width direction center position calculation step of determining the position of the width center of the coil by a second sensor fixedly provided opposite to the coil; and a coil carriage movement amount calculation step of calculating the movement amount of the coil carriage from the obtained coil width direction center position to a preset line reference position, a coil insertion method characterized by: raising and lowering the coil using a lifting means attached to the coil cart in accordance with the calculated lifting distance of the coil; aligning the axial center of the mandrel with the center of the inner diameter of the coil; and then moving the coil cart by the obtained coil cart movement distance to insert the coil into the mandrel.

2. 2. The coil insertion method according to claim 1, further comprising: a coil movement distance measuring step of measuring the movement distance of the moving coil by a third sensor fixed opposite the mandrel while the coil cart is moved to insert the coil into the mandrel; a coil movement distance vs. time relationship calculating step of calculating the relationship between the movement distance of the coil and time; and a coil tipping / contact determination step of determining whether the coil has fallen over or contacted something during insertion based on the obtained relationship between the movement distance of the coil and time.

3. The coil insertion method according to claim 2, further comprising a coil carriage travel control step of continuing the travel of the coil carriage if it is determined in the coil tipping / contact determination step that the coil has not tipped or contacted, and stopping the travel of the coil carriage if it is determined that the coil has tipped or contacted.

4. A coil insertion device for inserting a coil into a mandrel, a coil carriage having a lifting means for lifting the coil up and down, the coil carriage carrying the coil and traveling freely toward and away from the mandrel; a first sensor fixed to face a side surface of the coil and measuring the distance between the first sensor and each position on the side surface of the coil; a second sensor fixed to face the coil and measuring the distance between the first sensor and each position in the coil width direction; and a third sensor fixed to face the mandrel and measuring the moving distance of the moving coil, an analysis means for calculating the amount of lifting of the coil and the amount of movement of the coil carriage from the data of the distance measured by the first sensor and the data of the distance measured by the second sensor, and further for calculating the relationship between the movement distance of the coil and time from the data of the movement distance of the coil measured by the third sensor; a determining means for determining whether or not the coil has fallen over or come into contact with another coil during insertion based on the obtained relationship between the moving distance of the coil and time; A coil insertion device comprising:

5. 5. The coil insertion device according to claim 4, wherein the first sensor and the second sensor are scanning laser range finders.

Images