Patent Application
20230416043
The subject of this invention is an automatic system for tracking a reel of textile thread and a related method for automatically tracking the reel of thread using said system.
Even in the textile industry, due to the growing quality demands of the market, it has long been necessary to be able to provide the total traceability of the product, i.e., the ability to reconstruct the history of the finished textile product, whichever sector it refers to: clothing, home furnishings, automotive, etc., up to the origin of all the threads with which it was manufactured. The thread used is in turn the result of various steps and processes that together contribute to defining the quality features of the finished product.
In industrial production, the thread is wound onto a tube to form a reel using a machine called a winding machine. Essential in an industrial system is the automation of the process of moving the reels from the winding machine to the subsequent stages, such as the sorting line, the warehouse, or palletizing. In order to carry out these activities, the automatic handling systems include a machine called a “doffer” which is suitable to pick up the prepared reels of thread from the winders and transport them to the next station. For technical reasons, reels of thread must be able to be tracked and distinguished according to the production machine, production lot, and other quality-related parameters.
Currently, this tracking is done manually. The tube inside the reel is often made of cardboard, which provides a number of advantages such as low cost, good temperature resistance, the possibility of marking with symbols and colors and the ease of affixing tags therein.
In order to trace the path of the reels of thread, the most commonly used technology today involves the use of identification codes with graphic elements, such as a QR code or a bar code, applied internally to the tubes by directly marking the identification code or gluing on a tag containing said code.
However, this system still has some drawbacks: not only does it require the addition of a labeling station, but it also forces operators to use identification code recognition tools, which are sometimes difficult to locate inside the tube. For the same reason, automating the recognition of these tags is complex.
In order to have more and more automated and centrally controlled plants, it is necessary to be able to track the reels of thread automatically right from the start, i.e., from their exit from the winding machine.
The object of this invention is to solve problems associated with conventional thread reel tracking systems.
In particular, the object of this invention is to provide a system capable of fully automatic tracking of the reel of thread, immediately when it exits the winding machine.
This object is achieved by an automatic reading device for tracking reels of thread according to claim 1, a thread reel handling machine according to claim 6, an automatic thread reel tracking system according to claim 7, an automatic thread reel tracking method according to claim 8, a computer according to claim 12, and a computer program according to claim 13 to implement the automatic tracking method. The dependent claims describe preferred embodiments of the invention.
The features and advantages of the device according to this invention will appear more clearly from the following description, made by way of an indicative and non-limiting example with reference to the accompanying figures, wherein:
With reference to the above figures, in particular
Tube 3: cylinder on which thread is wound to form a reel of thread 1; often made of plastics or cardboard.
Reel of thread 1: is obtained by winding a thread accompanying it over a tube 3, maintaining a cylindrical symmetry. For mechanical-textile reasons, the reel of thread 1 may have different profiles depending on the physical-chemical nature of the thread collected.
RFID (Radio Frequency Identification): is the technology of automatic identification based on the propagation of electro-magnetic waves in the air, allowing the unambiguous, automatic (hands-free), massive and remote detection of objects, animals, and people both when static and in movement.
RFID TAG 5: also called a transponder or smart tag; its main component is a small silicon chip surrounded by an antenna, normally made of copper, to which it is connected and from which it receives the energy needed to operate when it is hit by an electromagnetic field of the appropriate frequency.
In summary therefore, as shown in
In an example embodiment, the tag 5 (RFID TAG) is a unidirectional type, i.e., it may be read/written according to a specific orientation with respect to the antenna. The optimal position for the tag 5 is in the central band of the tube, so that it is as far away as possible from the tags 5 on neighboring tubes. However, this is not essential; the system is designed to work regardless. If the tag 5 is unidirectional, then the orientation must be defined; if the tag 5 is omnidirectional then the orientation does not affect the reading/writing of the tag.
In a further example embodiment, the tag 5 (RFID TAG) is of the omnidirectional type, i.e., it may be read/written regardless of the orientation of its plane with respect to the antenna. Advantageously, such a solution allows the RFID tag 5 to be attached in any position within the tube 3 and in any orientation.
A subject of this invention is an automatic tracking system comprising an automatic reading device 100, shown in
The automatic reading device 100 comprises an antenna 101, connected via a connection cable 105 to a reader 102 connected to an electronic system 103.
The antenna 101 converses with the antenna of the RFID tag 5 by means of radio waves.
Preferably, the antenna 101 is of the coaxial type, i.e., capable of receiving and emitting signals 3600 in a plane. Advantageously, such a solution, combined with the use of an omnidirectional RFID tag 5, ensures the certainty of reading the RFID tag 5 within a tube 3, and thus the certainty of tracking the reel of thread 1.
The reader 102 is suitable on the one hand to exchange information with the RFID tag 5 by means of the antenna 101, and on the other hand to interact with the electronic system 103 to which it is connected.
Thus, the reader 102 has the function of managing the antenna 101 that transmits and receives the radio frequency signals.
The electronic system 103 comprises a central processing unit (CPU) suitable to manage the sending of data read by the reader 102 to at least one programmable logic controller (PLC) and/or at least one computer via industrial serial protocols.
The reader 102 and the electronic system 103 to which it is connected are housed within an electronic apparatus 104, provided with a casing 106, which may be easily positioned in a workstation of the textile plant, for example on the “doffer” machinery which is adapted to pick up the reels of thread 1 from the winders and transport them to the next station.
The antenna 101 is shown specifically in
The antenna 101 comprises a head 110 within which a seat 116 is made in which an antenna body 111 is housed, which is suitable to read/write to the RFID tag 5 by means of radio waves.
Preferably, the seat 116 wherein the antenna body 111 is housed flows into a front opening 119.
Preferably, the head 110 is made of a non-shielding material, i.e., a material that does not interfere with electromagnetic fields, such as a plastics material.
Preferably, the head 110 has a frustoconical shape, with a smaller diameter toward the terminal end.
The head 110 is closed at the rear by a bushing 117 that also closes the seat 116 wherein the antenna body 111 is contained.
A screen 114 is arranged to the rear of the bushing 117. Preferably, the screen 114 is made of a shielding material, such as metal.
The antenna body 111 is connected at the rear to an attenuator 112 connected to an adapter 113 for the connection cable 105. Both the attenuator 112 and the adapter 113 are arranged within the bushing 117, which is closed at the rear by the screen 114.
Note that the adapter 113 protrudes from the screen 114.
The connection cable 105, which makes the data connection between the antenna 101 and the electronic apparatus 104 in which the reader 102 and the electronic system 103 are contained, comprises a connector 115 connectable to the adapter 113 of the antenna 101.
The automatic reading device 100 is characterized in that it comprises a reel handling support 2 having a tip 21, on which a plurality of reels of thread 1 are inserted in sequence, and in particular in that the tip 21 is the antenna 101.
The reel handling support 2 is thus provided with an antenna 101 at the tip 21.
Advantageously, the antenna 101 is designed to replace the tip of the reel handling support 2, so as not to compromise the proper operation of other standard electronic devices already on the support 2.
The reel handling support 2, shown in
The hollow, circular-shaped reel handling support body 22 comprises, at the tip 21, an antenna seat 24 wherein the antenna 101 is at least partially inserted. For example, as in
Preferably, the reel handling support body 22, at the tip 21, also houses within it a spacer 24 wherein the end portion of the connection cable 105 is housed, which has a connector 115 connectable to the adapter 113 of the antenna 101.
Preferably, the connection cable 105 runs internally to the reel handling support body 22 and exits from its connection end 23. Therefore, the electronic apparatus 104 of the automatic reading device 100 is arranged at the connection end 23 of the reel handling support 2.
Preferably, the connection cable 105 runs within a shielded tube, for example a metal tube, arranged within the reel handling support body 22.
Preferably, the reel handling support body 22 further accommodates reel pushing means 26 within it, for example in the form of a pneumatic cylinder.
A subject of this invention is also a machine for handling the reels of thread 1, shown at least partially in
In one example embodiment, the machine is a “doffer” for picking up reels of thread 1 from the winders and transporting them to the next station.
Advantageously, the automatic reading device 100 according to this invention is sized, positioned, and set to read/write one RFID tag 5 at a time when the machine picks up/releases reels of thread 1 equipped with tubes 3 with RFID tags 5, all in an environment where tens of reels of thread 1 are found within a few meters.
An important step in the proper operation of the automatic reading device 100 is setting the antenna 101. In effect, the tubes 3 of the reels of thread have a predetermined length and as a function thereof the transmission power of the antenna signal is regulated. In effect, the automatic reading device 100 must read/write only one RFID tag 5 at a time and must do so only during the loading/unloading of the thread reel on the reel handling support 2.
A subject of this invention is also to provide a method for automatically tracking reels of thread 1.
The method according to this invention comprises at least the following steps:
The tracking algorithm allows the input order of the reels 1 to be recognized when they are inserted onto the reel handling support 2.
In particular, the tracking algorithm is performed by a computer and includes at least the following steps of the AUTOMATION CYCLE:
OPTIMAL CONDITION: If the antenna 101 was set correctly, i.e., so that only one RFID tag 5 is read at a time, and if the RFID tags 5 were positioned correctly in the tubes 3 so that they are read one at a time, then there will be a unique match between:
IMPERFECT CONDITION: If the power of the antenna 101 was oversized or if two RFID tags 5 from two consecutive tubes 3 were placed close together, then the antenna 101 will simultaneously pick up the signal from two consecutive RFID tags 5 even if they are different.
Two corrective logics intervene in this condition:
FAILED OR MISSING RFID CONDITION: If the number of RFID tags 5 detected is less than the number of reels expected, and thus one or more RFID tags is faulty or missing, the software uses the clock interval as corrective logic to understand which is the missing tube in the a-n series.
It is also a subject of this invention to provide a computer programmed to implement the automatic tracking method of the reel of thread 1 as described above.
It is also a subject of this invention to provide a computer program comprising portions of code that, when the program is executed on a computer, implement the method for automatically tracking the reel of thread 1 as described above.
The software expects five reels of thread 1, and therefore five different RFID tag CODES, which by way of example shall be called STRING1, STRING2, STRING3, STRING4, STRING5.
The software does not know a priori the codes it is expecting, so it samples RFID tag readings at a set frequency.
The sum of the clocks obtained at the end of the detection, and thus at the end of the movement of loading the reels of thread 1 onto the reel handling support 2, is divided by the expected number of tubes 3. In this way, virtual bands are obtained (in the example above, five bands with a value of 10 clocks) in each of which the system waits for the detection of an RFID tag to be read.
The algorithm reconstructs the correct order of the RFID tags read following the first reading of the UNIQUE CODE associated with the tag.
Having a counter allows for imperfect or missing tube conditions or other inconsistencies to be recognized; in the example table, the detection of the RFID tag associated with the fourth reel of thread was absent.
The tracking system according to this invention provides for a data exchange with the automation system. The on-board electronic system is designed to exchange data with standard industry protocols with the outside. In this way it is possible to connect a PC and/or a PLC, and therefore a DATABASE.
The tracking system according to this invention also provides for the possibility of writing on the RFID tag of the tube 3. In this way, it is possible to trace the path of the reel of thread 1 in a more complete way, for example by writing the date and time of production, the machine and position of origin, the rise in production, etc.
Innovatively, a device 100 for automatically tracing a reel of thread 1, the related machine, the related system, and the related automatic tracing method, make it possible to automate the tracing of the path of the reel of thread 1 in an industrial plant, and thus make it objective and rapid.
Advantageously, the system according to this invention allows the automation system to maintain high performance because the “doffer,” equipped with a reel handling support with a device 100 for tracking, may;
It is understood that a person skilled in the art could make modifications to the product described above, all of which are contained within the scope of protection as defined by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102020000032810 | Dec 2020 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2021/062243 | 12/23/2021 | WO |
