Digital creel system

Abstract

A creel system includes a plurality of tension controller apparatuses supporting wire spools, an air pressure control system operatively connected to the tension controller apparatuses, a loose wire detection system configured to detect a loose wire condition upon contact between a sensor bar and one or more wires, and a central control system in communication with the air pressure control system and the loose wire detection system. The central control system ascertains a wire tension of one or more wires based on data from an apparatus sensor and the air pressure control system, and the central control system is configured to actuate the air pressure control system in response to the wire tension to maintain air pressure between upper and lower pressure thresholds. The central control system is configured to generate a loose wire alarm when the loose wire detection system detects the loose wire condition.

What is claimed is: 
     
         1 . A creel system, comprising:
 a frame having a plurality of tension controller apparatuses for paying out wire under tension, each of the tension controller apparatuses having a brake shoe that is engageable with a spindle and a control arm that that is rotatable towards the spindle to move the brake shoe away from the spindle and rotatable away from the spindle to move the brake shoe towards the spindle;   an air pressure control system operatively connected to each of the tension controller apparatuses and actuatable to move the brake shoe towards the spindle, the tension controller apparatuses in communication with at least one apparatus sensor disposed on the frame;   a loose wire detection system operatively connected to a sensor bar and configured to detect a loose wire condition upon contact between the sensor bar and one or more wires; and   a central control system in communication with the air pressure control system and the loose wire detection system, wherein the central control system ascertains a wire tension of one or more wires based on data from the apparatus sensor and the air pressure control system, wherein the central control system is configured to actuate the air pressure control system in response to the wire tension to maintain air pressure between upper and lower pressure thresholds, and wherein the central control system is configured to generate a loose wire alarm when the loose wire detection system detects the loose wire condition.   
     
     
         2 . The creel system according to  claim 1 , wherein the sensor bar is a first sensor bar of a plurality of vertically spaced sensor bars, wherein the loose wire detection system is operatively connected to the plurality of vertically spaced sensor bars, wherein a wire tree supports the plurality of vertically spaced sensor bars, and wherein the wire tree is positioned downstream from the plurality of tension controller apparatuses. 
     
     
         3 . The creel system according to  claim 1 , wherein the central control system is configured to automatically stop operation of the creel system when the loose wire detection system detects the loose wire condition. 
     
     
         4 . The creel system according to  claim 1 , further comprising a tension monitoring system in communication with the central control system, the tension monitoring system comprising a tension monitoring stand positioned downstream from the frame and upstream from a calendar, the tension monitoring stand including at least one tension sensor that receives a wire from the frame,
 wherein the at least one tension sensor measures the tension of the received wire and generates a tension output signal that is sent to the central control system.   
     
     
         5 . The creel system according to  claim 4 , wherein the central control system actuates the air pressure control system based on the tension output signal. 
     
     
         6 . The creel system according to  claim 4 , wherein the central control system communicates with the calendar, and wherein the calendar is configured to compare an air pressure input of the air pressure control system with the tension output signal. 
     
     
         7 . The creel system according to  claim 4 , wherein the tension monitoring stand further comprises a left tension sensor, a center tension sensor, and a right tension sensor, wherein the left tension sensor is configured to receive wire from a left portion of a plane of wires, the central tension sensor is configured to receive wire from a central portion of the plane of wires, and the right tension sensor is configured to receive wire from a right portion of the plane of wires. 
     
     
         8 . The creel system according to  claim 1 , wherein the creel frame is arranged on a moveable platform and a proximity sensor is arranged on the moveable platform, and
 wherein the central control system is configured to determine a position of the creel frame based on a position reading of the position sensor.   
     
     
         9 . The creel system according to  claim 8 , wherein the platform includes a set of wheels that are driven by a motor, and wherein the motor is in communication with the central control system which is configured to instruct the motor to drive the platform to a target position. 
     
     
         10 . The creel system according to  claim 9 , further comprising an optical sensor arranged on the creel frame, wherein the central control system is configured to disable the moveable platform when the optical sensor detects an adjacent creel frame is within a threshold distance from the creel frame. 
     
     
         11 . The creel system according to  claim 8 , wherein the proximity sensor configured to generate a position signal in response to reading at least one feature plate. 
     
     
         12 . The creel system according to  claim 11 , wherein the feature plate comprises a plate body having a plurality of pockets, each pocket is configured to receive one of a steel and nylon pad, an order of steel and nylon pads creating a unique code read by the proximity sensor relating to the position of the platform within a creel room. 
     
     
         13 . The creel system according to  claim 9 , further comprising at least one mechanical travel limit switch in communication with the central control system configured to prevent over-travel of the moveable platform beyond a predetermined location. 
     
     
         14 . The creel system according to  claim 1 , further comprising at least one pull switch comprising a rope mounted at a front end of the creel frame, the pull switch generates a stop signal when pulled, the stop signal readable by the central control system to cease operation of the creel system. 
     
     
         15 . The creel system according to  claim 14 , wherein the central control system is configured to shut down the creel system up receiving the stop signal. 
     
     
         16 . The creel system according to  claim 1 , further comprising a data storage in communication with the central control system, the data storage configured to storage a log file. 
     
     
         17 . The creel system according to  claim 1 , wherein the central control system is configured to generate air pressure alarm if air pressure deviates from between the upper and lower pressure thresholds. 
     
     
         18 . The creel system according to  claim 1 , further comprising an environmental sensor in communication with the central control system, wherein the central control system is configured to generate an alarm when a threshold condition is detected by the environmental sensor. 
     
     
         19 . The creel system according to  claim 18 , wherein: the central control system is configured to shut off power to the creel system when the threshold condition is detected by the environmental sensor. 
     
     
         20 . The creel system according to  claim 18 , wherein:
 the environmental sensor is a temperature sensor, and the threshold condition is high or low heat content; and/or   the environmental sensor is a humidity sensor, and the threshold condition is high or low moisture content.