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Title:
LOW VOLTAGE LOOSE WIRE DETECTION SYSTEM WITH HUMAN MACHINE INTERFACE
Document Type and Number:
WIPO Patent Application WO/2022/040413
Kind Code:
A1
Abstract:
A loose wire detection system includes a plurality of loose wire sensors arranged on a wire tree. The sensors are integrated with a control circuit. When a wire becomes sufficiently loose to contact the sensor, the loose wire detection system provides indication that one of the wires is loose.

Inventors:
HILL CLINTON ANDREW PARK (US)
Application Number:
PCT/US2021/046662
Publication Date:
February 24, 2022
Filing Date:
August 19, 2021
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
RJS CORP (US)
International Classes:
B65H59/38; B65H49/20; B65H49/32; B65H57/18; B65H59/04
Foreign References:
US6375111B12002-04-23
US20150091383A12015-04-02
US20120187956A12012-07-26
US20150048199A12015-02-19
Attorney, Agent or Firm:
GUTTMAN, Scott M. et al. (US)
Download PDF:
Claims:
CLAIMS

What is claimed is:

1. A loose wire detection system for a creel system, comprising: a controller, and a wire tree including a plurality of loose wire sensors each connected to the controller, wherein the controller is configured to generate a loose wire detection signal when contacted by a wire, and a user interface connected to the controller and configured to generate a loose wire indication upon receiving the loose wire detection signal.

2. The loose wire detection system according to claim 1, the controller further comprising a normally open control circuit in communication with each of the sensors, wherein contact between the wire and any one of the sensors closes the control circuit.

3. The loose wire detection system according to claim 2, wherein the control circuit is open when the wires do not contact any one of the sensors.

4. The loose wire detection system according to claim 2, wherein the control circuit is at most a 20 volt circuit.

5. The loose wire detection system according to claim 4, wherein the control circuit is at most a 15 volt circuit.

6. The loose wire detection system according to claim 5, wherein the control circuit is at most a 12 volt circuit.

7. The loose wire detection system according to claim 6, wherein the control circuit is at most a 10 volt circuit.

8. The loose wire detection system according to claim 1, wherein the wire tree is positioned downstream from a frame and a plurality of tension controllers of the creel system.

9. The loose wire detection system according to claim 1, wherein the sensors are conductive rods laterally extending from the wire tree.

10. The loose wire detection system according to claim 9, wherein the wire tree includes a first set of the conductive rods laterally extending from a first side of the wire tree and a second set of the conductive rods laterally extending from a second side of the wire tree.

11. The loose wire detection system according to claim 1, wherein the user interface includes a touch screen display.

12. The loose wire detection system according to claim 1, further comprising a data storage in communication with the controller, the data storage configured to storage a log file.

13. The loose wire detection system according to claim 1, further comprising an enclosure within which the controller and the user interference are provided.

14. A loose wire detection system, comprising: control circuit, a wire tree having a plurality of loose wire sensors, wherein each of the sensors is integrated within the control circuit and the control circuit, wherein contact between a wire and any one of the sensors closes the control circuit and generates a signal, and a user interface connected integrated within the control circuit and configured to generate a loose wire indication upon receiving the signal.

15. The loose wire detection system according to claim 14, wherein the control circuit is a 12 volt circuit.

Description:
LOW VOLTAGE LOOSE WIRE DETECTION SYSTEM WITH HUMAN MACHINE INTERFACE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of pending U.S. Provisional Application No. 62/706,481 filed August 19, 2020, which is incorporated by reference herein in its entirety.

BACKGROUND

[0002] Filamentary materials are commonly utilized as reinforcements for plastic or elastomeric compounds or may themselves be fabricated into integral arrangements as utilized in the textile, hose, and tire industries. These filamentary materials, often referred to as wires, are stored on (wrapped around) spools. The wires may be comprised of various different materials, for example, natural or synthetic fibers, glass, or metal, etc. In addition, these wires may be provided in various forms, for example, in single and multiple strands, flat bands, or tubing produced in long lengths and wound on spools, etc.

[0003] Creel systems are utilized to pull the wires from their spools and manipulate them into final form. Creel systems include a creel frame supporting a plurality of tension controllers that each have a spindle that permit the spools to rotate as the wire is withdrawn (payed out) therefrom. The wire is under tension as it is payed out from the creel system, and the tension controllers may be utilized to apply tension to the wire during payout. Creel systems may further comprise a front organization stand into which wires are fed from the spools.

[0004] Front organization stands are often positioned downstream (in front of) the creel frame and may be configured to detect whether the wire being paid out is appropriately tensioned. For example, front organization stands may include one or more loose wire detectors for indicating when a wire(s) associated therewith is broken, loose, or otherwise inappropriately tensioned. These loose wire detectors are connected to a panel (or enclosure or box) configured to provide indication upon detection of a broken, loose, or otherwise insufficiently tensioned wire. For example, a main enclosure may include a plurality of indicator lights, with each light being associated with one or more tension controllers or one or more rows of tension controllers, and an audible alarm that may be triggered upon detection of one or more loose or broken wires. Thus, when the loose wire sensor is contacted by a loose or broken wire, the indicator light(s) associated with that sensor may be illuminated and an audible alarm may be sounded which persists until the broken or loose wire is cleared from the sensor, and the system is reset from the main enclosure.

[0005] Conventional loose wire detection systems, however, may present unsafe work conditions. Also, conventional loose wire detection systems provide limited user feedback and are not integrable with other systems that may be utilized at the end user facility. Accordingly, a need exists for an improved loose wire detection system.

SUMMARY

[0006] Embodiments described herein include a loose wire detection system for a creel system, comprising a controller, and a wire tree including a plurality of loose wire sensors each connected to the controller, wherein the controller is configured to generate a loose wire detection signal when contacted by a wire, and a user interface connected to the controller and configured to generate a loose wire indication upon receiving the loose wire detection signal. In some examples, the controller further comprising a normally open control circuit in communication with each of the sensors, wherein contact between the wire and any one of the sensors closes the control circuit. In some examples, the control circuit is open when the wires do not contact any one of the sensors. In some examples, the control circuit is at most a 20 volt circuit. In some examples, the control circuit is at most a 15 volt circuit. In some examples, the control circuit is at most a 12 volt circuit. In some examples, the control circuit is at most a 10 volt circuit. In some examples, the wire tree is positioned downstream from a frame and a plurality of tension controllers of the creel system. In some examples, the sensors are conductive rods laterally extending from the wire tree. In some examples, the wire tree includes a first set of the conductive rods laterally extending from a first side of the wire tree and a second set of the conductive rods laterally extending from a second side of the wire tree. In some examples, the user interface includes a touch screen display. In some examples, the loose wire detection system further comprises a data storage in communication with the controller, the data storage configured to storage a log file. In some examples, the loose wire detection system further comprises an enclosure within which the controller and the user interference are provided.

[0007] Embodiments described herein are further directed towards a loose wire detection system, comprising control circuit, a wire tree having a plurality of loose wire sensors, wherein each of the sensors is integrated within the control circuit and the control circuit, wherein contact between a wire and any one of the sensors closes the control circuit and generates a signal, and a user interface connected integrated within the control circuit and configured to generate a loose wire indication upon receiving the signal. In some examples, the control circuit is a 12 volt circuit.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The following figures are included to illustrate certain aspects of the present disclosure, and should not be viewed as exclusive embodiments. The subject matter disclosed is capable of considerable modifications, alterations, combinations, and equivalents in form and function, without departing from the scope of this disclosure.

[0009] FIG. 1A and FIG. IB are side views of an example creel system that may incorporate the principles of the present disclosure.

[0010] FIG. 2 illustrates a front organizing stand that may be utilized with a creel system similar to those of FIGS. 1A and IB.

[0011] FIGS. 3A-3E illustrate an exemplary loose wire detection system, according to one or more embodiments of the present disclosure.

[0012] FIGS. 4A-4G illustrate example graphical output that may be displayed on the human machine interface of FIG. 3A, according to one or more embodiments of the present disclosure. [0013] FIG. 5 illustrates an example enclosure that may be utilized embodiments described herein.

DETAILED DESCRIPTION

[0014] The present disclosure is related to creel systems and, more particularly, to loose wire detection and human machine interface therefor.

[0015] The embodiments described herein provide loose wire detection systems comprising a programmable controller ("PLC") capable of utilizing reduced voltage that helps reduce the risk of accidental shock and makes the system safer for end users. Other embodiments described herein provide a human machine interface ("HMI") operable with the programmable controller for providing the operator with real time feedback regarding operation of the loose wire detection system. For example, the HMI may allow the user to see a visual representation of the wire sensors, may display an alarm state screen, and may provide an event log which keeps history of alarms. In some embodiments, the HMI may also display system information and has language changing ability, such that the end user may switch between two or more output languages for use in various countries. In some embodiments, the presently disclosed loose wire detection system may be integrated within an existing system at the end use facility, for example, a plant's SCADA ("supervisory control and data acquisition") network.

[0016] FIGS. 1A and IB illustrate an exemplary creel system 100 that may incorporate aspects of the present disclosure. The depicted creel system 100 is just one example creel system that can suitably incorporate the principles of the present disclosure. Indeed, many alternative designs and configurations of the creel system 100 may be employed, without departing from the scope of this disclosure.

[0017] The creel system 100 may be utilized to deliver a plurality of cords, filaments, or wires W, for example, to a calendar or conveyor machine. The wires W may comprise various materials, such as fabric or steel. As illustrated, the creel system 100 may include one or more creel frames 102, at least one front organizing stand (FOS) 104, and a main organizing stand (MOS) 106, which are secured on a factory floor or ground G. In some embodiments, the creel frame 102, the FOS 104, and the MOS 106 are installed in a dedicated room commonly referred to as a creel room (not illustrated). The creel system 100 delivers wire W in direction D towards a calendaring operation/process (not illustrated) which processes the wire W into a form utilizable in the final product (i.e., tires). In some applications, the frame 102 is comprised of multiple frame segments , side by side, that each operate (one after the other, or in unison) to deliver the wire downstream to the same calendaring process, and in such application each side by side frame 102 is referred to as a creel row. FIG. 1A illustrates the creel system 100 comprising a single creel row, however, one or more additional creel rows (with the same and/or different configuration than the first creel row) may be implanted in the system 100. Each of the FOS 104 and MOS 106 provide organization for wires W in the system 100. Eventually, each layer of wires W may be oriented in one flat plane for entry into the calendar. The FOS 104 and MOS 106 are utilizable to gradually move the wires W into this position before they leave the creel room.

[0018] The wires W are provided on reels or spools 108. The creel frame 102 carries the spools 108 and may group or organize them in a series of rows that are vertically spaced (relative to the ground G) from each other. Thus, the wires W are payed- out from the spools 108 in a series of rows, where each such row comprises a bundle wires W. The wire W may be fed downstream in direction D to the FOS 104 and the MOS 106, and then further downstream for calendaring. FIG. 1A illustrates an example where the FOS 104 includes a wire tree 110, which may be configured detect loose wires in each row of wires W as they are fed further downstream. The wire tree 110 includes a plurality of detector rods or sensors arranged as branches that each correspond (or align) with a respective one of the rows of wires W, and the detector rods/sensors may be integrated within of a loose wire detection system (LWD System) 124 and placed on either or both sides of the creel frame 102 for detecting the presence of a loose or sagging wire W in the wire rows. Also in the illustrated example, the FOS 104 includes a direction change apparatus 112 for receiving each row of wire W as they pass through or beyond the wire tree 110. The direction change apparatus 112 may include a plurality of rollers configured to facilitate change of vertical direction of the wire W and facilitate its downstream delivery to the MOS 106 and any other downstream operations, for example, a downstream calendaring operation. In addition, the illustrated example illustrates the FOS 104 includes an organizing board apparatus 114, which may be either an "Eyelet Board" consisting of individual ceramic eyelets arranged in a steel plate, and/or a "Roller Board" comprised of a plurality of vertical and horizontal rollers, which define "Openings" through which the individual (or bundles) of wire W may be directed, and which further facilitates directing the wire W downstream in a particular vector depending on the end use application. Together, the direction change apparatus 112 and roller board apparatus 114 re-direct each row of wires W so that they may be received by the MOS 106. In some examples, the wire tree 110, the direction change apparatus 112, and/or the roller board apparatus 114 are separate (stand-alone) components and/or any one of them may be integral with either the creel frame 102. However, two or more of the wire tree 110, the direction change apparatus 112, and/or the organizing board apparatus 114 may be integrated together as a single structure, such as the FOS 104.

[0019] In the illustrated embodiments, the creel frame 102 is a structure comprising a plurality of horizontal members H and vertical members V configured to array the spools 108 in a rectangular grid. In other embodiments, however, the creel frame 102 may be differently configured without departing from the present disclosure. Thus, the creel frame 102 may carry the spools 108 in various arrangements or organizations, rectangular or otherwise. Here, for example, the creel frame 102 carries six rows and sixty-seven columns of spools 108. It will be appreciated, however, that the creel frame 102 may include more or less rows and/or columns of spools 108 without departing from the present disclosure. For example, the creel frame 102 may be taller and include one or more additional rows of spools 108, or may be shorter and include fewer rows of spools 108. Similarly, the creel frame 102 may be longer or shorter and include more or less columns of spools 108. In embodiments comprising a multitude of columns of spools 108, the creel frame 102 may include discrete frame sections or segments F. As will be appreciated, providing the creel frame 102 in discrete frame sections facilitates shipping and installation of creel frames 102 and provides the end-user the ability to scale creel operations up or down as needed. Here, for example, the creel frame 102 includes eight frame segments F1-F8 that together define an individual creel row, with frame segments Fl and F2 having six rows and six columns of spools 108, frame segment F3 having six rows and five columns of spools 108, and frame segments F4-F8 having six rows and ten columns of spools 108. Accordingly, the exemplary creel system 100 of FIG. 1A includes a single creel row of multiple frames supporting a total of four- hundred and two spools 108. However, the creel system 100 may have various other setups without departing from the present disclosure.

[0020] FIG. IB is a close up view of the front portion of the creel system 100, according to one or more embodiments of the present disclosure. In particular, FIG. IB illustrates the FOS 104 when installed proximate to a front portion (or flanged end pad) 102' of the creel frame 102, such as a mating flanged end pads.

[0021] The creel frame 102 supports a plurality of tension controllers 138, and each of the tension controllers 138 is configured to hold one of the spools 108 of wire W that is payed out of the system 100, through at least the FOS 104, under tension. The tension controllers 138 may be configured to apply and/or adjust tension on the wire W as it is payed out and withdrawn from the spool 108. In some embodiments, the creel frame 102, the FOS 104, the MOS 106, and the tension controllers 138 are installed in a dedicated room commonly referred to as a creel room (not illustrated). It should be appreciated that, for ease of illustration, FIG. IB illustrates just a single column of tension controllers 138 but that a tension controller 138 may be positioned at each spool location.

[0022] Thus, the wires W are payed-out from the spools 108 in a series of rows, where each such row comprises a bundle of wires W. The wire W is fed downstream to an organizing board 112, which is configured to receive each row of wires W as they are fed further downstream, for example, via a roller board and/or an eyelet board. The organizing board 112 may includes a series of apertures or branches that each correspond (align) with a respective one of the rows of wires W. The organizing board 112 may be integral with either the creel frame 102 or the FOS 104, or may instead be provided as a standalone structure. As discussed below, the FOS 104 may have various configurations, for example, an eyelet board FOS or a roller board FOS. [0023] FIG. 2 illustrates an exemplary front organizing stand ("FOS") 104 that is utilizable with aspects of the present disclosure. In the illustrated embodiment, the FOS 104 includes a base 130 on which the wire tree 110, the direction change apparatus 112, and the organizing board apparatus 114 are mounted such that they together define an individual unit. The creel system 100 may be configured for loose wire detection and, therefore, the creel system may include one or more sensors configured for sensing tension, or determining if there is a lack of tension or slack, in one or more wires W. In FIG. 2, the wire tree 110 includes a plurality of loose wire sensors 132. In some examples, the loose wire sensors 132 are provided as conductive rods or detector rods. Where utilized, the conductive rods may be part of an electrical control circuit that is normally open when the wire W is not in contact with the conductive rod, but is closed (or completed) when in contact with the wire W which may occur when the wire W becomes broken or is otherwise loose or insufficiently tensioned. In the illustrated example, the loose wire sensors 132 are conductive sensors that detect when one or more of the wires W has broken and fallen into contact with the sensor; however, in other embodiments, the loose wire sensors 132 may be differently configured (for e.g., having different shape(s), and/or utilizing non-conductive detection means, such as a switch), and in other examples they may be configured to detect when a predetermined number of wires has broken or fallen into contact therewith. Also, the loose wire sensors 132 may be oriented with the rows of tension controllers 138 and associated spools 108. Where the loose wire sensors 132 are provided as detector rods as illustrated, a sleeve may be provided on any one or more of the detector rods 132 to thereby cover or insulate at least a portion of each particular detector rod 132. For example, insulator sleeves may be provided around a portion (or length) of the detector rods 132 at which they may interact or engage (or be engaged by) the wire W. As mentioned above and further described below, the detector rods 132 may be integrated within of the LWD System 124.

[0024] The direction change apparatus 112 may include a plurality of direction changing roller assemblies 134 and the organizing board apparatus 114 may include a roller board assembly 136. With this arrangement, the FOS 104 facilitates re-directing (or re-direction of) the rows of wires W into 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 creel frame 102, such that the FOS 104 may be secured to the creel frame 102. In some examples, a mounting pad 142 may be included on the top of the FOS 104 frame, which may be utilized in some embodiments to support additional overhead structure. This mounting pad 142 may be provided in multiple sizes and configurations, and such that the frame extension 140 is configured to attach to the flanged end pad 102' of the creel frame 102 as shown in FIG. IB.

[0025] The creel system 100 may further include a control system 116 for controlling operation of the various sub-systems of the creel system 100. The control system 116 may comprise an industrial personal computer (IPC) that may be installed at various locations proximate to the creel system 100, for example, in the creel room, or may instead be provided at another location segregated or spaced away therefrom (e.g., outside of the creel room and/or in a separate control room). The central control system

116 may communicate with various sub-systems, sensors, or devices, for example, the central control system 116 may monitor and control the LWD system 124 and/or various other systems or sensors and aggregate data about overall operation.

[0026] The central control system 116 may be variously embodied without delineating from the scope of the present disclosure, for example, as an internal Programmable Logic Controller (PLC), personal computer, tablet, smartphone, etc. The central control system 116 may include a processor 115 that may be any of various commercially available processors including, without limitation, a single-core processor, a dual-core processor (or more generally by a multiple-core processor), a digital processor and cooperating math coprocessor, a digital controller, or the like. 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 creel system 100 to a user. The user interface

117 may also allow a user to input commands into the central control system 116 for the monitoring and controlling the various components. In some embodiments, the central control system 116 may be located in a creel room and/or at locations proximate to other control equipment (e.g., calendar equipment control interfaces). In other embodiments, the central control system 116 may be mounted on a portion of the creel system 100 itself, such as a portion of the frame 102. In even other embodiments, the central control system 116 is a remote device capable of operating the creel system from a distance, e.g., the central control system 116 is a device located in a room other than the creel room, or is a device held by an operator at a facility where the digital creel is installed or remotely.

[0027] The central control system 116 may also include a data storage 119. Implementation of the associated data storage 119 is capable of occurring on any mass storage device(s), for example, magnetic storage drives, a hard disk drive, optical storage devices, flash memory devices, or a suitable combination thereof. The associated data storage 119 may be implemented as a component of the central control system 116, e.g., resident in memory, or the like. The central control system 116 may then save data obtained during operation in a database or log file (event log) within the data storage 119 which may be utilized by operators, for example, to ensure efficient operation of the creel system and/or address logged errors, creating reports, etc.

[0028] The LWD system 124 may include a control circuit, and the user interface 117 may be integrated within the electrical control circuit for providing indication of a broken, looser, or otherwise insufficiently tensioned wire W. The user interface 117 may provide indication of a loose or broken wire W, to thereby alert the operator such that corrective action may be taken. The user interface 117 may include one or more buttons or switches operable to send a signal to the calendar to stop the system 100 and/or operable to start or stop at least a portion of the system, and or may include one or more indicator screens, indicator lights, and/or audible speakers for notifying the operator. Thus, when one or more of the wires W makes contact with the loose wire sensor (i.e., a detector rod 132), the control circuit is completed which thereby causes a signal to be sent to the user interface 117 to alert the operator of the same.

[0029] The loose wire sensors 132 and the user interface 117 may be integrated within the loose wire detection system 124. FIGS. 3A-3E illustrate schematics of an exemplary loose wire detection system 300, according to one or more embodiments of the present disclosure. In the illustrated example, the loose wire detection system 300 includes a PLC 302 and an HMI 304. Here, the HMI 304 is integrated within the user interface 117 and includes a touch screen display 305, but in some examples the HMI 304 and display 305 may be separate from the user interface 117. Also in the illustrated example, PLC 302 is integrated within the central control system 116, but in other examples, the may be separate systems. Here, the HMI 304 is connected to the PLC 302, and in communication therewith, via an Ethernet cable 307; however, in other examples, they are in wireless communication with each other directly or over the Internet. The PLC 302 is integrated within a control circuit 306 that is connected to the various loose wire sensors 132 and, as described above, closed or completed when the wire W contacts one of the loose wire sensors 204. FIGS. 3B-3E illustrate an exemplary control circuit 306 utilizable with the LWD 300, according to one or more embodiments of the present disclosure.

[0030] The system 300 includes a power supply. In some examples, one or more secondary power supplies may be integrated into the system 300. In the illustrated example, a secondary power supply 310 integrated within the control circuit 306. Here, the secondary power supply 310 reduces the voltage from 24Vdc to 12Vdc (or lOVdc or 5Vdc) and limits the current available at that voltage. Also, as shown in FIG. 3E, a plurality of low voltage relays 312 (e.g., CR1-CR10) are integrated within the control circuit 306 to complete the circuit. In the illustrated example, the low voltage relays 312 are configured to only require 0.07 amperes at the reduced voltage (e.g., a reduced voltage of 12vdc, lOvdc, or 5Vdc).

[0031] FIG. 3E illustrates the path that the voltage will travel to complete the circuit. The sensor rods 132 are integrated into the control circuit 306, with the common and ground 314 of the circuit 306 being connected to each such rod 132. Each relay 312 operates at a reduced voltage and the LWD sensor rods 132 switch the relays 312 when a loose wire contacts one of the rods 132 and thereby completes the circuit 306. The coil for each of the solid state relays 312 acts as an in line resistor, thereby reducing the flow of current on the circuit 306. Because the common 314 (and ground) connects to the LWD rods 132 and current is limited by the coil in the respective relays 312, the maximum current available is only 0.6a at 24vdc. If the circuit was reversed and the rods 132 were the positive (+) or line voltage side of the circuit, then the full ampacity of the power supply would be available at each LWD rod 132 and present a dangerous work environment. Thus, the presently disclosed relays 312 operate as a current limiting device reducing the amount of current on each completed circuit 306, thereby enhancing the safety of the lose wire detection system 300.

[0032] The control circuit 306 of the loose wire detection system 300 may be configured to work at various voltages. In some embodiments, the loose wire detection system 300 is configured to work on a reduced voltage. For example, the loose wire detection system 300 may work on a lOvdc system rather than on a 24vdc system. This reduction in voltage improves operator safety and reduces risk of electrical shock. This is beneficial because governmental agencies responsible for workplace safety (e.g. US Occupational Safety and Health Administration (aka "OSHA") has been systematically reducing the control voltage of equipment over the years in an effort to reduce incidents of accidental exposure to live circuits. While higher voltage systems, such as a 24vdc system, may conform to such safety standards, the loose wire detection system 300 may incorporate solid state electrical components that allows further reduction of the voltage. Providing the loose wire detection system 300 that is operable at lOvdc (or 12 Vdc or even 5Vdc) allows for line loss that may occur when conducting through the steel frame of the creel. Also, the relays have a range from 5vdc to 30vdc and, testing at lOdvc, an average voltage drop of 3vdc was found. Thus, selecting operable reduced voltage of lOvdc provides a safe range that is still operable to provide reliable readings to the operator. While the presently disclosed loose wire detection system 300 is described as working with a reduced voltage of lOvdc, other reduced voltages may be utilized, such as 20vdc or less, 15vdc or less, 12vdc or less, and lOvdc or less. In one example, the operable reduced voltage is 12 vdc. Thus, utilizing the operable reduced voltage permits reduction of voltage down to an amount that won't cause harmful side effects if it were to travel through human body while still providing reliable results when in use.

[0033] The PLC 302 may determine occurrence of broken, loose, or otherwise incorrectly tensioned wires W via completion (closing) of the control circuit 306 via the sensors 132, which is captured as a digital input to the PLC 302, and then the PLC 302 may send that signal to the HMI 304 via the Ethernet cable 307. The HMI 304 may then report information indicative of the same to the operator via the display 305. As mentioned, the PLC 302 is in communication with the HMI 304, for example, via the Ethernet cable 307, but other means may be utilized to establish communication between the PLC 302 and the HMI 304. For example, the PLC 302 and the HMI 304 may be in wireless communication with each other via one or more wireless communication protocols.

[0034] As mentioned, the HMI 304 allows the operator to see operational aspects of the loose wire detection system 300 via the display 305. FIGS. 4A-4G illustrate various visuals and types of information of the LWD system 300 that are displayable on the HMI 304 and/or display 305, according to one or more embodiments of the present disclosure. In particular, these figures illustrate a software or platform of the system 300 that may be run by the PLC 302 and HMI 304. In this example, the HMI 304 provides the operator with a visual representation of the sensors 132 (e.g., when provided as conductive rods), and may indicate whether any one or more of the sensors 132 are in an alarm state meaning a wire W has contacted the sensor 132 because such wire W is loose as shown in FIG. 4G. In some examples, the HMI 304 may display an alarm state screen as shown in FIG. 4F. In some examples, the HMI 304 may display an event log that maintains a history of alarms and/or other events during use of the loose wire detection system 300 and/or the creel system lOOin general as shown in FIG. 4D (with FIG. 4D illustrating an empty history/log). Thus, the PLC 302 and the HMI 304 may be programmed to cause display of various screens on the display of the HMI 304 concerning or indicative of various operational aspects of the loose wire detection system 300 and/or the creel system 100.

[0035] FIG. 4A illustrates an introduction screen 402 of the platform, according to one or more embodiments of the present disclosure. Here, the user may click through the introduction screen 402 to arrive at a home screen 404, as exemplified in FIG. 4B. FIG. 4B illustrates an example of the home screen 404, according to one or more embodiments, and here, the home screen includes several other functions selectable by the user, for example, a run option 406, an alarm option 408, and information option 410, and a maintenance option 414. However, it will be appreciated that the software platform may be differently programmed such that the home screen 402 presents more or less and/or different options to the user.

[0036] FIG. 4D illustrates an exemplary alarm and history log screen 416 that may be accessible by selection of the alarm option 412 on the home screen, according to one or more embodiments of the present disclosure. The alarm and history log screen 416 is accessible via the alarm screen button 412 on any of the preceding screens. The alarm and history log screen 416 includes a log of active alarms and a log of alarm history, and either or both log may track various statistics associated with each event, including but not limited to date, time, description, associated system, status, and action taken, etc. The screens may be customizable and may log additional data. For example, the operator may customize the either/both logs to list all or only list certain events that require immediate corrective action, and/or to allow for color coding of different events based on their status (e.g., events that have not yet been fixed may be highlighted in red, whereas events that are fixed are green and events that have been checked and/or under examination are yellow). Also, the operator may assign an event to one of his or her colleagues such that said colleague receives notification of the alert (e.g., on his or her mobile device with mobile application as hereinafter described) and may then take corrective action while the operator monitors the status of the event while his or her colleague addresses the same. Also, this screen may have buttons that the user may press to clear all of the logged alarms or just one or more selected logged alarms. The logged data and information may be exported to various different devices, including via USB download or other wireless transmission. The alarm and history log screen 416 exemplified in FIG. 4D doesn't include any logged events. Also, a home button may be located on the screen 416 to allow the operator to return to the home screen 404. Also, the alarm and history log screen 1022 may provide navigational buttons for migrating between screens, such as function screens and the home screen.

[0037] FIG. 4E illustrates an exemplary information screen 418 that may be accessible by selection of the information option 410 on the home screen, according to one or more embodiments of the present disclosure. Here, the platform includes language translation capabilities so that the user may select which language is displayed on the touch screen display, and FIG. 4E illustrates a translation selection screen 1004 of the platform, according to one or more embodiments of the present disclosure. In some embodiments, selection of the language will also change the units in which the measurements are displayed. For example, if an operator selects German translation, the units may be displayed in SI units, whereas if an operator selects English translation, the units may be displayed in either US customary units (e.g., for US users) or SI units (e.g., for British users).

[0038] FIG. 4C illustrates an exemplary maintenance screen 420 that may be accessible by selection of the maintenance option 414 on the home screen, according to one or more embodiments of the present disclosure. Here, the maintenance screen 420 allows the user to select a side of the creel system on which to perform maintenance and/or address an issue/problem/error state. Also, a home button may be located on the screen 420 to allow the operator to return to the home screen 404.

[0039] FIG. 4G illustrates an exemplary operation or run screen 422 that may be accessible by selection of the run option 406 on the home screen 404, according to one or more embodiments of the present disclosure. The operation screen 422 may be accessible by pressing the operation screen selection button 406. The operation screen 422 may be the main screen for the LWD system 300. Also, operation screen 422 may include selections to allow migration and navigation between screens on the system. The illustrated representation of the LWD system operation screen 422 illustrates the LWD 300 of a first creel during a dual creel operation, where the user may select between the first or second (i.e., right or left) creel via a selector button 423a, 423b on the touch screen. Thus, the user may use these selection buttons 423a, 423b to cycle between LWD systems on more than one creels during a multi creel operation (e.g., during a dual creel operation), but it will be appreciated that this present disclosure may be implemented with regard to just a single LWD system on a single creel or on a creel system using more than two creels. Here, the LWD operation screen 422 depicts a wire tree 110 with conductive sensors 132 of a first creel corresponding with the selection button 423a. The LWD operation screen 422 may indicate present of a loose or broken wire by highlighting the particular conductive rod that was tripped or that sensed a loose or broken wire. For example, 4G includes a graphical representation of a wire tree 424 with conductive rods 426 when unactivated (i.e., not an alarm state) and also a conductive rod 428 when activated (i.e., in an alarm state). Here, the operation screen 422 displays that a bottom right conductive rod 428 of the first creel has been activated/tripped, where conductive rod 428 corresponds with the actual conductive rod 132 located on the bottom right side of the wire tree 110 of the first creel 423. In this manner, the operator may readily determine the existence of and specific location of a broken or loose wire. In FIG. 4G, the screen 422 includes buttons 423a, 423b for selecting the particular LWD system (i.e., by selecting which creel the LWD is operating on) as mentioned above, but the screen 422 may also include a reset button 425 for resetting any tripped alarms.

[0040] Upon the LWD system being tripped via a loose wire hitting one of the sensors, an alarm state screen 430 may be presented to the user and/or an audible alarm may be triggered. FIG. 4F illustrates an alarm state screen 430 according to one or more embodiments. Here, the alarm state screen 430 alerts the user that a lose wire has been detected, and from there the user may return to the operation screen 422 to identify the location of the fault. In this example, the alarm state screen 430 includes a snooze button 432 which may be selected to return the user to the operation screen 422.

[0041] On or more of the above described screens, such as the information screen or the operation/run screen or the maintenance screen may provide temperature and humidity readings (or other environmental info) in real time, and also provide access to information that may be helpful to maintain and/or operate the system. For example, the operator may access electrical schematics of the various equipment, which he/or she may export to another device or printer for later use. Also, the operator may access the handbook, FAQ and/or other warranty info. In some embodiments, the operator can communicate with maintenance personnel via the software, for example, the operator could schedule a maintenance appointment via functionality accessible on the maintenance screen. Also, the maintenance screen may provide navigational buttons for migrating between screens, such as function screens and the home screen. [0042] The PLC 302 and the HMI 304 may be arranged at the same location within the operator's facility, e.g., in the control room, and/or they may be positioned in together in an enclosure. FIG. 5 illustrates an exemplary enclosure 500 for housing the PLC 302 and the HMI 304, according to one or more embodiments of the present disclosure. In the illustrated example, the enclosure 500 houses the PLC 302 and the HMI 304. The enclosure 500 may have a front door 502 that may be opened and closed, and locked via a locking mechanism. Here, the enclosure 500 is configured such that the display 305 of the HMI 304 is visible from an exterior of the enclosure 500 when the front door 502 is closed, for example, the display 305 may be positioned within a window 504 in the door 502. A master power 504 control switch/button may also be positioned on the front door 502 such that a user may quickly activate or deactivate the master power to the system 300 and/or the overall system 100.

[0043] The loose wire detection system 300 may identify loose, broken or otherwise incorrectly tensioned wires via the sensors 134, and then report that information to the operator via the human machine interface 304. In contrast to existing systems, which utilize high voltage direct current, the presently disclosed loose wire detection system utilizes low voltage direct current to identify which row(s) has a loose, broken, or otherwise incorrectly tensioned wire, and then this information may be indicated or reported on the human machine interface 304. The lower voltage and current levels of the presently disclosed loose wire detection system reduce the risk of injury, in cases of accidental contact, to a minimum. Also, the human machine interface provides improved communication with the operator, as compared to user interfaces comprised of push buttons and indicator lights. The improved communication provided by the human machine interface reduces the chance of inaccurate or misinterpreted results. Utilization of the human machine interface may also allow for communication with other equipment, for example, by means of a SCADA computer control system. In some examples, the loose wire detection system may include a human machine interface that may be integrated within another user interface of the creel system, such that the loose wire detection system is controllable with other sub-systems of the creel system 100. Accordingly, the presently disclosed loose wire detection system is safer because it utilizes reduced detection voltage, provides greater feedback and more information to the operator via the human machine interface, and may be integrated within a SCADA network.

[0044] Control of the LWD system 300 and the creel system 100, however, may also be implemented using remote devices, including through use of creel system control and/or visualization applications installed on computers, laptops, or mobile devices, etc. For example, a mobile device or smart phone "app" may be installed to communicate with the control system 116 including the LWD system 300. In this example, such mobile device could communicate with the central control system 116 to provide remote monitoring of the LWD system 300, such that the operator may remotely monitor operation parameters and/or environmental parameters of the creel operation. Such communication between the remote device and the control system 116 (or control console 900) may occur via various wireless or wired communication means, for example, wirelessly through BlueTooth™ or WiFi™, wirelessly through the Internet where the controller of the control system 116 is internet-enabled, via a hard hardwire (e.g., USB cable, Ethernet cable (e.g., CAT6 cable), etc.), or combinations thereof. The app may transmit information to and receive information from control system 116, or may directly transmit information to and receive information from one or more systems, sensors, or devices of creel system, such as the LWD system and/or the environmental monitoring system.

[0045] In alternative or complementary embodiments, the app may include the same operator input options as provided on control system 116 to monitor the LWD system 300 and in response to provide control commands to the controller to manually or automatically effect tensioning of the wire W and/or monitor (and/or adjust) environmental conditions of the creel room. In further alternative or complementary embodiments, security features may be provided through or built into the app. For example, the phone can implement a security control (e.g., password, PIN, code, pattern, biometric scan, and others) that may prevent total access to the platform, allow monitoring but prevent remote control, transmitting or receiving data to or from the app, or other activity related to creel system (e.g., changing environmental conditions in the creel room) based upon permission granted through successful passing of the security control.

[0046] Therefore, the disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is, therefore, evident that the particular illustrative embodiments disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of "comprising," "containing," or "including" various components or steps, the compositions and methods can also "consist essentially of" or "consist of" the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range is specifically disclosed. In particular, every range of values (of the form, "from about a to about b," or, equivalently, "from approximately a to b," or, equivalently, "from approximately a-b") disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles "a" or "an," as used in the claims, are defined herein to mean one or more than one of the elements that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

[0047] Directional terms such as above, below, upper, lower, upward, downward, left, right, and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward or upper direction being toward the top of the corresponding figure and the downward or lower direction being toward the bottom of the corresponding figure.

[0048] As used herein, the phrase "at least one of" preceding a series of items, with the terms "and" or "or" to separate any of the items, modifies the list as a whole, rather than each member of the list (i.e., each item). The phrase "at least one of" allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" each refer to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.