Description

Technical Field

[0001 ] The invention relates to a spool or a spider suitable to coil and store an elongated metal element such as a steel wire, a steel strand, a steel rope or a steel cord.

[0002] The invention also relates to a system for measuring, extracting, managing and processing information on spools.

Background Art

[0003] In an industry 4.0 environment there is an increasing need for automation, for collection and processing of data, for meeting consistent quality in the delivered products, for traceability in case of complaints, for localization of half-products and products, and for adding information to the products that is useful for the customers.

[0004] Industries manufacturing elongated metal elements such as steel wires, steel strands, steel ropes, steel cords, and steel fibres are faced with the problem that data about the products is not adapted to be managed centrally in an automated way.

[0005] More particularly, physical labels on spools carrying the elongated metal elements may become deteriorated or damaged in and industrial environment, which is detriment to their readability.

Spool tagging by laser marking is not robust enough since the laser marks may become damaged as well.

Passive RFID tags are not expensive but do not allow reaching the level of information exchange needed. Disclosure of Invention

[0006] From a general aspect, an object of the invention is to mitigate the drawbacks of the prior art.

[0007] More particularly, the invention aims to provide spools for coiling and storing elongated metal elements that allow full connection, monitoring, control, optimization or autonomy in an industry 4.0 environment or in an external environment as a self-sufficient system.

[0008] According to a first aspect of the invention, there is provided a spool or spider suitable to coil and store an elongated metal element. The spool comprises

- a sensor adapted to capture data relating to the spool, and

- an active communication device capable of sending and receiving information.

Both the sensor and the communication device are integrated in a single physical unit, e.g. in one single housing.

[0009] The information can be sent and received via a low power wide area network to an offsite platform, via satellite communication or via a remote network of equipment, e.g. machines where the spools can be installed.

[0010] The elongated metal element can be a steel wire, a steel strand, a steel rope, a steel cord, a bundle or yarn of steel fibres, hybrid elements comprising a combination of metal and polymer elements or a combination of metal and carbon elements.

[0011 ] The sensor (together with the communication device) is physically on the spool and is adapted to capture data directly relating to the spool or, preferably, also data indirectly relating to the elongated metal element wound on the spool. In some cases, a complement of the sensor for extra measurement or extra power capacity or charging may be placed physically on the rack or pallet that is carrying the spools. [0012] The communication device allows two-way communication in that it is able to both send and receive information.

[0013] Sending and receiving information preferably occur via a low power wide area network. Such a wide area network may preferably be based on at least one of the following standards: Dash7, Chirp spectrum based such as LoRa, Ultra narrowband technology such as Sigfox or Weightless,

Open standard Wize, 3GPP such as LTE-M or NarrowBand IOT, 4G, and 5G. The ultra narrowband technology of Sigfox has proved to be a preferred option.

[0014] Alternatively, a satellite communication system is used such as VSAT in case a network is not available. Satellite communication, however, consumes more electrical power than in case communication is done via a low power wide area network.

Use can also be made of an existing wide area network from existing assets as equipment.

[0015] Adding intelligence to the spool or spider facilitates monitoring and controlling the supply chain.

[0016] The sensor on the spool is preferably selected out of one of the following group of sensors: a localisation sensor, a temperature sensor, a humidity sensor, a speed sensor, a rotation sensor, a gyroscope, an accelerator sensor, an RFID reader or antenna, a pressure sensor, a force or tension sensor, an optic sensor, an electromagnetic field sensor, an acoustic sensor (including ultrasonic). An identification tag or beacon may be added.

[0017] In a preferable embodiment of the invention, the spool is equipped with either a sensor that is able to capture acceleration in at least two different directions or is equipped with at least two accelerator sensors, these two accelerator sensors being able to capture acceleration in two different directions. [0018] In a most preferable embodiment of the invention, the spool is equipped with three accelerator sensors. Each accelerator sensor is adapted to capture acceleration of the spool in a direction that is different from the direction of the two other accelerator sensors. Preferably, the three directions, X, Y and Z, are perpendicular to one another.

[0019] The localisation sensor allows to locate the spool both inside and outside the manufacturing plant, e.g. during transport or at the customer site. The localisation sensor may work via a global positioning system (GPS) or indirectly via triangulation. In a preferable embodiment, it is possible to shut off this sensor on purpose, e.g. when a spool is full of when the spool enters the customer premises. Alternatively, a beacon (such as a Bluetooth Low Energy beacons) may be added for better indoor localisation.

[0020] Alternatively, localisation of the spool may also be realized through the MAC or IP address by making use of a library where the addresses are linked to a physical location.

[0021 ] The temperature sensor allows determination of the ambient temperature at regular time intervals. This may be useful in case of quality complaints. Alternatively, an alarm is triggered in case a maximum or a minimum temperature is reached.

[0022] The humidity sensor allows measuring the humidity at the level of the spool. This is particularly relevant since elongated metal elements may be subject to corrosion. In that respect, temperature and humidity are usually monitored together.

[0023] The speed sensor or rotation sensor or accelerator sensor keeps track of the number of rotations of the spool during winding or unwinding. The linear winding or unwinding speed of the elongated metal element may be derived from its diameter in combination with the number of rotations. [0024] A sensor or the combination of the three accelerator sensors may measure the orientation of the spools and therefore the orientation of the elongated elements. Some applications typically require a partial rotation (e.g. 45° or 90° or 180°) on a regular basis. By measuring the current orientation, damage to the elongated element may be avoided.

[0025] The gyroscope, accelerator or acoustic sensor may detect shocks or vibrations of the spool. Data may be stored on the offsite platform about shocks and vibrations that a spool is undergoing during a standard way of manufacturing or processing a particular type of elongated metal element. For example, the spool undergoes a first type of shock during fixing the empty spool on the winding equipment. During winding the spool may undergo some vibrations with changing frequency or amplitude, since the spool is filling up. Finally, the spool is removed from the winding equipment with a second type of shock. This standard data may be compared with the actual shocks and vibrations a spool is undergoing in order to check whether or not the standard way of working is followed.

[0026] In a preferable use, chaotic movements of the spool may be detected by the X, Y, Z accelerometers or accelerator sensors. The chaotic movement, clearly different from the mere rotation of the spool, may define the end of winding, and thus a fool spool or the placement of an empty spool on the machine.

[0027] In another preferred use, the RFID reader or antenna may be used to localize the spool. This may be the case when the spool is on a particular machine that is equipped with an RFID tag. The RFID reader reads the tag and localizes the spool on that particular machine. In addition, or alternatively, the presence of the spool on that particular machine can be stored in memory for traceability. Generalizing this concept while keeping in mind that RFID tags are much cheaper than the RFID readers, RFID tags may be brought on every possible location of the spools, while the RFID readers are present on the spools themselves.

[0028] In an alternative way, the pressure sensor or pressure switch may detect the presence or absence of elongated material on the spool. A more sophisticated sensor may detect the amount of elongated material on the spool. Incomplete consumption of a spool may be an indication that something is wrong with the elongated material. So when a spool is not completely consumed, a signal may be generated to trigger actions to find out what went wrong.

[0029] In another alternative use, the optical sensor, such as an infrared sensor or camera, detects directly the amount of product remaining on the spool and therefore the consumption.

[0030] Preferably the spool further comprises one or more of the following devices: a memory, a battery, a power source, an antenna, a buzzer and a lamp.

[0031 ] The memory may be used to temporarily store data of the spool before these data are transmitted to the offsite network at regular time intervals. Data, such as an identification code that is possibly encrypted, may be used to prevent counterfeiting. Additionally or alternatively, the memory may have information for a longer time period about the spool itself or about the elongated metal element wound or to be wound or about the plant of manufacturing, ... [0032] The power source is preferably one with a ten year lifetime. The battery may be combined with a charging element such as an induction charger. Alternatively, the power source maybe a self-feeding element based upon solar energy, kinetic energy or electromagnetic energy.

[0033] The lifetime may be further increased by one or both of the following measures:

1 ) Use of a second battery; and / or

2) Use of one or more of the accelerometers as switch to wake up the other sensors.

[0034] In contrast to mobile phones, the antenna is not so strictly subjected to dimensional limits as there may be more space available on the spool.

[0035] The lamp or the buzzer may be used to have the spool generate a signal in order to facilitate localization or identification in a store full of spools.

[0036] The lamp may also function as a communication device, e.g. by giving a signal to release the spool yes or no.

[0037] In a preferable embodiment the spool comprises two or more of the above-mentioned sensors which form an array of sensors.

[0038] In a practical example of the invention, the spool has two flanges, wherein the sensor and the communication device are attached to one of the flanges.

[0039] The sensor and the communication device may be attached to the outer side of one of the flanges or to the inner side of one of the flanges. Attachment to the outer side of one of the flanges has the advantage that the communication signals to and from the communication device are not hindered by the cage of Farady formed by the elongated metal element on the spool. Attachment to the inner side of one of the flanges has the advantage that the sensor and communication device are better protected against possible damage.

Attachement of a sensor to the inner side of one of the flanges, close to the bottom, i.e. in a radially inner zone, close to the core of the spool, can have the advantage that once the sensor starts to send out clear communications signals, it means that the spool is getting empty.

[0040] At least one of the flanges of the spool may have recesses, for example to reinforce the flange. These recesses form a practical and advantageous location to position the sensor and the communication device since the recesses offer an additional protection against possible damages. These recesses may be present at the outer side of the flange, or at the inner side of the flange, or at both sides.

[0041 ] The spools may be of wood, plastic or metal sheet, such as steel sheet.

[0042] According to a second aspect of the invention, there is provided a system for managing and processing information on spools. This system comprises:

- two or more spools according to the first aspect of the invention; and

- a low power wide area network, a satellite communication system, or a remote network via which information to or about the two or more spools is passing; and

- an offsite platform where data about the two or more spools is managed and processed.

[0043] On the offsite platform data about the spools is processed so that it results in information on the elongated metal elements stored on the spools, or results in information on the spools, or results in information on the environment of the spools.

[0044] For example, making use of the diameter of the elongated metal element, the number of rotations, the particular way of winding and the dimensions of the spool the length of the elongated metal element may be calculated. The final result, the length of the elongated metal element, is sent back and can be stored on the memory element.The advantage of having an offsite platform is that the way of processing the data can be kept confidential.

[0045] An alternative and preferred way to determine the length of the elongated metal element on a spool is to measure both the time and the speed of winding the elongated element on the spool. This information can then be sent to the memory on the spool.

[0046] Viewed from another preferable and independent aspect of the invention, there is provided a communication system between spools and machines. The system comprises one or more spools equipped with a sensor and a communication device. The system further comprises machines equipped with a docking station adapted to receive said the communication device of the spools during the processing of the elongated metal elements on the machines. Information is sent from the spools to the machines or the other way around, without intervention of a network or a satellite.

This system allows to gather processing information or location of the spool at a remote location without interaction with a third party network thereby respecting the integrity and security of that third party network.

Brief Description of Figures in the Drawings

[0047] Figure 1 is a perspective view of a first example of a spool according to the invention;

[0048] Figure 2 is a schematic view of a sensor;

[0049] Figure 3 is a perspective view of a second example of a spool according to the invention;

[0050] Figure 4 is an example of a curve with data measured on a spool. Mode(s) for Carrying Out the Invention

[0051 ] Figure 1 gives a perspective view of a first example of a spool 100 according to the invention. The spool 100 made out of sheet metal has a core or barrel 102 and two flanges 104 and 106. Both flanges 104 and 106 are provided with recesses 108 to make the flanges stronger without increasing the thickness of the sheet metal. The recess 108 is provided at the inner side of the flanges 104 and 106 and result in a protruded part at the outer side of the flanges. The flanges 104 and 106 have a thickened border 110 also for strengthening purposes. This thickened border 110 is realized by folding the sheet metal at circumference.

[0052] The flange can be characterized by some of its dimensions:

- the diameter of the flange F;

- the diameter of the core or of the barrel C; - the external width or overall width W _e ;

- the internal width or traverse W,.

The table hereunder gives examples of some spools.

The depth of the recesses may range between 5 mm and 25 mm and may be fit to house a sensor and communication device 200.

[0053] Figure 2 schematically represents a sensor and communication device

200. This device 200 comprises a sensor or array of sensors 202, means 204 for attaching the sensor 202 to the spool, a lamp 206 and a buzzer 208.

[0054] Following sensors may be present:

[0055] There are different types of Temperature Sensors like Temperature Sensor ICs (like LM35), Thermistors, Thermocouples, RTD (Resistive Temperature Devices).

[0056] An example of a combined humidity and temperature sensor is DHT 11. The sensor includes a resistive sense of wet component and an NTC temperature measurement device, and is connected with a high- performance 8-bit microcontroller. The sensor contains a calibrated digital signal output of temperature and humidity.

Another example is a DHT22 temperature-humidity sensor.

Still another example is a Bosch BME680. [0057] Examples of a gyroscope sensor or 3-axial angular rate sensor are

BMG160 or BMG250 by Bosch, or CRS07 offered by Althen or Analog Device ADXRS652.

[0058] An example of an accelerometer sensor is 820M1 or Analog Device ADXL362 (3 axis).

[0059] By monitoring the acceleration that is spool is undergoing, a difference may be made between, on the one hand, low values of the acceleration corresponding to normal handling or normal working of the spool, i.e. rotation during winding or unwinding, and, on the other hand, high values of acceleration corresponding to exceptional or bad handling of the spool, for example, a spool that has fallen down.

[0060] In a highly preferable embodiment, the spool is equipped with three accelerometers, one capturing acceleration or g-force in the X-direction, one capturing acceleration or g-force in the Y-direction and one capturing acceleration or g-force in the Z-direction, the X-, Y- and Z-direction being perpendicular to each other.

[0061 ] The X- and Y-direction can correspond to the plane of the flange, i.e. the plane of rotation during winding and unwinding. The Z-direction is then the direction of the axis of the spool, perpendicular to the XY-plane. During winding or unwinding, acceleration values will be measured in the X-direction and the Y-direction in the form of two sinusoids, with a phase difference in-between. The number of full periods of the sinusoids corresponds to the number of rotation. During smoothly winding or unwinding, the acceleration in Z-direction will be small or non existing. A higher value of acceleration in Z-direction may point to vibrations, e.g. of the winding equipment.

[0062] VS1000 series by Safran are examples of vibration sensors.

[0063] An example of a GPS module is NEO-6M. [0064] Corrosion sensors can be optical fiber corrosion sensors. [0065] Proximity sensors can be based upon infrared. [0066] An example of a suitable battery is a Li-ion battery from Panasonic such as UR18650ZTA or UF103450P (Prismatic).

[0067] An example of an RFID Reader / Writer is TRF7960 provided by Texas Instruments.

[0068] Figure 3 is a perspective view of a second example of a spool 300 according to the first aspect of the invention. The difference with the spool shown in Figure 1 is that the sensor and communication device 200 is now located in one of the recesses 108 of the outer side of a flange.

[0069] Figure 4 illustrates how data of the spool are processed on an offsite platform and may lead to relevant information on the elongated element itself.

[0070] Curve 400 shows the amplitude of vibrations of the spool in function of time. During a short initial period 402, the spool undergoes heavy high- frequency vibrations, which may be the result of fixing the spool to the winding equipment. During a second period 404, the spool has regular lower frequency vibrations with a gradually decreasing amplitude. This may be the result of the rotations of the spool during winding. As the spool is being filled during winding, the amplitude of the vibrations diminish since the spool filled with the elongated metal element gets heavier. High frequency vibrations may characterize a third period. These vibrations may be due to detaching the spool from the winding equipment. A fourth period 408 with no vibrations may follow.

A standard vibration curve during the winding process may be determined and stored in a memory on the offsite platform. Each actually measured vibration curve is then compared with the standard curve to determine the type of operation that an elongated element has undergone and to monitor and log any deviations therefrom.

List of reference numbers

[0071] 100 first example of spool 102 core

104 first flange 106 second flange 108 recess 110 flange border 200 sensor and communication device

202 sensor 204 attachment means 206 lamp 208 buzzer 300 second example of spool

400 vibration curve 402 first period 404 second period 406 third period 408 fourth period