METHOD, REEL DEVICE AND COMPUTER PROGRAM FOR OPERATING THE REEL DEVICE

Abstract

SUBSTITUTE SPECIFICATION CLEAN COPY A reel device has a reel mandrel for winding up a strip. The reel mandrel has a plurality of segments distributed over the perimeter thereof, which are each joined via at least two link plates to a control rod that can be axially moved in the reel mandrel, for radially extending and retracting the segment. To reliably identify wear conditions of internal components of the reel mandrel that are not visible from the outside, a method for operating the reel device provides that, during the service life of the reel device, the segments are moved multiple times into certain operating positions and in each case the respective distances of the segments in relation to a stationary operating position are determined. The distances recorded at different points in time are evaluated whether they exceed or fall below a predefined threshold value, and wear condition is inferred therefrom.

Claims

1.-13. (canceled)

14. A method for operating a reel device (100), wherein the reel device comprises a reel mandrel (120) for winding up a strip (20), wherein the reel mandrel (120) has a segment (124) arranged at a perimeter of the reel mandrel (120), the segment (124) being joined via at least two link plates (125, 126) to a control rod (122) that can be axially moved in the reel mandrel (120), for radially moving the segment (124) into an operating position (P1, P2, P3), and wherein the reel mandrel (120) comprises a compression spring unit (150) for holding the segment (124) under a radial preload (FD), the method comprising: a) moving the segment (124) into the operating position (P1, P2, P3) multiple times during a service life of the reel device (100), in each case under the radial preload (FD), and thereby subjecting the link plates (125, 126) and/or the control rod (122) to wear; b) directly or indirectly determining and recording a radial distance (A1, A2, A3) of the segment (124) in the operating position in relation to a stationary reference position (P0) at different points in time during the service life; c) evaluating the radial distances (A1, A2, A3) recorded at the different points in time in terms of whether they exceed a predefined upper threshold value (S1, S3) or fall below a predefined lower threshold value (S2) during the service life of the reel device (100); and d) indirectly identifying a wear condition of the reel device (100) when the radial distances (A1, A2, A3) exceed the upper threshold value (S1, S3) or fall below the lower threshold value (S2) starting at one of the points in time.

15. The method according to claim 14, wherein the operating position is a pre-expanded wrapping position (P1) of the segment (124) without a wrapped strip (20), wherein, in step c), an increasing enlargement in the radial distance (A1) is detected during the service life of the reel device (100), and wherein, in step d), the wear condition is an undesired elongation of the link plates (125, 126), a widening of joint bores (127) on the link plates and/or of their fastening bolts (121) and is indirectly identified if the recorded distances (A1) exceed the predefined upper threshold value (S1).

16. The method according to claim 14, wherein the control rod (122) has a ramp (123) on the perimeter thereof, wherein the compression spring unit (150) has a housing (153) with an inclined lower side, and wherein the housing of the compression spring unit (150) slides with the inclined lower side along the ramp (123) when the segment (124) is moved radially during an axial movement of the control rod, wherein the operating position is a winding position (P2) of the segment (124), in which a plurality of turns of the strip (20) are wound up onto the segment and the reel mandrel (120), wherein, in step c), an increasing reduction of the radial distance (A2) is detected during the service life of the reel device (100), and wherein, in step d), the wear condition is undesired abrasion on a surface of the ramp (123) and/or on the lower side of the housing (153) of the compression spring unit (150) and is indirectly identified if the recorded radial distances fall below the predefined lower threshold value (S2).

17. The method according to claim 16, wherein a transition from a wrapping position (P1) to a winding position (P2) comprises: wrapping the strip (20) with one to seven coil turns on the reel mandrel (120) with the segment (124) in the wrapping position (P1), as a result of which a radial compression force is exerted on the compression spring unit (150) and the segment (124) is moved into a compression position, and moving the segment up against the compression force from the compression position into the winding position for further winding of the reel mandrel with the strip (20) to form a coil.

18. The method according to claim 14, wherein the operating position is a discharge position (P3) of the segment from the reel mandrel, wherein, in step c), an increasing enlargement in the radial distance (A3) of the segment (124) in relation to the radially further inward reference position (P0) is detected during the service life of the reel device (100), or vice versa, and wherein, in step d), the wear condition is an undesired elongation of the link plates (125, 126), a widening of joint bores (127) on the link plates and/or of their fastening bolts (121) and is indirectly identified if the recorded distances (A3) exceed the predefined upper threshold value (S3), or vice versa.

19. The method according to claim 14, wherein the upper and lower threshold values (S1, S2, S3) and the operating position (P1, P2, P3) are in an elastic spring range of the compression spring unit (150).

20. The method according to claim 14, further comprising: e) initiating maintenance of the reel mandrel (120) if the wear condition is indirectly identified in step d).

21. The method according to claim 14, wherein moving the segment (124) into the operating position and determining and recording the radial distance (A1, A2, A3) of the segment (124) in the operating position are carried out multiple times a day, multiple times a month, or multiple times a year, and wherein evaluating the distances (A1, A2, A3) is carried out with a same or a lower frequency as the recording of the distance.

22. A computer program product stored on a non-transitory computer-readable storage medium that can be loaded into an internal memory of a digital computer and comprises sections of software code with which steps in accordance with the method according to claim 14 are executed when the product is running on a computer.

23. A reel device (100), comprising: a reel mandrel (120) for winding up a strip; a rotary drive device (130) for driving the reel mandrel (120) in rotation for a coiling operation of the reel device (100); a push/thrust drive (110) for axially moving a control rod (122) in the reel mandrel (120); a control device (140) for controlling the rotary drive device (130) and the push/thrust drive; a segment (124) arranged radially expandable on a perimeter of the reel mandrel (120); at least two link plates (125, 126) connecting the segment (124) to the control rod (122) for radially extending and retracting the segment (124) into at least one operating position in accordance with a respective axial movement position of the control rod (122); at least one compression spring unit (150) arranged between the segment (124) and the control rod (122) for holding the segment (124) under a radial preload; a distance sensor (160) for the multiple direct or indirect determination of the radial distance (A1, A2, A3) of the segment (124) in the at least one operating position (P1, P2, P3) relative to a stationary reference position (P0); and a recording device (170) and an evaluation device (180) for recording and evaluating a plurality of the measured distances (A1, A2, A3) in terms of their change during a service life of the reel device (100) with regard to whether the measured radial distances (A1, A2, A3) exceed a predefined upper threshold value (S1, S3) or fall below a predefined lower threshold value (S2) over a course of time.

24. The reel device (100) according to claim 23, further comprising an inner stop for compression of the compression spring unit (150) when wrapping the strip, wherein the inner stop is formed by an upper edge of a housing (153) which partially surrounds the compression spring unit (150) in a non-compressed state.

25. The reel device (100) according to claim 23, wherein the stationary reference position (P0) is formed by an upper edge of a guide (128) in which the compression spring unit (150) is radially guided.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The description is accompanied by a total of 11 figures.

[0028] FIG. 1 shows a reel device;

[0029] FIG. 2 shows a compression spring unit with its characteristic curve;

[0030] FIG. 3 shows a longitudinal section through a reel mandrel with the segments in a first operating position without wear;

[0031] FIG. 4 shows the longitudinal sectional view in accordance with FIG. 3 with the extended segments in the first operating position with wear present;

[0032] FIG. 5 shows a diagram for illustrating the change in the distances A1 during the service life;

[0033] FIG. 6 shows a longitudinal section through the reel mandrel with the segments in a second operating position without wear;

[0034] FIG. 7 shows the longitudinal sectional view in accordance with FIG. 6 with the segments in the second operating position with wear present;

[0035] FIG. 8 shows a diagram for illustrating the change in the distances A2 over time during the service life of the reel mandrel;

[0036] FIG. 9 shows a longitudinal sectional view of the reel mandrel with the segments in a third operating position without wear;

[0037] FIG. 10 shows the longitudinal sectional view in accordance with FIG. 9 with wear present; and

[0038] FIG. 11 shows the change in distance A3 during the service life of the reel mandrel.

DETAILED DESCRIPTION

[0039] The invention is described in detail below with reference to the specified figures in the form of exemplary embodiments. In all figures, the same technical elements are designated with the same reference signs.

[0040] FIG. 1 shows a reel device 100. It has a reel mandrel 120 for winding up a strip, in particular a metal strip. The reel mandrel 120 is driven in rotation by a rotary drive device 130. The rotary drive device 130 is controlled by a control device 140. The reel mandrel itself has a control rod 122, which can be axially moved within the reel mandrel 120 with the aid of a push/thrust drive 110. The push/thrust drive 110 is likewise controlled by the control device 140. The reel mandrel 120 has at least one, but typically a plurality of radially expandable segments 124 at its periphery, which are arranged in a manner distributed over the perimeter of the reel mandrel 120. The segments 124 are typically joined to the control rod 122 via at least two link plates 125, 126. In this manner, the segments 124 can be radially extended into different operating positions and also retracted again, depending on the axial movement position of the control rod 122. The segments 124 are in each case held under a radial preload FD with the aid of at least one compression spring unit between the segment and the control rod. The compression spring units 150 are guided in a radial direction in the reel device 100 with the aid of guides 128, see FIG. 3. When the segment is extended/retracted in a radial direction, the compression spring units 150 are likewise moved in a radial direction. This is carried out by sliding along a ramp 123 of the control rod 122 with the inclined lower sides of their housings if the control rod is moved in the axial direction.

[0041] FIG. 2 shows the compression spring unit 150, which holds the segment 124 under the radial preload FD. For the present disclosure, it is assumed that the compression spring unit 150 is operated in a manner wear-free in its elastic working range. The compressive force FD exerted by the compression spring unit 150 is linearly dependent on its spring travel.

[0042] The linearly increasing characteristic curve in FIG. 2 shows the radial movement of the surface of the housing 153 as a function of the spreading stroke of the control rod 122 with its ramp 123. The simultaneous radial movement of the unloaded (i.e. no strip is wound up) segments 124 shows the bent curve above them. The non-linear course is due to the fact that the link plates 125, 126 perform a rotational movement about their bearing point during radial expansion. The spring in the compression spring unit 150 compensates for the discrepancy between linear movement and rotational movement with the spring travel. As a result, the segment 124 is always tensioned radially outwards in the unloaded state.

[0043] FIG. 3 shows a longitudinal section through the reel mandrel 120 in detail. The compression spring unit 150 can be seen, which presses against the segment 124 from below with the compressive force FD exerted by it and in this manner holds the segment under a radial preload. The compression spring unit 150 is guided in the radial direction R and slides with the inclined lower side of its housing 153 on a ramp 123 of the control rod 122. If the control rod 122 is moved in the axial direction L, said sliding movement occurs and the compression spring unit 150 is moved in the radial direction in this manner. Since the compression spring unit 150 holds the segment 124 under said preload, not only the compression spring unit 150, but also the segment 124, is radially moved/positioned when the control rod 122 is axially moved. Specifically, the segment 124 can be moved/positioned in different radial operating positions in this manner. So that said preload can be built up on the segment 124, this is limited in its radial freedom of movement against the compressive force FD of the compression spring unit 150 with the aid of two link plates 125, 126. The link plates 125, 126 are in each case joined at one of their lower ends to the reel mandrel 120, in particular the control rod 122, via fastening bolts 121, and in each case they have an elongated hole at their opposite upper end, in which the segment 124 is mounted in a joined manner.

[0044] As can also be seen in FIG. 6, the surface/upper side of the housing 153 of the compression spring unit 150 forms an upper/inner stop for the compression of the compression spring unit. That is, at maximum compression, the segment 124 rests on the surface of the housing 153 of the compression spring unit 150.

[0045] A distance sensor 160 is provided for measuring the distance of the segment 124 in a first operating position P1, in a second operating position P2 or in a third operating position P3, in each case in relation to a stationary operating position P0. This stationary operating position P0 is selected in FIG. 3, for example, in the form of the upper edge of the radial guide 128. In principle, however, any other position in space that is stationary in relation to the relative movement of the segment 124 is also suitable as the reference position.

[0046] In the lower half of FIG. 3, a measurement chain is shown for the measurement signal measured by the distance sensor 160, which represents the direct or indirect radial distance of the segment 124 in one of the operating positions in each case. The distance values determined by the distance sensor are recorded in a recording device 170 and evaluated in an evaluation device 180 in terms of any wear condition of individual components of the reel mandrel. In the event of identified wear, a corresponding message is sent to an operator of the reel device 100/to an alarm center, preferably together with a recommendation to replace the worn components of the reel mandrel 120. The output of the message is symbolized in the measurement chain by the reference sign 190.

[0047] The design of the reel device 100 and in particular of the reel mandrel 120 just described with reference to FIG. 3 applies equally to FIGS. 4, 6 and 7 and to FIGS. 9 and 10.

[0048] The method for operating the reel mandrel described is explained in more detail below with reference to the figures mentioned for different operating positions. FIGS. 3, 6 and 9 in each case show the reel mandrel in a wear-free state, while FIGS. 4, 7 and 10 show the reel mandrel with wear.

[0049] For identifying a wear condition of the link plates 125, 126, the method for operating a reel device provides that the segment 124 is moved multiple times into a first operating position P1, also referred to as the approach position, during the service life of the reel device. The radial movement is carried out in each case under the preload applied by the compression spring unit 150. In the approach position, the segment 124 has moved up slightly in the radial direction in relation to the collapsed state of the reel mandrel, specifically to a distance A1 in relation to the stationary reference position P0. The radial distance A1 is determined and recorded at different points in time during the service life. The joint bores 127 in the link plates 125, 126 are subject to wear during the service life of the reel mandrel due to the large radial forces acting on them; i.e., these joint bores 127 can wear out. Alternatively or additionally, the link plates 125, 126 themselves may also be subject to wear, in which they undergo plastic elongation with increasing endurance. The fastening bolts 121 can also wear locally with the consequence that their diameter is then reduced locally, for example. These three aforementioned wear phenomena result in the measured radial distances A1 for the first operating position P1 becoming increasingly larger during the service life of the reel mandrel 120. Therefore, the recorded distances A1 are evaluated in accordance with the method for operating a reel device to determine whether they exceed a predefined upper threshold value S1 at a certain point in time during the service life. If the reaching or exceeding of this first upper threshold value S1 is identified, the method for operating a reel device provides for indirect identification/inference of said wear conditions of the link plates 125, 126 or the fastening bolts 121.

[0050] As mentioned above, FIG. 3 shows a wear-free/low-wear condition of the reel mandrel, in which the determined distance A1 is still smaller than the first upper threshold value S1. In contrast, FIG. 4 shows the same reel mandrel 120 in a state in which the link plates 125, 126, their joint bores 127 and/or the fastening bolts 121 are subject to wear. The wear condition can be seen in FIG. 4 in that the determined distance A1 is greater than in FIG. 3 and has already reached the upper threshold value S1.

[0051] FIG. 5 illustrates the development of the distances A1 over time during the service life of the reel mandrel 120. It can be seen that the measured distances A1 are smaller at an early point in time, at which the link plates 125, 126 are not yet subject to any or only slight wear, than at a later point in time, at which the link plates are subject to wear. FIG. 5 schematically shows the distances determined at different points in time in each case, wherein each black dot corresponds to the distance determined at a certain point in time. Over the course of time/during the service life of the reel mandrel, a movement of such a cluster of measured values towards larger distances can be identified. In practice, instead of the large number of individual measured values, it may be advisable to determine and evaluate average values of the distances A1 in certain time windows.

[0052] FIGS. 3, 4 and 5 illustrate the method for operating a reel device, as already mentioned, for the first operating position, i.e. the so-called approach position, as explained above in the general part of the description.

[0053] In contrast, FIGS. 6, 7 and 8 relate to the method for operating a reel device in the so-called winding position, as likewise explained above in the general part of the description. In FIGS. 6 and 7, it can be seen that in the second operating position, i.e. the winding position, the compression spring unit 150 is maximally compressed, i.e. the segment 124 rests on the upper edge of the housing 153 of the compression spring unit 150. The radial compression force, which counteracts the compressive force FD of the compression spring unit 150, is generated by the strip tension of the plurality of coil turns of the strip 20, which are wound up onto the segments 124 of the reel mandrel 120 in the winding position. At the same time, the compression spring unit 150 is extended in the winding position in the radial direction to the distance A2 in relation to the stationary reference position P0, in order to ensure a sufficiently tight coil of the strip 20 on the segments 124. In the wear-free state, as shown in FIG. 6, the distance A2 is greater than a lower threshold value S2. The radial extension of the segments 124 to the distance A2 is carried out by moving the control rod 122 axially to the left; the compression spring unit 150, which is guided in the radial direction R by the guides 128, then slides upwards in the radial direction R on the ramp 123 of the control rod 122.

[0054] During the service life of the reel mandrel 120, the sliding surface 129 between the inclined lower side of the housing 153 of the compression spring unit 150 and the upper side of the ramp 123 is subject to wear, as shown in FIG. 7. Due to wear, i.e. as a result of abrasion, the sliding surface 129 in FIG. 7 is lowered in relation to the wear-free state in accordance with FIG. 6. Therefore, [0055] when the control rod 122 is moved axially by the same amount, the compression spring unit 150 no longer reaches the same radial distance A2 as without wear in accordance with FIG. 6. Rather, the radial extension state, represented by the distance A2 of the segment 124 in relation to the stationary reference position P0, decreases continuously during the service life of the reel mandrel, see FIG. 8. As soon as the wear has reached a certain size, the radial distance A2 drops to the lower distance threshold value S2 or below. If the evaluation of the radial distances in accordance with the method for operating a reel device identifies this situation, the presence of severe wear of said sliding surfaces is inferred and a corresponding recommendation for replacing the control rod 122 and/or the housing 153 is issued.

[0056] Finally, FIGS. 9 to 11 relate to a third operating position for the reel mandrel, the so-called discharge position. FIG. 9 shows a wear-free state; FIGS. 10 and 11 show the state with wear. Once the strip 20 has been completely wound into a coil in the winding position, the segments on the reel mandrel must be retracted radially slightly, in order to be able to pull the coil off the reel mandrel. This position of the segments is said discharge position, represented in FIGS. 9 to 11 by the radial distance A3 in relation to the stationary reference position P0. The distance A3 measured at different points in time during the service life of the reel mandrel 120 is also suitable for indirectly identifying a wear condition of the link plates 125, 126, of their joint bores 127 and/or of the fastening bolts 121. For the transition from the winding position to the discharge position, the control rod 122 is moved to the right, as a result of which the compression spring unit 150 is lowered on the ramp 123 in a sliding manner to the distance A3. In the wear-free state of the link plates in accordance with FIG. 9, the radial distance A3/the third operating position is below a predetermined second upper threshold value S3. As can be seen in FIGS. 10 and 11, this radial distance A3 increases with increasing wear during the service life of the reel mandrel 120. After a certain service life, the radial distance A3 reaches the upper threshold value S3. In this case, the method for operating a reel device indirectly identifies the presence of said wear condition in the link plates 125, 126, in their joint bores 127 and/or in the fastening bolts 121 for the link plates. In this case as well, said wear condition is reported and the replacement of the link plates is recommended.

LIST OF REFERENCE SIGNS

[0057] 20 Strip, in particular metal strip [0058] 100 Reel device [0059] 110 Push/thrust drive for control rod [0060] 120 Reel mandrel [0061] 121 Fastening bolt for link plate [0062] 122 Control rod [0063] 123 Ramp [0064] 124 Segment [0065] 125, 126 Link plate [0066] 127 Joint bore in the link plate [0067] 128 Radial guide for compression spring unit [0068] 129 Sliding surface between compression spring unit and ramp [0069] 130 Rotary drive device [0070] 140 Control device [0071] 150 Compression spring unit [0072] 153 Housing [0073] 160 Distance sensor [0074] 170 Recording device [0075] 180 Evaluation device [0076] 190 Output of message [0077] A1 Radial distance [0078] A2 Radial distance [0079] A3 Radial distance [0080] FD Radial compressive force, radial preload [0081] L Axial direction [0082] P0 Stationary reference position [0083] P1 1. Operating position (=wrapping position) [0084] P2 2. Operating position (=winding position) [0085] P3 3. Operating position (=discharge position) [0086] R Radial direction [0087] S1 Upper distance threshold value for wrapping position [0088] S2 Lower distance threshold value for winding position [0089] S3 Upper distance threshold value for discharge position