Patent Description:
Even in the textile industry, due to the growing quality demands of the market, it has long been necessary to be able to provide the total traceability of the product, i.e., the ability to reconstruct the history of the finished textile product, whichever sector it refers to: clothing, home furnishings, automotive, etc., up to the origin of all the threads with which it was manufactured. The thread used is in turn the result of various steps and processes that together contribute to defining the quality features of the finished product.

In industrial production, the thread is wound onto a tube to form a reel using a machine called a winding machine. Essential in an industrial system is the automation of the process of moving the reels from the winding machine to the subsequent stages, such as the sorting line, the warehouse, or palletizing. In order to carry out these activities, the automatic handling systems include a machine called a "doffer" which is suitable to pick up the prepared reels of thread from the winders and transport them to the next station. For technical reasons, reels of thread must be able to be tracked and distinguished according to the production machine, production lot, and other quality-related parameters.

Currently, this tracking is done manually. The tube inside the reel is often made of cardboard, which provides a number of advantages such as low cost, good temperature resistance, the possibility of marking with symbols and colors and the ease of affixing tags therein.

In order to trace the path of the reels of thread, the most commonly used technology today involves the use of identification codes with graphic elements, such as a QR code or a bar code, applied internally to the tubes by directly marking the identification code or gluing on a tag containing said code.

However, this system still has some drawbacks: not only does it require the addition of a labeling station, but it also forces operators to use identification code recognition tools, which are sometimes difficult to locate inside the tube. For the same reason, automating the recognition of these tags is complex.

In order to have more and more automated and centrally controlled plants, it is necessary to be able to track the reels of thread automatically right from the start, i.e., from their exit from the winding machine.

An automatic reading device for tracking reels of thread with a tube provided with an RFID label according to the preamble of claim <NUM> is disclosed in <CIT> and in <CIT>.

The object of this invention is to solve problems associated with conventional thread reel tracking systems.

In particular, the object of this invention is to provide a system capable of fully automatic tracking of the reel of thread, immediately when it exits the winding machine.

This object is achieved by an automatic reading device for tracking reels of thread according to claim <NUM>, a thread reel handling machine according to claim <NUM>, an automatic thread reel tracking system according to claim <NUM>, and an automatic thread reel tracking method according to claim <NUM>. The dependent claims describe preferred embodiments of the invention.

The features and advantages of the device according to this invention will appear more clearly from the following description, made by way of an indicative and non-limiting example with reference to the accompanying figures, wherein:.

With reference to the above figures, in particular <FIG>, some definitions useful for understanding the invention are given below.

Tube <NUM>: cylinder on which thread is wound to form a reel of thread <NUM>; often made of plastics or cardboard.

Reel of thread <NUM>: is obtained by winding a thread accompanying it over a tube <NUM>, maintaining a cylindrical symmetry. For mechanical-textile reasons, the reel of thread <NUM> may have different profiles depending on the physical-chemical nature of the thread collected.

RFID (Radio Frequency Identification): is the technology of automatic identification based on the propagation of electro-magnetic waves in the air, allowing the unambiguous, automatic (hands-free), massive and remote detection of objects, animals, and people both when static and in movement.

RFID TAG <NUM>: also called a transponder or smart tag; its main component is a small silicon chip surrounded by an antenna, normally made of copper, to which it is connected and from which it receives the energy needed to operate when it is hit by an electromagnetic field of the appropriate frequency.

In summary therefore, as shown in <FIG>, the reel of thread <NUM> comprises a tube <NUM> within which a tag <NUM> with RFID is affixed, allowing for unique identification of the tube <NUM> and thus the reel of thread <NUM>.

In an example embodiment, the tag <NUM> (RFID TAG) is a unidirectional type, i.e., it may be read/written according to a specific orientation with respect to the antenna. The optimal position for the tag <NUM> is in the central band of the tube, so that it is as far away as possible from the tags <NUM> on neighboring tubes. However, this is not essential; the system is designed to work regardless. If the tag <NUM> is unidirectional, then the orientation must be defined; if the tag <NUM> is omnidirectional then the orientation does not affect the reading/writing of the tag.

In a further example embodiment, the tag <NUM> (RFID TAG) is of the omnidirectional type, i.e., it may be read/written regardless of the orientation of its plane with respect to the antenna. Advantageously, such a solution allows the RFID tag <NUM> to be attached in any position within the tube <NUM> and in any orientation.

A subject of this invention is an automatic tracking system comprising an automatic reading device <NUM>, shown in <FIG> and <FIG>, and a plurality of tubes <NUM> having RFID tags <NUM>, as in <FIG>.

The automatic reading device <NUM> comprises an antenna <NUM>, connected via a connection cable <NUM> to a reader <NUM> connected to an electronic system <NUM>.

The antenna <NUM> converses with the antenna of the RFID tag <NUM> by means of radio waves. Preferably, the antenna <NUM> is of the coaxial type, i.e., capable of receiving and emitting signals <NUM>° in a plane. Advantageously, such a solution, combined with the use of an omnidirectional RFID tag <NUM>, ensures the certainty of reading the RFID tag <NUM> within a tube <NUM>, and thus the certainty of tracking the reel of thread <NUM>.

The reader <NUM> is suitable on the one hand to exchange information with the RFID tag <NUM> by means of the antenna <NUM>, and on the other hand to interact with the electronic system <NUM> to which it is connected. Thus, the reader <NUM> has the function of managing the antenna <NUM> that transmits and receives the radio frequency signals.

The electronic system <NUM> comprises a central processing unit (CPU) suitable to manage the sending of data read by the reader <NUM> to at least one programmable logic controller (PLC) and/or at least one computer via industrial serial protocols.

The reader <NUM> and the electronic system <NUM> to which it is connected are housed within an electronic apparatus <NUM>, provided with a casing <NUM>, which may be easily positioned in a workstation of the textile plant, for example on the "doffer" machinery which is adapted to pick up the reels of thread <NUM> from the winders and transport them to the next station.

The antenna <NUM> is shown specifically in <FIG> and <FIG>. The antenna <NUM> comprises a head <NUM> within which a seat <NUM> is made in which an antenna body <NUM> is housed, which is suitable to read/write to the RFID tag <NUM> by means of radio waves.

Preferably, the seat <NUM> wherein the antenna body <NUM> is housed flows into a front opening <NUM>.

Preferably, the head <NUM> is made of a non-shielding material, i.e., a material that does not interfere with electromagnetic fields, such as a plastics material.

Preferably, the head <NUM> has a frustoconical shape, with a smaller diameter toward the terminal end.

The head <NUM> is closed at the rear by a bushing <NUM> that also closes the seat <NUM> wherein the antenna body <NUM> is contained.

A screen <NUM> is arranged to the rear of the bushing <NUM>. Preferably, the screen <NUM> is made of a shielding material, such as metal.

The antenna body <NUM> is connected at the rear to an attenuator <NUM> connected to an adapter <NUM> for the connection cable <NUM>. Both the attenuator <NUM> and the adapter <NUM> are arranged within the bushing <NUM>, which is closed at the rear by the screen <NUM>.

Note that the adapter <NUM> protrudes from the screen <NUM>.

The connection cable <NUM>, which makes the data connection between the antenna <NUM> and the electronic apparatus <NUM> in which the reader <NUM> and the electronic system <NUM> are contained, comprises a connector <NUM> connectable to the adapter <NUM> of the antenna <NUM>.

The automatic reading device <NUM> is characterized in that it comprises a reel handling support <NUM> having a tip <NUM>, on which a plurality of reels of thread <NUM> are inserted in sequence, and in particular in that the tip <NUM> is the antenna <NUM>. The reel handling support <NUM> is thus provided with an antenna <NUM> at the tip <NUM>.

Advantageously, the antenna <NUM> is designed to replace the tip of the reel handling support <NUM>, so as not to compromise the proper operation of other standard electronic devices already on the support <NUM>.

The reel handling support <NUM>, shown in <FIG>, comprises a reel handling support body <NUM> terminating on one side in a tip <NUM> through which the reels of thread <NUM> are loaded, and on the opposite side in a connection end <NUM> with the machine.

The hollow, circular-shaped reel handling support body <NUM> comprises, at the tip <NUM>, an antenna seat <NUM> wherein the antenna <NUM> is at least partially inserted. For example, as in <FIG>, the end portion of the antenna <NUM>, namely the bushing <NUM> followed by the screen <NUM>, is inserted into the antenna seat <NUM>.

Preferably, the reel handling support body <NUM>, at the tip <NUM>, also houses within it a spacer <NUM> wherein the end portion of the connection cable <NUM> is housed, which has a connector <NUM> connectable to the adapter <NUM> of the antenna <NUM>.

Preferably, the connection cable <NUM> runs internally to the reel handling support body <NUM> and exits from its connection end <NUM>. Therefore, the electronic apparatus <NUM> of the automatic reading device <NUM> is arranged at the connection end <NUM> of the reel handling support <NUM>.

Preferably, the connection cable <NUM> runs within a shielded tube, for example a metal tube, arranged within the reel handling support body <NUM>.

Preferably, the reel handling support body <NUM> further accommodates reel pushing means <NUM> within it, for example in the form of a pneumatic cylinder.

A subject of this invention is also a machine for handling the reels of thread <NUM>, shown at least partially in <FIG>. Said machine comprises a plurality of reel handling supports <NUM> on which a series of reels of thread <NUM> having an RFID tag <NUM> inserted inside the tube <NUM> are loaded in sequence, starting from the tip <NUM>. In particular, each reel handling support <NUM> is provided with an antenna <NUM> at the tip <NUM>.

In one example embodiment, the machine is a "doffer" for picking up reels of thread <NUM> from the winders and transporting them to the next station.

Advantageously, the automatic reading device <NUM> according to this invention is sized, positioned, and set to read/write one RFID tag <NUM> at a time when the machine picks up/releases reels of thread <NUM> equipped with tubes <NUM> with RFID tags <NUM>, all in an environment where tens of reels of thread <NUM> are found within a few meters.

An important step in the proper operation of the automatic reading device <NUM> is setting the antenna <NUM>. In effect, the tubes <NUM> of the reels of thread have a predetermined length and as a function thereof the transmission power of the antenna signal is regulated. In effect, the automatic reading device <NUM> must read/write only one RFID tag <NUM> at a time and must do so only during the loading/unloading of the thread reel on the reel handling support <NUM>.

A subject of this invention is also to provide a method for automatically tracking reels of thread <NUM>.

The method according to this invention comprises at least the following steps:.

The tracking algorithm allows the input order of the reels <NUM> to be recognized when they are inserted onto the reel handling support <NUM>.

In particular, the tracking algorithm is performed by a computer and includes at least the following steps of the AUTOMATION CYCLE:.

OPTIMAL CONDITION: If the antenna <NUM> was set correctly, i.e., so that only one RFID tag <NUM> is read at a time, and if the RFID tags <NUM> were positioned correctly in the tubes <NUM> so that they are read one at a time, then there will be a unique match between:.

IMPERFECT CONDITION: If the power of the antenna <NUM> was oversized or if two RFID tags <NUM> from two consecutive tubes <NUM> were placed close together, then the antenna <NUM> will simultaneously pick up the signal from two consecutive RFID tags <NUM> even if they are different.

Two corrective logics intervene in this condition:.

FAILED OR MISSING RFID CONDITION: If the number of RFID tags <NUM> detected is less than the number of reels expected, and thus one or more RFID tags is faulty or missing, the software uses the clock interval as corrective logic to understand which is the missing tube in the a-n series.

A non-claimed embodiment provides a computer programmed to implement the automatic tracking method of the reel of thread <NUM> as described above.

A further non-claimed embodiment provides a computer program comprising portions of code that, when the program is executed on a computer, implement the method for automatically tracking the reel of thread <NUM> as described above.

The software expects five reels of thread <NUM>, and therefore five different RFID tag CODES, which by way of example shall be called STRING1, STRING2, STRINGS, STRING4, STRINGS.

The software does not know a priori the codes it is expecting, so it samples RFID tag readings at a set frequency.

The sum of the clocks obtained at the end of the detection, and thus at the end of the movement of loading the reels of thread <NUM> onto the reel handling support <NUM>, is divided by the expected number of tubes <NUM>. In this way, virtual bands are obtained (in the example above, five bands with a value of <NUM> clocks) in each of which the system waits for the detection of an RFID tag to be read.

The algorithm reconstructs the correct order of the RFID tags read following the first reading of the UNIQUE CODE associated with the tag.

Having a counter allows for imperfect or missing tube conditions or other inconsistencies to be recognized; in the example table, the detection of the RFID tag associated with the fourth reel of thread was absent.

The tracking system according to this invention provides for a data exchange with the automation system. The on-board electronic system is designed to exchange data with standard industry protocols with the outside. In this way it is possible to connect a PC and/or a PLC, and therefore a DATABASE.

The tracking system according to this invention also provides for the possibility of writing on the RFID tag of the tube <NUM>. In this way, it is possible to trace the path of the reel of thread <NUM> in a more complete way, for example by writing the date and time of production, the machine and position of origin, the rise in production, etc..

Innovatively, a device <NUM> for automatically tracing a reel of thread <NUM>, the related machine, the related system, and the related automatic tracing method, make it possible to automate the tracing of the path of the reel of thread <NUM> in an industrial plant, and thus make it objective and rapid.

Advantageously, the system according to this invention allows the automation system to maintain high performance because the "doffer," equipped with a reel handling support with a device <NUM> for tracking, may;.

Claim 1:
An automatic reading device (<NUM>) for tracking reels of thread (<NUM>) with a tube (<NUM>) provided with an RFID label (<NUM>), comprising:
- an antenna (<NUM>);
- a reader (<NUM>), connected to the antenna (<NUM>) by means of a connection cable (<NUM>), adapted to exchange information with an RFID label (<NUM>) by means of the antenna (<NUM>) ;
- an electronic system (<NUM>), connected to the reader (<NUM>), comprising a central processing unit;
- a reel handling support (<NUM>) provided with a tip (<NUM>) on which a plurality of reels of thread (<NUM>) with a tube (<NUM>) provided with an RFID label (<NUM>) may be inserted in sequence, and wherein the tip (<NUM>) is the antenna (<NUM>); characterized in that the antenna (<NUM>) comprises a head (<NUM>) provided with an internal seat (<NUM>) in which an antenna body (<NUM>) is accommodated, said seat (<NUM>) being closed at the rear by a screen (<NUM>).