A successful manufacturer of specialty industrial yarns makes fibreglass and glass thread products for applications in the automotive, aerospace, military and composite materials industries. To help maintain their high standards and minimise costly product returns, it established a goal of zero product defects. To meet this goal, the company needed an automated thread inspection system.
The challengeIndustrial spooling machines rotate constantly at high speed, making standard wired monitoring solutions difficult to implement. The lack of an auxiliary power supply necessitates an independently powered solution. A customised wired solution would require equipment designed specifically to work on rotating machinery, raising costs and complicating system design and operation.
The solutionThe SureCross DX80 FlexPower wireless network was the ideal solution. The node is protected by a rugged IP67 rated enclosure and deployed inside the winder. The open design of the node made it easy to integrate a third-party inductive proximity sensor into the solution. One internal battery supplies power to the node and the sensor and has an expected battery life of two or more years in this application.
System design was simple and effective. As the thread is spooled it passes through a die. In the event of a defect or a ‘blob’, the die will move. The movement is detected by the proximity sensor, communicated to the node and transmitted to a remotely located gateway. Because of the quick response time (65 ms), the system can be stopped almost as soon as the error has been detected, allowing the operator to remove the blob and save the spool.
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