PC Based Multi-Gage System for Wire Diameter Measurement

NORMAL OPERATION: All heads are simultaneously receiving all necessary operating waveforms from the shared sources at the PC. Then, in sequence, each gage head receives a pulse from the PC to trigger the LED light pulse which initiates the measurement on that head only. The returning pixel stream from the CCD (representing the diameter of the wire) is routed to shared A/D circuits within the PC. Microseconds later, the next pixel stream from the next head will follow. For each raw digital diameter reading, the gage calibration data for that head, stored on the hard drive, corrects the raw reading to produce the calibrated reading. This reading is compared to the target diameter, also stored on the hard drive, to produce the deviation data.

Continuing to take advantage of the increased cost/performance of the PC, a shared hard drive stores set-up, tolerances, and gage calibration data for all lines and provides a huge storage capacity for current and historical diameter data for all lines.

The color monitor displays performance data of all lines on a single screen with dedicated screens available to display detailed data for a single line. An example is an oscilloscope screen which can display the optical waveform of any gage head in order to see if the lens needs cleaned, or if the wire is out of the measurement zone, or if poor guide pulleys or misalignment is causing excessive vibration of the wire.

TOLERANCE ALARMS: One of the inputs to the set-up menu is an out-of-tolerance diameter (or deviation figure). When this parameter is reached or exceeded the system provides an alarm output capable of operating horns, beacons, or similar devices or a logic level output.

GAGEHEAD CALIBRATION: Initially, multipoint calibration is performed using many certified diameter wires over the range of the head. Corrections are stored permanently on the hard disk of the PC for that head serial number. In use, calibration can be bumped up or down to compensate for tension effects or for any other reason with no interruption of data flow.

Initial calibration can be restored with a single command.

All diameter data is correlated with spool length and time-of-day. The X axis of graphical displays of diameter deviation also uses spool length and/or time in order to simplify visual interpretation of trends and tolerance alarms and the spool where located. Spool changes and file numbers are clearly shown when scrolling along multiple spool displays for long term trend viewing.

PASSWORD PROTECTION: A password menu is provided to allow selection of the password and which functions to protect.

PLANT NETWORKS: Since the PC acts as the hub of the system in all operational respects, not jus as a data gatherer, all data and many internal system functions are available for viewing throughout the plant. Many of the set-up and tolerance parameters can be changed at selected stations and are password protected.