Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
(OP)
Hello, I'm a wire-knitting machine operator with very little knowledge on circuits. I want to install a system on each one of the machines so that when one of the wires feeding the machine breaks the machine shuts down.
My idea is to install a low voltage circuit that is closed with the wire being knitted(.011" and .006" 304Lss wire), so when the wire breaks it opens the circuit de-energising a relay coil, thus opening a NO contact connected in series with the power source, shutting off the machine.
Some questions I have:
-Is my idea feasible?
-How can I get the power for this low voltage circuit? What kind of components do I need? The machines have 180VDC motors and my power supply is 220VAC.
Any comments will be highly appreciated. I got many machines and a solution to this problem will decrease the downtime a lot.
Thanks a lot.
My idea is to install a low voltage circuit that is closed with the wire being knitted(.011" and .006" 304Lss wire), so when the wire breaks it opens the circuit de-energising a relay coil, thus opening a NO contact connected in series with the power source, shutting off the machine.
Some questions I have:
-Is my idea feasible?
-How can I get the power for this low voltage circuit? What kind of components do I need? The machines have 180VDC motors and my power supply is 220VAC.
Any comments will be highly appreciated. I got many machines and a solution to this problem will decrease the downtime a lot.
Thanks a lot.





RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
The most obvious sensor would be two contacts bridged by the metal wire. The less obvious problem is that it might not be sufficiently reliable. Metal on metal contacts are a science unto themselves, not to mention wear out.
A better sensor might be something activated by weight or tension. Then you simply string the wires through the loops and they apply sufficiently force to activate a simple switch. Obviously this is going to require N sensors where N is probably a large number.
Perhaps there's a way to detect any broken wire when it falls down, and then one sensor per machine might be possible.
Whatever sensor you use needs to be wired into an intelligent circuit that imposes a time delay before reacting.
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
Weights or tensioners as suggested might work. Optical sensor may be another method.
Get some help from someone experienced in this area. You are working with some pretty good voltages and large motors.
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
Mike Halloran
Pembroke Pines, FL, USA
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
I'll go from here for now...thx
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
Etc.
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
Momentary dead man type bypass is a good suggestion if needed.
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
Thank you all for your answers. Attached is the circuit diagram I came up with. As a I told you before I don't know much about electric circuits, but my idea it to have everything ready for the electrician to come in and hook things up.
The relay and the lever micro switch (to work as a tension sensor) are these.
Switch: Z-15HW78-B (Omron)
SS Relay: CSW2410 (Crydom)
The motor is 180VDC, 5amp.
I'd really appreciate your comments on the circuit and components.
Thanks.
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
But if that's not a problem, then... ...it's not a problem.
Should you add a key-operated bypass switch in case it doesn't work and you require production to resume while you troubleshoot?
RE: Feeding-wire sensor for wire-knitting machines. Relay circuit in mind.
I don't think the wire tension variations will be a problem since the wire will pass through a loop at the end of the switch lever. The only possible way to trigger the circuit should be by wire breakage.
The key-operated bypass I think it's absolutely necessary. I'll include it in the circuit.
Thank you for your inputs.