Method of automating and optimizing coil formation in a wire rod line cooling conveyor

A method as implemented by a processor configured to automate and optimize coil formation in a wire rod cooling conveyor, the method comprising:

• (a) receiving a speed of a material entering a laying head as measured by a speed measuring device;
• (b) computing an optimal speed of the laying head as a function of the following parameters:
• the speed of the material entering the laying head, a laying head ring diameter, and a gear ratio associated with the laying head;
• and
• (c) outputting one or more instructions based on the computed optimal speed to a motor associated with the laying head to match the speed of the material entering the laying head, wherein the processor dynamically computes the optimal speed of the laying head as the speed of the material changes.

A method as implemented by a processor configured to automate and optimize coil formation in a wire rod cooling conveyor, the method comprising:

• (a) receiving a speed of a material entering a laying head as measured by a speed measuring device;
• (b) computing an optimal speed of the laying head as a function of the following parameters:
• the speed of the material entering the laying head, a laying head ring diameter, and a gear ratio associated with the laying head;
• (c) outputting one or more instructions based on the computed optimal speed to a motor associated with the laying head to match the speed of the material entering the laying head, wherein the processor dynamically computes the optimal speed of the laying head as the speed of the material changes;
• (d) receiving a feedback input from a camera monitoring indicating a coil pattern is not central;
• and
• (e) incrementally adjusting the optimal speed by a pre-determined amount until the feedback input from the camera indicates that the coil pattern is central.

A system for automating and optimizing coil formation in a wire rod cooling conveyor comprising:

• (a) a speed measuring device measuring a speed of a material entering a laying head;
• (b) a processor that:
• (1) receives, as input, the speed measured in (a), (2) computes an optimal speed of the laying head based on the received speed of the material entering the laying head;
• wherein the processor dynamically computes the optimal speed of the laying head as the speed of the material changes;
• and
• (c) a camera, the camera monitoring actual ring formation on the wire rod cooling conveyor at an exit point of the laying head and outputting a feedback signal to the processor when a coil pattern is not central;
• and
• wherein the processor incrementally adjusts the optimal speed by a pre-determined amount until the feedback signal from the camera indicates that the coil pattern is central.