Method for implementing a correct winding of a wire on a spool

Method for implementing a correct winding of a wire on a spool, said method comprising the following steps:

• (f1) setting the main geometrical data of the spool on an operation panel of the electronic control unit (by means of dedicated formulas or by means of manually entered data);
• (f2) loading a spool on the machine;
• (f3) acquiring the position of the spool flanges by means of a sensor;
• (f4) calculating the actual spool position and comparing it with the “spool data” set in advance in the electronic control unit in order to check whether the spool loading was successful and whether the spool is consistent with what expected;
• (f5) keeping on if the check is positive;
• or stopping and reporting the problem by means of an alarm signal;
• (f6) manually binding the wire to the spool;
• an operator starts the production by activating a specific command;
• (f7) detecting the dancer position and transforming the measured value into a measure of wire tension based on the geometry and structure of the dancer;
• (f8) calculating the servodiameter according to the spool data, the production data and the dancer position;
• and
• (f9) calculating the speed of the spool motor according to the servodiameter with the aim of maintaining a constant winding tension;
• said method being characterized in that it comprises a further step for calculating the angular speed of a motor displacing the wire dispensing device according to the wire winding step and according to the dancer error, detected by a position sensor that provides an analogical signal with respect to a zero position and to a tolerance value, in order to determine the presence of a possible “valley error”, or of a possible “peak error”;
• and in that if during the spool winding a “valley error” or a “peak error” is detected, the control device decides whether to slow down or to increase the speed of the wire dispensing device with the aim of filling the depression or skipping the peak.