Method for managing operating data in a textile device equipped with a plurality of yarn feeders

Abstract

The present application relates to a method for managing operating data in a textile plant equipped with a plurality of yarn feeders. The textile plant is provided with textile machines (KM' and KM") fed by a plurality of yarn feeders (A1', A2',..., An' and A1", A2",..., An", B1', B2',..., Bn' and B1", B2",..., Bn"), in order to exchange operating data, the yarn feeders are connected to a field bus (FB', FB'), which is connected to a local network (FN) by means of a gateway (GW', GW"). The gateway (GW', GW") is programmed to periodically read from the yarn feeders (A1', A2',..., An', B1', B2',..., Bn' and A1", A2",..., An", B1", B2",..., Bn") operating data relating to process parameters and send them to a server (SS), which is programmed to organize and record the operating data in a database (DB) for subsequent maintenance analysis and / or predictive analysis and / or diagnostic analysis.

Description

[0001] This invention relates to a method for managing operational data in a textile apparatus equipped with a plurality of yarn feeders.

[0002] As is well known, in a typical textile apparatus, multiple yarns can be supplied to a textile machine (e.g., a knitting machine) via a corresponding yarn feeder of the so-called accumulation type or positive type.

[0003] A typical accumulator yarn feeder may include a drum adapted to support multiple yarn turns wound on it to form a reserve. Yarn unwinding from the drum according to requirements from the textile machine passes through a weft braking device, which controls its tension based on signals received from a load cell. When the drum is empty, fresh yarn is picked up from an upstream spool and wound onto the drum by a weft winding motor via a flywheel or by rotating the drum itself.

[0004] Active yarn feeders typically feature a motorized reel on which yarn is repeatedly wound (e.g., 3 or 4 turns) to adhere to it through friction. By rotating the reel, the yarn is unwound from the upstream spool and supplied to the downstream textile machine. During processing, the reel speed can be adjusted based on signals received from a force sensor that measures the tension of the yarn supplied to the textile machine to stabilize it at a fixed value or a user-defined profile.

[0005] Remote control of yarn feeders, especially in the field of knitting machines, is well-known. Typically, to exchange operational data, all yarn feeders supplying yarn to the same textile machine are connected to a fieldbus (usually a CAN bus), which is then connected to a local network (usually RJ-45, 802.X Wi-Fi, or high-speed Ethernet) via a gateway. Terminals connected to the local network, such as personal computers, laptops, and tablets, are configured with applications for communicating with the gateway (usually via TCP / IP).

[0006] The aforementioned network architecture makes it possible to remotely monitor and modify various parameters (such as supply tension) that are useful in optimizing the yarn supply process.

[0007] The object of the present invention is to provide a method for managing operational data in textile apparatus of the above type, which makes it possible to further improve the performance of the textile apparatus relative to known solutions.

[0008] In this regard, the objective of the present invention is to provide a method for managing operational data in a textile apparatus, which can be easily implemented.

[0009] Another objective of this invention is to provide a method for managing operational data in textile equipment that is low-cost and has specific applications.

[0010] This objective and these and other goals are achieved by means of methods having the features described in this application, as will become more apparent below, while the dependent claims define other advantageous features of the invention, although they are dependent features. Attached Figure Description

[0011] The invention will now be described in more detail with reference to some preferred, but not exclusive, embodiments thereof, which are illustrated in the appendix. Figure 1 To illustrate with non-restrictive examples, see Appendix Figure 1 This is a block diagram of a textile apparatus that applies the method according to the present invention.

[0012] First refer to Figure 1 In a typical textile apparatus 10, multiple yarns can be supplied to one or more textile machines, such as one or more knitting machines, via corresponding yarn feeders.

[0013] exist Figure 1 In the example, there are two knitting machines, KM' and KM'', each of which is supplied with a corresponding set of yarn feeders. For each of the knitting machines KM' and KM'', some yarn feeders indicated by the reference numerals A1', A2', ..., An' and A1'', A2'', ..., An'' are so-called cumulative type, while other yarn feeders indicated by the reference numerals B1', B2', ..., Bn' and B1'', B2'', ..., Bn'' are also so-called cumulative type.

[0014] In a manner known per se, a typical accumulator yarn feeder may include a drum adapted to carry multiple yarn turns wound on itself to form a yarn reservoir. Yarn unwound from the drum according to the requirements of the textile machine passes through a weft braking device that controls its mechanical tension based on a signal received from a force sensor. When the drum is emptied, new yarn is drawn from an upstream spool and wound onto the drum by a weft winding motor via a flywheel or by rotating the drum itself. For example, an accumulator yarn feeder of the above type is described in EP 3608460 B1 in the name of the same applicant.

[0015] Active yarn feeders typically feature a movable spool on which yarn is repeatedly wound (e.g., 3 or 4 turns) to adhere to it via friction. By rotating the spool, the yarn is unwound from an upstream bobbin and supplied to the downstream textile machine. During processing, the speed of the spool can be adjusted based on a signal received from a force sensor that measures the tension of the yarn supplied to the textile machine to stabilize it at a fixed value or a user-defined curve. For example, an active yarn feeder of this type is described in EP 3257984 B1, in the name of the same applicant.

[0016] To exchange operational data, all yarn feeders supplying yarn to the same textile machine KM' or KM'' are connected to the corresponding fieldbus FB', FB'' (usually a CAN bus). This fieldbus FB', FB'' (usually a CAN bus) is connected to the local network FN (usually RJ-45, Wi-Fi 802.X high-speed Ethernet) via the corresponding gateway GW', GW''. Terminals (e.g., personal computers PCs and / or other control devices, such as laptops, tablets, etc. (not shown)) are connected to the local network FN. All terminals are configured with applications for communication (usually via TCP / IP protocol) with the gateway GW', GW''.

[0017] In a manner known per se, the aforementioned network architecture makes it possible to remotely monitor and modify various parameters (such as the supply tension of each yarn feeder) that are useful for optimizing the yarn supply process.

[0018] According to the present invention, in order to further improve the performance of the textile apparatus relative to known solutions, each of the gateways GW', GW'' is programmed to periodically read operational data related to at least one process parameter from the yarn suppliers A1', A2', ..., An', B1', B2', ..., Bn' and A1'', A2'', ..., An'', B1'', B2'', ..., Bn'', and send them to the server SS, which is programmed to organize and record the operational data in a database DB for subsequent maintenance analysis and / or predictive analysis and / or diagnostic analysis.

[0019] The reading intervals for gateways GW' and GW'' can include, for example, between a few seconds and a few minutes (e.g., 1 minute).

[0020] For example, some process parameters that can be periodically read by gateways GW' and GW'' are: yarn supply speed, torque transmitted to the shaft of the weft winding motor in the cumulative yarn supply, the tension read and / or the desired tension of the tension control system, bus voltage, characteristic data of sensors on the supply or along the supply line (e.g., compensation current applied to the photoelectric emitter in the case of phototube sensors), yarn consumption, etc.

[0021] Advantageously, upstream of the server SS, the message broker MB collects and distributes data from textile machines KM' and KM'' identified by the corresponding topics.

[0022] Advantageously, the operational data in the database DB is analyzed in the analysis block SA by means of algorithms configured to perform the aforementioned maintenance analysis and / or predictive analysis and / or diagnostic analysis.

[0023] During maintenance analysis, the value of each relevant process parameter of interest in the yarn feeder is compared to the average value of the same process parameter in other yarn feeders. If the difference exceeds a specific threshold indicating a possible anomaly, an alarm is generated on the operator's terminal PC connected to the local network FN.

[0024] In predictive analytics, process parameters of interest are analyzed to predict future failures of components associated with the yarn feeder, and in the event of a potential failure, messages are generated that recommend replacement of the components at risk in order to avoid impairing the productivity of the textile equipment.

[0025] In diagnostic analysis, process parameters are analyzed to identify any inefficiencies and to provide operators with instructions on any corrections that can be applied to the process parameters themselves to improve performance. For example, some controllable process parameters include the output of the textile machine, the number of alarms or errors generated by the yarn feeder within a preset time period, and other similar parameters.

[0026] Advantageously, the operational data recorded in the database DB, along with the results of the aforementioned maintenance analysis and / or predictive analysis and / or diagnostic analysis, are displayed on the interface system FE downstream of the analysis block SA. The interface system FE may advantageously include a web portal with dedicated access credentials.

[0027] As will be readily understood by those skilled in the art, all of the aforementioned software / hardware devices / components can be separated or combined into a single device, which can be virtual or physical, depending on the scope of the data and the scalability of the system.

[0028] Furthermore, the software components can be deployed on a local network FN, or preferably on a network such as... Figure 1 In the cloud architecture shown, the high-speed network FN is separated from the cloud CL by a firewall FW. In this last case, clients C1, C2, ..., Cn can advantageously access the analysis results from anywhere by using a regular web browser to access the interface system FE via a public network (usually the Internet).

[0029] The following describes some examples of applications of the method according to the present invention.

[0030] As is well known, yarn feeders associated with textile machines can be divided into multiple groups, each group of yarn feeders being configured with the same parameters, such as the same supply tension.

[0031] For example, the 84 yarn feeders associated with a single textile machine can be divided into four groups, with 21 feeders in each group, wherein:

[0032] Group 1 includes feeders numbered 1, 5, 9, etc.

[0033] Group 2 includes feeders numbered 2, 6, 10, etc.

[0034] Group 3 includes feeders numbered 3, 7, 11, etc.

[0035] Group 4 includes feeders numbered 4, 8, 12, etc.

[0036] In a first example of the application of the method according to the invention, it refers to an accumulator yarn feeder equipped with a movable flywheel to wind yarn turns onto a drum. An excessive value of torque transmitted by the weft winding motor relative to the average value among the same group of yarn feeders may indicate the degree of criticality at the point where the yarn enters the yarn guide tube at the feeder inlet.

[0037] The severity of the hazard could be due to, for example, a yarn insertion angle that deviates too far from the ideal yarn insertion angle (0° relative to the axis of the yarn guide tube), or a malfunction of the yarn guide tube (in which the yarn exits from the yarn guide tube, generating friction, etc.).

[0038] The system can be programmed to alert the operator in such situations, enabling the operator to control the insertion of the yarn into the specific feeder and prevent adverse conditions caused by overheating of the weft winding motor and excessive yarn tension upstream of the feeder (which carries the risk of yarn breakage).

[0039] In a second example of the application of the method according to the invention, it again refers to the cumulative yarn feeder. An excessively high value (e.g., >40mA) of the compensation current on the turn count photoelectric element, relative to the average value among the same group of yarn feeders, may indicate excessive dirt or dust on the photoelectric element. This situation may alter the count of the number of turns wound. The system can be programmed to alert the user in such cases, allowing the user to clean the sensor.

[0040] In a third example of the application of the method according to the invention, it again refers to the cumulative yarn feeder, where a measurement of yarn consumption that differs too much from the values ​​measured on other yarn feeders in the same group may indicate incorrect operation of the turns-counting photoelectric element. The system can be programmed to alert the user in such cases so that, if the problem persists, the user can replace the turns-counting photoelectric element or the feeder.

[0041] In a fourth example of the application of the method according to the invention, an excessively high value (e.g., >40mA) of the compensation current on the photoelectric element detecting potential yarn breakage at the inlet of the feeder, relative to the average value in the same group of yarn feeders, may indicate excessive dirt or dust on the photoelectric element. This situation may lead to frequent false alarms. The system can be programmed to alert the user in such situations, allowing the user to clean the sensor.

[0042] In a fifth example of the application of the method according to the invention, a significant difference between the degree of braking applied and the average degree of braking applied in the same group of yarn feeders set at the same reference tension may indicate an operational malfunction in the force sensor (e.g., excessive offset or failure of the force sensor). The system can be programmed to alert the user in such cases, allowing the user to check or replace the force sensor.

[0043] While preferred embodiments of the invention have been described with reference to some application examples, those skilled in the art will certainly apply different modifications or variations within the scope of the claims; furthermore, all details can be replaced with other technically equivalent elements.

[0044] In the example embodiments shown, the features given for a particular example may actually be interchanged with other different features present in other example embodiments.

Claims

1. A method for managing operational data in a textile apparatus, the textile apparatus comprising at least one textile machine supplied by a plurality of yarn suppliers, wherein, for exchanging operational data, the yarn suppliers are connected to a fieldbus (FB', FB''), the fieldbus being connected to a local network (FN) via a gateway (GW', GW''), wherein, The gateways (GW', GW'') are programmed to periodically read operational data related to at least one process parameter from the yarn feeder and send the operational data to a server (SS), which is programmed to organize and record the operational data in a database (DB) for subsequent maintenance analysis and / or predictive analysis and / or diagnostic analysis; wherein the operational data in the database (DB) is analyzed in an analysis block (SA) by means of an algorithm configured to perform the maintenance analysis and / or predictive analysis and / or diagnostic analysis.

2. The method according to claim 1, characterized in that, The process parameters include at least one of the following: yarn supply speed, torque transmitted to the shaft of the weft winding motor in the cumulative yarn supply, tension and / or desired tension read from the system for controlling the tension of the yarn, bus voltage, characteristic data of at least one sensor on the supply or along the supply line, and yarn consumption.

3. The method according to claim 1 or 2, characterized in that, Upstream of the server (SS), the message broker (MB) collects and distributes data from the textile machine (KM', KM'') identified by the corresponding topic.

4. The method according to claim 1 or 2, characterized in that, The maintenance analysis includes the following steps: The values ​​of the process parameters of interest associated with a yarn feeder belonging to a group of yarn feeders configured with the same parameters are compared with the average value of the same process parameters of other yarn feeders in the same group. If the difference between the compared values ​​exceeds a specific threshold indicating a possible anomaly, an alarm is generated on the terminal (PC) connected to the local network (FN).

5. The method according to claim 3, characterized in that, The maintenance analysis includes the following steps: The values ​​of the process parameters of interest associated with a yarn feeder belonging to a group of yarn feeders configured with the same parameters are compared with the average value of the same process parameters of other yarn feeders in the same group. If the difference between the compared values ​​exceeds a specific threshold indicating a possible anomaly, an alarm is generated on the terminal (PC) connected to the local network (FN).

6. The method according to claim 4, wherein, The yarn feeder is an accumulator feeder, characterized in that the process parameters are at least one of the following: the torque transmitted by the weft winding motor, the compensation current on the turn counting photoelectric element that counts the number of turns of yarn unwound from the drum, and the amount of yarn consumed.

7. The method according to claim 5, wherein, The yarn feeder is an accumulator feeder, characterized in that the process parameters are at least one of the following: the torque transmitted by the weft winding motor, the compensation current on the turn counting photoelectric element that counts the number of turns of yarn unwound from the drum, and the amount of yarn consumed.

8. The method according to claim 4, characterized in that, The process parameters are at least one of the applied braking degree and the tension measured by a force sensor adapted to measure the tension of the yarn downstream of the yarn feeder.

9. The method according to claim 5, characterized in that, The process parameters are at least one of the applied braking degree and the tension measured by a force sensor adapted to measure the tension of the yarn downstream of the yarn feeder.

10. The method according to claim 1, characterized in that, The predictive analysis includes the following steps: Analyze the process parameters of interest to predict future failures of components associated with the yarn feeder, and In the event of a potential failure, a message is generated that recommends replacing the component at risk.

11. The method according to claim 1, characterized in that, The diagnostic analysis includes the following steps: Analyze the process parameters to identify any inefficiencies, and Provide operators with instructions on any corrections to be applied to the process parameters themselves in order to improve performance.

12. The method according to claim 11, characterized in that, The process parameters include at least one of the following: the output of the textile machine, the number of alarms or errors generated by the yarn supplier within a preset time period.

13. The method according to claim 1, characterized in that, The operational data recorded in the database (DB) and the results of the maintenance analysis and / or predictive analysis and / or diagnostic analysis are visually displayed on the interface system (FE) downstream of the analysis block (SA).

14. The method according to claim 13, characterized in that, The interface system (FE) includes a web portal with dedicated access credentials.

15. The method according to claim 1, characterized in that, The software components suitable for providing the method are arranged on the local network (FN).

16. The method according to claim 1, characterized in that, The software components suitable for providing the method are arranged in a cloud architecture.

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