Wheel changer success rate statistical method and device

Abstract

This invention discloses a method and apparatus for calculating the success rate of an automatic wheel changer. The success rate calculation method includes the following steps: after each automatic winding machine reaches a fixed length in automatic mode, the automatic full-wheel count is incremented by one; timing begins, and the restart time for this wheel change is recorded; the restart time is compared with a preset successful wheel change time; if the restart time falls within the preset successful wheel change time, the wheel change is classified as a successful wheel change, and the automatic wheel change count is incremented by one; the percentage of the automatic wheel change count to the automatic full-wheel count is calculated to obtain the automatic wheel change success rate. This invention provides a method and apparatus for calculating the success rate of an automatic wheel changer, which can quickly determine the efficiency of the automatic wheel changer.

Description

Technical Field

[0001] This invention relates to a method and apparatus for calculating the success rate of an automatic wheel changing machine, belonging to the field of electrical control technology for automated equipment. Background Technology

[0002] An automatic reel-changing take-up machine is an automated device that automatically knots, unloads finished products from a full reel, loads an empty I-beam reel, winds the yarn onto an empty reel, and then proceeds to the next production cycle after taking up the yarn to a fixed length. It reduces manual labor and its continuous production efficiency is higher than manual operation. However, the automatic reel-changing process involves multiple mechanical components, cylinder drives, and various electrical switches. Accurate debugging and consistent maintenance are essential to maintain high efficiency. Automatic reel-changing machines with substandard efficiency require close monitoring and maintenance; those with acceptable efficiency require only minor maintenance (insufficient precision in some adjustment points can cause occasional failures that are difficult to pinpoint); and those with excellent efficiency require no maintenance. Currently, there is a pressing need for a method to quickly determine the efficiency of an automatic reel-changing machine. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide a method and device for statistical analysis of the success rate of automatic wheel changers, which can quickly determine the efficiency of automatic wheel changers.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0005] A method for calculating the success rate of an automatic wheel changer includes the following steps:

[0006] After each time the take-up machine runs to a fixed length in automatic mode, the automatic full-wheel count is incremented by one.

[0007] Start timing and record the restart time for this wheel change;

[0008] The restart time for wheel replacement is compared with the preset successful wheel replacement time. If the restart time for wheel replacement is within the preset successful wheel replacement time, the wheel replacement start is classified as a successful wheel replacement and the automatic wheel replacement count is incremented by one.

[0009] The percentage of automatic wheel-changing counts relative to the automatic full wheel counts is used to determine the automatic wheel-changing success rate.

[0010] The preset successful wheel replacement time is set to 2 minutes.

[0011] The automatic wheel-changing success rate includes the overall automatic wheel-changing success rate, the success rate of automatic wheel-changing per number of rounds, and the success rate of automatic wheel-changing per multiple ten rounds. The overall automatic wheel-changing success rate is the percentage of the cumulative value of the automatic wheel-changing count to the cumulative value of the automatic full-round count. The success rate of automatic wheel-changing per number of rounds is the percentage of the increase in the automatic wheel-changing count during the non-zero units digit of the automatic full-round count. The success rate of automatic wheel-changing per multiple ten rounds is calculated by taking the most recent fifty rounds, resulting in five sets of success rates for automatic wheel-changing per multiple ten rounds.

[0012] An automatic wheel-changing machine success rate statistics device includes:

[0013] The automatic full-reel counting module is used to increment the automatic full-reel count by one after each time the take-up machine runs to a certain length in automatic mode;

[0014] The wheel-changing time recording module is used to start timing and record the wheel-changing restart time;

[0015] The wheel replacement start classification module is used to compare the wheel replacement restart time with the preset successful wheel replacement time. If the wheel replacement restart time meets the preset successful wheel replacement time, the wheel replacement start is classified into the successful wheel replacement and the automatic wheel replacement count is incremented by one.

[0016] The automatic wheel-changing success rate calculation module is used to calculate the percentage of automatic wheel-changing counts to automatic full wheel counts, thus obtaining the automatic wheel-changing success rate.

[0017] The full wheel counting module, wheel replacement recording module, wheel replacement start classification module, and automatic wheel replacement success rate calculation module are integrated into the PLC control system.

[0018] The beneficial effects of this invention are as follows: This invention provides a method and apparatus for calculating the success rate of an automatic wheel changer. First, the automatic full wheel count is obtained, then the automatic full wheel count is obtained again, and finally, the percentage of the automatic wheel change count to the automatic full wheel count is calculated to obtain the automatic wheel change success rate. The entire process can be automatically statistically analyzed and calculated by a control system such as a PLC, enabling real-time and rapid acquisition of the automatic wheel change success rate. Debugging personnel can determine the wheel change efficiency of the take-up machine based on the automatic wheel change success rate data and can choose to maintain and debug from simple to complex, from frequent to occasional issues, thereby reducing a lot of unnecessary maintenance and debugging time while maintaining the continuity of production to the greatest extent. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the screen editing software of the present invention;

[0020] Figures 2 to 4 This is a schematic diagram illustrating the on-site operation effect of the equipment according to the present invention;

[0021] Figure 5 This is a flowchart illustrating a specific implementation of the present invention. Detailed Implementation

[0022] The present invention will be further described below with reference to the accompanying drawings. The following embodiments are only used to illustrate the technical solution of the present invention more clearly, and should not be used to limit the scope of protection of the present invention.

[0023] like Figure 5 As shown, this invention discloses a method for statistically analyzing the success rate of an automatic wheel-changing machine, comprising the following steps:

[0024] Step 1: In manual mode, after reaching the set length, the "① Manual Full Reel" counter increments by one; in automatic mode, after reaching the set length, the "② Automatic Full Reel" counter increments by one. See the detailed operation interface for details. Figure 1 .

[0025] Step two: Start timing and record the restart time for this wheel change.

[0026] Step 3: Compare the reel change restart time with the preset successful reel change time. If the reel change starts within 2 minutes of the take-up machine reaching the set length in automatic mode, this reel change start is classified as a successful reel change, and the "③ Automatic reel change within 2 minutes" count is incremented by one. The automatic reel change take-up take 100 to 110 seconds from taking up the line to the set length and then restarting; a reel change completed within 2 minutes is considered a successful reel change. Additionally, if the take-up machine restarts within 2-10 minutes of reaching the set length, the "⑤ 2-10 minute reel change" count is incremented by one; if it restarts after more than 10 minutes, the "⑥ More than 10 minutes reel change" count is incremented by one; if the take-up machine starts reel change within 2 minutes of reaching the set length in manual mode, the "⑦ Manual reel change within 2 minutes" count is incremented by one.

[0027] Step four: Calculate the percentage of automatic wheel-changing counts relative to the automatic full-wheel counts to obtain the automatic wheel-changing success rate. The automatic wheel-changing success rate includes the overall automatic wheel-changing success rate, the success rate for a single round of wheel changes, and the success rate for rounds of ten. The overall automatic wheel-changing success rate (i.e.,...) Figure 1 The success rate of automatic wheel changing (④) is equal to the count of "automatic wheel changing within 2 minutes" divided by the count of "automatic full wheel" multiplied by 100%.

[0028] The success rate of automatic wheel switching in a given round is the percentage increase in the automatic wheel switching count relative to the non-zero units digit of the automatic full wheel count during the automatic full wheel counting process. Data "⑧ Recent Automatic Full Wheel Count" refers to the units digit in data ②; data ⑨ refers to the number of automatic wheel switching operations within 2 minutes in data ⑧; the success rate of automatic wheel switching in a given round (i.e., ...) is... Figure 1 The data "⑩ Recent Automatic Wheel Changing Success Rate" is equal to data ⑨ divided by data ⑧ multiplied by 100%.

[0029] The success rate of automatic wheel replacement for multiples of ten is the percentage increase in the automatic wheel replacement count relative to multiples of ten during the automatic full wheel counting process. When data ⑧ reaches 10, data ⑨ will be transferred to the data " In the "Number of automatic wheel changes within 2 minutes in the most recent set of ten rounds"; original data Input data Chinese; Original Data Input data Chinese; Original Data Input data Chinese; Original Data Input data Then set data ⑧ and ⑨ to zero. The success rate of automatic wheel switching over multiple rounds is calculated by taking the most recent fifty rounds, resulting in five sets of success rates for automatic wheel switching over multiple rounds.

[0030] Long press " "Data Reset" will reset all data on the current screen to zero after 5 seconds. The system will record the current reset time. Since the data reset, the total number of full reels produced by the take-up machine = ① + ② = ③ + ⑤ + ⑥ + ⑦. Data ④ reflects the overall success rate of reel replacement. Data ⑧, ⑨, ... This reflects the recent successful wheel replacement results for automatic full-wheel operation (50-59). (Reference) Figure 2 The automatic mode produced a total of 1652 rounds (data ②), with an automatic wheel-changing success rate of 97.58% in these 1652 rounds (data ④). Data ⑧ and ⑨ indicate that wheel changes were successful in 2 rounds between rounds 1651 and 1652. This indicates that 10 wheel replacements were successfully completed in rounds 1641-1650. (Data) This indicates that 10 wheel replacements were successfully completed between rounds 1631 and 1640. This indicates that a total of 9 wheel replacements were successfully completed between rounds 1621 and 1630. This indicates that 10 wheel replacements were successfully completed in rounds 1611-1620. (Data) This indicates that 10 rounds of wheel replacement were successfully completed in rounds 1601-1610.

[0031] Figure 2 This is a schematic diagram of the on-site equipment operation. This machine tool has stable wheel changing. Since the start of recording, it has automatically filled 1652 wheels and successfully changed 1612 wheels, with a wheel changing success rate of 97.58%. In the most recent 52 wheels, 51 wheels were successfully changed, requiring no maintenance or attention.

[0032] Figure 3 This diagram illustrates the operational status of the equipment on-site. The overall success rate of wheel replacement for this machine tool is 84.76%, which originally only required minor maintenance. However, recently, very few wheel replacements have been successfully completed out of 51, so the wheel replacement process needs to be closely monitored.

[0033] Figure 4 This is a schematic diagram of the on-site equipment operation. The overall success rate of wheel replacement for this machine tool is 86.47%. In the most recent fifth group of 10 wheels, only 5 wheels were successfully replaced. In the four groups of 10 wheels since the maintenance, 9 wheels have been successfully replaced in each group. Going forward, we only need to monitor the wheel replacement status during off-peak hours.

[0034] This invention also discloses an automatic wheel-changing machine success rate statistical device, comprising: an automatic full-wheel counting module, used to increment the automatic full-wheel count by one after each automatic winding machine reaches a fixed length in automatic mode; a wheel-changing time recording module, used to start timing and record the wheel-changing restart time; a wheel-changing start classification module, used to compare the wheel-changing restart time with a preset successful wheel-changing time, and if the wheel-changing restart time meets the preset successful wheel-changing time, then classify the wheel-changing start into successful wheel-changing and increment the automatic wheel-changing count by one; and an automatic wheel-changing success rate calculation module, used to calculate the percentage ratio of the automatic wheel-changing count to the automatic full-wheel count, thus obtaining the automatic wheel-changing success rate. Furthermore, the full-wheel counting module, wheel-changing recording module, wheel-changing start classification module, and automatic wheel-changing success rate calculation module are integrated into a PLC control system, and the entire automatic wheel-changing machine success rate statistical method is implemented through the PLC control system.

[0035] This invention uses a PLC to calculate, record, and statistically analyze the data for each round, especially the most recent 50 to 59 rounds of the take-up machine. This data is divided into six groups (one group for every ten rounds, plus another group for the last digit of the round number), and all data is displayed on the take-up machine screen. Later, the backend big data can be accessed via a network to directly understand the wheel-changing efficiency of all machine tools.

[0036] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A success rate statistics device for an automatic wheel changing machine, characterized in that: A method for calculating the success rate of an automatic wheel changer, the method comprising the following steps: After each time the take-up machine runs to a fixed length in automatic mode, the automatic full-wheel count is incremented by one. Start timing and record the time for wheel replacement and restart; The restart time for wheel replacement is compared with the preset successful wheel replacement time. If the restart time for wheel replacement is within the preset successful wheel replacement time, the wheel replacement start is classified as a successful wheel replacement and the automatic wheel replacement count is incremented by one. The success rate of automatic wheel changing is calculated by determining the percentage of automatic wheel changing counts relative to the automatic full wheel count. This success rate includes the overall automatic wheel changing success rate, the success rate for a specific number of rounds, and the success rate for rounds totaling ten. Specifically, the overall success rate is the percentage of the cumulative automatic wheel changing count relative to the cumulative automatic full wheel count; the success rate for a specific number of rounds is the percentage of the increase in the automatic wheel changing count during the non-zero units digit of the automatic full wheel count; and the success rate for rounds totaling ten is the percentage of the increase in the automatic wheel changing count during the tenth round of the automatic full wheel count. The statistical device includes: The automatic full-reel counting module is used to increment the automatic full-reel count by one after each time the take-up machine runs to a certain length in automatic mode; The wheel-changing time recording module is used to start timing and record the wheel-changing restart time; The wheel replacement start classification module is used to compare the wheel replacement restart time with the preset successful wheel replacement time. If the wheel replacement restart time meets the preset successful wheel replacement time, the wheel replacement start is classified into the successful wheel replacement and the automatic wheel replacement count is incremented by one. The automatic wheel-changing success rate calculation module is used to calculate the percentage of automatic wheel-changing counts to automatic full wheel counts, thus obtaining the automatic wheel-changing success rate.

2. The automatic wheel changing machine success rate statistics device according to claim 1, characterized in that: The preset successful wheel replacement time is set to 2 minutes.

3. The automatic wheel changing machine success rate statistics device according to claim 1, characterized in that: The success rate of automatic wheel changing in multiples of ten is calculated by taking the most recent fifty rounds, resulting in five sets of success rates for automatic wheel changing in multiples of ten.

4. The automatic wheel changing machine success rate statistics device according to claim 1, characterized in that: The automatic full wheel counting module, wheel changing time recording module, wheel changing start classification module, and automatic wheel changing success rate calculation module are integrated into the PLC control system.

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