Yarn consumption monitoring method, system and computer readable medium for a knitting machine

Abstract

This invention relates to a method, system, and computer-readable medium for monitoring yarn consumption on a knitting machine, comprising: Step S1: obtaining the current number of knitted turns completed for the current knitted product and calculating the current number of knitted segments; Step S2: calculating the yarn consumption of various yarn types for each knitted segment based on preset style information; Step S3: converting the yarn consumption to the corresponding yarn feeders for each yarn type; Step S4: summing the yarn consumption of each yarn feeder within each knitted segment to obtain the current yarn consumption of each yarn feeder; Step S5: calculating the cumulative yarn consumption of the corresponding yarn feeder based on historical yarn consumption and the current yarn consumption; Step S6: determining whether knitted product production can continue based on the cumulative yarn consumption of the yarn feeders; if the determination is negative, issuing an alarm to replenish the yarn corresponding to the yarn feeder. This invention can accurately monitor the yarn consumption of a knitting machine using a low-cost data analysis method.

Description

Technical Field

[0001] This invention relates primarily to the field of knitted product manufacturing technology, and specifically to a method, system, and computer-readable medium for monitoring yarn consumption in a knitting machine. Background Technology

[0002] With the application and promotion of digital technology in knitted product production, knitting factories can monitor the working status of knitting machines, a technological advancement that has greatly boosted production efficiency. To further shorten the production cycle of knitted products and increase overall capacity, the knitting industry is actively seeking to reduce downtime caused by yarn depletion through intelligent and automated methods. Ideally, if accurate or approximate estimations of yarn consumption on the machines can be achieved, knitting factories can predict the optimal time for bobbin replacement in advance and arrange for automated guided vehicles (AGVs) or staff to transport spare bobbins to designated machine locations. This allows for timely bobbin replacement before yarn depletion, effectively shortening downtime due to yarn shortages and improving production efficiency.

[0003] Existing technology discloses a spandex yarn feeder (publication number: CN206188994U), which detects yarn consumption through a hardware device. Specifically, this spandex yarn feeder uses a built-in photoelectric sensor to detect the consumption of spandex yarn and reminds the user to replace the yarn or automatically stops the machine when the yarn is nearly exhausted. The application of this device has certain limitations. It not only increases the complexity of the yarn feeder design and manufacturing cost, but it is also primarily designed for spandex yarn and is difficult to directly apply to the detection of other types of yarn. Furthermore, its implementation relies on additional sensing accessories installed on the yarn feeding and conveying devices, which not only requires modification of existing equipment but also increases the complexity and cost of developing new equipment, and is not suitable for older knitting machines already in use.

[0004] In the actual production process of knitted products, many knitting factories still face the dilemma of not being able to accurately predict when to replace yarn bobbins. This often leads them to adopt a passive response strategy, that is, replacing yarn bobbins only after the machine stops due to yarn exhaustion, thus inevitably bearing the losses caused by decreased production efficiency. Currently, knitting factories cannot accurately monitor the yarn consumption of knitting machines in a low-cost manner. Summary of the Invention

[0005] The technical problem to be solved by this application is to provide a method, system and computer-readable medium for monitoring yarn consumption of knitting machines. Without the need for complex hardware modifications, the yarn consumption of knitting machines can be accurately monitored using low-cost data analysis methods. This method is applicable to various types of yarn and knitting machine equipment.

[0006] The technical solution adopted in this application to solve the above-mentioned technical problems is a method for monitoring the yarn consumption of a knitting machine, including: Step S1: Obtain the current number of knitting turns completed for the current knitting product, and calculate the current number of knitting segments based on the current number of knitting turns; Step S2: Calculate the yarn consumption of various yarn types in each knitting segment in the current number of knitting segments based on the preset style information of the knitting product; Step S3: Convert the yarn consumption of various yarn types in each knitting segment to the corresponding yarn feeder for each yarn type; Step S4: Sum the yarn consumption of each yarn feeder in each knitting segment to obtain the current yarn consumption of each yarn feeder; Step S5: Obtain the historical yarn consumption of each yarn feeder corresponding to historical knitting products, and calculate the cumulative yarn consumption of the corresponding yarn feeder based on the historical yarn consumption and the current yarn consumption; Step S6: Determine whether the production of knitting products can continue based on the cumulative yarn consumption of the yarn feeders. If the determination is yes, production continues and the process returns to step S1; if the determination is no, an alarm is triggered to replenish the yarn corresponding to the yarn feeder.

[0007] In one embodiment of this application, the preset style information includes yarn configuration information, which includes: the yarn feeders fd of each yarn feeder. i Each yarn nozzle fn ij Corresponding yarn number y ij Yarn type, net yarn weight (nw) ij yarn tube sp ij And the knitting segments of each individual knitted product during the production process. k Each yarn number (sn) within the yarn kr The corresponding theoretical consumption syw kr Where, subscript i represents the i-th yarn feeder, 1≤i≤n, and n represents the total number of yarn feeder paths; subscript j represents the j-th yarn nozzle, 1≤j≤m, and m represents the number of yarn nozzles that a single yarn feeder can support; subscript k represents the k-th knitting segment, 1≤k≤l, and l represents the total number of knitting segments; subscript r represents the r-th yarn type, 1≤r≤h, and h represents the number of different yarn types with different yarn numbers used in the knitting segment.

[0008] In one embodiment of this application, the yarn configuration information further includes: each knitting segment sg k The number of knitting loops to finish when the entire knitting is complete (in seconds) k Each knitted segment sg k The starting number of knitting loops (ssc) k , among which, ssc k =sec k-1 +1, ssc1 = 0.

[0009] In one embodiment of this application, in step S2, during the calculation of yarn consumption, the yarn consumption of various yarn types in each knitting segment is calculated in a manner that the yarn consumption of yarns with the same yarn number in a single knitting segment is proportional to the number of knitting loops completed in the single knitting segment.

[0010] In one embodiment of this application, if the current knitted product is a finished knitted product pr s In step S4, the current yarn consumption for each yarn feeder is calculated using the following formula.

[0011]

[0012] in, superscript sp ij This indicates the yarn bobbin corresponding to the yarn feeder; the subscript 's' indicates the finished product; 'l' indicates the total number of knitted segments; R kr y represents the yarn number used when knitting the k-th knitting segment. ij The number of identical yarn bobbins.

[0013] In one embodiment of this application, if the current knitted product is a knitted waste product pd d Then, in step S4, the step of summing the yarn consumption of each yarn feeder in each knitting segment to obtain the current yarn consumption of each yarn feeder includes: Step S4a: Calculate the first yarn consumption based on the number of completed knitting segments; Step S4b: Calculate the second yarn consumption based on the knitting segment where the product was discarded; Step S4c: Calculate the current yarn consumption of each yarn feeder using the following formula.

[0014]

[0015] in, This indicates the amount of the first yarn consumed; Indicates the consumption of the second yarn; superscript sp ij The subscript d indicates the yarn bobbin corresponding to the yarn nozzle; the subscript d indicates a defective product; the subscript d_f indicates that the defective product has been segmented; the subscript d_uf indicates that the defective product has not been segmented.

[0016] In one embodiment of this application, in step S4a, the first yarn consumption is calculated using the following formula.

[0017]

[0018] Where f-1 represents the number of complete knitting segments; R kr y represents the yarn number used when knitting the k-th knitting segment. ij The number of identical yarn bobbins.

[0019] In one embodiment of this application, in step S4b, the second yarn consumption is calculated using the following formula.

[0020]

[0021] Among them, PFC d This indicates the current number of knitting loops completed; the subscript f indicates the knitting segment where the product was discarded; ssc f This indicates the starting number of knitting loops when knitting segment f; sec f This indicates the cutoff number of knitting loops when knitting segment f; syw fr R represents the theoretical consumption of each yarn number when knitting segment f; fr y represents the yarn number used when knitting segment f. ij The number of identical yarn bobbins.

[0022] In one embodiment of this application, in step S5, the cumulative yarn consumption of the corresponding yarn feeder is calculated using the following formula.

[0023]

[0024] Among them, the superscript sp ij g1 represents the number of finished knitted products in the past and present knitted products; g2 represents the number of waste knitted products in the past and present knitted products. Indicates from the yarn tube sp ij The amount of yarn consumed in the production of the tth product since the replacement time.

[0025] In one embodiment of this application, step S6, the step of determining whether it is possible to continue producing knitted products, includes: calculating the net weight of the remaining yarn in the yarn bobbin corresponding to the yarn nozzle based on the cumulative yarn consumption of the yarn nozzle; if the net weight of the remaining yarn is less than a preset threshold, it is determined that it is impossible to continue producing knitted products; if the net weight of the remaining yarn is greater than or equal to the preset threshold, it is determined that it is possible to continue producing knitted products.

[0026] In one embodiment of this application, after the alarm prompts to replenish the yarn corresponding to the yarn feeder in step S6, the method further includes: step S6a: replacing the yarn feeder fn. ij Corresponding yarn tube sp ij Step S6b: Update the yarn bobbin sp ij Corresponding yarn number y ij Net weight of yarn (nw) ij Step S6c: Record the yarn package sp ij Replacement time stij Continue production and proceed to step S1.

[0027] To address the aforementioned technical problems, this application also proposes a yarn consumption monitoring system for a knitting machine, comprising: a memory for storing instructions executable by a processor; and a processor for executing the instructions to implement the yarn consumption monitoring method for the knitting machine as described above.

[0028] To address the aforementioned technical problems, this application also proposes a computer-readable medium storing computer program code, which, when executed by a processor, implements the above-mentioned method for monitoring yarn consumption in a knitting machine.

[0029] The technical solution of this application, by acquiring the number of knitting loops and knitting segments of the current knitted product in real time and combining it with preset style information, can accurately calculate the consumption of various yarn types within each knitting segment, and further convert these consumption amounts to specific yarn feeders. This real-time monitoring method ensures the accuracy and timeliness of yarn consumption data calculation during the production of knitted products. By converting the yarn consumption amount to each yarn feeder, it is possible to determine whether knitted product production can continue based on the cumulative yarn consumption of each yarn feeder, and to issue timely alarm prompts for replenishing yarn when production cannot continue, thus avoiding production interruptions due to yarn depletion and improving production efficiency. This application can accurately monitor the yarn consumption of knitting machines using a low-cost data analysis method without complex hardware modifications, and is applicable to various types of yarn and knitting machine equipment.

[0030] The technical solution of this application can be combined with an automated yarn feeding mechanism to further reduce the downtime of the machine due to yarn shortage and improve the machine's production efficiency. This application can be implemented through software functions and integrated into the production management software system of a knitting factory. In application, it does not rely on additional detection and sensing hardware and can be used to monitor the yarn consumption of old knitting machines that are already in production and use. Attached Figure Description

[0031] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the specific embodiments of this application will be described in detail below with reference to the accompanying drawings, wherein:

[0032] Figure 1 This is an exemplary flowchart of a yarn consumption monitoring method for a knitting machine according to an embodiment of this application;

[0033] Figure 2 This is an overall flowchart of the production of knitted products in a knitting factory according to one embodiment of this application;

[0034] Figure 3 This is a schematic diagram of a worker inputting yarn configuration information for a knitted product style in one embodiment of this application;

[0035] Figure 4 This is a schematic diagram of a worker inputting yarn consumption information for knitting segments in one embodiment of this application;

[0036] Figure 5 This is a diagram of the software system interface operated by a worker when performing a yarn-laying task in one embodiment of this application;

[0037] Figure 6 This is a system block diagram of a yarn consumption monitoring system for a knitting machine according to an embodiment of this application. Detailed Implementation

[0038] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the specific embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0039] Many specific details are set forth in the following description in order to provide a full understanding of this application. However, this application may also be implemented in other ways different from those described herein, and therefore this application is not limited to the specific embodiments disclosed below.

[0040] As indicated in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" are not specifically singular and may include plural forms. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.

[0041] Flowcharts are used in this application to illustrate the operations performed by the system according to embodiments of this application. It should be understood that the preceding or following operations are not necessarily performed in exact order. Instead, various steps can be processed in reverse order or simultaneously. Furthermore, other operations may be added to these processes, or one or more steps may be removed from these processes.

[0042] This application proposes a method for monitoring yarn consumption in knitting machines, which can be used to monitor the yarn consumption of each yarn bobbin on knitting machines such as circular knitting machines, seamless knitting machines, and sock knitting machines. This method can run internally within the knitting machine, for example, within the machine's controller, or it can run on a cloud platform. When the method runs on a cloud platform, the knitting machine's data and the cloud platform's data interact via a wireless network. For example, the cloud platform can include a private cloud, public cloud, hybrid cloud, community cloud, distributed cloud, interconnected cloud, and multiple clouds, or any combination thereof. This application does not limit the operating environment of the method for monitoring yarn consumption in knitting machines.

[0043] Figure 1This is an exemplary flowchart of a yarn consumption monitoring method for a knitting machine according to an embodiment of this application, with reference to... Figure 1 As shown, the yarn consumption monitoring method for a knitting machine in this embodiment includes the following steps:

[0044] Step S1: Obtain the current number of knitted turns completed for the current knitted product, and calculate the current number of knitted segments based on the current number of knitted turns.

[0045] Step S2: Calculate the yarn consumption of each yarn type in the current knitting segment based on the preset style information of the knitted product.

[0046] Step S3: Calculate the yarn consumption of each yarn type for each knitting segment and convert it to the corresponding yarn feeder for each yarn type.

[0047] Step S4: Sum the yarn consumption of each yarn feeder in each knitting segment to obtain the current yarn consumption of each yarn feeder.

[0048] Step S5: Obtain the historical yarn consumption of each yarn feeder corresponding to the historical knitted products, and calculate the cumulative yarn consumption of the corresponding yarn feeder based on the historical yarn consumption and the current yarn consumption.

[0049] Step S6: Determine whether knitted products can continue to be produced based on the cumulative yarn consumption of the yarn feeder. If the determination is yes, continue production and proceed to step S1; if the determination is no, issue an alarm to replenish the yarn corresponding to the yarn feeder.

[0050] The following details steps S1 to S6 described above:

[0051] In step S1, the current number of knitted turns completed for the current knitted product is obtained, and the current number of knitted segments is calculated based on the current number of knitted turns. For example, by obtaining the current number of knitted turns and the current number of knitted segments in real time, the production progress of the current knitted product can be accurately monitored.

[0052] In step S2, the yarn consumption of various yarn types in each knitting segment of the current knitting segment is calculated based on the preset style information of the knitted product. For example, the preset style information of the knitted product can be pre-entered by staff (e.g., sampling personnel, machine modification personnel, machine change personnel, etc.). For instance, before starting production of a certain style of seamless product or socks, the sampling personnel input the style information of the product through the software function module of the knitting machine system. During the production process of the knitted product, this application will calculate the yarn consumption of various yarn types on the knitting machine producing the product based on the preset style information entered by the sampling personnel.

[0053] In some embodiments, the preset style information includes yarn configuration information, which includes: the yarn feeders fd of each yarn feeder. i Each yarn nozzle fn ij Corresponding yarn number y ij Yarn type, net yarn weight (nw) ij yarn tube sp ij And the knitting segments of each individual knitted product during the production process. k Each yarn number (sn) within the yarn kr The corresponding theoretical consumption syw kr Where, subscript i represents the i-th yarn feeder, 1≤i≤n, and n represents the total number of yarn feeder paths; subscript j represents the j-th yarn nozzle, 1≤j≤m, and m represents the number of yarn nozzles that a single yarn feeder can support; subscript k represents the k-th knitting segment, 1≤k≤l, and l represents the total number of knitting segments, i.e., the number of knitting segments in the knitted product, and the yarn consumption used in knitting within the same segment is assumed to be uniform; subscript r represents the r-th yarn type, 1≤r≤h, and h represents the number of different yarn types with different yarn numbers used in the knitting segment.

[0054] For example, the yarn configuration information for producing a certain knitted product can be entered by the sample maker. Figure 3 This is a schematic diagram illustrating the yarn configuration information for a knitted product style input by a worker in one embodiment of this application. (Reference) Figure 3 As shown, area 310 illustrates one yarn feeder (i.e. Figure 3 The number of yarn feeders in the middle is 1) with 3 yarn feeders (i.e. Figure 3 The yarn feeders 1, 2, and 3 in the diagram correspond to the yarn number, yarn type, and yarn color information, respectively. For example, yarn feeder 1 corresponds to the yarn type "covered yarn," the yarn color "bare yarn," and the yarn number "Y010011." In practical applications, knitting factories assign different yarn numbers to different yarns, and it is necessary to ensure that the same type of yarn has a unique and identical yarn number.

[0055] In actual production, sample makers need to subdivide the knitting process of a knitted product into a sufficient number of knitting segments to ensure that the yarn consumption of yarns with the same yarn number can be considered uniform within the same knitting segment. Once all knitting segments are determined, the sample makers can also determine the theoretical weight information of the yarns with each yarn number required to knit each segment.

[0056] Figure 4 This is a schematic diagram illustrating the input of yarn consumption information for knitting segments by a worker in one embodiment of this application. For example, refer to... Figure 4 As shown, region 410 illustrates a knitted segment (i.e. Figure 4The information on the required yarn consumption in segment 1) is as follows: the number of knitting loops in segment 1 is 26, and 4 types of yarn need to be configured. For example, one of the yarns is set as follows: yarn type is "nylon", yarn color is "bare color", yarn number is "Y020073", and the theoretical consumption is "8.6 grams".

[0057] In some embodiments, the yarn configuration information further includes: sg for each knitted segment. k The number of knitting loops to finish when the entire knitting is complete (in seconds) k Each knitted segment sg k The starting number of knitting loops (ssc) k , among which, ssc k =sec k-1 +1, ssc1 = 0.

[0058] For example, suppose the knitting production process of a certain product can be divided into l knitting segments, and for any knitting segment sg k The yarn sn number used for knitting this segment. kr Consumption is considered uniform. When inputting knitting segment information, staff need to input the sg value for each knitting segment. k The number of knitting loops to finish when the entire knitting is complete (in seconds) k Then each knitting segment sg k The starting number of knitting loops (ssc) k =sec k-1 +1, ssc1 = 0; in addition, you also need to input sg for each knitted segment of the complete knit. k At that time, the yarn sn with different yarn numbers kr Theoretical consumption required syw kr .

[0059] In some embodiments, in step S2, during the calculation of yarn consumption, the yarn consumption of each yarn type in a single knitting segment is calculated in a manner that the yarn consumption of the same yarn number within a single knitting segment is proportional to the number of knitting loops completed within that single knitting segment. For example, the yarn consumption can subsequently be used to calculate the yarn consumption of each yarn feeder (fn). ij The corresponding yarn tube sp ij Total yarn consumption and net weight of remaining yarn ynw ij .

[0060] In actual production, after the sample maker inputs the style information, the knitting factory's modification personnel will modify the knitting machines used to produce that product according to the style. Specifically, the modification personnel will configure the corresponding yarns for each yarn feeder used to produce that product based on the style information, that is, place the corresponding yarn bobbins on the appropriate yarn racks and connect the yarns to the yarn feeders.

[0061] Assuming that producing a certain knitted product requires the use of n yarn feeders, the machine modification personnel need to modify the fd of each yarn feeder. i Each inner yarn nozzle fn ij All are configured with the corresponding yarn number y ij After configuring the yarn for the corresponding yarn feeders in each yarn feeder, the machine modification personnel input the fn values ​​for each yarn feeder in the knitting machine software system. ij The corresponding yarn tube sp ij This information allows the software system to obtain the yarn bobbin replacement time for each yarn feeder within each yarn feeder. ij and the net weight of the yarn (nw) ij Information.

[0062] After the modification and debugging are completed, the knitting machine can begin producing the product according to the preset knitting program. During the product production process, this application will calculate the spindle speed (SP) of each yarn bobbin in each yarn feeder based on the product production status of the knitting machine. ij Yarn consumption. For example, the products produced by the machine can be divided into two categories: finished knitted products and knitted waste products. This application will calculate the corresponding yarn consumption for each of these two categories.

[0063] In step S3, the yarn consumption of each yarn type in each knitting segment is converted to the corresponding yarn feeder for each yarn type. For example, this application will calculate the yarn feeder fn based on the corresponding configuration information of each yarn feeder and each yarn number. ij The corresponding yarn tube sp ij Yarn consumption.

[0064] In step S4, the yarn consumption of each yarn feeder within each knitting segment is summed to obtain the current yarn consumption of each yarn feeder. For example, this application will calculate the current yarn consumption separately for both finished knitted products and knitted waste.

[0065] In some embodiments, if the current knitted product is a finished knitted product... s In step S4, the current yarn consumption of each yarn feeder is calculated using the following formula (1).

[0066]

[0067] in, superscript sp ij This indicates the yarn bobbin corresponding to the yarn feeder; the subscript 's' indicates the finished product; 'l' indicates the total number of knitted segments; R kr y represents the yarn number used when knitting the k-th knitting segment. ij The number of identical yarn bobbins.

[0068] For example, when a knitted finished product pr s Upon completion of production, this application uses the above formula (1) to calculate the total number of yarns per bobbin used in knitting the product. ij Corresponding yarn number y ij The amount of yarn consumed, which is the sum of the yarn consumption of each yarn bobbin when each knitting segment is completed. ij Corresponding yarn number y ij Yarn consumption.

[0069] In some embodiments, if the current knitted product is a knitted waste product (pd) d Then, in step S4, the step of summing the yarn consumption of each yarn feeder in each knitting segment to obtain the current yarn consumption of each yarn feeder includes:

[0070] Step S4a: Calculate the first yarn consumption based on the number of completed knitting segments;

[0071] Step S4b: Calculate the second yarn consumption based on the knitting segment where the product was discarded;

[0072] Step S4c: Calculate the current yarn consumption for each yarn feeder using the following formula (2).

[0073]

[0074] in, This indicates the amount of the first yarn consumed; Indicates the consumption of the second yarn; superscript sp ij The subscript d indicates the yarn bobbin corresponding to the yarn nozzle; the subscript d indicates a defective product; the subscript d_f indicates that the defective product has been segmented; the subscript d_uf indicates that the defective product has not been segmented.

[0075] For example, when a knitting machine produces a defective knitted product (PD) due to a quality problem... d At that time, the knitting machine records the number of knitting loops completed when the defective product is produced (pfc). d This application will calculate the number of yarn packages per yarn package for the product in an incomplete manner based on the number of completed knitting rounds. ij Corresponding yarn number y ijThe yarn consumption is the cumulative total of the number of complete knitted segments completed when the product is produced and the number of yarn bobbins in the current knitted segment when the product is discarded. ij Corresponding yarn number y ij The yarn consumption. Assume the waste yarn for this piece of knitted fabric is pd. d It is knitted PFC d If a knitted segment is discarded upon completion, the number of completed knitted segments f-1 can be calculated, along with the f-th segment where the knitted segment was located when the product was discarded. The relationship is: ssc f ≤pfc d <ssc f+1 , among which, ssc f This indicates the starting number of knitting loops when knitting segment f.

[0076] In some embodiments, for the first f-1 segment that has been knitted, in step S4a, the first yarn consumption is calculated using the following formula (3).

[0077]

[0078] Where f-1 represents the number of complete knitting segments; R kr y represents the yarn number used when knitting the k-th knitting segment. ij The number of identical yarn bobbins.

[0079] In some embodiments, for the f-th segment where the knitting is not yet completed, in step S4b, the second yarn consumption is calculated using the following formula (4).

[0080]

[0081] Among them, PFC d This indicates the current number of knitting loops completed; the subscript f indicates the knitting segment where the product was discarded; ssc f This indicates the starting number of knitting loops when knitting segment f; sec f This indicates the cutoff number of knitting loops when knitting segment f; syw fr R represents the theoretical consumption of each yarn number when knitting segment f; fr y represents the yarn number used when knitting segment f. ij The number of identical yarn bobbins.

[0082] In step S5, the historical yarn consumption of each yarn feeder corresponding to the historical knitted product is obtained, and the cumulative yarn consumption of the corresponding yarn feeder is calculated based on the historical yarn consumption and the current yarn consumption. For example, this application calculates the yarn consumption of each bobbin under different conditions for both single knitted finished products and knitted waste products.ij Corresponding yarn number y ij After calculating the yarn consumption, it can be based on the sp of each yarn bobbin. ij Replacement time st ij and the net weight of the yarn when changing yarn bobbins (nw) ij Calculate the yarn package sp ij Net weight of remaining yarn ynw ij .

[0083] In some embodiments, in step S5, the cumulative yarn consumption of the corresponding yarn feeder is calculated using the following formula (5).

[0084]

[0085] Among them, the superscript sp ij g1 represents the number of finished knitted products in the past and present knitted products; g2 represents the number of waste knitted products in the past and present knitted products. Indicates from the yarn tube sp ij The amount of yarn consumed in the production of the tth product since the replacement time.

[0086] For example, suppose that the yarn bobbin sp ij Replacement time st ij Since then, the knitting machine has produced g1 finished products and g2 defective products, which can be recorded as g1 + g2 products. So, from the yarn tube sp ij Replacement time st ij Since then, the above formula (5) has been used to calculate the yarn bobbin sp. ij Corresponding yarn number y ij Yarn consumption.

[0087] In step S6, it is determined whether knitted product production can continue based on the cumulative yarn consumption of the yarn feeder. If the determination is yes, production continues and the process proceeds to step S1; if the determination is no, an alarm is triggered to replenish the yarn corresponding to the yarn feeder. For example, workers can prepare replacement yarn bobbins in advance based on the alarm information, in case the knitting machine experiences a yarn feeder failure. ij The corresponding yarn tube sp ij When the yarn runs out and the machine stops, the yarn loading task is performed. That is, the staff goes to the knitting machine, replaces the corresponding yarn bobbin with the yarn rack, and then enters the yarn bobbin replacement information into the software system.

[0088] Figure 5 This is a diagram of the software system interface operated by a worker when performing a yarn-laying task, according to one embodiment of this application. (Reference) Figure 5As shown, staff can input the yarn feeder, yarn number, and net yarn weight corresponding to a specific yarn path in area 510.

[0089] This application, by calculating yarn consumption, can help knitting factories respond in advance to the yarn consumption of each bobbin on seamless knitting machines, sock knitting machines, etc., and the time when bobbins need to be replaced. This allows new bobbins to be delivered to the machines in advance at the appropriate time, thereby reducing the downtime of knitting machines due to yarn shortage and improving the production efficiency of knitting machines.

[0090] In some embodiments, step S6, determining whether knitted products can continue to be produced, includes: based on the cumulative yarn consumption of the yarn feeder. Calculate the yarn feeder fn ij Corresponding yarn tube sp ij Net weight of remaining yarn ynw ij If the net weight of the remaining yarn is ynw ij If the remaining yarn weight is less than a preset threshold, it is determined that knitted products cannot continue to be produced; if the remaining yarn weight is ynw ij If the value is greater than or equal to the preset threshold, it is determined that the production of knitted products can continue.

[0091] For example, during the production process of a knitting machine, each time a product (finished or defective) is produced, this application can continuously monitor each yarn bobbin. ij Corresponding yarn number y ij The yarn consumption is calculated, and the corresponding yarn bobbin sp for each yarn nozzle is calculated. ij Net weight of remaining yarn ynw ij In the remaining yarn net weight ynw ij When the yarn level falls below a given threshold, a message indicating that the yarn in the yarn bobbin is about to run out is sent. (Yarn bobbin sp) ij Corresponding yarn number y ij Net weight of remaining yarn ynw ij The following formula (6) can be used for calculation.

[0092]

[0093] In some embodiments, step S6, after the alarm prompts to replenish the yarn corresponding to the yarn feeder, further includes:

[0094] Step S6a: Replace the yarn feeder fn ij Corresponding yarn tube sp ij ;

[0095] Step S6b: Update the yarn bobbin sp ij Corresponding yarn number y ij Net weight of yarn (nw) ij ;

[0096] Step S6c: Record the yarn package sp ij Replacement time st ij Continue production and proceed to step S1.

[0097] For example, after the operator changes the yarn bobbin, the knitting machine will continue knitting and producing products (finished or defective) until the next yarn shortage stop, or until the knitting machine automatically stops due to completion of the production task. During the production process of the knitting machine, this application can continuously calculate the yarn consumption of each yarn feeder based on the product output and issue yarn depletion messages to the yarn bobbins in a timely manner to help the knitting factory transport the yarn bobbins to the designated location in advance and reduce the machine downtime due to yarn shortage.

[0098] Here is an example illustrating the process of a knitting factory producing knitted products.

[0099] Figure 2 This is an overall flowchart of a knitting factory producing knitted products according to one embodiment of this application. For example, refer to... Figure 2 As shown, in step S210, the sampling personnel create a new knitted product style and input yarn configuration information and theoretical consumption information; in step S220, the machine changer adjusts the machine to change the style and updates the yarn bobbin replacement information; in step S230, the knitting machine performs knitting production and records the knitted finished product information and knitted waste information; if production needs to continue and a yarn shortage alarm has been triggered, the process proceeds to step S240; if production does not need to continue, the process proceeds to step S260; in step S240, yarn bobbins are delivered; in step S250, the machine operator loads yarn, updates the yarn bobbin replacement information, and proceeds to step S230; in step S260, production of the knitted product style ends.

[0100] The technical solution of this application, by acquiring the number of knitting loops and knitting segments of the current knitted product in real time and combining it with preset style information, can accurately calculate the consumption of various yarn types within each knitting segment, and further convert these consumption amounts to specific yarn feeders. This real-time monitoring method ensures the accuracy and timeliness of yarn consumption data calculation during the production of knitted products. By converting the yarn consumption amount to each yarn feeder, it is possible to determine whether knitted product production can continue based on the cumulative yarn consumption of each yarn feeder, and to issue timely alarm prompts for replenishing yarn when production cannot continue, thus avoiding production interruptions due to yarn depletion and improving production efficiency. This application can accurately monitor the yarn consumption of knitting machines using a low-cost data analysis method without complex hardware modifications, and is applicable to various types of yarn and knitting machine equipment.

[0101] The technical solution of this application can be combined with an automated yarn feeding mechanism to further reduce the downtime of the machine due to yarn shortage and improve the machine's production efficiency. This application can be implemented through software functions and integrated into the production management software system of a knitting factory. In application, it does not rely on additional detection and sensing hardware and can be used to monitor the yarn consumption of old knitting machines that are already in production and use.

[0102] This application also includes a yarn consumption monitoring system for a knitting machine, comprising a memory and a processor. The memory stores instructions executable by the processor; the processor executes these instructions to implement the yarn consumption monitoring method for the knitting machine described above.

[0103] Figure 6 This is a system block diagram of a yarn consumption monitoring system for a knitting machine according to an embodiment of this application. (Reference) Figure 6 As shown, the yarn consumption monitoring system 600 for the knitting machine may include an internal communication bus 601, a processor 602, a read-only memory (ROM) 603, a random access memory (RAM) 604, and a communication port 605. The yarn consumption monitoring system 600 may also include a hard disk 606. The internal communication bus 601 enables data communication between the components of the yarn consumption monitoring system 600. The processor 602 can perform judgments and issue prompts. In some embodiments, the processor 602 may consist of one or more processors. The communication port 605 enables data communication between the yarn consumption monitoring system 600 and external devices. In some embodiments, the yarn consumption monitoring system 600 can send and receive information and data from a network via the communication port 605. The yarn consumption monitoring system 600 for this knitting machine may also include different types of program storage units and data storage units, such as a hard disk 606, a read-only memory (ROM) 603, and a random access memory (RAM) 604, capable of storing various data files used for computer processing and / or communication, as well as possible program instructions executed by the processor 602. The processor executes these instructions to implement the main part of the method. The results of the processor processing are transmitted to the user equipment via a communication port and displayed on the user interface.

[0104] The above-described method for monitoring yarn consumption of a knitting machine can be implemented as a computer program, stored in hard disk 606, and loaded into processor 602 for execution, in order to implement the yarn consumption monitoring method for knitting machines of this application.

[0105] This application also includes a computer-readable medium storing computer program code that, when executed by a processor, implements the yarn consumption monitoring method for a knitting machine described above.

[0106] When a method for monitoring yarn consumption in a knitting machine is implemented as a computer program, it can also be stored as an article of manufacture in a computer-readable storage medium. For example, a computer-readable storage medium may include, but is not limited to, magnetic storage devices (e.g., hard disks, floppy disks, magnetic stripes), optical discs (e.g., compact discs (CDs), digital multifunction discs (DVDs)), smart cards, and flash memory devices (e.g., electrically erasable programmable read-only memory (EPROM), cards, sticks, key drives). Furthermore, the various storage media described herein can represent one or more devices and / or other machine-readable media used for storing information. The term "machine-readable medium" may include, but is not limited to, wireless channels and various other media (and / or storage media) capable of storing, containing, and / or carrying code and / or instructions and / or data.

[0107] It should be understood that the embodiments described above are merely illustrative. The embodiments described herein may be implemented in hardware, software, firmware, middleware, microcode, or any combination thereof. For hardware implementation, the processor may be implemented within one or more application-specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices (PLDs), field-programmable gate arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, and / or other electronic units designed to perform the functions described herein, or combinations thereof.

[0108] Some aspects of this application can be executed entirely by hardware, entirely by software (including firmware, resident software, microcode, etc.), or by a combination of hardware and software. The aforementioned hardware or software may be referred to as a "data block," "module," "engine," "unit," "component," or "system." The processor may be one or more application-specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DAPDs), programmable logic devices (PLDs), field-programmable gate arrays (FPGAs), processors, controllers, microcontrollers, microprocessors, or combinations thereof. Furthermore, aspects of this application may manifest as computer products residing in one or more computer-readable media, including computer-readable program code. For example, computer-readable media may include, but are not limited to, magnetic storage devices (e.g., hard disks, floppy disks, magnetic tapes, etc.), optical discs (e.g., compressed CDs, digital multifunction DVDs, etc.), smart cards, and flash memory devices (e.g., cards, sticks, key drives, etc.).

[0109] A computer-readable medium may contain a propagated data signal containing computer program code, for example, on baseband or as part of a carrier wave. This propagated signal may take various forms, including electromagnetic, optical, and so on, or suitable combinations thereof. A computer-readable medium can be any computer-readable medium other than a computer-readable storage medium, which can be connected to an instruction execution system, apparatus, or device to enable communication, propagation, or transmission of a program for use. The program code located on the computer-readable medium can be propagated through any suitable medium, including radio, cable, fiber optic cable, radio frequency signals, or similar media, or any combination of the above media.

[0110] The basic concepts have been described above. Obviously, for those skilled in the art, the above disclosure is merely illustrative and does not constitute a limitation of this application. Although not explicitly stated herein, those skilled in the art may make various modifications, improvements, and corrections to this application. Such modifications, improvements, and corrections are suggested in this application, and therefore remain within the spirit and scope of the exemplary embodiments of this application.

[0111] Furthermore, this application uses specific terms to describe embodiments of the application. For example, "an embodiment," "one embodiment," and / or "some embodiments" refer to a particular feature, structure, or characteristic related to at least one embodiment of the application. Therefore, it should be emphasized and noted that "an embodiment," "one embodiment," or "an alternative embodiment" mentioned twice or more in different locations in this specification do not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of the application can be appropriately combined.

[0112] In some embodiments, numbers describing the quantity of components and attributes are used. It should be understood that such numbers used in the description of embodiments are modified in some examples with the terms "approximately," "approximately," or "generally." Unless otherwise stated, "approximately," "approximately," or "generally" indicates that the numbers are allowed to vary by ±20%. Accordingly, in some embodiments, the numerical parameters used in the specification and claims are approximate values, which may be changed depending on the characteristics required by individual embodiments. In some embodiments, numerical parameters should take into account specified significant digits and employ a general method of digit reservation. Although the numerical ranges and parameters used to confirm their breadth of scope in some embodiments of this application are approximate values, in specific embodiments, such values ​​are set as precisely as feasible.

Claims

1. A method for monitoring yarn consumption on a knitting machine, characterized in that, include: Step S1: Obtain the current number of knitted turns completed for the current knitted product, and calculate the current number of knitted segments based on the current number of knitted turns; Step S2: Calculate the yarn consumption of various yarn types for each knitting segment in the current number of knitting segments based on the preset style information of the knitted product; Step S3: Calculate the yarn consumption of each yarn type in each knitting segment to the corresponding yarn feeder for each yarn type; Step S4: Sum the yarn consumption of each yarn feeder in each knitting segment to obtain the current yarn consumption of each yarn feeder; Step S5: Obtain the historical yarn consumption of each yarn feeder corresponding to the historical knitted products, and calculate the cumulative yarn consumption of the corresponding yarn feeder based on the historical yarn consumption and the current yarn consumption; Step S6: Determine whether the production of knitted products can continue based on the cumulative yarn consumption of the yarn feeder. If the determination is yes, continue production and proceed to step S1; if the determination is no, issue an alarm to replenish the yarn corresponding to the yarn feeder.

2. The yarn consumption monitoring method as described in claim 1, characterized in that, The preset style information includes yarn configuration information, which includes: the fd of each yarn feeder. i Each yarn nozzle fn ij Corresponding yarn number y ij Yarn type, net yarn weight (nw) ij yarn tube sp ij And the knitting segments of each individual knitted product during the production process. k Each yarn number (sn) within the yarn kr The corresponding theoretical consumption syw kr Where, subscript i represents the i-th yarn feeder, 1≤i≤n, and n represents the total number of yarn feeder paths; subscript j represents the j-th yarn nozzle, 1≤j≤m, and m represents the number of yarn nozzles that a single yarn feeder can support; subscript k represents the k-th knitting segment, 1≤k≤l, and l represents the total number of knitting segments; subscript r represents the r-th yarn type, 1≤r≤h, and h represents the number of different yarn types with different yarn numbers used in the knitting segment.

3. The yarn consumption monitoring method as described in claim 2, characterized in that, The yarn configuration information also includes: sg for each knitting segment. k The number of knitting loops to finish when the entire knitting is complete (in seconds) k Each knitted segment sg k The starting number of knitting loops (ssc) k , among which, ssc k =sec k-1 +1, ssc1 = 0.

4. The yarn consumption monitoring method as described in claim 1 or 2, characterized in that, In step S2, during the calculation of yarn consumption, the yarn consumption of various yarn types in each knitting segment is calculated by using the method that the yarn consumption of yarns with the same yarn number in a single knitting segment is proportional to the number of knitting turns completed in the single knitting segment.

5. The yarn consumption monitoring method as described in claim 2, characterized in that, If the current knitted product is a finished knitted product pr s In step S4, the current yarn consumption of each yarn feeder is calculated using the following formula. in, superscript sp ij This indicates the yarn bobbin corresponding to the yarn feeder; the subscript 's' indicates the finished product; 'l' indicates the total number of knitted segments; R kr y represents the yarn number used when knitting the k-th knitting segment. ij The number of identical yarn bobbins.

6. The yarn consumption monitoring method as described in claim 2, characterized in that, If the current knitted product is a knitted waste product (pd) d Then, in step S4, the step of summing the yarn consumption of each yarn feeder within each knitting segment to obtain the current yarn consumption of each yarn feeder includes: Step S4a: Calculate the first yarn consumption based on the number of completed knitting segments; Step S4b: Calculate the second yarn consumption based on the knitting segment where the product was discarded; Step S4c: Calculate the current yarn consumption for each yarn feeder using the following formula. in, This indicates the amount of the first yarn consumed; Indicates the consumption of the second yarn; superscript sp ij The subscript d indicates the yarn bobbin corresponding to the yarn nozzle; the subscript d indicates a defective product; the subscript d_f indicates that the defective product has been segmented; the subscript d_uf indicates that the defective product has not been segmented.

7. The yarn consumption monitoring method as described in claim 6, characterized in that, In step S4a, the first yarn consumption is calculated using the following formula. Where f-1 represents the number of complete knitting segments that have been completed; R kr y represents the yarn number used when knitting the k-th knitting segment. ij The number of identical yarn bobbins.

8. The yarn consumption monitoring method as described in claim 6, characterized in that, In step S4b, the second yarn consumption is calculated using the following formula. Among them, PFC d This indicates the current number of knitting loops completed; the subscript f indicates the knitting segment where the product was discarded; ssc f This indicates the starting number of knitting loops when knitting segment f; sec f This indicates the cutoff number of knitting loops when knitting segment f; syw fr R represents the theoretical consumption of each yarn number when knitting segment f; fr y represents the yarn number used when knitting segment f. ij The number of identical yarn bobbins.

9. The yarn consumption monitoring method as described in claim 2, characterized in that, In step S5, the cumulative yarn consumption of the corresponding yarn feeder is calculated using the following formula. Among them, the superscript sp ij g1 represents the number of finished knitted products among the historical knitted products and the current knitted products; g2 represents the number of waste knitted products among the historical knitted products and the current knitted products. Indicates from the yarn tube sp ij The amount of yarn consumed in the production of the tth product since the replacement time.

10. The yarn consumption monitoring method as described in claim 1, characterized in that, In step S6, the step of determining whether knitted products can continue to be produced includes: calculating the net weight of the remaining yarn in the yarn bobbin corresponding to the yarn nozzle based on the cumulative yarn consumption of the yarn nozzle; if the net weight of the remaining yarn is less than a preset threshold, it is determined that knitted products cannot continue to be produced; if the net weight of the remaining yarn is greater than or equal to the preset threshold, it is determined that knitted products can continue to be produced.

11. The yarn consumption monitoring method as described in claim 2, characterized in that, In step S6, after the alarm prompts to replenish the yarn corresponding to the yarn feeder, the method further includes: Step S6a: Replace the yarn feeder fn ij Corresponding yarn tube sp ij ; Step S6b: Update the yarn bobbin sp ij Corresponding yarn number y ij Net weight of yarn (nw) ij ; Step S6c: Record the yarn package sp ij Replacement time st ij Production continues and the process switches to step S1.

12. A yarn consumption monitoring system for a knitting machine, characterized in that, include: Memory is used to store instructions that can be executed by the processor; A processor for executing the instructions to implement the yarn consumption monitoring method for a knitting machine as described in any one of claims 1-11.

13. A computer-readable medium storing computer program code, characterized in that, The computer program code, when executed by a processor, implements the yarn consumption monitoring method for a knitting machine as described in any one of claims 1-11.

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