Processing workshop management system and method based on cotton spinning production line

Abstract

The invention relates to the technical field of management systems, in particular to a processing workshop management system and method based on cotton spinning production lines, and the system comprises a broken end monitoring unit which recognizes the broken end condition of each spindle position in a spinning frame, generates a broken end processing interval, and calculates the broken end processing duration; the cyclic detection unit is preset with an acquisition interval, images of a plurality of roving bobbins on each spinning frame are recorded as roving images twice continuously based on the acquisition interval, and the roving images acquired twice form a comparison combination; the roving dimensions in the two roving images are recognized respectively, the depletion duration is analyzed and calculated based on the dimension difference in combination with the collection interval, a redundancy proportion is preset, and a depletion interval is obtained through calculation in combination with the depletion duration and the redundancy proportion; and the bobbin replacement analysis unit is used for recording the minimum management unit for uniformly replacing the roving bobbins as a bobbin replacement unit, analyzing by combining the energy consumption of the spinning frame based on the depletion interval of each roving bobbin, and determining the target bobbin replacement time of the bobbin replacement unit.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of management system, in particular to a processing workshop management system and method based on a cotton textile production line. BACKGROUND

[0002] The cotton textile production line is a complete processing system from cotton fiber to fabric. Its process starts from the pre-spinning process, in which the raw cotton is opened, cleaned and carded to form a sliver. Then, the sliver is combined and drawn to improve the evenness and is spun into roving. Subsequently, the roving enters the core spinning process, in which the roving is highly drawn and twisted by a spinning machine to produce yarn that meets the strength requirements. Then, the yarn is processed through winding, beaming, sizing and threading to form warp and weft yarns for weaving. Finally, the fabric is formed on a loom through the interlacing of warp and weft yarns.

[0003] With the development of machine automation and artificial intelligence, cotton textile workshops are becoming more and more intelligent. The existing technology has realized the intelligent unified replacement of roving pipes and yarn pipes and automatic doffing in the spinning process. However, due to the quality and length difference of the roving on the roving pipe, the complete unwinding time of the roving on the same spinning machine is not consistent, which leads to waste of part of the roving, reduces the utilization rate of raw materials in the spinning process, and affects the overall output efficiency of the process, thus having certain defects. SUMMARY

[0004] In view of the above-mentioned defects of the prior art, the present application provides a processing workshop management system and method based on a cotton textile production line, which can effectively solve the problem of poor utilization efficiency of raw materials in the spinning process of the prior art.

[0005] To achieve the above-mentioned purposes, the present application realizes the following technical solutions: The present application provides a processing workshop management system based on a cotton textile production line, which at least comprises: a broken end monitoring unit that identifies the broken end condition of each spindle position in the spinning machine, generates a broken end instruction, records the broken end generation time and the broken end termination time to form a broken end processing interval, and calculates the broken end processing time length; a cycle detection unit that is pre-set with a collection interval, collects images of multiple roving pipes on each spinning machine based on the collection interval, and forms a comparison combination of the two collected roving images; According to the order of collection time, the two roving images in the comparison combination are recorded as a first roving image and a second roving image, respectively, the roving dimensions in the two roving images are identified, the consumption time length is analyzed and calculated based on the dimension difference and the collection interval, a redundancy ratio is pre-set, the collection time of the second roving image is taken as a time anchor point, and the consumption interval is calculated based on the consumption time length and the redundancy ratio; A tube changing analysis unit, taking the minimum management unit of uniformly replacing the roving tube as a tube changing unit, analyzes the tube changing unit based on the depletion interval of each roving tube in combination with the energy consumption of the spinning machine to determine the target tube changing timing of the tube changing unit.

[0006] Further, the roving dimension acquisition process is as follows: Extracting the roving tube contour in the roving image as a target contour, presetting the side view contour of the roving tube in the idle state as a positioning contour, moving the positioning contour so that the positioning contour is completely covered by the roving tube contour, taking the center line of the positioning contour as a reference line, drawing a straight line perpendicular to the reference line and intersecting the target contour as a target straight line, moving the target straight line and acquiring the length of the line segment of the target straight line located in the target contour as a transverse width value, and extracting the transverse width value as the roving dimension when the transverse width value reaches the maximum value.

[0007] Further, the depletion duration calculation process is as follows: Taking the roving dimensions corresponding to the first roving image and the second roving image as the first dimension and the second dimension respectively, drawing two circles with the first dimension and the second dimension as the diameters of the circles respectively and calculating the areas to obtain the first area and the second area, calculating the area difference and dividing it by the collection interval to obtain the consumption coefficient, acquiring the diameter of the roving tube as the roving tube diameter and calculating the corresponding circular area as the reference area, calculating the difference between the second area and the reference area and dividing it by the consumption coefficient to obtain the depletion duration.

[0008] Further, when a broken end occurs at any arbitrary spindle position, the output result of the corresponding depletion interval is adjusted based on the broken end processing interval, wherein: When the broken end generation time is located before the collection interval, the depletion interval is not adjusted; When the broken end generation time is located within the collection interval, the actual collection interval is taken as the collection interval minus the broken end processing duration, and the depletion interval of the corresponding roving tube is recalculated; When the broken end generation time is located after the collection interval, the front and rear endpoints of the depletion interval are both added by the broken end processing duration.

[0009] Further, the target tube changing timing determination process is as follows: A time axis is constructed and the depletion intervals of the plurality of roving tubes corresponding to the tube changing unit are represented in the time axis, each depletion interval is represented as a depletion line segment using a line segment, and any two depletion line segments do not intersect each other, a plurality of straight lines perpendicular to the time axis are constructed as to-be-determined straight lines, and the vertical point of the to-be-determined straight line is the right endpoint of the depletion line segment. Based on the depletion line segment distribution on both sides of the to-be-determined straight line in combination with the energy consumption of each spindle in the idle state, the efficiency index corresponding to each to-be-determined straight line is calculated, the minimum value of the efficiency index is screened out, and the corresponding time point is taken as the target tube changing timing.

[0010] Further, the efficiency index calculation process is as follows: Mark the exhausted line segment with the right end point on the left side of the to-be-determined straight line as a completed line segment, mark the exhausted line segment with the right end point on the right side of the to-be-determined straight line as a surplus line segment, mark the exhausted line segment not intersecting with the to-be-determined straight line as a separated line segment, mark the shortest distance between the separated line segment and the to-be-determined straight line as a split distance, mark the split distance between the right end point of the completed line segment and the to-be-determined straight line as an idle time length, mark the split distance between the right end point of the surplus line segment and the to-be-determined straight line as a redundant time length, preset a tube replacement influence threshold, and remove the exhausted line segment with the idle time length or the redundant time length greater than or equal to the idle tube replacement threshold; Calculate the sum of the idle time lengths of the completed line segments and multiply the sum by a preset idle energy consumption coefficient to obtain an idle evaluation index; Calculate the distance between the right end point of the surplus line segment and the to-be-determined straight line as a surplus distance of the surplus line segment, multiply the surplus distance by the consumption coefficient corresponding to the surplus line segment to obtain a unit consumption value, and calculate the sum of the unit consumption values corresponding to all the surplus line segments to obtain a waste evaluation index; The idle evaluation index and the waste evaluation index each correspond to a preset proportion coefficient, the idle evaluation index and the waste evaluation index are each multiplied by the corresponding proportion coefficient and summed to obtain an efficiency index.

[0011] The cotton textile production line-based processing workshop management method comprises the following steps: Step one: mark the roving tube with the idle time length greater than or equal to the idle tube replacement threshold as a to-be-processed tube, mark the to-be-processed tube corresponding to the broken end instruction as a problem tube when the broken end instruction is received, obtain the exhausted interval corresponding to the problem tube, and generate an independent tube replacement instruction when the broken end occurrence time is located in the exhausted interval corresponding to the problem tube; Step two: mark the roving tube with the redundant time length greater than or equal to the idle tube replacement threshold as a to-be-replaced tube, calculate the unit consumption value of the surplus line segment corresponding to the replacement tube as a replacement surplus, and store all the to-be-replaced tubes at a fixed position and mark them as tube storage points; Step three: obtain the idle time length corresponding to the problem tube when the independent tube replacement instruction is received, analyze the positions of the problem tube, the stopper, and the tube storage points, and determine the replacement demand quantity corresponding to the problem tube; Step four: multiply the replacement demand quantity by a fault tolerance proportion to obtain an actual demand quantity, screen the replacement tubes based on the actual demand quantity to obtain target replacement tubes, and replace the target replacement tubes with the problem tube.

[0012] Further, store the replacement surplus data in the RFID chip of the replacement tube, preset a plurality of storage counters, each of which corresponds to a surplus interval, and store the replacement tubes in the corresponding storage counters according to the replacement surplus; The storage counter is equipped with a movable push rod with RFID identification. The movable push rod pushes out the corresponding replacement yarn tube based on the required replacement margin.

[0013] Furthermore, the replacement demand calculation process is as follows: The distance between the real-time location of the machine operator and the location of the yarn tube storage point is recorded as the first distance. The distance between the yarn tube storage point and the location of the problematic yarn tube is recorded as the second distance. The sum of the first distance and the second distance is calculated and divided by the preset walking speed to obtain the first duration. There is a preset replacement duration. The time difference between the time of the yarn breakage and the timing of the tube replacement is recorded as the second duration. The first duration and the replacement duration are subtracted from the second duration to obtain the reserve duration. The reserve duration is multiplied by the corresponding consumption coefficient to obtain the replacement requirement.

[0014] Furthermore, the screening criteria for target yarn tube replacement include: Condition 1: The replacement margin of the target yarn tubes is greater than the actual demand. Condition 2: The replacement allowance for the target yarn tube is the minimum value that satisfies Condition 1.

[0015] The technical solution provided by this invention has the following advantages compared with the known prior art: 1. Compared with the existing technology, which only records the number of yarn breaks, the present invention records the time interval of yarn breakage. This allows for further analysis of the continuous impact of yarn breakage, thereby optimizing the processing and improving the efficiency of yarn breakage handling. Furthermore, by replacing the target replacement bobbin with the problematic bobbin, the unused roving bobbin can be fully utilized. In addition, the selection of the target replacement bobbin is based on the subsequent unwinding requirements of the spindle, which can further avoid roving waste in the spinning process and improve the uniformity of the product quality of the spinning machine, thereby improving the overall efficiency of the spinning process.

[0016] 2. This invention can reduce the required standard for fully loaded roving tubes in the spinning process, and adjust the depletion range based on the time point of yarn breakage, so that the depletion range is more consistent with the time range of complete roving consumption on the roving tube, thereby improving the accuracy of the system. In addition, the calculation of replacement demand not only considers the remaining length required for the spindle corresponding to the problem roving tube, but also the time consumption of the machine operator when manually changing the tube, making the calculated replacement demand more accurate, thereby further reducing roving waste. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are merely some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without any creative effort.

[0018] Figure 1 This is an overall module block diagram of the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0020] The present invention will be further described below with reference to embodiments.

[0021] See Figure 1 The processing workshop management system based on cotton textile production lines is mainly used to assist machine operators in the spinning workshop in managing machines.

[0022] It should be noted that the spinning process is a crucial stage in the spinning process. Its main function is to process roving into fine yarn that meets specifications through drafting and twisting, and then wind the fine yarn into bobbins. The core function of the spinning machine operator is to ensure the stable operation of the equipment during the spinning process and to handle problems that arise during the operation of the spinning machine, thereby improving the production efficiency of the spinning machine.

[0023] It is worth noting that although a collective doffing system and a yarn breakage detection system have been developed, fully automatic intelligent splicing technology still faces technical bottlenecks on spinning machines. This is because the splicing operation after a yarn breakage is difficult to perform mechanically, especially for spinning yarn splicing. The splicing operation needs to be carried out on a high-speed rotating spindle in an extremely confined space. Under these circumstances, it is relatively difficult for machines to perform a series of actions such as finding the yarn head, guiding the yarn, attaching the traveler, and splicing. Moreover, the application cost and stability are not as good as manual. Therefore, the spinning machine operator plays an irreplaceable role in the existing cotton textile production line.

[0024] include: The yarn breakage monitoring unit intelligently identifies yarn breakage at each spindle position in the spinning machine. Upon detecting a breakage, it generates a breakage command and records the breakage occurrence time and breakage termination time. The breakage termination time refers to the time it takes for the spindle to resume operation after the breakage is repaired. Each roving tube is equipped with an RFID tag for identification and is assigned an identification serial number, known as the roving tube number. The breakage occurrence time and breakage termination time form a breakage processing interval and are bound to the corresponding roving tube number. The difference between the breakage occurrence time and breakage termination time is recorded as the breakage processing duration.

[0025] It should be noted that decapitation identification is an existing technology, and will not be elaborated on further here. Compared to existing methods that only record the number of decapitations, recording the time interval of decapitations allows for further analysis of the ongoing impact of decapitations, thereby optimizing the processing and improving decapitation processing efficiency.

[0026] The cyclic detection unit is equipped with an unmanned vehicle (UAV) carrying image acquisition equipment. The UAV shuttles through the aisles between each spinning machine and sequentially acquires images of multiple roving tubes on each spinning machine, recording them as roving images. The acquired roving images are bound to the corresponding roving tube numbers. A preset acquisition interval is used as the departure interval to control the UAV to acquire roving tube images twice consecutively. The two acquired roving images are combined into a comparison set. Based on the comparison set, image recognition analysis is performed to determine the depletion interval of each roving tube. The depletion interval refers to the time range within which the roving on the roving tube is completely unwound.

[0027] It should be noted that the unmanned vehicle with automatic guidance and driving functions is existing technology, and the roving tubes are suspended on spindles at fixed positions (meaning the image capture position for each roving tube is fixed). Therefore, by simply stopping the unmanned vehicle at a fixed position in front of each roving tube and taking a picture, images of the roving tubes throughout the entire workshop can be collected sequentially. Continuous acquisition of roving tube images needs to be carried out while the spinning machine is running to ensure that the roving tubes are in operation during both acquisitions. This allows for analysis of the roving consumption and consumption rate on the roving tubes based on the differences between the two acquired images.

[0028] Specifically, the image analysis process is as follows: Based on the chronological order of data acquisition, the two roving images in the comparison set are designated as the first roving image and the second roving image, respectively. The roving dimensions in each image are identified. The exhaustion time is calculated based on the dimension difference and the acquisition interval. A redundancy ratio (i.e., the error range of the exhaustion time, set by the staff based on experience; in a specific embodiment, it is set to 5%) is preset. Using the acquisition time of the second roving image as the time anchor point, the exhaustion interval is calculated by combining the exhaustion time and the redundancy ratio. Let the time anchor point be... Duration of exhaustion is The redundancy ratio is The exhaustion interval is represented as .

[0029] More specifically, the process for obtaining the roving dimension is as follows: Extract the roving tube outline (including the roving yarn wrapped on the roving tube) from the roving image and record it as the target outline. Preset the side view outline of the roving tube in the unloaded state and record it as the positioning outline. Move the positioning outline so that the positioning outline is completely covered by the roving tube outline (at this time there is only one case, that is, the positioning outline is aligned with the roving tube in the target outline). Using the center line of the positioning outline as the reference line, draw a straight line perpendicular to the reference line and intersecting the target outline and record it as the target line. Move the target line and obtain the length of the line segment of the target line within the target outline and record it as the horizontal width value. When the horizontal width value reaches the maximum value, extract the horizontal width value and record it as the roving dimension.

[0030] It should be noted that by comparing the current profile of the roving tube with the unloaded profile of the roving tube, the profile of the roving on the roving tube can be separated. Then, based on the width of the roving profile and the diameter of the roving tube, the dimension of the roving can be analyzed to determine the remaining amount of roving (for roving rolls that are wound layer by layer and have a cylindrical shape, the remaining amount can be directly represented by the dimension, while for roving rolls with a non-ideal cylindrical shape, the error in the remaining amount calculation can be offset by the redundancy ratio). This method can be directly implemented through image recognition technology on the one hand, and on the other hand, it can make up for the deficiency in the existing technology that it is difficult to collect the remaining amount of roving during the unwinding process of the roving tube.

[0031] More specifically, the calculation process for exhaustion time is as follows: The roving dimensions corresponding to the first and second roving diagrams are denoted as the first dimension and the second dimension, respectively. Two circles are drawn with the first and second dimensions as the diameters of the circles, and the areas are calculated to obtain the first area and the second area. The area difference is calculated and divided by the acquisition interval to obtain the consumption coefficient. The diameter of the roving tube is obtained and denoted as the roving tube diameter, and the corresponding circle area is calculated and denoted as the reference area. The difference between the second area and the reference area is calculated and divided by the consumption coefficient to obtain the exhaustion time. All values ​​in the above calculations are dimensionless values.

[0032] It should be noted that since the operating parameters of the spinning machine are fixed and the quality of the roving on the same roving tube is relatively stable, the consumption rate of the roving on the roving tube can be regarded as constant. That is to say, the roving consumption rate per unit time can be regarded as the rate at which the volume of the roving on the roving tube decreases. For a roving roll with a standard cylindrical shape, its volume is proportional to its cross-sectional area.

[0033] Furthermore, when a breakage occurs at a certain spindle position, the output result of the exhaustion interval is adjusted based on the breakage handling interval, where: When the time of the head break occurs before the acquisition interval, no adjustment is made to the exhaustion interval; When the breakage time is within the acquisition interval, the acquisition interval minus the breakage processing time is used as the actual acquisition interval to calculate the depletion interval of the roving tube corresponding to the breakage. When the time of the head break occurs after the acquisition interval, the head break processing time is added to both the beginning and end of the exhaustion interval.

[0034] Adjusting the exhaustion interval based on the time point of yarn breakage can make the exhaustion interval more consistent with the time range in which the roving on the roving tube is completely consumed, thereby improving the accuracy of the system.

[0035] The tube replacement analysis unit defines the smallest management unit that uniformly replaces the roving tubes (referred to as tube replacement) as the tube replacement unit (the management units of a ring spinning machine are divided into whole machine, single face, single section and single spindle, while uniform tube replacement is usually carried out uniformly for the whole ring spinning machine). Based on the depletion range of each roving tube, combined with the energy consumption of the ring spinning machine, the unit analyzes and determines the target tube replacement time.

[0036] Specifically, the process for determining the timing of the target pipe replacement is as follows: Construct a time axis (extending from left to right) and represent the depletion intervals of multiple roving tubes corresponding to the tube changing unit on the time axis. Each depletion interval is represented by a line segment and denoted as a depletion line segment. Any two depletion line segments do not intersect each other. Construct multiple straight lines perpendicular to the time axis and denoted as undetermined lines. The perpendicular point of the undetermined lines is the right endpoint of the depletion line segment (each depletion line segment corresponds to an undetermined line). Based on the distribution of depletion line segments on both sides of the undetermined lines and the energy consumption of each spindle when it is idle, calculate the efficiency index corresponding to each undetermined line. Select the minimum efficiency index and take the corresponding time point as the target tube changing time. At this time, uniform tube changing can reduce the remaining roving length on the roving tube as much as possible while ensuring the operating efficiency of the spinning machine, reducing roving waste and improving the efficiency of roving to fine yarn conversion.

[0037] More specifically, the efficiency index calculation process is as follows: The depleted segment with its right endpoint to the left of the line to be determined is recorded as the completed segment (corresponding to the roving tube that has been completely unwound before the unified tube replacement time arrives). The depleted segment with its right endpoint to the right of the line to be determined is recorded as the surplus segment (corresponding to the roving tube that has not been completely unwound before the unified tube replacement time arrives and exceeds a certain surplus). The depleted segment that does not intersect with the line to be determined is recorded as the separation segment. The shortest distance between the separation segment and the line to be determined is recorded as the split distance. The split distance between the right endpoint of the completed segment and the line to be determined is recorded as the no-load time. The split distance between the right endpoint of the surplus segment and the line to be determined is recorded as the redundancy time. There is a preset tube replacement impact threshold (set based on empirical values). Depleted segments with no-load time or redundancy time greater than or equal to the no-load tube replacement threshold are removed (a few roving tubes with extreme unwound situations are removed for manual management, and other roving tubes are managed uniformly). The total idle time of the completed line segment is calculated and multiplied by a preset idle energy consumption coefficient (representing the energy wasted per unit time under idle conditions, set by staff based on experience) to obtain the idle assessment index. The calculation formula is expressed as follows: ,in denoted by , g represents the no-load duration, X represents the no-load energy consumption coefficient, and n represents the no-load evaluation index. The no-load assessment index reflects the energy consumption level of the spindle during no-load operation if a uniform tube replacement is carried out at this time. The higher the no-load assessment index, the higher the power waste of the spinning machine.

[0038] The distance between the right endpoint of the remaining line segment and the line to be determined is denoted as the remaining distance of the remaining line segment. Multiplying the remaining distance by the consumption coefficient corresponding to the remaining line segment yields the unit consumption value. The sum of the unit consumption values ​​corresponding to all remaining line segments is calculated to obtain the waste assessment index. The calculation formula is expressed as follows: ,in Indicates the margin distance. Y represents the waste assessment index, and i is the sequence number of the remaining line segment. It should be noted that the waste assessment index reflects the amount of roving wasted if uniform tube replacement is carried out at this time. The larger the value, the more excess roving there will be after the tube replacement is completed.

[0039] The no-load assessment index and the scrap assessment index each correspond to a preset proportional coefficient. The efficiency index is obtained by multiplying the no-load assessment index and the scrap assessment index by their respective proportional coefficients and summing the results. Let the proportional coefficients corresponding to the no-load assessment index and the scrap assessment index be respectively... and (To ensure that the two numerical values ​​are of the same magnitude), the formula for calculating the efficiency index is: All values ​​are dimensionless.

[0040] The processing workshop management method based on cotton textile production lines includes the following steps: Step 1: Record the roving tubes with an idle time greater than or equal to the idle tube replacement threshold as the roving tubes to be processed. When a breakage command is received, record the roving tube to be processed corresponding to the breakage command as the problem roving tube. Obtain the exhaustion interval corresponding to the problem roving tube. When the breakage time is within the exhaustion interval corresponding to the problem roving tube, generate an independent tube replacement command.

[0041] It should be noted that this break-off command usually means that the roving on the roving tube has been unwound prematurely, and the roving tube needs to be replaced to reduce the difference in the yarn length of the corresponding yarn tube of the spindle position with the yarn length of other yarn tubes on the same machine.

[0042] Step 2: Record the roving tubes with redundant duration greater than or equal to the no-load tube replacement threshold as the roving tubes to be replaced, calculate the unit consumption value of the corresponding remaining line segment of the replacement tube and record it as the replacement reserve, store the replacement reserve data in the RFID chip of the replacement tube, and store all the roving tubes to be replaced in a fixed location and record it as the roving tube storage point. Furthermore, multiple storage counters are pre-set, each corresponding to a reserve range. Replacement yarn tubes are stored in the corresponding storage counter according to the replacement reserve. The inside of the storage counter is equipped with a movable push rod with RFID identification. The movable push rod pushes out the corresponding replacement yarn tube based on the required replacement reserve, making it convenient for staff to retrieve the required replacement yarn tube.

[0043] It should be noted that storing roving tubes that are not yet exhausted and still have value can be used to replace them when the roving tubes are exhausted before the uniform tube replacement, thereby making full use of the roving tubes that still have roving tail material when the tubes are replaced, and at the same time ensuring that the yarn length of each roving tube on the same spinning machine is uniform.

[0044] Step 3: Upon receiving an independent tube replacement instruction, obtain the idle time corresponding to the problematic yarn tube, and analyze it in conjunction with the location of the problematic yarn tube, the operator stopping the machine, and the location of the yarn tube storage point to determine the replacement demand for the problematic yarn tube.

[0045] Specifically, the calculation process for replacement demand is as follows: The distance between the real-time location of the machine operator and the location of the yarn tube storage point is recorded as the first distance. The distance between the yarn tube storage point and the location of the problematic yarn tube is recorded as the second distance. The sum of the first and second distances is calculated and divided by the preset walking speed (set based on experience) to obtain the first duration. There is a preset replacement duration (equal to the average time for the machine operator to replace the roving tube manually). The time difference between the time of yarn breakage and the timing of tube replacement is calculated and recorded as the second duration. The first duration and the replacement duration are subtracted from the second duration to obtain the reserve duration. The reserve duration is multiplied by the corresponding consumption coefficient to obtain the replacement requirement.

[0046] It should be noted that the calculation of replacement demand not only takes into account the remaining length required by the spindle corresponding to the problem yarn tube, but also the time consumed by the machine operator when manually changing the tube, making the calculated replacement demand more accurate, thereby further reducing roving waste, because the spindle cannot continue to operate during this period, so it needs to be specially excluded.

[0047] Step 4: Multiply the replacement demand by a tolerance ratio (to further ensure that the roving length of the replacement tube is sufficient to support the operation of the spindle until the doffing is completed, which is set by the staff based on experience, and in a specific embodiment, the value is 1.2) to obtain the actual demand. Based on the actual demand, the replacement tubes are screened to obtain the target replacement tubes, and the target replacement tubes are replaced with the problematic tubes.

[0048] Furthermore, the screening criteria for target yarn tube replacement include: Condition 1: The replacement margin of the target yarn tubes is greater than the actual demand. Condition 2: The replacement allowance for the target yarn tube is the minimum value that satisfies Condition 1.

[0049] It should be noted that when the quality of the roving on the roving tube is poor or the winding length of the corresponding batch of the roving tube is short, the roving on the roving tube will be unwound prematurely. That is, the roving tube corresponding to the depletion segment with an idle time greater than or equal to the idle tube replacement threshold will be idle for too long. When the roving tube breaks, the depletion time of the roving tube will be delayed accordingly. This means that the depletion time of the roving tube may be later than the unified replacement time of the roving tube (the intelligent workshop in the current technology has realized the unified replacement of roving tubes. Through the centralized management mode, the overall machine operating efficiency and production stability are maximized, and the continuous and stable output of equipment capacity is ensured). This will result in too much roving allowance on the roving tube, that is, the redundant time is greater than or equal to the depletion segment corresponding to the roving tube with an idle time greater than or equal to the idle tube replacement threshold.

[0050] By replacing the target replacement bobbin with the problematic bobbin, the unused roving bobbins can be fully utilized. Furthermore, the selection of the target replacement bobbin is based on the subsequent unwinding requirements of that spindle position, which can further avoid roving waste in the spinning process and improve the uniformity of the spinning machine's product quality (i.e., the length of the roving on each bobbin), thereby improving the overall efficiency of the spinning process. In addition, the above method can also reduce the requirement standard for fully loaded roving bobbins in the spinning process. That is to say, roving bobbins with less roving can also participate in the replacement of the same batch of roving bobbins (because the roving production can be supplemented by manual bobbin replacement in the subsequent process).

[0051] A computer device includes a memory and a processor, the memory storing a computer program, and the processor executing the computer program to implement the steps in the above method.

[0052] A computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, implements the steps in the above method.

[0053] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions will not cause the essence of the corresponding technical solutions to deviate from the protection scope of the technical solutions of the embodiments of the present invention.

Claims

1. A processing workshop management system based on a cotton textile production line, characterized in that, include: The yarn breakage monitoring unit identifies yarn breakage at each spindle position in the spinning machine, generates a yarn breakage command, records the yarn breakage occurrence time and the yarn breakage termination time to form a yarn breakage processing interval, and calculates the yarn breakage processing time. The cyclic detection unit has a preset acquisition interval. Based on the acquisition interval, two consecutive images of multiple roving tubes on each spinning machine are recorded as roving images, and the two acquired roving images are combined for comparison. Based on the order of acquisition time, the two roving images in the comparison combination are recorded as the first roving image and the second roving image, respectively. The roving dimension in the two roving images is identified. The exhaustion time is calculated based on the dimension difference and the acquisition interval. A redundancy ratio is preset. The acquisition time of the second roving image is used as the time anchor point. The exhaustion interval is calculated by combining the exhaustion time and the redundancy ratio. The tube replacement analysis unit defines the smallest management unit that uniformly replaces the roving tube as the tube replacement unit. Based on the depletion range of each roving tube and combined with the energy consumption of the spinning machine, the unit analyzes and determines the target tube replacement timing.

2. The processing workshop management system based on cotton textile production lines according to claim 1, characterized in that, The process of obtaining the roving dimension is as follows: Extract the roving tube outline from the roving image and record it as the target outline. Preset the side view outline of the roving tube in the unloaded state and record it as the positioning outline. Move the positioning outline so that the positioning outline is completely covered by the roving tube outline. Using the center line of the positioning outline as the reference line, draw a straight line perpendicular to the reference line and intersecting the target outline and record it as the target line. Move the target line and obtain the length of the line segment of the target line within the target outline and record it as the horizontal width value. When the horizontal width value reaches the maximum value, extract the horizontal width value and record it as the roving dimension.

3. The processing workshop management system based on cotton textile production lines according to claim 2, characterized in that, The calculation process for exhaustion time is as follows: The roving dimensions corresponding to the first and second roving diagrams are denoted as the first dimension and the second dimension, respectively. Two circles are drawn with the first and second dimensions as the diameters of the circles, and the areas are calculated to obtain the first area and the second area. The area difference is calculated and divided by the acquisition interval to obtain the consumption coefficient. The diameter of the roving tube is obtained and denoted as the roving tube diameter, and the corresponding circle area is calculated and denoted as the reference area. The difference between the second area and the reference area is calculated and divided by the consumption coefficient to obtain the exhaustion time.

4. The processing workshop management system based on cotton textile production line according to claim 3, characterized in that, When a break occurs at any spindle position, the output result of the corresponding depletion interval is adjusted based on the breakage handling interval, where: When the time of the head break occurs before the acquisition interval, no adjustment is made to the exhaustion interval; When the breakage time is within the acquisition interval, the acquisition interval is taken as the acquisition interval minus the breakage processing time, and the depletion interval of the corresponding roving tube is recalculated. When the time of the head break occurs after the acquisition interval, the head break processing time is added to both the beginning and end of the exhaustion interval.

5. The processing workshop management system based on cotton textile production line according to claim 3, characterized in that, The process for determining the timing of the target pipe replacement is as follows: Construct a time axis and represent the depletion intervals of multiple roving tubes corresponding to the tube changing unit in the time axis. Each depletion interval is represented by a line segment and denoted as a depletion line segment. Any two depletion line segments do not intersect each other. Construct multiple straight lines perpendicular to the time axis and denoted as undetermined straight lines. The perpendicular point of the undetermined straight lines is the right endpoint of the depletion line segment. Based on the distribution of depletion segments on both sides of the undetermined straight line and the energy consumption of each spindle when it is unloaded, the efficiency index corresponding to each undetermined straight line is calculated, the minimum value of the efficiency index is selected, and the corresponding time point is taken as the target tube replacement time.

6. The processing workshop management system based on cotton textile production line according to claim 5, characterized in that, The efficiency index is calculated as follows: The depleted line segment whose right endpoint is to the left of the line to be determined is called the completed line segment. The depleted line segment whose right endpoint is to the right of the line to be determined is called the surplus line segment. The depleted line segment that does not intersect with the line to be determined is called the separation line segment. The shortest distance between the separation line segment and the line to be determined is called the split distance. The split distance between the right endpoint of the completed line segment and the line to be determined is called the no-load time. The split distance between the right endpoint of the surplus line segment and the line to be determined is called the redundancy time. There is a preset pipe replacement impact threshold. Depleted line segments with no-load time or redundancy time greater than or equal to the no-load pipe replacement threshold are removed. The total no-load time of the completed line segment is calculated and multiplied by the preset no-load energy consumption coefficient to obtain the no-load evaluation index; The distance between the right endpoint of the margin segment and the undetermined straight line is recorded as the margin distance of the margin segment. The margin distance is multiplied by the consumption coefficient corresponding to the margin segment to obtain the unit consumption value. The sum of the unit consumption values ​​corresponding to all margin segments is calculated to obtain the waste assessment index. The no-load assessment index and the waste assessment index each have a preset proportional coefficient. The efficiency index is obtained by multiplying the no-load assessment index and the waste assessment index by their respective proportional coefficients and summing them.

7. A processing workshop management method based on a cotton textile production line, applied to the processing workshop management system based on a cotton textile production line as described in any one of claims 1 to 6, characterized in that, Includes the following steps: Step 1: Record the roving tubes with an idle time greater than or equal to the idle tube replacement threshold as the roving tubes to be processed. When a breakage command is received, record the roving tube to be processed corresponding to the breakage command as the problem roving tube. Obtain the exhaustion interval corresponding to the problem roving tube. When the breakage time is within the exhaustion interval corresponding to the problem roving tube, generate an independent tube replacement command. Step 2: Record the roving tubes with redundant duration greater than or equal to the no-load tube replacement threshold as the roving tubes to be replaced, calculate the unit consumption value of the corresponding margin line segment of the replacement roving tube and record it as the replacement margin, and store all the roving tubes to be replaced in a fixed location and record it as the roving tube storage point. Step 3: Upon receiving an independent tube replacement instruction, obtain the no-load duration corresponding to the problematic yarn tube, and analyze it in conjunction with the location of the problematic yarn tube, the operator stopping the machine, and the location of the yarn tube storage point to determine the replacement demand for the problematic yarn tube. Step 4: Multiply the replacement demand by a tolerance ratio to obtain the actual demand. Based on the actual demand, filter the replacement yarn tubes to obtain the target replacement yarn tubes, and replace the target replacement yarn tubes with the problematic yarn tubes.

8. The processing workshop management system based on cotton textile production line according to claim 7, characterized in that, The remaining replacement data is stored in the RFID chip of the replacement yarn tube. There are multiple storage counters, each corresponding to a remaining range. Replacement yarn tubes are stored in the corresponding storage counter according to the remaining replacement amount. The storage counter is equipped with a movable push rod with RFID identification. The movable push rod pushes out the corresponding replacement yarn tube based on the required replacement margin.

9. The processing workshop management method based on cotton textile production line according to claim 7, characterized in that, The replacement demand calculation process is as follows: The distance between the real-time location of the machine operator and the location of the yarn tube storage point is recorded as the first distance. The distance between the yarn tube storage point and the location of the problematic yarn tube is recorded as the second distance. The sum of the first distance and the second distance is calculated and divided by the preset walking speed to obtain the first duration. There is a preset replacement duration. The time difference between the time of the yarn breakage and the timing of the tube replacement is recorded as the second duration. The first duration and the replacement duration are subtracted from the second duration to obtain the reserve duration. The reserve duration is multiplied by the corresponding consumption coefficient to obtain the replacement requirement.

10. The processing workshop management method based on cotton textile production line according to claim 9, characterized in that, The screening criteria for target yarn tube replacement include: Condition 1: The replacement margin of the target yarn tubes is greater than the actual demand. Condition 2: The replacement allowance for the target yarn tube is the minimum value that satisfies Condition 1.

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