A polyester POY spinning and DTY elastic linkage quality traceability method and system

Abstract

The present application belongs to the field of chemical fiber intelligent manufacturing and quality tracing technology, and discloses a quality tracing method and system for polyester POY spinning and DTY elasticization linkage. The method generates a bobbin identification for the POY bobbin when the POY winding is completed, divides the bobbin layer interval according to the winding length, winding time or bobbin weight gain, and forms a POY bobbin layer quality portrait. When the DTY elasticization is online, a mapping relationship between the bobbin layer interval and the DTY elasticization time window is established, and the corresponding DTY processing portrait is collected. The DTY finished product grade result is reversely bound to the bobbin layer interval, and the POY source abnormality mark, the DTY time window abnormality mark or the DTY spindle position abnormality mark is generated according to the abnormal repeatability and abnormal synchronicity. The method can realize the segmented quality tracing of POY spinning and DTY elasticization across processes.

Description

Technical Field

[0001] This invention belongs to the field of intelligent manufacturing and quality traceability technology of chemical fibers, specifically involving a quality traceability method and system for linking polyester POY spinning and DTY texturing. Background Technology

[0002] Polyester filament is a crucial product in the chemical fiber industry. POY, as a pre-oriented polyester yarn, is typically formed through polyester melt spinning, cooling, oiling, pre-networking, and winding. It can then be processed into low-elasticity yarn through a DTY texturing process. There is a strong quality correlation between POY spinning and DTY texturing. For example, fluctuations in melt pressure, component pressure differential, unstable side blowing, oiling volume, abnormal pre-networking air pressure, or winding tension during POY spinning can all manifest as unstable unwinding, tension fluctuations, yarn breakage, fuzzing, abnormal crimping performance, uneven dyeing, or a decrease in finished product grade during the subsequent DTY texturing process. Simultaneously, temperature deviations in the hot box, abnormal false twister status, network air pressure fluctuations, guide wear, or abnormal single-spindle yarn path during DTY texturing can also lead to a decline in finished product quality. Therefore, in continuous production scenarios of polyester POY and DTY, determining whether quality abnormalities originate from the POY spinning end or the DTY texturing end is a critical issue in production quality management.

[0003] In existing technologies, digital traceability, electronic tags, MES systems, and digital twins have been gradually introduced into the production process of chemical fiber filaments. For example, CN115238529B discloses a method, device, and storage medium for tracing the process of chemical fiber filaments based on digital twins. This method acquires the status data of each piece of equipment in each process flow by building a digital twin model, and achieves process traceability by encoding information for each filament cake, providing data support for process monitoring and subsequent traceability. This type of solution can solve the problems of process data recording, filament cake identification, and process flow reconstruction in the production of chemical fiber filaments, and has positive significance for improving the traceability of the production process.

[0004] However, in the integrated production of POY spinning and DTY texturing, simply coding the entire yarn cake or POY bobbin is insufficient to meet the requirements for refined quality traceability. This is because a POY bobbin, during winding, forms different bobbin layers such as the outer, middle, and inner layers. The spinning time, winding tension, oiling status, and cooling conditions may differ for each layer. Furthermore, during DTY texturing, the POY bobbin continuously enters the texturing yarn path during the unwinding process, with different bobbin layers corresponding to different texturing time windows. If only the entire POY bobbin is used as the traceability unit, when abnormal dyeing, fuzzy fibers, or crimping occur in the finished DTY product, it is usually only possible to trace back to a specific POY bobbin, a specific production batch, or a specific texturing spindle position. It is difficult to further determine whether the abnormality is concentrated in a specific bobbin layer area.

[0005] Furthermore, existing traceability methods typically focus on data recording and process reconstruction, lacking a mechanism to differentiate between POY source anomalies, DTY common time window anomalies, and DTY single-spindle anomalies. For example, when the same type of quality anomaly repeatedly occurs in different texturing spindle positions within the same POY bobbin layer, the anomaly is more likely related to the local process conditions at the POY spinning end; when tension, network air pressure, or fuzz anomalies occur simultaneously at multiple texturing spindle positions within the same DTY texturing time window, the anomaly is more likely related to the common process conditions of the texturing machine; when the anomaly is concentrated at a single texturing spindle position and accompanied by anomalies in the false twister, guide, or network nozzle at that spindle position, it is more likely to be a DTY spindle position anomaly. If existing methods cannot simultaneously establish the correspondence between POY bobbin layer areas, DTY texturing time windows, and DTY finished product grade results, it is difficult to perform the above-mentioned stratified attribution, resulting in a large scope of quality investigation, unclear responsibility boundaries between the spinning end and the texturing end, and a lack of precise basis for subsequent production scheduling and equipment maintenance.

[0006] Therefore, it is necessary to provide a quality traceability method for the continuous production process of polyester POY spinning and DTY texturing, which can establish a mapping relationship between the internal bobbin layer intervals of POY bobbins and the DTY texturing time window, and reverse bind the finished product grade results to the corresponding bobbin layer intervals, thereby realizing cross-process and segmented quality traceability and differentiation of abnormal sources. Summary of the Invention

[0007] The purpose of this invention is to provide a quality traceability method and system that links polyester POY spinning and DTY texturing, so as to solve the problems that existing traceability methods based on whole rolls or yarn cakes are difficult to locate POY roll layer anomalies and difficult to distinguish POY source anomalies, DTY time window anomalies and DTY spindle position anomalies.

[0008] To achieve the above-mentioned technical objectives, the present invention provides the following technical solution.

[0009] In a first aspect, the present invention provides a quality traceability method linking polyester POY spinning and DTY texturing, comprising:

[0010] S1. When POY winding is completed, generate a bobbin identifier for each POY bobbin, and divide the POY bobbin into multiple bobbin layer intervals according to winding length, winding time or bobbin weight gain. Record the spinning position, spinning spindle position, component information, melt pressure, side blowing parameters, oiling parameters, pre-network parameters and winding tension corresponding to each bobbin layer interval to form a POY bobbin layer quality profile.

[0011] S2. When the POY bobbin is loaded with DTY, read the bobbin identifier, collect the unwinding length, unwinding time, breakage continuation position and loading spindle position, and establish the mapping relationship between the bobbin layer interval and the DTY loading time window.

[0012] S3. Collect data on yarn feeding tension, drafting tension, hot box temperature, false twister status, network air pressure, yarn breakage and fuzz detection within the DTY texturing time window to form a DTY processing profile corresponding to the DTY texturing time window.

[0013] S4. Bind the strength, curling, dyeing or appearance grade results of the DTY finished bobbin to the corresponding bobbin layer interval in reverse according to the DTY texturing time window, and generate a quality correlation record between the bobbin layer interval, the DTY texturing time window and the grade results.

[0014] S5. When the grade result is abnormal, based on the abnormal repeatability of the same cylinder layer in different DTY springing time windows or different springing positions, and the abnormal synchronization of multiple springing positions within the same DTY springing time window, generate POY source abnormality markers, DTY time window abnormality markers or DTY springing position abnormality markers, and output quality traceability records.

[0015] Specifically, in step S1, the cylinder layer interval includes an outer layer interval, a middle layer interval, and an inner layer interval, or includes multiple intervals continuously divided according to a preset winding length; each cylinder layer interval records the start and end winding time, start and end winding length, start and end cylinder weight, average winding tension, tension fluctuation level, and the winding speed corresponding to that cylinder layer interval.

[0016] Specifically, in step S1, the component information includes the spinning component number, spinneret number, component pressure difference, metering pump number, and metering pump speed; the side blowing parameters include air temperature, air pressure, air speed, and air window number; the oiling parameters include oil concentration, oil temperature, oiler speed, and oil consumption per unit time; and the pre-network parameters include pre-network air pressure, pre-network nozzle number, and pre-network air pressure fluctuation level.

[0017] Specifically, in step S1, before forming the POY cylinder layer quality profile, the melt pressure, side blowing parameters, oiling parameters, pre-network parameters and winding tension within the same cylinder layer range are time-aligned, and unstable sampling data corresponding to shutdown, component replacement or head generation processes are removed.

[0018] Specifically, in step S1, when the component pressure difference, melt pressure fluctuation, side blowing wind speed fluctuation, oil application amount fluctuation, or winding tension fluctuation in the same cylinder layer interval exceed the corresponding preset range, a POY cylinder layer warning label is generated in that cylinder layer interval.

[0019] Specifically, in step S2, establishing the mapping relationship between the bobbin layer interval and the DTY texturing time window includes: determining the start and end times of each bobbin layer interval entering the texturing yarn path based on the POY bobbin's online time, texturing machine number, texturing spindle position, yarn path number, unwinding speed, cumulative unwinding length, and breakage reconnection time, and generating a bobbin layer interval mapping table.

[0020] Specifically, when a break, tube change, or re-start occurs during the DTY loading process, the unwinding length corresponding to the break, tube change, or re-start is recorded. The original DTY loading time window is divided into multiple sub-time windows with the break, tube change, or re-start time as boundaries, so that each sub-time window corresponds to the tube layer interval before and after the break, tube change, or re-start.

[0021] Specifically, the DTY processing profile includes the average tension, peak tension, number of tension fluctuations, actual temperature deviation of the hot box, deviation of the false twister speed, vibration level of the false twister, network air pressure fluctuation level, number of head breaks, and number of fuzzes within each DTY texturing time window.

[0022] Specifically, in step S3, when the tension fluctuation, actual temperature deviation of the hot box, false twister status, network air pressure fluctuation, number of breakages or number of fuzzes exceed the corresponding preset range within the DTY texturing time window, a DTY processing early warning label is generated within the DTY texturing time window.

[0023] Specifically, in step S4, the reverse binding of the DTY finished bobbin grade result to the corresponding bobbin layer interval includes: matching the DTY finished bobbin inspection time, finished bobbin identifier, texturing machine number, texturing spindle position and winding section position to determine the DTY texturing time window corresponding to the grade result; then determining the corresponding POY bobbin identifier and bobbin layer interval number according to the mapping relationship, and writing the grade result into the quality association record.

[0024] Specifically, in step S5, the abnormal repeatability includes: multiple DTY finished cylinders corresponding to the same cylinder layer interval, or the same type of strong elongation abnormality, curling abnormality, dyeing abnormality or appearance abnormality repeatedly appearing in different DTY texturing time windows and different texturing spindle positions in the same cylinder layer interval; when the abnormal repeatability reaches the preset repeatability judgment condition, and the DTY processing image in the corresponding DTY texturing time window does not exceed the preset processing abnormality range, a POY source abnormality mark is generated.

[0025] Specifically, in step S5, the abnormal synchronization includes: within the same DTY texturing time window, two or more texturing spindles simultaneously exhibit abnormal tension fluctuations, abnormal hot box temperature deviations, abnormal false twister status, abnormal network air pressure, abnormal breakage, or abnormal filaments; when the abnormal synchronization reaches the preset synchronization judgment condition, a DTY time window abnormality mark is generated.

[0026] Secondly, the present invention also provides a quality traceability system linking polyester POY spinning and DTY texturing, for implementing the method described in the first aspect, the system comprising:

[0027] The POY data acquisition module is used to collect information on spinning position, spinning spindle position, component information, melt pressure, side blowing parameters, oiling parameters, pre-network parameters, and winding tension during the POY spinning and winding process.

[0028] The bobbin layer generation module is used to generate a bobbin identifier for each POY bobbin and divide the POY bobbin into multiple bobbin layer intervals according to winding length, winding time or bobbin weight gain, forming a POY bobbin layer quality profile.

[0029] The texturing mapping module is used to read the bobbin identifier when the POY bobbin is loaded with DTY, and to establish a mapping relationship between the bobbin layer interval and the DTY texturing time window based on the unwinding length, unwinding time, breakage continuation position and texturing spindle position.

[0030] The DTY data acquisition module is used to collect data on yarn feeding tension, drafting tension, hot box temperature, false twister status, network air pressure, yarn breakage and fuzz detection data within the DTY texturing time window, forming a DTY processing profile.

[0031] The quality binding module is used to reverse bind the strength, curling, staining or appearance grade results of DTY finished bobbins to the corresponding bobbin layer interval according to the DTY springing time window, and generate quality association records.

[0032] The anomaly attribution module is used to generate POY source anomaly markers, DTY time window anomaly markers, or DTY spindle position anomaly markers based on anomaly repeatability and anomaly synchronization, and output quality traceability records.

[0033] Thirdly, the present invention also provides a computer-readable storage medium having a computer program or instructions stored thereon, wherein when the computer program or instructions are executed by a processor, the quality traceability method for linking polyester POY spinning and DTY texturing as described in the first aspect is implemented.

[0034] Fourthly, the present invention also provides an electronic device, including a processor, a memory, and a computer program or instructions stored in the memory and executable by the processor, wherein the processor executes the computer program or instructions to implement the quality traceability method for linking polyester POY spinning and DTY texturing as described in the first aspect.

[0035] This invention refines the quality record of POY spinning from the whole-boom level to the bobbin level by dividing the bobbin into sections based on winding length, winding time, or bobbin weight gain after POY winding, and creating a quality profile for each POY bobbin. It establishes a mapping relationship between bobbin sections and DTY texturing time windows by collecting unwinding length, unwinding time, breakage reconnection position, and texturing spindle position during DTY texturing. This allows for a traceable correspondence between local POY bobbins and the DTY processing process. Furthermore, by reverse-binding the strength, crimp, dyeing, or appearance grade results of the finished DTY bobbins to the corresponding bobbin sections and generating different anomaly markers based on anomaly repeatability and synchronicity, it can distinguish between POY source anomalies, DTY time window anomalies, and DTY spindle position anomalies after a finished product anomaly occurs. This narrows the scope of quality investigation, improves the granularity of cross-process anomaly location, and provides data for subsequent POY bobbin allocation, texturing spindle position selection, and equipment maintenance. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the quality traceability method for linking polyester POY spinning and DTY texturing according to the present invention;

[0037] Figure 2 This is a schematic diagram illustrating the mapping relationship between the POY cylinder layer interval and the DTY springing time window in this invention;

[0038] Figure 3 This is a functional block diagram of the quality traceability system for the linkage between polyester POY spinning and DTY texturing of the present invention. Detailed Implementation

[0039] The embodiments of the present invention will be described below with reference to the accompanying drawings and examples. It should be understood that the following embodiments are used to illustrate the implementation process of the present invention and are not intended to limit the scope of protection of the present invention. Those skilled in the art can make adaptive adjustments to the sampling frequency, the number of cylinder layers, the threshold setting, and the data interface form according to the production line equipment model, POY specifications, DTY texturing machine model, quality inspection standards, and data acquisition conditions.

[0040] This invention relates to a quality traceability method and system for polyester POY spinning and DTY texturing. POY refers to pre-oriented polyester yarn, typically formed from polyester melt through spinning, cooling, oiling, pre-networking, and winding. DTY refers to low-elasticity polyester yarn formed from POY through texturing processes such as unwinding, drawing, hot box heating, cooling, false twisting, networking, oiling, and winding. The "quality profile" referred to in this invention is a structured collection of process data, equipment data, quality data, and anomaly tags established around the same traceability object. It can be stored in the form of database tables, time-series data fragments, key-value records, or production traceability files, and is not limited to a specific mathematical model or machine learning model.

[0041] I. Overall Implementation Method

[0042] like Figure 1 As shown, the quality traceability method of the present invention includes processes such as generating a POY cylinder layer quality profile, mapping cylinder layer intervals to DTY springing time windows, generating a DTY processing profile, reverse binding of finished product grade results, and outputting anomaly source markers.

[0043] Traditional POY and DTY traceability typically uses a single POY bobbin or a single DTY finished bobbin as the basic traceability unit. When DTY finished products exhibit abnormalities in dyeing, fuzziness, elongation, or curling, the traceability results usually only pinpoint a specific POY bobbin, production batch, texturing machine, or texturing spindle position. Because a POY bobbin undergoes different winding stages (outer, middle, and inner layers) during winding, the melt pressure, side blowing, oil application, pre-network air pressure, and winding tension may differ at each stage. Furthermore, during DTY texturing, the POY bobbin continuously enters the yarn path during the unwinding process, with different bobbin layers corresponding to different texturing time windows. Therefore, using only the entire bobbin as the traceability unit makes it difficult to determine whether the finished product abnormality originates from a specific bobbin layer, a common time window abnormality during DTY texturing, or a single spindle equipment abnormality.

[0044] This invention divides POY bobbins into multiple bobbin layer sections and establishes a mapping relationship between the bobbin layer sections and the DTY texturing time window based on the unwinding length, unwinding time, breakage reconnection position, and texturing spindle position after DTY texturing. Then, the strength, curling, staining, or appearance grade results of the finished DTY bobbins are reverse-bound to the corresponding bobbin layer sections according to the texturing time window. If an anomaly repeatedly occurs across different time windows or different spindle positions within the same bobbin layer section, a POY source anomaly marker can be generated; if an anomaly occurs simultaneously at multiple spindle positions within the same texturing time window, a DTY time window anomaly marker can be generated; if an anomaly is concentrated at the same texturing spindle position and is accompanied by an abnormal processing state at that spindle position, a DTY spindle position anomaly marker can be generated.

[0045] The above methods can be used to trace finished product quality abnormalities from the bobbin level down to the POY bobbin layer range, DTY texturing time window, or DTY texturing spindle position, thereby providing a basis for process inspection at the spinning end, equipment maintenance at the texturing end, and subsequent production scheduling management.

[0046] II. Method Implementation

[0047] S1, POY tube layer division and POY tube layer quality profile formation

[0048] Upon completion of POY winding, the system generates a bobbin identifier for each POY bobbin. The bobbin identifier can be a QR code, barcode, RFID tag, or electronic batch number. Preferably, the bobbin identifier is a combination of the production line number, production date, spinning position number, spindle position number, and serial number to ensure that each POY bobbin has a unique identity within the same production cycle.

[0049] After generating the bobbin identifier, the system divides the POY bobbin into multiple bobbin layer intervals based on winding length, winding time, or bobbin weight gain. These layer intervals can be set according to the company's quality traceability requirements and product specifications. For example, for ordinary batch products, a POY bobbin can be divided into outer, middle, and inner layer intervals; for high-grade orders or specifications sensitive to quality fluctuations, it can be continuously divided into more intervals based on preset winding lengths or preset weight gains.

[0050] In one implementation, a single POY bobbin weighs approximately 15 kg, and can be divided into ten bobbin intervals with a weight increase of 1.5 kg. If the company uses winding length as the measurement method, it can also divide the intervals into 10 km, 20 km, or 50 km winding lengths. If winding time data is readily available on the production line, the intervals can be divided into 5 min, 10 min, or 15 min intervals. The above division methods can be used individually or in combination. For example, the system can use winding time as the primary basis for division and adjust the interval boundaries using bobbin weight increases.

[0051] For each bobbin section, at least the start and end winding times, start and end winding lengths, start and end bobbin weights, corresponding winding speeds, average winding tension, and tension fluctuation levels are recorded. Simultaneously, the system collects POY spinning data corresponding to that bobbin section to create a POY bobbin quality profile.

[0052] A POY core layer quality profile may include the following data:

[0053] Basic spinning information, including production batch, spinning thread number, spinning position, spinning spindle position, product specifications, and POY bobbin identification;

[0054] Component information, including spinning component number, spinneret number, component differential pressure, metering pump number, and metering pump speed;

[0055] Melt state information, including melt temperature, melt pressure, melt pressure fluctuation range, and filtration pressure difference;

[0056] Side-blowing information, including side-blowing air temperature, air pressure, air speed, air window number, and air speed fluctuation level;

[0057] Oiling information includes oil concentration, oil temperature, oil tanker speed, oil pump operating status, and oil consumption per unit time;

[0058] Pre-network information, including pre-network pressure, pre-network nozzle number, and pre-network pressure fluctuation level;

[0059] Winding information includes winding speed, winding tension, peak tension, tension fluctuation level, bobbin weight, and bobbin drop time.

[0060] To ensure consistency among different data points within the same POY winding layer, the system performs time alignment on all collected data before generating a POY winding layer quality profile. Specifically, using the timestamp of the winding control system as a reference, melt pressure, component differential pressure, side blowing parameters, oiling parameters, pre-network parameters, and winding tension are written onto the same time axis. For data with high sampling frequency, the mean, maximum, minimum, fluctuation amplitude, or number of anomalies can be calculated within the winding layer interval; for data with low sampling frequency, the most recent valid value or a representative value of the interval can be used.

[0061] During production, stages such as start-up, shutdown, component replacement, drum dropping, and abnormal alarm recovery typically do not represent a stable production state. The system can mark the data corresponding to these stages as unstable sampled data. Unstable sampled data can be excluded when calculating the interval mean and fluctuation level, or it can be saved as a separate event record. This reduces the interference of unstable processes on the drum quality profile.

[0062] In one implementation, the system can generate POY cylinder layer early warning tags based on parameter fluctuations within the cylinder layer range. For example, when the component differential pressure exceeds a preset upper limit, a component differential pressure early warning tag is generated; when the melt pressure fluctuation exceeds a preset range, a melt pressure fluctuation early warning tag is generated; when the side-blowing air velocity fluctuation exceeds a preset range, a side-blowing air velocity fluctuation early warning tag is generated; when the oil application amount fluctuation exceeds a preset range, an oil application fluctuation early warning tag is generated; and when the winding tension fluctuation exceeds a preset range, a winding tension fluctuation early warning tag is generated. These early warning tags can serve as supplementary evidence in subsequent anomaly attribution, but are not directly equivalent to the final conclusion of quality anomalies.

[0063] For example, the winding time for the middle layer section of a certain POY bobbin is from 10:25:00 to 10:34:59. Within this period, the system records an average component differential pressure of 12.4 MPa, a melt pressure fluctuation of 0.28 MPa, a side-blowing air velocity fluctuation of 0.12 m / s, an oil application fluctuation of 4.5%, and a winding tension fluctuation of 3.1 cN. If the company sets an oil application fluctuation exceeding 4.0% to generate an early warning, then an oil application fluctuation early warning label can be generated for this bobbin layer section.

[0064] S2. Establish the mapping relationship between the cylinder layer interval and the DTY (Dual-Temperature Type) springing time window.

[0065] like Figure 2 As shown, after winding, the POY bobbin is not traced as a single unit of mass. Instead, it is divided into multiple bobbin layers according to winding length, winding time, or bobbin weight gain, such as bobbin layer L1, L2, L3, L4, and L5. These bobbin layers are not distributed from top to bottom along the bobbin axis, but rather form radial rings as the yarn bundle reciprocates across the winding surface and winds layer by layer. Specifically, the first winding portion near the paper tube or core forms the inner bobbin layer. As winding time and length increase, the yarn layers gradually accumulate radially outwards, with the later winding portion forming the outer bobbin layer. Therefore, bobbin layers L1, L2, L3, L4, and L5 can be understood as annular winding sections distributed sequentially from the inside out or from the outside in along the radial direction of the POY bobbin, rather than vertical segments distributed along the bobbin height. If numbering is based on the unwinding process sequence, the outermost section that first unwinds into the DTY texturing path is typically designated as section L1, followed by sections L2, L3, L4, and L5, with the innermost section closest to the core entering the DTY texturing path last. If numbering is based on the POY winding formation sequence, the numbering direction is reversed. However, the system establishes a correspondence between each section based on its start and end winding lengths, cumulative unwinding length, and unwinding time, without affecting the mapping between the section and the DTY texturing time window. Each section corresponds to a different time period and process state during the POY winding process, and therefore is associated with a corresponding POY section quality profile.

[0066] When a POY bobbin is put into DTY texturing, the system reads the POY bobbin identifier and records data such as texturing machine number, texturing spindle position, yarn path number, entry time, unwinding speed, unwinding time, cumulative unwinding length, breakage reconnection position, and bobbin change time. As the POY bobbin is continuously unwinded, different bobbin layers sequentially enter the DTY texturing yarn path. Based on the cumulative unwinding length and the start and end lengths of each bobbin layer, the system maps bobbin layers L1, L2, L3, L4, and L5 to the corresponding DTY texturing time windows T1, T2, T3, T4, and T5, respectively. Therefore, different bobbin layers within the POY bobbin no longer participate in traceability only as whole bobbins, but can establish a one-to-one or segmented correspondence with specific time windows in the DTY texturing process.

[0067] Within the DTY texturing time window, the system simultaneously collects data on yarn feed tension, drafting tension, hot box temperature, false twister status, network air pressure, yarn breakage, and fuzz detection, forming a DTY processing profile for the corresponding time window. When yarn breakage, re-starting, or bobbin replacement occurs, the system uses the breakage reconnection time, re-starting time, or bobbin replacement time as boundaries to split the original DTY texturing time window, recording the bobbin layer intervals and processing status before and after the breakage separately, thus avoiding mixing abnormal data before and after the breakage reconnection into the same quality traceability unit.

[0068] After the DTY finished bobbins complete inspection, the system reverse-matches the results of strength, crimp, dyeing, or appearance grades according to the finished bobbin identifier, texturing machine number, texturing spindle position, winding section position, and inspection time to the corresponding DTY texturing time window. Then, the DTY texturing time window is used to determine the corresponding POY bobbin layer range. Therefore, the DTY finished product grade result can be traced back to a specific POY bobbin layer range, rather than just to the entire POY bobbin or production batch.

[0069] Furthermore, the system according to Figure 2 The mapping and reverse binding relationships shown are used for anomaly attribution. When the same type of graded anomaly repeatedly occurs in different DTY texturing time windows or different texturing spindle positions within the same POY bobbin layer, while the corresponding DTY processing profile does not show obvious anomalies, the system generates a POY source anomaly marker; when multiple texturing spindle positions within the same DTY texturing time window simultaneously experience tension, hot box temperature, network air pressure, yarn breakage, or fuzzing anomalies, the system generates a DTY time window anomaly marker; when anomalies are concentrated in the same texturing spindle position, accompanied by anomalies in the false twister, guide, or network nozzle status of that spindle position, the system generates a DTY spindle position anomaly marker. Through this mapping relationship, Figure 2 This demonstrates the complete traceability logic of this implementation method, from the POY cylinder layer interval to the DTY pop-up time window, and then from the finished product grade result back to the cylinder layer interval.

[0070] This step involves establishing a mapping relationship between POY bobbin layer intervals and DTY texturing time windows. Since POY bobbins are continuously unwound into the yarn path during DTY processing, different bobbin layer intervals of a single POY bobbin will enter different DTY texturing time windows according to the unwinding sequence. The system determines the start and end times of each bobbin layer interval entering the texturing yarn path based on the unwinding length and unwinding time, and generates a bobbin layer interval mapping table.

[0071] In one implementation, the system obtains the cumulative unwinding length via an unwinding length encoder, roller speed signal, texturing machine winding speed signal, or unwinding tension wheel length signal. If the bobbin layer is divided according to winding length, the bobbin layer to which the current unwound yarn segment belongs is directly determined based on the cumulative unwinding length. If the bobbin layer is divided according to winding time or bobbin weight gain, the winding time or bobbin weight gain can be pre-converted into the corresponding winding length range and then matched with the cumulative unwinding length.

[0072] In one implementation, the cumulative unwinding length can be calculated as follows:

[0073]

[0074] In the formula, This indicates the cumulative unwinding length since the POY bob was loaded with DTY springs. This indicates the launch time of POY (Polygenous Yard). Indicates the current sampling time. This indicates the unwinding speed.

[0075] When the unwinding length range corresponding to a certain cylinder section is The point in time when the cumulative unwinding length enters this range is taken as the starting point of the DTY texturing time window for that bobbin section; the point in time when the cumulative unwinding length leaves this range is taken as the ending point of the DTY texturing time window. Based on this, the system generates a bobbin section mapping table including POY bobbin identifier, bobbin section number, texturing machine number, texturing spindle position, starting unwinding length, ending unwinding length, starting time and ending time.

[0076] Different winding forms and unwinding methods may result in different unwinding sequences for outer or inner layer sections. During implementation, the system should set the layer section sequence according to the actual unwinding direction. For example, if the outer layer enters the yarn path first during DTY unwinding, the outer layer section formed later in POY winding will correspond to the springing time window first; if the equipment uses other unwinding methods, the section sequence should be set according to the actual unwinding path.

[0077] When a breakage, tube replacement, or re-creation occurs during DTY texturing, the system records the corresponding unwinding length at each point. The original DTY texturing time window is then divided into multiple sub-time windows, using the breakage reconnection time, tube replacement time, or re-creation time as boundaries. The breakage reconnection process can be recorded as a transition segment and can be removed during subsequent POY source anomaly repeatability checks to avoid mistaking tension impacts during the re-creation process for POY source anomalies.

[0078] For example, if a certain section of the winding core corresponds to a DTY (Dual Time Tolerance) rewinding time window of 13:20:00 to 13:31:00 under normal unwinding conditions, but a break occurs at 13:25:30 and a new break occurs at 13:27:00, the system will divide this time window into two valid sub-time windows: 13:20:00 to 13:25:30 and 13:27:00 to 13:31:00. The period from 13:25:30 to 13:27:00 will be marked as the break-and-reconnection transition section. When subsequently binding the finished product quality, the system can perform matching based on these valid sub-time windows.

[0079] S3, Creating a DTY-processed image

[0080] Within each DTY texturing time window, the system collects data on the feed tension, drafting tension, hot box temperature, false twister status, network air pressure, and breakage and fuzz detection at the corresponding texturing spindle position, forming a DTY processing profile.

[0081] DTY profile processing can include the following data:

[0082] Tension data, including average feed tension, average drafting tension, peak tension, trough tension, number of tension fluctuations, and duration of tension anomalies;

[0083] Hot box data, including hot box set temperature, hot box actual temperature, actual temperature deviation, temperature deviation duration, and temperature zone number;

[0084] False twister data, including false twister speed, speed deviation, vibration level, motor current fluctuation and friction disc condition;

[0085] Network data includes network pressure setpoint, actual network pressure, network pressure fluctuation level, and network nozzle status;

[0086] Abnormal event data includes the number of times the head breaks off, the number of times it regenerates, the number of times the hair is broken, machine alarm records, and manual handling records.

[0087] In one implementation, the number of tension fluctuations can be determined according to the following rule: when the tension value is higher than the preset upper tension limit or lower than the preset lower tension limit, and continues for more than a preset time, a tension fluctuation is recorded. The actual temperature deviation of the hot box can be the absolute value of the difference between the actual temperature and the set temperature, or it can be the average value, maximum value, or number of times the temperature deviation exceeds the limit within a time window. The network air pressure fluctuation level can be determined based on the difference between the maximum and minimum air pressure values ​​within a time window.

[0088] When tension fluctuations, actual oven temperature deviations, false twister status, network air pressure fluctuations, and the number of thread breaks or lint counts exceed the corresponding preset ranges within the DTY texturing time window, the system can generate a DTY processing warning label within that DTY texturing time window. The DTY processing warning labels can include tension fluctuation warnings, oven temperature deviation warnings, false twister status warnings, network air pressure warnings, thread breakage warnings, and lint warnings. These warning labels are used to subsequently determine whether the abnormality originates from the DTY processing process.

[0089] In this step, the DTY processing profile is not recorded in isolation, but is associated with the POY bobbin quality profile through the mapping relationship established in S2. This way, when an anomaly occurs in the finished DTY bobbin, the system can view both the spinning status of the corresponding POY bobbin section and the processing status of that section when it enters the DTY texturing stage.

[0090] S4. Reverse-bind the DTY finished product grade result to the cylinder section.

[0091] After DTY finished bobbins are wound, they can undergo strength, elongation at break, curling, dyeing, or appearance grade inspections. Strength and elongation tests can include breaking strength and elongation at break; curling tests can include curling shrinkage and curling stability; dyeing tests can include dyeing color difference, dyeing uniformity, or dyeing judgment results; appearance inspections can include results such as fuzz, cobwebs, oil stains, end face abnormalities, poor forming, and collapsed edges.

[0092] The system matches the inspection time, finished product bobbin identifier, texturing machine number, texturing spindle position, and winding section position of the DTY finished bobbin to determine the DTY texturing time window corresponding to the grade result. Subsequently, the system determines the corresponding POY bobbin identifier and bobbin layer number according to the bobbin layer interval mapping table, and writes the grade result into the quality association record.

[0093] Quality-related records may include DTY finished cylinder identifier, POY cylinder identifier, cylinder layer interval number, DTY texturing time window, texturing machine number, texturing spindle position, grade result, anomaly type, POY cylinder layer quality profile summary, and DTY processing profile summary.

[0094] If a DTY finished bobbin corresponds to multiple POY bobbin layers, the system can perform segmented binding based on the finished product winding section position or finished product formation time. If the company's inspection result is a whole bobbin inspection result, the system can simultaneously write this level of result into the corresponding multiple bobbin layers and mark it as a whole bobbin inspection result in the record. If the company has the capability for segmented dyeing inspection, segmented appearance inspection, or online fuzz positioning, then segmented inspection results are preferred for binding.

[0095] For example, a DTY finished bobbin has a dyeing grade of B, and the detection system records an anomaly in the middle section of the bobbin. The system determines the DTY texturing time window corresponding to this middle section based on the finished bobbin winding time and texturing spindle position, and then determines the corresponding POY bobbin middle layer section based on the bobbin layer section mapping table. Thus, the dyeing grade anomaly can be reverse-linked to the corresponding POY bobbin layer section, rather than just to the entire POY bobbin.

[0096] S5. Generate anomaly markers based on abnormal repeatability and abnormal synchronization.

[0097] When the tensile strength, curling, dyeing, or appearance grade results of DTY finished bobbins are abnormal, the system determines the source of the abnormality based on quality correlation records, POY bobbin quality profiles, and DTY processing profiles. Abnormal grade results can be caused by tensile strength indexes falling below the lower limit of the specification, curling indexes exceeding the specified range, dyeing grades falling below the preset grade, appearance fuzz counts exceeding the allowable number, or other abnormalities defined in the company's quality standards.

[0098] This invention primarily determines the source of anomalies through abnormal repetition and abnormal synchronization.

[0099] 1. POY source anomaly marker

[0100] Abnormal repeatability is used to determine whether the same type of abnormality repeatedly occurs in different DTY loading time windows or different loading positions within the same cylinder layer interval.

[0101] In one implementation, when multiple DTY finished cylinders corresponding to the same cylinder layer interval, or when the same type of tensile abnormality, curling abnormality, dyeing abnormality, or appearance abnormality repeatedly occurs in different DTY texturing time windows or different texturing spindle positions in the same cylinder layer interval, and the DTY processing image within the corresponding DTY texturing time window does not exceed the preset processing abnormality range, the system generates a POY source abnormality mark.

[0102] The preset duplicate judgment criteria can be set as follows: the same type of abnormality appears in no less than two quality correlation records for the same bobbin interval or the same bobbin interval in the same spinning position; or the abnormality ratio corresponding to the same bobbin interval in a production batch reaches a preset ratio. The specific threshold can be set according to the company's historical pass rate, product grade requirements, and testing items.

[0103] For example, if multiple POY bobbins produced continuously at the same spinning station all show abnormal dyeing grades in the DTY finished products corresponding to the same middle layer, while the tension, hot box temperature, false twister status, and network air pressure are all within the normal range during the corresponding DTY processing time window, the system will generate a POY source abnormality flag and associate the abnormality with the corresponding spinning station, spinning assembly, side blowing parameters, or oiling parameters.

[0104] 2. DTY Time Window Anomaly Marking

[0105] Abnormal synchronization is used to determine whether multiple texturing spindles simultaneously experience processing abnormalities or finished product abnormalities within the same DTY texturing time window.

[0106] In one implementation, when two or more texturing spindles simultaneously exhibit abnormal tension fluctuations, abnormal hot box temperature deviations, abnormal false twister status, abnormal network air pressure, abnormal breakage, or abnormal fuzz within the same DTY texturing time window, and these abnormalities overlap in time, the system generates a DTY time window abnormality marker.

[0107] The preset synchronization judgment condition can be set as follows: the number of abnormal springing positions within the same DTY springing time window is not less than two, or the proportion of abnormal springing positions to the number of participating springing positions is not less than a preset proportion; at the same time, the overlap duration of the abnormal start and end times is not less than the preset overlap duration.

[0108] For example, if multiple spindle positions of a texturing machine simultaneously experience low network air pressure and increased filament count within the same time window, and the corresponding POY bobbin layer ranges come from different POY bobbins and different spinning positions, and no warning of the same type appears in the POY bobbin layer quality profile, then the system generates a DTY time window anomaly marker and associates the anomaly with the network air path, compressed air branch, or common air pressure control unit.

[0109] 3. DTY spindle position anomaly marker

[0110] When the grade results are concentrated in the same texturing spindle position, and the false twister status, guide status, network nozzle status or tension fluctuation status corresponding to that texturing spindle position exceeds the preset normal range, the system generates a DTY spindle position abnormality mark.

[0111] For example, if POY bobbins from different spinning positions are continuously processed at the same texturing spindle position, but the finished products all show abnormal fuzziness; at the same time, the vibration level of the false twister at this spindle position is continuously higher than the preset range, and no synchronous abnormality occurs at other spindle positions within the same time window, then the system generates a DTY spindle position abnormality mark and prompts to check the false twister, guide, or network nozzle corresponding to this spindle position.

[0112] 4. Output of quality traceability records

[0113] The system ultimately outputs a quality traceability record. This record may include DTY finished product cylinder identification, POY cylinder identification, cylinder layer interval number, DTY spring-load time window, anomaly source marker, anomaly type, associated process parameters, warning labels, and suggested inspection targets. The quality traceability record is available for querying by quality personnel, process personnel, and equipment maintenance personnel, and can also serve as the basis for subsequent production scheduling suggestions and risk level updates.

[0114] III. System Implementation

[0115] like Figure 3 As shown, this invention also provides a quality traceability system that links polyester POY spinning with DTY texturing. This system can be deployed in an enterprise MES system, industrial data platform, texturing machine data acquisition system, or independent quality traceability server, or it can be implemented collaboratively by multiple systems.

[0116] The system includes a POY data acquisition module, a cylinder layer interval generation module, a springing mapping module, a DTY data acquisition module, a quality binding module, and an anomaly attribution module.

[0117] The POY data acquisition module is used to collect information on spinning position, spindle position, component information, melt pressure, side blowing parameters, oiling parameters, pre-network parameters, and winding tension during the POY spinning and winding process. This module can be implemented through a PLC, DCS, industrial gateway, sensor interface, or MES data interface.

[0118] The bobbin layer generation module is used to generate bobbin identifiers for each POY bobbin and divide the POY bobbin into multiple bobbin layer intervals according to winding length, winding time, or bobbin weight gain, forming a POY bobbin layer quality profile.

[0119] The texturing mapping module is used to read the bobbin identifier when the POY bobbin is subjected to DTY texturing, and to establish a mapping relationship between the bobbin layer interval and the DTY texturing time window based on the unwinding length, unwinding time, breakage reconnection position, and texturing spindle position. This module may include code reading function, unwinding length counting function, time window generation function, and breakage reconnection correction function.

[0120] The DTY data acquisition module is used to collect data on yarn feeding tension, drafting tension, hot box temperature, false twister status, network air pressure, yarn breakage and fuzz detection within the DTY texturing time window, forming a DTY processing profile.

[0121] The quality binding module is used to reverse bind the strength, curling, staining or appearance grade results of DTY finished bobbins to the corresponding bobbin layer interval according to the DTY springing time window, and generate quality association records.

[0122] The anomaly attribution module is used to generate POY source anomaly markers, DTY time window anomaly markers, or DTY spindle position anomaly markers based on anomaly repeatability and anomaly synchronization, and output quality traceability records.

[0123] In one embodiment, the system may further include a risk feedback module. The risk feedback module is used to update the risk level of the corresponding spinning position, spinning spindle, spinning assembly, spinneret, or POY bobbin layer area based on POY source anomaly markers; to update the risk level of the corresponding texturing machine, heating box, compressed air branch, or network air path based on DTY time window anomaly markers; and to update the risk level of the corresponding texturing spindle, false twister, guide, or network nozzle based on DTY spindle position anomaly markers.

[0124] When the risk level of a POY bobbin layer or a POY bobbin exceeds the preset risk level of the raw yarn, the system can restrict the POY bobbin from entering high-grade DTY orders, or prompt for visual re-inspection, oil content testing, or yarn evenness testing. When the risk level of a texturing spindle, false twister, or network nozzle exceeds the preset equipment risk level, the system can restrict the texturing spindle from accepting high-grade POY bobbins, or generate a maintenance prompt.

[0125] This invention can also be implemented by a computer program or instructions. The computer program or instructions can be stored in a computer-readable storage medium, such as a read-only memory, random access memory, flash memory, hard disk, solid-state drive, removable storage medium, or other media capable of storing program instructions. When the computer program or instructions are executed by a processor, the aforementioned quality traceability method linking polyester POY spinning and DTY texturing can be implemented, including steps such as POY bobbin layer division, bobbin layer mapping with DTY texturing time window, DTY processing profile generation, reverse binding of finished product grade results, and output of anomaly source markers.

[0126] This invention can also be implemented using electronic devices. The electronic device can be a server, industrial computer, edge computing terminal, MES system server, quality traceability platform server, or a data processing terminal that communicates with POY spinning equipment and DTY texturing equipment. The electronic device includes a processor, a memory, and computer programs or instructions stored in the memory and executable by the processor. When the processor executes the computer program or instructions, it calls POY spinning data, DTY texturing data, and finished product inspection data, establishes a mapping relationship between the bobbin layer interval and the DTY texturing time window, generates quality correlation records, and outputs POY source anomaly markers, DTY time window anomaly markers, or DTY spindle position anomaly markers based on abnormal repeatability and abnormal synchronicity.

[0127] IV. Examples

[0128] 4.1 Example 1: Tracing the anomalies in the POY cylinder layer area

[0129] A chemical fiber company produces polyester POY with a target specification of 83 dtex / 72f. Each POY bobbin weighs approximately 15 kg. The subsequent processing produces DTY finished yarn with a target specification of 55 dtex / 72f. The company collects data at the POY spinning end, including melt pressure, component pressure difference, side-blowing air velocity, oiling agent consumption, pre-network air pressure, and winding tension. At the DTY texturing end, it collects data on texturing spindle position, unwinding speed, tension, hot box temperature, false twister status, network air pressure, and data on yarn breakage and fuzz detection.

[0130] In this embodiment, each POY bobbin is divided into ten bobbin layers based on weight, with each layer weighing approximately 1.5 kg. The system determines the outer layer layer to enter the DTY texturing path first, followed by the inner layer layer, based on the actual unwinding direction. After winding, the system generates a QR code for each POY bobbin and records the start and end winding times, start and end weights, average winding tension, and corresponding process parameters for each bobbin layer.

[0131] In a certain batch, the fifth layer of POY bobbin P-A08-006 recorded an oil application fluctuation of 4.5%, exceeding the company's set threshold of 4.0%, while the winding tension fluctuation was 3.1 cN. The system generated oil application fluctuation warning tags and winding tension fluctuation warning tags for this bobbin layer.

[0132] The POY bobbin was fed into the 36th spindle of the No. 2 DTY texturing machine. The system read the POY bobbin identifier and determined the DTY texturing time window corresponding to the fifth bobbin layer interval to be from 14:12:00 to 14:26:30 based on the unwinding length and unwinding time. Within this time window, the DTY processing profile showed that the feed tension, drafting tension, hot box temperature, false twister status, and network air pressure all did not exceed the preset processing anomaly range.

[0133] After testing the DTY finished product bobbins, the dyeing grade was B, and the abnormal section was located in the middle of the finished product. Based on the position of the finished product winding section and the texturing time window, the system reverse-linked this dyeing abnormality to the fifth layer section of POY bobbins P-A08-006. Subsequently, the system queried other POY bobbins produced at the same spinning station in the same batch at similar times and found that their fifth layer sections also exhibited the same type of dyeing abnormality after processing at different texturing spindle stations, while the corresponding DTY processing profiles did not exceed the preset processing abnormality range. Based on this, the system generated a POY source abnormality marker and suggested checking the oil supply stability, component status, and side-blowing stability of that spinning station in the traceability record.

[0134] In this embodiment, the tracing results are not limited to the POY bobbin level, but are located to the fifth bobbin layer of the POY bobbin. Combined with the repeated anomalies in different texturing spindle positions, it is determined that the source tends to be the POY spinning end.

[0135] 4.2 Example 2: Tracing DTY Time Window Anomalies

[0136] A batch of POY bobbins originated from different spinning stations and were fed into multiple spindles on the same DTY texturing machine. Between 15:08:00 and 15:18:00, the system detected network air pressure below the preset range at multiple spindles, and simultaneously, the number of fuzz detections increased at multiple spindles. The corresponding POY bobbin layers originated from different POY bobbins and different spinning stations, and no identical bobbin layer warning tags appeared in the POY bobbin layer quality profile.

[0137] The DTY finished product inspection results showed that the finished products corresponding to multiple spindle positions exhibited a decline in appearance grade, with fuzziness being the primary abnormality type. The system determined that multiple texturing spindle positions within the same DTY texturing time window simultaneously experienced network air pressure and fuzziness abnormalities, meeting the preset synchronization judgment conditions, and generated a DTY time window abnormality marker. The quality traceability record recommends checking the network air path, compressed air branch, and common air pressure control valve corresponding to this time window.

[0138] In this embodiment, the system attributes the source of the anomaly to the DTY common processing condition anomaly based on the synchronization anomaly of multiple spindles in the same time window, thus avoiding attributing the anomaly to multiple POY cylinders.

[0139] 4.3 Example 3: Traceability of DTY Spindle Position Anomalies

[0140] A batch of POY bobbins from different spinning positions, after being processed by the 28th spindle of the same texturing machine, showed abnormalities in the filament grade of multiple DTY finished bobbins. System queries of the DTY processing profile for the 28th spindle revealed that the false twister vibration level at that spindle was consistently higher than the preset range, and the peak feed tension repeatedly exceeded the set upper limit. Meanwhile, no synchronous abnormalities were observed at other texturing spindles within the same time window. The same abnormality was not repeated in other spindles within the corresponding POY bobbin layer range.

[0141] The system identifies anomalies concentrated in the same texturing spindle position, accompanied by abnormal processing conditions at that position, and generates a DTY spindle position anomaly marker. The tracing record suggests checking the false twister friction disc, guide wear condition, and yarn path position at the 28th spindle position.

[0142] In this embodiment, the system locates the source of the anomaly to a single texturing spindle, avoiding unnecessary batch shutdowns for troubleshooting at the POY spinning end.

[0143] V. Comparison and Effect Description

[0144] To illustrate the effectiveness of this invention, the following comparative examples are provided. All schemes use the same production batch, the same DTY texturing equipment, and the same finished product testing standards, differing only in the traceability method.

[0145] 5.1 Comparative Example 1: Using only POY tube-level traceability

[0146] In Comparative Example 1, each POY bobbin generates only one bobbin identifier, without dividing the bobbin layer range. The system records the overall spinning parameters and overall DTY processing parameters of the POY bobbin. When an anomaly occurs in the DTY finished product, it can only trace back to the corresponding POY bobbin and texturing spindle position, and cannot determine whether the anomaly corresponds to the outer layer, middle layer, or inner layer, nor can it determine whether the same bobbin layer range has repeated anomalies in different texturing spindle positions.

[0147] In the same production batch as Example 1, Comparative Example 1 can only output the record "POY bobbin P-A08-006 corresponds to DTY finished product dyeing grade B", and cannot further identify the fifth bobbin layer interval, nor can it associate it with the repetitive anomaly of the same bobbin layer interval in the same spinning position.

[0148] 5.2 Comparative Example 2: Only DTY processing data was collected.

[0149] In Comparative Example 2, the system collects data on the tension of the DTY texturing machine, the temperature of the hot box, the status of the false twister, and the network air pressure, but does not read the POY bobbin layer range, nor does it establish a mapping relationship between the bobbin layer range and the DTY texturing time window. When an abnormality occurs in the finished product, the system can only determine whether there is an abnormality in the texturing process based on the DTY processing profile. If the DTY processing profile does not exceed the preset range, it cannot continue to locate the source of the abnormality.

[0150] In the same production batch as Example 1, since the DTY processing profile is within the normal range, Comparative Example 2 can only output "No obvious DTY processing abnormality found", and cannot further correlate it with the oiling fluctuation at the POY spinning end and the repeated abnormality in the same bobbin area.

[0151] 5.3 Comparative Example 3: Judgment of abnormal repeatability and abnormal synchronicity is not adopted.

[0152] In Comparative Example 3, the system establishes a connection between POY bobbins and DTY finished bobbins, but only determines the source of anomalies based on a single incident. If a DTY finished product is abnormal but the corresponding DTY processing profile is normal, it is directly determined to be a POY anomaly; if DTY processing parameters are abnormal within a certain time window, it is directly determined to be a DTY anomaly.

[0153] This method is susceptible to detection errors, joint sections, temporary tension fluctuations, or occasional appearance defects. For example, an occasional abnormality in the fuzz of a single finished bobbin may be directly attributed to the POY end; an abnormality in the false twister of a single spindle may also be misjudged as an abnormality in the time window of the entire texturing machine.

[0154] 5.4 Comparative Tests and Results

[0155] Data was reviewed using three consecutive days of production records, including 240 POY cylinders, 228 DTY finished cylinders, and 32 abnormal DTY finished cylinders. Different traceability methods were compared based on the company's quality inspection records and equipment maintenance records for manual verification.

[0156] To verify the effectiveness of the traceability method described in this invention in locating anomalies across processes, continuous production records were selected for data playback. Enterprise quality inspection records and equipment maintenance records were used as the basis for manual verification. The implementation method of this invention was compared with different traceability methods. The comparison results are shown in Table 1. Specifically, three consecutive days of POY spinning, DTY texturing, and finished product inspection records from the same production line were selected as test data. The data included POY bobbin identification, bobbin layer division records, DTY texturing time windows, texturing spindle positions, tension, hot box temperature, network air pressure, end breakage, filament detection, and finished product strength, crimp, dyeing, and appearance grade results. Data playback was performed according to the implementation method of this invention, POY bobbin-level traceability only, DTY processing data traceability only, and traceability methods without anomaly repeatability and anomaly synchronicity judgment. The anomaly source judgment results for each scheme were output. Subsequently, the enterprise quality inspection records, equipment maintenance records, and on-site process personnel verification results were used as the basis for manual verification, and the number of anomalies whose judgment results matched the manual verification results was counted.

[0157] Table 1 Comparison of Quality Traceability Results with Different Traceability Methods

[0158]

[0159] As shown in Table 1, the embodiments of the present invention can pinpoint the source of anomalies to the POY bobbin layer interval, the DTY texturing time window, or the DTY texturing spindle position. While Comparative Example 1 can achieve bobbin-level traceability, it cannot identify differences between different bobbin layer intervals within the same POY bobbin. Comparative Example 2 can detect some DTY processing anomalies, but when the DTY processing parameters are normal while there are quality fluctuations in local POY bobbin layers, further traceability is impossible. Comparative Example 3 does not use anomaly repeatability and anomaly synchronicity judgments, making it susceptible to the influence of single anomalies.

[0160] The above results show that by dividing POY bobbin layers into intervals, mapping DTY texturing time windows, reverse binding of finished product grades, and judging abnormal repeatability and abnormal synchronization, the positioning granularity of cross-process quality traceability between POY spinning and DTY texturing can be improved, and it helps to distinguish between POY source anomalies, DTY common time window anomalies, and DTY single spindle anomalies.

[0161] VI. Other Instructions

[0162] This invention does not require companies to replace all POY spinning equipment or DTY texturing equipment. For companies that already have MES systems, texturing machine data acquisition systems, or quality inspection systems, this can be achieved by adding logic for POY bobbin identification reading, bobbin layer division, unwinding length counting, time window generation, and quality binding. If a company does not yet have the conditions for online filament detection or online tension detection, it can first implement basic traceability using breakage records, hot box temperature, network air pressure, and finished product inspection results; once the testing equipment is improved, the data fields for the DTY processing profile can be expanded.

[0163] The preset thresholds in this invention can be set according to product specifications, equipment models, enterprise quality standards, and historical production records. For example, the tension fluctuation threshold can be determined based on the tension fluctuation statistical range of qualified batches of products of the same specification; dyeing anomalies can be determined using the enterprise's current dyeing grading standards; the anomaly repeatability threshold can be set to the occurrence of the same anomaly in at least two quality-related records within the same cylinder layer interval; and the anomaly synchronization threshold can be set to the simultaneous occurrence of the same or related anomalies in at least two texturing spindle positions within the same DTY texturing time window. All of the above thresholds can be adjusted according to on-site production conditions.

[0164] The data processing of this invention can be implemented using conventional databases, industrial control interfaces, and rule logic. POY cylinder layer quality profiles, DTY processing profiles, quality correlation records, and anomaly markers can all be stored using structured tables. Those skilled in the art can implement the technical solution of this invention based on the above steps.

Claims

1. A quality traceability method linking polyester POY spinning and DTY texturing, characterized in that, include: S1. When POY winding is completed, generate a bobbin identifier for each POY bobbin, and divide the POY bobbin into multiple bobbin layer intervals according to winding length, winding time or bobbin weight gain. Record the spinning position, spinning spindle position, component information, melt pressure, side blowing parameters, oiling parameters, pre-network parameters and winding tension corresponding to each bobbin layer interval to form a POY bobbin layer quality profile. S2. When the POY bobbin is loaded with DTY, read the bobbin identifier, collect the unwinding length, unwinding time, breakage continuation position and loading spindle position, and establish the mapping relationship between the bobbin layer interval and the DTY loading time window. S3. Collect data on yarn feeding tension, drafting tension, hot box temperature, false twister status, network air pressure, yarn breakage and fuzz detection within the DTY texturing time window to form a DTY processing profile corresponding to the DTY texturing time window. S4. Bind the strength, curling, dyeing or appearance grade results of the DTY finished bobbin to the corresponding bobbin layer interval in reverse according to the DTY texturing time window, and generate a quality correlation record between the bobbin layer interval, the DTY texturing time window and the grade results. S5. When the grade result is abnormal, based on the abnormal repeatability of the same cylinder layer in different DTY loading time windows or different loading spindle positions, and the abnormal synchronization of multiple loading spindle positions within the same DTY loading time window, generate POY source abnormality mark, DTY time window abnormality mark or DTY spindle position abnormality mark, and output quality traceability record. The abnormal repeatability includes multiple DTY finished cylinders corresponding to the same cylinder layer interval, or the same type of strong elongation abnormality, curling abnormality, dyeing abnormality or appearance abnormality repeatedly appearing in different DTY texturing time windows and different texturing spindle positions in the same cylinder layer interval; when the abnormal repeatability reaches the preset repeatability judgment condition, and the DTY processing image in the corresponding DTY texturing time window does not exceed the preset processing abnormality range, a POY source abnormality mark is generated. The abnormal synchronization includes the simultaneous occurrence of abnormal tension fluctuations, abnormal hot box temperature deviations, abnormal false twister status, abnormal network air pressure, abnormal head breakage, or abnormal filaments at two or more texturing spindle positions within the same DTY texturing time window; when the abnormal synchronization reaches the preset synchronization judgment condition, a DTY time window abnormality mark is generated. When the grade results are concentrated in the same texturing spindle position, and the false twister status, guide status, network nozzle status or tension fluctuation status corresponding to that texturing spindle position exceeds the preset normal range, a DTY spindle position abnormality mark is generated.

2. The quality traceability method for linking polyester POY spinning and DTY texturing according to claim 1, characterized in that, In step S1, the bobbin layer interval includes an outer layer interval, a middle layer interval, and an inner layer interval, or includes multiple intervals continuously divided according to a preset winding length; each bobbin layer interval records the start and end winding time, start and end winding length, start and end bobbin weight, average winding tension, tension fluctuation level, and the winding speed corresponding to that bobbin layer interval; and / or, the component information includes the spinning component number, spinneret number, component pressure difference, metering pump number, and metering pump speed; the side blowing parameters include air temperature, air pressure, air speed, and air window number; the oiling parameters include oil concentration, oil temperature, oiler speed, and oil consumption per unit time; the pre-network parameters include pre-network air pressure, pre-network nozzle number, and pre-network air pressure fluctuation level.

3. The quality traceability method for linking polyester POY spinning and DTY texturing according to claim 1, characterized in that, In step S1, before forming the POY cylinder layer quality profile, the melt pressure, side blowing parameters, oiling parameters, pre-network parameters and winding tension within the same cylinder layer range are time-aligned, and unstable sampling data corresponding to shutdown, component replacement or head generation processes are removed. And / or, when the component pressure difference, melt pressure fluctuation, side blowing wind speed fluctuation, oil application amount fluctuation, or winding tension fluctuation in the same cylinder layer section exceed the corresponding preset range, a POY cylinder layer warning label is generated in that cylinder layer section.

4. The quality traceability method for linking polyester POY spinning and DTY texturing according to claim 1, characterized in that, In step S2, establishing the mapping relationship between the bobbin layer interval and the DTY texturing time window includes: determining the start and end times of each bobbin layer interval entering the texturing yarn path based on the POY bobbin's online time, texturing machine number, texturing spindle position, yarn path number, unwinding speed, cumulative unwinding length, and breakage reconnection time, and generating a bobbin layer interval mapping table; and / or, when a breakage, bobbin replacement, or regeneration occurs during the DTY texturing process, recording the corresponding unwinding length at the time of the breakage, bobbin replacement, or regeneration, and dividing the original DTY texturing time window into multiple sub-time windows with the breakage reconnection time, bobbin replacement time, or regeneration time as boundaries, so that each sub-time window corresponds to the bobbin layer interval before and after the breakage, bobbin replacement, or regeneration.

5. The quality traceability method for linking polyester POY spinning and DTY texturing according to claim 1, characterized in that, In step S3, the DTY processing profile includes the average tension, peak tension, number of tension fluctuations, actual temperature deviation of the hot box, deviation of the false twister speed, vibration level of the false twister, network air pressure fluctuation level, number of head breaks, and number of fuzzes within each DTY texturing time window; and / or, when the tension fluctuation, actual temperature deviation of the hot box, false twister status, network air pressure fluctuation, number of head breaks, or number of fuzzes within the DTY texturing time window exceeds the corresponding preset range, a DTY processing warning label is generated within that DTY texturing time window.

6. The quality traceability method for linking polyester POY spinning and DTY texturing according to claim 1, characterized in that, In step S4, the reverse binding of the DTY finished bobbin grade result to the corresponding bobbin layer interval includes: matching the DTY finished bobbin inspection time, finished bobbin identifier, texturing machine number, texturing spindle position and winding section position to determine the DTY texturing time window corresponding to the grade result; then determining the corresponding POY bobbin identifier and bobbin layer interval number according to the mapping relationship, and writing the grade result into the quality association record.

7. A quality traceability system linking polyester POY spinning and DTY texturing, characterized in that, The system for implementing the method according to any one of claims 1 to 6, the system comprising: The POY data acquisition module is used to collect information on spinning position, spinning spindle position, component information, melt pressure, side blowing parameters, oiling parameters, pre-network parameters, and winding tension during the POY spinning and winding process. The bobbin layer generation module is used to generate a bobbin identifier for each POY bobbin and divide the POY bobbin into multiple bobbin layer intervals according to winding length, winding time or bobbin weight gain, forming a POY bobbin layer quality profile. The texturing mapping module is used to read the bobbin identifier when the POY bobbin is loaded with DTY, and to establish a mapping relationship between the bobbin layer interval and the DTY texturing time window based on the unwinding length, unwinding time, breakage continuation position and texturing spindle position. The DTY data acquisition module is used to collect data on yarn feeding tension, drafting tension, hot box temperature, false twister status, network air pressure, yarn breakage and fuzz detection data within the DTY texturing time window, forming a DTY processing profile. The quality binding module is used to reverse bind the strength, curling, staining or appearance grade results of DTY finished bobbins to the corresponding bobbin layer interval according to the DTY springing time window, and generate quality association records. The anomaly attribution module is used to generate POY source anomaly markers, DTY time window anomaly markers, or DTY spindle position anomaly markers based on anomaly repeatability and anomaly synchronization, and output quality traceability records.

8. A computer-readable storage medium having a computer program or instructions stored thereon, characterized in that, When the computer program or instructions are executed by the processor, they implement the quality traceability method for linking polyester POY spinning and DTY texturing as described in any one of claims 1 to 6.

9. An electronic device, characterized in that, It includes a processor, a memory, and a computer program or instructions stored in the memory and executable by the processor. When the processor executes the computer program or instructions, it implements the quality traceability method for linking polyester POY spinning and DTY texturing as described in any one of claims 1 to 6.

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