Controller for a spinning machine and method for controlling a spinning machine

Abstract

A spinning controller (c1) for a spinning machine (1) and a method for controlling a spinning machine (1) for producing a cop (C) with wound yarn from a roving (R) are configured to: access a quality curve (qu) of a reference cop (rC) with wound yarn, the quality curve (qu) defining a quality of the wound reference yarn depending on a position (y) of the wound reference yarn relative to the cop (C), the quality curve (cu) having been determined with the reference cop (rC) being unwound at a winding machine (2), determine based on the quality curve (qu) a spinning curve (sp) which defines a spindle speed of a spindle (10) of the spinning machine (1) for producing the cop (C) depending on a position (y) of the yarn being wound relative to the cop (C), control the spinning machine (1) for producing the cop (C) according to the spinning curve (sp).

Description

[0001] CONTROLLER FOR A SPINNING MACHINE AND METHOD FOR CONTROLLING A SPINNING MACHINE

[0002] Field of invention

[0003] This disclosure relates to a spinning controller for a spinning machine for producing one or more cops with wound yam and a method for controlling a spinning machine for producing one or more cops with wound yam.

[0004] Description of related art

[0005] Spinning controllers for spinning machines operate respective spinning machines for producing cops with wound yam from roving. In ring spinning machines, roving passes downwards to drafting rollers to a thread guide that is adjusted centrally above a spindle assembly, where the roving is threaded through a traveller which moves along a ring. A cop is fixed on a spindle, which is driven at a specific speed, and receives the thread for producing a cop with wound yam. Completed cops with wound yam are doffed from the machine.

[0006] The cops are received in winding machines, where yam is unwound from the cops and rewound on bobbins, for example for producing bobbins adapted to predefined applications.

[0007] Spinning controllers can monitor and / or control spinning machines for proper operation, for example regarding doffing upon completion of cops, etc. At winding machines, a quality of yam can be determined.

[0008] JPH05302222A discloses that (A) the initial revolving speed of a spindle at the beginning of winding and (B) the speed gradients for the revolving speeds of the spindle corresponding to respective blocks resulting from dividing the production volume from the beginning of wrapping to the full-packaged state are stored in an operational memory.

[0009] JPH11350263A discloses a fine spinning frame which is equipped with a speed regulator. Revolutions at upper end of the chase is kept high in the first chase speed change range based on the standard number of revolutions and kept low in the second chase speed change range and gradually decreased so that speed change difference of chase becomes maximum in full package and variation width of spinning tension is made small and average number of revolutions is made large to increase productivity.

[0010] Brief summary of the invention

[0011] There may be a need for an improved spinning controller for a spinning machine for producing cops with wound yam from roving, and for an improved method for controlling a spinning machine for producing cops with wound yam from roving.

[0012] Such a need may be met by the subject-matter of the independent claims. Advantageous embodiments are defined in the dependent claims.

[0013] An aspect of the invention relates to a spinning controller for a spinning machine for producing a cop with wound yam from a roving. The spinning controller is configured to: access a quality curve of a reference cop with wound reference yam, the quality curve defining a quality of the wound reference yam depending on a position of the wound reference yam relative to the reference cop, the quality curve having been determined with the reference cop being unwound at a winding machine, determine based on the quality curve a spinning curve which defines a spindle speed of a spindle of the spinning machine for producing the cop depending on a position of the yam being wound relative to the cop, control the spinning machine for producing the cop according to the spinning curve. For example, performance at the spinning machine and / or the winding machine can be increased. For example, yam breaks at the spinning machine and / or the winding machine can be decreased.

[0014] In some embodiments, the spinning curve and / or the quality curve depends on a plurality of zones relative to the cop and / or the reference cop. For example, determining the spinning curve can be simplified.

[0015] In some embodiments, the spinning controller is configured to determine the spinning curve based on operating information which includes one or more of a yam count, a roving quality, a twist level, a fiber strength, and a fiber elasticity. For example, operating information can relate to current or past operating information. For example, the spinning curve can be adapted to properties of the textile material. In some embodiments, the spinning controller is configured to determine the spinning curve based on operating information which includes one or more of a yarn break rate, a temperature, a humidity and an energy consumption. For example, the spinning curve can be adapted to parameters which are widely recorded in spinning mills.

[0016] In some embodiments, the spinning controller is configured to determine the spinning curve based on operating information which includes one or more of a tension of the yam in the spinning machine and / or a tension of the yam in the winding machine. For example, the spinning curve can be adapted to tension problems during spinning and / or winding.

[0017] In some embodiments, the spinning controller is configured to determine the spinning curve based on operating information which includes a traveller life cycle. For example, after replacement of a traveller, the spinning curve can be adapted accordingly.

[0018] In some embodiments, the spinning controller is configured to determine the spindle curve based on a spindle size and / or design.

[0019] In some embodiments, the spinning controller is configured to determine the spinning curve based on a trend in operating information of the spinning machine and / or the winding machine. For example, trends relating to doffing times, group of machines, etc. can be used for determining the spinning curve.

[0020] In some embodiments, the spinning controller is configured to determine the spinning curve based on a wear based signature or pattern in the operating information of the spinning machine and / or the winding machine. For example, an increased energy consumption can indicate a wear and the spinning curve can be adapted accordingly.

[0021] In some embodiments, the spinning controller is configured to determine the spinning curve using an artificial intelligence machine.

[0022] The invention further relates to a spinning mill management system including a spinning controller as described.

[0023] The invention further relates to a method for controlling a spinning machine for producing a cop with wound yam from a roving. The method comprises the steps executed at a spinning controller of: accessing a quality curve of a reference cop with wound yam, the quality curve defining a quality of the wound reference yam depending on a position of the wound yam relative to the reference cop, the quality curve having been determined with the reference cop being unwound at a winding machine, determining based on the quality curve a spinning curve which defines a spindle speed of a spindle of the spinning machine for producing the cop depending on a position of the yam being wound relative to the cop, controlling the spinning machine for producing the cop according to the spinning curve.

[0024] In some embodiments, the spinning curve and / or the quality curve depends on the plurality of zones relative to the cop and / or the reference cop.

[0025] In some embodiments, the method further comprises: determining the spinning curve based on operating information which includes one or more of a yam count, a roving quality, a twist level, a fiber strength, and a fiber elasticity.

[0026] In some embodiments, the method further comprises: determining the spinning curve based on operating information which includes one or more of a tension of the yam in the spinning machine and / or a tension of the yam in the winding machine.

[0027] In some embodiments, the method further comprises: determining the spinning curve based on operating information which includes a traveller life cycle.

[0028] Brief description of drawings

[0029] The invention will be better understood with the aid of the description of an embodiment given by way of example an illustrated by the figures, in which:

[0030] Fig. 1 illustrates schematically a spinning controller for controlling a spinning machine according to the present invention,

[0031] Fig. 2 illustrates schematically a cop,

[0032] Fig. 3 illustrates schematically an example of a spinning curve according to the present invention, Fig. 4 illustrates schematically in vertical direction from bottom to top: a spinning curve, a cop and a plurality of quality curves,

[0033] Fig. 5 illustrates schematically possible method steps of a method for controlling a spinning machine according to the present invention.

[0034] Detailed Description of the invention

[0035] Fig. 1 illustrates schematically a spinning controller c1 for controlling a spinning machine 1 according to the present invention.

[0036] The spinning machine 1 has a plurality of spinning units 10. Each spinning unit 10 receives roving R for producing cops C with wound yam. The spinning machine 1 can include a piecing robot 10 for repairing ends down that occur while the spinning machine 1 is running or during doffing.

[0037] Fig. 1 further illustrates a winding machine 2 which has a plurality of winding units 20. Each winding unit 20 receives reference cops rC which were produced by the spinning machine 1 for producing bobbins B. The reference cops rC are unwound at the winding machine 2 for producing bobbins B. The cops C produced by the spinning machine 1 are transported to the winding machine 2. At the winding machine 2, the cops are denominated as reference cops rC, as will be described in more detail below.

[0038] Fig. 2 illustrates schematically a cop C, which can also relate to a reference cop rC (not illustrated in Fig. 2). The cop C includes a cop tube T with wound yam A. During production of the cop C at the spinning machine 1 , the empty cop tube T gets arranged in a spinning unit 10 of the spinning machine 1 . While the cop tube T is rotated with a predetermined speed, yam A is wound onto the cop tube T at positions y along the length of the cop tube T.

[0039] As illustrated in Fig. 1 , the spinning controller c1 is configured to access a quality curve qu of a reference cop rC with wound reference yam, the quality curve qu defining a quality of the wound reference yam depending on a position y of the wound reference yam relative to the reference cop rC, the quality curve qu having been determined with the reference cop rC being unwound atthe winding machine 2. For example, the quality curve qu relates to cops C which were produced at a particular spinning unit 10 of the spinning machine 1 , wherein the cops C were transported to the winding machine 2 and being unwound at the winding machine 2 as reference cops rC, wherein the quality curve qu of the reference cops rC is determined at the winding machine 2. Thus, at the winding machine 2 it is determined that this spinning unit 10 produces cops C having the quality curve qu. For example, the quality curve qu relates to cops C which were produced earlier at this spinning unit 10, wherein it is assumed that producing a cop at this spinning unit 10 results in a cop C having this quality curve qu.

[0040] For example, the quality curve qu can relate to a surface index, which can have a spread of for example +- 10%.

[0041] For example, the spinning controller c1 is configured to access a database of the winding machine 2 having stored quality curves qu of reference cops rC. For example, the spinning controller c1 is configured to access information about the location of cops C produced at the spinning machine 1 , about the location of these cops C arranged as reference cops rC at the winding machine 2. For example, the spinning controller c1 is configured to access a database of a mill management system having stored quality curves of reference cops rC, locations of cops C at the spinning machine 1 respectively of reference cops rC at the winding machine 2.

[0042] As illustrated in Fig. 1 , the spinning controller c1 is configured to determine based on the quality curve qu a spinning curve sp which defines a spindle speed of the spinning unit 10 of the spinning machine 1 for producing the cop C depending on the position y of the yarn being wound relative to the cop C. For example, the quality curve qu relates to cops C respectively reference cops rC which were produced earlier at the spinning unit 10.

[0043] For example, the spinning curve sp relates to a spindle speed curve. For example, the spinning curve sp relates to a traveller speed curve.

[0044] The spinning controller c1 is configured to control the spinning machine 1 for producing the cop C according to the spinning curve sp. As illustrated in Fig. 2, the cop C (respectively the reference cop rC) can have assigned a plurality of zones z1 , z2, , zn relative to the cop C (respectively the reference cop rC). For example, the spinning curve sp can depend on the zones z1 , z2, ... , zn. For example, the quality curve qu can depend on the zones z1 , z2, ... , zn. For example, the zones z1 , z2, ... , zn can relate to five zones z1 , z2, ... z5, to seven zones z1 , z2, ... , z7, etc. Assigning zones z1 , z2, ... , zn to the cop C (respectively the reference cop rC) can simplify determining the spinning curve sp.

[0045] Fig. 3 illustrates schematically an example of a spinning curve sp according to the present invention. At position y1 , spinning starts up. At position y2, first layers are wound on the cop tube T, wherein the spindle speed can be kept constant, which is in particular beneficial with nep issues at the base of the cop tube T, wherein the duration can be selected via the meters delivered. At position y3, which relates to a base build-up, yarn tension compensation is applied, with a higher yam tension as a result of a higher spindle speed, wherein reduced production from the previous point is compensated. At position y4, which relates to a base finish, an approximately lower spindle speed as of ring rail position applies. At position y5, a maximal spindle speed as of ring position applies, which is applied until position y6. At position y7, the cop is full and spinning-out applies.

[0046] The spinning curve sp can be determined based on operating information oi, for example by accessing knowledge base stored in a knowledge base database and / or with an artificial intelligence machine, as follows.

[0047] The spinning curve sp can be determined depending on a yam count. Higher yam counts can require slower speeds to maintain proper tension.

[0048] The spinning curve sp can be determined depending on a yam quality, such as a strength, thickness, etc. Lower quality yams can require slower spindle speeds to prevent breaks.

[0049] The spinning curve sp can be determined depending on a twist level. Higher twist levels can require slower speeds to prevent yam breakage.

[0050] The spinning curve sp can be determined depending on a temperature and / or humidity, or depending on other climatic conditions. High temperatures and humidity can cause the yarn to expand, which can increase tension and cause breaks. Low temperatures and humidity can cause the yam to contract and become dry, which can increase tension on the yarn and cause breaks. Slower spindle speeds can be required to maintain proper tension. High temperatures can degrade lubricants, which can increase friction and cause yam breaks. Slower spindle speeds can be required to avoid an increase in friction causing yam breaks.

[0051] The spinning curve sp can be determined depending on a spindle size and / or design, for example depending on the geometry of a cop tube T. Larger spindles can require slower spindle speeds to prevent yam breakage.

[0052] The spinning curve sp can be determined depending on a fiber quality, such as a strength, elasticity, etc. Lower quality fibers can require slower spindle speeds to prevent breaks.

[0053] The spinning curve sp can be determined depending on an operator skill and / or depending on machine settings.

[0054] The spinning curve sp can be determined depending on an energy consumption. For example, overall energy consumption can be minimized while avoiding yam breaks.

[0055] The spinning curve sp can be determined depending on a yam tension indication. For example, a yam tension indication can be determined according to CN107190377B, CN107201577A or CN218088345U. Yam tension indication can be determined using other facilities. Yam tension indication can be determined indirectly, for example by analyzing a spinning speed and a rate of yam breaks.

[0056] The spinning curve sp can be determined depending on a traveller life cycle. Travellers are small, circular rings that transfer the yam from the spinning ring to the cop. As the traveller wears out, its diameter decreases, and it becomes less effective at transferring the yam. This can cause an increase in tension on the yam. A decrease in the spindle speed can be required. A worn traveller can cause the yam to slip and the yam to break more frequently, which can lead to a decrease in yam quality and efficiency. To minimize the impact of traveller life on ring frame spindle speed, it is important to regularly inspect and replace the travellers as needed. The replacement of traveller should be done in time before they become too worn, which can help to maintain proper tension and prevent yam breaks. The spindle speed can be adjusted when replacing the traveller. For example, the speed can be decreased to compensate for the change in tension caused by the new traveller.

[0057] The spinning curve sp is determined depending on a position y along a length of a cop tube T (cf. Fig. 2). Yam breaks can occur on the nose and bottom of the cop C. Yam breaks on the nose of the cop are typically caused by tension issues, while yam breaks on the bottom of the cop are typically caused by issues with the winding process. The spindle speed can be adjusted to ensure that the proper tension and / or winding is maintained while winding yam onto the cop C at positions y along the length of the cop tube T.

[0058] The spinning curve sp can be determined depending on a drafting roller gap. A larger gap can result in a lower spindle speed, while a smaller gap can result in a higher spindle speed.

[0059] The spinning curve sp can be determined depending on a spindle belt slippage. When the belt slips, the spindle can slow down or stop, which can lead to a yam break. A worn belt can cause an increase in breaks, which can require slower spindle speeds to prevent breaks.

[0060] The spinning curve sp can be determined depending on a grinding of a top roller. Improper grinding can result in uneven wear and cause variations in the tension. Dust generated from the grinding process can cause increased yam breaks. Grinding debris can cause contamination of lubricants. A slower spindle speed can be required.

[0061] The spinning curve sp can be determined depending on a lifecycle of a top apron. Worn or damaged aprons can cause irregular yam tensions. Tom or frayed aprons can cause increased fiber entanglement and yam breaks. Worn or damaged aprons can cause increased fiber abrasion, leading to increased fiber damage. A slower spindle speed can be required.

[0062] The spinning controller c1 can be configured to record operating information oi from the spinning machine 1 and / or winding machine 2 via one or more sensors attached to the spinning machine c1 and / or winding machine 2. For example, the spinning controller c1 includes a communication interface for communicating via a computer network with the sensors attached to the spinning machine 1 and / or the winding machine 2.

[0063] Fig. 4 illustrates schematically in vertical direction from bottom to top: a spinning curve sp, a cop C and a yam breakage rate for different yam qualities q1 , q2, , qn. As illustrated in Fig. 4, during cop building, the spinning speed according to the spinning curve sp assumes different speeds from start to stop of building the cop. As illustrated in Fig. 4, a first quality q1 of yam has a yam breakage rate which is different to a yam breakage rate of a second quality q2 of yam. For example, at the end of cop building, the second quality q2 has a higher yam breakage rate than the first quality q1 , while before, the second quality q2 has a lower breakage rate than the first quality q1 . For example, by determining a spinning curve sp having a slower spinning speed at the end of cop building, the yam breakage rate of the second quality q2 can be reduced.

[0064] The winding machine 2 includes sensors for determining the quality of the yam of the reference cops rC. For example, the quality can relate to a surface index, etc.

[0065] For example, a winding controller can be configured to determine a yam quality q1 , q2, ... , qn. For example, the winding controller can be configured to determine a yam quality q1 , q2, ... , qn depending on a plurality of zones z1 , z2, ... , zn. Thus, the winding controller can be configured to determine a quality signature of the reference cop rC.

[0066] The spinning controller c1 and / or the winding controller can be configured to determine a deviation from a nominal quality signature of the determined quality signature of the reference cop rC. In case of a deviation from a nominal quality, the spinning controller c1 and / or the winding controller can be configured to adapt operation of the spinning machine 1 and / or the winding machine 2 accordingly.

[0067] The spinning controller c1 and the winding controller can relate to one or more computers which include one or more applications for executing the functions of the spinning controller c1 and the winding controller as described above. An artificial intelligence machine can be arranged for determining the spinning curve sp based on a long term analysis of an operation of the spinning machine 1 and / or the winding machine 2.

[0068] As illustrated in Fig. 1 , the spinning controller c1 and / or the winding controller can be ar- ranged within a spinning mill management system mgt for a spinning mill.

[0069] Fig. 5 illustrates schematically possible method steps of a method for controlling a spinning machine 1. The steps include executed at a spinning controller c1 of: accessing S1 a quality curve qu of a reference cop rC with wound reference yarn, the quality curve qu defining a quality of the wound reference yarn depending on a position y of the wound reference yam relative to the reference cop rC, the quality curve cu having been determined with the reference cop rC being unwound at a winding machine 2, determining based on the quality curve qu a spinning curve sp which defines a spindle speed of a spindle 10 of the spinning machine 1 for producing the cop C depending on a position y of the yam being wound relative to the cop C, controlling S3 the spinning machine 1 for producing the cop C according to the spinning curve sp.

[0070] Finally, it should be noted that the term "comprising" does not exclude other elements or steps and the "a" or "an" does not exclude a plurality. Also elements described in association with different embodiments may be combined. It should also be noted that reference signs in the claims should not be construed as limiting the scope of the claims.

[0071] Reference numerals / signs

[0072] I spinning machine

[0073] 10 spinning unit

[0074] I I piecing robot 2 winding machine

[0075] 20 winding unit c1 spinning controller db database

[0076] R roving C cop rC reference cop oi operating information

[0077] B bobbin mgt spinning mill management system

Claims

Claims1 . A spinning controller (c1 ) for a spinning machine (1 ) for producing a cop (C) with wound yam from a roving (R), the spinning controller (c1 ) being configured to: access a quality curve (qu) of a reference cop (rC) with wound reference yarn, the quality curve (qu) defining a quality of the wound reference yarn depending on a position (y) of the wound reference yam relative to the reference cop (rC), the quality curve (qu) having been determined with the reference cop (rC) being unwound at a winding machine (2), determine based on the quality curve (qu) a spinning curve (sp) which defines a spindle speed of a spindle (10) of the spinning machine (1 ) for producing the cop (C) depending on a position (y) of the yam being wound relative to the cop (C), control the spinning machine (1 ) for producing the cop (C) according to the spinning curve (sp).

2. The spinning controller (c1 ) according to claim 1 , wherein the spinning curve (sp) and / or the quality curve (qu) depends on a plurality of zones (z1 , z2, zn) relative to the cop (C) and / or the reference cop (rC).

3. The spinning controller (c1 ) according to claim 1 or 2, further configured to determine the spinning curve (sp) based on operating information (oi) which includes one or more of a yam count, a roving quality, a twist level, a fiber strength, and a fiber elasticity.

4. The spinning controller (c1 ) according to one of claims 1 to 3, further configured to determine the spinning curve (sp) based on operating information (oi) which includes one or more of a yam break rate, a temperature, a humidity and an energy consumption.

5. The spinning controller (c1 ) according to one of claims 1 to 4, further configured to determine the spinning curve (sp) based on operating information (oi) which includes one or more of a tension of the yam in the spinning machine and / or a tension of the yam in the winding machine (2).

6. The spinning controller (c1 ) according to one of claims 1 to 5, further configured to determine the spinning curve (sp) based on operating information (oi) which includes a traveller life cycle.

7. The spinning controller (c1 ) according to one of claims 1 to 6, further configured to determine the spinning curve (sp) based on a spindle size and / or design.

8. The spinning controller (c1 ) according to one of claims 1 to 7, further configured to determine the spinning curve (sp) based on a trend in operating information (oi) of the spinning machine (1 ) and / or the winding machine (2).

9. The spinning controller (c1 ) according to one of claims 1 to 7, further configured to determine the spinning curve (sp) based on a wear based signature or pattern in the operating information (oi) of the spinning machine (1 ) and / or the winding machine (2).

10. A spinning mill management system (mgt) including a spinning controller (c1 ) according to one of claims 1 to 9.11 . A method for controlling a spinning machine (1 ) for producing a cop (C) with wound yam from a roving (R), the method comprising the steps executed at a spinning controller (c1 ) of: accessing a quality curve (qu) of a reference cop (rC) with wound reference yam, the quality curve (qu) defining a quality of the wound reference yam depending on a position (y) of the wound reference yam relative to the reference cop (rC), the quality curve (cu) having been determined with the reference cop (rC) being unwound at a winding machine (2), determining based on the quality curve (qu) a spinning curve (sp) which defines a spindle speed of a spindle (10) of the spinning machine (1 ) for producing the cop (C) depending on a position (y) of the yam being wound relative to the cop (C), controlling the spinning machine (1 ) for producing the cop (C) according to the spinning curve (sp).

12. The method according to claim 11 , wherein the spinning curve (sp) and / or the quality curve (qu) depends on a plurality of zones (z1 , z2, ... , zn) relative to the cop (C) and / or the reference cop (rC).

13. The method according to claim 11 or 12, further comprising determining the spin- ning curve (sp) based on operating information (oi) which includes one or more of a yam count, a roving quality, a twist level, a fiber strength, and a fiber elasticity.

14. The method according to one of claims 11 to 13, further comprising determining the spinning curve (sp) based on operating information (oi) which includes one or more of a tension of the yarn in the spinning machine and / or a tension of the yarn in the winding machine (2).

15. The method according to one of claims 11 to 14, further comprising determining the spinning curve (sp) based on operating information (oi) which includes a traveller life cycle.

Images