Anomaly diagnosis system, anomaly diagnosis method

Abstract

This invention provides an abnormality diagnosis system and method for diagnosing abnormalities in the moving mechanism of a package manufacturing apparatus. [Solution] The abnormality diagnosis system diagnoses abnormalities in a package manufacturing machine that manufactures packages with wound yarn. The abnormality diagnosis system comprises a moving part, a moving mechanism, a first sensor, and a control unit. The moving part moves between a first position and a second position. The moving mechanism moves the moving part. The first sensor detects that the moving part is within a predetermined detection range that includes the first position. The control unit diagnoses abnormalities in the moving mechanism based on a first moving time, which is the time taken from when the moving part starts moving from the second position until the first sensor detects the moving part.

Description

Technical Field

[0007] , ,

[0001] The present invention relates to an abnormality diagnosis system and an abnormality diagnosis method for diagnosing an abnormality in a package manufacturing apparatus that manufactures a package wound with a yarn.

Background Art

[0002] There is known a yarn feeding device used in a package manufacturing apparatus that manufactures a package wound with a yarn. The yarn feeding device unwinds the yarn from the surface of a bobbin around which the yarn supplied to the package is wound, and sucks the yarn end into the core of the bobbin.

[0003] For example, Patent Document 1 (Japanese Patent Application Laid-Open No. 2009-242027) discloses a yarn unwinding mechanism that unwinds yarn from the surface of a bobbin using a suction cylinder, and a cylinder lifting device (moving mechanism) that moves the suction cylinder up and down between a standby position above the bobbin and a lowered position covering the surface of the bobbin.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In this type of yarn feeding device, there is room for improvement in the method of detecting an abnormality in the moving mechanism that moves the suction cylinder.

[0006] An object of the present invention is to provide an abnormality diagnosis system and an abnormality diagnosis method for diagnosing an abnormality in a moving mechanism of a package manufacturing apparatus.

Means for Solving the Problems

[0007] The following describes several embodiments as means of solving the problem. These embodiments can be combined as needed.

[0008] An anomaly diagnosis system according to a first aspect of the present invention diagnoses anomalies in a package manufacturing apparatus that manufactures packages with wound yarn. The anomaly diagnosis system comprises a moving part, a moving mechanism, a first sensor, and a control unit. The moving part moves between a first position and a second position. The moving mechanism moves the moving part. The first sensor detects that the moving part is within a predetermined detection range including the first position. The control unit diagnoses an anomaly in the moving mechanism based on a first moving time, which is the time taken from when the moving part starts moving from the second position until the first sensor detects the moving part.

[0009] This anomaly diagnosis system can diagnose abnormalities in the movement mechanism based on the first movement time.

[0010] An anomaly diagnosis system according to a second aspect of the present invention is an anomaly diagnosis system according to a first aspect, wherein the second position is the position furthest from the first position within the range in which the moving mechanism moves the moving part.

[0011] The second position is the position furthest from the first position within the range of movement the moving part can reach. Therefore, the anomaly diagnosis system does not need to detect that the moving part is in the second position using sensors or the like. As a result, this anomaly diagnosis system helps to suppress increases in the manufacturing costs of the package manufacturing equipment.

[0012] A third aspect of the present invention is an anomaly diagnosis system according to the first or second aspect, wherein a control unit compares a first movement time with a predetermined first threshold and diagnoses that an anomaly has occurred in the movement mechanism.

[0013] This anomaly diagnosis system can diagnose abnormalities in the movement mechanism based on the first movement time.

[0014] The abnormality diagnosis system according to the fourth aspect of the present invention is either the abnormality diagnosis system according to the first or second aspect, wherein the control unit compares the average value of a plurality of first movement times with a predetermined second threshold and diagnoses that an abnormality has occurred in the movement mechanism.

[0015] This anomaly diagnosis system can diagnose abnormalities in the movement mechanism based on the first movement time.

[0016] The fifth aspect of the present invention is an anomaly diagnosis system according to either the first or second aspect, wherein the control unit compares the standard deviation of a plurality of first movement times with a predetermined third threshold and diagnoses that an anomaly has occurred in the movement mechanism.

[0017] This anomaly diagnosis system can diagnose abnormalities in the movement mechanism based on the first movement time.

[0018] The abnormality diagnosis system according to the sixth aspect of the present invention is either the abnormality diagnosis system according to the first aspect or the second aspect, wherein the control unit diagnoses that an abnormality has occurred in the movement mechanism based on the number of times the first movement time exceeds a predetermined fourth threshold.

[0019] This anomaly diagnosis system can diagnose abnormalities in the movement mechanism based on the first movement time.

[0020] An anomaly diagnosis system according to the seventh aspect of the present invention is any of the anomaly diagnosis systems according to the first aspect to the sixth aspect, wherein a movable part is connected to the lower end of a flexible cylinder that can extend and retract vertically. The movable mechanism has an air cylinder. The first position is the position of the movable part when the air cylinder is retracted. The second position is the position of the movable part when the air cylinder is extended. The anomaly diagnosis system performs a spouting process that unwinds the yarn from the surface of the bobbin around which the yarn supplied to the package is wound and sucks the yarn into the core of the bobbin.

[0021] This abnormality diagnosis system can diagnose abnormalities in air cylinders.

[0022] The abnormality diagnosis system according to the eighth aspect of the present invention is the abnormality diagnosis system according to the seventh aspect, and the abnormality diagnosis system switches between and executes a first operation mode for diagnosing an abnormality of a moving mechanism and a second operation mode for repeatedly executing a mouthpiece process.

[0023] This abnormality diagnosis system can execute a mouthpiece process and diagnose an abnormality of an air cylinder.

[0024] The abnormality diagnosis system according to the ninth aspect of the present invention is any one of the abnormality diagnosis systems according to the first aspect to the eighth aspect, and the control unit diagnoses an abnormality of the moving mechanism based on a second moving time, which is the time from when the movement from the first position starts until it goes out of the detection range.

[0025] This abnormality diagnosis system can diagnose an abnormality of the moving mechanism based on the first moving time and the second moving time.

[0026] The abnormality diagnosis system according to the tenth aspect of the present invention diagnoses an abnormality of a package manufacturing apparatus that manufactures a package wound with yarn. The abnormality diagnosis system includes a moving part, a moving mechanism, a first sensor, and a control unit. The moving part moves between a first position and a second position. The moving mechanism moves the moving part. The first sensor detects that the moving part is within a predetermined detection range including the first position. The control unit diagnoses an abnormality of the moving mechanism based on a third moving time, which is the time from when the movement of the moving part starts from the first position until it goes out of the detection range.

[0027] This abnormality diagnosis system can diagnose an abnormality of the moving mechanism based on the third moving time.

[0028] The abnormality diagnosis system according to the eleventh aspect of the present invention is any one of the abnormality diagnosis systems according to the first aspect to the tenth aspect, and the abnormality of the moving mechanism is any one of a crack in the bracket, a breakage of the bracket, and a deposition of air foam in the moving mechanism.

[0029] This anomaly diagnosis system can diagnose any of the following: cracks in the bracket, damage to the bracket, accumulation of foam in the moving mechanism, or malfunction of the moving mechanism.

[0030] An anomaly diagnosis method according to the twelfth aspect of the present invention diagnoses an anomaly in a package manufacturing apparatus that manufactures packages wound with yarn. The package manufacturing apparatus comprises a moving part, a moving mechanism, a first sensor, and a control unit. The moving part moves between a first position and a second position. The moving mechanism moves the moving part. The first sensor detects that the moving part is within a predetermined detection range that includes the first position. The anomaly diagnosis method diagnoses an anomaly in the moving mechanism based on a first moving time, which is the time taken from when the moving part starts moving from the second position until the first sensor detects the moving part.

[0031] According to this diagnostic method, abnormalities in the movement mechanism are diagnosed based on the first movement time. [Brief explanation of the drawing]

[0032] [Figure 1] This is a schematic side view of the spout device 100. [Figure 2] This is a schematic diagram showing the connections between the control unit 50 and each component. [Figure 3] This is a flowchart showing the control flow of the abnormality diagnosis process performed by the control unit 50 of the output device 100. [Figure 4] This is a schematic diagram illustrating the process of interfering with decisions. [Figure 5] This flowchart shows the process of switching between the first operating mode and the second operating mode. [Figure 6] This is a flowchart showing the control flow of the abnormality diagnosis process performed by the control unit 50 of the output device 101. [Figure 7] This flowchart shows the control flow of the abnormality diagnosis process performed by the control unit 50 of the output device 101 according to Modification 1. [Modes for carrying out the invention]

[0033] <First Embodiment> (1) Structure of the spouting device 100 Figure 1 is a schematic side view of a thread-out device 100 used in a package manufacturing apparatus 1 according to the present invention. The package manufacturing apparatus 1 includes a winding device that winds up yarn to manufacture a package (not shown). The thread-out device 100 comprises an unwinding mechanism 10, a moving mechanism 20, a cutting mechanism 30, an output unit 40, and a control unit 50. In the following description, the up and down directions correspond to the up and down directions indicated by arrows in Figure 1.

[0034] As will be described in detail later, the thread dispenser 100 performs thread dispenser processing and abnormality diagnosis processing. In the thread dispenser processing, the thread dispenser 100 unwinds the end of the thread Y (also called the thread end) from the surface of the bobbin B, which is wound with the thread Y supplied to the package onto a cylindrical core C, and sucks it into the core C of the bobbin B. In the abnormality diagnosis processing, the thread dispenser 100 diagnoses abnormalities in the moving mechanism 20. The thread dispenser 100 is an example of an abnormality diagnosis system.

[0035] (1-1) Unwinding mechanism 10 The unwinding mechanism 10 unwinds the yarn Y from the surface of the bobbin B, which is transported in an orientation where its axial direction is aligned with the vertical direction. The unwinding mechanism 10 includes a fan 11, a first suction pipe 12, a yarn detection sensor 13, a flexible cylinder 14, a suction cylinder 15, a bobbin sensor 16, a second suction pipe 17, and a pair of nozzles 19.

[0036] Fan 11 generates a suction airflow. Fan 11 is controlled by control unit 50.

[0037] The first suction pipe 12 has one end connected to the intake port of the fan 11 and the other end facing downwards.

[0038] The thread detection sensor 13 is located inside the first suction pipe 12 and detects the cut thread. The thread detection sensor 13 is an example of a second sensor.

[0039] The flexible cylinder 14 is an expandable and contractible cylindrical member having a bellows section. The flexible cylinder 14 is positioned so that its axial direction is aligned with the vertical direction. One end of the flexible cylinder 14 communicates with the end of the first suction pipe 12 opposite to the fan 11, and the other end is connected to the suction pipe 15.

[0040] The suction tube 15 is a cylindrical member fixed to the other end of the flexible tube 14. The inner diameter of the suction tube 15 is slightly larger than the diameter of the bobbin B with the thread Y wound around it. As will be described in detail later, the suction tube 15 moves between a first position P1 and a second position P2 located below the first position P1. The suction tube 15 is an example of a moving part.

[0041] The bobbin sensor 16 is a sensor that detects the winding state of bobbin B. The bobbin sensor 16 is located below the suction cylinder 15 and is integrated with the suction cylinder 15. Based on the external shape of bobbin B detected by the bobbin sensor 16, the control unit 50 determines whether bobbin B is a fully wound bobbin, a half-ball bobbin with part of the yarn layer wound by the winder, or a small ball bobbin with a small amount of yarn remaining.

[0042] One end of the second suction pipe 17 is connected to the intake port of the fan 11, and the other end is in communication with the lower end of the winding core C of the bobbin B, which is being transported in an orientation with its axial direction aligned with the vertical direction.

[0043] The shutter 18 is installed inside the second suction pipe 17. The shutter 18 changes between an open state that allows the flow of suction airflow in the second suction pipe 17 and a closed state that restricts the flow of suction airflow in the second suction pipe 17. The shutter 18 is controlled by the control unit 50.

[0044] The nozzle 19 blows compressed air from below toward the surface of the conveyed bobbin B.

[0045] (1-2) Moving mechanism 20 The moving mechanism 20 moves the suction cylinder 15. The moving mechanism 20 includes two guide shafts 21, two brackets 22, two sliders 23, a connecting part 24, an air cylinder 25, and a piston sensor 26.

[0046] The guide shaft 21 is a rod-shaped member that guides the slider 23. The guide shaft 21 is positioned so that its axial direction is aligned with the vertical direction.

[0047] The bracket 22 supports the two guide shafts 21 from above and below.

[0048] The slider 23 moves by being guided vertically by the guide shaft 21. The slider 23 is provided on each of the two guide shafts 21.

[0049] The connecting portion 24 is a plate-shaped (bracket-shaped) member that connects the two sliders 23, the suction cylinder 15, and the piston rod 25c (described later).

[0050] The air cylinder 25 moves the slider 23 vertically. The air cylinder 25 has a cylinder tube 25a, a piston 25b, and a piston rod 25c. The air cylinder 25 is controlled by the control unit 50.

[0051] The cylinder tube 25a has a cylinder chamber (not shown) inside. The cylinder tube 25a is positioned so that the piston 25b moves along it in the vertical direction.

[0052] The piston 25b is housed inside the cylinder tube 25a. Powered by compressed air, the piston 25b moves between an upward end Eu and a downward end Eb within the cylinder tube 25a. The upward end Eu is the highest position within the range of movement of the piston 25b. The downward end Eb is the lowest position within the range of movement of the piston 25b.

[0053] The piston rod 25c is positioned so that its axial direction is aligned with the vertical direction, with its lower end connected to the connecting portion 24 and its upper end connected to the piston 25b. The piston rod 25c moves vertically in conjunction with the movement of the piston 25b.

[0054] As the piston 25b moves vertically, the air cylinder 25 extends and retracts vertically. That is, when the piston 25b is at its upper end Eu, the air cylinder 25 is in its most contracted state. Conversely, when the piston 25b is at its lower end Eb, the air cylinder 25 is in its most extended state.

[0055] The piston sensor 26 detects that the piston 25b is within a predetermined detection range that includes the upper end Eu. In this embodiment, the piston sensor 26 is a Hall sensor, although this is not limited to this embodiment. The piston sensor 26 is positioned in the cylinder tube 25a near the upper end Eu. The piston 25b is formed of metal, at least in part, so that its position can be detected by the piston sensor 26. The piston sensor 26 is an example of a first sensor.

[0056] As the air cylinder 25 extends and retracts, the slider 23 and the suction cylinder 15 move vertically. For convenience, the position of the suction cylinder 15 when the air cylinder 25 is most retracted (when the piston 25b is at the upper end Eu) is referred to as the first position P1 (see Figure 1). The position of the suction cylinder 15 when the air cylinder 25 is most extended (when the piston 25b is at the lower end Eb) is referred to as the second position P2 (see Figure 1). Therefore, the second position P2 is the position furthest from the first position P1 within the range in which the moving mechanism 20 moves the suction cylinder 15. The piston sensor 26 detects that the piston 25b is within a detection range that includes the upper end Eu, thereby detecting that the suction cylinder 15 is within a predetermined detection range a that includes the first position.

[0057] (1-3) Cutting mechanism 30 The cutting mechanism 30 cuts the thread Y unwound by the unwinding mechanism 10, and also closes and opens the lower end of the first suction pipe 12. The cutting mechanism 30 includes a shutter cutter 31, a stepping motor 32, a sliding screw shaft 33, a female screw body 34, a connecting part 35, and a pressing lever 36.

[0058] The shutter cutter 31 has a cutter blade 31a. The cutter blade 31a is positioned near the lower end of the first suction pipe 12. The cutter blade 31a is driven by an actuator (not shown) and changes position between closing the lower end of the first suction pipe 12 and opening the lower end of the first suction pipe 12. The shutter cutter 31 is also controlled by a control unit 50.

[0059] The stepping motor 32 rotates the sliding screw shaft 33 in the circumferential direction. The stepping motor 32 is controlled by the control unit 50.

[0060] The sliding screw shaft 33 is positioned so that its axial direction is aligned with the vertical direction. One end of the sliding screw shaft 33 is connected to the stepping motor 32, and the other end is supported by a bracket.

[0061] The female threaded body 34 is screwed onto the sliding screw shaft 33 and moves vertically as the sliding screw shaft 33 rotates.

[0062] The connecting portion 35 is a component that connects the shutter cutter 31 and the female screw body 34.

[0063] The presser lever 36 holds the thread Y against the upper circumferential surface of the core C during the thread end-out process (see Figure 4(c)). The presser lever 36 is moved between a standby position and a pressing position where the thread Y is held against the core C by an actuator (not shown). The presser lever 36 is controlled by the control unit 50.

[0064] (1-4) Output section 40 The output unit 40 outputs the results of the abnormality diagnosis process. While not limited to these, the output unit 40 may be a display, touch panel, etc., used in computers, mobile terminals, etc. The output unit 40 may also be a storage device.

[0065] (1-5) Control unit 50 The control unit 50 controls each part of the threading device 100 to perform threading and abnormality diagnosis processing. The control unit 50 is electrically connected to the fan 11, thread detection sensor 13, shutter 18, nozzle 19, air cylinder 25, piston sensor 26, shutter cutter 31 (actuator), stepping motor 32, press lever 36 (actuator), and output unit 40 so as to be able to send and receive control signals, detection signals, etc. Figure 2 is a schematic diagram showing the connections between the control unit 50 and each part. The operation of each part in threading and abnormality diagnosis processing will be described later.

[0066] The control unit 50 is implemented by a computer. The control unit 50 includes a control arithmetic unit and a memory device (neither of which are shown in the figure). The control arithmetic unit is a processor such as a CPU or GPU. The control arithmetic unit reads a program stored in the memory device and performs predetermined processing according to this program. Furthermore, the control arithmetic unit writes calculation results to the memory device and reads information stored in the memory device according to the program.

[0067] (2) Operation of the output device 100 When the package manufacturing device 1 is started, the lead dispenser 100 switches between a first operating mode and a second operating mode and executes. In the first operating mode, the lead dispenser 100 performs abnormality diagnosis processing. In the second operating mode, the lead dispenser 100 repeatedly performs lead dispenser processing each time the bobbin B is transported by the package manufacturing device 1.

[0068] (2-1) Regarding abnormality diagnosis processing Figure 3 is a flowchart showing the control flow of the abnormality diagnosis process. The lead device 100 starts the abnormality diagnosis process when the operating mode becomes the first operating mode.

[0069] In step S100, the control unit 50 sets the air cylinder 25 to its most extended state and proceeds to step S110. In other words, in step S100, the control unit 50 positions the piston 25b at its lowered end Eb.

[0070] In step S110, the control unit 50 measures the first movement time Tm1, which is the time it takes for the air cylinder 25 to move from its most extended state to its most retracted state, and proceeds to step S120. Specifically, the control unit 50 defines the first movement time Tm1 as the time it takes from when the piston 25b starts moving from its lowered end Eb until the piston sensor 26 detects the piston 25b. In other words, the first movement time Tm1 is the time it takes from when the suction cylinder 15 starts moving from its second position P2 until the piston sensor 26 detects that the suction cylinder 15 is within a predetermined detection range a that includes the first position.

[0071] In step S120, the control unit 50 diagnoses an abnormality in the movement mechanism 20 based on the first movement time Tm1 and proceeds to step S130 or step S140. Specifically, if the first movement time Tm1 is greater than the first threshold Th1 (yes), the control unit 50 proceeds to step S130, and if the first movement time Tm1 is not greater than the first threshold Th1 (no), it proceeds to step S140.

[0072] In step S130, the control unit 50 outputs a diagnosis result indicating that an abnormality has occurred in the moving mechanism 20 to the output unit 40, and terminates the abnormality diagnosis process.

[0073] In step S140, the control unit 50 outputs a diagnosis result to the output unit 40 indicating that no abnormality has occurred in the moving mechanism 20, and terminates the abnormality diagnosis process.

[0074] The abnormalities of the moving mechanism 20 diagnosed by the abnormality diagnosis process include, for example, cracks in the bracket 22, damage to the bracket 22, accumulation of air cotton in the moving mechanism 20, and malfunctions of the moving mechanism 20. Malfunctions of the moving mechanism 20 are not limited to, but may include wear of the packing (not shown) used in the air cylinder 25, air leakage due to grease loss in the air cylinder 25, and abnormalities in the piping that supplies air to the air cylinder 25.

[0075] (2-2) Regarding handling of interjections Figure 4 is a schematic diagram showing the nozzle operation of the nozzle device 100. When the nozzle operation is started, the nozzle device 100 first retracts the air cylinder 25 and moves the suction cylinder 15 to the first position P1. Also, when the nozzle operation is started, the nozzle device 100 closes the shutter 18.

[0076] When the bobbin B, positioned with its axial direction aligned with the vertical direction, is transported to above the second suction pipe 17 in the transport tray 1a of the package manufacturing apparatus 1, the nozzle 19 blows out compressed air. In a previous process near the lead-out device 100, the thread Y that is wound and fixed around the upper or lower end of the core C of the bobbin B being transported by the transport tray 1a has been cut by a cutting device (not shown). As a result, the thread Y of the bobbin B is blown upward by the compressed air.

[0077] Next, the shutter cutter 31 moves from a position that closes the lower end of the first suction pipe 12 to a position that opens it. As a result, the suction airflow flows inside the suction cylinder 15 and the flexible cylinder 14.

[0078] Next, as shown in Figure 4(a), the air cylinder 25 extends, causing the suction cylinder 15 to descend from the first position P1 (see Figure 1). As the descended suction cylinder 15 begins to cover the outer surface of the bobbin B, an upward suction airflow flows between the inner surface of the suction cylinder 15 and the outer surface of the bobbin B. As a result, the thread end, which was blown upward by the nozzle 6, is sucked into the first suction pipe 12 through the suction cylinder 15, the flexible cylinder 14, and the shutter cutter 31, as shown in Figure 4(b).

[0079] When the thread detection sensor 13 detects that the thread Y has been sucked into the suction tube 5, the air cylinder 25 stops extending and then begins to retract. As a result, the suction tube 15 returns to the first position P1, as shown in Figure 4(c). If the thread detection sensor 13 cannot detect the thread Y even though the lower end of the suction tube 15 has reached the second position P2 or the lower end of the bobbin B, the suction tube 15 may be returned to the first position P1 and then lowered again.

[0080] When the thread detection sensor 13 detects the thread Y, and the suction cylinder 15 returns to the first position P1, the press lever 36 presses and holds the middle portion of the thread Y that has been unwound from the bobbin B against the upper circumferential surface of the winding core C, as shown in Figure 4(c). In this state, the cutter blade 31a of the shutter cutter 31 moves to a position that closes the lower end of the first suction pipe 12. As a result, the cutter blade 31a closes the lower end of the first suction pipe 12, blocking the suction airflow and cutting the thread Y.

[0081] Simultaneously with the driving of the cutter blade 31a, the shutter 18 opens. This generates a downward suction airflow inside the winding core C, and as shown in Figure 4(d), the cut end of the thread Y is drawn into the winding core C. Subsequently, the transport tray 1a transports the bobbin B to the next process.

[0082] (2-3) Switching operating modes Figure 5 is a flowchart showing the switching process between the first operating mode and the second operating mode.

[0083] When the package manufacturing device 1 is started, the lead dispenser 100 sets its operating mode to the first operating mode and performs an abnormality diagnosis process in step S200. Once the abnormality diagnosis process is complete, the lead dispenser 100 proceeds to step S210.

[0084] In step S210, the lead device 100 sets its operating mode to the second operating mode and starts executing the lead processing, then proceeds to step S220.

[0085] In step S220, the lead device 100 determines whether a predetermined time Tp1 (for example, 8 hours) has elapsed since the start of the second operating mode, and proceeds to step S200 or step S220. Specifically, if the predetermined time has elapsed since the start of the second operating mode (yes), the lead device 100 proceeds to S200, and if the predetermined time has not elapsed since the start of the second operating mode (no), it proceeds to S220. In other words, the lead device 100 repeats step S220 until the predetermined time has elapsed since the start of the second operating mode.

[0086] The lead dispenser 100 repeats the switching process between the first and second operating modes described above until the package manufacturing device 1 stops.

[0087] (3) Variant (3-1) Variation 1 The control unit 50 may diagnose that an abnormality has occurred in the movement mechanism 20 by comparing the average value Ta of a plurality of first movement times Tm1 with a predetermined second threshold Th2. Specifically, the control unit 50 may diagnose that an abnormality has occurred in the movement mechanism 20 if the average value Ta is greater than the second threshold Th2.

[0088] (3-2) Modification 2 The control unit 50 may diagnose that an abnormality has occurred in the movement mechanism by comparing the standard deviation D of a plurality of first movement times Tm1 with a predetermined third threshold Th3. Specifically, the control unit 50 may diagnose that an abnormality has occurred in the movement mechanism 20 if the standard deviation D is greater than the third threshold Th3.

[0089] (3-3) Modification example 3 The control unit 50 may diagnose that an abnormality has occurred in the moving mechanism based on the number of times N that the first moving time Tm1 exceeds the fourth threshold Th4 during a predetermined period. Specifically, the control unit 50 may diagnose that an abnormality has occurred in the moving mechanism 20 when the number of times N is greater than the fourth threshold Th4.

[0090] (3-4) Modification 4 The abnormality diagnosis process may be performed by a computer (cloud) located in a separate location from the output device 100 and connected to the control unit 50 via a network.

[0091] (3-5) Modification 5 The lead-out device 100 may also perform lead-out processing when executing abnormality diagnosis processing. This allows the lead-out device 100 to perform lead-out processing for a larger number of bobbins B.

[0092] (3-6) Modification 6 Switching from the second operating mode to the first operating mode may be performed based on the number of times the output process has been executed. Specifically, in step S220, the output device 100 may determine whether the number of times the output process has been executed is greater than or equal to a predetermined number, and proceed to step S200 or step S220. Furthermore, switching from the second operating mode to the first operating mode may be performed based on instructions from an operator or the like who operates the package manufacturing apparatus 1. Specifically, in step S220, the spouting device 100 may determine whether or not there are instructions from an operator or the like who operates the package manufacturing apparatus 1, and proceed to step S200 or step S220.

[0093] (4) Features (4-1) The lead dispenser 100 diagnoses abnormalities in the package manufacturing apparatus 1, which manufactures packages wound with yarn Y. The lead dispenser 100 comprises a suction cylinder 15, a moving mechanism 20, a piston sensor 26, and a control unit 50. The suction cylinder 15 moves between a first position P1 and a second position P2. The moving mechanism 20 moves the suction cylinder 15. The piston sensor 26 detects that the suction cylinder 15 is within a predetermined detection range a, which includes the first position P1. The control unit 50 diagnoses abnormalities in the moving mechanism 20 based on a first movement time Tm1, which is the time taken from when the suction cylinder 15 starts moving from the second position P2 until the piston sensor 26 detects the suction cylinder 15.

[0094] The lead device 100 can diagnose abnormalities in the movement mechanism 20 based on the first movement time Tm1.

[0095] (4-2) The second position P2 is the position furthest from the first position P1 within the range in which the moving mechanism 20 moves the suction cylinder 15.

[0096] The second position P2 is the position furthest from the first position P1 within the range in which the suction cylinder 15 can move. Therefore, the spouting device 100 does not need to detect, using a sensor or the like, that the suction cylinder 15 is in the second position P2. As a result, the spouting device 100 helps to suppress an increase in the manufacturing cost of the package manufacturing apparatus 1.

[0097] (4-3) The control unit 50 compares the first movement time Tm1 with a predetermined first threshold Th1 and diagnoses that an abnormality has occurred in the movement mechanism 20.

[0098] The lead device 100 can diagnose abnormalities in the movement mechanism 20 based on the first movement time Tm1.

[0099] (4-4) The control unit 50 compares the average value Ta of multiple first movement times Tm1 with a predetermined second threshold Th2 and diagnoses that an abnormality has occurred in the movement mechanism 20.

[0100] The lead device 100 can diagnose abnormalities in the movement mechanism 20 based on the first movement time Tm1.

[0101] (4-5) The control unit 50 compares the standard deviation D of multiple first movement times Tm1 with a predetermined third threshold Th3 and diagnoses that an abnormality has occurred in the movement mechanism 20.

[0102] The lead device 100 can diagnose abnormalities in the movement mechanism 20 based on the first movement time Tm1.

[0103] (4-6) The control unit 50 diagnoses that an abnormality has occurred in the movement mechanism 20 based on the number of times N the first movement time Tm1 exceeds a predetermined fourth threshold Th4.

[0104] The lead device 100 can diagnose abnormalities in the movement mechanism 20 based on the first movement time Tm1.

[0105] (4-7) The suction cylinder 15 is connected to the lower end of a flexible cylinder 14 that can extend and retract vertically. The moving mechanism 20 has an air cylinder 25. The first position P1 is the position of the suction cylinder 15 when the air cylinder 25 is retracted. The second position P2 is the position of the suction cylinder 15 when the air cylinder 25 is extended. The thread dispenser 100 performs a thread dispenser process that unwinds the thread Y from the surface of the bobbin B around which the thread Y supplied to the package is wound, and sucks the thread Y into the core C of the bobbin B.

[0106] The output device 100 can diagnose abnormalities in the air cylinder 25.

[0107] (4-8) The lead-out device 100 switches between a first operating mode for diagnosing abnormalities in the moving mechanism 20 and a second operating mode for repeatedly performing lead-out processing.

[0108] The nozzle device 100 can perform nozzle processing and also diagnose abnormalities in the air cylinder 25.

[0109] (4-9) An abnormality in the moving mechanism 20 is one of the following: cracking of the bracket 22, damage to the bracket 22, accumulation of blown material in the moving mechanism 20, or malfunction of the moving mechanism 20.

[0110] The lead device 100 can diagnose any of the following: cracks in the bracket 22, damage to the bracket 22, accumulation of blown cotton in the moving mechanism 20, or malfunction of the moving mechanism 20.

[0111] (4-10) The lead dispenser 100 performs an abnormality diagnosis method to diagnose abnormalities in the package manufacturing apparatus 1, which manufactures packages wound with yarn Y. This abnormality diagnosis method diagnoses abnormalities in the moving mechanism 20 based on a first movement time Tm1, which is the time taken from when the suction cylinder 15 starts moving from the second position P2 until the piston sensor 26 detects the suction cylinder 15.

[0112] According to this abnormality diagnosis method, an abnormality in the movement mechanism 20 is diagnosed based on the first movement time Tm1.

[0113] <Second Embodiment> (1) Overview of the spout device 101 In the following, the spouting device 101 used in the package manufacturing apparatus 1 according to the second embodiment of the present invention will be described, focusing on the differences from the spouting device 100. The difference between the spouting device 101 and the spouting device 100 is that the control unit 50 of the spouting device 101 diagnoses abnormalities in the moving mechanism 20 based on a first movement time Tm1 and also diagnoses abnormalities in the moving mechanism 20 based on a second movement time Tm2. The second movement time Tm2 is the time from when the suction cylinder 15 starts moving from the first position P1 until it moves out of the detection range a.

[0114] Figure 6 is a flowchart showing the control flow of the abnormality diagnosis process performed by the control unit 50 of the lead device 101. Below, the differences from the flowchart in Figure 3 will be explained in detail, and explanations of the same or corresponding steps will be omitted by using the same reference numerals.

[0115] (2) Regarding abnormality diagnosis processing As shown in Figure 6, the control unit 50 of the spout device 101 executes step S101 instead of step S100, and steps S131 and S132 instead of step S130.

[0116] In step S101, the control unit 50 measures the second movement time Tm2 by moving the air cylinder 25 from its most retracted state to its most extended state, and then proceeds to step S110. Specifically, the control unit 50 measures the time it takes for the piston 25b to move out of the detection range of the piston sensor 26 from its upper end Eu as the second movement time Tm2. In other words, the second movement time Tm2 is the time from when the suction cylinder 15 starts moving from the first position P1 until it moves out of a predetermined detection range a.

[0117] In step S131, the control unit 50 determines whether the second travel time Tm2 is greater than the fifth threshold Th5, and proceeds to step S132 or step S140. Specifically, if the second travel time Tm2 is greater than the fifth threshold Th5 (yes), the control unit 50 proceeds to step S132, and if the second travel time Tm2 is not greater than the fifth threshold Th5 (no), it proceeds to step S140.

[0118] In step S132, the control unit 50 outputs a diagnosis result indicating that an abnormality has occurred in the moving mechanism 20 to the output unit 40, and terminates the abnormality diagnosis process.

[0119] (3) Variation 1 The control unit 50 of the spout device 101 may diagnose an abnormality in the movement mechanism 20 based on a third movement time Tm3, which is the time from when the suction cylinder 15 starts moving from the first position P1 until it moves out of the detection range a, without considering the first movement time Tm1.

[0120] Figure 7 is a flowchart showing the control flow of the abnormality diagnosis process performed by the control unit 50 of the output device 101 according to Modification 1. In the following, the differences from the flowchart in Figure 3 will be explained in detail, and explanations of the same or corresponding steps will be omitted by using the same reference numerals.

[0121] As shown in Figure 7, the control unit 50 of the spout device 101 according to Modification 1 executes step S102 instead of step S100, step S111 instead of step S110, and step S121 instead of step S120.

[0122] In step S102, the control unit 50 measures the third movement time Tm3 by moving the air cylinder 25 from its most retracted state to its most extended state, and then proceeds to step S121. Specifically, the control unit 50 measures the time it takes for the piston 25b to move out of the detection range of the piston sensor 26 from its upper end Eu as the third movement time Tm3. In other words, the third movement time Tm3 is the same as the second movement time Tm2, ​​from the time the suction cylinder 15 starts moving from the first position P1 until it moves out of the predetermined detection range a.

[0123] In step S111, the control unit 50 sets the air cylinder 25 to its most contracted state and proceeds to step S121.

[0124] In step S121, the control unit 50 diagnoses an abnormality in the movement mechanism 20 based on the third movement time Tm3 and proceeds to step S130 or step S140. Specifically, if the third movement time Tm3 is greater than the sixth threshold Th6 (yes), the control unit 50 proceeds to step S130, and if the third movement time Tm3 is not greater than the sixth threshold Th6 (no), it proceeds to step S140.

[0125] (4) Features (4-1) The output device 101, and the control unit 50, diagnoses abnormalities in the movement mechanism based on a second movement time Tm2, ​​which is the time from when the suction cylinder 15 starts moving from the first position P1 until it leaves the detection range a.

[0126] The lead device 101 can diagnose abnormalities in the moving mechanism 20 based on the first moving time Tm1 and the second moving time Tm2.

[0127] (4-2) The lead dispenser 101 diagnoses abnormalities in a package manufacturing machine that produces packages wound with yarn Y. The lead dispenser 101 comprises a suction cylinder 15, a moving mechanism 20, a piston sensor 26, and a control unit 50. The suction cylinder 15 moves between a first position P1 and a second position P2. The moving mechanism 20 moves the suction cylinder 15. The piston sensor 26 detects that the suction cylinder 15 is within a predetermined detection range a, which includes the first position P1. The control unit 50 diagnoses abnormalities in the moving mechanism based on a third movement time Tm3, which is the time from when the suction cylinder 15 starts moving from the first position P1 until it leaves the detection range a.

[0128] The lead device 101 can diagnose abnormalities in the movement mechanism 20 based on the third movement time Tm3.

[0129] <Third Embodiment> In the embodiments described above, the lead-out devices 100 and 101 were examples of an abnormality diagnosis system, but the abnormality diagnosis system may be other devices in the package manufacturing apparatus 1 that utilize a moving mechanism. Specifically, the abnormality diagnosis system may be a capture device in the winding device that sucks and captures the yarn Y from the package when the yarn Y is broken and guides the captured yarn Y to the yarn splicing device, a cradle device that separates the package from the winding drum, or a moving device that moves the yarn splicing device back and forth. Furthermore, the abnormality diagnosis system may also be applied to an air spinning machine.

[0130] <Conclusion> Although one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications are possible without departing from the spirit of the invention. In particular, the multiple embodiments and modifications described herein can be arbitrarily combined as needed. [Explanation of Symbols]

[0131] 1: Package manufacturing equipment 1a: Transport tray 5: Suction pipe 6: Nozzle 10: Unwinding mechanism 11: Fan 12: First suction pipe 13: Thread detection sensor 14: Flexible tube 15: Suction cylinder (movable part) 16: Bobbin sensor 17: Second suction pipe 18: Shutter 19: Nozzle 20: Movement mechanism 21: Guide axis 22: Bracket 23: Slider 24:Connection part 25: Air Cylinder 25a: Cylinder tube 25b: Piston 25c: Piston rod 26: Piston sensor (first sensor) 30: Cutting mechanism 31: Shutter Cutter 31a: Cutter blade 32: Stepping motor 33: Screw shaft 34: Female threaded body 35:Connection part 36: Pressing lever 40: Output section 50: Control Unit 100: Probe device (anomaly diagnosis system) 101: Probe device (anomaly diagnosis system) a: Detection range B: Bobbin C: Winding core D: standard deviation Eb: descending end Eu: rising end N: Number of times P1: 1st position P2: 2nd position Tm1: First travel time Tm2: Second travel time Tm3: 3rd travel time Ta: Average value Th1: First threshold Th2: Second threshold Th3: Third threshold Th4: Fourth threshold Th5: Fifth threshold Th6: 6th threshold Y: Thread

Claims

1. An abnormality diagnosis system (100, 101) for diagnosing abnormalities in a package manufacturing apparatus (1) that manufactures a package wound with thread (Y), A movable part (15) that moves between a first position (P1) and a second position (P2), A moving mechanism (20) for moving the aforementioned moving part, A first sensor (26) detects that the moving part is in a predetermined detection range (a) including the first position (P1), A control unit (50) diagnoses an abnormality in the moving mechanism (20) based on a first movement time (Tm1), which is the time taken from when the moving part (15) starts moving from the second position (P2) until the first sensor (26) detects the moving part (15). An anomaly diagnosis system (100, 101) equipped with the following features.

2. The second position (P2) is, The position furthest from the first position (P1) within the range in which the moving mechanism (20) moves the moving part (15), The abnormality diagnosis system (100, 101) according to claim 1.

3. The control unit (50) The first movement time (Tm1) is compared with a predetermined first threshold (Th1) to diagnose that an abnormality has occurred in the movement mechanism (20). An abnormality diagnosis system (100, 101) according to claim 1 or 2.

4. The control unit (50) The average value (Ta) of multiple first movement times (Tm1) is compared with a predetermined second threshold (Th2) to diagnose that an abnormality has occurred in the movement mechanism (20). An abnormality diagnosis system (100, 101) according to claim 1 or 2.

5. The control unit (50) The standard deviation (D) of a plurality of the first movement times (Tm1) is compared with a predetermined third threshold (Th3) to diagnose that an abnormality has occurred in the movement mechanism (20). An abnormality diagnosis system (100, 101) according to claim 1 or 2.

6. The control unit (50) Based on the number of times (N) the first movement time (Tm1) exceeds a predetermined fourth threshold (Th4), it is diagnosed that an abnormality has occurred in the movement mechanism (20). An abnormality diagnosis system (100, 101) according to claim 1 or 2.

7. The aforementioned movable part (15) A suction cylinder (15) connected to the lower end of a flexible cylinder (14) that can extend and retract vertically, The aforementioned moving mechanism (20) is It has an air cylinder (25), The first position (P1) is, This is the position of the suction cylinder (15) when the air cylinder (25) is retracted. The second position (P2) is, This is the position of the suction cylinder (15) when the air cylinder (25) is extended. The process involves unwinding the yarn (Y) from the surface of the bobbin (B) around which the yarn (Y) supplied to the package is wound, and then drawing the yarn (Y) into the core (C) of the bobbin (B). An abnormality diagnosis system according to any one of claims 1 to 6 (100, 101).

8. The system switches between a first operating mode for diagnosing abnormalities in the moving mechanism (20) and a second operating mode for repeatedly executing the input process. The abnormality diagnosis system (100, 101) according to claim 7.

9. The control unit (50) An abnormality in the moving mechanism (20) is diagnosed based on a second moving time (Tm2), which is the time from when the moving part (15) starts moving from the first position (P1) until it leaves the detection range (a). An abnormality diagnosis system (101) according to any one of claims 1 to 8.

10. An abnormality diagnosis system (100) for diagnosing abnormalities in a package manufacturing apparatus (1) that manufactures a package wound with thread (Y), A movable part (15) that moves between a first position (P1) and a second position (P2), A moving mechanism (20) for moving the aforementioned moving part (15), A first sensor (26) detects that the moving part (15) is in a predetermined detection range (a) that includes the first position (P1), A control unit (50) diagnoses an abnormality in the moving mechanism (20) based on a third moving time (T3), which is the time from when the moving part (15) starts moving from the first position (P1) until it moves out of the detection range (a). An abnormality diagnosis system (101) equipped with the following:

11. An abnormality in the aforementioned moving mechanism (20) is The cause is any of the following: cracking of the bracket (22) supporting the moving mechanism (20), damage to the bracket (22), accumulation of blown material in the moving mechanism (20), or malfunction of the moving mechanism. An abnormality diagnosis system according to any one of claims 1 to 10 (100, 101).

12. An abnormality diagnosis method for diagnosing abnormalities in a package manufacturing apparatus (1) that manufactures packages wound with thread (Y), The package manufacturing apparatus (1) is A movable part (15) that moves between a first position (P1) and a second position (P2), A moving mechanism (20) for moving the aforementioned moving part (15), A first sensor (26) detects that the movable part (15) is in a predetermined detection range (a) including the first position (P1) and Equipped with, An abnormality in the moving mechanism (20) is diagnosed based on a first moving time (Tm1), which is the time taken from when the moving part (15) starts moving from the second position (P2) until the first sensor detects the moving part (15). Methods for diagnosing abnormalities.

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