Anomaly diagnosis system and anomaly diagnosis method

Abstract

This involves diagnosing abnormalities in the drive mechanism of a manufacturing machine that winds thread to produce packaging. [Solution] The abnormality diagnosis system 70 comprises a movable cylinder 34, a drive mechanism 40, a home sensor 55, a control unit 71, and a diagnostic unit 74. The movable cylinder 34 moves between a home position and a second position. The drive mechanism 40 moves the movable cylinder 34. The home sensor 55 detects the movable cylinder 34 located at the home position. The control unit 71 controls the movement of the movable cylinder 34 by controlling the drive mechanism 40. Based on a first control value obtained when the movable cylinder 34 is moved from the home position to the second position, the control unit 71 performs movement control to move the movable cylinder 34 from the second position towards the home position. The diagnostic unit 74 diagnoses an abnormality in the drive mechanism 40 based on the detection result of the home sensor 55 after the movement control.

Description

Technical Field

[0001] The present invention relates to an abnormality diagnosis system and an abnormality diagnosis method for a manufacturing apparatus that manufactures a package by winding a yarn supplied from a yarn supply unit.

Background Art

[0002] A yarn winding device that applies tension to a yarn unwound from a supply bobbin and winds the yarn to form a package is known. The yarn winding device has a yarn unwinding assisting device for regulating a balloon generated when unwinding the yarn from the supply bobbin and stabilizing the unwinding tension. Such an unwinding assisting device controls the formation of the balloon by lowering a regulating member as the chess portion (the tapered end portion on the yarn unwinding side of the yarn layer of the supply bobbin) of the supply bobbin descends and maintaining a constant distance from the chess portion.

[0003] The drive mechanism for lowering the regulating member has a male screw member and a female screw member that engages with the male screw member. The female screw member is configured to be movable integrally with the regulating member, and when the male screw member is rotated by a motor, the regulating member moves up and down together with the female screw member.

[0004] The yarn unwinding assisting device of Patent Document 1 can precisely control the position of the regulating member in fine steps of pulse units by pulse control for a stepping motor.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] The female threaded component of the drive mechanism gradually wears down as it moves while screwed onto the male threaded component. As wear progresses, it becomes difficult to control the position of the regulating component, which may cause the thread unwinding assist device to malfunction.

[0007] The object of the present invention is to provide an abnormality diagnosis system for diagnosing abnormalities in the drive mechanism of a manufacturing apparatus that winds yarn to produce a package. [Means for solving the problem]

[0008] Several embodiments for solving the problem are described below. These embodiments can be combined as needed.

[0009] The present invention relates to an anomaly diagnosis system for a manufacturing apparatus that winds yarn supplied from a yarn feeding unit to manufacture a package. The anomaly diagnosis system comprises a moving unit, a drive mechanism, a detection unit, a control unit, and a diagnosis unit. The moving unit moves between a first position and a second position. The drive mechanism moves the moving unit. The detection unit detects the moving unit when it is located at the first position. The control unit controls the movement of the moving unit by controlling the drive mechanism.

[0010] The control unit performs movement control to move the movable part from the second position to the first position, based on the first control value obtained when the movable part is moved from the first position to the second position. The diagnostic unit diagnoses any abnormalities in the drive mechanism based on the detection results of the detection unit after the movement control.

[0011] This anomaly diagnosis system diagnoses abnormalities in the drive mechanism based on the detection results after movement control. In other words, it can diagnose abnormalities in the drive mechanism without the operator having to visually inspect the details of the drive mechanism.

[0012] In the abnormality diagnosis system described above, the control unit may, in motion control, use the same value as the first control value to move the moving part from the second position toward the first position. With this configuration, if motion control is completed successfully, the moving part returns to the first position.

[0013] In the abnormality diagnosis system described above, the control unit may, in motion control, use a value obtained by adding a predetermined value to the first control value to move the moving part from the second position toward the first position. As wear progresses on the components constituting the drive mechanism, the distance the moving part moves relative to the control value may decrease. With this configuration, if the degree of wear is low, the moving part can be returned to the first position by motion control.

[0014] In the abnormality diagnosis system described above, the control unit may move the movable part from the first position to the second position with multiple instructions. Alternatively, the control unit may move the movable part from the second position toward the first position with a single instruction. The first control value may be the sum of the control values ​​used in each of the multiple instructions.

[0015] In this anomaly diagnosis system, the moving part moves in response to multiple instructions, so the position of the second position changes each time. With this configuration, anomalies in the drive mechanism can be diagnosed based on the sum of the control values ​​and the detection results after movement control.

[0016] In the above-described anomaly diagnosis system, the control unit may issue an alarm if the moving part is not detected by the detection unit after movement control. This configuration allows the operator to be notified of the occurrence of an anomaly.

[0017] In the abnormality diagnosis system described above, the control unit may issue an alarm based on the number of consecutive times the moving part is not detected by the detection unit after movement control. Even if the drive mechanism is functioning normally, the moving part may not return to the first position for a small number of times, such as once, after movement control. This configuration reduces the workload on the operator by reducing the number of alarms issued and prevents a decrease in the cycle time of the manufacturing equipment.

[0018] In the above-described anomaly diagnosis system, the diagnostic unit may diagnose an anomaly in the drive mechanism based on the number of movement control operations and the number of alarm sounds. From the number of movement control operations and the number of alarm sounds, the percentage of times the moving part does not return to the first position due to movement control (anomaly occurrence rate) can be calculated. Even if the drive mechanism is functioning normally, the moving part may not return to the first position after movement control. However, as the anomaly occurrence rate increases, the likelihood of an anomaly in the drive mechanism increases. This configuration can improve the accuracy of anomaly diagnosis in the drive mechanism.

[0019] In the above-described anomaly diagnosis system, the diagnostic unit may diagnose an anomaly in the drive mechanism based on the number of movement control operations and the number of times the moving part was not detected by the detection unit after movement control. From the number of movement control operations and the number of times the moving part was not detected by the detection unit after movement control, the percentage of times the moving part does not return to the first position by movement control (anomaly occurrence rate) can be calculated. With such a configuration, the accuracy of anomaly diagnosis in the drive mechanism can be improved.

[0020] The present invention relates to a method for diagnosing abnormalities in a manufacturing apparatus that winds yarn supplied from a yarn feeding unit to manufacture a package. The manufacturing apparatus includes a moving unit, a drive mechanism, a detection unit, and a control unit. The moving unit moves between a first position and a second position. The drive mechanism moves the moving unit. The detection unit detects the moving unit when it is located at the first position. The control unit controls the movement of the moving unit by controlling the drive mechanism. The abnormality diagnosis method comprises a movement control step and an abnormality diagnosis step.

[0021] In the movement control step, movement control is performed to move the moving part from the second position to the first position, based on the first control value obtained when the moving part is moved from the first position to the second position. In the abnormality diagnosis step, abnormalities in the drive mechanism are diagnosed based on the detection results of the detection unit after the movement control.

[0022] In this abnormality diagnosis method, based on the detection result after movement control, the abnormality of the drive mechanism is diagnosed. That is, the abnormality of the drive mechanism can be diagnosed without the operator visually checking the details of the drive mechanism.

Effects of the Invention

[0023] According to the abnormality diagnosis system or method according to the present invention, the abnormality of the drive mechanism of a manufacturing apparatus that winds the yarn supplied from the yarn supply unit to manufacture a package can be diagnosed.

Brief Description of the Drawings

[0024] [Figure 1] It is a diagram showing the configuration of a winding device. [Figure 2] It is a functional block diagram of a yarn unwinding assisting device and an abnormality diagnosis system. [Figure 3] It is a partial cross-sectional view of a yarn unwinding assisting device. [Figure 4A] It is a partial cross-sectional view of a yarn unwinding assisting device. [Figure 4B] It is a partial cross-sectional view of a yarn unwinding assisting device. [Figure 5] It is a flowchart showing the control flow of a yarn unwinding assisting device. [Figure 6] It is a flowchart showing the flow of notification processing. [Figure 7] It is a flowchart showing the flow of abnormality diagnosis. [Figure 8] It is a flowchart showing the flow of abnormality diagnosis of Modification B.

Modes for Carrying Out the Invention

[0025] 1. First Embodiment (1) Winding device 1 First, an example of a yarn winding device 1 in which an abnormality is diagnosed by the abnormality diagnosis system 70 will be explained with reference to Figure 1. Figure 1 is a diagram showing the configuration of the yarn winding device 1. The yarn winding device 1 is a device that winds yarn Y unwound from the yarn bobbin B onto the surface of a winding tube 22 to form a yarn layer. The yarn layer formed on the surface of the winding tube 22 is called a package 23. In other words, the yarn winding device 1 is a package manufacturing device.

[0026] The yarn winding device 1 comprises a winding unit 2 having a yarn feeding section 3, and a unit control unit 60 that controls the winding unit 2. The yarn feeding section 3 supplies yarn Y for manufacturing the package 23. The winding unit 2 performs a winding operation in which it winds the yarn Y, unwound from the yarn bobbin B held in the yarn feeding section 3, onto the surface of the winding tube 22 to form the package 23. In this embodiment, the yarn winding device 1 is a drum-type winding device, but the yarn winding device 1 may also be an arm traverse type winding device or a belt traverse type winding device. The yarn winding device 1 is mounted, for example, on an automatic winder that uses multiple yarn winding devices 1 arranged in a row.

[0027] (1-1) Winding Unit 2 The winding unit 2 is equipped with, in order from the yarn supply bobbin B toward the winding tube 22, a yarn unwinding assist device 30, a tensioning device 11, a splicer device 12, a clearer 13, a waxing device 14, a cleaning pipe 15, and a package forming device 20. In this embodiment, the yarn supply bobbin B is located at the bottom and the winding tube 22 is located at the top, but the arrangement of each device is not limited to this.

[0028] The yarn unwinding assist device 30 is a device for regulating the expansion (ballooning) of the yarn Y during unwinding and stabilizing the unwinding tension. The yarn unwinding assist device 30 has a movable cylinder (movable part) 34. The yarn unwinding assist device 30 lowers the movable cylinder 34, which covers the core tube of the yarn supply bobbin B, in conjunction with the unwinding of the yarn Y from the yarn supply bobbin B. This regulates the ballooning of the yarn Y during unwinding.

[0029] The tension-applying device 11 is a device that applies a predetermined tension to the moving thread Y. For example, a gate-type tension-applying device 11 can be used, which has movable comb teeth 11b arranged relative to fixed comb teeth 11a. The tension-applying device 11 applies a constant tension to the winding thread Y, thereby improving the quality of the package 23.

[0030] The splicer device 12 is a device that splices the thread Y on the thread supply bobbin B side (hereinafter referred to as the lower thread) and the thread Y on the package 23 side (hereinafter referred to as the upper thread) when the clearer 13 detects a thread defect and cuts the thread, or when the thread breaks during unwinding from the thread supply bobbin B. As such a thread splicing device for joining the upper and lower threads, mechanical devices or devices that use fluids such as compressed air can be used.

[0031] The Clearara 13 comprises a Clearara head 17 and an analyzer (not shown). The Clearara head 17 is equipped with a sensor for detecting the thickness of the yarn Y. The analyzer processes the yarn thickness signal from the sensor. The Clearara 13 is configured to detect yarn defects such as slabs by monitoring the yarn thickness signal from the sensor. A cutter 16 is provided near the Clearara head 17 to immediately cut the yarn Y when the Clearara 13 detects a yarn defect.

[0032] The lower thread guide pipe 19 is positioned upstream (below in this embodiment) of the splicer device 12 in the direction of thread travel during thread winding. The upper thread guide pipe 18 is positioned downstream (above in this embodiment) of the splicer device 12 in the direction of thread travel during thread winding. When the thread Y is split, the lower thread guide pipe 19 captures the lower thread on the thread supply bobbin B side and guides it to the splicer device 12. The upper thread guide pipe 18 captures the upper thread on the package 23 side and guides it to the splicer device 12. The lower thread guide pipe 19 and the upper thread guide pipe 18 are configured to be rotatable around axes 19a and 18a, respectively. A suction port 19b is formed at the tip of the lower thread guide pipe 19, and a suction mouth 18b is provided at the tip of the upper thread guide pipe 18. The lower thread guide pipe 19 and the upper thread guide pipe 18 are each connected to an appropriate negative pressure source, which generates a suction flow at the suction port 19b and the suction mouth 18b, enabling the upper and lower thread ends to be sucked and captured.

[0033] The waxing device 14 is a device that applies an appropriate amount of wax to the running yarn Y.

[0034] The cleaning pipe 15 is a device that sucks up and removes foreign matter attached to the moving thread Y.

[0035] The package forming apparatus 20 comprises a cradle 24, a winding tube 22, and a swivel drum 21. The cradle 24 supports the package 23 so that it can rotate around a predetermined axis by clamping the winding tube 22 from both ends in the longitudinal direction of the winding tube 22. The cradle 24 is also configured to rotate around a pivot axis 25, and is configured to absorb the increase in yarn layer diameter that occurs when yarn Y is wound onto the winding tube 22 by the rotation of the cradle 24.

[0036] The ridge drum 21 is a cylindrical member that is rotationally driven around its axis by a motor (not shown). With the outer circumference of the package 23 in contact with the ridge drum 21, the ridge drum 21 is rotationally driven, thereby providing a driving force to the package 23, which then rotates in accordance with the rotation of the ridge drum 21.

[0037] Furthermore, spiral grooves are formed on the cylindrical side surface of the ridge-vibration drum 21. While the ridge-vibration drum 21 is rotationally driven, the package 23 rotates in response, and at the same time, the yarn Y unwound from the yarn supply bobbin B is traversed across the surface of the package 23 at a constant width by the grooves. As a result, the yarn Y supplied by being unwound from the yarn supply bobbin B is wound up while traversing across the surface of the package 23. This results in the formation of a package 23 with a constant winding width.

[0038] (1-2) Unit control unit 60 The unit control unit 60 (not shown) is connected in a communication manner to sensors for detecting the position and state of the thread Y, sensors and switches for detecting the state of each device in the winding unit 2, etc. Through this, the unit control unit 60 controls the operation of each device that makes up the winding unit 2.

[0039] The unit control unit 60 is a computer having a processor (e.g., CPU), a storage device (e.g., ROM, RAM, HDD, SSD, etc.), and various interfaces (e.g., A / D converter, D / A converter, communication interface, etc.). The unit control unit 60 performs various control operations by executing programs stored in the memory unit (corresponding to part or all of the storage area of ​​the storage device).

[0040] The unit control unit 60 may consist of a single processor, or it may consist of multiple independent processors for each control. Some or all of the functions of the unit control unit 60 may be implemented as programs executable on a computer system. In addition, some of the functions of the unit control unit 60 may be made up of custom ICs. In this embodiment, the unit control unit 60 has the functions of an anomaly diagnosis system 70.

[0041] (2) Anomaly Diagnosis System 70 Figure 2 is a functional block diagram of the abnormality diagnosis system 70 and the thread unwinding assistance device 30. The abnormality diagnosis system 70 mainly consists of a control unit 71, a storage unit 75, and an output unit 76. The drive motor 44, detection sensor 32, and origin sensor (detection unit) 55, which constitute the thread unwinding assistance device 30, are connected to the abnormality diagnosis system 70.

[0042] The output unit 76 outputs various types of information and is composed of various displays and speakers. The abnormality diagnosis system 70 may also have a communication unit that can communicate with other devices (for example, other computers or portable information terminals). This communication unit may also function as the output unit 76 that transmits information to other devices (outputs information). The communication unit is an interface for connecting the unit control unit 60 to a network such as a LAN or the Internet.

[0043] The control unit 71 is a processor such as a CPU, and it performs various information processing by reading and executing programs stored in the memory unit 75. The memory unit 75 may be part of the memory area of ​​the memory device of the unit control unit 60, or it may be a memory device of another computer connected via the communication unit (for example, ROM, RAM, HDD, SSD, etc.).

[0044] The control unit 71 has a diagnostic unit 74 as a functional block. The diagnostic unit 74 diagnoses abnormalities in the drive mechanism 40 of the yarn unwinding assist device 30, as described later. The functions of the diagnostic unit 74 may be implemented by one or more other computers connected via a communication unit. These other computers may be, for example, machine control devices for an automatic winder composed of multiple yarn winding devices 1, controllers which are higher-level systems for the automatic winder, or supercomputers, workstations, or cloud computing systems.

[0045] (3) Detailed configuration of the thread unraveling and loosening assistance device 30 The yarn unwinding and loosening assist device 30 will be described in detail with reference to Figures 3, 4A, and 4B. Figures 3, 4A, and 4B are partial cross-sectional views of the yarn unwinding and loosening assist device 30. In Figures 3, 4A, and 4B, the yarn supply bobbin B is held in the winding position.

[0046] As shown in Figure 3, the yarn unwinding assist device 30 is attached to the frame 9 that constitutes the yarn winding device 1. The yarn unwinding assist device 30 includes a movable cylinder 34, a retaining cover member 31, a fixed cylinder 33, and a drive mechanism 40.

[0047] The movable cylinder 34 is a cylindrical member that assists in unwinding the yarn Y by contacting a balloon formed on the upper part of the yarn bobbin B through the rotation and centrifugal force of the yarn Y unwound from the yarn bobbin B, thereby applying appropriate tension to the balloon. The movable cylinder 34 is supported by the second holder 37. The movable cylinder 34 is positioned above the yarn bobbin B, which is held in an upright position at the winding position, so as to cover the upper part of the yarn bobbin B. The movable cylinder 34 has a straight cylindrical portion 34a whose inner diameter does not change in the direction of the cylinder axis, and a tapered cylindrical portion 34b formed at the lower end of the straight cylindrical portion 34a, the diameter of which increases towards the bottom. The movable cylinder 34 is configured to move downward as the yarn layer of the yarn bobbin B moves downward.

[0048] The retaining cover member 31 is supported by the second holder 37 and is configured to move integrally with the movable cylinder 34. The retaining cover member 31 is equipped with a detection sensor 32 for detecting the position of the yarn supply bobbin B and the checkered portion of the yarn supply bobbin B (the tapered end on the yarn unwinding side of the yarn layer of the yarn supply bobbin B). The detection sensor 32 detects the checkered portion of the yarn supply bobbin B (the tapered end on the yarn unwinding side of the yarn layer of the yarn supply bobbin B). The detection sensor 32 is an optical sensor having a light receiving portion 32a and a light emitting portion 32b arranged on both sides of the yarn supply bobbin B.

[0049] The fixed cylinder 33 is a cylindrical member that is fixedly positioned directly above the yarn supply bobbin B in the winding position and regulates the balloon of yarn Y. The fixed cylinder 33 is supported by the first holder 35, and a yarn guide 36 is provided at its lower end. As shown in Figure 3, the lower end of the fixed cylinder 33 is positioned above the upper end of the yarn supply bobbin B. The yarn guide 36 has a tapered surface that widens towards the bottom. Since the outer diameter of the fixed cylinder 33 is smaller than the inner diameter of the movable cylinder 34, the movable cylinder 34 can move vertically while covering the outside of the fixed cylinder 33. In addition, the small inner diameter of the fixed cylinder 33 suppresses fluctuations in the balloon of yarn Y unwound from the checkerboard section, and as a result, the size of the formed balloon is stabilized.

[0050] The drive mechanism 40 has a sliding screw 43 consisting of a male screw member 41 and a female screw member 42 screwed onto the male screw member 41. The male screw member 41 extends in the vertical direction and is rotated around its axis by a drive motor 44. The drive motor 44 is a stepping motor. When the male screw member 41 is rotated around its axis, the female screw member 42 moves up and down along the male screw member 41. The female screw member 42 is often made of a softer resin than the male screw member 41. Also, because the female screw member 42 moves while screwed onto the male screw member 41, it gradually wears down. As wear progresses, it becomes difficult to control the position of the movable cylinder 34.

[0051] The female threaded member 42 is fixed to the slider 45 with a portion of it inserted into a mounting hole 45a formed in the slider 45. The slider 45 is guided vertically by a guide member 46 that extends parallel to the male threaded member 41. The mounting hole 45a is formed along the axial direction of the male threaded member 41. The male threaded member 41 and the guide member 46 are supported at their upper ends by an upper support member 47 and at their lower ends by a lower support member 48. The male threaded member 41 is rotatably supported around its axis by bearings 49 provided on the upper support member 47 and the lower support member 48. The upper support member 47 is fixed to a casing 51, which will be described later, but the lower support member 48 is not fixed to any other member.

[0052] The yarn unwinding assist device 30 is further equipped with a dustproof mechanism 50. The dustproof mechanism 50 surrounds the sliding screw 43 and the drive motor 44 to prevent the blown-out cotton generated during yarn unwinding from adhering to the sliding screw 43 and the drive motor 44. The dustproof mechanism 50 has a casing 51, a bellows member 52, and a cup member 53.

[0053] The casing 51 is a housing for the drive motor 44. An upper support member 47 is fixed to the casing 51, as is a first holder 35 that supports the fixed cylinder 33. The bellows member 52 is a cylindrical member that can expand and contract in the vertical direction, and is provided to surround mainly the upper half of the male screw member 41 and the guide member 46. The upper end of the bellows member 52 is attached to the casing 51, and the lower end is connected to the cup member 53 via a ring-shaped connecting member 54. The cup member 53 is a bottomed cylinder with an open upper end, and is provided to surround mainly the lower half of the male screw member 41 and the guide member 46. The upper end of the cup member 53 is attached to the connecting member 54. The male screw member 41 and the guide member 46 are arranged in the space surrounded by the bellows member 52 and the cup member 53.

[0054] A slider 45 is fixed to the inner circumferential surface of the ring-shaped connecting member 54, and a second holder 37 that supports the movable cylinder 34 is fixed to the outer circumferential surface. In other words, the female screw member 42 is connected to the movable cylinder 34 via the slider 45, the connecting member 54, and the second holder 37 so that it can move up and down together. When the drive motor 44 is driven, the male screw member 41 rotates, causing the female screw member 42 to move up and down along the male screw member 41, as well as the slider 45 and the movable cylinder 34. At this time, the cup member 53 attached to the connecting member 54 also moves up and down together.

[0055] When the movable cylinder 34 moves up and down, the upper end of the bellows member 52 does not move up or down because it is fixed to the casing 51, but the lower end of the bellows member 52 moves up and down because it is attached to the connecting member 54. Therefore, the bellows member 52 expands and contracts vertically in accordance with the movement of the movable cylinder 34. When the movable cylinder 34 moves down, the bellows member 52 expands as shown in Figure 4A, and when the movable cylinder 34 moves up, it contracts as shown in Figure 4B. In this way, by expanding and contracting the bellows member 52 in accordance with the movement of the movable cylinder 34, the blown cotton does not enter the inside of the dustproof mechanism 50 even when the movable cylinder 34 is moved up and down.

[0056] The uppermost position of the movable cylinder 34's movable vertical stroke is defined as the origin position (first position). The arrival of the movable cylinder 34 at the uppermost position can be determined by causing an origin sensor 55, such as a limit switch, to detect the slider 45. In other words, the origin sensor 55 detects whether or not the movable cylinder 34 is at the origin position. The origin sensor 55 is supported, for example, by an upper support member 47 and is fixed in a position where it can detect the slider 45 when the movable cylinder 34 is at the origin. The origin sensor 55 may also be an optical sensor or a capacitive sensor.

[0057] When the origin sensor 55 detects that the movable cylinder 34 is at the origin position, it outputs an origin signal to the control unit 71. Upon receiving the origin signal, the control unit 71 stops the upward movement of the movable cylinder 34. In other words, when the origin sensor 55 detects that the movable cylinder 34 is at the origin position, the upward movement of the movable cylinder 34 stops.

[0058] (4) Control flow of the thread unraveling and loosening assist device 30 Next, with reference to Figures 5 and 6, the control flow of the thread unwinding assistance device 30 by the abnormality diagnosis system 70 will be explained.

[0059] As shown in Figure 5, when the control flow starts, the control unit 71 drives the drive motor 44 to raise the movable cylinder 34 of the thread unwinding assist device 30 to the origin position (step S1). After that, the control unit 71 resets the first control value to zero (step S2). Here, the first control value is a control value corresponding to the distance traveled when the movable cylinder 34 is lowered from the origin position to a predetermined position. Here, it is the number of predetermined pulses that the control unit 71 transmits to the drive motor 44 in order to lower the movable cylinder 34. Since step S1 is an initial operation, the control unit 71 may continue to drive the drive motor 44 until the origin sensor 55 detects that the movable cylinder 34 is in the origin position. Also, if the origin sensor 55 detects that the movable cylinder 34 is in the origin position at the start of the control flow, steps S1 and S2 can be skipped.

[0060] When a new yarn supply bobbin B is supplied, the control unit 71 determines whether the detection sensor 32 has detected the checkerboard portion of the yarn supply bobbin B (step S3).

[0061] If the control unit determines that the chess piece is not detected (the answer is No in step S3), the control unit 71 sends a predetermined number of drive pulses to the drive motor 44, causing the movable cylinder 34 to descend (step S4). The control unit 71 adds the number of drive pulses sent to the first control value (step S5) and returns to step S3. The first control value is stored in the storage unit 75.

[0062] The control unit 71 repeatedly executes steps S3 to S5 until the detection sensor 32 detects the chess piece. This allows the control unit 71 to lower the movable cylinder 34 from the origin position to the position where the detection sensor 32 detects the chess piece (hereinafter referred to as the detection position). In addition, the number of drive pulses transmitted when moving the movable cylinder 34 from the origin position to the detection position is stored in the storage unit 75 as the first control value.

[0063] On the other hand, if it is determined that the chess piece has been detected (if the answer is Yes in step S3), the process proceeds to step S6 and the winding operation begins.

[0064] If no breakage (thread breakage or thread severance) of thread Y occurs during the winding operation (if No in step S7), and winding is not yet complete (if No in step S15), the process returns to step S3. That is, if the unwinding of thread Y progresses and the checkerboard pattern is no longer detected by the detection sensor 32, the control unit 71 lowers the movable cylinder 34 until the checkerboard pattern is detected again by the detection sensor 32.

[0065] If the thread Y is interrupted (cut or broken) during the winding operation (if the answer is Yes in step S7), the control unit 71 performs movement control to raise the movable cylinder 34 to the origin position (step S8). Here, the position of the movable cylinder 34 when the thread Y is interrupted is called the second position. At this time, the total number of drive pulses transmitted when moving the movable cylinder 34 from the origin position to the second position is stored in the storage unit 75 as the first control value. As described above, the control unit 71 moves the movable cylinder 34 from the origin position to the second position by multiple instructions (transmission of drive pulses). Therefore, the first control value is the sum of the control values ​​used in each of the multiple instructions. In movement control, the control unit 71 transmits drive pulses equal to the first control value to the drive motor 44 and raises the movable cylinder 34. In other words, in movement control, the control unit 71 uses the same control value as the first control value to move the movable cylinder 34 from the second position towards the origin position. Furthermore, the control unit 71 moves the movable cylinder 34 from the second position toward the origin position with a single instruction.

[0066] After movement control, the control unit 71 determines whether the movable cylinder 34 is located at the origin position based on the origin signal from the origin sensor 55 (step S9).

[0067] If the control unit 71 receives a home signal from the home sensor 55 (if the answer is Yes in step S9), it determines that the movable cylinder 34 is in the home position. It then waits until the thread splicing operation is completed (step S12).

[0068] When the thread splicing operation is completed (if Yes in step S12), the control unit 71 adds 1 to the number of movements (step S13). The number of movements is stored in the memory unit 75. Thus, the number of movements is a count of the number of times the thread splicing by the splicer device 12 was successful. Also, as described above, the movable cylinder 34 moves from the origin position to the second position, and then moves from the second position towards the origin position by movement control. After that, the movable cylinder 34 remains at the origin position until the thread splicing operation is completed. Therefore, the number of movements can also be said to be the number of movement control operations in step S8.

[0069] The control unit 71 resets the first control value stored in the memory unit 75 to zero (step S14), and returns to step S3.

[0070] On the other hand, if the origin signal from the origin sensor 55 is not received (the result is No in step S9), the control unit 71 determines that the movable cylinder 34 is not in the origin position and proceeds to the notification process in step S10. Step S10 consists of steps S101 to S106 in Figure 6.

[0071] The control unit 71 adds 1 to the trial count (step S101). The trial count is stored in the storage unit 75. Here, the trial count is the number of times after the movement control in step S8 the system proceeds to the notification process without receiving the origin signal. In other words, the trial count corresponds to the number of consecutive times after the movement control the system does not detect the movable cylinder 34 by the detection unit.

[0072] The control unit 71 determines whether the number of trials is equal to or greater than a predetermined number (step S102). The predetermined number is predetermined based on the number of trials and the possibility of an abnormality occurring in the drive mechanism 40, and is stored in the memory unit 75. Specifically, for example, if the number of trials is 1, the possibility of an abnormality occurring in the drive mechanism 40 is low. In this case, there is no need to notify the operator of an alarm. However, for example, if the number of trials is 3, it is assumed that there is a high possibility of an abnormality occurring in the drive mechanism 40. In this case, the predetermined number may be set to 3.

[0073] If the control unit 71 determines that the number of trials is not equal to or greater than a predetermined number (if the result is No in step S102), the control unit 71 raises the movable cylinder 34 until it receives a home signal from the home sensor 55, and then terminates the notification process (step S103). In other words, the control unit 71 raises the movable cylinder 34 to the home position.

[0074] On the other hand, if the control unit 71 determines that the number of trials has exceeded a predetermined number (if the answer is Yes in step S102), the control unit 71 notifies the operator, for example, by displaying the details of the abnormality (alarm) on the display, which serves as the output unit 76 (step S104). The control unit 71 may also sound an alarm to inform the operator that an abnormality has occurred. In other words, the control unit 71 sounds an alarm if the movable cylinder 34 is not detected by the origin sensor 55 after movement control. The control unit 71 also sounds an alarm based on the number of consecutive times the movable cylinder 34 is not detected by the origin sensor 55 after movement control.

[0075] The control unit 71 adds 1 to the notification count (step S105). The notification count is stored in the memory unit 75. Thus, the notification count is the number of times the alarm was notified to the operator.

[0076] The control unit 71 resets the number of trials to zero (step S106) and terminates the notification process.

[0077] The operator performs the necessary work based on the nature of the abnormality. Once the abnormality is resolved (if the answer is Yes in step S11), the process proceeds to step S12, and the operator waits until the thread splicing operation is completed.

[0078] The control unit 71 repeatedly executes steps S3 to S14 described above until the winding of the thread Y is completed (step S15).

[0079] (5) Flow of abnormality diagnosis Next, with reference to Figure 7, the flow of abnormality diagnosis of the drive mechanism 40 of the thread unwinding assist device 30 by the abnormality diagnosis system 70 will be described. The abnormality diagnosis may be performed after the notification process described above, or at a predetermined timing. The diagnosis unit 74 diagnoses an abnormality in the drive mechanism 40 based on the detection result of the origin sensor 55 after movement control.

[0080] First, the diagnostic unit 74 obtains the number of movements and the number of notifications (step S21). If the number of movements is zero, the diagnostic unit 74 terminates the process (if the answer is Yes in step S22).

[0081] On the other hand, if the number of movements is not zero (if the result is No in step S22), the diagnostic unit 74 calculates the abnormality rate from the number of movements and the number of notifications (step S23). Here, an abnormality means that the movable cylinder 34 does not return to the origin position after movement control. In this embodiment, the abnormality rate can be expressed as "abnormality rate = number of notifications ÷ number of movements".

[0082] The diagnostic unit 74 determines whether the rate of abnormal occurrence is equal to or greater than a predetermined frequency (step S24). The predetermined frequency is predetermined based on the rate of abnormal occurrence and the probability that an abnormality has occurred in the drive mechanism 40, and is stored in the memory unit 75. Specifically, for example, if the rate of abnormal occurrence is 1 in 20 times, the probability of an abnormality occurring in the drive mechanism 40 is low, so there is no need to report the diagnostic result. However, for example, if the rate of abnormal occurrence is 1 in 5 times, it is assumed that there is a high probability that an abnormality has occurred in the drive mechanism 40. In this case, the predetermined frequency may be set to 1 in 5 times.

[0083] If the diagnostic unit 74 determines that the rate of abnormal occurrences is not above a predetermined frequency (i.e., No in step S24), it terminates the process.

[0084] On the other hand, if the diagnostic unit 74 determines that the rate of abnormalities is above a predetermined frequency (if the answer is Yes in step S24), it determines that there is a high probability that an abnormality has occurred in the drive mechanism 40 and notifies the diagnostic result (step S25). In other words, the diagnostic unit 74 diagnoses an abnormality in the drive mechanism 40 based on the number of movement control operations and the number of alarm notifications. The diagnostic result includes, for example, the identification name of the yarn winding device 1 in which the abnormality occurred, and the details of the abnormality (the possibility of an abnormality in the drive mechanism 40 of the yarn unwinding assist device 30). The diagnostic unit 74 may also notify the administrator by displaying the diagnostic result on the display, which serves as the output unit 76. Alternatively, the diagnostic unit 74 may send the diagnostic result to the administrator's email address.

[0085] After reporting the diagnostic result, the diagnostic unit 74 resets the number of movements and the number of reports to zero (step S26) and terminates the process. As a result, the period for counting the number of movements and the number of reports is from the time the previous diagnostic result was reported until the present time.

[0086] 2. Other Embodiments 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.

[0087] (1) Variation A The order and content of each process in the flowchart described above can be modified as appropriate without departing from the spirit of the present invention.

[0088] (2) Modification B In this embodiment, the diagnostic unit 74 calculates the abnormality rate from the number of movements and the number of notifications. However, the diagnostic unit 74 may also calculate the abnormality rate from the number of movements and the number of notifications. The number of notifications refers to the number of times the notification process in step S10 of Figure 5 is performed. In other words, the number of notifications refers to the number of times the movable cylinder 34 was not detected by the origin sensor 55 after the first movement control (the number of times the movable cylinder 34 did not return to the origin position).

[0089] Figure 8 is a flowchart showing the abnormality diagnosis process in this modified example.

[0090] The diagnostic unit 74 obtains the number of movements and the number of notification processes (step S31). If the number of movements is zero, the diagnostic unit 74 terminates the process (if Yes in step S32).

[0091] On the other hand, if the number of movements is not zero (if the result is No in step S32), the diagnostic unit 74 calculates the abnormality rate from the number of movements and the number of notification processes (step S33). In this modified example, the abnormality rate can be expressed as "abnormality rate = number of notification processes ÷ number of movements".

[0092] The diagnostic unit 74 determines whether the rate of abnormal occurrence is above a predetermined frequency (step S34). The predetermined frequency is predetermined based on the rate of abnormal occurrence and the possibility of an abnormality occurring in the drive mechanism 40, and is stored in the memory unit 75.

[0093] If the diagnostic unit 74 determines that the rate of abnormal occurrences is not above a predetermined frequency (i.e., No in step S34), it terminates the process.

[0094] On the other hand, if the diagnostic unit 74 determines that the rate of abnormalities is above a predetermined frequency (if the answer is Yes in step S34), it determines that there is a high probability that an abnormality has occurred in the drive mechanism 40 and reports the diagnostic result (step S35). In other words, the diagnostic unit 74 diagnoses an abnormality in the drive mechanism 40 based on the number of movement control operations and the number of times the movable cylinder 34 was not detected by the origin sensor 55 after the movement control operations.

[0095] After reporting the diagnostic result, the diagnostic unit 74 resets the number of movements and the number of reporting processes to zero (step S36) and terminates the process. As a result, the period for counting the number of movements and the number of reporting processes is from the time the previous diagnostic result was reported until the present time.

[0096] (3) Variation C In this embodiment, the control unit 71 sends drive pulses to the drive motor 44 equal to the first control value during movement control, thereby raising the movable cylinder 34 (step S8 in Figure 5). However, the control unit 71 may also send drive pulses to the drive motor 44 equal to the first control value plus a predetermined value during movement control, thereby raising the movable cylinder 34.

[0097] (4) Modification D In this embodiment, after notifying the diagnostic result, the diagnostic unit 74 resets the number of movements and the number of notifications to zero (step S26 in Figure 7). However, the number of movements and the number of notifications may be reset to zero at the start of the control flow. This allows the period for counting the number of movements and notifications to be from the start of the control flow to the present time.

[0098] (5) Variation E The number of movements and notifications may be reset to zero at the start of the first control flow after a predetermined time, day of the week, or date. This allows the period for counting the number of movements and notifications to be a predetermined period.

[0099] (6) Modification F In this embodiment, the control unit 71 counted the number of times the splicer device 12 successfully spliced ​​the thread as the number of movements. However, the control unit 71 may also count the number of times movement control was performed as the number of movements.

[0100] (7) Variation G In step S4 of Figure 5, the control unit 71 may lower the movable cylinder 34 until the detection sensor 32 detects the chess piece. In step S5 of Figure 5, the control unit 71 may add the number of drive pulses transmitted by the detection sensor 32 until the chess piece is detected to the first control value.

[0101] (8) Modification H The present invention can be used for components that move from a standby position to a working position by controlling a motor. For example, it can be applied to the abnormality diagnosis of the drive mechanisms of the lower thread guide pipe 19 and upper thread guide pipe 18, which are rotatable (movable) from the thread Y capture position to the standby position.

[0102] 3. Features of the Embodiment The above embodiment can also be described as follows. (1) The abnormality diagnosis system 70 of this embodiment is an abnormality diagnosis system for a manufacturing apparatus that winds up yarn Y supplied from the yarn supply unit 3 to manufacture a package 23. The abnormality diagnosis system 70 comprises a movable cylinder 34, a drive mechanism 40, a home sensor 55, a control unit 71, and a diagnostic unit 74. The movable cylinder 34 moves between a home position and a second position. The drive mechanism 40 moves the movable cylinder 34. The home sensor 55 detects the movable cylinder 34 located at the home position. The control unit 71 controls the movement of the movable cylinder 34 by controlling the drive mechanism 40.

[0103] The control unit 71 performs movement control to move the movable cylinder 34 from the second position toward the origin position, based on the first control value obtained when the movable cylinder 34 is moved from the origin position toward the second position. The diagnostic unit 74 diagnoses any abnormalities in the drive mechanism 40 based on the detection result of the origin sensor 55 after the movement control.

[0104] This abnormality diagnosis system 70 diagnoses abnormalities in the drive mechanism 40 based on the detection results after movement control. In other words, it can diagnose abnormalities in the drive mechanism 40 without the operator having to visually inspect the drive mechanism 40 in detail.

[0105] (2) In the movement control, the control unit 71 moves the movable cylinder 34 from the second position toward the origin position using the same value as the first control value. In this abnormality diagnosis system 70, if the movement control is completed normally, the movable cylinder 34 returns to the origin position.

[0106] (3) In movement control, the control unit 71 moves the movable cylinder 34 from the second position toward the origin position using a value obtained by adding a predetermined value to the first control value. If the parts constituting the drive mechanism 40 wear out, the distance the movable cylinder 34 moves relative to the control value may become shorter. In this abnormality diagnosis system 70, if the degree of wear is low, the movable cylinder 34 can be returned to the origin position by movement control.

[0107] (4) The control unit 71 moves the movable cylinder 34 from the origin position to the second position with multiple instructions. The control unit 71 also moves the movable cylinder 34 from the second position towards the origin position with a single instruction. The first control value is the sum of the control values ​​used in each of the multiple instructions.

[0108] In this anomaly diagnosis system 70, the movable cylinder 34 moves in response to multiple instructions, so the position of the second position changes each time. Therefore, it is difficult to control the position of the movable cylinder 34 by the movement time. With this configuration, anomalies in the drive mechanism 40 can be diagnosed based on the sum of the control values ​​and the detection results after movement control. In other words, anomalies in the drive mechanism 40 can be diagnosed without adding any other sensors.

[0109] (5) After movement control, the control unit 71 sounds an alarm if the movable cylinder 34 is not detected by the origin sensor 55. This abnormality diagnosis system 70 can notify the operator of the occurrence of an abnormality.

[0110] (6) The control unit 71 issues an alarm based on the number of consecutive times the movable cylinder 34 is not detected by the origin sensor 55 after movement control. Even if the drive mechanism 40 is functioning normally, the movable cylinder 34 may not return to the origin position for a small number of times, such as once, after movement control. This abnormality diagnosis system 70 reduces the workload on the operator by reducing the number of alarms issued and prevents a decrease in the cycle time of the manufacturing equipment.

[0111] (7) The diagnostic unit 74 diagnoses abnormalities in the drive mechanism 40 based on the number of movement control operations and the number of alarm sounds. From the number of movement control operations and the number of alarm sounds, the percentage of times the movable cylinder 34 does not return to the origin position by movement control (abnormality rate) can be calculated. Even if the drive mechanism 40 is functioning normally, the movable cylinder 34 may not return to the origin position after movement control. However, as the abnormality rate increases, the likelihood of an abnormality in the drive mechanism 40 increases. This abnormality diagnosis system 70 can improve the accuracy of abnormality diagnosis of the drive mechanism 40.

[0112] (8) The diagnostic unit 74 diagnoses abnormalities in the drive mechanism 40 based on the number of movement control operations and the number of times the movable cylinder 34 was not detected by the origin sensor 55 after movement control. From the number of movement control operations and the number of times the movable cylinder 34 was not detected by the origin sensor 55, the percentage of times the movable cylinder 34 does not return to the origin position due to movement control (abnormality rate) can be calculated. This abnormality diagnosis system 70 can improve the accuracy of abnormality diagnosis of the drive mechanism 40.

[0113] (9) The abnormality diagnosis method of this embodiment is an abnormality diagnosis method for a manufacturing apparatus that winds up yarn Y supplied from the yarn supply unit 3 to manufacture a package 23. The manufacturing apparatus comprises a movable cylinder 34, a drive mechanism 40, a home sensor 55, and a control unit 71. The movable cylinder 34 moves between a home position and a second position. The drive mechanism 40 moves the movable cylinder 34. The home sensor 55 detects the movable cylinder 34 located at the home position. The control unit 71 controls the movement of the movable cylinder 34 by controlling the drive mechanism 40. The abnormality diagnosis method comprises a movement control step and an abnormality diagnosis step.

[0114] In the movement control step, movement control is performed to move the movable cylinder 34 from the second position toward the origin position based on the first control value obtained when the movable cylinder 34 is moved from the origin position toward the second position (step S8 in Figure 5). In the abnormality diagnosis step, abnormalities in the drive mechanism 40 are diagnosed based on the detection result of the origin sensor 55 after the movement control (Figures 7 and 8).

[0115] This abnormality diagnosis method diagnoses abnormalities in the drive mechanism 40 based on the detection results after movement control. In other words, abnormalities in the drive mechanism 40 can be diagnosed without the operator having to visually inspect the drive mechanism 40 in detail. [Industrial applicability]

[0116] The present invention can be broadly applied to yarn winding devices and textile machinery for manufacturing fibers. Textile machinery for manufacturing fibers also includes preparation devices for air spinning and winding devices. [Explanation of Symbols]

[0117] 1 Thread winding device 2 winding units 3 Yarn feeding section 9 frames 11. Tension-applying device 12 Splicer device 13 Cleara 14. Waxing device 15 Cleaning pipe 16 cutters 17 Clear Head 18 Upper thread guide pipe 19. Bobbin guide pipe 20 Package forming apparatus 21 Ayaburi Drum 22 Reeling pipe 23 packages 24 Cradle 25 Rotation axis 30. Thread-releasing and loosening assist device 31 Retaining cover member 32 detection sensors 33 Fixed barrel 34 Movable cylinder, moving part 35 First Holder 36 Thread Guide 37 Second Holder 40 Drive mechanism 41 Male threaded member 42 Female threaded member 43. Slide screw 44 Drive motor 45 Slider 46 Guide member 47 Upper support member 48 Lower support member 49 Bearings 50 Dustproof mechanism 51 Casing 52 Bellows member 53 Cup component 54 Connecting member 55 Origin sensor, detection unit 60 Unit Control Unit 70 Anomaly Diagnosis System 71 Control Unit 74 Diagnostic Department 75 Memory section 76 Output section B. Thread feeding bobbin Y thread

Claims

1. An abnormality diagnosis system for a manufacturing apparatus that winds up yarn supplied from a yarn feeding unit to manufacture a package, A movable part that moves between a first position and a second position, A drive mechanism for moving the aforementioned movable part, A detection unit for detecting the moving part located at the first position, A control unit that controls the movement of the moving part by controlling the drive mechanism, Diagnostic Department, Equipped with, The control unit performs movement control to move the moving part from the second position toward the first position based on the first control value when the moving part is moved from the first position toward the second position. The diagnostic unit diagnoses an abnormality in the drive mechanism based on the detection result of the detection unit after the movement control. An anomaly diagnosis system.

2. The control unit, in the movement control, moves the moving part from the second position toward the first position using the same value as the first control value. The abnormality diagnosis system according to claim 1.

3. The control unit, in the movement control, uses a value obtained by adding a predetermined value to the first control value to move the moving part from the second position toward the first position. The abnormality diagnosis system according to claim 1.

4. The control unit, By multiple instructions, the movable part is moved from the first position to the second position. With a single instruction, the movable part is moved from the second position toward the first position. The first control value is the sum of the control values ​​used in each of the multiple instructions. An abnormality diagnosis system according to any one of claims 1 to 3.

5. The control unit shall, after the movement control, sound an alarm if the moving part is not detected by the detection unit. An abnormality diagnosis system according to any one of claims 1 to 4.

6. The control unit issues the alarm based on the number of consecutive times the moving part is not detected by the detection unit after the movement control. The abnormality diagnosis system according to claim 5.

7. The diagnostic unit diagnoses an abnormality in the drive mechanism based on the number of times the movement control is performed and the number of times the alarm is sounded. The abnormality diagnosis system according to claim 5 or 6.

8. The diagnostic unit diagnoses an abnormality in the drive mechanism based on the number of times the movement control is performed and the number of times the movement unit was not detected by the detection unit after the movement control. An abnormality diagnosis system according to any one of claims 1 to 7.

9. A method for diagnosing abnormalities in a manufacturing apparatus that winds up yarn supplied from a yarn feeding section to manufacture a package, The aforementioned manufacturing apparatus, A movable part that moves between a first position and a second position, A drive mechanism for moving the aforementioned movable part, A detection unit for detecting the moving part located at the first position, A control unit that controls the movement of the moving part by controlling the drive mechanism, It has, A movement control step is performed to move the moving part from the second position toward the first position based on a first control value when the moving part is moved from the first position toward the second position, An abnormality diagnosis step is performed to diagnose an abnormality in the drive mechanism based on the detection result of the detection unit after the movement control, Equipped with, Methods for diagnosing abnormalities.

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