Parallel Analysis Network for Synthetic Thread Machine Control
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Solution Overview
Problem
Existing machine systems for producing or treating synthetic yarns face limitations in ensuring consistent process quality and rapid reaction times due to the limitations in transmission speed and capacity of bus systems used for data and signal exchange, particularly in cases of process disturbances.
Innovation Solution
The implementation of a parallel data transfer system where control components are coupled to a central analysis station via a real-time analysis network, separate from the machine network, allowing for real-time data analysis and control, with the machine network using Industrial Ethernet and the analysis network using a real-time bus system like ProfiNet, enabling rapid diagnosis and correction of process disturbances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a bus system is used for data transmission in machine systems, then device complexity is reduced and ease of operation is improved, but transmission speed and reaction time deteriorate
Solution Approach 1:
The network system is segmented into two separate networks: a machine network for control data transmission and an analysis network for real-time data analysis. This segmentation allows each network to be optimized for its specific purpose, with the analysis network achieving real-time transmission speeds without compromising the overall system complexity
2Loss of information
If all data transmission is handled through a single machine network, then device complexity is minimized, but transmission capacity and analysis speed deteriorate
Solution Approach 1:
Data transmission is segmented into control functions (machine network) and analysis functions (analysis network). This ensures that all relevant data for process analysis is captured and transmitted to the central analysis station without being bottlenecked by control network constraints
Solution Approach 2:
The control components act as intermediaries that receive data from machine components via the machine network and forward selected data to the central analysis station via the analysis network, enabling efficient data routing and preprocessing
3Loss of time
If a single network is used for both control and analysis, then ease of operation is improved, but reaction time to process disturbances deteriorates
Solution Approach 1:
The network infrastructure is segmented into dedicated control and analysis channels, allowing simultaneous operation of control functions and real-time data analysis without mutual interference, thereby achieving rapid response to process disturbances
Solution Approach 2:
Data is continuously collected and preprocessed in real-time through the analysis network before disturbances occur, enabling the central analysis station to detect and respond to process anomalies immediately when they arise
Data Source
AI summary
Techniques involve a machine system for producing or treating synthetic threads, comprising a plurality of machine components, having actuators and/or sensors, that are associated with a plurality of control components. The control components are connected by a machine network to a central machine control station. In order to remedy process disruptions as quickly as possible and to ensure uniform product quality, the control components are coupled in parallel to a central analysis station by an analysis network.