Yarn Spindle Station-Passing Control Across PLC Online-Offline Modes

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Solution Overview

Problem

The challenge in chemical fiber production is the inefficient station-passing of yarn spindles, which affects overall production pace and efficiency, leading to a bottleneck in output capacity.

Innovation Solution

A system involving a Manufacturing Execution System (MES), a first Programmable Logic Controller (PLC), and multiple second PLCs, with an offline caching mechanism to store station-passing records when disconnected from the MES, ensuring continuous operation and data integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the first PLC operates in offline mode without MES connection, then production continuity is maintained, but data synchronization and centralised monitoring are compromised

Engineering Contradiction:

Improvestation-passing efficiencyVSAvoiddata integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary actions by storing station-passing records in an offline cache area before potential disconnection occurs. This allows the first PLC to maintain production operations while preserving data for later synchronization, resolving the contradiction between maintaining productivity during offline operation and ensuring data integrity.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the system continuously monitors PLC modes and caches offline data, then data loss is minimized, but system complexity increases

Engineering Contradiction:

Improvedata synchronizationVSAvoidcontrol system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The first PLC automatically monitors its own operational mode and autonomously caches station-passing records when in offline mode. This self-service mechanism eliminates the need for external monitoring systems, thereby improving data synchronization reliability while avoiding additional system complexity.

Inventive Principle:

Principle #25Self-service

3Productivity

If manual intervention is reduced for station-passing operations, then productivity increases, but control flexibility decreases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidcontrol flexibility

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The control system dynamically adapts between online and offline modes, automatically adjusting its behavior based on MES connection status. In online mode, it operates under centralized control for flexibility; in offline mode, it autonomously continues station-passing operations for high productivity, thus resolving the contradiction between automated efficiency and operational flexibility.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20260093228A1Method for controlling automatic station-passing of yarn spindle, electronic device and storage medium

Publication Date: 2026.04.02 ZHEJIANG HENGYI PETROCHEMICAL CO LTD

AI summary

Provided are a method for controlling automatic station-passing of a yarn spindle, an electronic device and a storage medium, relating to the technical field of chemical fiber intelligent manufacturing. The method includes: monitoring whether a control button of a first PLC is in an offline mode and whether a control button of a second PLC corresponding to a target station is in an online mode; and storing offline data to an offline cache area if the first PLC generates station-passing indication information for the target station, responsive to determining that the control button of the first PLC is in the offline mode and the control button of the second PLC corresponding to the target station is in the online mode.