Spinning Machine Workstation Optical Display for Batch Change Downtime
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Solution Overview
Problem
Batch changes on spinning machines require significant time and lead to longer downtimes due to the need for extensive conversion work at individual workstations, especially in centrally driven systems where all workstations must be changed simultaneously.
Innovation Solution
A method is introduced to quickly identify and address manual maintenance needs at workstations that have reached the end of a batch by using optical display elements, such as graphic displays, to guide operators in prioritizing and completing necessary tasks, thereby reducing downtime and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch changes are performed at multiple workstations, then productivity is improved through continuous production, but downtime increases due to extensive manual maintenance activities required at each workstation
Solution Approach 1:
The system enables workstations to automatically detect when they have reached the end of a batch and to signal their own maintenance needs without requiring continuous operator monitoring. The automated detection and signaling system allows the machine to serve its own monitoring function, reducing the need for manual intervention and minimizing downtime.
Solution Approach 2:
The patent implements a feedback mechanism where optical display elements provide real-time visual information to operators about which workstations require attention. This feedback system allows operators to quickly identify and prioritize workstations that have reached end of batch, enabling faster response times and reduced overall downtime across the production line.
2Loss of time
If optical display elements are added to indicate maintenance needs, then operator response time is reduced, but device complexity increases
Solution Approach 1:
The patent employs optical display elements that use color changes or different optical signals to indicate maintenance needs at workstations. This visual signaling method provides immediate, intuitive information to operators without requiring complex interfaces or additional machinery, achieving fast response times with minimal added complexity.
Solution Approach 2:
The system replaces manual monitoring and physical inspection methods with optical display elements that automatically indicate maintenance needs. This substitution of mechanical/manual monitoring with optical signaling reduces operator response time while adding only minimal system complexity compared to traditional manual monitoring approaches.
Data Source
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AI summary
In a method for operating a semi- or fully automatic, cross-wound spinning machine (1), in particular an open-end rotor spinning machine, with a plurality of identical, adjacent, at least partially self-contained workstations (2), each of the workstations (2) has a spinning device (3) for producing a yarn (6) and a winding device (4) with a bobbin holder (5) for winding the yarn (6) onto a cross-wound bobbin (10). When a batch end is reached at one of the workstations (2), the respective workstation (2) is stopped. At the workstation (2) that has reached the batch end, a requirement to perform at least one manual maintenance task is indicated.A cross-coil-producing spinning machine (1), in particular an open-end rotor spinning machine, with a plurality of similar working stations (2) arranged side by side, wherein each of the working stations (2) has a spinning device (3) for producing a thread (6) and a winding device (4) having a bobbin holder (5) for winding the thread (6) onto a cross-coil (10), has a control device and a display element (12) for carrying out the method as described above.