Yarn Supply Package Exchange Prediction System
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Solution Overview
Problem
Conventional package exchanging systems for yarn supply packages in textile machines rely on sensors to detect yarn levels, leading to potential delays in identifying when a yarn supply package is running low, resulting in inefficient yarn joining and exchange operations.
Innovation Solution
A package exchanging system with a running unit, acquisition unit, and prediction unit that continuously monitors the remaining yarn amount and predicts when the yarn will run out, allowing for timely and automated yarn joining and exchange operations without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a sensor is provided in the working carrier to detect yarn supply package state in three stages (full, half, small), then the exchange operation can be performed efficiently at detected moments, but the yarn supply package state cannot be monitored continuously, causing the synthetic yarn to disappear without acquiring the state when sensing interval time is long
Solution Approach 1:
The prediction unit predicts the timing when synthetic yarn is likely to disappear based on the current state (full, half, small) detected by the sensor and the remaining amount of yarn. This preliminary prediction allows the system to prepare for yarn exchange before the actual yarn depletion occurs, eliminating the need for continuous monitoring while ensuring reliable timing accuracy.
Solution Approach 2:
The prediction unit acts as an intermediary between the sensor detection and the actual yarn exchange operation. It processes the discrete sensor readings and yarn consumption rate to generate predicted timing information, bridging the gap between intermittent sensing and continuous monitoring requirements.
2Device complexity
If the sensing interval time is long, then the system complexity is reduced, but the synthetic yarn may disappear without acquiring the state, leading to loss of time for yarn joining operation
Solution Approach 1:
The prediction unit calculates the predicted timing of yarn disappearance in advance based on current sensor readings and consumption rates. This allows the system to maintain simple, intermittent sensing while achieving accurate timing prediction, enabling timely yarn exchange operations without requiring frequent sensing or complex continuous monitoring systems.
3Ease of operation
If manual yarn joining operation is performed when yarn supply package is depleted, then the operation can be completed, but the efficiency is reduced due to the need for human intervention and the delayed timing
Solution Approach 1:
The system performs self-monitoring through the sensor and self-prediction through the prediction unit, which calculates when yarn depletion will occur based on current state and consumption rate. This enables the system to autonomously determine the optimal timing for yarn exchange, eliminating the need for manual monitoring and timely triggering automated or prepared exchange operations.
Solution Approach 2:
The sensor provides feedback on the current yarn supply package state (full, half, small), which is fed into the prediction unit. The prediction unit processes this feedback along with yarn consumption rate information to generate predicted timing, creating a closed-loop system that continuously adapts to actual yarn usage patterns.
Data Source
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AI summary
A package exchanging system (100) includes: a running carrier (30) which is provided so as to be movable in one direction along creel stands (20) arranged in the one direction; a running control unit (90b) which controls the running of the running carrier (30); a sensor (131) which is provided in the running carrier (30) and acquires a remaining amount of a yarn (Y) wound on a yarn supply package (P1) held by the creel stand (20); and a prediction unit (90a) which predicts a timing at which the yarn (Y) disappears from the yarn supply package (P1) on the basis of the remaining amount of the yarn (Y) acquired by the sensor (131).