Yarn Processing Facility Sudden Package Replacement Reset
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Solution Overview
Problem
Yarn processing facilities face challenges in accurately predicting yarn run-out timing when a yarn supply package is suddenly replaced due to quality defects, leading to discrepancies in remaining amount and time information.
Innovation Solution
A yarn processing facility with an information management unit that acquires and resets remaining amount and time information, using initial values, unwinding unit amounts, and cumulative time to ensure accurate predictions and prevent calculation errors during sudden replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If remaining amount and time information is continuously calculated during yarn unwinding, then production management prediction is improved, but calculation accuracy deteriorates when sudden replacement occurs
Solution Approach 1:
The system performs preliminary detection of sudden replacement events during the unwinding process. When replacement is detected before it affects calculations, the information management unit proactively resets the cumulative time and recalculates remaining amount information, preventing accuracy deterioration from occurring in the first place
Solution Approach 2:
The system establishes a feedback mechanism where the information management unit continuously monitors for sudden replacement events and receives feedback about replacement occurrences. Upon detecting replacement feedback, the system automatically resets cumulative time values and recalculates remaining amount and time information, ensuring continuous accuracy of production management predictions
2Productivity
If yarn supply packages are suddenly replaced due to quality defects, then production continuity is maintained, but calculation accuracy of remaining information deteriorates
Solution Approach 1:
The information management unit monitors for sudden replacement events and receives feedback when replacement occurs. Upon detecting replacement feedback, the system automatically resets cumulative time values and recalculates remaining amount and time information, ensuring that production continuity through replacement does not compromise calculation accuracy
Solution Approach 2:
When sudden replacement is detected, the system changes the parameter state by resetting cumulative time to initial values and recalculating remaining amount and time information. This parameter reset ensures that the calculation basis remains accurate even as physical yarn packages are replaced during production
Data Source
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AI summary
An object of the present invention is to solve a problem occurring when a yarn supply package from which a yarn is unwound is suddenly replaced with a new yarn supply package. An information management unit 110 of a yarn processing facility 100 is configured to acquire at least one of the following sets of information by means of a calculation at a desired reference time point: remaining amount information regarding a remaining amount of a yarn Y in one of yarn supply packages Ps, the yarn Y being unwound from the one of the yarn supply packages Ps; and remaining time information regarding a remaining time in which the yarn Y can be supplied from the one of the yarn supply packages Ps at the reference time point. When sudden replacement information indicating execution of sudden replacement in which unwinding of a yarn Y from one of the yarn supply packages Ps has started and has not ended yet and the one of the yarn supply packages Ps is replaced with another of the yarn supply packages Ps is acquired, the information management unit 110 performs a reset process of resetting the at least one of the remaining amount information and the remaining time information to a predetermined initial value.