CN108291338B - Integrated monitoring system for textile weaving machine and method for identifying fault or deterioration - Google Patents

Integrated monitoring system for textile weaving machine and method for identifying fault or deterioration Download PDF

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CN108291338B
CN108291338B CN201680065590.3A CN201680065590A CN108291338B CN 108291338 B CN108291338 B CN 108291338B CN 201680065590 A CN201680065590 A CN 201680065590A CN 108291338 B CN108291338 B CN 108291338B
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loom
monitoring system
measuring
parameters
main
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CN108291338A (en
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克里斯蒂安·洛卡泰利
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Camozzi Digital Srl
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    • DTEXTILES; PAPER
    • D03WEAVING
    • D03JAUXILIARY WEAVING APPARATUS; WEAVERS' TOOLS; SHUTTLES
    • D03J1/00Auxiliary apparatus combined with or associated with looms
    • D03J1/006Controlling a group of looms
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B23/00Testing or monitoring of control systems or parts thereof
    • G05B23/02Electric testing or monitoring
    • G05B23/0205Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults
    • G05B23/0218Electric testing or monitoring by means of a monitoring system capable of detecting and responding to faults characterised by the fault detection method dealing with either existing or incipient faults
    • G05B23/0224Process history based detection method, e.g. whereby history implies the availability of large amounts of data
    • G05B23/0227Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions
    • G05B23/0232Qualitative history assessment, whereby the type of data acted upon, e.g. waveforms, images or patterns, is not relevant, e.g. rule based assessment; if-then decisions based on qualitative trend analysis, e.g. system evolution
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00Program-control systems
    • G05B2219/30Nc systems
    • G05B2219/45Nc applications
    • G05B2219/45192Weaving

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Textile Engineering (AREA)
  • Looms (AREA)
  • Auxiliary Weaving Apparatuses, Weavers' Tools, And Shuttles (AREA)

Abstract

An integrated monitoring system for a textile loom, comprising: a local monitoring system (400) arranged in the textile mill (500), associated with the respective loom (1); a master transmission device (670) connected to the local monitoring system (400); a main storage device located remotely with respect to the textile mill (500); and a main processing device, located remotely with respect to the weaving mill (500), suitable for processing the high-volume parameters to identify deviations of the operation of the loom (1) with respect to a reference operation.

Description

Integrated monitoring system for textile weaving machine and method for identifying fault or deterioration
Technical Field
The invention relates to a system for monitoring operating parameters of components of a textile weaving machine.
Background
It is known that, in order to make the investment worthwhile, it is necessary to operate the high-cost machines (for example weaving machines) continuously without interruption due to a malfunction.
However, the maintenance required to restore the operation of the loom usually results in production stoppages of a period of time that varies according to the degree of failure and the intervention time.
It is therefore important to intervene in time on the machine before a breakage or fault occurs, to perform regular maintenance or to perform maintenance assisted by the monitoring system. This method of maintenance management is referred to as "predictive maintenance".
However, it is very complicated to implement a predictive maintenance system efficiently because the prediction of an interruption or failure (based on which to perform an intervention) is only dependable based on experience learned from a large number of cases (i.e., by a large number of machines, a large amount of working time, and an archive of large application and operating conditions).
Disclosure of Invention
The object of the present invention is to provide a reliable system for monitoring the operating parameters of components of a textile machine in order to detect in time deviations of the machine operation from a nominal optimum operation.
This object is achieved by the following system manufactured according to the invention.
The invention provides a comprehensive monitoring system for a weaving loom, comprising: -at least one local monitoring system arranged in the textile mill, the local monitoring system being associated with a respective loom and comprising: a sensor for measuring an operating parameter of a component of the weaving machine; a local management device for providing state parameters of the loom; and remote transmission means of operating parameters and status parameters; -a master transmission device operatively connected with the transmission device of the local monitoring system; -a main storage device, located remotely with respect to the textile mill, operatively connected to the main transmission device and suitable for storing parameters of a high-capacity local monitoring system; -main processing means operatively connected to the main transport means and/or operatively connected to main storage means located remotely with respect to the weaving mill, the main processing means being adapted to process the high-capacity parameters to identify deviations of the operation of the weaving loom from a reference operation, wherein the reference operation is an idle running condition of the weaving loom obtained by measuring the state parameters and the operating parameters of the weaving loom without producing fabric, and wherein the main processing means are adapted to compare the reference operation of the idle running with the idle running at a given moment in time to identify deviations.
Drawings
The characteristics and advantages of the monitoring device according to the invention will be apparent from the following description, given by way of non-limiting example, with reference to the accompanying drawings, in which:
figure 1 schematically illustrates some components of a textile machine to which a local monitoring system according to the invention is applied;
FIG. 2 shows a diagrammatic representation of the air delivery mechanism of the weft yarn;
FIG. 3 shows a diagrammatic representation of a gripper transport mechanism for weft threads;
FIG. 4 shows a diagrammatic representation of a clamp delivery mechanism for weft thread;
FIG. 5 shows a diagrammatic representation of a support structure of a textile machine;
FIG. 6 illustrates a local monitoring system according to one embodiment of the present invention;
fig. 7 illustrates an integrated system according to the present invention.
Detailed Description
The weaving machine 1 is installed in a weaving factory 500. The term "textile mill" means an industrial plant that performs a process consisting of a series of operations required to transform a yarn into a fabric. Preferably, a plurality of weaving looms 1 are installed in the weaving factory.
The weaving machine 1 comprises an unwinder roller 2, which supports a beam 4 constituted by a winding of the yarn intended to form the warp yarns 6 of the fabric 8, and an unwinder roller motor 10 connected to the unwinder roller 2 to rotate it upon command.
The local monitoring system 400 according to the present invention preferably includes a temperature sensor 12 operatively coupled to the unwind roll motor 10 to measure the temperature T10 of the motor; in addition, at least one status parameter is available for the decoiler roll motor 10, such as the value of the absorbed current I10.
In addition, the unwinder roller 2 is supported in rotation by an unwinder roller bearing and the local monitoring system 400 comprises a temperature sensor 13 for detecting the temperature T2 of said bearing.
The local monitoring system 400 further comprises a load cell 15 for measuring the tension S2 of the warp yarn unwound from the unwinder roller 2.
In addition, the loom 1 includes: a back roller 14 over which the warp yarn 6 passes to be appropriately transferred; a warp stop dog 16 to detect breakage of warp yarns; a shaft 18 provided with a heddle; and a reed 20 which is moved by the stranding member 22.
Downstream of the reed 20, weft yarns 50 are inserted transversely to the direction of advance of the warp yarns 6 to weave the fabric 8.
The stranding member 22 (fold) having a reciprocating rotary motion is driven by the stranding shaft, which is generally carried out by means of a conversion mechanism (for example, a connecting rod-crank mechanism or a cam mechanism) adapted to convert the continuous rotary motion in said reciprocating rotary motion.
The rotation of the stranding shaft is supported by the stranding shaft bearings and the local monitoring system 400 includes a temperature sensor 23 for detecting the temperature T22 of the bearings.
In addition, the loom comprises an electric stranding member drive shaft 37, which is operated by a current I37, provided with a temperature sensor 39 for measuring the temperature T37 of the motor.
In addition, it is preferred that the conversion mechanism is housed in a cartridge in an oil bath, and that the local monitoring system 400 includes a temperature sensor for measuring the temperature T25 of the oil in the cartridge.
The fabric 8 is pulled by the pulling roll 24, which is rotated by an electric pulling roll motor 26 coupled to a temperature sensor 28 for measuring the temperature T26, which motor draws a current that generates a current value I26.
In addition, the pulling roll 24 is supported for rotation by a pulling roll bearing, and the local monitoring system 400 includes a temperature sensor 29 for detecting the temperature T24 of the bearing.
In addition, the monitoring system comprises a load cell 27 for measuring the tension S24 of the fabric pulled by the pulling roll 24.
The fabric 8 is finally wound on the beam 30, placed on the winder roller 32, by a plurality of return rollers, which are rotated by a winder roller motor 34. The motor 34 is coupled to a temperature sensor 36 for measuring a temperature T34 and draws a current that generates a current value I34.
In addition, the winder roller 32 is supported for rotation by a winder roller bearing, and the local monitoring system 400 includes a temperature sensor 33 for detecting the temperature T32 of the bearing.
In addition, the monitoring system comprises a load cell 31 for measuring the tension S32 of the fabric wound on the winder roller 32.
The weaving machine 1 is further provided with a mechanism for transferring weft yarns in order to insert them between warp yarns and to transfer them from one side of the machine to the other.
According to a first embodiment (fig. 2), the weft yarn transferring means is an air nozzle.
According to this embodiment, the weft yarns are carried from one side of the warp yarns to the other using a flow of compressed air through channels formed transversely in the reed 20.
Air is blown from the main nozzle 39 and a plurality of auxiliary nozzles 41 (referred to as flow passages 88), the weft yarn wound on the spool 52 is inserted into the main nozzle 39 at the beginning, and the auxiliary nozzles 41 blow air according to a specific synchronized sequence and timing.
The nozzles 39, 41 are supplied with compressed air via a solenoid valve connected to a compressed air tank.
Preferably, the local monitoring system 400 comprises a pressure transducer 40 coupled to the compressed air tank to measure a pressure value p40 in the tank.
According to another embodiment, the weft yarn transferring mechanism is a water jet.
According to this embodiment, the weft thread is transported via a high-pressure water stream flowing out through the nozzle.
According to yet another embodiment, the transfer mechanism is referred to as a "gripper" (FIG. 3).
According to such an embodiment, the weft yarn 50 wound on the reel 52 is fixed to the gripper by a clamp arranged at the tail of the gripper 54.
The transfer mechanism further comprises a mechanical launching device 56 equipped with a torsion bar 58, adapted to release the potential mechanical energy stored in the torsion bar 58 towards the gripper 54, launching it from one side of the reel 52 to the other side of the machine, and following the path formed by the alignment hook 60.
The torsion bar 58, which is supported by a rod bearing and fixed at one end, rotates and the local monitoring system 400 includes a temperature sensor 62 for measuring the temperature T58 of the bearing.
Additionally, the torsion bar 58 is rotationally engaged with the bar load shaft at the opposite end of the fixed end, typically via splines, and is rotationally moved by a toggle and cam mechanism to twist the bar 58.
The load shaft rotation is supported by the load shaft bearing and the local monitoring system 400 includes a temperature sensor 64 for measuring the temperature T64 of the bearing.
In addition, the toggle and cam mechanism includes an oleo damper, and the local monitoring system 400 provides a temperature sensor 66 for measuring a temperature T66 of the oleo damper.
The transfer mechanism further comprises a braking device 62 arranged on the other side of the machine to engage and brake the gripper, and a return mechanism (for example a chain) to return the gripper 54 to the side of the reed.
According to yet another embodiment, the transfer mechanism is a clamping mechanism (fig. 4).
In this embodiment, the weft yarn 50 wound in the reel 52 is coupled by the gripper of the first clamp 70, moved by the conveyor 72 to the centre of the weaving machine 1. The second clamp 74 is moved from the opposite side to the centre of the weaving machine and is moved by a second conveyor 76 to take up the weft thread carried by the first clamp 70 and bring it to the opposite side, completing the insertion.
The conveyors 72, 76 are moved by respective cogwheels 78 (called cogarella) which are arranged on cogwheel shafts, supported for rotation by cogwheel bearings. The local monitoring system 400 comprises a temperature sensor 80 for measuring the temperature T78 of the bearing.
According to a first variant of this embodiment, the transfer system is a negative-clamp system, i.e. the passage of the weft thread between the clamps is not positively controlled, but the second clamp passes jointly through the first clamp and releases the end of the weft thread from the first clamp.
According to another variant of this embodiment, the transfer system is a "positive clamp" system, i.e. the passage of the weft thread from the first clamp to the second clamp is achieved by controlled opening and closing of the clamps.
The weaving machine 1 further comprises a lubrication system with pressurized oil, comprising an oil pump, an oil tank and a distribution circuit for lubrication of critical components, such as those mentioned above.
The local monitoring system 400 includes a temperature sensor 90 for measuring the temperature T90 of the lubricating oil.
Furthermore, the local monitoring system 400 comprises a pressure transducer 92 for measuring a pressure value P92 of the oil in the oil distribution circuit.
According to a preferred embodiment of the invention, the loom 1 comprises a dobby for controlling the raising of the shafts according to a predetermined pattern. The dobby is moved by a dobby shaft supported for rotation by bearings. The local monitoring system 400 comprises a temperature sensor 97 for measuring the temperature T97 of the bearing.
In addition, the loom 1 includes a dobby motor 81 to move a dobby shaft. The local monitoring system 400 comprises a temperature sensor 83 for measuring the temperature T81 of the motor. Dobby motor 81 is powered by current I81.
According to another embodiment, the loom 1 is of the jacquard type (mechanical or electronic). In the case of mechanical jacquard looms, loom 1 comprises a plurality of hooks for the command shaft, which are moved by the jacquard shaft supported in rotation by bearings. The local monitoring system 400 comprises a temperature sensor 99 for measuring the temperature T99 of the bearing.
In addition, loom 1 includes a jacquard motor 85 to move the jacquard shaft. The local monitoring system 400 includes a temperature sensor 87 for measuring the temperature T85 of the motor. The jacquard motor 85 is powered by current I85.
In addition, the weaving machine 1 comprises a support structure 100 (fig. 5), which generally comprises a pair of shoulders 102a, 102b, generally made of cast iron, which are crosswise spaced and suitable for supporting the machine components.
The local monitoring system 400 preferably includes a vibration sensor 104 for measuring the vibration V100 of the support structure 100.
Finally, the local monitoring system 400 preferably comprises an image acquisition device 110, for example a web camera for capturing images W110 related to the loom as a whole or its mechanism (organ).
The loom 1 is also equipped with local management means 120, such as an electronic card, PLC or microprocessor, for the management of the machining, which itself measures (and possibly stores) loom state data, such as the speed of one or more mechanisms, the power absorbed, the current absorbed by these motors, the temperature of certain mechanisms, etc.
The local monitoring system 400 further comprises transmission means 130, for example operating by wireless technology (Wi-Fi type), suitable for transmitting the values of the measured parameters and of the status parameters of the loom 1 to the outside of the textile plant.
Preferably, the local monitoring system 400 further comprises a local storage device 140 connected to the transmission device 130 and/or to a component of the machine for storing the measured parameters and/or to the local management device 120 for storing the status parameters.
Furthermore, the local monitoring system 400 preferably comprises processing and local display means 150, for example comprising a computer, operatively connected to the transmission means 130 and/or to the components of the machine for storing the measured parameters and/or to the local management means 120 and/or to the local storage means 140, for processing the measured parameters and status parameters and displaying the results of the processing.
According to the invention, the integrated monitoring system comprises: a local monitoring system 400 of each loom 1; a main storage 660 for storing the measured parameters and status parameters of each loom 1; and a master transmission device 670, for example consisting of components for internet connectivity, operatively connected to the transmission device 130 of the local monitoring system 400.
The main storage 660 is located in a control room 700, which is located remotely with respect to the textile mill 500.
Preferably, the locally collected information and possibly captured images are continuously transmitted over time to the remote main storage 660 ("real-time" mode); according to other embodiments, such information is transmitted at a predetermined frequency, such as daily or weekly (batch mode); according to a further embodiment, such information is transmitted upon the occurrence of a predetermined event, for example in the case of a machine shutdown, or in the case of an approaching planned intervention ("event-based" mode).
In addition, the integrated monitoring system includes a processing device 680, such as a PC, operatively connected to the internet and/or the main storage device 660 for processing information from each textile mill 500.
Innovatively, the integrated monitoring system according to the invention allows to perform an efficient maintenance, since, through a special calculation algorithm, it warns the operator of the deviation of the functioning of the loom from the reference function, which is considered optimal.
The integrated monitoring system enables in particular to send the required signals to perform preventive maintenance, since this makes it possible to collect, store and analyze a huge amount of data from a large number of machines in one or more textile buildings (big data, i.e. so large in terms of capacity, speed and variety that a certain technique and analysis method is required to extract the values).
Moreover, advantageously, the system according to the invention makes it possible to collect and store a large amount of data over a very long period of time, thus allowing to detect deviating phenomena, or statistical phenomena, which are generally symptoms of malfunctions or slow deterioration of operating conditions, generally unrecognizable or unrecognizable.
According to another advantageous aspect, the system according to the invention has the ability to collect and store different parameters of the machine, identifying correlations among these parameters, for example between speed, energy consumption and temperature. In addition, the system makes it possible to analyze the data collected in the frequency domain to identify periodic phenomena with respect to a single parameter or with respect to the results of the above-mentioned correlations.
Analyzing the interrelationships between the parameters means, for example, identifying a trend of the generic parameters P1 and P2 as a function of another generic parameter X and correlating them with each other via a correlation function Φ { P1, P2(X) }, or identifying a trend of the generic parameter P1 as a function of time t.
The architecture thus identified, which allows to identify, develop and evolve gradually and continuously the correlation functions and the prediction algorithms, has such flexibility and ability to accumulate a large amount of information and data (big data) and to extend the processing and calculation functions of a single central system with historical trends of the operating parameters of the weaving machine.
For example, the system according to the invention makes it possible to measure the vibrations of the support structure of the loom by means of a vibration sensor, to perform an analysis in the frequency domain and to correlate certain frequencies with a stop segment of the loom (for example due to interruptions, technical problems, mechanical faults). Thus, it is possible to determine what frequency is associated with an operational problem and schedule predictive maintenance operations.
Furthermore, it is advantageously possible to measure the operating parameters and the state parameters of the weaving loom without producing a fabric, to define the conditions of idle running, and to compare the reference conditions of idle running with the idle running at a set moment, detecting any deviation.
Further, advantageously, the monitoring system according to the invention enables online support of services by means of remote detection of abnormal operations, deviations in number or any other abnormality.
According to another advantageous aspect, the monitoring system according to the invention makes it possible to update the machine management software remotely, without requiring local intervention.
Obviously, a person skilled in the art may modify the above-described monitoring system to meet contingent needs while remaining within the scope of protection of the following claims.

Claims (10)

1. Method for identifying malfunctions or degradations of the operation of a weaving loom (1), comprising the steps of:
-providing in a textile mill (500): at least one loom (1); a local monitoring system (400) applied to the loom (1) to collect operating parameters of components of the loom and status parameters of the loom; and transmission means (130) for transmitting said operating parameters and said status parameters;
-providing a main transmission device (670) operatively connected with the transmission device (130);
-providing a main storage device (660) located remotely with respect to said textile mill (500), operatively connected with a main transmission device (670) and suitable for storing high capacity parameters of said local monitoring system (400);
-providing main treatment means (680) operatively connected with said main transport means (670) and/or with said main storage means (660) located remotely with respect to said textile mill (500), said main treatment means being suitable for treating high-capacity parameters;
-identifying trends of a generic parameter (P1, P2) based on another generic parameter (X), transforming the trends in the frequency domain and correlating these trends with each other using a correlation function to identify deviations of the operation of the weaving loom (1) from a reference operation based on massive data;
-measuring said state parameters and said operating parameters of said loom without manufacturing a fabric, so as to define the condition of idle running as said reference operation, and comparing said reference operation of idle running with the idle running at a given moment in time to identify said deviation.
2. The method of claim 1, wherein the loom includes a support structure, and the method further comprises the steps of: measuring vibrations of the support structure of the weaving machine by means of a vibration sensor, and analyzing the vibrations in the frequency domain and associating a specific frequency with a stop segment of the weaving machine in order to schedule a predictive maintenance operation.
3. Method according to claim 1, wherein at least one loom (1) for each of said textile plants is provided in a plurality of textile plants (500).
4. An integrated monitoring system for a textile loom, comprising:
-at least one local monitoring system (400) arranged in a textile mill (500), said local monitoring system being associated with a respective loom (1) and comprising: a sensor for measuring an operating parameter of a component of the loom; -local management means (120) providing status parameters of the loom (1); and remote transmission means (130) of said operating parameters and said status parameters;
-a master transmission device (670) operatively connected with the transmission device (130) of the local monitoring system (400);
-a main storage device (660), remotely located with respect to said textile mill (500), operatively connected with said main transmission device (670) and suitable for storing high capacity parameters of said local monitoring system (400);
-main processing means (680) operatively connected with said main transport means (670) and/or with said main storage means (660) located remotely with respect to said textile mill (500), said main processing means being suitable for processing high-volume parameters to identify deviations of the operation of said loom (1) with respect to a reference operation,
wherein the reference operation is a condition of idle operation of the weaving loom obtained by measuring the state parameter and the operating parameter of the weaving loom without manufacturing a fabric, and wherein the main processing means (680) are adapted to compare the reference operation of idle operation with idle operation at a given moment in time to identify the deviation.
5. An integrated monitoring system according to claim 4, wherein the master transmission device (670) comprises means for internet connection.
6. Integrated monitoring system according to claim 4 or 5, wherein said sensors comprise at least one temperature sensor (12, 39, 28, 36, 83, 87) for measuring the temperature of a motor (10, 37, 26, 34, 81, 85) or for measuring the temperature of a support bearing of a rotating mechanism of the weaving machine or for measuring the temperature of a lubricating oil.
7. An integrated monitoring system according to any of the claims 4 to 5, wherein the sensor comprises at least one pressure transducer for measuring the pressure in a pressure chamber or in a pressurised oil distribution circuit.
8. An integrated monitoring system according to any of the claims from 4 to 5, wherein said sensor comprises at least one load cell (15, 27, 31) for measuring the tension of the warp yarn unwound from the unwinder roller (2) (S2), or for measuring the tension of the fabric pulled by the pulling roller (24) (S24), or for measuring the tension of the fabric wound on the winder roller (32) (S32).
9. An integrated monitoring system according to any of the claims 4 to 5, wherein said sensors comprise at least one vibration sensor (104) for measuring vibrations (V100) of a support structure (100) of the weaving loom (1).
10. An integrated monitoring system according to any of the claims 4 to 5, comprising image acquisition means (110) for capturing images (W110) relating to the loom (1) as a whole or to the mechanisms of the loom.
CN201680065590.3A 2015-11-12 2016-11-08 Integrated monitoring system for textile weaving machine and method for identifying fault or deterioration Active CN108291338B (en)

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IT102015000071820 2015-11-12
ITUB2015A005502A ITUB20155502A1 (en) 2015-11-12 2015-11-12 MONITORING SYSTEM OF PARAMETERS OF FUNCTIONING OF COMPONENTS OF A FRAME FOR WEAVING
PCT/IB2016/056714 WO2017081605A1 (en) 2015-11-12 2016-11-08 System for monitoring operating parameters of components of a weaving loom

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JP2018537597A (en) 2018-12-20

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