WO2024126031A1 - A method of controlling the technological process of yarn manufacturing on a spinning machine, a spinning machine for performing the method, a computer program for performing the method on the spinning machine and a computer-readable medium with the computer program - Google Patents

A method of controlling the technological process of yarn manufacturing on a spinning machine, a spinning machine for performing the method, a computer program for performing the method on the spinning machine and a computer-readable medium with the computer program Download PDF

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Publication number
WO2024126031A1
WO2024126031A1 PCT/EP2023/083373 EP2023083373W WO2024126031A1 WO 2024126031 A1 WO2024126031 A1 WO 2024126031A1 EP 2023083373 W EP2023083373 W EP 2023083373W WO 2024126031 A1 WO2024126031 A1 WO 2024126031A1
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WIPO (PCT)
Prior art keywords
yarn
breakage
sensor
spinning
machine
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PCT/EP2023/083373
Other languages
French (fr)
Inventor
Pavel Kousalik
Zdenek Beran
Jiri Sloupensky
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Maschinenfabrik Rieter Ag
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Application filed by Maschinenfabrik Rieter Ag filed Critical Maschinenfabrik Rieter Ag
Publication of WO2024126031A1 publication Critical patent/WO2024126031A1/en

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Classifications

    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01HSPINNING OR TWISTING
    • D01H13/00Other common constructional features, details or accessories
    • D01H13/32Counting, measuring, recording or registering devices
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01HSPINNING OR TWISTING
    • D01H1/00Spinning or twisting machines in which the product is wound-up continuously
    • D01H1/14Details
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01HSPINNING OR TWISTING
    • D01H13/00Other common constructional features, details or accessories
    • D01H13/14Warning or safety devices, e.g. automatic fault detectors, stop motions ; Monitoring the entanglement of slivers in drafting arrangements
    • D01H13/16Warning or safety devices, e.g. automatic fault detectors, stop motions ; Monitoring the entanglement of slivers in drafting arrangements responsive to reduction in material tension, failure of supply, or breakage, of material
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01HSPINNING OR TWISTING
    • D01H13/00Other common constructional features, details or accessories
    • D01H13/26Arrangements facilitating the inspection or testing of yarns or the like in connection with spinning or twisting
    • DTEXTILES; PAPER
    • D01NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01HSPINNING OR TWISTING
    • D01H4/00Open-end spinning machines or arrangements for imparting twist to independently moving fibres separated from slivers; Piecing arrangements therefor; Covering endless core threads with fibres by open-end spinning techniques

Definitions

  • the invention relates to a method of controlling the technological process of yarn manufacturing on a spinning machine, in particular a rotor or air-jet spinning machine, in which yarn is monitored by at least one sensor for monitoring the physical parameters of the yarn, which is coupled to an evaluation device equipped with software.
  • the invention relates to a spinning machine for performing the method, comprising a plurality of workstations arranged next to one another, each of which is provided with means for ensuring a change of technological parameters during yarn production and comprises a spinning unit and a sensor for monitoring the physical parameters of the spun yarn at least from the group consisting of diameter, weight or homogeneity, colour, image and/or foreign matter, wherein the sensor for monitoring the physical parameters of the yarn is coupled to an evaluation device equipped with software.
  • the invention relates to a computer program for performing the method according to the invention on the spinning machine according to the invention and to a computer-readable medium with the computer program according to the invention.
  • Yam is produced on textile machines provided with a device for transforming a fibre semi-finished product in the form of a suitably arranged bundle of fibres into yarn.
  • Different methods of yarn production and different yarn producing devices associated with them are known.
  • Yam is produced, for example, on ring spinning machines, rotor spinning machines, as well as air-jet spinning machines.
  • the yarn produced on rotor or air-jet spinning machines is wound on crosswound bobbins from which the yarn is subsequently directly processed, i.e. , used in the knitting or weaving of textiles.
  • These machines are usually equipped with a yarn quality sensor to ensure that the yarn produced is free of defects.
  • the sensor can be a capacitive sensor or different types of optical sensors.
  • Yam breaks occur for a variety of reasons. Yam breaks reduce the productivity of yarn production, i.e., they reduce the productivity of the machine. In order to achieve the highest possible productivity on the spinning machine, yarn breaks are removed in different ways depending on the degree of automation of the machine concerned, either manually on manually operated machines (e.g. according to DE 10 084 607) or by means of an attending device which is adapted to operate more spinning units arranged next to one another (e.g. according to US 4295330) or which is individual and designed to operate only one spinning unit, so-called unit automation (e.g., according to US 4369620).
  • manually on manually operated machines e.g. according to DE 10 084 607
  • an attending device which is adapted to operate more spinning units arranged next to one another (e.g. according to US 4295330) or which is individual and designed to operate only one spinning unit, so-called unit automation (e.g., according to US 4369620).
  • Yam breaks occur for various reasons. They are caused, for example, by unevenness of the fibre sliver supplied, impurities in the fibre sliver, technological or air-technical parameters of yarn production that are inappropriately set or changed over time, or even by contamination or wear of individual components of the spinning unit.
  • each break Apart from the loss of yarn production due to the interruption of yarn production by a yarn break, the occurrence of each break also leads to a reduction in the overall quality of the yarn produced, since each single yarn break is replaced by a piecer or another connection (for example, a splicer) when the yarn production is resumed, i.e., the point of connection of the originally produced yarn and the newly connected newly produced yarn. Any piecer or other joining of the yarn, despite all efforts to minimise its effects on the quality and appearance of the yarn, appears as a quality defect in the yarn. It is also important to note that there is practically no yarn production without the occurrence of yarn breaks during production. It is therefore in the interests of the spinning machine operator to keep the "breakage rate" of the yarn, i.e.
  • This root cause analysis is generally based on an analysis of the type of yarn breakage, i.e., an analysis of the shape, arrangement and geometric parameters of the broken yarn end, including an analysis of the relatively long section of yarn before the place of the breakage itself.
  • the analysis of the type of breakage is important for identifying the causes of the breakage and for the subsequent implementation of adequate interventions in the textile technological process and, if necessary, also individual interventions at a specific spinning unit, all with the aim of maintaining or reducing the number of yarn breaks to acceptable values.
  • This unwound yarn end section of the necessary length, including the broken end of the yarn itself, is subjected to visual examination, usually in a laboratory with the aid of image magnification, to determine the geometric, morphological and other properties not only of the broken end of the yarn itself, but usually also of a certain length of the yarn section before the very place of the broken end of the yarn. The result of this examination of every single yarn break is recorded.
  • the object of this invention is to propose a method and a device that will eliminate or at least minimize or at least reduce the disadvantages of the background art, will contribute to increasing the efficiency of yarn production on spinning machines, whether rotor or air-jet spinning machines, or will enable automatic or at least partially automated regulation of the parameters of the spinning process at the workstation, in the technological process of the machine, or in the technological process of a group of machines, or in the technological process of the entire spinning mill.
  • the automatic or at least partially automated regulation of the parameters of the technological process of yarn manufacturing at the workstation based on an evaluation of the number of occurrences of yarn breakage on the spinning machine is the subject of e.g., EP 1 281 959 or EP 2 565 306.
  • the disadvantage of these solutions is that they work only with the absolute number of yarn breaks without evaluating the type of break and without identifying the causes of the yarn breaks, and so the regulation of the spinning parameters on the machine occurs even in the case of breaks which cannot be influenced by the regulation of the spinning parameters.
  • the object of the present invention is achieved by a method of controlling the technological process of yarn manufacturing on a spinning machine, in particular a rotor or air-jet spinning machine, in which yarn is monitored by at least one sensor for monitoring the physical parameters of the yarn, which is coupled to an evaluation device equipped with software, wherein specific features of the method are described in the independent claim 1 .
  • the evaluation device After each break, the evaluation device identifies the type of breakage according to pre-set criteria and store the information about the type of breakage in the memory of the number of the respective type of breakage for the respective workstation.
  • the information from the individual memories is statistically processed after a predetermined statistically relevant period of machine operation and, according to the result of the processing, interventions are made in the spinning process on the entire machine or at individual workstations, or no interventions are made in the process but only a specific break is removed. It follows that interventions in the spinning process are only carried out when such intervention has a positive effect on the process, either at the workstation or on the entire machine.
  • a part of the length of the spun yarn at each workstation of the spinning machine is monitored by the sensor for monitoring the physical parameters of the yarn, and information about the course of the monitored physical parameter/s of the yarn over a predetermined length is continuously recorded and stored in the cache memory for that length until a break occurs.
  • the recorded information about the monitored physical parameter/s of the yarn on the last recorded length of the yarn before the break is retrieved and evaluated.
  • the evaluated information is used to identify the type of yarn breakage and classify the breakage into one of the predefined types of yarn breakage, and the information about the breakage is recorded in the memory of the number of individual types of yarn breakage assigned to each workstation.
  • Statistical evaluation of the number of individual types of breakage from the memory of the number of individual breaks is carried out for each workstation by the machine control system either for each workstation and/or for a group of workstations and/or for the entire spinning machine. On the basis of the evaluation it is decided, according to pre-set criteria, whether it is an individual deviation in the yarn breakage rate of a particular workstation of the machine, or whether the yarn breakage rate is distributed in a group of workstations spinning the same lot of the yarn, or whether it is distributed on the entire machine and finally, a decision is made on the type of intervention and the method of its implementation.
  • the statistically recorded numbers of breaks of each type recorded in the memories of the number of individual types of yarn breaks for all workstations of individual machines or the entire technological group of machines are evaluated and on the basis of pre-set criteria, it is decided whether there has been an increase in yarn breakage in the entire technological group above the specified limit and a decision is made on the type and method of intervention for the entire technological group of machines.
  • the type of intervention may be only operator intervention at a specific workstation, or a call to replace or repair sliver at one or more workstations, or an adjustment to spinning parameters on the entire machine or in a group of workstations.
  • the sensor of the physical parameters of the yarn is a capacitive sensor that monitors the weight, or homogeneity, of the spun yarn.
  • the most widely used sensors for the physical parameters of the yarn are optical sensors which include at least one radiation source and at least one radiation sensitive element which is capable of monitoring information about the course of the yarn diameter.
  • the optical yarn sensor comprises an optical yarn quality sensor comprising a linear radiation sensor which is capable of providing sufficiently extensive and detailed information about the visual form, i.e., the image of the yarn, including an image of the broken yarn end.
  • a further refinement of the identification of the type of break can be achieved by a yarn sensor which is also capable of detecting coloured and/or foreign matter in the yarn. In this manner, it is possible to distinguish breaks caused by impurities or foreign matter captured at the end of the yarn break.
  • the image of the yarn is sensed by a linear optical sensor, it is advantageous to use the method of digital image analysis of the sensed image of the yarn and the image of the broken yarn end to evaluate the kind of the break.
  • the recorded types of breakage and their number in the individual memories of the breaks are used after a certain period of machine operation by their statistical evaluation for each workstation and/or for the entire spinning machine and according to pre-set criteria, a decision is made whether it is an individual deviation in the breakage rate of a certain type of yarn at a specific workstation which will need to be removed individually at the respective workstation, or whether it is a distribution of a certain type of breakage on the entire machine, and based on this decision, it will be necessary to adjust the technological process on the entire machine.
  • the type of intervention is then decided on according to pre-set criteria, i.e., whether it will be an intervention at a specific workstation, or a group of workstations, or in the technological process of the machine, or in the technological process of the entire technological group of machines, i.e., in the entire spinning mill.
  • a decision is made on the timing of the intervention, i.e., whether the intervention will be carried out immediately or later at a more technologically favourable time according to pre-set criteria.
  • a decision is made on the method of intervention, i.e., whether the intervention will be carried out by the operator or automatically by the machine control system or by the control system of the attending device.
  • the spinning machine comprises a sensor for monitoring the physical parameters of yarn, which is coupled via a cache memory to an evaluation device for the identified types of yarn breakage, whose outputs are connected to the memories of the number of individual types of yarn breakage which are connected to a statistical evaluation device. According to the results of the statistical evaluation, interventions are carried out in the technological process of spinning on the entire machine, in a group of workstations or at the individual workstations of the machine.
  • the sensor for monitoring the physical parameters of yarn may be a capacitive sensor or especially one of the well-known optical yarn quality sensors.
  • the invention is based on the fact that the identification of the type of yarn breakage can be realized by a sensor of the physical parameters of the yarn, in particular an optical yarn sensor, using a special method of detailed processing of the obtained information describing the yarn section before the yarn break, in particular the gradient of the decrease in the yarn diameter depending on the length, furthermore, an image of impurities or fibre cluster occurring at the end of the yarn after the yarn has broken, the sensor of the physical parameters of the yarn being preferably supplemented by a sensor for impurities and foreign matter in the yarn, operating on the principle of reflected light from the yarn.
  • optical yarn sensors are in principle known, especially optical yarn quality sensors which evaluate yarn diameter defects and yarn hairiness defects, as well as sensors of foreign matter in the yarn.
  • separate yarn break sensors which are usually located on spinning machines between the yarn draw-off mechanism and the winding device. These sensors are useful for the present invention provided that they allow sufficiently accurate and fast acquisition and processing of data on the character of the yarn end just before the yarn break. It is then advantageous to use sensors whose sensing element or elements provide sufficient resolution to obtain visual information relevant for detecting the type of breakage in the rotor or air-jet yarn.
  • An advantageous sensing element or elements include, for example, a single-row or multi-row optical sensing element with a sufficient density of radiation sensitive elements in a row arranged next to each other across the path of movement of the yarn at a spinning station of an air-jet or rotor spinning machine, as well as sensors that detect changes in colour or contrast in reflected light.
  • the settings for optical monitoring and evaluation of the type of yarn breakage can be made individually for different types of machines (rotor or air-jet) as well as for different types of textile materials and yarn fineness, simply by software modifications and changes to the relevant parameters of the evaluation algorithm within the method and/or spinning machine according to the present invention, which is fast and relatively inexpensive.
  • optical yarn sensor can be common for sensing the type of yarn breakage according to the present invention, as well as for the previously used optical sensing and yarn quality evaluation based on the principle of yarn diameter defects and yarn hairiness defects, or for detecting foreign matter in the yarn, which is economically advantageous and simplifies the design of the spinning unit and the workstation of the rotor or air-jet spinning machine.
  • present invention can also be implemented as a solution independent of existing means for evaluating the yarn quality, for example, by a separate optical or capacitive sensor.
  • Fig. 1 shows an arrangement of a spinning machine
  • Fig. 2 shows an arrangement of one workstation of a rotor spinning machine
  • Fig. 2a shows a classic arrangement of an optical sensor (a source, yarn, a sensor)
  • Fig. 2b shows the optical sensor supplemented by sensing reflected light from the yarn
  • Fig. 3 represents an arrangement of one workstation of an air-jet spinning machine
  • Fig. 4 shows a detail of the general arrangement of the device according to the invention at one workstation of the spinning machine (block diagram)
  • Figs. 5a to 5f show detailed examples of possible types of yarn breakage.
  • the invention will be described with reference to an example of embodiment of a method of controlling the technological process of yarn manufacturing on a spinning machine, in particular a rotor or air-jet spinning machine, which is based on monitoring the physical parameters of yarn breaks, wherein the physical parameters are selected from a group consisting of diameter, weight or homogeneity, colour, image, foreign matter, etc., and on identification and statistical evaluation of the types of yarn breakage during the production of yarn at a workstation of the rotor or air-jet spinning machine, on monitoring and statistical evaluation of the number of individual types of yarn breakage within a predetermined time interval, or on the basis of predetermined number of a specific type of breakage on individual machines and/or monitoring and statistical evaluation of types of yarn breakage within a predetermined time interval or on the basis of a predetermined number of a specific type of break in the entire spinning mill.
  • interventions are made in the technological process at the respective workstation and/or on the entire machine and/or in the entire spinning mill.
  • Interventions in the technological process are carried out either by the operator, i.e., a human operator, or by an attending device at the individual spinning units, where the attending device may be part of the machine workstation, or it may consist of an automatic attending device OZ which is displaceable along the machine.
  • Interventions can also be carried out by the central control system 81 of the entire machine on the respective machine, or the central control system of the entire spinning room for all machines, or just for selected machines. If the operator is a human operator, information about the type of breakage and the method of intervention is displayed on the operator's panel 82 on the machine or it is displayed by signalling means of the workstation.
  • a rotor or air-jet spinning machine comprises at least one row of identical workstations 1 arranged next to one another.
  • Each workstation 1 comprises a reservoir of fibrous material for producing the yarn 3, the reservoir consisting of a sliver can 10 in which sliver 11 is stored.
  • Each workstation 1 comprises a spinning unit 2 which is adapted to transform a fibrous structure made from sliver 11 into yarn 3, either by a combination of an opening roller 21 and a spinning rotor in the rotor spinning machine or a combination of a drafting device 210 of sliver and a spinning air nozzle 20 in the air-jet spinning machine.
  • the yarn 3 is drawn off from the spinning unit 2 by a draw-off mechanism 4 arranged at the workstation 1 in the direction P of the movement of the fibrous material, here already in the form of yarn 3, downstream of the spinning unit 2.
  • the workstation 1 further comprises a traversing and winding device 5 of yarn 3 onto a bobbin 50 which is arranged at the workstation 1 in the direction of the movement P of the fibrous material downstream of the draw-off mechanism 4 of yarn 3 and which is adapted to distribute the yarn 3 across the width of the rotating bobbin 50 and to wind the yarn 3 onto the rotating bobbin 50.
  • a yarn break sensor 41 is usually mounted downstream of the draw-off mechanism 4.
  • At least one sensor 66 for monitoring the physical parameters of the yarn 3 is arranged between the output of the yarn 3 from the spinning unit 2 and the traversing and winding device 5 of the yarn 3 on the bobbin 50 at each workstation 1.
  • the sensor 66 for monitoring the physical parameters of the yarn 3 can consist of any known sensor of the physical parameters of the yarn, for example, a capacitive sensor, which is not shown, but to a person skilled in the art it is known that it comprises a plate capacitor between the plates of which the yarn 3 passes and from the change in capacitor capacity, the weight or homogeneity of the spun yarn 3 is derived.
  • the sensors 66 of the physical parameters of the yarn 3 most often consist of optical sensors_6 which comprise at least one radiation source 60 and one radiation sensitive element 6100, adapted for the optical monitoring of the diameter or image of the yarn 3 during its production at the workstation 1 of the spinning machine.
  • the sensor 66 for monitoring the physical parameters of the yarn 3 is, via the cache memory P1 arranged at the workstation 1, coupled to an evaluation device 7 which comprises means for processing information about the monitored physical parameters of the yarn 3 and is arranged at the workstation 1.
  • the output of the sensor 66 for monitoring the physical parameters of the yarn is connected to the cache memory P1 for continuous retrieval of information D1 about the physical parameters of the yarn 3 at the respective workstation 1 and at the same time to the evaluation device 7 of the workstation for transmitting information about the yarn break from the sensor 66, wherein the output of the yarn break sensor 41 is connected to the evaluation device 7 of the respective workstation 1 for transmitting information about the yarn breakage.
  • the evaluation device 7 includes a database of information about the typical course of the monitored physical parameters of the yarn 3 for predetermined types A, B, C, D, E, F, G, H of yarn breakage.
  • the evaluation device 7 is connected to the cache memory P1 to retrieve information D1 about the monitored physical parameters at the end of the broken yarn 3 after the yarn break.
  • the evaluation device 7 generates data D2 from the information D1 about the form of the break end and classifies it into the corresponding type A, B, C, D, E, F, G, H of breakage.
  • the information about the identified type of breakage is transmitted to the breakage type memory PA, PB, PC, PD, PE, PF, PG, PH of the number of each type of break, in which the numbers of breaks of the corresponding type of breakage are stored.
  • the individual memories PA, PB, PC, PD, PE, PF, PG, PH of the number of types of breakage are part of the statistical evaluation device SV, which, in the embodiment of Fig. 4, is part of the control system 81 of the machine or are connected to it.
  • the statistical evaluation device SV After a predetermined relevant time of machine operation, the statistical evaluation of the number of breaks of the respective type is carried out and on its basis a decision is made on the type and method of intervention in the technological process of yarn manufacturing.
  • Information means for the operator are connected to one output of the statistical evaluation device SV, and to the other output are connected means for correcting the spinning parameters at the respective workstation 1 or a group of workstations 1_, or on the entire machine, or in the entire technological group of machines. If the operator is a human operator, information is displayed on the operator's panel 82, if the operator is an automatic attending device OZ, the information is transmitted to its control system.
  • optical sensors 6 are currently most often used as sensors 66 for monitoring the physical parameters of the yarn 3, the inclusion of these optical sensors 6 in the method a device according to the present invention will be described in more detail below.
  • the optical sensor 6 of yarn 3 is via cache memory P1 coupled to the evaluation device 7, which comprises electronics provided with software and is adapted to process information about the visual character of the produced yarn
  • the optical sensor 6 of yarn 3 is formed by an optical yarn quality sensor, which is capable of providing sufficiently extensive and detailed information D1 about the visual form, i.e., the image of the yarn 3, which is continuously stored in the cache memory P1 during spinning, and after the break, the information D1 about the visual form of the yarn 3 before the break and in the area of the yarn break, i.e., the end of the broken yarn 3, is stored in the cache memory P1.
  • the optical sensor 6 shown, for example, in Fig. 2a comprises a radiation source 60 and a linear sensor 61 of radiation having a length L, which are arranged in a suitable position with respect to the yarn 3, or in a suitable position with respect to the path of the yarn 3 passing through a gap 62 between the source 60 and the sensor 61 of radiation of the optical sensor 6.
  • Assigned to the source 60 is collimation optics 600 which creates a field of light radiation 63.
  • the yarn 3 located in the field of light radiation 63 produces an image 9 the yarn on the linear sensor 610.
  • the optical sensor 6 allowing to sense and store information about the diameter and/or image of the yarn 3 according to one of the above-mentioned documents.
  • the optical sensor 6 is supplemented by foreign matter detectors which consist of sensors 70 of radiation reflected from the yarn 3, for example, according to document CH701902.
  • an optical sensor 6 of the yarn 3, quality consisting of a plurality of radiation sensitive elements 6100, which is located just above the yarn outlet from the spinning unit 2 with information from the yarn break sensor 41 , which is usually located between the draw-off mechanism 4 and the yarn traversing and winding device_5 in the rotor or air-jet spinning machines, for example according to DE 19832002. If breakage is indicated by the yarn break sensor 41 and the yarn 3 is still present in the optical yarn quality sensor 6, it is most likely yarn breakage between the draw-off mechanism 4 and the winding device 5, which allows relatively reliable identification and classification of such breaks.
  • the evaluation device 7 with its control software comprises hardware elements which provide computing power and logic to perform software operations for processing the output of the continuous monitoring of the yarn 3 by the optical sensor 6 and continuously storing this information D1 about the diameter or image of a predetermined portion of the length of the spun yarn 3 in the cache memory P1.
  • the output of the optical sensor 6 is thus connected to the cache memory P1 for continuous retrieval of information D1 about the visual form of the yarn 3 and to the evaluation device 7 for transmitting information about the yarn break, and also the output of the yarn break sensor 41 is connected to the evaluation device 7 for transmitting information about the yarn break.
  • the evaluation device 7 comprises a database of information about the typical course of diameters, images and other monitored physical parameters during the yarn break for predetermined types A, B, C, D, E, F, G, H of yarn breakage.
  • the evaluation device 7 is connected to the cache memory P1 for retrieving information D1 about the visual form of the end of the broken yarn 3 after the yarn break.
  • the evaluation device 7 From the information DI , the evaluation device 7 generates data D2 on the appearance of the broken end and classifies it into the corresponding type A, B, C, D, E, F, G, H of breakage.
  • the outputs of the evaluation device 7 are connected to the memories PA, PB, PC, PD, PE, PF, PG, PH of the individual types of breakage, in which numbers of breakages of respective type are stored.
  • the individual memories PA, PB, PC, PD, PE, PF, PG, PH of the number of the individual types of breakage are connected to the statistical evaluation device SV, in which, after the statistical evaluation of the number of breaks of individual types, a decision is made on the type and method of intervention.
  • Information means for the operator are connected to one output of the statistical evaluation device SV, and to the other output are connected means for automatic correction of the spinning parameters at the respective workstation, or in a group of workstations, or on the entire machine, or in the entire technological group of machines.
  • the automatic correction of the parameters can, of course, be conditioned by the confirmation of intervention by human operators for reasons of safety. In such a case, the evaluation device SV only issues a proposal for automatic repair, and this is only carried out after confirmation by the operator.
  • the evaluation device 7 comprises a microprocessor with a memory or a gate array or a custom ASIC-type electronic circuit or a suitable combination of at least two of these elements, i.e. , a microprocessor, a gate array and a custom ASIC-type electronic circuit, thus forming means adapted to perform software operations for processing the output of the optical sensor 6 sensing the yarn 3 and for identifying the type A, B, C, D, E, F, G, H of yarn breakage.
  • the memories PA, PB, PC, PD, PE, PF, PG, PH of the number of individual types A, B, C, D, E, F, G, H of breakage at the respective workstation 1 are part of the evaluation device 7 and/or the statistical evaluation device SV, to which the information about the type A, B, C, D, E, F, G, H of breakage is transmitted by the evaluation device 7.
  • the control software of the evaluation device 7 consists of program blocks, i.e. instructions which are designed to perform software operations for processing the output signal from the yarn monitoring sensor 66 for monitoring the physical parameters and for identifying the type A, B, C, D, E, F, G, H of yarn breakage at the workstation 1 of the rotor or air-jet spinning machine, and which ensure that the entire device for identifying the type A, B, C, D, E, F, G, H of yarn breakage according to the present invention, operates according to the required method, i.e., performs the steps of the method according to the present invention.
  • program blocks i.e. instructions which are designed to perform software operations for processing the output signal from the yarn monitoring sensor 66 for monitoring the physical parameters and for identifying the type A, B, C, D, E, F, G, H of yarn breakage at the workstation 1 of the rotor or air-jet spinning machine, and which ensure that the entire device for identifying the type A, B, C, D, E, F, G, H of yarn
  • the computer readable medium for this invention comprises a computer program, i.e., software to perform the method according to the above paragraph.
  • Yarn breakage occurs during the production of yarn 3 on the spinning machine for various reasons, which can be identified in advance and classified into pre-specified types, either according to their causes or their appearance. Some of these breaks are due to defects in the sliver being processed or to contamination or wear of the components of the spinning unit, while others are due to incorrect setting of the spinning parameters on at a particular workstation, in a group of workstations or on the entire spinning machine.
  • Some types of breakage can only be eliminated by direct operator or automatic operator intervention and do not need to be addressed in terms of monitoring the productivity of the spinning machines and/or the entire spinning mill, wherein other types of breakage may influence the productivity of the machine or even on the productivity of the entire spinning mill.
  • Type A represents breakage with foreign matter embedded yarn end (Fig. 5a).
  • An unopened end is formed by a cluster of fibres at the end of the broken yarn, which is usually due to imperfect fibre opening in the opening device of the spinning unit, which may be caused by a large number of short fibres in the sliver, or by a fault in the opening device (the opening roller or the drafting device).
  • This type of breakage is removed by the operator and in case of a high frequency at one of the workstations, the evaluation device informs about a probable mechanical defect on the spinning unit. If the operator is a human operator, the information is displayed on the operator panel 82 on the machine.
  • Type C represents breakage with a part of a cotton seed at the end (Fig. 5c).
  • This type of breakage is removed by the operator, and in case of a high frequency at one of the workstations, the operator receives instruction from the evaluation device to replace the sliver, or the sliver can, because a large number of this type of breakage at one workstation signals low-quality sliver.
  • Type D represents breakage with trash particle embedded end (Fig. 5d).
  • This type of break occurs mainly for two reasons, namely when there is blockage or improper suction in the suction tube of the impurity removal channel, or in case of very light waste materials, such as very small fractions of cotton fibres, present in large quantities in the feed sliver. If the suction tube becomes clogged or the suction pressure is very low, small trash particles follow the fibre path and are carried into the spinning rotor instead of entering the waste chamber and are deposited inside the spinning rotor groove. Because they are comparatively heavier than cotton fibres, these small waste particles go on accumulating in the rotor groove and after a certain time these particles come out of the rotor groove along with a ribbon of fibres and cause yarn breakage.
  • This type of breakage is removed by the operator, and if there is a high frequency at one of the workstations, the evaluation device instructs him to replace the sliver can, because a large number of this type of breakage at one workstation signals low-quality sliver.
  • Type E represents breakage with a long tapered end (Fig. 5e).
  • This type of breakage occurs in the spinning rotor due to a low twist, which can be caused by improperly set spinning parameters on the entire machine, or by a fault at the workstation of the machine.
  • this type of breakage occurs repeatedly at one workstation, the operator receives information from the evaluation device about a probable fault at the workstation.
  • the evaluation device issues a command to adjust the spinning parameters on the machine, and if the repetition of this type of break concerns the entire spinning mill, the command to adjust the spinning parameters is issued on the entire spinning mill, i.e. , on all machines.
  • Type F represents breakage with a blunt end (Fig. 5f).
  • the operator receives information from the evaluation device about a probable fault at the workstation. If the operator is a human operator, the information is displayed on the operator's panel 82 on the machine. In the case of the distribution of repetitions of this type of breakage at more workstations of the machine, the evaluation device issues a command to adjust the spinning parameters on the machine, and if the repetition of this type of break concerns the entire spinning mill, the command to adjust the spinning parameters is issued on the entire spinning mill, i.e., on all machines.
  • Type G represents breakage between the draw-off mechanism and the winding device of yarn.
  • This type of breakage occurs due to improperly set spinning parameters on the entire machine or a fault at the workstation of the machine, the breakage being detected by the yarn break sensor arranged at each workstation of the machine between the draw-off mechanism 4 and the yarn traversing and winding device 5.
  • this type of breakage repeatedly occurs at one machine workstation, the operator receives information about a probable defect at the workstation from the evaluation device. If the operator is a human operator, the information is displayed on the operator's panel 82 on the machine. In the case of spreading the repetition of this type of breakage at several workstations of the machine, the control system 81 of the spinning machine issues a command to adjust the spinning parameters on the machine, and if the repetition of this type of breaks concerns the entire spinning mill, a command is issued to adjust the spinning parameters in the entire spinning mill, i.e., on all machines.
  • Type H represents breakage caused by the yarn quality sensor.
  • the yarn quality sensor which consists of an optical sensor 6 arranged at each workstation of the machine and which senses an image of the yarn. If the yarn quality sensor is also provided with monitoring foreign matter based on the principle of reflected light from the yarn, the presence of foreign matter in the yarn may also be the cause of a forced break from the yarn quality sensor.
  • the operator receives information about a probable fault at the workstation from the evaluation device 7 via the control system 81 of the spinning machine and/or control system 8 of the workstation 1., the information being displayed for the human operator on the operator panel 82.
  • the control system 81 of the spinning machine issues a command to adjust the spinning parameters on the machine, and if the repetition of this type of breakage concerns the entire spinning mill, a command is issued to adjust the spinning parameters in the entire spinning mill, i.e. , on all machines.
  • Air-jet spinning machines are:
  • Type H - breakage caused by the yarn quality sensor
  • the method of identification of type of breakage at the workstation 1 of the rotor or air-jet spinning machine consists in that the optical sensor 6 of yarn 3 continuously senses a predetermined portion of the length of the yarn 3, whereby information D1 about the diameter or image of the yarn 3 is continuously obtained from this optical sensing of the yarn 3 for cache memory P1. This information is cyclically recorded during spinning and subsequently erased and replaced by other information corresponding to the diameter or image of the yarn currently being processed 3.
  • the yarn break sensor 41 or the optical sensor 6 issues a signal about the yarn break to the evaluation device 7, and the latter downloads from cache memory P1 information D1 about the form of the end of the yarn 3, meaning information about the visual form of the end of the broken yarn 3 before the break, during the break and up to the end of the break.
  • information D1 about the form of the end of the yarn 3 before the break, during the break and up to the end of the break.
  • descriptive data D2 about the appearance of the end of the break is subsequently extracted, which will enable to identify the type of breakage and classify into the appropriate type A, B, C, D, E, F, G, H of breakage, as well as to store the information about another break to the respective memory PA, PB, PC, PD, PE, PF, PG, PH of types of breakage of the respective workstation 1.
  • the statistical evaluation device SV statistically evaluates the numbers of each type A, B, C, D, E, F, G, H of yarn breakage recorded in the memories PA, PB, PC, PD, PE, PF, PG, PH of the number of individual types of breakage at each workstation 1.
  • This evaluation is performed for each workstation 1 and/or for the entire spinning machine and/or for the entire technological group of machines and on the basis of the evaluation it is decided, according to pre-set criteria, whether it is an individual deviation in the breakage rate of yarn 3 of a specific workstation1 of the machine, or the distribution of the breakage rate of yarn 3 in a group of workstations 1 or the distribution of the breakage rate of yarn 3 on the entire machine and a decision is made on the type of intervention and the method of intervention.
  • the type of intervention is either the intervention of the operator, or the adjustment to the spinning parameters at the respective workstation, or in the group of workstations 1., where the same lot of the yarn 3 is spun, or on the entire machine, or in the entire technological group of machines.
  • the data on the type A, B, C, D, E, F ,G, H of yarn breakage and/or the memory contents PA, PB, PC, PD, PE, PF, PG, PH of the number of individual types A, B, C, D, E, F, G, H of breakage of individual workstations 1 are transmitted via existing communication channels to the central control system of the machine or spinning mill representing the technological group of machines. This information is then used by the central control system to identify the likely location of the anomaly in the spinning process and alerts the operator to the need for intervention even outside the spinning mill itself. For example, if there is an increase in the number of breakages caused by foreign matter, it will focus intervention on the point in the preparation line where the foreign matter is to be removed.
  • the invention can be used in spinning mills to increase the efficiency of yarn production on rotor or air-jet spinning machines.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Spinning Or Twisting Of Yarns (AREA)

Abstract

Title of the invention: A method of controlling the technological process of yarn manufacturing on a spinning machine, a spinning machine for performing the method, a computer program for performing the method on the spinning machine and a computer-readable medium with the computer program The invention relates to a method of controlling the technological process of yarn manufacturing on a spinning machine, especially a rotor or air-jet spinning machine, in which yarn (3) is monitored by at least one sensor (66) for monitoring the physical parameters of the yarn (3), wherein the sensor (66) for monitoring the physical parameters of the yarn is coupled to an evaluation device (7) equipped with software. The evaluation device (7) identifies the type (A, B, C, D, E, F, G, H) of breakage on the basis of information about the monitored physical parameters of the yarn (3) according to pre-set criteria and stores the information about the type of breakage for the respective workstation (1) in the memory (PA, PB, PC, PD, PE, PF, PG, PH) of the respective type of breakage, wherein the information from the memories (PA, PB, PC, PD, PE, PF, PG, PH) about the number of individual types (A, B, C, D, E, F, G, H) of breakage is statistically processed and evaluated and, according to the results of the statistical processing and evaluation, interventions are made in the technological process of spinning on the entire machine, a group of workstations (1) of the machine or at the individual workstations (1) of the machine. In a preferred embodiment, the sensor (66) for monitoring physical parameters of the yarn (3) is formed by one of the types of optical sensors (6), for example a yarn quality sensor, which can be supplemented with a sensor of foreign matter in the yarn. In addition, the invention relates to a spinning machine and a computer program to perform this method and to a computer-readable medium having stored the above-mentioned program thereon.

Description

A method of controlling the technological process of yarn manufacturing on a spinning machine, a spinning machine for performing the method, a computer program for performing the method on the spinning machine and a computer-readable medium with the computer program
Technical field
The invention relates to a method of controlling the technological process of yarn manufacturing on a spinning machine, in particular a rotor or air-jet spinning machine, in which yarn is monitored by at least one sensor for monitoring the physical parameters of the yarn, which is coupled to an evaluation device equipped with software.
Furthermore, the invention relates to a spinning machine for performing the method, comprising a plurality of workstations arranged next to one another, each of which is provided with means for ensuring a change of technological parameters during yarn production and comprises a spinning unit and a sensor for monitoring the physical parameters of the spun yarn at least from the group consisting of diameter, weight or homogeneity, colour, image and/or foreign matter, wherein the sensor for monitoring the physical parameters of the yarn is coupled to an evaluation device equipped with software.
In addition, the invention relates to a computer program for performing the method according to the invention on the spinning machine according to the invention and to a computer-readable medium with the computer program according to the invention.
Background art
Yam is produced on textile machines provided with a device for transforming a fibre semi-finished product in the form of a suitably arranged bundle of fibres into yarn. Different methods of yarn production and different yarn producing devices associated with them are known. Yam is produced, for example, on ring spinning machines, rotor spinning machines, as well as air-jet spinning machines. The yarn produced on rotor or air-jet spinning machines is wound on crosswound bobbins from which the yarn is subsequently directly processed, i.e. , used in the knitting or weaving of textiles. These machines are usually equipped with a yarn quality sensor to ensure that the yarn produced is free of defects. The sensor can be a capacitive sensor or different types of optical sensors. Another important parameter for determining the quality of the yarn produced and wound on the bobbin is the number of yarn breaks that occur during yarn production while the spinning machines are in operation. Yam breaks occur for a variety of reasons. Yam breaks reduce the productivity of yarn production, i.e., they reduce the productivity of the machine. In order to achieve the highest possible productivity on the spinning machine, yarn breaks are removed in different ways depending on the degree of automation of the machine concerned, either manually on manually operated machines (e.g. according to DE 10 084 607) or by means of an attending device which is adapted to operate more spinning units arranged next to one another (e.g. according to US 4295330) or which is individual and designed to operate only one spinning unit, so-called unit automation (e.g., according to US 4369620).
Yam breaks occur for various reasons. They are caused, for example, by unevenness of the fibre sliver supplied, impurities in the fibre sliver, technological or air-technical parameters of yarn production that are inappropriately set or changed over time, or even by contamination or wear of individual components of the spinning unit.
Apart from the loss of yarn production due to the interruption of yarn production by a yarn break, the occurrence of each break also leads to a reduction in the overall quality of the yarn produced, since each single yarn break is replaced by a piecer or another connection (for example, a splicer) when the yarn production is resumed, i.e., the point of connection of the originally produced yarn and the newly connected newly produced yarn. Any piecer or other joining of the yarn, despite all efforts to minimise its effects on the quality and appearance of the yarn, appears as a quality defect in the yarn. It is also important to note that there is practically no yarn production without the occurrence of yarn breaks during production. It is therefore in the interests of the spinning machine operator to keep the "breakage rate" of the yarn, i.e. , the number of yarn breaks per length of yarn produced or the number of yarn breaks per time at a constant yarn production speed as low as possible. In the event of an increase in the number of breaks or an increase in the number of breaks over time, it is necessary to perform a root cause analysis to identify the reason for the break and to prevent further breaks. This root cause analysis is generally based on an analysis of the type of yarn breakage, i.e., an analysis of the shape, arrangement and geometric parameters of the broken yarn end, including an analysis of the relatively long section of yarn before the place of the breakage itself. The analysis of the type of breakage is important for identifying the causes of the breakage and for the subsequent implementation of adequate interventions in the textile technological process and, if necessary, also individual interventions at a specific spinning unit, all with the aim of maintaining or reducing the number of yarn breaks to acceptable values.
Currently, it is only possible to analyse the type of yarn breakage by stopping the spinning unit after a yarn break without subsequently resuming the spinning process, i.e., without starting the system to remove the yarn break, etc. Subsequently, qualified personnel unwind from a yarn winding bobbin the required length of yarn with a broken yarn end, the yarn being wound onto the bobbin due to the inertia of the bobbin rotation and the slower braking of the bobbin after the yarn break. This unwound yarn end section of the necessary length, including the broken end of the yarn itself, is subjected to visual examination, usually in a laboratory with the aid of image magnification, to determine the geometric, morphological and other properties not only of the broken end of the yarn itself, but usually also of a certain length of the yarn section before the very place of the broken end of the yarn. The result of this examination of every single yarn break is recorded.
Subsequently, when another yarn break occurs, the same analysis of the type of yarn breakage is carried out again and only on the basis of the results of the analyses of the type of yarn breakage for a large number of yarn breaks and their statistical evaluation is it possible to arrive at a relevant evaluation of the causes of the yarn breaks and subsequently to carry out appropriate interventions in the technological process of yarn manufacturing and/or appropriate interventions, changes and adjustments, or repairs, at the specific workstation from which the evaluated yarn breaks originate. Interventions at that specific workstation are carried out especially when the occurrence of yarn breaks at that specific workstation is significantly higher compared to other workstations of the given machine, etc.
The issue of yarn breakage type analysis is described, for example, in the publication:
-Cizek L, Supervision of the BD 200 Spinning machine, cited in “Open- end spinning” (Elsevier scientific publishing company, New York) 1975, 319
- Apurba Das and Saiyed Muzaffar Ishtiaque - End breakage in rotor spinning: Effect of different variables on cotton yarnend breakage, AUTEX Research Journal, Vol. 4, No2, June 2004 © ALITEX. Pictures of typical yarn breaks on rotor spinning machines are taken from this publication.
- Team of workers of VUB - Summary of findings from textile technological research of a spinning unit of the BDA 20 machine... Report of the research task H-28-124-410 - June 1988 - Page 74a
- MIZERA, Zdenek. Morphology of breakage in BD yarns. Liberec: University of Engineering and Textiles in Liberec, 1989. Diploma thesis. Thesis supervisor Bohumila Koskova.
- SAFAR, Jiri. Yarn breakage analysis. Liberec: University of Engineering and Textiles in Liberec, 1988. Diploma thesis. Thesis supervisor Petr Ursiny.
In terms of textile technology, various types of yarn breakage are evaluated in the laboratory for yarns produced on rotor spinning machines in order to analyze the causes of these yarn breaks and subsequently take appropriate measures which will reduce the number of yarn breaks to an acceptable level.
For example, according to the publication - A. Apurba & S. M. Ishtiaque: End breakage in rotor spinning: Effect of different variables on cotton yarn end breakage, AUTEX Research Journal, Vol. 4, No2, June 2004, classification of the types of breakage can be as follows: A = Broken end with foreign matter embedded yarn end
B = Broken end with unopened fibrous end
C = Broken end with seed coat embedded end
D = Broken end with trash particle embedded yarn end
E = Broken end with tapered end
F = Broken end with blunt yarn end
G = Miscellaneous type of breakage - e.g., breakage between the draw-off mechanism and the winding device
H = breakage caused by the quality sensor which senses an image of the produced yarn
However, these types of yarn breakage are identified in standing yarn in laboratory conditions using laboratory instruments and aids, such as yarn defect identification means, image magnification means, means for dimensional diagnosis of a fibre structure, etc. Such a procedure is described, for example, in the publication of V.K. Yadava, S.D. Joshib, S.M. Ishtiaquea & J.K. Chatterjeeb; Yam fault classification: a signal processing approach using multiple projections; Department of Textile Technology, Indian Institute of Technology Delhi, New Delhi, India; Department of Electrical Engineering, Indian Institute of Technology Delhi, New Delhi, India; published online: 16 April 2014. The pictures of typical yarn breaks 5a - 5f on rotor spinning machines are taken from this publication.
For air-jet spinning machines, where the mechanics of yarn formation is different from that of rotor spinning machines, the general methodology for evaluating types of yarn breakage has not yet been developed so extensively. Even here, i.e., with air-jet spinning machines, the following types of yarn breakage can also be identified, for example:
1 . Breakage with foreign matter embedded end (A)
2. Breakage with tapered end (E)
3. Breakage with blunt end (F)
4. Breakage caused by the quality sensor (H) which senses an image of the yarn A common disadvantage of the current background art is the fact that in order to carry out a sufficiently accurate and reliable analysis of yarn breakage and to identify the type of yarn breakage and its causes, it is necessary to shut down the respective workstation to perform this sufficiently accurate and reliable analysis of yarn breakage in laboratory conditions, during which time the workstation does not produce yarn, i.e., which leads to production loss. Another disadvantage is the fact that performing a sufficiently accurate and reliable yarn breakage analysis and correctly identifying the type of yarn breakage as well as the causes of the yarn breakage is largely dependent on the qualifications of the personnel performing the analysis, therefore the correctness and objectivity of the evaluation cannot be guaranteed under all circumstances. Also, the subsequent statistical processing of the results of the analysis and identification of the type of yarn breakage is demanding in terms of qualifications and can therefore cause a high error rate, which has consequences for the subsequent production phases. Another drawback is that, for technical and economic reasons, the analysis of the yarn breakage and the identification of the type of yarn breakage with the shutdown of the respective workstation cannot be carried out continuously after each break and, therefore, the correction of increased breakage rate or lower yarn quality is delayed for at least the time before the analysis starts to be carried out.
The object of this invention is to propose a method and a device that will eliminate or at least minimize or at least reduce the disadvantages of the background art, will contribute to increasing the efficiency of yarn production on spinning machines, whether rotor or air-jet spinning machines, or will enable automatic or at least partially automated regulation of the parameters of the spinning process at the workstation, in the technological process of the machine, or in the technological process of a group of machines, or in the technological process of the entire spinning mill.
The automatic or at least partially automated regulation of the parameters of the technological process of yarn manufacturing at the workstation based on an evaluation of the number of occurrences of yarn breakage on the spinning machine is the subject of e.g., EP 1 281 959 or EP 2 565 306. The disadvantage of these solutions, however, is that they work only with the absolute number of yarn breaks without evaluating the type of break and without identifying the causes of the yarn breaks, and so the regulation of the spinning parameters on the machine occurs even in the case of breaks which cannot be influenced by the regulation of the spinning parameters.
Principle of the invention
The object of the present invention is achieved by a method of controlling the technological process of yarn manufacturing on a spinning machine, in particular a rotor or air-jet spinning machine, in which yarn is monitored by at least one sensor for monitoring the physical parameters of the yarn, which is coupled to an evaluation device equipped with software, wherein specific features of the method are described in the independent claim 1 .
After each break, the evaluation device identifies the type of breakage according to pre-set criteria and store the information about the type of breakage in the memory of the number of the respective type of breakage for the respective workstation. The information from the individual memories is statistically processed after a predetermined statistically relevant period of machine operation and, according to the result of the processing, interventions are made in the spinning process on the entire machine or at individual workstations, or no interventions are made in the process but only a specific break is removed. It follows that interventions in the spinning process are only carried out when such intervention has a positive effect on the process, either at the workstation or on the entire machine.
During spinning, a part of the length of the spun yarn at each workstation of the spinning machine is monitored by the sensor for monitoring the physical parameters of the yarn, and information about the course of the monitored physical parameter/s of the yarn over a predetermined length is continuously recorded and stored in the cache memory for that length until a break occurs. After a yarn break, the recorded information about the monitored physical parameter/s of the yarn on the last recorded length of the yarn before the break is retrieved and evaluated. The evaluated information is used to identify the type of yarn breakage and classify the breakage into one of the predefined types of yarn breakage, and the information about the breakage is recorded in the memory of the number of individual types of yarn breakage assigned to each workstation.
Statistical evaluation of the number of individual types of breakage from the memory of the number of individual breaks is carried out for each workstation by the machine control system either for each workstation and/or for a group of workstations and/or for the entire spinning machine. On the basis of the evaluation it is decided, according to pre-set criteria, whether it is an individual deviation in the yarn breakage rate of a particular workstation of the machine, or whether the yarn breakage rate is distributed in a group of workstations spinning the same lot of the yarn, or whether it is distributed on the entire machine and finally, a decision is made on the type of intervention and the method of its implementation.
If we focus on monitoring the entire technological group of machines, the statistically recorded numbers of breaks of each type recorded in the memories of the number of individual types of yarn breaks for all workstations of individual machines or the entire technological group of machines are evaluated and on the basis of pre-set criteria, it is decided whether there has been an increase in yarn breakage in the entire technological group above the specified limit and a decision is made on the type and method of intervention for the entire technological group of machines.
The type of intervention may be only operator intervention at a specific workstation, or a call to replace or repair sliver at one or more workstations, or an adjustment to spinning parameters on the entire machine or in a group of workstations.
According to one embodiment of the invention, the sensor of the physical parameters of the yarn is a capacitive sensor that monitors the weight, or homogeneity, of the spun yarn.
Currently, the most widely used sensors for the physical parameters of the yarn are optical sensors which include at least one radiation source and at least one radiation sensitive element which is capable of monitoring information about the course of the yarn diameter. Preferably, the optical yarn sensor comprises an optical yarn quality sensor comprising a linear radiation sensor which is capable of providing sufficiently extensive and detailed information about the visual form, i.e., the image of the yarn, including an image of the broken yarn end.
A further refinement of the identification of the type of break can be achieved by a yarn sensor which is also capable of detecting coloured and/or foreign matter in the yarn. In this manner, it is possible to distinguish breaks caused by impurities or foreign matter captured at the end of the yarn break.
If the image of the yarn is sensed by a linear optical sensor, it is advantageous to use the method of digital image analysis of the sensed image of the yarn and the image of the broken yarn end to evaluate the kind of the break.
The recorded types of breakage and their number in the individual memories of the breaks are used after a certain period of machine operation by their statistical evaluation for each workstation and/or for the entire spinning machine and according to pre-set criteria, a decision is made whether it is an individual deviation in the breakage rate of a certain type of yarn at a specific workstation which will need to be removed individually at the respective workstation, or whether it is a distribution of a certain type of breakage on the entire machine, and based on this decision, it will be necessary to adjust the technological process on the entire machine.
Similarly, after a certain period of operation of the technological group of machines, a statistical evaluation of the types and numbers of yarn breaks of individual types is carried out for the entire technological group of machines, and on the basis of the evaluation, according to pre-set criteria, it is decided whether there has been an increase in the rate of breakage above the set limit in the entire technological group.
On the basis of the above decisions, the type of intervention is then decided on according to pre-set criteria, i.e., whether it will be an intervention at a specific workstation, or a group of workstations, or in the technological process of the machine, or in the technological process of the entire technological group of machines, i.e., in the entire spinning mill. Next, a decision is made on the timing of the intervention, i.e., whether the intervention will be carried out immediately or later at a more technologically favourable time according to pre-set criteria. At the same time, a decision is made on the method of intervention, i.e., whether the intervention will be carried out by the operator or automatically by the machine control system or by the control system of the attending device.
The principle of the device, i.e., the device for performing the method according to the invention, is described by the features of independent claim 10. The spinning machine comprises a sensor for monitoring the physical parameters of yarn, which is coupled via a cache memory to an evaluation device for the identified types of yarn breakage, whose outputs are connected to the memories of the number of individual types of yarn breakage which are connected to a statistical evaluation device. According to the results of the statistical evaluation, interventions are carried out in the technological process of spinning on the entire machine, in a group of workstations or at the individual workstations of the machine.
The sensor for monitoring the physical parameters of yarn may be a capacitive sensor or especially one of the well-known optical yarn quality sensors.
The invention is based on the fact that the identification of the type of yarn breakage can be realized by a sensor of the physical parameters of the yarn, in particular an optical yarn sensor, using a special method of detailed processing of the obtained information describing the yarn section before the yarn break, in particular the gradient of the decrease in the yarn diameter depending on the length, furthermore, an image of impurities or fibre cluster occurring at the end of the yarn after the yarn has broken, the sensor of the physical parameters of the yarn being preferably supplemented by a sensor for impurities and foreign matter in the yarn, operating on the principle of reflected light from the yarn. From the image of the end of the yarn before the break, sensed by the optical sensor, characteristic features of the yarn break, typical of the different causes of the break, are determined and the break is classified into the appropriate type and added to the memory of the number of breaks of the respective types of breakage assigned to a specific workstation. The information thus obtained is then processed statistically, wherein it is primarily monitored whether there are significant deviations in the number of certain types of breakage only for certain workstations or whether it is a statistically significant or even distribution of breaks on the entire spinning machine.
As it follows from the essence of the matter, optical yarn sensors are in principle known, especially optical yarn quality sensors which evaluate yarn diameter defects and yarn hairiness defects, as well as sensors of foreign matter in the yarn. Also known are separate yarn break sensors which are usually located on spinning machines between the yarn draw-off mechanism and the winding device. These sensors are useful for the present invention provided that they allow sufficiently accurate and fast acquisition and processing of data on the character of the yarn end just before the yarn break. It is then advantageous to use sensors whose sensing element or elements provide sufficient resolution to obtain visual information relevant for detecting the type of breakage in the rotor or air-jet yarn. An advantageous sensing element or elements include, for example, a single-row or multi-row optical sensing element with a sufficient density of radiation sensitive elements in a row arranged next to each other across the path of movement of the yarn at a spinning station of an air-jet or rotor spinning machine, as well as sensors that detect changes in colour or contrast in reflected light. The settings for optical monitoring and evaluation of the type of yarn breakage can be made individually for different types of machines (rotor or air-jet) as well as for different types of textile materials and yarn fineness, simply by software modifications and changes to the relevant parameters of the evaluation algorithm within the method and/or spinning machine according to the present invention, which is fast and relatively inexpensive. A further advantage is that the optical yarn sensor can be common for sensing the type of yarn breakage according to the present invention, as well as for the previously used optical sensing and yarn quality evaluation based on the principle of yarn diameter defects and yarn hairiness defects, or for detecting foreign matter in the yarn, which is economically advantageous and simplifies the design of the spinning unit and the workstation of the rotor or air-jet spinning machine. At the same time, however, it should be noted that the present invention can also be implemented as a solution independent of existing means for evaluating the yarn quality, for example, by a separate optical or capacitive sensor. Since the vast majority of rotor or jet spinning machines are provided with a yarn quality sensor, it is advantageous to use the information obtained from these sensors also for the purpose of identifying and analysing the type and subsequent causes of breaks on rotor and air-jet spinning machines. In this case, it is advantageous to use optical sensors with a linear sensor having several optical elements arranged next to each other, which can provide a sufficient amount of information that can be processed and further used according to the method of the present invention. In a preferred embodiment, it is possible to supplement this sensor with a sensor of foreign matter in the yarn, working on the principle of reflected light from the yarn.
Various types of optical sensors are described in numerous documents, e.g., CZ 306117, CZ 305265, EP 2827132, US371274, EP 0 627 623, JP 4 756 411 , US 6 219 135, US 5 270 787, US 5 654 554, US 5,521 ,395, WO 2011 026 249 and others. If the sensors according to one of the above-mentioned inventions or according to a similar solution provide a sufficiently reliable digital image of the end of the broken yarn, possibly also information about foreign matter in the yarn (for example, according to CH701902), they can be used for the solution according to this invention.
Brief description of drawings
The invention is schematically represented in the enclosed drawings, wherein Fig. 1 shows an arrangement of a spinning machine, Fig. 2 shows an arrangement of one workstation of a rotor spinning machine, Fig. 2a shows a classic arrangement of an optical sensor (a source, yarn, a sensor), Fig. 2b shows the optical sensor supplemented by sensing reflected light from the yarn, Fig. 3 represents an arrangement of one workstation of an air-jet spinning machine, Fig. 4 shows a detail of the general arrangement of the device according to the invention at one workstation of the spinning machine (block diagram), Figs. 5a to 5f show detailed examples of possible types of yarn breakage.
Figure imgf000015_0001
of Embodiments
The invention will be described with reference to an example of embodiment of a method of controlling the technological process of yarn manufacturing on a spinning machine, in particular a rotor or air-jet spinning machine, which is based on monitoring the physical parameters of yarn breaks, wherein the physical parameters are selected from a group consisting of diameter, weight or homogeneity, colour, image, foreign matter, etc., and on identification and statistical evaluation of the types of yarn breakage during the production of yarn at a workstation of the rotor or air-jet spinning machine, on monitoring and statistical evaluation of the number of individual types of yarn breakage within a predetermined time interval, or on the basis of predetermined number of a specific type of breakage on individual machines and/or monitoring and statistical evaluation of types of yarn breakage within a predetermined time interval or on the basis of a predetermined number of a specific type of break in the entire spinning mill. According to the results of the statistical processing, interventions are made in the technological process at the respective workstation and/or on the entire machine and/or in the entire spinning mill. Interventions in the technological process are carried out either by the operator, i.e., a human operator, or by an attending device at the individual spinning units, where the attending device may be part of the machine workstation, or it may consist of an automatic attending device OZ which is displaceable along the machine. Interventions can also be carried out by the central control system 81 of the entire machine on the respective machine, or the central control system of the entire spinning room for all machines, or just for selected machines. If the operator is a human operator, information about the type of breakage and the method of intervention is displayed on the operator's panel 82 on the machine or it is displayed by signalling means of the workstation.
A rotor or air-jet spinning machine comprises at least one row of identical workstations 1 arranged next to one another. Each workstation 1 comprises a reservoir of fibrous material for producing the yarn 3, the reservoir consisting of a sliver can 10 in which sliver 11 is stored.
Each workstation 1 comprises a spinning unit 2 which is adapted to transform a fibrous structure made from sliver 11 into yarn 3, either by a combination of an opening roller 21 and a spinning rotor in the rotor spinning machine or a combination of a drafting device 210 of sliver and a spinning air nozzle 20 in the air-jet spinning machine. The yarn 3 is drawn off from the spinning unit 2 by a draw-off mechanism 4 arranged at the workstation 1 in the direction P of the movement of the fibrous material, here already in the form of yarn 3, downstream of the spinning unit 2. The workstation 1 further comprises a traversing and winding device 5 of yarn 3 onto a bobbin 50 which is arranged at the workstation 1 in the direction of the movement P of the fibrous material downstream of the draw-off mechanism 4 of yarn 3 and which is adapted to distribute the yarn 3 across the width of the rotating bobbin 50 and to wind the yarn 3 onto the rotating bobbin 50. A yarn break sensor 41 is usually mounted downstream of the draw-off mechanism 4.
At least one sensor 66 for monitoring the physical parameters of the yarn 3 is arranged between the output of the yarn 3 from the spinning unit 2 and the traversing and winding device 5 of the yarn 3 on the bobbin 50 at each workstation 1. The sensor 66 for monitoring the physical parameters of the yarn 3 can consist of any known sensor of the physical parameters of the yarn, for example, a capacitive sensor, which is not shown, but to a person skilled in the art it is known that it comprises a plate capacitor between the plates of which the yarn 3 passes and from the change in capacitor capacity, the weight or homogeneity of the spun yarn 3 is derived. Currently, the sensors 66 of the physical parameters of the yarn 3 most often consist of optical sensors_6 which comprise at least one radiation source 60 and one radiation sensitive element 6100, adapted for the optical monitoring of the diameter or image of the yarn 3 during its production at the workstation 1 of the spinning machine. The sensor 66 for monitoring the physical parameters of the yarn 3 is, via the cache memory P1 arranged at the workstation 1, coupled to an evaluation device 7 which comprises means for processing information about the monitored physical parameters of the yarn 3 and is arranged at the workstation 1.
The output of the sensor 66 for monitoring the physical parameters of the yarn is connected to the cache memory P1 for continuous retrieval of information D1 about the physical parameters of the yarn 3 at the respective workstation 1 and at the same time to the evaluation device 7 of the workstation for transmitting information about the yarn break from the sensor 66, wherein the output of the yarn break sensor 41 is connected to the evaluation device 7 of the respective workstation 1 for transmitting information about the yarn breakage. The evaluation device 7 includes a database of information about the typical course of the monitored physical parameters of the yarn 3 for predetermined types A, B, C, D, E, F, G, H of yarn breakage. The evaluation device 7 is connected to the cache memory P1 to retrieve information D1 about the monitored physical parameters at the end of the broken yarn 3 after the yarn break. The evaluation device 7 generates data D2 from the information D1 about the form of the break end and classifies it into the corresponding type A, B, C, D, E, F, G, H of breakage. The information about the identified type of breakage is transmitted to the breakage type memory PA, PB, PC, PD, PE, PF, PG, PH of the number of each type of break, in which the numbers of breaks of the corresponding type of breakage are stored. The individual memories PA, PB, PC, PD, PE, PF, PG, PH of the number of types of breakage are part of the statistical evaluation device SV, which, in the embodiment of Fig. 4, is part of the control system 81 of the machine or are connected to it. In the statistical evaluation device SV, after a predetermined relevant time of machine operation, the statistical evaluation of the number of breaks of the respective type is carried out and on its basis a decision is made on the type and method of intervention in the technological process of yarn manufacturing. Information means for the operator are connected to one output of the statistical evaluation device SV, and to the other output are connected means for correcting the spinning parameters at the respective workstation 1 or a group of workstations 1_, or on the entire machine, or in the entire technological group of machines. If the operator is a human operator, information is displayed on the operator's panel 82, if the operator is an automatic attending device OZ, the information is transmitted to its control system.
Considering that optical sensors 6 are currently most often used as sensors 66 for monitoring the physical parameters of the yarn 3, the inclusion of these optical sensors 6 in the method a device according to the present invention will be described in more detail below.
The optical sensor 6 of yarn 3 is via cache memory P1 coupled to the evaluation device 7, which comprises electronics provided with software and is adapted to process information about the visual character of the produced yarn
3
Preferably, the optical sensor 6 of yarn 3 is formed by an optical yarn quality sensor, which is capable of providing sufficiently extensive and detailed information D1 about the visual form, i.e., the image of the yarn 3, which is continuously stored in the cache memory P1 during spinning, and after the break, the information D1 about the visual form of the yarn 3 before the break and in the area of the yarn break, i.e., the end of the broken yarn 3, is stored in the cache memory P1.
The optical sensor 6 shown, for example, in Fig. 2a comprises a radiation source 60 and a linear sensor 61 of radiation having a length L, which are arranged in a suitable position with respect to the yarn 3, or in a suitable position with respect to the path of the yarn 3 passing through a gap 62 between the source 60 and the sensor 61 of radiation of the optical sensor 6. Assigned to the source 60 is collimation optics 600 which creates a field of light radiation 63. The yarn 3 located in the field of light radiation 63 produces an image 9 the yarn on the linear sensor 610.
The optical sensor 6 is implemented according to some known solution, usually as a linear sensor according to one of the documents CZ299647, US9255889, US2022162778, CZ306117, CZ305265, EP2827132,
US2019195854, EP1408332, DE10163849, CZ2013567, or other documents, disclosing detailed solutions of optical sensors of yarn, capable of providing data on the end of the broken yarn 3 for the purposes of use according to this invention.
In the exemplary embodiment shown in Fig. 2a, there is a basic embodiment of the optical sensor 6, allowing to sense and store information about the diameter and/or image of the yarn 3 according to one of the above-mentioned documents. In the exemplary embodiment of Fig. 2b, the optical sensor 6 is supplemented by foreign matter detectors which consist of sensors 70 of radiation reflected from the yarn 3, for example, according to document CH701902.
It is also advantageous to combine an optical sensor 6 of the yarn 3, quality, consisting of a plurality of radiation sensitive elements 6100, which is located just above the yarn outlet from the spinning unit 2 with information from the yarn break sensor 41 , which is usually located between the draw-off mechanism 4 and the yarn traversing and winding device_5 in the rotor or air-jet spinning machines, for example according to DE 19832002. If breakage is indicated by the yarn break sensor 41 and the yarn 3 is still present in the optical yarn quality sensor 6, it is most likely yarn breakage between the draw-off mechanism 4 and the winding device 5, which allows relatively reliable identification and classification of such breaks.
The evaluation device 7 with its control software comprises hardware elements which provide computing power and logic to perform software operations for processing the output of the continuous monitoring of the yarn 3 by the optical sensor 6 and continuously storing this information D1 about the diameter or image of a predetermined portion of the length of the spun yarn 3 in the cache memory P1.
The output of the optical sensor 6 is thus connected to the cache memory P1 for continuous retrieval of information D1 about the visual form of the yarn 3 and to the evaluation device 7 for transmitting information about the yarn break, and also the output of the yarn break sensor 41 is connected to the evaluation device 7 for transmitting information about the yarn break. The evaluation device 7 comprises a database of information about the typical course of diameters, images and other monitored physical parameters during the yarn break for predetermined types A, B, C, D, E, F, G, H of yarn breakage. The evaluation device 7 is connected to the cache memory P1 for retrieving information D1 about the visual form of the end of the broken yarn 3 after the yarn break. From the information DI , the evaluation device 7 generates data D2 on the appearance of the broken end and classifies it into the corresponding type A, B, C, D, E, F, G, H of breakage. The outputs of the evaluation device 7 are connected to the memories PA, PB, PC, PD, PE, PF, PG, PH of the individual types of breakage, in which numbers of breakages of respective type are stored. The individual memories PA, PB, PC, PD, PE, PF, PG, PH of the number of the individual types of breakage are connected to the statistical evaluation device SV, in which, after the statistical evaluation of the number of breaks of individual types, a decision is made on the type and method of intervention. Information means for the operator are connected to one output of the statistical evaluation device SV, and to the other output are connected means for automatic correction of the spinning parameters at the respective workstation, or in a group of workstations, or on the entire machine, or in the entire technological group of machines. The automatic correction of the parameters can, of course, be conditioned by the confirmation of intervention by human operators for reasons of safety. In such a case, the evaluation device SV only issues a proposal for automatic repair, and this is only carried out after confirmation by the operator.
Preferably, the evaluation device 7 comprises a microprocessor with a memory or a gate array or a custom ASIC-type electronic circuit or a suitable combination of at least two of these elements, i.e. , a microprocessor, a gate array and a custom ASIC-type electronic circuit, thus forming means adapted to perform software operations for processing the output of the optical sensor 6 sensing the yarn 3 and for identifying the type A, B, C, D, E, F, G, H of yarn breakage. The memories PA, PB, PC, PD, PE, PF, PG, PH of the number of individual types A, B, C, D, E, F, G, H of breakage at the respective workstation 1 are part of the evaluation device 7 and/or the statistical evaluation device SV, to which the information about the type A, B, C, D, E, F, G, H of breakage is transmitted by the evaluation device 7.
The control software of the evaluation device 7 consists of program blocks, i.e. instructions which are designed to perform software operations for processing the output signal from the yarn monitoring sensor 66 for monitoring the physical parameters and for identifying the type A, B, C, D, E, F, G, H of yarn breakage at the workstation 1 of the rotor or air-jet spinning machine, and which ensure that the entire device for identifying the type A, B, C, D, E, F, G, H of yarn breakage according to the present invention, operates according to the required method, i.e., performs the steps of the method according to the present invention.
The computer readable medium for this invention comprises a computer program, i.e., software to perform the method according to the above paragraph.
Yarn breakage occurs during the production of yarn 3 on the spinning machine for various reasons, which can be identified in advance and classified into pre-specified types, either according to their causes or their appearance. Some of these breaks are due to defects in the sliver being processed or to contamination or wear of the components of the spinning unit, while others are due to incorrect setting of the spinning parameters on at a particular workstation, in a group of workstations or on the entire spinning machine.
Some types of breakage can only be eliminated by direct operator or automatic operator intervention and do not need to be addressed in terms of monitoring the productivity of the spinning machines and/or the entire spinning mill, wherein other types of breakage may influence the productivity of the machine or even on the productivity of the entire spinning mill.
Therefore, based on experience and observation of the various causes of yarn breakage rate, the applicant concluded that in order to increase the economy of operation of the individual spinning machines and the entire spinning mill, it would be advisable to adjust the spinning parameters on the individual spinning machines and/or in the entire spinning mill only on the basis of the types of breakage that are not random and are caused by repeated errors in the adjustment to the individual means of the workstations of the spinning machines, or by repeating faults in the processed fibrous structure 12.
Therefore, the applicant divided breakages according to the cause of their occurrence into eight types for rotor spinning machines and four basic types for jet spinning machines.
Rotor spinning machines:
Type A represents breakage with foreign matter embedded yarn end (Fig. 5a).
Foreign materials are generally coarser than normal cotton and in the technological process are separated out before spinning during blow-room and carding. If the long and strong fibrous materials are conveyed up to the spinning rotor or the spinning air-jet, they will not be spun with normal cotton fibres into a ribbon of fibres and the spun yarn will break, wherein the foreign matter is usually attached to the broken end. This type of breakage is removed by the operator, i.e. , the human operator or the attending device, and if there is a high frequency at one of the workstations, the evaluation device instructs the operator to replace the sliver can, because a large number of this type of breakage at one workstation signals low-quality sliver. Type B represents breakage with unopened fibrous end (Fig. 5b).
An unopened end is formed by a cluster of fibres at the end of the broken yarn, which is usually due to imperfect fibre opening in the opening device of the spinning unit, which may be caused by a large number of short fibres in the sliver, or by a fault in the opening device (the opening roller or the drafting device).
This type of breakage is removed by the operator and in case of a high frequency at one of the workstations, the evaluation device informs about a probable mechanical defect on the spinning unit. If the operator is a human operator, the information is displayed on the operator panel 82 on the machine.
Type C represents breakage with a part of a cotton seed at the end (Fig. 5c).
This type of breakage occurs as a result of poor cleaning of the cotton fibres in the previous operations, when there is a part of the cotton seed between the cotton fibres in the sliver being processed, around which fibres gather in the rotor and do not become spun in the ribbon of fibres, and breakage occurs.
This type of breakage is removed by the operator, and in case of a high frequency at one of the workstations, the operator receives instruction from the evaluation device to replace the sliver, or the sliver can, because a large number of this type of breakage at one workstation signals low-quality sliver.
Type D represents breakage with trash particle embedded end (Fig. 5d).
This type of break occurs mainly for two reasons, namely when there is blockage or improper suction in the suction tube of the impurity removal channel, or in case of very light waste materials, such as very small fractions of cotton fibres, present in large quantities in the feed sliver. If the suction tube becomes clogged or the suction pressure is very low, small trash particles follow the fibre path and are carried into the spinning rotor instead of entering the waste chamber and are deposited inside the spinning rotor groove. Because they are comparatively heavier than cotton fibres, these small waste particles go on accumulating in the rotor groove and after a certain time these particles come out of the rotor groove along with a ribbon of fibres and cause yarn breakage. This type of breakage is removed by the operator, and if there is a high frequency at one of the workstations, the evaluation device instructs him to replace the sliver can, because a large number of this type of breakage at one workstation signals low-quality sliver.
Type E represents breakage with a long tapered end (Fig. 5e).
This type of breakage occurs in the spinning rotor due to a low twist, which can be caused by improperly set spinning parameters on the entire machine, or by a fault at the workstation of the machine.
If this type of breakage occurs repeatedly at one workstation, the operator receives information from the evaluation device about a probable fault at the workstation. In the case of the distribution of repetitions of this type of breakage at more workstations of the machine, the evaluation device issues a command to adjust the spinning parameters on the machine, and if the repetition of this type of break concerns the entire spinning mill, the command to adjust the spinning parameters is issued on the entire spinning mill, i.e. , on all machines.
Type F represents breakage with a blunt end (Fig. 5f).
This type of breakage occurs in the rotor as a result of yarn overtwisting, which can be caused by improperly set spinning parameters on the entire machine, or by a malfunction at the workstation of the machine.
If this type of breakage occurs repeatedly at one workstation, the operator receives information from the evaluation device about a probable fault at the workstation. If the operator is a human operator, the information is displayed on the operator's panel 82 on the machine. In the case of the distribution of repetitions of this type of breakage at more workstations of the machine, the evaluation device issues a command to adjust the spinning parameters on the machine, and if the repetition of this type of break concerns the entire spinning mill, the command to adjust the spinning parameters is issued on the entire spinning mill, i.e., on all machines. Type G represents breakage between the draw-off mechanism and the winding device of yarn.
This type of breakage occurs due to improperly set spinning parameters on the entire machine or a fault at the workstation of the machine, the breakage being detected by the yarn break sensor arranged at each workstation of the machine between the draw-off mechanism 4 and the yarn traversing and winding device 5.
If this type of breakage repeatedly occurs at one machine workstation, the operator receives information about a probable defect at the workstation from the evaluation device. If the operator is a human operator, the information is displayed on the operator's panel 82 on the machine. In the case of spreading the repetition of this type of breakage at several workstations of the machine, the control system 81 of the spinning machine issues a command to adjust the spinning parameters on the machine, and if the repetition of this type of breaks concerns the entire spinning mill, a command is issued to adjust the spinning parameters in the entire spinning mill, i.e., on all machines.
Type H represents breakage caused by the yarn quality sensor.
This is a forced break of the yarn due to poor yarn quality as assessed by the yarn quality sensor, which consists of an optical sensor 6 arranged at each workstation of the machine and which senses an image of the yarn. If the yarn quality sensor is also provided with monitoring foreign matter based on the principle of reflected light from the yarn, the presence of foreign matter in the yarn may also be the cause of a forced break from the yarn quality sensor.
If this type of breakage occurs repeatedly at one workstation, the operator receives information about a probable fault at the workstation from the evaluation device 7 via the control system 81 of the spinning machine and/or control system 8 of the workstation 1., the information being displayed for the human operator on the operator panel 82. In the case of spreading the repetition of this type of breakage at several workstations of the machine, the control system 81 of the spinning machine issues a command to adjust the spinning parameters on the machine, and if the repetition of this type of breakage concerns the entire spinning mill, a command is issued to adjust the spinning parameters in the entire spinning mill, i.e. , on all machines.
Air-jet spinning machines:
The following types of breakage are particularly relevant for air-jet spinning machines:
Type A - breakage with foreign matter embedded yarn end (Fig. 5a).
Type E - breakage with tapered end (Fig. 5e).
Type F - breakage with blunt yarn end (Fig. 5f).
Type H - breakage caused by the yarn quality sensor.
The method of identification of type of breakage at the workstation 1 of the rotor or air-jet spinning machine consists in that the optical sensor 6 of yarn 3 continuously senses a predetermined portion of the length of the yarn 3, whereby information D1 about the diameter or image of the yarn 3 is continuously obtained from this optical sensing of the yarn 3 for cache memory P1. This information is cyclically recorded during spinning and subsequently erased and replaced by other information corresponding to the diameter or image of the yarn currently being processed 3. As soon as a break occurs, the yarn break sensor 41 or the optical sensor 6 issues a signal about the yarn break to the evaluation device 7, and the latter downloads from cache memory P1 information D1 about the form of the end of the yarn 3, meaning information about the visual form of the end of the broken yarn 3 before the break, during the break and up to the end of the break. From this data D1, descriptive data D2 about the appearance of the end of the break is subsequently extracted, which will enable to identify the type of breakage and classify into the appropriate type A, B, C, D, E, F, G, H of breakage, as well as to store the information about another break to the respective memory PA, PB, PC, PD, PE, PF, PG, PH of types of breakage of the respective workstation 1.
After a certain time of machine operation, the statistical evaluation device SV statistically evaluates the numbers of each type A, B, C, D, E, F, G, H of yarn breakage recorded in the memories PA, PB, PC, PD, PE, PF, PG, PH of the number of individual types of breakage at each workstation 1. This evaluation is performed for each workstation 1 and/or for the entire spinning machine and/or for the entire technological group of machines and on the basis of the evaluation it is decided, according to pre-set criteria, whether it is an individual deviation in the breakage rate of yarn 3 of a specific workstation1 of the machine, or the distribution of the breakage rate of yarn 3 in a group of workstations 1 or the distribution of the breakage rate of yarn 3 on the entire machine and a decision is made on the type of intervention and the method of intervention. The type of intervention is either the intervention of the operator, or the adjustment to the spinning parameters at the respective workstation, or in the group of workstations 1., where the same lot of the yarn 3 is spun, or on the entire machine, or in the entire technological group of machines.
For the purposes of statistical processing, the data on the type A, B, C, D, E, F ,G, H of yarn breakage and/or the memory contents PA, PB, PC, PD, PE, PF, PG, PH of the number of individual types A, B, C, D, E, F, G, H of breakage of individual workstations 1 are transmitted via existing communication channels to the central control system of the machine or spinning mill representing the technological group of machines. This information is then used by the central control system to identify the likely location of the anomaly in the spinning process and alerts the operator to the need for intervention even outside the spinning mill itself. For example, if there is an increase in the number of breakages caused by foreign matter, it will focus intervention on the point in the preparation line where the foreign matter is to be removed.
Industrial applicability
The invention can be used in spinning mills to increase the efficiency of yarn production on rotor or air-jet spinning machines. List of references
1 workstation
10 sliver can
11 sliver
2 spinning unit
20 spinning air nozzle of an air-jet spinning machine
21 opening roller of the rotor spinning machine
210 drafting device of sliver of an air-jet spinning machine
3 yarn
4 draw-off mechanism
41 yarn break sensor
5 yarn traversing and winding device
50 bobbin
66 sensor of the physical parameters of the yarn
6 optical sensor
60 radiation source
600 collimation optics
61 sensor of radiation
610 row of radiation sensitive elements
6100 radiation sensitive element
62 measuring gap for the passage of the yarn
63 light radiation
7 evaluation device
70 sensor of light reflected from the yarn
8 control system of the workstation
81 control system of the machine
82 operator's panel
9 image of the yarn
L length of the row of radiation sensitive elements
P direction of yarn movement during yarn production
P1 cache memory
A to H types of breakage
PA to PH memories of the number of types of breakage
D1 information about the physical parameters of the yarn
D2 data on the appearance of the break end
SV statistical evaluation device
OZ automatic attending device

Claims

PATENT CLAIMS
1 . A method of controlling the technological process of yarn manufacturing on a spinning machine, especially a rotor or air-jet spinning machine, in which yarn (3) is monitored by at least one sensor (66) for monitoring the physical parameters of the yarn (3), wherein the sensor (66) for monitoring the physical parameters of the yarn is coupled to an evaluation device (7) equipped with software, characterized in that the evaluation device (7) identifies the type (A, B, C, D, E, F, G, H) of breakage on the basis of information about the monitored physical parameters of the yarn (3) according to pre-set criteria and stores the information about the type of breakage for the respective workstation (1 ) in the memory (PA, PB, PC, PD, PE, PF, PG, PH) of the respective type of breakage, wherein the information from the memories (PA, PB, PC, PD, PE, PF, PG, PH) about the number of individual types (A, B, C, D, E, F, G, H) of breakage is statistically processed after collecting sufficient information about the number of individual types of breakage, wherein after evaluating the number of each type of breakage at/for each workstation and on the basis of the pre-set criteria for each type of breakage, interventions are made in the spinning process on the entire machine, group of workstations (1 ) of the machine or at the individual workstations (1 ) of the machine in order to prevent occurrence of the respective type of breakage and/or at least reduce the number of such breakages.
2. The method according to claim 1 , characterized in that during spinning, a part of the length of the spun yarn (3) is continuously monitored by the sensor (66) for monitoring the physical parameters of the yarn and information (D1 ) on the course of the monitored at least one physical parameter of the yarn (3) on a predetermined length of the yarn (3) is recorded continuously in a cache memory (P1 ),
- after the yarn (3) has broken, from the information recorded in the cache memory (P1 ) about the monitored at least one physical parameter of the yarn (3), the course of the monitored physical parameter of the yarn (3) is evaluated on a part of the length of the yarn (3) before the break, during the break up to the end of the yarn break (3), - from the evaluated course of the monitored physical parameter of the yarn (3), the breakage is classified according to pre-set criteria into one of the predefined types (A, B, C, D, E, F, G, H) of the yarn (3) breakage and the information about the type of breakage is recorded in the memory (PA, PB, PC, PD, PE, PF, PG, PH) of the number of individual types (A, B, C, D, E, F, G, H) of the yarn (3) breakage assigned to each workstation (1 ).
3. The method according to any of the preceding claims 1 or 2, characterized in that after a predetermined statistically relevant period of operation of the machine, statistical evaluation of the recorded number of breaks in the individual types (A, B, C, D, E, F, G, H) of the yarn (3) breakage recorded in the memories (PA, PB, PC, PD, PE, PF, PG, PH) of the number of individual types of the yarn (3) breakage is started for each workstation (1 ), wherein this evaluation is carried out for each workstation (1 ) and/or for a group of workstations (1 ) and/or for the entire spinning machine, and on the basis of the evaluation, a decision is made, according to the pre-set criteria, whether it is an individual deviation in the breakage rate of the yarn (3) of a particular workstation (1 ) of the machine, or whether it is distribution of the breakage rate of the yarn (3) in a group of workstations producing the same yarn (3) lot, or whether it is distribution of the breakage rate on the entire machine, and a decision is made on the type of intervention and the method of carrying out the intervention.
4. The method according to any of the preceding claims 1 to 3, characterized in that after a predetermined statistically relevant period of operation of a technological group of machines, the recorded numbers of individual types (A, B, C, D, E, F, G, H) of the yarn (3) breakage recorded in the memories (PA, PB, PC, PD, PE, PF, PG, PH) of the number of individual types of the yarn (3) breakage is started to be evaluated for all workstations (1 ) of individual machines or all spinning machines of the entire technological group of machines and on the basis of the evaluation, a decision is made, according to pre-set criteria, whether there has been an increase in the yarn breakage rate in the entire technological group above the set limit and a decision is made on the type of intervention and the method of carrying out the intervention for the entire technological group of machines.
5. The method according to claim 3 or 4, characterized in that the type of intervention is only the intervention of the operator at a specific workstation (1 ), or a request to replace or repair sliver at one or more workstations (1 ), or adjustment to the spinning parameters on the entire machine or group of workstations (1 ).
6. The method according to any of the preceding claims 1 to 5, characterized in that the physical parameters of the yarn are monitored by a capacitive sensor.
7. The method according to any of claims 1 to 5, characterized in that the physical parameters of the yarn (3) are monitored by an optical sensor (6) comprising at least one radiation source (60) and at least one radiation sensitive element (6100).
8. The method according to claim 6 or 7, characterized in that the physical parameters of the yarn (3) are monitored by a yarn (3) quality sensor.
9. The method according to claim 8, characterized in that the physical parameters of the yarn (3) are monitored by a sensor of quality and foreign matter in the yarn (3).
10. A spinning machine for performing the method according to any of claims 1 to 9, comprising a plurality of workstations (1 ) arranged next to one another, each of which is provided with means for ensuring a change of technological parameters during the yarn (3) production, and comprises a spinning unit (2) and a sensor (66) for monitoring the physical parameters of the spun yarn (3) selected at least from the group consisting of diameter, weight or homogeneity, colour, image and/or foreign matter, wherein the sensor (66) for monitoring the physical parameters of the yarn (3) is coupled to an evaluation device (7) equipped with software, characterized in that the sensor (66) for monitoring the physical parameters of the yarn is coupled to a cache memory (P1 ), which is coupled to the evaluation device (7) which contains a database of information about the course of the monitored physical parameters of the ends of the yarn breakage (3) for predetermined types (A, B, C, D, E, F, G, H) of yarn breakage and software for classifying the breakage into the appropriate type (A, B, C, D, E, F, G, H) of breakage, wherein the evaluation device (7) is coupled to the memories (PA, PB, PC, PD, PE, PF, PG, PH) of the number of individual types of breakage, which are connected to a statistical evaluation device (SV) the outputs of which are connected to information means for the operator and means for adjusting the spinning parameters at the respective workstation (1 ), or a group of workstations, or on the entire machine, or in the entire technological group of workstations (1 ).
11. The spinning machine according to claim 10, characterized in that the sensor (66) for monitoring the physical parameters of the yarn (3) is a capacitive sensor.
12. The spinning machine according to claim 10, characterized in that the sensor (66) for monitoring the physical parameters of the yarn (3) is an optical sensor (6) which comprises at least one radiation source (60) and at least one radiation sensitive element (6100).
13. The spinning machine according to claim 12, characterized in that the optical sensor (6) comprises a linear radiation sensor (61 ), a gap being formed between the radiation source (60) and the linear radiation sensor (61 ) for the passage of the yarn (3).
14. The spinning machine according to any of claims 11 , 12 or 13, characterized in that the sensor (6) is formed by a yarn (3) quality sensor.
15. The spinning machine according to claim 14, characterized in that the sensor (6) is formed by a sensor of the yarn (3) quality and foreign matter in the yarn (3).
16. The spinning machine according to claim 15, characterized in that the sensor (6) /is formed by the sensor of the quality and foreign matter in the yarn (3), comprising a linear radiation sensor (61 ) which is arranged in the radiation direction behind the yarn (3) and a sensor (70) of radiation reflected from the yarn (3), wherein between the radiation source (60) and the linear radiation sensor (61 ) is formed a gap for the passage of the yarn (3).
17. A computer program containing instructions for causing the spinning machine according to any one of claims 10 to 16 to perform the steps of the method according to any of claims 1 to 9.
18. A computer-readable medium having stored a computer program thereon according to claim 17.
PCT/EP2023/083373 2022-12-12 2023-11-28 A method of controlling the technological process of yarn manufacturing on a spinning machine, a spinning machine for performing the method, a computer program for performing the method on the spinning machine and a computer-readable medium with the computer program WO2024126031A1 (en)

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