Classifications

• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01H—SPINNING OR TWISTING
  • D01H13/00—Other common constructional features, details or accessories
  • D01H13/14—Warning or safety devices, e.g. automatic fault detectors, stop motions ; Monitoring the entanglement of slivers in drafting arrangements
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01H—SPINNING OR TWISTING
  • D01H13/00—Other common constructional features, details or accessories
  • D01H13/32—Counting, measuring, recording or registering devices

Definitions

• the invention relates to a method for rectifying faults on machines, in particular on spinning machines, fault signals being sent from the machine to a process control computer which controls the remedy of the faults.
• blinking lights in a spinning room or on a single machine or corresponding acoustic signals are known as alarm systems.
• these alarms are non-specific, place unnecessary strain on the staff and do not indicate the type of fault, the location and the priority.
• Optical alarm lights must be attached from everywhere, acoustic signals are often difficult to hear due to the background noise of the machines.
• Screen monitoring systems for entire machine groups are also known. However, this requires a person who continuously monitors the screen or who has to go to the screen after an alarm.
• DE-OS 31 35 333 discloses a method for controlling the use of an operator or a mobile maintenance device in a spinning plant with a large number of operating points, according to which operating cases occurring are recorded by type and location and are transmitted to a central data store.
• This central data memory is queried in terms of its need for operation (propensity to damage) according to operating cases that have occurred and at least the location, and possibly also the type of operation to be performed, of the operator's most frequent operating case or the mobile maintenance device is given up as the operating point to be serviced.
• This method has the disadvantage that only the query itself detects a malfunction.
• the inventor has set itself the goal of developing a method of the type mentioned above, with which occurring faults can be eliminated as quickly as possible according to their priority.
• the solution to this task is that the process control computer controls an alarm call transmitter which calls a desired specialist to a specific machine to remedy the fault.
• planned maintenance such as lubrication, cleaning, regular inspection, preventive replacement or refurbishment of components, and the elimination of incidental faults.
• maintenance is carried out by unskilled personnel trained on the machine in question.
• the organization corresponds to a normal, productive work assignment.
• the supervision and control is carried out by a professionally qualified specialist who also trains the staff.
• a basic activity (“filling work") consists of demanding but not fixed maintenance work or the supervision of the maintenance team.
• special tasks such as the diagnosis and troubleshooting.
• it is stressful for the specialist if, in the case of several simultaneous faults, he has to grasp the overall situation, assess it and determine the priority in processing himself.
• the fault in the machine itself should preferably be classified. This means that the fault is assigned to a specific specialist, for example a foreman or a maintenance specialist, and given a specific priority.
• This information is then passed on from the machine to the process control computer, which monitors a large number of machines and collects corresponding signals.
• the process control computer then again arranges the signals of the machines according to their priority and accordingly calls a desired specialist via the alarm call transmitter.
• the process control computer also has the task of storing the status and the operations for each machine in the form of a log book, so that any faults that occur are recorded consistently and reliably, without the staff being burdened with administrative work.
• the location and type of the fault should be specified in the alarm call of the alarm call transmitter itself, so that the specialist can immediately find the right machine and take appropriate repair material with him to remedy a specific fault. On the machine itself, he can then read off on a display device where the error is that needs to be remedied.
• the basic idea of the present invention is therefore to create an alarm system which collects fault reports from a large number of machines and transport systems, continuously evaluates them according to the process-related priorities, alerts the responsible personnel and informs them of the location and type of the fault.
• the fault rectification is also monitored, since the specialist only issues a corresponding message when the fault is rectified. Furthermore, a fault log is kept for the entire system and also for each individual machine.
• the right specialist is automatically guided through the process control computer of the system to the right place with the right tools.
• Appropriate treatment of a large number of faults takes place, even if they occur overlapping, by integrating the priority evaluation into the process control.
• a reliable logbook is kept all disturbances, which in turn serve as the basis for improvements.
• a corresponding alarm system for carrying out the method according to the invention consists of various components.
• the process control computer which receives appropriate signals from the individual machine in the event of a fault, should be mentioned here in the first place.
• these signals are generated by the machine control itself, the signal preferably containing information about the urgency of the fault rectification, the type of fault and the group of people to be requested (operator, mechanic, foreman).
• a central evaluation of the malfunction signals then takes place in the process control computer, which evaluates the individual malfunctions, classifies them into a priority queue and stores the status of the individual machines in the manner of a log book.
• This function is preferably taken over by an existing process control computer which is also responsible for other functions.
• the process control computer also has the task of central monitoring of the individual specialists, which continuously shows the availability of the individual people, knows and takes into account their possible uses and stores their uses using a log book. This function is also taken over by an existing process control computer that is also responsible for other functions.
• the process control computer is assigned an alarm call transmitter with a selective call for the individual receivers.
• This alarm call transmitter is in radio communication with the receivers that the individual specialists carry with them.
• This personal call receiver preferably also has an alphanumeric display for short texts, so that the specialist can already be informed of the location and type of the fault. In this way, the specialist can carry the specific equipment required.
• a communication network connects the machine to the process control computer, and both the machine and the process control computer have the necessary programs.
• This combination of components in an alarm system according to the invention largely uses devices which are required anyway for guiding the production process. It is therefore significantly cheaper than comparable systems. Only the alarm call device and the programs for the additional functions of the process control computer and possibly the machine are required as additional parts.
• FIG. 1 is a block diagram representation of components of an alarm system according to the invention and their linkage
• FIG. 2 is a block diagram representation of software modules of the alarm system according to FIG. 1,
• FIG. 3 is a plan view of a receiver
• FIG. 4 shows a schematic representation of a spinning mill for the production of combed yarns from cotton or cotton / chemical fiber blends
• FIG. 7 shows an "area” according to FIG. 6, further details of the communication connections within the area being explained and
• FIG. 8 shows further details of a system according to FIG. 7.
• each machine 1 has a machine control 4, the reverse sensors 5, in particular for determining faults, and a display plus keyboard 6.
• the corresponding machine In the event of a fault, the corresponding machine emits a signal via the network 2 to the host computer 3. As a rule, the signal is output via the machine control 4, the signal being intended to contain information about the type of fault, the urgency of the fault rectification and the group of personnel to be requested (operator, mechanic, foreman).
• the process control computer 3 receives the fault signals, evaluates the individual faults itself and arranges them in a priority queue. The status of the individual machines is also stored in the process control computer 3 in the manner of a log book.
• the process control computer 3 preferably also performs the central monitoring of the individual groups of people. This includes knowledge of the availability of each individual person, their possible use and the storage of the assignments using a log book.
• An alarm call transmitter 7 can be controlled by the process control computer 3.
• This alarm call transmitter 7 has a selective call for individual receivers, in particular pocket receivers, which are identified by the reference number 8 and are shown by way of example in FIG. 3.
• the corresponding radio connections 9 are indicated by dashed lines.
• a master M, a maintenance specialist W or an operator B are informed about these receivers 8, which are generally pocket receivers and emit a sound signal or have a short text display 8a.
• the correspondingly alarmed person can now go to the corresponding machine la-le, where the display device 6 gives them complete information about the location, type and urgency of the fault.
• These gears are marked with dashed numbers 10 and 11 for the operator and the maintenance specialist.
• a terminal 13 should also be accessible to the master M via a path 12, from which he can read information or enter new information. This terminal is usually in its permanent place of work.
• the process control computer 3 is also connected to an operations control computer 14, wherein the information given by the process control computer to the operations control computer 14 can be called up by a operations manager L via a terminal 15.
• This combination of components according to FIG. 1 largely uses devices which are required anyway for the management of the production process.
• the alarm call device and the programs for additional functions of the process control computer or on the machine are essentially required as additional parts. These additional programs are shown schematically in FIG. 2.
• An alarm evaluation 16 and an alarm dialog 17 result on the machine la-le as additional programs.
• the process control computer 3 is equipped with the following programs: priority setting 18, personnel scheduling 19, alarm evaluation 20 (similar to alarm evaluation 16) and alarm statistics 21.
• the process control computer 14 is also assigned a process simulation 22. This creates a prediction of the consequences of the malfunctions that have occurred on the process flow and production. This prediction again influences the priority classification of the individual interventions 18 and is accessible to the master M via the dialogue 17.
• the alarm system according to the invention works as follows:
• a malfunction is detected on machine 1 or the transport system.
• the fault is classified in the machine according to the type and urgency of the intervention. A classification is given below as an example. A fault is found
• the machine has failed due to a fault.
• the machine has only limited operability due to a fault c) machine as a result of winding d) machine with a high thread breakage rate as a result of contamination e) lubrication interval exceeded.
• intervention of the maintenance specialist is immediately necessary; to b) intervention by the maintenance specialist is recommended; * to c) control by operator immediately necessary; d) Control by the operator is recommended; to e) inspection or maintenance work without time pressure.
• the controller sends the following signals to the process control computer, the abbreviations meaning:
• the Jerusalemnessens ⁇ ⁇ r 3 which receives appropriate signals from a plurality of machines 1, classifies them and arranges them according to the priority. Then there he sends corresponding signals to the alarm call transmitter, via whose paging the corresponding maintenance specialists or operators can be reached. This person then goes to the notified machine, where their location of the fault and the intervention to be expected is displayed. The person then acknowledges the alarm, rectifies the fault and reports the success or the result.
• the manager L's main task is to allocate personnel and adjust process parameters. The latter is especially true for changing priorities.
• the spinning mill shown in FIG. 4 comprises a bale opener 120, a coarse cleaning machine 122, a mixing machine 124, two fine cleaning machines 126, twelve cards 128, two draw frames 130 (first draw frame passage), two comb preparation machines 132, ten Combing machines 136, four lines 138 (second line passage), five flyers 140 and forty ring spinning machines 142.
• This is one today conventional arrangement for the production of a so-called combed ring yarn.
• the ring spinning process can be replaced by a newer spinning process (eg rotor spinning), in which case the flyers are then superfluous.
• the explanation in connection with conventional ring spinning is also sufficient for the application of the invention in connection with new spinning processes.
• the winder which is eliminated in any case for new spinning processes (for example rotor spinning).
• the spinning mill according to FIG. 4 is again shown schematically in FIG. 5, in the latter case the machines having been combined into “processing stages”.
• the bale opener 120 and the coarse cleaning machine 122, mixing machine 124 and fine cleaning machines 126 together form a so-called cleaning shop 42, which supplies the carding machine 44 with largely opened and cleaned fiber material.
• the fiber material is transported from machine to machine in a pneumatic transport system (air flow), which system is terminated in the carding machine.
• the cards 128 each supply a band as an intermediate product, which has to be deposited in a suitable container (a so-called "can”) and transported further.
• the first route passage (through the routes 130) and the second route passage (through the routes 136) each form a processing stage 46 or 52 (FIG. 5).
• the combing preparation machines 132 form a processing stage 48 (FIG. 5) and the combing machines 134 form a processing stage 50 (FIG. 5).
• the flyers 138 form a spin xing stage 54 (FIG. 5) and the ring spinning machines 140 form a final spinning stage 56 (FIG. 5).
• the end result of the schematically illustrated spinning process is influenced by a large number of factors which are not to be dealt with individually here. An important factor is the raw material to be processed, which can be represented as a group of individually ascertainable fiber properties (eg fiber fineness, fiber type, fiber strength, etc.).
• Material flow tracking therefore plays an essential role for the spinning mill. 4 shows the complexity of this task - imagine the number of possible “paths" between bale storage (for raw cotton) up to the final spinning stage. In the past this task was solved by the manager and his teams.
• the area B1 includes the blowroom 42 and the carding machine 44 (FIG. 5).
• the area B2 comprises both the route sections 146, 152 (FIG. 5) as well as the combing preparation stage 148 and the combing 150.
• the area B3 comprises the flyer 154 and the final spinning stage 156 (FIG. 5), possibly also a winder.
• the low-staff spinning mill can of course only be achieved by automating the functions previously performed by the teams. These functions include, in particular, the transport of the material between the processing stages and the introduction of the material into the machine, which it should process further.
• the staff is also responsible for monitoring the system and troubleshooting. The assumption of part of this task by the automation and the control system is explained in more detail below with reference to FIG. 7.
• the area B3 (FIG. 6) serves as an example here.
• FIG. 7 A practical implementation of the area B3 for an automated system is shown in FIG. 7, but still schematically around the IT aspects of the system to represent.
• the system part shown comprises (in the order of the process stages, ie the "chaining" of the machines):
• Each processing stage 300, 320, 330 comprises a plurality of main work units (machines), each of which is provided with its own control. This control is not shown in FIG. 7, but is explained in more detail below. Attached to the respective machine control are robotics units (automatic controls) that are directly assigned to this machine. A separate doffer is provided for each flyer of level 300 in FIG. 7 - the function "flyer opening" is indicated in FIG. 7 with the box 302.
• One possible implementation is e.g. shown in EP 360 149 and in ⁇ DE-OS 3 702 265.
• an automatic control unit per row of spinning stations for operating the spinning stations and a push-on operation for the roving feed are also provided for each ring spinning machine of stage 320.
• the "spinning station control" function is indicated by boxes 322, 324 (one box per row of spinning stations) and the "roving feed” function is indicated by boxes 326.
• a possible embodiment is shown, for example, in EP 394 708 and 392 482.
• the roving transport system 310 is also provided with its own control system, which will not be explained in more detail here.
• System 310 includes a roving bobbin cleaning unit before being returned to flyer stage 300.
• the function "roving bobbin cleaner" is indicated by the box 312.
• a possible embodiment of this plant part is shown in part in EP 392 482.
• the ring spinning machines of stage 320 and winding machines of stage 330 together form a "machine network", whereby the transport of the cops to the winding machines is ensured. This assembly is controlled by the winder.
• a network 350 is provided, whereby all the machines of the stages 300, 320, 330 and the system 310 for signal exchange (data transmission) are connected to a process control computer 340.
• the computer 340 directly operates an alarm system 342 and an operator 344 e.g. in a control center or in a master's office.
• a very important function of the rewinding of ring spun yarn is the so-called yarn cleaning, which is indicated by the box 360.
• the yarn cleaner is connected to the process control computer 340 via the network 350. Yarn defects are eliminated by this device and at the same time information (data) is obtained which enables conclusions to be drawn about the preceding process stages.
• the thread cleaning function is carried out on the winder.
• Each machine is also provided with a "user interface" which is connected to the respective control and enables human-machine (or even robot-machine) communication.
• the "user interface” can also be referred to as an "operating console”.
• An example of one User interface is shown in DE-OS 37 34 277, however not for a ring spinning machine, but for a draw frame. The principle is the same for all such controls.
• the system is programmed and designed in such a way that the host computer 340 can provide operating support via the user interface of the respective machine, i.e. the master computer can send control commands via the network 350 and the machine controls can receive and follow such control commands, so that the state of the user interface is determined by the master computer 340 via the respective controller.
• the machine can of course be provided with more than one "operator interface". It is important here that the or each such user interface is connected to the machine control so that signals can be exchanged between the user interface and the machine control. Where e.g. If an auxiliary device on a machine is provided with its own user interface, but the device is subordinate to the machine control system, then the operating surface of the device must be assigned to the machine.
• FIG. 8 shows a possible variant of the architecture for a process control according to FIG. 7.
• FIG. 8 again shows the master computer 340 and the network 350 together with a computer 390 of a machine control of the system (for example the roving transport system 310, which is used to explain the Information can be equated to a "machine").
• Each computer 340, 390 has memories 343, 345 or 391 assigned to it and drivers 347, 349 or 393, 394, 395, 396.
• the drivers 349 and 394 determine the interfaces necessary for the computers 340, 390 to communicate with them respective user interfaces, indicated here as display, operation and printer.
• the driver 347 determines the interface between the host computer 340 and the network 350 and the driver 393 the interface between the network 350 and the machine controller 390.
• the driver 395 determines the interfaces between the machine control 390 and the drives (actuators) controlled thereby.
• the driver 396 determines the interface between the machine control 390 and the sensor system assigned to it.
• Important actuator elements in a spinning machine are those which are used for "stopping" a spinning station, “stopping” here being understood as “effectively producing spinning station”. In most cases, when a single spinning station is shut down, not all the working elements of this spinning station are brought to a standstill, but the spinning is interrupted in this spinning station. This can e.g. by cutting off the material supply and / or by creating a thread break.
• a largely automated machine e.g. the rotor spinning machine
• this can easily be done from a central machine control by one or the other possibility.
• the drive to the feed roller can be interrupted in order to prevent the supply of material to the opening roller or the rotor of the spinning station.
• a so-called quality check can also be carried out in the quality monitoring of the spinning station in order to interrupt the thread run.
• a sliver clamp to interrupt the supply of material will be important in all types of machines where the original material is delivered to the spinning elements via a drafting system, because normally it is impossible to park an individual position of a drafting system.
• An actuating device can of course also be assigned to the sliver clamps of the individual spinning positions. These can then also be operated from a central machine control. Examples of such match clips can be found in EP 322 636 and EP 353 575.
• the invention is implemented in a system according to FIGS. 7 and 8, ie in a system in which at least one machine controller has a user interface and the process control computer uses this user interface to communicate with a person on this machine can.
• This arrangement makes it relatively easy to ensure that a definite meaning is assigned to a certain signal in the entire system controlled by the computer.
• This can be compared to a system according to which the operator support is provided via a system independent of the machine controls, for example according to US 4 194 349.
• the advantages of the combination according to this invention are particularly pronounced if a process control computer influences both the operator support and the control of the machines , for example in a doff management system for ring spinning machines, similar to a system according to US 4,665,686.
• the operator support via the operator interface on the relevant machine naturally also ensures that the help is offered where it is necessary.
• the alarm or call system must of course still ensure that the operator is informed of the urgency or priority of the operator call or that the correct operator or operator (doffing aid, maintenance, thread break repair, etc.) is addressed to the person concerned Machine is called.
• An instruction can be given to the operator via the user interface to take an action which cannot be carried out by the machine control itself, e.g. because the necessary actuators are not available in the relevant machine or are not under the control of the machine control.
• An example of such an action is the decommissioning of a poorly working spinning station, where the machine control cannot intervene directly in the spinning stations.
• the operator is also preferably able (or is even "forced") to cause the generation of a signal which represents the execution of the instruction and communicates this to the machine control or the process control computer.
• the operator support therefore preferably comprises the following aspects:
• this person should receive additional information about the necessary use at or near the place of use (e.g. localization of a defect within a machine or a component or details of the necessary changes to the machine when changing a lot) .
• the process control computer only needs information from the person regarding the success or failure of its use, in particular if this success or failure has an effect on the efficiency of the system.
• the overall problem is solved as follows: - The personnel is relieved by the process control computer regarding the monitoring of the system;
• the staff can be made aware of a necessary operation selectively, only the minimal information having to be conveyed via the call system;
• the additional information is (if necessary) available on the user interface of the machine or auxiliary device concerned;
• Feedback from man to the computer is preferably transmitted via the machine itself, e.g. the user interface comprises signal generating means for sending a suitable feedback via the network to the computer.
• the call system merely notifies a recipient (e.g. by a "beep") that he is required for an operation. He receives the necessary information about the location separately e.g. via a telephone network or a central display.
• a recipient e.g. by a "beep”
• He receives the necessary information about the location separately e.g. via a telephone network or a central display.
• the more detailed operator support is preferably available on site. This possibility therefore requires a "distribution" of the system:
• the call, the urgency and the announcement of the place of use are preferably combined in a receiving device.
• a process control computer (with or without an operations control computer) is also able (if the appropriate programming is provided) to provide further support, namely by simulating the operating assignment over an upcoming period of use.
• the controlled system (or the controlled system part) is "represented” by equations. These equations represent connections between the essential performance data of the system (of the system part).
• "Scenarios” can be worked through according to the program on the basis of various assumptions, whereby “optimal” or “problematic” scenarios for the operational use can be determined. The operator support can then are adapted accordingly in order to follow “optimal” scenarios as far as possible or to avoid “problematic” scenarios.
• the period of use that should be simulated depends on several factors. In any case, the available computing capacity must be taken into account. The simulation must not take up so much computing capacity that the other tasks of the process control computer suffer. It can therefore make sense to pass this task on to an operations control computer if such a computer is available and has free capacity. If, however, the capacity is also available in the process control computer, the simulation can be carried out on the "process control level".
• the "simulated period of use” should include more than a single operating layer, so that the "second” or a further layer does not merely have to solve problems from the "optimized” layer.
• the spinning mill is geared towards “flexible manufacturing” (with frequent changes of batches or assortments), there is no point in simulating many operating shifts, since the whole organization tends to change quickly to adapt to one ⁇ must change situation.
• relatively stable production conditions can be maintained over a longer period, it is more worthwhile to simulate correspondingly longer periods and to select "long-term" optimal scenarios.
• the operator is usually unable to correctly assess the priority in troubleshooting.
• the computer does this as follows:
• the computer takes over the reporting of the operating status of the individual machines. This is a general function of every process control system.
• the computer takes over the number of non-productive spindles from a ring spinning machine. Certain limit parameters are defined in the computer as a function of the current operating state. An alarm is generated when these limits are exceeded.
• a ring spinning machine is in the current operating state "start after doffing". The limit for the proportion of non-productive spindles is 10%. This limit is given by the correction capacity of the operating robot (see also DE-OS 39 28 755).
• the generated alarm is classified by the computer using a priority list.
• the priority is determined by the computer on the basis of predetermined rules.
• the extrapolated follow-up costs are decisive for priority classes 3 - 5 (see above).
• the computer determines this with a simulation based on the current operating state of the system.
• the computer keeps a schedule of the individual operators. It compares the priority of the current job with the priority list and generates an alarm call to the operator with the current task of the lowest priority as soon as an alarm with a higher priority is present.
• the operational plan of the operator team is shown on the display of the process control system and can be adapted by the supervisor (master, operations manager).
• a particular advantage of this procedure is that no distinction is made between maintenance work and troubleshooting. These limits are very fluid in operational practice. Especially the juxtaposition of planned maintenance work and unplanned Troubleshooting must be mastered for low-personnel operation. Systems that are restricted to one or the other task come into conflict with operational practice.
• the generally known solution consists in that any operator acknowledges the detection of the alarm. The fault condition remains until it is remedied, while the alarm is "silent" and limited to a fault display. This display disappears when the fault has been rectified.
• the computer has determined a new application for the operator. It transmits this via the call transmitter to the recipient of the particular operator.
• the receiver alerts the operator with a conspicuous signal and at the same time shows the new location and the new task (keyword).
• the operator acknowledges the recognition of the new order at the receiver.
• the operator completes his current work, goes to the new location and uses the user interface of the machine in question to orient himself about the details of the order.
• the operator executes the job. If this is recognized by the control of the machine in question, this leads to the disappearance of the faulty state and thus automatically to the next job order (see 2.). If the control in question cannot determine the lifting directly via its sensors, the operator reports that the work has been carried out via the local user interface.
• the operator keys in his detection / call for help / alarm on site on the machine's user interface.
• This alarm is treated like any other alarm originating from the machine control and thus automatically leads to the involvement of additional operators under changed priorities.
• the alarm system should support the transmission of messages to the individual operator or user without having to leave their work place. They should do without an extensive text display so that they do not hinder the user due to their dimensions and weight.
• the supervisor keys in his message in the office on the user interface of the process control computer.
• the process control system uses the alarm list to determine the machine on which each operator is working.
• the operator is called to the machine's surface by means of a normal alarm (urgency according to the input of the superior). 5. Occupational psychological stress due to multiple alarms
• the individual inserts are taken into account with a minimum time which is sufficient to run under 'nor ⁇ painting conditions. During this time, competing alarms of the same priority are completely suppressed.
• the number of alarms per shift is evaluated by the computer and in a "load factor" analogous to the professional qualification of Eedier.cr ⁇ .
• the computer takes this load factor into account in the same way as the operator's professional qualifications.
• the exemplary applications 1 to 5 are possible individually or in combination.

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• 1991
  • 1991-04-23 WO PCT/CH1991/000097 patent/WO1991016481A1/de not_active Application Discontinuation
  • 1991-04-23 EP EP91907541A patent/EP0481033A1/de not_active Withdrawn
  • 1991-04-23 US US07/778,813 patent/US5347449A/en not_active Expired - Fee Related
  • 1991-04-23 JP JP3506722A patent/JPH05500838A/ja active Pending

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