EP0512442A1 - Planning and control of the production for a spinning installation - Google Patents

Abstract

An auxiliary device for use in production planning in a spinning mill comprises means for determining a production plan which provides for the distribution of a specific production quantity of a predetermined yarn over machines of the final spinning stage of the spinning mill. There are also means to estimate the production quantity per unit time per machine, specifically in dependence on the yarn to be produced, on the machine settings provided and on the environment of the relevant machine. The effect of the machine environment can be taken into account in the form of an empirically verifiable performance. <IMAGE>

Description

The invention relates to devices, methods and systems for supporting the head of a plant which consists of textile machines (in particular spinning machines).

State of the art

The "automation" of production planning and control by means of a computer has been proposed in US 3922642. A system according to this US patent would be able, based on information regarding the total production required for each yarn type over a month (column 11, lines 35 to 40), to determine the corresponding machine allocation of the yarn-producing machines, to control the final spinning machines accordingly, and to prepare the preparation machines to operate in such a way that the final spinning machines are continuously supplied with original material according to the production plan. We are still a long way from such a facility today.

It is also known to store sets of operating data (“recipes”) and to call them up from the machine if necessary (DE-C-3438962 or DE-A-3928831). Furthermore, it has already been proposed to define a "speed curve" for the ring spinning machine in order to change the spindle speed according to a predetermined program during the formation of the bobbin, e.g. according to US 4944143 or EP 49013 or DOS 3928755.

The invention

This invention is intended to support the work of people who still do the basic work of production planning and control of a spinning plant. An entire spinning mill should not necessarily be taken into account here - the help of the system is also useful if, for example, only the production planning for the final spinning stage is supported.

According to a first aspect of the invention, an auxiliary device is provided for use in production planning in a spinning mill. The auxiliary device comprises means for establishing a production plan which provides for the distribution of a specific production quantity of a given yarn over machines of the final spinning stage of the spinning mill. Means are also available for estimating the amount of production per unit of time per machine, depending on the yarn to be produced, on the machine settings provided and on the environment of the machine in question. The impact of the machine environment can be taken into account in the form of an empirically verifiable benefit.

The information required for the production of a particular yarn can be summarized in at least one "operating data record" ("recipe"), and a separate recipe can be provided for each machine for this yarn. The production quantity per unit of time for a specific machine can then be determined using the corresponding recipe.

The auxiliary device can be provided as an element of a production planning and production control system ("PPS system"), means being provided to selectively transfer the recipes to their respective machines (after production planning).

The invention sees a process control system in a second aspect for at least the final spinning stage of a spinning plant. The system is provided with means for establishing recipes for the manufacture of various yarn products ("articles") by the various machines of the controlled final spinning stage, each recipe comprising a compilation of at least the essential operating data of a particular machine for the manufacture of a particular type of yarn. The system also has means for establishing a production schedule consisting of production orders, each order providing at least a predetermined amount of a particular yarn product and determining the distribution of the required amount over a plurality of the production sites of the controlled final spinning stage, only for the fulfillment of a given order those machines can be taken into account for which a recipe for the production of the corresponding yarn type already exists. The system also includes means for causing the recipe for fulfilling an order determined according to the plan to be or can be made effective on a machine defined according to the plan at a time determined according to the production plan.

The type of "effectiveness" of the recipe on the appropriate machine must at least be adapted to the nature of the machine itself. Insofar as the machine is designed and programmed to adjust itself according to control commands of the process control system, the "effectiveness" of the recipe can provide for such a readjustment of the machine (without human intervention). If, however, the machine cannot readily respond to a control command from the process control computer, the appropriate intervention by the operator must be provided, for which the recipe can be made effective by the relevant values to be set by the operator on the machine (or at least nearby) of the machine) of the controls.

Means can be provided to transfer the production schedule to the machines, e.g. by transferring the recipes determined by the plan to the corresponding machines in an order specified by the plan. A communication system for use in transmission has been described both in our Swiss patent application No. 189/91 from January 23, 1991 and in our Swiss patent application No. 1025/91 from April 5, 1991.

The machines and the system can be coordinated with one another in such a way that only a small number of recipes are stored in one machine at the same time. For example, only two recipes can be present in the machine at a given time, namely the currently active recipe and its successor recipe.

The schedule preferably defines the order rather than the times for the transfer of the recipes to the machine.

In another aspect, the invention provides a production planning and control system ("PPS system") having means for defining an article and means for establishing a recipe for manufacturing the article on a particular machine. The system is arranged in such a way that the setting of the article together with the setting of the recipe gives an empirically verifiable estimate of the production of this machine when the article is produced according to this recipe. This estimate can appear in a suitable form at an output from the PPS system, for example on a display device on a user interface, or as a data signal for transmission to, for example, an operations control computer.

The empirically verifiable estimate of the production consists e.g. from a mathematically determinable maximum production and an empirically verifiable utility value. The maximum production that can be calculated arises from the machine configuration and the machine settings.

The means for specifying an article can consist of a means for specifying a name that uniquely identifies the article and a corresponding recipe. In this case, all information about the properties of the corresponding product is in the recipe, which therefore includes both information about the product and information about the necessary machine settings. The recipe preferably also contains information on the machine configuration which, together with the settings, enables a calculation of the maximum production of the product. The information regarding the empirically verifiable efficiency can also be included in the recipe.

Fig. 1

schematisch einen Querschnitt durch eine Ringspinnmaschine als Beispiel der Maschinentypen, die zur Anwendung der Erfindung besonders geeignet sind;

Fig. 2

eine "Drehzahlkurve" für den Betrieb einer Maschine nach Fig. 1;

Fig. 3

einen Kops, der durch die Maschine nach Fig. 1 mittels einer Drehzahlkurve nach Fig. 2 hergestellt werden kann;

Fig. 4

eine schematische Darstellung vom Layout einer Spinnereianlage mit Spinnmaschinen nach Fig. 1 und Vorbereitungsmaschinen zur Belieferung der Spinnmaschinen mit zu verspinnendem Vorlagematerial;

Fig. 5

eine schematische Darstellung der Anlage nach Fig. 4, wobei die Einzelmaschinen zu "Prozessstufen" zusammengefasst werden;

Fig. 6

eine mögliche Zuordnung der Prozessstufen nach Fig. 5 zu Prozessleitrechnern;

Fig. 7

eine schematische Darstellung einer Kommunikationsverbindung zwischen einem Prozessleitrechner und den von ihr gesteuerten Maschinen;

Fig. 8

weitere Einzelheiten der Kommunikationsverbindung nach Fig. 7.

Fig. 9

bis 12 zeigen Masken eines Systems nach dieser Erfindung.

The invention will now be explained in more detail using exemplary embodiments and the figures. It shows:

Fig. 1

schematically shows a cross section through a ring spinning machine as an example of the machine types that are particularly suitable for application of the invention;

Fig. 2

a "speed curve" for the operation of a machine of FIG. 1;

Fig. 3

a cop, which can be produced by the machine of Figure 1 by means of a speed curve of Figure 2;

Fig. 4

a schematic representation of the layout of a Spinning plant with spinning machines according to FIG. 1 and preparation machines for supplying the spinning machines with original material to be spun;

Fig. 5

a schematic representation of the system of Figure 4, wherein the individual machines are combined into "process stages";

Fig. 6

a possible assignment of the process stages according to FIG. 5 to process control computers;

Fig. 7

a schematic representation of a communication link between a process control computer and the machines controlled by it;

Fig. 8

Further details of the communication link according to FIG. 7.

Fig. 9

through 12 show masks of a system according to this invention.

1 to 3, the ring spinning machine (as an example for spinning machines) will first be explained, after which certain aspects of the production of a yarn on a ring spinning machine will be explained. A spinning plant with a process control system is then explained with reference to FIGS. 4 to 8. The use of the process control system as an aid in production planning according to this invention is then further explained with reference to FIGS. 9 to 12.

The ring spinning machine

In this application, the ring spinning machine serves as an example of a "slitting machine". Other slitting machines are flyers, the spinning machines of the new spinning processes (Rotor spinning machines, jet spinning machines), winding machines, twisting machines (eg double-wire twisting machines) and false-wire texturing machines for processing continuous filaments.

FIG. 1 is a copy of FIG. 15 of our European patent application No. 419968. The machine 220 of FIG. 1 comprises a double-sided frame 226 which stands on the floor 224 above foot parts 222. The stable frame 226 carries two rows of spinning stations, which are each arranged on one side of a central plane CP of the machine. In a modern machine, each such row of spinning positions contains between 500 and 600 closely spaced spinning positions.

Each spinning station comprises a drafting system 228, thread guide elements 232 and a bobbin-forming unit 230. The unit 230 contains individual working elements, e.g. Spindle 231, ring and runner, which are carried on an up and down movable ring bench 229, but do not play a role in this invention and are not shown individually. These elements are known to the person skilled in the art and are e.g. can be seen from EP-A 382943. A doffing machine is provided for each row of spinning stations, which serves all spinning stations of the spinning station row assigned to it at the same time. The doffing machine for the left row of spinning stations is indicated schematically in FIG. 1 by reference number 237. The doffing machine for the right row of spinning positions is not shown. These machines are not described in detail here, details of which can be found from EP-A 303877.

The machine is also assigned at least one operating device 239, which can be moved along the respective row or the rows of spinning stations and can perform operating operations at the individual spinning stations. Details of a such operating device can be found, for example, in EP-A 388938.

The frame 226 carries a gate 236 which is formed from vertical rods 238 and cross members 240. In a system according to EP 419968, each cross member 240 can be provided with an extension 258, so that rails 256 can be mounted on the outer ends of the cross members 34. The rails 256 extend in the longitudinal direction of the machine and each rail serves as a guideway for a trolley train which leads new spools 254 to the gate 236. Details of such a trolley train can be found in CH 3779/89.

The transport system for the supply spools is not an essential aspect of this invention. The dashed parts of FIG. 1, which are all directly related to the coil transport, are not described in detail here. This applies both to the new introduction of supply spools from the trolley train into gate 236 and to the further transport of the used spools 252 into a "conveying space" 250 on the central plane CP. An alternative solution for the transport task can be found in our Swiss patent applications 4113/90 from December 21, 1990 and 3795/90 from November 30, 1990. However, the present invention can also be used if there is no automated transport system for the supply spools. The rest of the description therefore deals primarily with the parts of the machine which are shown in full and which are present in all cases.

The carriers 240 are provided with hanging pins 242 for supply spools 244, 246, which supply the individual spinning stations with roving.

The machine configuration

This term refers in particular to machine parameters, whereby different individual machines can differ, but are specified in a specific machine because they are fixed during the construction of this machine and can only be changed afterwards by means of a major modification. Examples of such parameters are: the number of spinning positions (spindles), the ring diameter, the tube length (i.e. the length of the thread carrier that can be used to form a bobbin in this machine). These parameters have a significant influence, among other things, on the yarn production of the machine per unit of time.

Other examples of such parameters are the (spindle) pitch (i.e. the distance between adjacent spindles in a row) and the whorl diameter (i.e. the diameter of the drive whorl on the spindles of a machine with a central drive). These parameters have no direct influence on the yarn production per unit of time, but nevertheless on the economy of the yarn manufacturing process, e.g. about energy consumption and the attainable use of space in the spinning hall.

The actuators of the (ring) spinning machine

The machine's actuators include both the installed and attached elements and units. The actuators for the built-in elements comprise at least drives for the spindles 231, the drafting systems 228 and ring bench 229. A modernly designed system (single drive) for driving the spindles, ring bench and drafting systems of a ring spinning machine is shown in EP 349831 and 392255, after which for each spindle and a separate drive motor is also provided for individual drafting system rows. The most used today Drive system (central drive) for the ring spinning machine comprises a main motor in the drive head 235 of the machine and transmission means (for example longitudinal shafts, belts or gear wheels) in order to transmit the drive forces from the main motor to the drive elements.

In each case in a machine according to FIG. 1, an additional motor must be provided for the doffing devices 237. The actuators for the built-in elements also include the drives for the transport devices for cops (e.g. according to DOS 3610838) or for empty sleeves in the attachment (e.g. according to EP 419968).

The attached auxiliary units naturally include both robots e.g. Robot 239 as well as transport trolleys for supply spools 254, which are temporarily positioned on the machine. Other examples of such units are cleaning devices or other mobile machines e.g. for the runner change.

Some of these units have their own drives (mobile automatic controls). Others may not have their own drive but are dependent on a drive installed or installed on the machine (see, for example, the trolley drive according to FIGS. 16 to 18 of WO 90/12133) or a drive according to European patent application No. 90117808.7 from September 15. 1990. The drives of these auxiliary units are also to be regarded as the actuators of the spinning machine, provided that they can be influenced by the machine control.

Important actuator elements are those which serve to "shut down" a spinning station, with "shutdown" here being understood as "effectively spinning station producing". 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 spinning becomes interrupted in this spinning station. This can happen, for example, by cutting off the material supply and / or by deliberately creating a thread break.

In a largely automated machine (e.g. the rotor spinning machine), this can easily be done from a central machine control using one or the other option. For example, the drive to the feed roller can be interrupted in order to prevent the material supply to the opening roller or the rotor of the spinning station. However, a so-called quality cut can also be carried out in the quality monitoring of the spinning station in order to interrupt the thread run.

Such possibilities are not available in today's conventional ring spinning machine, since the actuators of the individual spinning stations are not under the direct control of the central machine control. In such machines, however, a spinning station can be shut down by a mobile auxiliary unit, e.g. according to the system of Swiss patent application No. 697/91 dated March 7, 1991, i.e. by operating a match clamp to prevent the material supply.

The use of a sliver clamp to interrupt the supply of material will be important in all types of machines where the original material is supplied to the spinning elements via a drafting system, since it is normally impossible to park a single position of a drafting system. An operating device can of course also be assigned to the match 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 322636 and EP 353575.

The control of the spinning machine and its auxiliary units

The ring spinning machine (with central drive), which is conventional today, normally has a central microprocessor control which generates suitable control signals for the central drive system (usually by controlling a frequency converter). A single drive system can e.g. a "distributed" control according to EPO 389849. Newer spinning machines (rotor or air spinning machines) are definitely provided with distributed controls - see e.g. EP 295406 or the article "Microelectronics - Current and Future Areas of Use in Spinning Mills" in Melliand Textile Reports 6/1985, pages 401 to 407, but the distributed control units are usefully subordinate to a central machine control unit.

The mobile auxiliary units each have their own autonomous control - see e.g. EP 295406, EP 394671 or EP 394708. Although these controls work autonomously, each is hierarchically subordinate to the machine control. With an upcoming doffing e.g. the robot 239 is commanded by the coordinating machine control from the work areas of the doffing machines 237 (e.g. according to DOS 2455495).

The sensors of the (ring) spinning machine

Compared to the machines for new spinning processes (e.g. the rotor or the nozzle spinning machine), the sensor technology of today's ring spinning machine is extremely poor. The rotor spinning machine, for example, has long been provided with a sensor system which reflects both the condition of the individual spinning position and the quality of the yarn produced therein (see EP 156153 and the prior art mentioned therein. For modern monitoring - see ITB yarn production 1/91 , Pages 23 to 32.4). Similar systems are also for that Filament processing has been developed in the false twist texturing machine - see, for example, DOS 3005746. The winding machine, which processes the cops of the ring spinning machine into cross-wound bobbins, is already equipped with a sophisticated sensor system - see, for example, DOS 3928831, EP 365901 or EP 415222.

Proposals are known according to which the ring spinning machine should also be provided with a highly developed internal communication system and a corresponding sensor system - see e.g. EP 322698 and EP 389849 (= DOS 3910181). Such proposals require (for their realization) the reworking of the entire ring spinning machine, which because of the associated costs - and the corresponding effects on the competitiveness of the process - cannot happen suddenly, but only gradually.

For this reason, the ring spinning machine will probably not receive an internal communication system in the near future. Information about the states of the individual spinning stations will therefore not have to be collected from individual sensors at the respective spinning stations, but rather by means of mobile monitoring devices. Such devices have been known for a long time (e.g. from DOS 2731019) - a newer variant, according to which the monitoring is integrated in an automatic thread breakage remover, has been shown in EP 39467 (= DOS 3909746). Further sensors of the ring spinning machine, which are important for the loading of the attachment, can be found, for example, in WO 90/12133 (Obj. 907). Additional sensors are necessary for the operation of the cop or empty-sleeve transport device, such sensors being known today and therefore not described in detail here.

It should be noted that the sensors of the spinning machine can be attached instead of being installed. An example of such a system is in the article "Monitoring the Quality of OE rotor yarns "can be found in ITB Garnfertigung 1/91, pages 23 to 32.

Product, machine settings, efficiency

• die Liefergeschwindigkeit des Streckwerkes
• der Verzug, und
• die Spindeldrehzahl.

Die Drehrichtung des Garnes ("S" oder "Z"-Drehung) wird auch in der Spinnstelle in Abhängigkeit von der Drehrichtung der Spindel bestimmt.The product of a spinning station is a yarn of a determinable quality, ie with a set of verifiable properties. Certain properties of a yarn are determined for a given submission fineness directly by setting the machine (spinning station). The main properties that are determined in this way in the spinning station are the yarn count (the "yarn numbers") and the twist (turns per meter or per inch). The machine settings that influence these properties are:

• the delivery speed of the drafting system
• the default, and
• the spindle speed.

The direction of rotation of the yarn ("S" or "Z" twist) is also determined in the spinning station depending on the direction of rotation of the spindle.

Other properties of the finished spun yarn cannot be influenced by the machine settings, mostly because they are determined during the preparation of the original material and are essentially no longer changeable within the spinning station. Examples of such properties are those of the fiber material (e.g. cotton, synthetic or blend) from which the yarn is made.

Even more yarn properties are indirectly influenced by complex interactions between the machine settings and other factors. For example, the number of thread breaks per unit of time (a quality feature) is determined by the Interaction between the spindle speed and the machine environment (especially the climate) is strongly influenced.

Other yarn properties are affected by the condition of the spinning station regardless of the machine setting. The uniformity of the yarn is e.g. significantly influenced by the condition (precision) of the drafting system. The spinning tension (and therefore the thread break rate) is influenced by the accuracy of the spindle centering or the rest / unrest of the run by the runner on the ring.

• Ueber sein Gewicht übt der Läufer einen Einfluss auf die Spinnspannung und daher auf die Fadenbruchrate aus; innerhalb gewisser Grenzen ist dies durch die Auswahl des Läufers einstellbar.
• Der Läufer (und der Ring, worauf er läuft) ist ein Verschleissteil und sein Zustand übt auch einen Einfluss auf die Spinnspannung aus; dies ist nur insofern "einstellbar", als man allenfalls einen vorbestimmten Läuferwechselintervall bestimmt und einhält.
• Der Läufer ist aber auch ein Fadenführungselement, so dass seine Oberfläche, die in Berührung mit dem Garn eintritt, einen Einfluss auf das Aussehen des Garns (z.B. seine Haarigkeit) ausüben kann. Dies wäre z.B. durch die Auswahl vom Querschnitt des Läuferdrahtes einstellbar, aber in den meisten Fällen wird diese "Auswahl" durch andere Faktoren derart eingeschränkt sein, dass sie praktisch vernachlässigt werden kann.

The number of factors that influence one or the other yarn property is very large, and the effects of the individual factors can only be determined empirically. Taking the runner type as an example, the following rough effects can be listed:

• The runner exerts an influence on the spinning tension and therefore on the thread break rate via his weight; this can be set within certain limits by selecting the runner.
• The runner (and the ring on which it runs) is a wear part and its condition also has an influence on the spinning tension; this is only "adjustable" insofar as a predetermined rotor change interval is determined and adhered to at most.
• The runner is also a thread guide element, so that its surface, which comes into contact with the thread, can have an influence on the appearance of the thread (eg its hairiness). This could be set, for example, by selecting the cross-section of the rotor wire, but in most cases this "selection" is made other factors are so limited that they can be practically neglected.

All of these effects of the rotor depend on the spindle speed, but also on the material to be processed.

To what extent all these different influences are important is not a question of the spinning technology as such, but of the intended end use for the yarn. The requirements for fine yarn to be used for clothes are different from the requirements for coarse yarn to be used for cleaning rags.

However, it will be clear from the foregoing that spinning machines can only be "configured" and set to the intended application to a very limited extent. There are only a few machine parameters that can be selectively adjusted to take into account a large number of possible influencing factors. The success or failure of a given adaptation of the machine can be printed out as a "benefit". This represents the effective (usable for the desired purpose) production in relation to the theoretical maximum production with the predetermined machine configuration and machine settings.

The useful effect therefore represents the effect of lost production time. Such time losses arise partly due to malfunctions (eg thread breaks, defective spinning positions) and partly due to necessary production interruptions (eg doffing processes, rotor change, reel change in the creel, etc.). They are therefore related both to the configuration (e.g. ring diameter, pitch - hence coil size or running time between interruptions) and to the settings (e.g. spindle speed). However, they are also influenced by the machine environment, especially the climate.

The benefit is not affected by any production losses due to inferiority of the product. It is assumed in a benefit calculation that the entire effective production can be used for the purpose. This cannot be predicted in advance for a specific product, so that a benefit can never be calculated theoretically.

The benefit must rather be determined empirically, by collecting and evaluating empirical values over a sufficient test period. The given machine (with its given configuration) must be set in such a way that the quality losses (rejects, inferior goods) are kept at an acceptable level. At most, certain spinning positions have to be switched off for a certain product, because for temporarily insurmountable reasons they are unable to produce an acceptable yarn under the given spinning conditions. This is reflected in the benefit for this product on this machine.

As just mentioned, the benefit for a particular product is not easily transferable from machine to machine. Since every machine (even with the same configuration and setting) has small "idiosyncrasies" compared to every other machine, the same and the same set machines will result in smaller or greater differences in their benefits for the same product.

Speed curve

The spindle speed is preferably not kept constant at a predetermined level during the formation of a cop, but is varied according to a predetermined course (the “speed curve”). This allows the different Spinning conditions are taken into account in the course of the bobbin formation, which enables a reduction in the number of thread breaks (see, for example, the article "Thread break detection, minimization and elimination on ring spinning machines" by H. Herdtle in Melliand Textile Reports, 6/1984, pages 379 to 383). An example of such a curve is explained in more detail below with reference to FIGS. 2 and 3.

Fig. 3 shows schematically half of a horizontal cop, the reference symbol C indicating the longitudinal axis of the cop, H the sleeve and G the yarn turns. HF is the sleeve base that forms the lower end of the sleeve attached to the vertical spindle during operation. The "bobbin structure" of the yarn package results in a lug A, a cylindrical part ZT and a cone K, the lug A being built as the first part of the bobbin. Distances from the lowest end of the cop are entered on the horizontal axis of FIG. 3. The total length of the cop results from the sum of the axial length HUB from the cone K and the distance C3 between this cone K and the lower end of the cop.

Fig. 2 shows diagrammatically the speed curve from the beginning of the formation of the cops to the end. The time is entered on the horizontal axis.

When piecing, at the beginning of the new bobbin, yarn must be wound up directly on the sleeve H, in the vicinity of the sleeve base HF, i.e. furthest from the drafting system. Because of the resulting high thread tension and the corresponding risks of thread breaks, the "operating speed" is not used, but rather a relatively low tightening speed An (FIG. 2).

The spindle speed can be increased continuously during a first section I of the speed curve if approach A is built until a "lower operating speed" Bu (Fig. 2) is reached when approach A is finished. The spindle speed can then be further increased slightly (up to an "upper operating speed" Bo) during a second section II, when the cylindrical part ZT is completed, because the distance between the winding point and the drafting device during this phase of the cop assembly in Average is reduced, which results in a decrease in yarn tension. Shortly before the cylindrical part is finished, the spindle speed should be reduced again in the third section III until a "unwinding speed" Ab is reached when the cylindrical part ZT is ready.

The speed curve can be defined by the speed values An, Bu, Bo and Ab (Fig. 2) and the distances 1₁, 1₂ and 1₃ (Fig. 3), the change from section I to section II or from section II to section III takes place after covering the distance 1₁ or 1₂.

Accordingly, not only an operating speed but rather a speed curve is preferably set. This curve can also differ from product to product.

Production planning, lot change

The spinning mill has to adapt its production to its customer orders "as optimally as possible". Only in the rarest of cases can the machines be set up for the production of a single yarn type and then operated continuously for the production of this yarn. Since customers require different types of yarn, "lot changes" have to be carried out occasionally or more often, with a machine being set up to produce another type of yarn after the production of a first type of yarn. This often requires both the readjustment of the machine and the provision of a different original material.

Changing the batch means unproductive time for the spinning mill. It is therefore important to coordinate the various production orders with one another in accordance with the business strategy of the individual spinning mill, particularly with regard to the sequence of processing. This is the job of production planning, which still has to be done by people.

The result of this activity is a certain order of "production plans", of which each production plan provides for the production of a given quantity of yarn of a given type by a machine or "machine group" (multiple machines) defined according to the plan.

Recipe, article

• das gewünschte Produkt
• die vorgesehene Vorlage
• die Konfiguration und Einstellungen der Maschine
• die Umgebung.

The creation of a production plan (production order) requires a clear "definition" (determination, description, identification) of the necessary production conditions. These include:

• the desired product
• the proposed template
• the configuration and settings of the machine
• the environment.

It is reasonable, but not essential, to summarize the material parameters of the definition. The summary of these parameters can be referred to as an "article". The other definition parameters together with the item parameters form a "recipe" that is used to manufacture the product defined in the item in one given machine gives the necessary operating data. For production planning, which is described below with reference to FIGS. 9 and 10, it is advantageous to also specify the efficiency in the recipe or at least to assign it to the recipe.

The spinning plant

The importance of a process control computer for future low-personnel spinning mills can hardly be overstated. While in the past whole teams were available for the various operating and maintenance work in the spinning mill, in future only individuals will be available to keep the whole spinning mill in operation. The importance of this change will now be clarified with reference to FIG. 4. A possible organizational scheme for the construction of a process control system and then details of the communication connections within such a system are first explained using the further figures.

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 combing preparation machines 132, ten combing machines 136, four draw frames 138 ( second route passage), five flyers 140 and forty ring spinning machines 142. This is a conventional arrangement today 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. However, since the principles of this invention can be used regardless of the type of final spinning stage, the explanation in connection with conventional ring spinning is also sufficient for the Application of the invention in connection with new spinning processes. Not shown in FIG. 4 is 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”. According to this approach, 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. Inside the blow room, the fiber material is transported from machine to machine in a pneumatic transport system (air flow), which system is completed in the carding machine. The cards 128 each provide a strip as an intermediate product which has to be placed 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). In between, the combing preparation machines 132 form a processing stage 48 (FIG. 5) and the combing machines 134 form a processing stage 50 (FIG. 5). Finally, the flyers 138 form a spinning preparation stage 54 (FIG. 5) and the ring spinning machines 140 form a final spinning stage 56 (FIG. 5).

• die Putzerei,
• die Karderie,
• die Kämmerei.

The end result of the schematically represented 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 individual ascertainable fiber properties (e.g. fiber fineness, fiber type, fiber strength, etc.). When processing natural fibers (especially from Cotton fibers) it is not possible to "order" a raw material with a predetermined stack diagram. Rather, the desired diagram must be generated by suitable processing of fibers from different origins ("provenances"). In particular, there are three processing stages that can influence the stack diagram of the material to be spun, namely:

• the blowroom,
• the carding machine,
• the combing.

Material flow tracking therefore plays an important role for the spinning mill. 4 shows the complexity of this task - imagine the number of possible "paths" between bale storage (for raw cotton) to the final spinning stage. This task was solved in the past by the manager and his teams.

In our German patent application No. 3924779 from June 26, 1989 we describe a process control system according to which a spinning mill is organized in "areas" and signals from one area can be used to control or regulate previous areas. An example of such a system is shown schematically in FIG. 6, the system comprising three areas B1, B2 and B3 and each area being assigned its own process control computer R1, R2, R3. Each computer R1, R2, R3 is connected for signal exchange (indicated schematically in FIG. 6 by connections 86). It will be clear to the person skilled in the art that the representation of FIG. 6 is purely schematic. Of course, a single process control computer can be provided, which is connected to all areas of the spinning plant and carries out the desired signal exchange between these areas. The version shown with a process computer R per area B but represents a reasonable execution, which is adopted for this explanation.

The area B1 comprises the blowroom 42 and the carding machine 44 (FIG. 5).

The area B2 comprises the two route passages 146, 152 (FIG. 5) as well as the comb preparation stage 148 and the comb 150.

The area B3 comprises the flyer 154 and the final spinning stage 156 (FIG. 5), possibly also a winder.

The low-manpower 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. 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.

• a) die Flyerstufe 300,
• b) eine Endspinnstufe 320, in diesem Fall durch Ringspinnmaschinen gebildet,
• c) ein Vorgarntransportsystem 310, um Flyerspulen von der Flyerstufe 300 an die Endspinnstufe 320 und leere Hülsen von der Endspinnstufe 320 zurück an die Flyerstufe 300 zu tragen, und
• d) eine Umspulstufe 330, um die an den Ringspinnmaschinen gebildeten Kopse in grösseren (zylindrischen oder konischen) Packungen umzuwandeln.

A practical implementation of the area B3 for an automated system is shown in FIG. 7, but still schematically, in order to represent the IT aspects of the system. The system section shown comprises (in the order of the process stages, ie the "chaining" of the machines):

• a) flyer level 300,
• b) a final spinning stage 320, in this case formed by ring spinning machines,
• c) a roving transport system 310 for carrying flyer bobbins from flyer stage 300 to final spinning stage 320 and empty tubes from final spinning stage 320 back to flyer stage 300, and
• d) a rewinding stage 330 in order to convert the cops formed on the ring spinning machines into larger (cylindrical or conical) packs.

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 version is e.g. shown in EP 360149 and DE-0S 3702265.

In FIG. 7, 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. One possible version is e.g. shown in EP 394708 and 392482.

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. In Fig. 7 the function "roving bobbin cleaner" indicated by box 312. A possible embodiment of this plant part is shown in part in EP 392482.

The ring spinning machines of stage 320 and winding machines of stage 330 together form a "machine network", which ensures the transport of the cops to the winding machines. This assembly is controlled by the winding machine.

A network 350 is provided, whereby all machines of stages 300, 320, 330 and 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 winding machine.

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 "operator console". An example of such a user interface is shown in DE-0S 3734277, but not for a ring spinning machine, but for a draw frame. The principle is the same for all such controls.

According to a Swiss patent application No. 189/91 dated January 23, 1991, 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 over 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 over the respective controller.

The machine can of course be provided with more than one "user interface". It is important 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 user interface 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 control 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 Computer science can be equated to a "machine"). Each computer 340, 390 has memories 343, 345 and 391 and drivers 347, 349 and 393, 394, 395, 396 assigned to it.

The drivers 349 and 394 determine the necessary interfaces for the communication of the computers 340, 390 with their respective user interfaces, indicated here as a display, operator 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.

In the preferred embodiment, the invention is implemented in a system according to FIGS. 7 and 8, i.e. in a system, in which at least one machine control has a user interface and the process control computer can use this user interface to communicate with a person on this machine. 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, e.g. according to US 4194349. The advantages of the preferred combination are particularly pronounced when a process control computer influences both the operating support and the control of the machines, e.g. in a doff management system for ring spinning machines, similar to a system according to US 4665686.

The operator support via the operator interface on the appropriate machine naturally also ensures that the help is offered where it is necessary. This also allows the alarm or call system to be simplified, since in principle the operator now only has to be directed to the machine concerned without being informed beforehand of the action required. The alarm or call system must of course still ensure that operation via the Urgency or the priority of the operator call is informed or that the correct operator or operator (doffing aid, maintenance, thread break repair, etc.) is called to the affected machine.

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 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.

PPS tools

The process control according to FIGS. 7 and 8 is to be equipped according to this invention as a production planning and control aid. It is assumed that the "display" and "operation", which are assigned to the computer 340 in FIG. 8, are in the form of a screen or a keyboard. 9 and 10 show "screen masks" of a process control computer 340 programmed according to this invention.

Fig. 9 shows a mask for the creation of recipes for the production of a certain type of yarn. This mask includes four "windows" 400, 402, 404, 406, with windows 404 (accessibility) and 406 (recipes created) being of minor importance for this invention. As already indicated in this description, a "recipe" for one defined "article" can be determined. The window 400 accordingly serves to define the article and the window 402 serves to define the corresponding machine-related parameters of the recipe.

Sortiment

- einen Hinweis auf den vorgesehenen Endverbrauch des Produktes (fakultativ)

Material

- eine Beschreibung des zu verspinnenden Fasermaterials

Vorlagebezeichnung

- legt die Flyerlunte fest

Abgabebezeichnung

- legt den Garntyp fest

Vorlage

- gibt die Nummer (Feinheit) der Flyerlunte an

Abgabe

- gibt die Nummer (Feinheit) des Garns an

Verzug

- gibt den notwendigen Gesamtverzug des Streckwerkes an (ergibt sich dementsprechend aus den Angaben zur Vorlage und Abgabe)

Artikelname

- eine Bezeichnung des Artikels, die auch als Aufruf für das Rezept dient

Artikelkurznummer

- eine Alternativbezeichnung des Artikels in der Form einer Ziffer.

Drehkoeff

- der sogenannte Drehungskoeffizient, der eine Beziehung zwischen der Drehung und der Garnfeinheit darstellt

Drehrichtung

- "S" oder "Z"

Drehung

- die Garndrehung als Drehungen pro Meter oder pro Zoll.

The following data can be entered in the written fields 408 of the window 400:

range

- an indication of the intended end use of the product (optional)

material

- a description of the fiber material to be spun

Template name

- sets the flyer fuse

Delivery name

- defines the yarn type

template

- specifies the number (fineness) of the flyer fuse

Levy

- indicates the number (fineness) of the yarn

Delay

- specifies the necessary total delay of the drafting system (results accordingly from the information on submission and delivery)

Product Name

- A description of the article, which also serves as a call for the recipe

Article short number

- an alternative name for the item in the form of a number.

Rotary coefficient

- the so-called twist coefficient, which represents a relationship between the twist and the yarn count

Direction of rotation

- "S" or "Z"

rotation

- the yarn twist as twists per meter or per inch.

The window 402 comprises five fields 410, which each define a machine by means of a machine number. Each field 400 is assigned a "column" 412, 414, 416, 418, 420 of fields, the fields of a particular column specifying both the configuration of the corresponding machine and the machine settings according to this recipe and the resulting effect.

Instead of specifying a spindle speed ("speed"), the desired rotor speed ("V rotor") can be specified. The spindle speed then results from the known relationships between the rotor speed and the ring diameter.

The delivery speed of the drawn fiber material at the exit of the drafting system (the "delivery") results from the rotation and the speed. Two of these parameters are sufficient to automatically calculate the third parameter.

Upper (+) and lower (-) limit values for the spindle speed can also be entered.

The window 400 shows a list of the recipes that have already been created and the window 404 shows input aids in the form of predefined information which can be transferred from the window 404 to the window 400 or 402.

10 shows a mask for the creation of production plans based on the recipes created. The mask comprises three windows 422, 424 and 426, of which window 424 is to be described as the most important window for the time being.

A field name (article name) must be entered in field 430 of window 424. The production plan to be created is then based on the data of this recipe. Those machines for which this recipe has already been defined then appear as machine numbers in the input help window 422.

An order number is entered in field 432 and "name" of the production plan then appears in field 434 - this name consists of the recipe name and the order number.

Field 436 lists the machines that should work on this job. The list can be created by transferring information from the input window 422. In any case, only one machine can be listed, for which the relevant recipe has already been defined. The details of a machine include at least the identification of the machine (its number) and the expected benefit. From the available data, the computer calculates the hourly production and the average value of the machine use effects and displays this data in field 438. Accordingly, the expected production can be compared by the user with the order to be fulfilled.

If the user is satisfied with the plan, the plan can be confirmed as valid using the keyboard and is then placed in the window 426 at the bottom of the list of production plans already created. The plans are processed in sequence via the process control system (as will be described below), with the plan appearing at the top of the list being the next one by the Process control system is brought to bear. If, therefore, the new plan is actually given a higher priority than is shown by its position at the bottom, it can be moved up using the keyboard and thus come earlier than the previously created plans.

11 and 12 further details of the system will now be briefly explained. A recipe (Fig. 9) includes not only a spindle speed, but also a speed curve (Fig. 2 and 3). This is created using a separate mask (Fig. 11). In window 440 of this mask, the essential features (operating speed above, operating speed below, tightening speed and unwinding speed, as well as the corresponding distances 1₁, 1₂ and 1₃) according to FIGS. 2 and 3 are entered. The speed curve is identified by a number and can be called up via this number for use in a recipe. The speed curves created are displayed in window 442.

The spinning process can be accessed directly via the mask according to FIG. 12, despite the fact that the corresponding machine works according to a predetermined plan. This means that the personnel are free to adapt an ongoing plan with regard to new experiences with the process control system.

The mask of Figure 12 includes a window 444 listing all the machines controlled by the system. A machine can be selected from this list using a cursor, the relevant data appearing in window 446 and being able to be changed there.

Fig. 12 shows an example of a mask for changing the upper speed (operating speed above - speed curve), the already valid speed appearing in field 448 and can be changed using the keyboard. The change can be made by Change in absolute speed or by a percentage change.

Fig. 12 shows another example of the direct control intervention in the form of a spin-off command. This command can be answered in the negative (field 450) or with a doff (field 452) or without a doff (field 454).

Of course, further direct interventions can be carried out via the process control system, provided that the corresponding machines are equipped to receive and execute such control commands. As was already indicated on the basis of the description of FIG. 1, only a few such control commands can be followed by the conventional machines today.

Transfer of the recipes

Regardless of whether the machines are equipped to independently execute all "control commands" of a recipe or not, it is advantageous to transfer the recipe to the appropriate machine at a given time. This is done via the communication link according to FIGS. 7 and 8. The recipe is then available in the machine as operating support when changing the batch.

The transmission could take place "on demand", i.e. when the operator sends a corresponding call signal to the process control computer. In the preferred embodiment, however, the process control computer ensures that each machine is "supplied" with two recipes, namely the current recipe and the next recipe after the production plans have been listed. Recipes are preferably not stored in the machines for a longer period of time, but are always re-transmitted from the process control computer.

Claims (7)

An auxiliary device for use in production planning in a spinning mill, characterized by means for establishing a production plan which provides for the distribution of a specific production quantity of a given yarn over machines of the final spinning stage of the spinning mill, and means for estimating the production quantity per unit of time per machine, and depending on the yarn to be produced, the intended machine settings and the environment of the machine in question. A device according to claim 1, characterized in that the information required for the production of a particular yarn is summarized in at least one "operating data record" ("recipe"), and a separate recipe is provided for this machine for each machine. A device according to claim 1 or 2, characterized in that the auxiliary device is provided as an element of a production planning and production control system ("PPS system"), means being provided to selectively (according to production planning) the recipes to their respective machines ) transferred to. A process control system for at least the final spinning stage of a spinning plant, characterized by means for defining recipes for the production of different yarn products by the different machines of the controlled final spinning stage, each recipe comprising a compilation of at least the essential operating data of a specific machine for producing a specific yarn type, and Means to set a production plan, which consists of production orders, of which each order provides at least a predetermined quantity of a certain yarn product and determines the distribution of the required quantity over a plurality of production sites of the controlled final spinning stage, whereby only those machines can be taken into account for the fulfillment of a given order, for which purpose a recipe for the production of the corresponding yarn type already exists, and means for causing the recipe to be effective or to be effective at a time determined according to the production plan for the fulfillment of an order determined according to the plan on a machine defined according to the plan . A system according to claim 4, characterized in that means are provided to transfer the production schedule to the machines, e.g. by transferring the recipes specified by the plan to the corresponding machines in an order specified by the plan. A production planning and control system ("PPS system"), characterized by means for defining an article and means for establishing a recipe for manufacturing the article on a particular machine, the system being arranged such that the setting of the article together with the determination of the recipe an empirically verifiable estimate of the production of this machine results in the production of the article according to this recipe. A system according to claim 6, characterized in that the empirically verifiable estimate of the production there is a calculable maximum production and an empirically verifiable utility value.

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