EP1475470A1 - Data acquisition and processing system for controlling and operating a set of industrial sewing machines and method for controlling and operating this set with a data acquisition and processing system - Google Patents

Abstract

An installation (2) of industrial sewing machines (3) has a central computer (11) and memory (18). A communication device (7) is connected to each machine controller (4) with a standard interface by a first signal path (6) and to the central computer (11) by a second signal path (12) through a local network (9). The communication device (7) can deal with processing conditions, machine control, operator details and servicing requirements in the form of data packets. An independent claim is also included for the control and monitoring of industrial sewing machines by collecting data from individual machines (3) and transmitting it to a communication device (7). It is then transmitted to a central computer (11) where it is monitored and processed. Control data can be initially determined from a sample sewing machine (14) and then evaluated statistically from plant data.

Description

The invention relates to a data acquisition and processing system for Monitoring and controlling a network of industrial sewing machines and a method for monitoring and controlling such a network with a data acquisition and processing system.

From US 5,970,894 A is a data acquisition and processing system for monitoring and controlling a network of industrial sewing machines known in which a plurality of industrial sewing machines respectively Separately with a central monitoring and control computer is connected, which specifies sewing process data for the sewing machines and repair relevant Data stored individually in each industrial sewing machine are interrogated. For connecting a single industrial sewing machine on Control and monitoring computer is a variety of special solutions proposed, in particular the connection via a local network. The storage of repair-relevant data in storage media of the individual Sewing machines then poses a problem when the sewing machine so fails that on the central control and monitoring computer no access to the internal memory of the sewing machine is possible. Older sewing machine types also have no interfaces for connection to the currently used local networks. The Adaptation of each individual sewing machine to a currently used local one Network is again too expensive.

It is therefore an object of the present invention to provide a data acquisition and processing system of the type mentioned in such a way, that it is flexible and reliable even for a sewing machine network can be used, which includes older sewing machines.

This object is achieved by a Datenerfassungs- and - Processing system with the features specified in claim 1.

According to the invention, it was recognized that instead of the complex connection every single older sewing machine connected to a local network For example, an RS232 interface and a so-called gateway possible is to connect a plurality of sewing machines of the composite to use a single data communication device. This reduces the Equipment costs when connecting the sewing machines to the local network considerably. Through such a connection to the local network In addition, the possibility has been created for all sewing machines of the composite, So also for older types of sewing machines, one of the respective Sewing machine separate storage of the working data of the sewing machine make. Working data can in this case sewing process data, ie data to the sewing tasks of the individual sewing machine, and operating data of the sewing machine his. In particular, a transmission is via the local network qualified error messages from the respective sewing machine the central monitoring and control computer possible, resulting in an efficient Service of the sewing machines guaranteed. Also is a documentation the entire operation of the sewing machine network possible. The storage of the working data removed from the respective sewing machine can in the data communication device, in a server of the local Network or in the central data store of the central monitoring and Control computer done. The interfaces through which a connection the sewing machines to the data communication device, depend on respective sewing machine type. Older sewing machines usually have an RS232 interface or an RS485 interface. In older Sewing machine types may additionally be required for realization the data exchange with the data communication device processor components to exchange the respective machine control. This is with little effort possible. Depending on the design of the monitoring and control software of the central monitoring and control computer is an operation tailored to the respective sewing application the data acquisition and processing system possible. The central data store ensures quick access to all in the context of Monitoring and control of collected data.

Data packets according to claim 2, both Nähprozess- and operating data packets his. Such data packets can be via standard interfaces simply transfer.

Coded entries according to claim 3 reduce the scope of operation the data acquisition and processing system between the sewing machines and the central monitoring and control computer to be exchanged Dates. A division of the data packets into a function address and a function number is particularly clear.

The local area networks according to claim 4 are reliable and ensure one for operating the data acquisition and processing system sufficient data transfer rate.

A data communication device according to claim 5 can be adapted to different Adapt types of industrial sewing machines.

An input interface according to claim 6 increases the flexibility of the Data acquisition and processing system. The most sewing machines already existing data input device can in this way into the system, for example, for the registration of operators, for adaptation of sewing process data or for repair information or service request be used. Alternatively, it is possible to have a special one the data acquisition and processing system tailored data entry device provided with each sewing machine of the composite.

A buffer of the data communication device according to claim 7 allows retrieval of cached data there in larger Time intervals, for example daily.

An internal clock of the data communication device according to claim 8 allowed a data storage with assigned real-time information. It is then possible, the exact time of creation of the respective stored Working date with automatically file, in particular for the monitoring and for a statistical analysis of the working data is advantageous.

An evaluation module according to claim 9 provides the ability to specifically determine Error types or frequencies or other significant information during operation of the industrial sewing machine network. This creates the possibility of repairing errors occurring to make corrections to the concept of the industrial sewing machine group, to avoid particularly common mistakes.

Another object of the invention is to provide a method of monitoring and controlling an industrial sewing machine network with the invention Specify data acquisition and processing system.

This object is achieved according to the invention by a method according to claim 10th

With such a method is in particular an operation monitoring all industrial sewing machines possible without the individual industrial sewing machines consuming to be converted.

Further advantages of the method according to the invention will be apparent from the above discussion of the data acquisition and -verarbeitungssystems.

The connection of a pattern sewing machine according to claim 12 allows a specification of sewing process data that is exactly matched to the respective sewing situation through the central monitoring and control computer.

When inputting work data via a data input device according to Claim 14 is, if a bidirectional data transfer via the data input device is given, also an acknowledgment for example one Service request possible. The data input device can in particular Also be designed so that a voice message is possible.

Caching according to claim 15 reduces the requirements to the local network. Alternatively to such a caching is also an online monitoring possible.

The presentation of the data according to claim 18 may also be the possibility Sorting the data according to certain sorting algorithms or a search function for certain transmitted work data include. If data packets with function addresses and function numbers can be transmitted according to claim 3, for example, according to certain Function addresses or function numbers are searched for to detect the occurrence of certain individual events.

Fig. 1

schematisch die Datenkommunikation innerhalb eines Datenerfassungs- und -verarbeitungssystems zur Überwachung und Steuerung eines Verbundes von Industrienähmaschinen;

Fig. 2

schematisch den internen Aufbau eines Datenkommunikationsgeräts des Datenerfassungs- und -verarbeitungssystems von Fig. 1;

Fig. 3

ein Ablaufdiagramm eines Verfahrens zur Überwachung und Steuerung eines Verbundes von Industrienähmaschinen mit dem Datenerfassungs- und -verarbeitungssystems der Fig. 1 und 2; und

Fig. 4

ein Datenpaket, mit dem Daten innerhalb des Datenerfassungs- und - verarbeitungssystems der Fig. 1 transferiert werden.

An embodiment of the invention will be explained in more detail with reference to the drawing. In this show:

Fig. 1

schematically the data communication within a data acquisition and processing system for monitoring and controlling an assembly of industrial sewing machines;

Fig. 2

schematically the internal structure of a data communication device of the data acquisition and processing system of Fig. 1;

Fig. 3

a flow chart of a method for monitoring and control of a combination of industrial sewing machines with the data acquisition and processing system of Figures 1 and 2. and

Fig. 4

a data packet with which data is transferred within the data acquisition and processing system of FIG.

A data acquisition system denoted overall by the reference numeral 1 in FIG. and processing system is used for monitoring and control of a composite 2 of industrial sewing machines 3. Any industrial sewing machine 3 has its own machine control 4 and one executed as a terminal 5 Data input device. Each terminal 5 has a control panel as well as a display.

Via a first bidirectional signal path 6 is every machine control 4 with a data communication device 7 in connection. The signal path 6 may be, for example, a signal line connected to the machine control 4 communicates via an RS232 interface. Others too Types of signal connections and interfaces can - depending on Type of sewing machine 3 to be connected - used in the signal path 6 come. This may include a wireless signal connection.

In the data acquisition and processing system 1 shown in FIG is a single data communication device 7 for data communication with all industrial sewing machines 3 of the composite 2 provided. In an alternative Data acquisition and processing system 1 can also several Data communication devices 7 may be provided. The number of data communication devices 7, however, is less than or equal to that of Industrial sewing machines 3.

Via a bidirectional signal connection 8 is the data communication device 7 with a local network 9 in connection. The latter is via a further bidirectional signal connection 10 with a central Surveillance and control computer 11 of the data acquisition and processing system 1 in conjunction.

The two signal connections 8, 10 corresponding to the first signal path 6 may be formed together with the local network 9 shows a second signal path 12 for connecting the data communication device 7 with the central monitoring and control computer 11.

Another bidirectional signal connection 13 is the central monitoring and control computer 11 also via the network 9 with a Pattern sewing machine 14 with machine control 15 and terminal 16 connected.

Another bidirectional signal connection 17 provides a data connection between the central monitoring and control computer 11 and a central data memory 18. The latter comprises several, in FIG. 1 a total of six, data storage modules 19.

The internal structure of the data communication device 7 is shown schematically Fig. 2. A microprocessor 20 of the data communication device 7 is over a first section 21 of an internal bus system 22 with a RAM 23 as a storage unit, a flash ROM 24 and an internal real time clock 25 in connection. Via a second section 26 of the internal bus system 22 is the microprocessor 20 with a flash card interface 27, a Universal Asynchronous Receiver / Transmitter (UART) 28, a Ethernet Interface 29, a Profibus / CAN Bus Interface 30, a universal Serial Bus (USB) Interface 31, a multi-port I / O device (Multiport I / O) 32 and a terminal interface 33 in connection. The UART 28 in turn has data lines 34 with a total of sixteen RS232 interfaces 35 and over a data line 36 with an RS485 interface 37 in conjunction. to electrical supply of the data communication device 7 is used Power supply 38.

The various interface variants 27 to 37 of the data communication device 7 can each for connecting the data communication device 7 with the industrial sewing machines 3 and the local network 9 be used. In the data acquisition and processing system 1 of the Embodiment according to FIGS. 1 to 3, the connection of the data communication device takes place 7 with the industrial sewing machines 3 on the RS232 interfaces 35. In this embodiment, the connection is made of the data communication device 7 with the local network 9 via the ethernet interface 29.

FIG. 4 shows a data packet 39. In the form of such data packets 39 will be working data within the data collection and processing system 1 transfers. The work data may be Sewing process data or operating data or service requests the industrial sewing machines 3 act. Each data packet 39 is a specific process or operating situation of industrial sewing machines 3 and includes a function address 40 and a function number 41st

The function address 40 refers to a central monitoring and Control computer 11 stored general function and can, for example be a four-digit decimal number. The function number 41 is used for the individualization of the function to which the function address refers, and may be, for example, an eight digit decimal number. The data packets 39 is still a real-time information in the data communication device 7 assigned. For this purpose, the microprocessor 20 asks the internal Real-time clock 25 off. The establishment of a function address 40 and a Function number 41 has the advantage of providing an open system whose functionality is used by every user of the data acquisition and processing system 1 can be set individually.

A method for monitoring and controlling the network 2 with the Data acquisition and processing system 1 proceeds as follows:

First, a Nähdatenprogrammierung, which then can be omitted, if on the industrial sewing machines 3 always the same sewing program expires. In sewing data programming, in a default step 42 initially given sewing process data. To do this, with the help of Pattern mower stitched 14 pattern seams until all parameters and Boundary conditions for the applied with the industrial sewing machines 3 Seams are fixed. The operation of the pattern sewing machine 14 can from the central monitoring and control computer 11 via the bidirectional Signal connection 13 can be influenced. After completing the pattern sewing process The sewing process data thus determined are transmitted via the signal connection 13 from the pattern sewing machine 14 to the central monitoring and control computer 11 transmitted. This then controls in one Filing step 43 the filing and cataloging of sewing process data in the data storage modules 19 of the central data memory 18th

In a first forwarding step 44, the central monitoring and Control computer 11, the Nähprozessdaten on the second signal path 12th to the data communication device 7 on. The sewing process data is coming on the Ethernet interface 29 of the data communication device 7 and, controlled by the microprocessor 20, directed to the UART 28. If necessary, the sewing process data may also be stored in the storage unit 23 of the Data communication device 7 are stored. This caching takes place in a buffer step 45. The cached Sewing process data may be requested by the machine controls 4 from Data communication device 7 retrieved via the RS232 interfaces 35 become. The UART 28 distributes the sewing process data over the data lines 34 and the RS232 interfaces 35 and the first signal paths 6 to the Machine controls 4 of industrial sewing machines 3. This is done in one second forwarding step 46.

This concludes the procedure for sewing data programming. The Sewing process data, as a record or as a parameter in the machine controls 4 can also be deposited via the terminals 5 of the industrial sewing machines 3 programmed or dependent be changed by the sewing process by the operator. Either by hand as well as with the help of the described method for sewing data programming can use multiple seam patterns in the machine controls 4 and retrieved depending on the article to be sewn become.

About taking place with the help of the described Nähdatenprogrammierung Specification of sewing process data by the central monitoring and Control computer 11 is a complete seam documentation during the Operation of the composite 2 possible.

Furthermore, to monitor and control the network 2 with help the data acquisition and processing system 1 also an administration and evaluation of the working data of the individual industrial sewing machines 3 of the composite 2. For this purpose, operating data of the sewing machine 3 in a Detection step 47 detected by means of appropriate sensors and encoders. These operating data may include the following data: actual speed, Power ON state, drive running, seam end, free seam active, counted seam active, sewing foot lift active, locking active, thread trimmer active as well as error status. Other data that are collected are those in the respective Machine control 4 present sewing process data. In the end Work data can also be in the course of an input step 48 via the terminal 5 are entered by hand in the machine control 4. The entered or entered data are then in another Forwarding step 49 from the machine controls 4 over the first Signal paths 6 transmitted to the data communication device 7 and come there via the RS232 interfaces 35. The data is then over the UART 28 and, controlled by the microprocessor 20, to the Ethernet Interface 29 forwarded. Alternatively or additionally, the detected Data controlled by the microprocessor 20 in the memory unit 23 in one Intermediate storage step 50 filed and retrieved as needed. Instead of caching the work data in the staging steps 45 and 50 may be a forwarding of the work data also online, for example every 500 ms. Via the ethernet interface 29 then enter the acquired data via the second signal path 12 to the central monitoring and control computer 11. This is done in a second forwarding step 51. Subsequently the recorded work data, controlled by the central monitoring and control Control computer 11, stored in the central data memory 18. This is done in a storage step 52. The storage of the acquired work data in central data memory 18 takes place in a standard database format, for example in the format DBASE.

The work data recorded during a production day, for example are then in an evaluation step 53 from the central monitoring and Control computer 11 evaluated. The evaluation can be done with, for example Help one of the known database programs done. The evaluation in the evaluation step 53 takes place in an evaluation module 53 a of the central Monitoring and control computer 11.

As part of the input step 48, the respective industrial sewing machine 3, for example, be assigned a serial number. There are the operator who has installed the industrial sewing machine 3, a Data packet 39 via the terminal 5 of the industrial sewing machine 3 a. It takes place First, enter the function address 40, which is used for entering the Serial number is available. Subsequently, the function number 41 is the Enter the serial number of the machine. With the input step 48 can also the registration of an operator at the beginning of a commissioning the industrial sewing machine 3 done. This is also a data package 39 entered. First, the input is made for entering a personnel number standing function address 40. Subsequently, as a function number 41 entered the personnel number of the operator. In the same way can also by entering appropriate data packets 39 a mechanic will be logged in. Also, for example, the conclusion of a Service process can by entering a corresponding data packet 39 are entered. For this purpose, besides one representing the service end Function address 40 still as function number 41 the kind entered the service or repair work.

With the help of the input step 48, a service request can also be made. For this purpose, the operator gives a data packet 39 with a service request representative function address 40 and a specific Service content relevant function number. Such a function number 41 can, for example, for the service order "replace thread bobbin" stand. The receipt of such service requests can be done via the central Monitoring and control computer 11 are acknowledged. The service request can then be further processed. This can be for example an automatic request for information to a service mechanic by phone call, email, SMS.

For entering longer sequences of data packets 39, for example at the specification of sewing process data comes at input step 48 Software input masks for use.

As part of the statistical evaluation in the evaluation step 53 For example, the total number of repairs during a given period Period or the number of repairs of an industrial machine 3 during a certain period or the number of all repaired parts be put together during a certain period of time. Appropriate Compilations are also with the transferred service requests possible.

The evaluated work data are then in a presentation step 54 on a screen of the central monitoring and Control computer 11 shown. Depending on the user's choice, this is done Representation for example in tabular form, with a column selection and a sorting preset can be specified. The table shown can be used for Example the industrial sewing machines 3 used in the production Manufacturer and type and with serial number as well as to each include sewing order. Also, for example, the currently active operators or the currently active mechanics or the service work currently being performed or the one not currently being performed Service requests are presented. The working data can in the presentation step 54 also in terms of time based on the associated real-time information the data packets 39 are sorted. In the frame of the evaluation step 53 are also search functions, for example, according to certain Function addresses 40 or function numbers 41 possible. The in the presentation step 54 work data shown can be deleted on request, changed or re-entered.

The operating data can also be evaluated and correspondingly, in particular also graphically represented.

Claims (18)

Data acquisition and processing system (1) for monitoring and controlling a composite (2) of industrial sewing machines (3) with a central monitoring and control computer (11), which is connected to a central data memory (18), with at least one data communication device (7), which via a first signal path (6) with machine controls (4) of a plurality of sewing machines (3) of the composite (2) is connectable, is connected via a second signal path (12) at least temporarily via a local network (9) to the central monitoring and control computer (11), and wherein the data communication device (7) has a standard interface (27 to 37) for connection to the respective machine control (4). Data acquisition and processing system according to claim 1, characterized in that the data communication device (7) is designed such that it labor data, for example, operating data, program data of the controller or the drive, maintenance data, personal data (service / operator), service requests, operating hours counter data , which forwards sewing machines (3) in the form of data packets (39). Data acquisition and processing system according to claim 2, characterized in that the data packets (39) encoded entries (40, 41) associated with certain process or operating situations, wherein the data packets (39) in particular a function address (40), the refers to a in the central monitoring and control computer (11) stored general function, and in particular a function number (41) to customize the function included. Data acquisition and processing system according to one of claims 1 to 3, characterized in that the local area network (9) is a LAN, in particular Ethernet, or a field bus, such as CAN. Data acquisition and processing system according to one of claims 1 to 4, characterized in that the data communication device (7) has a plurality of network interfaces (29 to 32) for connection to different types of local networks and / or multiple communication interfaces (27, 35, 37 ) for connection to different types of sewing machines (3). Data acquisition and processing system according to one of claims 1 to 5, characterized in that the data communication device (7) has an input interface (33) for connection to a data input device (5) on the respective sewing machine (3). Data acquisition and processing system according to one of claims 1 to 6, characterized in that the data communication device (7) has a rewritable latch (23, 24) for storing work data of the data communication device (7) connected to sewing machines (3). Data acquisition and processing system according to one of claims 1 to 7, characterized in that the data communication device (7) has an internal clock (25). Data acquisition and processing system according to one of Claims 1 to 8, characterized in that the central monitoring and control computer (11) has an evaluation module (53a) for the statistical evaluation of the working data received by the data communication device (7). Method for monitoring and controlling a composite (2) of industrial sewing machines (3) with a data acquisition and control system Processing system (1) according to one of claims 1 to 9, comprising the following steps: Detecting (47) work data of the sewing machines (3) via the respective machine control (4), Forwarding (49) the work data from the respective machine controller (4) to the data communication device (7), Forwarding (51) the working data from the data communication device (7) to the central monitoring and control computer (11), Monitoring (53, 54) the work data by the central monitoring and control computer (11). Method according to claim 10, characterized by the following steps: Predetermining (42) sewing process data for at least one of the sewing machines (3), Forwarding (44) the Nähprozessdaten from the central monitoring and control computer (11) to the data communication device (7), Forwarding (46) the sewing process data from the data communication device (7) to the respective machine control (4). A method according to claim 11, characterized in that the presetting (42) of the Nähprozessdaten using a via the local network (9) connected to the central monitoring and control computer (11) pattern sewing machine (14). Method according to claim 11 or 12, characterized in that the sewing process data are stored (43) in the central data memory (18). Method according to one of claims 10 to 13, characterized in that the working data via a data input device (5) of the respective sewing machine (3) is entered (48). Method according to one of claims 10 to 14, characterized by a buffering (45, 50) of the working data in the data communication device (7) until the retrieval of the working data. Method according to one of Claims 10 to 15, characterized by a statistical evaluation (53) of the working data received by the data communication device (7) in the central monitoring and control computer (11). Method according to one of claims 10 to 16, characterized by a storage (52) of the working data in a database format. Method according to one of claims 10 to 17, characterized by displaying (54) the working data.

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