EP2483461A1

EP2483461A1 - Method for optimizing a textile production process

Info

Publication number: EP2483461A1
Application number: EP10763582A
Authority: EP
Inventors: Thomas Nasiou
Original assignee: Uster Technologies AG
Current assignee: Uster Technologies AG
Priority date: 2009-10-02
Filing date: 2010-10-01
Publication date: 2012-08-08
Also published as: CN102575388B; CN102575388A; WO2011038525A1; JP2013506059A; JP5792730B2; CH702009A1

Abstract

The invention relates to a method for optimizing a textile production process (101), in which a textile end product is produced. The production process (101) is represented in a mathematical model (102) that contains a parameter set ({x₁,..., x_n}) with at least one parameter (x₁,..., x_n) as an element. At least one variation parameter (x_i) from the parameter set ({x₁,..., x_n}) is varied (106) in the model (102) by respectively one variation (Δx_i). An effect of the at least one variation (Δx_i) onto a financial value (P) of the end product is evaluated (108). As a function of the result of the evaluation (108), the at least one variation (Δx_i) is carried over (109) into the production process.

Description

METHOD FOR OPTIMIZING A TEXTILE

PRODUCTION PROCESS

AREA OF EXPERTISE

The invention is in the field of textile production, in particular of spinning. It relates to a method for optimizing a textile production process, a computer program product for carrying out the method and a textile plant according to the independent patent claims.

STATE OF THE ART

In textile factories, raw materials or intermediates are processed into a final product of the production process in a textile production process. For example, a spinning mill processes raw cotton in several processing steps via intermediate products such as sliver into a yarn. The raw cotton and the intermediates in different workstations go through different

Processing steps such as opening, cleaning, carding, combing, drawing, pre-spinning, fine spinning and finally spools.

WO-2005/054551 AI describes a method and an apparatus for

Job control of a manufacturing process for a fiber product. In order to control and monitor a manufacturing order based on the manufacturing process, an actual target evaluation is made between one by the production order

predetermined target specification and an actual state of the manufacturing process performed. The determined deviation from the target specification is displayed. This enables planning to execute production orders. The teaching of WO-2005/054551 AI deals well with the production time and the production volume, but not with the financial value and quality of the

Final product. The EP-0'415'290 AI sets itself the task, the working speed of a

To regulate the ring spinning machine so that their production yield is close to the maximum of the achievable economic yield. To solve the actually existing yarn breakage recovery capacity is determined, and a target specification for the rotational speed of the spindle is determined as a function of the number of determined yarn breaks per unit time and the actually existing yarn breakage capacity. The determination of the setpoint for the speed is carried out by a fixed

Speed setpoint profile, which provides a basic value for the speed as a function of

Spinnkopsaufbauzyklus is corrected with correction values. The correction values are automatically determined in an optimization procedure. In this case, the gain can be maximized as a function of speeds in different areas of Kopsbildung. This optimization method is valid only for a certain ring spinning machine or a certain category for ring spinning machines. In addition, the whole thing is running

Optimization procedure automatically, without an operator would have the opportunity to influence it according to their own ideas.

PRESENTATION OF THE INVENTION

It is an object of the present invention to provide a method which makes it possible to optimize a complex textile production process. The results should be as general as possible and independent of the machine types used. The method should offer the possibility to try out different scenarios and to compare them, without the new settings having to be taken over into the production process.

These and other objects are achieved by the method, the computer program product textile operation, as defined in the independent claims. Advantageous embodiments are given in the dependent claims.

The invention starts at a higher level than EP-0'415'290 AI. In a mathematical model of the textile production process to be optimized such Variation parameter varies depending on the starting material, an intermediate, the final product and / or the production process itself, but not on the

Refer to the production process used machines. This achieves that

Process according to the invention a generality that allows it to be used in a variety of textile manufacturing plants, regardless of which specific machines are used in the relevant plant. Furthermore, in the method according to the invention, an effect of the variation on a financial value of the end product is evaluated. The assessment, possibly incorporating other aspects such as the resulting quality of the final product and / or the duration of the production, will lead to a decision as to whether or not the variation will be incorporated into the production process. Preferably, an operator may intervene to specify the variation and / or to make the assessment. Trying out different scenarios leads to a deeper understanding of the production process, which can therefore be optimized. Alternatively, the method may proceed automatically without the intervention of an operator.

Accordingly, in the inventive method for optimizing a textile production process in which at least one starting material is a textile

The production process is mapped in a mathematical model containing a set of parameters with at least one parameter as an element. At least one variation parameter from the parameter set relating to the at least one starting material, an intermediate product, the end product and / or the production process but not to machines used in the production process is varied by one variation in the model. An impact of at least one

Variation on a financial value of the final product is assessed.

The corresponding models, algorithms and formulas needed for the calculations are known per se, e.g. From the following publications:

W. Klein, "The Technology of Short Staple Spinning," The Textile Institute, 2 ^nd ed., 1998

• "Rieter Spinning Documentation", Rieter Marketing, 1999

• "Short Staple Spinning", Bräcker AG, 2008. They therefore need not be further elaborated here.

In a preferred embodiment of the method according to the invention, the at least one variation in the production process is adopted depending on the outcome of the evaluation. The textile production process is z. Spun or spun yarn, and the at least one variation parameter is selected from the following set:

Number of cuts per yarn length or per unit of time, proportion of combing in the case of

Combing, number of end breaks in ring spinning, replacement time of ring traveler in ring spinning, delivery speed of the line, quality of raw cotton, proportion of outliers in the yarn. In addition to the financial value, further aspects such as quality of the end product and / or production time can be included in the evaluation. In this case, a choice of the variation parameter, a choice of the parameter values and / or a choice of the variation are preferably made so that the quality of the end product remains approximately the same or at least not significantly reduced.

The choice of the at least one variation may be made by an operator through an input on an input device. Alternatively, a selection of the at least one variation parameter and / or the selection of the at least one variation can be carried out automatically by a computer.

Preferably, after the at least one variation, the effect of the at least one variation on the financial value is output on an output unit and the evaluation is made by an operator. In this case, it is advantageous if, after each input, the effect of the entered at least one variation on the financial value is calculated and output immediately. Alternatively, however, the

Evaluation to be performed automatically by a calculator.

An electronic display unit preferably provides a user interface with input and output fields, which is advantageously displayed on a single screen page. The inventive computer program product includes program code stored on a machine-readable carrier for carrying out the method according to the invention when the program product runs on a computer.

The inventive textile operation is for the execution of a textile

Established production process and includes a calculator on which the

inventive computer program product expires.

TITLE OF DRAWINGS

The invention and an advantageous embodiment will now be described with reference to

Drawings described in more detail.

FIG. 1 shows a flowchart with the method according to the invention.

FIG. 2 shows an embodiment of a user interface as shown in FIG

inventive method for optimizing a Garnspulproze!

Can be made available.

EMBODIMENT OF THE INVENTION

FIG. 1 shows in a flow chart the basic idea of the method according to the invention. The starting point is a textile operation in which a textile production process 101 is carried out. This is, for example, a spinning mill that produces a yarn as a final product from raw cotton delivered in bales as a starting material. Intermediate processes in this production process 101, that of different

Work stations are running, z. For example: opening, cleaning, mixing, carding, doubling, combing, drawing, spinning and / or winding. Each of these intermediate processes may be characterized by various parameters relating to the starting product, an intermediate product, the end product, the workstations, and / or environmental conditions during the production process 101 can. These parameters or a subset thereof ultimately characterize the entire production process 101.

A mathematical model 102 of the production process 101 is set up, which contains parameters of the production process 101. The model 102 provides a

production volume

M = M (x _i , ..., x _n ), where {x _i , x _n } is an amount of the parameters entering the model 102, and n is a natural number indicating the number of parameters considered. The

Production amount M preferably refers to the final product. You can z. B. refer to a unit of time or to a certain amount of the final product.

At least one variation parameter Xj, which is to be varied, is calculated from the

Parameter set {xi, x _n} is selected 103, where 1 <i <n. It is to such a parameter related to the starting material, an intermediate, the final product and / or the production process 101, but not in the production process 101 used machines relates. The variation parameter Xj should also be able to be varied within certain limits in the real production process 101. The selection 103 of the variation parameter Xj can be done manually by an operator or automatically in a computer.

In a next step, the values of the parameters x _l5 x "are set 104. These are preferably those values that are currently set in the production process 101 to be optimized. Also, a price p per quantity M of the final product to which the production quantity M refers is input 105. A financial value P - or a total price which can be obtained with the production quantity M (per unit time, per quantity of the starting product, etc.) -, is accordingly

P = p - M The selected variation parameter Xj is varied 106. For this purpose, a variation Δχ; or a new variation parameter value

A ' ₍ .' = X _t + Δχ ₍ .

From the model 102 and inputs 103-106 as described above will now be a difference in value or change in value ΔΡ between the financial value P ', which is achieved with the varied parameter set {xi, Xj + Δχ ;, x _n}, and the financial value P , which matches the original parameter set {x _{l 5} ... , Xj, ..., x _n } is calculated automatically 107:

AP = FP = p ^■ [(x,... + Δχ,,..., X-M (x _l x,, ..., x _n )] or, in differential notation,

AP = FP = p. Ax. ~ M (x _} , ..., x _n ).

Oxi

The value difference ΔΡ can be positive, negative or zero. A positive value difference (ΔΡ> 0) means that with an assumption of the variation Δχ; a higher price could be achieved in the production process 101 than with the original variation parameter Xj and vice versa.

The value difference ΔΡ goes into a valuation 108 of the variation Δχ; one. It may, but need not be, the only quantity considered in Rating 108. Other variables that can be included in the rating 108, z. B. a quality of

End product or a production time, or the corresponding differences of the varied model compared to the unvaried model. The quality can be estimated from experience or numerically quantified by one or more quality indicators become. The score 108 may be made by an operator or automatically by a computer.

If the outcome of the rating 108 is satisfactory, then the new one

Variation parameter value

taken over in the real textile operation 109. As a result, the production process 101 is optimized. Otherwise, one or more of the inputs 103-106 described above are changed, e.g. B. a new variation parameter Xj and / or a new variation Axj chosen, and thus calculates again the value difference ΔΡ 107. The acquisition 109 can be done manually by an operator or automatically. In the latter case, one can arrive at a controlled textile production process 101 in which the variation parameter Xj is the controlled variable.

The sequence of individual steps 103-106 in the exemplary method according to FIG. 1 can be reversed. So it is z. For example, the choice 103 of the variation parameter x; after entering 105 the price p per quantity, etc.

As mentioned above several steps 102-109 of the inventive method can be performed by an operator or automatically by a computer. Both variants can have their applications. It could, however, be particularly advantageous, in particular, for the selection 103 of the variation parameter xj and / or the selection 106 of the variation ΔXj to be carried out automatically by a computer. A computer is particularly well able to perform these selections. It can numerically derive its partial derivatives from the given function M (xi, x ") for all i = 1, n compute. In those places where the partial derivatives are large, the greatest effect can be achieved with a variation Axj. Therefore, such a variation brings Δχ; the most effective optimization.

At the same time, a plurality of variation parameters XÜ, Xß,... From the parameter set {xi, x "} can be selected 103 and varied 106. The above description, for the sake of simplicity, refers to a single variation parameter Xj, which, however, is the

Generality of the invention is not intended to limit.

Figure 2 shows an example of a user interface 2, as they are for the inventive method on an electronic display unit, for. As a computer screen, can be provided. The embodiment relates to the influence of cutting numbers when winding yarn. The user interface 2 contains fields for input and output as well as, optionally, further information. The inputs can via an electronic input unit, eg. As a computer mouse or a keyboard can be made. The display unit and the input unit can be combined in a touch screen. Especially clear, simple and therefore advantageous is the user interface 2 on a single

Screen page. This means that all fields for inputs and outputs are visible on the display unit at the same time.

In the exemplary embodiment of FIG. 2, input fields 21 1-215 for inputs 104 (see FIG. 1) of five parameter values x _l5 ..., X5 are located in an upper part 21 of the user interface. The inputs 104 are made by means of sliders or numerical entries in input boxes, which are located at the top left. The five parameters are the following:

At the top right in FIG. 2, there are further input fields 221-224 for inputs 104, 106 of two variation parameters x ₆ , x ₇ and their variations. These entries can be made by means of pointers or numerical entries in corresponding entry boxes. The two variation parameters in this example are the following:

For input 106 of the variations Δχ ₆ , Δχ ₇ , the variation parameters are provided below the input fields 221, 222 for the original parameter values x ₆ , x ₇ input fields 223, 224 for new or desired values χ ₆ ', x ₇ '. The exemplary new values are: x ₆ '= 22 cuts / 100 km,

x ₇ '= 33 cuts / 100 km.

Below the input fields 223, 224 for the new variation parameters χ ₆ ', x ₇ ' are input fields 231, 232 for the input 104 of two further parameter values x ₈ , X9, namely:

These inputs 104 can be made by incremental buttons or by numeric entries in corresponding input boxes.

Below the input fields 231, 232 for the two further parameter values x ₈ , X9 is an input field 241 for the input 105 of a price p per coiled yarn amount, which in the exemplary embodiment of FIG. 2 amounts to $ 2.5 / kg. The price entry 105 can be made in the same way as the entries 104 of the two further parameters x ₈ , X9. It goes without saying that the inputs of the parameter values xi,..., X9 can be made in other ways known per se than those described above by way of example. The total number of parameters n may differ from the example value 9.

Finally, at the bottom right on the user interface 2, an output field 251 for the output 107 of an automatically calculated value difference ΔΡ between the financial value P ', with the varied parameter set {x _l5 ..., χ ₆ ', x ₇ ', ... , xs _> }, and the financial value P obtained with the original parameter set {xi, x ₆ , x ₇ , X9}. According to the embodiment of Figure 2 can be saved with the input reduction of the cutting numbers $ 9 736 per year.

In addition, 2 further outputs can be provided in the lower left part of the user interface. In the embodiment of Figure 2, this is a bar graph 260 for various efficiency losses expressed as a percentage. A first pillar 261 indicates efficiency losses due to dyno changes, eg 11%, a second pillar 262 efficiency losses due to the original cut numbers, eg 11%, and a third pillar 263 efficiency losses due to the new cut numbers, eg 9%. The calculated value difference ΔΡ results from the increase in efficiency, as can be seen from the comparison between the second 262 and the third 263 column.

A positive value difference (ΔΡ> 0), as it results in the embodiment of Figure 2, does not necessarily have to a takeover 109 of the varied

Parameter set {xi, ..., χ ', χ ₇ ', ..., X9} lead into the production process 101. Before such a takeover 109 further calculations and / or considerations should be made. These can, in addition to the financial value P, z. For example, consider the following aspects:

• Quality of the final product. The desired reduction of the cutting numbers can also change the quality of the yarn produced. The reduction in quality may also result in a reduction of the achievable price p per kilogram of yarn. This could be taken into account in the model 102 by providing on the user interface 2 another (not shown) input field for the new price p 'per kilogram. Alternatively could a table or a function are stored in a memory of the executing computer, which assigns each yarn quality (or each set number of cuts) the corresponding price p 'per kilogram. In a preferred

Embodiment of the invention, however, the choice 103 of

Variationsparameters X ;, the choice of the parameter values x _l5 ..., x _n and / or the choice 106 of the variation Δχ; made so that the quality of the final product remains approximately the same or at least not significantly reduced. In other words: Advantageously, the method according to the invention is carried out in a region in which the variation Δχ; a small change AQ »0 of the quality, but causes the largest possible change ΔΡ» 0 of the financial value. A computer can find such areas particularly well. In this preferred case, the variation Axj does not affect the price p per set.

• Time required for the production process 101. In the embodiment of Figure 2, the time is taken sufficiently into account by the parameters x ₄ and x ₅ .

Results of calculations on such further aspects may be made on the

User interface 2 are displayed in graphical and / or numerical form.

The choice 103 of the cut numbers x ₆ , x ₇ as variation parameters is only one of many possibilities. Examples of further variation parameters Xj in a spinning mill are the following:

• proportion of combing rings when combing

• Number of end breaks during ring spinning

• Replacement time of the ring traveler during ring spinning

• Delivery speed of the route

• Quality of raw cotton

• Share of outliers in the yarn during spinning and winding.

Depending on the choice 103 of the at least one variation parameter x; can the parameter set {x _1? x _n } be different. The choice 103 of the at least one variation parameter x; can be done by selecting the appropriate user interface 2. Alternatively, a single user interface 2 can be provided, on which the at least one variation parameter x, is selected. Of course, the present invention is not limited to those discussed above

Limited embodiments. With knowledge of the invention, the skilled person will be able to derive further variants, which also belong to the subject of the present invention.

LIST OF REFERENCE NUMBERS

101 production process

102 Model of the production process

103 Selection of the variation parameter

104 Input of parameter values

105 Enter a price per quantity

106 Choice of Variation

107 Calculation of the value difference

108 rating

109 Acquisition of variation in the production process

2 user interface

211-215 Input fields for parameter values

221, 222 Input fields for original values of the variation parameters

223, 224 Input fields for new values of the variation parameters

231, 232 Input fields for further parameter values

241 Input field for the price per quantity

251 Output field for the value difference

260 bar chart

261-263 columns for efficiency losses

Claims

1. A method for optimizing a textile production process (101), in which at least one starting material, a textile end product is produced, wherein the production process (101) in a mathematical model (102) having a parameter set ({xi, x "}) with at least one parameter (xi, x _n ) is included as an element,

characterized in that

at least one of the at least one starting material, an intermediate, the final product and / or the production process (101), but not in the

Production process (101) used machines related variation parameter (x,) from the parameter set ({x _l5 x _n }) in the model (102) by a variation (Axj) is varied (106) and

an effect of at least one variation (Δχ;) on a financial value (P) of the final product is assessed (108).

2. The method of claim 1, wherein depending on the outcome of the evaluation (108), the at least one variation (Δχ in the production process (101) is adopted (109).

3. The method according to any one of the preceding claims, wherein the textile

Production process (101) Spinning or winding of yarn and selecting at least one variation parameter (Δχ from the following quantity: number of cuts per yarn length or unit time, proportion of combing on combing, number of ring breaker failures, ring traveler replacement time

Ring spinning, delivery speed of the line, quality of the raw cotton, share of outliers in the yarn.

4. The method according to any one of the preceding claims, wherein in addition to the financial value (P) other aspects such as quality of the final product and / or production time incorporated into the evaluation.

5. Method according to claim 4, wherein a choice (103) of the variation parameter (xj), a choice of the parameter values (xi, ..., x ") and / or a selection (106) of the variation (λXj) are made that the quality of the final product remains approximately the same or at least not significantly reduced.

A method according to any one of the preceding claims, wherein the selection (106) of the at least one variation (Δχ,) is made by an operator by an input on an input device.

7. The method according to any one of claims 1-5, wherein a choice (103) of the at least one variation parameter (xj) and / or the choice (106) of the at least one variation (ÄXj) is performed automatically by a computer.

8. The method according to claim 1, wherein after the at least one variation, the effect of the at least one variation on the financial value is output on an output unit and the evaluation is performed by an operator ,

9. The method according to claims 6 and 8, wherein after each input, the effect of the input at least one variation (Δχ,) on the financial value (P) is calculated and output immediately.

The method of any one of claims 1-7, wherein the score (108) is automatically performed by a computer.

11. The method according to any one of the preceding claims, wherein on an electronic display unit, a user interface (2) with fields (211-215, 221-224, 231, 232, 241, 251, 260) is provided for inputs and outputs.

12. The method of claim 11, wherein the user interface (2) is displayed on a single screen page.

13. Compute rogrammprodukt with stored on a machine-readable carrier program code for performing the method according to any one of claims 1 to 12, when the program product runs on a computer.

14. Textile plant used to carry out a textile production process (101)

is set up, wherein the textile operation includes a computer on which runs a computer program product according to claim 13.