JP2002088598A - Online quality control system for yarn texturing machine - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an online quality control system for a yarn texturing machine, stably and accurately monitoring without contact the quality of the yarns in total, even the united yarns. SOLUTION: In this online quality control system for a yarn processing machine, capable of monitoring qualities of finished yarn produced by a yarn texturing machine online, the online quality control system for a yarn processing machine is equipped with a data collection part for measuring the shape of a finished yarn, subjecting the measured signal to an A/D conversion into measured data of digital value at a fixed sampling period and successively memorizing measured data in an at least latest fixed time and a quality monitoring part for obtaining quality indexes related to qualities of a finished yarn from the memorized measured data by each fixed time and monitors the qualities of a finished yarn by the quality indexes online.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an online quality control system for a yarn processing machine capable of monitoring the quality of processed yarn produced by a yarn processing machine such as a false twisting machine and an air processing machine on-line.

[0002]

2. Description of the Related Art False twisting machine, Airtaslan (registered trademark)
In a yarn processing machine such as a processing machine, quality inspection of a processed yarn package is performed so that a product having an abnormal quality, that is, a processed yarn package is not shipped. This quality inspection is usually performed manually and has a problem that requires manual operation. In addition, the inspection with the processed yarn package is an inspection of the surface layer, and there is an unavoidable problem that the quality abnormality in the inner layer cannot be inspected.

On the other hand, Japanese Patent Application Laid-Open No. Hei 7-138828 discloses a quality control device for a draw false twisting machine, which detects the tension of a running yarn being processed by a draw false twisting machine and detects a fluctuation of a predetermined value or more. A device for evaluating the package quality based on the number of times of integration and the time of integration has been proposed. Also, Japanese Patent Application Laid-Open No. 2000-119
Japanese Patent No. 924 discloses a loop unevenness detecting method for detecting loop unevenness which is an important quality of an air-processed yarn. A method of detecting loop unevenness of an air-processed yarn by detecting a yarn swaying state has been proposed.

[0004]

The above-mentioned prior art is effective for the above-mentioned problem in quality control of the processed yarn, but its application range is limited. Japanese Patent Laid-Open No. Hei 2
Japanese Patent Application Laid-Open No. 000-119924 requires an imaging means, and if this is provided for each weight, there is a problem in terms of equipment cost.
Japanese Unexamined Patent Publication No. Hei 7-138828 has a problem in application to a plying yarn in that a tension detector for measuring the contact with the yarn is used. Further, the demands for online quality management have become more sophisticated along with the enhancement of the function of the yarn, and a new online quality management system capable of managing quality that cannot be managed by the conventional method has been required.

The present invention has been made in view of the above situation, and is a non-contact yarn processing machine capable of stably and accurately monitoring the quality of plying yarns and the like, and capable of managing the overall quality. The purpose is to provide an online quality management system.

[0006]

That is, the present invention measures the form of a processed yarn in an online quality control system of the yarn processing machine which monitors the quality of the processed yarn produced by the yarn processing machine online. A data collection unit for A / D converting the measurement signal into digital value measurement data at a predetermined sampling period and sequentially storing the measurement data at least for the latest predetermined time; An online quality management system for a yarn processing machine, comprising: a quality monitoring unit that obtains a quality index related to the quality of a processed yarn from data; and monitors the quality of the processed yarn online using the quality index.

As described above, the present invention stores measurement data of the variation in the form of the processed yarn during a certain period of time, and obtains a quality index relating to quality from a large number of the stored measurement data at a certain period of time. With such a configuration, a comprehensive online quality management system can be realized in which stable and accurate quality indicators can be measured and different quality information can be simultaneously monitored by measuring one physical quantity. Further, since the variation in the form of the yarn can be stably measured by the photoelectric sensor, the present invention can be realized with a non-contact and inexpensive system.

In the present invention, the following are examples of the quality index monitored by the quality monitoring unit. One of them is CV (= standard deviation 偏差 average value) obtained by dividing the standard variance value of the measurement data in the form of a thread having a good correlation with the visual evaluation of the quality of a thread spot or the like by the average value. Note that this CV
The reason why the overall quality evaluation equivalent to that of visual observation is possible is considered to be the measurement of morphological changes including the important qualities of the processed yarn, such as conjugation, thickness, and variation.

Therefore, the average value or frequency distribution of CVs per package from the start of winding to full winding, or more specifically, the frequency distribution of CVs per package obtained by dividing the value range into a plurality of sections having a predetermined width. In addition, comprehensive evaluation of packages related to textile quality is also possible.

In addition, the overall evaluation of the package also includes the cumulative frequency distribution of CVs from the start of the measurement data to the full winding of the measurement data of the package, and the frequency distribution obtained by subjecting the measurement data to fast Fourier transform. No. It is possible to monitor another quality of the processed yarn, for example, the dyeability, from the time-series variation of the component in the specific frequency region. The system of the present invention has the advantage that it can be realized in a small system such as a microcomputer by processing the data collection unit with the highest priority interrupt processing of a fixed period and processing the quality management unit with a lower priority. is there.

From the above description, it is preferable that the form of the processed yarn is measured by a photoelectric sensor that detects the form based on the amount of reflected light or transmitted light of the light beam from the light emitting element. A two-optical axis photoelectric sensor including two sets of light-receiving elements and light-emitting elements that are orthogonal to each other and using the larger output as the sensor output is preferable from the viewpoint of stable detection. In particular, the effect is remarkable in the stable detection of the composite yarn showing a complicated morphological change.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to an embodiment using an air task run machine. FIG. 1 is an explanatory diagram of a basic configuration of one spindle of an air tasrun machine according to an embodiment.
Actually, this configuration is arranged in parallel with a predetermined weight.

As is apparent from the drawing, the air taslan processing machine of this embodiment has the same configuration as that disclosed in Japanese Patent Application Laid-Open No. H11-107093. That is, the core yarn A and the sheath yarn B to be processed are supplied from the respective packages of the yarn supply stand (not shown) through the yarn cutter 1 for the yarn cutting process. And the core yarn A shown by the dashed line in the figure is:
After passing through the yarn cutter 1, the yarn feeder 7A, the yarn guide 8
Is supplied to the fluid jet machining device 4 below the yarn guide through the yarn guide.

On the other hand, the sheath yarn B shown by a dotted line in the figure also passes through the yarn cutter 1, and thereafter, the yarn feeder 7B, the heating pin 2, the yarn feeder 7C, the yarn feeder 7D, the yarn heating device 3, and the yarn It is heated to a predetermined temperature by the yarn guide composed of the feed roller device 9A and supplied to the fluid jet processing device 4.

Here, the yarn feeders 7A to 7D are composed of a feed roller and an apron belt, and are adapted to press the yarn against the feed roller with an apron belt and feed the yarn at a predetermined speed. Each of the yarn feed roller devices 9A to 9B includes a feed roller and a nip roller, and feeds the yarn at a predetermined speed by pressing the yarn against the feed roller with the nip roller. As the yarn heating device 3, a device incorporating a tube heater based on a heating medium heating method was used.

The core yarn A and the sheath yarn B supplied to the fluid jet processing device 4 are processed by a jet jet and combined to form a predetermined processed yarn C shown by a solid line in the figure. The processing yarn C from the fluid jet processing device 4 is provided with oil by an oiling device (not shown) or the like as necessary, formed on the processing yarn package 6 by the winding machine 5, and is appropriately ball-shaped by a doff device not shown. It is configured to be fried.

In this embodiment, as shown in the drawing, in order to manage the operation status and the quality of the processed yarn package 6 of the product in the air turbulence processing machine having the above-described configuration, the yarn guide before winding is controlled. A yarn sensor 11 for detecting the form of the processed yarn C is provided. This thread sensor 1
For example, a well-known photoelectric sensor or the like may be used as long as it can continuously detect the form of a yarn traveling at a constant speed.

In the present embodiment, the yarn sensor 11 is
A two-optical axis photoelectric sensor comprising two sets of light-emitting elements and light-receiving elements whose optical axes are orthogonal to each other as disclosed in, for example, Japanese Patent Application Laid-Open No. 1-350269, and outputs the larger of the two output signals as a sensor measurement signal. Was used. Then, the measurement was performed such that the processed yarn C passed through the intersection of the optical axes in the same manner as disclosed in the publication. This makes it possible to detect the morphological change stably and accurately under a wide range of processing conditions up to a processing speed of 600 m / min with a processing yarn of up to 500 denier even with a processed yarn showing a complex morphological change, especially a plied yarn. It was confirmed that data necessary for detection and quality control could be obtained online.

In the quality control system of this embodiment, the quality of the processed yarn is continuously managed on-line based on the measurement signal from the yarn sensor 11. The details will be described below with reference to FIGS. FIG. 2 is a block diagram of the basic configuration of the quality management system of this example, FIG. 3 is a flowchart of a data collection unit of the management unit, FIG. 4 is a flowchart of a quality monitoring unit, and FIG. It is a flowchart figure.

The quality management system of this embodiment has the following configuration as shown in FIG. That is, a yarn sensor 11 provided on each weight for detecting a change in the form of the yarn, a scanning circuit 12 for sequentially switching and outputting the measurement signal from the yarn sensor 11 for each weight, and a measurement signal from the scanning circuit 12 D
An A / D conversion circuit 13 for converting the data into digital value measurement data; an interface circuit 14 for receiving the measurement data from the A / D conversion circuit 13; a computer 15 for reading and processing the measurement data of the interface circuit 14; The yarn cutter 1 is operated via the interface circuit 14 based on the processing result of the management means stored in the computer 15 to perform the yarn break processing.

The management means stored in the computer 15 includes:
A data collection unit shown in FIG. 3, a quality monitoring unit shown in FIG.
The display unit displays the measurement results and the like in response to the display request instruction shown in FIG. 5, and is configured to operate as follows. Although not shown, the management means can transmit and receive necessary information via the interface circuit 14 with a control device of the machine.

In the quality management system, the data collection unit shown in FIG. 3 collects measurement data from each yarn sensor 11 as follows. The data collection unit is activated at a constant period by an interrupt signal from a timer having the highest priority of processing. In this example, this period can be selected from 0.1 ms to 5 ms. This cycle is 0.5 mm to 2 mm in the sampling interval at the yarn length at a processing speed of 300 m / min.
This corresponds to 5 mm, which is a sufficiently small sampling interval for measurement of morphological variation, and can sufficiently cope with a processing speed of about 600 m / min in the above cycle.

When the data collection unit is started, it first enters a weight number setting step, and first sets a weight number for data collection to, for example, a first weight. Then, first, the process enters a winding flag determination step indicating whether or not the weight is being wound, in other words, is being processed, and determines whether or not the winding flag is ON.

If the winding flag is not ON and "NO", a winding start determining step is entered, and whether or not the weight has started winding is determined by a signal from the winding machine. If the winding is to be started, the process proceeds to "YES", and in the winding flag setting step, the winding flag is set to ON, and the process proceeds to a data reading step described later. "N" which is not the winding start
In the case of "O", the weight skips data collection, and proceeds to a step of determining the end of all weights described below.

When the winding flag is ON and when the above-mentioned winding is started, a data reading step is entered, and the weight of the set weight number, that is, the weight of the first weight in the first processing, specifically, the first processing is performed. The measurement signal of the yarn sensor 11 is read in the following manner. That is, a first weight selection command is issued to the scanning circuit 12, the first weight thread sensor 11 is selected and connected to the A / D conversion circuit 13, and the measurement signal is sampled by the A / D conversion circuit 13. A / D conversion is performed, and the obtained measurement data is read via the interface circuit 14.

Then, in the next data storage step, the read current measurement data is sequentially stored in the corresponding weight in the weight-specific storage area of a predetermined capacity. By the way, in the storage of the measurement data, all the measurement data during a certain period is stored, and this is updated every certain period. In this example, all the measurement data for one second is stored and updated in a one-second cycle for each weight. In this example, the interrupt cycle is 2 milliseconds, so that the latest 500 pieces of measurement data for each weight are stored in a one-second cycle. Therefore, in the present embodiment, whether or not data collection for a certain period has been completed is determined based on the number of stored data.

Therefore, when the data storage is completed, the process proceeds to a data number determination step, and it is determined whether or not the stored number of measured data has reached the predetermined value, in this example, the above-mentioned 500 data. 5
When the number reaches 00, the process proceeds to “YES”, and the process proceeds to the step of turning on the collection flag, and the collection flag for controlling the execution of the process is set to ON by a quality monitoring unit described later, and
500 measurement data are stored in a storage area for storage.

After this processing or when the number of stored measurement data is 5
If "NO" is less than 00, the process immediately proceeds to the step of determining the end of all the spindles. Then, in this determination step, it is determined whether or not the data collection for all the weights has been completed by the weight number.
In the case of “YES” of the end of all the spindles, this processing is exited and the operation is suspended until the next interrupt timing. On the other hand, "N
In the case of "O", the process proceeds to the step of incrementing the spindle number, increments the spindle number to be processed by 1, returns to the data reading step,
Next, the process proceeds to data collection of the second spindle. As described above, the data collection unit is configured to repeatedly store all the measured data during the predetermined period, in this example, every one second, accurately at the highest priority level for all the weights.

On the other hand, the quality monitoring unit serves as a quality index of the processed yarn based on the measurement data collected and stored in the data collection unit, and in this example, is useful for the management of the overall quality similar to the visual evaluation of the processed yarn. The configuration shown in FIG. 4 is such that the confirmed CV is obtained and monitored. This quality monitoring unit is processed at a lower priority level than the interrupt processing, and is started when the machine starts operating.

Then, first, a step of setting the weight number is performed. Here, the weight for processing the weight number first, for example, the first of the machine base is set.
Set on the weight. Next, the process proceeds to a determination step during operation to determine whether or not the machine is operating. If the machine is not operating and stops, the process proceeds to “NO” and the process ends. That is, in this example, the following quality monitoring process is repeatedly performed during operation, and the process is terminated only when operation is stopped.

If the vehicle is in operation, the process proceeds to "YES" and the following quality monitoring process is performed. First, a collecting flag determining step is entered, and it is determined whether or not the collecting flag of the weight is ON, that is, whether or not 500 data has been collected. If not completed, the process proceeds to “NO”, enters a weight number raising step, advances the weight number, and proceeds to a determination step of determining the end of all weights.

In this step, it is determined whether or not all the weights have been completed based on the weight number. If all the weights have not been completed, the process proceeds to “NO”, returns to the above-described determination step during operation, and proceeds to the next weight process. On the other hand, in the case of end of all weights,
Proceeding to "YES", the process returns to the above-mentioned weight number setting step, and processing is performed from the first weight. In other words, the quality monitoring process is repeatedly executed for each spindle sequentially while the vehicle is in operation.

As described above, when the number of data collected and stored in the data collection unit reaches 500, the collection flag becomes O.
Since the answer is N, the result of this determination is "YES", and the following quality monitoring process is executed. That is, the quality monitoring process is executed every 500 data collections, that is, at a period of approximately one second.

First, an average calculation step is entered, and an average value of 500 pieces of measurement data for one second stored in a storage area for storage is obtained. Next, proceed to the standard deviation calculation step,
A standard deviation value of the measurement data is obtained. And the next CV
In the calculation step, the CV of the quality index is obtained by the following equation.

[0035]

## EQU1 ## CV = standard deviation value ÷ average value

Next, a CV determination step is entered, and the obtained CV value is compared with a preset CV threshold value. And
If this value is equal to or larger than the CV threshold, it is determined as "CV abnormality" and "YE
S ". Then, in the thread break processing step,
The thread cutter 1 is operated to perform the thread break processing. As a result, the amount of defective products can be reduced. After this processing, the process proceeds to the step of resetting the winding flag.

On the other hand, in the case of "NO" below the CV threshold,
In the CV data storing step, the obtained CV value and the measurement time, that is, the main processing time are stored in the weight-specific CV file. Next, a step of determining whether the package is full is entered.
It is determined whether or not the processed yarn package of the weight is full. This determination is made based on a signal from the winder or the like. And
In the case of “NO” before full winding, the quality monitoring process of the weight is ended, and the process returns to the weight number incrementing step.

On the other hand, in the case of "YES" indicating that the winding is full, as in the case of the CV abnormality, the winding flag is reset and the winding flag is turned off. Next, the process enters a package file creation step. In this step, all the CV measurement data from the start of winding to the end of winding is stored in a storage location for each package and for each package as a file of the fully wound or thread-cut package. After this processing, the process returns to the step of raising the spindle number, and proceeds to the processing of the next spindle.

As described above, for the packages processed by all the weights, CV data necessary for quality control is collected and stored for each package. Then, the quality control system of the present example displays the result on the display unit as required. The display unit of this example is configured as shown in FIG.

When a display request is input from an input device such as a keyboard of the computer 15, the computer starts up, and first enters a display setting step to set contents to be displayed, for example, a weight, a range of a package, and the like. For this setting, a setting table in a predetermined format is displayed and input to the setting table. In this example, a weight range, a package range, and a display method can be specified. The display method will be described later.

Then, when the input is completed, the process enters a data extraction step, in which data necessary for the designated display is extracted and processed. That is, the data of the designated weight and package is read from the package file, and the processing according to the content, for example, if the average value, the average value for each package is obtained and stored in a predetermined storage area. Then, a display step is entered, and the display is performed on a display device such as a liquid crystal display of the computer 15 in a designated display method, for example, a graph.

Next, the display end determination step is entered.
It is determined whether there is a display end request from the input device. If there is a display end request, display end processing is performed in an end processing step, and the display unit ends the processing. If there is no end request, the process proceeds to [No], and enters a display change request determination step. In this step, it is determined whether or not there is a display change request from the input device. If there is a change request, the process proceeds to “Yes” and returns to the display setting step. If there is no request, the process proceeds to “No” and the current display is continuously displayed.

By the way, in the present embodiment, the quality index can be displayed by the following various display methods by designation. In other words, in this example, the starting point of the winding of the processed yarn package is set as the origin, the elapsed time after that is set as the horizontal axis, the CV time-series variation graph in which the CV value is plotted on the vertical axis, and the CV value range is set as the horizontal axis. C is divided into a predetermined number of sections having a constant width, and the vertical axis represents the number of CV data measured from the start to the full winding of the processed yarn package belonging to each section.
The V frequency distribution graph and the weight-based list graph for displaying the average value of packages processed at the same time in all weights by weight can be displayed by the respective display methods.

FIG. 6 shows an example of the CV measurement result. This example is a measurement example of nylon Taslan yarn. It is a frequency distribution graph showing the average value of the CV measurement value of the surface layer portion of each processed yarn package manufactured at the same time by all the weights of the Taslan processing machine having the above-mentioned weight configuration having 108 weights. In this graph, a package having an average CV of 13% or more was determined to be a nonstandard product. This determination is based on a visual inspection of the surface layer. The results show that the correlation with the visual inspection is stable, and that the quality can be evaluated by CV.

As described above, according to the present embodiment, the quality control of the whole processed yarn package, which has been overlooked in the conventional quality control of only the surface layer portion, can be performed, and the inspection work of the quality control can be rationalized. Also, in this example, the data collection unit that does not allow processing delay is processed to the highest priority interrupt processing to ensure reliable data collection, and the quality monitoring unit that allows time delay in processing is given a lower priority level The display unit processes only when necessary, and can be processed sufficiently by a computer such as an inexpensive microcomputer.

As described above, the present invention has been described based on an example in which the present invention is applied to an air tasrun machine. However, it is apparent from the gist that the present invention is not limited to such an embodiment. For example, it is effective in the processing of ply yarn, but can also be applied to the processing of single yarn. The processing method can be applied to not only the air taslan processing but also false twist processing.

[0047]

As described above, the present invention provides a new quality index CV to control the overall quality of a processed yarn package by using a new quality index, CV, which has been difficult in the past, especially on-line quality control in the processing of yarn. Realized quality control that enables quality assurance from the beginning to the full winding of the package in the yarn processing process, which contributes to labor saving, and furthermore, to a large contribution to stable production and improvement of productivity. To do.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a basic configuration of an air task run machine to which the present embodiment is applied.

FIG. 2 is a block diagram of a basic configuration of a quality management system according to the present embodiment.

FIG. 3 is a flowchart of the data collection unit and the abnormality processing unit.

FIG. 4 is a flowchart of the quality monitoring unit.

FIG. 5 is a flowchart of the display unit.

FIG. 6 is a graph of a CV measurement result.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Yarn cutter 2 Heating pin 3 Thread heating device 4 Fluid jet processing device 5 Winding machine 6 Processing thread package 7A to 7D Thread feed device 8 Thread guide 9A to 9B Thread feed roller device 10 Oiling roller 11 Thread sensor 12 Scanning circuit 13 A / D conversion circuit 14 Interface circuit 15 Computer

Claims (7)

[Claims] 1. An online quality control system for a yarn processing machine for monitoring the quality of a processed yarn produced by the yarn processing machine online, the form of the processed yarn is measured, and a measurement signal is digitally output at a predetermined sampling period. A data collection unit that A / D converts the measured data into values and sequentially stores the measured data at least in a predetermined cycle, and a quality monitor that obtains a quality index related to the quality of the processed yarn from the stored measured data in the predetermined cycle And an on-line quality control system for the yarn processing machine, wherein the quality index of the processed yarn is monitored online by the quality index. 2. The CV obtained by dividing the standard deviation value of the stored measurement data by the average value of the quality index (= standard deviation value ÷
The online quality control system for a yarn processing machine according to claim 1, wherein the average quality is an average value. 3. The quality index further includes a CV for each package.
3. The online quality control system for a yarn processing machine according to claim 2, further comprising a frequency distribution of CV for each package obtained by dividing an average value and / or a value range of CV into a plurality of sections having a predetermined width. 4. The online thread processing machine according to claim 1, wherein the data collection unit is processed by an interrupt process of the highest priority in a fixed cycle, and the quality control unit is processed by a lower priority. Quality control system. 5. The yarn processing machine according to claim 1, wherein the yarn processing machine is an air processing machine.
5. An online quality control system for the yarn processing machine according to any one of items 4 to 4. 6. The quality control system for a yarn processing machine according to claim 1, wherein a form of the processed yarn is detected by a photoelectric sensor. 7. The processing yarn is a plying yarn, and the photoelectric sensor includes two sets of light receiving elements and light emitting elements whose optical axes intersect at right angles.
7. The quality control system for a yarn processing machine according to claim 6, wherein the quality control system is a two-optical axis type photoelectric sensor that uses a larger output as a sensor output.