The invention concerns, at the least, one exchangeable machine component, that is to say, a replaceable part of a spinning machine, which component possesses an identification recognition symbol for automatic detection by a sensor apparatus.
EP 0 922 797 A2 discloses a spin rotor for an open end spinning machine, in which an identification marking is placed at the outer circumferential rim of the rotor bowl. The identification marking is read in a non-contact manner by a sensor on a service unit. This signal, which is captured by the sensor apparatus with the aid of the identification marking, is compared with data in a control arrangement. The service unit can delay a resumption of spinning, if the signal from the identification marking does not coincide with the pre-input data of comparison. By this means, assurance is provided, that only technically safe, fully qualified spin rotors are allowed to be installed. Identification markings have been proposed which take the form of a bar code or of a transponder. The sensor apparatus can also detect an identification marking either optically or by induction. For the detection of the identification marking, the covering of a spin-box, in which the spin rotor is placed, must be opened and the spin rotor driven by an auxiliary power wheel, so that the identification marking is rotated in proximity to the sensor apparatus.
EP 1 035 241 A1 likewise makes known a spin rotor, in the case of which, on the outside of the outer circumference of the rotor bowl, a recognition symbol is placed, which, upon stillstand of the spin rotor can be visually recognized by a person. This system, however, excludes any automatic control of the spin rotor.
Thus it is the purpose of the invention, to develop an exchangeable component of a spinning machine in such a manner, that an automated control and/or quality control system can be converted to use on the said machine.
This purpose is achieved by the features of the Claims 1, 24, 28 or 35.
In accord with Claim 1, an identification recognition statement for the automatic capture of the of the recognition by means of a sensor apparatus is placed on the inner circumference and/or on the bottom of a bowl of a spin rotor. The placement of the identification symbol on the inside of the rotor bowl makes possible an automatic reading of the marking (or recognition symbol) during either the turning or the stillstand of the spin rotor. Advantageously, for the said reading, the spin box, under which the rotor is housed, does not have to be opened. For example, although the rotor box is closed, by means of entry through a thread withdrawal nozzle and a thread withdrawal tube, a detector can be inserted into the spin box and positioned to survey the inner surface of the rotor bowl. The advantage is that when this is done it is not necessary that changes to a conventional spin box need be made. Such detection can, for example, be carried out with an apparatus similar to an endoscope, as is described in the following.
At the same time, because of the placement of the identification recognition symbol on an inner surface of the rotor bowl, a contamination of the bowl can be detected. Such a contamination occurs, for example, during a long run of the spin rotor, when unclean materials secrete themselves in the start materials of the fiber band. Contamination can also occur, when individual fibers are not bound into the withdrawn yarn but accumulate, for example, near to the rotor grooving or it the center at the axis of rotation. The impurities degrade the yarn quality and lead, for example, to a thread monitor giving a fault signal. In spite of automatic rotor cleansing, before a resumption of spinning, such contamination can remain behind and leads then, after the spinning has begun, once again to a deterioration of the yarn quality, which finally results in a creeping lessening of the value of the yarn. Such difficulties can, from a statistical standpoint, only be recognized and determined after a long period of time.
By means of the placement of the identification symbol on an inner surface of the rotor, then such contamination coats over an area close to or on the identification symbol, so that this becomes illegible for the automatic detection apparatus. By means of the identification symbol, the contamination is detected because, the identification symbol cannot be read or the strength of the signal from the identification symbol falls below a specified set value. In this way, before the generation of a gradual deterioration of the yarn, by means of the detection of the identification symbol, such a contamination is discovered in good time. After the recognition of such a contamination, a fault announcement is emitted, which then signals to the operating personnel, that the rotor must be changed or cleaned.
The rotor bowl is, in this exercise, a machine element, that is a component of a rotor spinning machine, which is changeable, dependent on the desired product characteristics or if subject to wear. For example, the rotor diameter is chosen because of the desired speed of production of the yarn. Likewise, the type of rotor, that is to say, the make-up of its surface and its shaping, has an influence on the quality of the yarn. Or the type of rotor depends on what kind of threads are intended to be to be spun to a particular yarn. All of the pertinent information for these data can be extracted from the identification symbol and subsequently can be transmitted to a machine control mechanism. In this way, for example, data evaluation can take place, as to whether or not the desired kind of yarn, which was input to the machine control is compatible with the detected, exchangeable machine component. That is, as to whether or not the desired kind of yam can be produced with the type of an exchangeable machine component which is in use at that particular spinning station. In this way, an automatic configuration determination for each single spinning station on a spinning machine is made possible. This advantageous determination is an assist to the quality control sector.
Besides the rotor bowl, a spinning station of a rotor spring machine possesses additional, exchangeable components and machine parts which, likewise, have influence on the kind of yarns produced and their quality. Other than quality control factors, the automatic detection of the identification mark and the comparison of these with the allowable components for the spinning machine, provide a possible way for increasing the operational safety and the protection of the operating personnel of the spinning machine.
The above advantages to the rotor bowl are also correspondingly valid for many exchangeable components, which my directly or indirectly have an effect on the type of yarn and its quality, which means also affecting the type and quality of the products of a textile operation. The exchangeable components are, for example, insofar as a rotor spinning machine is concerned: a disintegrator roll, a rotor shaft of the spin rotor, a support disk for the bearing system of the spin rotor, a withdrawal nozzle, a thread out-take tube, a feed hopper or a fiber beard support or a sensor for the quality of yarn.
In general, the range of spinning machines includes a rotor spinning machine, a friction spinning machine, a ring machine, a carding machine, a stretch works, a air-jet spinning machine and the like, which respectively possess at least one exchangeable component or replaceable part, which either directly or indirectly has an influence on the product quality.
Advantageously, the identification recognition symbol is the same, in construction or application, in all exchangeable components, so that for the reading of the identification symbol a uniform, identical capture system with, for example, the same detection equipment can be installed.
If the identification symbol is a spectral identifiable color marking, then, for example, for the construction type of the exchangeable component, for each construction type, a characteristic base color can be used. If the base color lies in the visual perception area, then the operational person can recognize by the different colors alone—that is the different base colors representing the different construction types—what construction type is involved and which construction type has actually been installed in the spinning station. In this case, the color marking is easily detected and can be assigned without failure by the operational personnel. It is of advantage, if, for a specific kind of the yarn to be produced, all exchangeable components are provided with the same color markings, so that the operational personnel on a spinning works machine need only to monitor the agreement of the colors. In this way, the safety is increased in regard to the furnishing of a spinning machine (or spinning station) and the automatic detection system would, on this account have fewer fault-displays as a result.
If, in the case of the color markings, different color portions are employed, then the complex recognition pattern, possesses a higher degree of information input, than by means of one color area, because of the several spectral colors which can be differentiated.
When this is done, the information density over the same surface available for the marking, need not call for too great a spatial optical separation, i.e., resolution. For instance, in such a case, the colors could be overlapped, and, by means of the sensor element (for which the resolution is in the spectral realm) the colors could still be differentiated. Especially, in the case of spin rotors which are rotating at an extremely great RPM, it is not necessary to call for a high spatial separation of the marking by means of the sensor element. Because of the relative speed of the identification marking, relative to the sensor element, by exclusively spatial marking, such as a bar code, a likewise extremely high scanning rate of the sensor would be required.
By means of the application of the ultraviolet and/or the infrared bands of the spectrum at the color markings, the relevant information content increases with thereby achieved extension of the spectral band. The use of the infra red spectral band allows the sensor to be relatively free of disturbances due to dirt accumulation thereon during the measurement. On the other hand, a measurement in the UV spectral band, brings about a greater spatial resolution.
If the identification recognition marking is provided in an area on the exchangeable component, which is subject to abrasive attack, simultaneously, along with the identification, this can become a test of the degree of wear. For instance abrasive wear to an intolerable degree is in effect as soon as the identification symbol is so far worn away, that this can no longer be read, or as soon as the signal threshold of the detector sensor drops below a specified set value. For instance, the spectral sample of the coating on the teeth on a disintegrator of a fiber band disassociation apparatus is in itself useful as an identification recognition symbol. As soon as the abrasion protection coating wears, at the same time the failure to read the identification recognition symbol, is also a measurement of the degree of wear.
If the periodicity of the signals obtained from the identification recognition symbol is monitored, then, from this, in the case of a rotatably, bearing set, component, the RPM thereof can be measured. This makes possible a comparison of the actual RPM with a specified RPM input into the machine control. In the case of a deviation of the RPM from a given tolerance range, a fault-announcement can be made. In this way, a recognition of failure and a preventive quality control put in action.
If the identification recognition symbol is marked in the form of a profile on a surface of an exchangeable component, then, for example, by means of scanning by a propinquity sensor, or by recognition of a pattern of the said surface profile, the recognition can be carried out. For example on the covering of a support disk, by means of the number and the type of the aeration ridges on the running surface of the said support disk, the type of the disk can be recognized.
Likewise, for example, with the aid of the diameter of the rotor bowl, the type of the spin rotor can be determined, when, at the spin box of a rotor spinning machine, rotors of different diameters are used.
Where the identification is concerned for an exchangeable machine component, in accord with Claim 24, by the capture of the identification recognition symbol, each individual machine component can be individually recognized and identified. This enables Quality Control to determine that the complete operating life of the so determined component is in normal progress. Thereby, the sequence of use in production of the machine component, which, possibly is put to use in various machines. Further, a record can be made of later tracking of the applications of the said machine component. This is of value, if a spin rotor is run for a certain period at the spinning station, and then, for the purpose of the production of another yarn, is taken out and inventoried for a particular interim. At a later point in time, then this spin rotor is again installed and used further. With an identifying recognition for its individuality, it is possible to protocol and evaluate the entire life of a single spin rotor and upon need, therewith also the achieved degree of quality.
Alternatively to, or in addition to, the individualized identification recognition symbol, the production batch number for the exchangeable machine component can be obtained.
With the aid of the component-batch recognition, it is possible, with a parallel record of thread production, to correlate with this batch recognition, such fault announcements as have been registered, or yarn quality determinations, with the production batch number, and thereby to determine, in a preventive manner, whether, and which batch could have possibly led to an operation running outside of the a tolerance limit. With such information, the Quality Control is allowed to select the complete batch of the exchangeable machine components in question from the total inventory of the similarly made machine components. Additionally, one obtains in regard to the source of said component, information about its manufacture and by which production method optimal or less than optimal machine components were made.
In the case of the spinning station in accord with Claim 28, the measurement/sensor head is particularly assigned to one particular spinning station. The measurement head, on this account, is securely installed proximal to the exchangeable machine component, which is to be monitored, and, for its scanning, need not be brought in to the neighborhood of the said machine component by a mechanism appropriate for such movement. This is particularly of advantage, where machine components, such as support disks or a disintegration roll are concerned, which are placed at difficulty accessible locations in the spin box.
The sensor head, in such operations, can be an active or a passive element of the sensor apparatus, such as being, for instance, an electrical or a electromagnetic signal receiver/sender apparatus, or an objective lens for an optical detector, or yet a CCD element with spectral-resolving optical elements for color scanning or the like.
On a cost-reduction basis, it is of advantage, to switch the measured or detected signals from a plurality of exchangeable components, through a multiplexer and the transducer/evaluator unit, before they are transduced and before the evaluation of such signals as must be evaluated. Then, in spite of a multiplicity of measurement points, in this way, only one transducer or evaluator unit need be provided.
A particularly fault-free transmission occurs in the case of light fiber lines, in which the transmitted optical signals are subjected to no electromagnetic disturbances. If the identification recognition symbol is read off optically, then, in the simplest case, a single measurement head will suffice, if one end of the light fiber line of the identification recognition lies facing a machine component.
The central detection apparatus and/or evaluation unit, in these operations, can be installed in one of the spinning station supporting service units, that is, in a service robot for the resumption of spinning of a spinning station, so that, in spite of a multiplicity of spinning stations to be monitored, only one detection and/or evaluation unit is required.
Advantageously, for a signal transmission connection between the spinning station and the supporting service unit, a contact-free, optical send/receive apparatus is provided. This can advantageously be infrared transmission. Alternative thereto, the available communication interface which in any event is between the machine control and the service vehicle can be put to use.
For the monitoring of the technical furnishings of a spinning station, where at least one exchangeable machine component is present, for each spinning station, in accord with Claim 35, a display and/or interrogation device is provided. This can be, for instance, an LCD-display with one or more lines or a monitor, which, for the interrogation apparatus is equipped with an appropriate input touch provision or a computer key-board. With such equipment, it is then possible for an operator to call up the actual configuration at the spinning station and to oversee the same.
The display or interrogation, in this matter, as need calls for it, can be located at each spinning station, centrally placed at the spinning machine, at a decentralized control point for the spinning machine, in the central principal control for the spinning works, or externally installed in a central service location.
Particularly of advantage, is that the interrogation facility allows the configuration of each spinning station on a spinning machine to be called up and these so acquired data then be correlated through the said interrogation facility or through an evaluation unit with other data available from the spinning station.
For example, the measured degree of quality of the produced yarn can be correlated with the appurtenances of the station, or the total life expectancy of an exchanged machine component monitored, so that, from these data statistical quality analyses can be carried out. If, for instance, the yarn quality at one spinning station lies frequently outside of the accepted tolerance thresholds, then first, a determination may be made as to whether or not the configuration of exchangeable machine components at that particular spinning station is appropriate for the desired quality, or second, if with the aid of other values based on experience, it may be determined if the quality of the yarn, as a matter of data history, can be traced back to a special machine component.
In accord with the control system as set forth in Claim 44, the so determined and evaluated data from the spinning station are used to optimize control parameters for the spinning machine, or the spinning station, and accordingly input corresponding, optimized parameters at the spinning machine or at the spinning station. With the aid of the acquired results from the quality control, in this way, active measures can be undertaken, in order to increase the quality of the spun yarn.
The display and/or the interrogation apparatus and the control system are not for installation in only one spinning station of one spinning machine, but are appropriate for the detection, monitoring and control of other types of spinning machinery in a spinning works. Examples for such spinning machines with at least one exchangeable component would be, for instance, a carding machine, a stretch machine or a ring machine.