Description:4. DESCRIPTION
FIELD OF THE INVENTION
This invention relates to a device and a method for monitoring quality of two or more yarn twisted on a multi spindle twisting machine. Present invention more particularly relates to a device and a method that uses noncontact type sensor for monitoring twist per unit time of a yarn and combines this data with the twisting machine spindle revolution per minute (rpm) and package diameter from the master controller in real time basis for predicting turns per meter which is most important yarn quality parameter.
All manufacturers are concern with output quality of twisted yarns. It is always beneficial if quality check is done during the production phase itself. These real time data related to turns per meter are stored and compared with the input threshold value (i.e. required value) of the turns per meter (TPM) for evaluating consistency and quality of twisted yarn under observation/production to be monitored and verified on real time basis. The device and method as per present invention identifies yarn breakage, turns per meter of yarn twisted and deviation of the turns per meter of yarn from the targeted threshold value. Installation of the said device and implementation of the said method on the twisting machine helps in minimising or eliminating wastage of yarn and energy by taking corrective actions in case of yarn breakage and twisting of yarns by false turns per meter.
BACKGROUND OF THE INVENTION
Twisting is a process of formation of yarn where twisting of two or more yarns together to form a single twisted yarn is performed. Twist is introduced to fibers during the spinning process, where individual staple fibers or filaments are combined to form a continuous strand. “Twist” could be elaborated as the spiral disposition of the components of a thread as a result of the relative rotation of the two ends. The presence of twist in a yarn binds the fibers together and helps to keep them in their corresponding positions. It provides coherence between the fibers and adequate strength to the yarn. Twisting is one of the most essential processes in textile production affecting tensile strength, luster, moisture absorption, wearing properties, aesthetics, crepe and curling of the final fabric or yarn. The effects are attained by combining yarns with different twist levels and twist directions in the fabric. Twist is usually expressed as the number of turns per unit length of yarn, for example, turns per inch or turns per meter.
DESCRIPTION OF THE RELATED ART
Now a day, yarn twisting machines are very common in use. Many manufacturers are manufacturing such machines. But monitoring of the final twisted yarn quality on real time basis is always challenging and not addressed properly. For quality check, twist counting per meter is done manually after production. Hence, whole twisted yarn package is rejected if twist per meter is not as per requirement. This result into great loss in terms of (i) wastage of raw yarn, (ii) production, (iii) labour and (iv) energy. So there is a need to monitor the quality of twisted yarn on-line on real time basis to minimize the poor quality production.
Patent no. US5210594A disclosed a process for optically measuring the twist of a textile yarn, in which the yarn is lit up by means of a beam of light, to form a spot of light which corresponds to the light diffracted by the surface fibres of the compact core of this yarn and a device for application of said process.
Patent publication no. WO2014012189A1 provides a device for photoelectrically monitoring the rotational movement of a yarn in a ring-spinning unit and thus for detecting the undesired phenomena of broken yarn and slipper spindle. The invention offers the advantages of small size, low cost, easy installation, easy replacement and immunity to electromagnetic-interference. It is less sensitive to changes of the operating distance than the electromagnetic sensor known from the prior art.
Known different approaches applied to measure twist are: (i). the angle of inclination of yarn is measured by optical device preventing deformation of the yarn and, (ii) mechanical approaches in which the yarn is subjected to untwisting or number of untwisting and retwisting cycles.
Known approaches are indirect approaches and are not suitable for online monitoring of yarn quality in real time basis and hence none of these well-known methods are really satisfactory.
OBJECT OF THE INVENTION
The present invention proposes to overcome limitations of the inventions disclosed in prior art by providing an apparatus and method for real time monitoring of yarn twisting.
Principal object of the present invention is to provide a device and a method that is capable of predicting turns per meter of twisted yarn on real time basis.
Another object of the present invention is to provide a device and a method that can be retrofitted and implemented on any existing twisting machines without major modifications in the twisting machine.
Another object of the present invention is to provide a device and a method that is capable of identifying yarn breakage, turns per meter of yarn twisted and deviation of the turns per meter of yarn from the targeted threshold value online on real time basis and helps in minimising or eliminating wastage of yarn and energy by taking corrective actions in case of yarn breakage and twisting of yarns by false turns per meter.
Another object of the present invention is to provide a device and a method that is stops operation of a particular spindle to avoid degraded quality and hence production loss on violation of the threshold limit of turns per meter for twisting of yarn.
Another object of the present invention is to provide a device and a method that uses stored data for evaluating soundness of the quality of twisted yarn under observation/production to be monitored and verified on real time basis.
Another object of the present invention is to provide a device and a method that avoid post-production quality check of twisted yarn resulting into saving time and labour for inspection and increased production rate.
Another object of the present invention is to provide a device and a method that is simple in construction, easy to install, easy to operate and economical.
SUMMARY OF THE INVENTION
An apparatus and a method for real time monitoring of yarn twisting in twisting / cabling machine where two or more yarns to processed for twisting together is provided. An apparatus for real time monitoring of yarn twisting is consisting of a plurality non-contact type sensor and an interface circuitry for interfacing of the non-contact type sensors and a master controller of a twisting machine. Present apparatus and method utilizes real time data on number of twist of yarn per unit time and linear velocity of twisted yarn for predicting number of turns per meter of twisted yarn for online monitoring of the quality of twisted yarn. These real time data related to turns per meter are stored and compared with the input threshold value (i.e. required value) of the turns per meter (TPM) for evaluating consistency and quality of twisted yarn under observation/production to be monitored and verified on real time basis. The device and method as per present invention identifies yarn breakage, turns per meter of yarn twisted and deviation of the turns per meter of yarn from the targeted threshold value. Installation of the said device and implementation of the said method on the twisting machine helps in minimising or eliminating wastage of yarn and energy by taking corrective actions in case of yarn breakage and twisting of yarns by false turns per meter.
Embodiment of the present invention is described in detail with the help of accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The features of the invention as per the present patent application are described with reference to the following drawings in which like elements are labeled similarly. The present invention will be more clearly understood from the detailed description and the accompanying drawings, wherein:
FIG 1 is a schematic block diagram of a noncontact type sensor used for real time monitoring of yarn twisting in accordance with the principles of present invention.
FIG 2 is a schematic block diagram showing system interfacing of multiple noncontact type sensor mounted on a twisting machine in accordance with the principles of present invention.
FIG 3 is a schematic block diagram showing interfacing of a noncontact type sensor and a master controller in accordance with the principles of present invention.
FIG 4 is a schematic block diagram of a central processing unit in accordance with the principles of present invention.
FIG. 5 is a flow chart depicting the method (600) of working of an apparatus for sensing turns per unit time of a twisted yarn using the noncontact type sensor (100).
FIG 6 is a schematic diagram showing incorporation of an apparatus for real time monitoring of yarn twisting in the twisting machine according to the principles of present invention.
FIG 7 is a flowchart depicting the overall method steps of working of an apparatus for real time monitoring of yarn twisting in accordance with the principles of present invention.
List of designations/ reference numbers in figure
100. a non-contact type sensor
101. a controller
102. a Mod/ CAN bus
103. a signal conditioner
104. a filter
105. an infrared (IR) transmitter
106. an infrared (IR) receiver
200. an interface circuitry
201. a standard HMI display keypad device
301. a master controller
400. a display
401. a Mod/ CAN bus
403. a keypad
501. a processor
502. a program memory
503. a data memory
504. counters
505. timers
506. a communication device
507. a pulse generator
508. an input output (I/O) device
600. a method
701. Input yarn feed packages
702. Input yarn feed packages
703. an accumulator disc
704. a twisted yarn
705 a yarn eyelets
706. a traverse guide
707. a yarn guide
709. a package
710. a drum roller
711. a central hollow pin
712. a twisting spindle basket
713. a yarn
714. a yarn
DETAILED DESCRIPTION OF THE INVENTION
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or its uses.
The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered as a part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms and directives thereof are for convenience of description only and do not require that the apparatus be constructed or operated in a particular manner unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar references to a relationship wherein structures are secured or attached either directly or indirectly through intervening structures, as well as both movable and rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto.
An apparatus and a method for real time monitoring of yarn twisting is to be used in twisting / cabling machine where two or more yarns to processed for twisting together.
An apparatus for real time monitoring of yarn twisting is consisting of a plurality non-contact type sensor (100) and an interface circuitry (200) for interfacing of the non-contact type sensors (100) and a master controller (301) of a twisting machine.
FIG 1 is a schematic block diagram of a noncontact type sensor (100) according to present invention. The noncontact type sensor (100) is consisting of an infrared (IR) transmitter (105) in electronic communication with a controller (101), an infrared (IR) receiver (106) in electronic communication with the controller (101) via. a filter (104) and a signal conditioner (103) and, a Mod/ CAN bus (102) in electronic communication with the controller (101).
FIG 2 is a schematic block diagram showing system interfacing of multiple noncontact type sensors (100) mounted on the twisting machine using a standard HMI display keypad device (201) for standalone operation. The input data values and the final results are being displayed on a display (400). The multiple noncontact type sensors (100) are interfaced with the standard HMI display keypad device (201) using a Mod/ CAN bus (401).
As shown in FIG 3, the noncontact type sensors (100) are in electronic communication with the master controller (301) installed on the twisting machine via the standard HMI display keypad device (201). Using the master controller (301) user can configure, control and observe system operation.
As shown in FIG. 4, the controller (101) is consisting of various components such as a processor (501), a program memory (502), a data memory (503), counters (504), timers (505), a communication device (506), a pulse generator (507) and an input output (I/O) device (508) that are in electronic communication with each other.
The processor (501) in electronic communication with the program memory (502) executes a method (600) for real time monitoring of yarn twisting using the present device. The data values are being stored in the data memory (503) which includes interim calculations results, input data values, final data values etc. The timers (505) are being used for time calculation intern at the end of time event it gives trigger to the processor (501). The counters (504) count input events given as input. The pulse generator (507) is used to signal the devices under control. The input output (I/O) device (508) is used to signal the processor (501) from external peripheral devices. The communication device (506) is used to connect data from this apparatus to the external devices such as standard HMI display keypad device (201).
FIG. 5 is a flow chart depicting working of an apparatus for sensing turns per unit time of a twisted yarn using the noncontact type sensor (100). Infrared (IR) transmission from the infrared (IR) transmitter (105) is being controlled by the controller (101). Infrared (IR) beam is detected for interruption by the infrared (IR) receiver (106). The output from the infrared (IR) receiver (106) is then filtered out in the filter (104) for noise rejection, converted to acceptable level using the signal conditioner (103). This conditioned or shaped output from the signal conditioner (103) is fed to the counter (504) of the controller (101). This data from the counter (504) is further communicated and stored to the data memory (503).
Real time twisting machine spindle revolution per minute (rpm) and package diameter data from the master controller (301) and data from the counter (504) are utilized by the controller (101) for calculating turns per meter (TPM) on real time basis. Calculated results are store in the data memory (503) and also sent to the interface circuitry (200) using the communication device (506) for display on the standard HMI display keypad device (201).
FIG 6 shows mounting of the noncontact type sensors (100) on the twisting machine for real time monitoring of yarn twisting according to the principles of present invention. The parts of the twisting machine not necessary for understanding the present invention has been omitted for clarity. Other than the noncontact type sensors (100) are the standard parts of the twisting machine and are shown for explanation purpose. These parts can have variation from manufacturer to manufacturer. Input yarn feed packages (701, 702) are supported within a twisting spindle basket (712). Central axes for these packages (701, 702) are aligned with an axis of a central hollow pin (711). Yarns (713, 714) are unwound with upward delivery of the input yarn feed packages (701, 702) respectively. The yarns (713, 714) are combined jointly and inserted in the hollow pin (711) from the top. As twisting spindle rotates, the yarns (713, 714) are getting twisted together and leaving out from an accumulator disc (703) as a combined twisted yarn (704). This twisted yarn (704) is taken upward towards a yarn guide eyelet (705). Because of twisting spindle’s rotational speed, the twisted yarn (704) forms a balloon with the central vertex restricted by the yarn guide eyelet (705). Later this twisted yarn (704) is passes from a yarn guide (707) and then from an optional roller guide (708), a traverse guide (706) for cross turn winding purpose and finally winding on a package (709). The package (709) rotates by frictional contact with a drum roller (710).
The system hardware from different manufacturers can have variation like use of optional overfeed rollers, direct coupling of the package (709) to the drum electronics etc.
The noncontact type sensors (100) of the apparatus for real time monitoring of yarn twisting are mounted centrally aligned above the yarn eyelets (705).
Because of continuous rotational movement of the twisting spindle basket (712) and the twisted yarn (704) forms a balloon which then passes out from the yarn eyelet (705) and the noncontact type sensor (100). This rotational circular movement of the twisted yarn (704) is presented between the infrared (IR) transmitter (105) and the infrared (IR) receiver (106) of the noncontact type sensor (100).
The infrared (IR) transmitter (105) emits infrared (IR) rays which are then projected on the infrared (IR) receiver (106) which is an infrared (IR) photo receiver. The infrared (IR) receiver (106) receives a light signal which is light strength modulated because of the twisted yarn (704) interruption.
Output of the infrared (IR) receiver (106) is then filtered out for extracting the desire signals in the filter (104). Then this filtered signal is strengthen and presented to the amplitude demodulator within signal conditioning (103) to extract presence of the twisted yarn (704) under observation in the shape of pulses for subsequent processing purpose. This output defines presence of the twisted yarn (704) within or outside the transmitted light beam in digital form.
The controller (101) receives these digital signals and presents the resultant count value for the unit time. The processor (501) is employing an embedded software algorithm as per the method (600) within the program memory (502) which is applied for data processing on this count value to derive actual revolution of the twisted yarn in a unit time. This actual revolution of the twisted yarn in a unit time is then stored in the data memory (503).
At a unit time interval, these values of actual revolution of the twisted yarn in a unit time are updated and stored in the data memory (503). These values of actual revolution of the twisted yarn in a unit time is then compared against the input threshold value given via a keypad (403) and displayed on a display (400) of the standard HMI display keypad device (201).
The noncontact type sensor (100) and the interface circuitry (200) are in electronic communication via the Mod/ CAN bus (102) of the noncontact type sensor (100) and the Mod/ CAN bus (401) of the standard HMI display keypad device (201).
The standard HMI display keypad device (201) is in electronic communication with the master controller (301) via the Mod/ CAN bus (401). Hence, the controller (101) of the noncontact type sensor (100) is in electronic communication with the master controller (301) via the Mod/ CAN bus (102) of the noncontact type sensor (100) and the Mod/ CAN bus (401) of the standard HMI display keypad device (201).
Data related to real time twisting machine spindle revolution per minute (rpm) and package diameter from the master controller (301) is extracted using the processor (501) of the controller (101) employing an embedded software as per the method (600) stored within the program memory (502). These data are stored in the data memory (503) and used by the controller (101) for calculating linear velocity of the twisted yarn at which it is winding on the package (709). Data related to linear velocity of the twisted yarn and actual revolution of the twisted yarn in a unit time is used for calculating the turns per meter (TPM) to which twisted yarn is subjected to.
At a unit time interval, these values of turns per meter (TPM) of the twisted yarn are updated and stored in the data memory (503). These values of actual turn per meter (TPM) of the twisted yarn is then compared against the input threshold value given via a keypad (403) and displayed on a display (400) of the standard HMI display keypad device (201).
These stored data related to actual revolution of the twisted yarn in a unit time and actual turns per meter (TPM) of the twisted yarn are utilized for evaluating soundness of the quality of twisted yarn (704) under observation/production to be monitored and verified on real time basis.
The apparatus and method (600) for real time monitoring of yarn twisting as per present invention also detect breakage of the twisted yarn (704) i.e. the situation where no twisted yarn (704) is produced. In the situation of breakage of the twisted yean (704), the infrared (IR) receiver (106) continuously receives transmitted infrared (IR) rays without any interruption. Hence modulated signal have only one state - outside infrared (IR) beam. This information is utilized by the controller (101) for detection of the twisted yarn (704) breakage or absence and can gives alert signal to the standard HMI display keypad device (201) as well as to the master controller (301).
This can further be utilized to cut the input yarns (713, 714) provided, the master controller (301) has instructed to do so to avoid wastage of raw yarns. This may prevent production of undesired – unsuitable yarn to guarantee soundness of quality of the yarn package (709).
Use of the apparatus and the method (600) for real time monitoring of yarn twisting in the system (700) as per method steps as shown in FIG 7 illustrated can be modified for described component with an equivalent component in use without compromising the scope of invention. , Claims:We Claim:
1. An apparatus for real time monitoring of yarn twisting comprising of:
a plurality non-contact type sensor (100) and;
an interface circuitry (200) for interfacing of the non-contact type sensors (100) and a master controller (301) of a twisting machine;
characterized in that
the noncontact type sensor (100) is consisting of an infrared (IR) transmitter (105) which is in electronic communication with a controller (101), an infrared (IR) receiver (106) which is in electronic communication with the controller (101) via. a filter (104) and a signal conditioner (103) and, a Mod/ CAN bus (102) which is in electronic communication with the controller (101),
the noncontact type sensor (100) of the apparatus for real time monitoring of yarn twisting is mounted centrally aligned above a yarn eyelets (705) and before a yarn guide (707) of the twisting machine wherein the yarn eyelet (705) is used to restrict a balloon of the twisted yarn formed with a central vertex because of twisting spindle’s rotational speed,
the noncontact type sensor (100) mounted on the twisting machine is interfaced with a standard HMI display keypad device (201) by interfacing the Mod/ CAN bus (102) of the noncontact type sensor (100) with a Mod/ CAN bus (401) of the standard HMI display keypad device (201) for standalone operation,
the noncontact type sensors (100) mounted on the twisting machine are in electronic communication with the master controller (301) of the twisting machine and configured to control and observe the twisting machine spindle operation via the standard HMI display devices (201) and,
the controller (101) of the noncontact type sensor (100) is consisting of a processor (501), a program memory (502), a data memory (503), counters (504), timers (505), a communication device (506), a pulse generator (507) and an input output (I/O) device (508) that are in electronic communication with each other wherein, the processor (501) in electronic communication with the program memory (502) executes a method (600) for real time monitoring of yarn twisting using the present device by collecting data related to real time twisting machine spindle revolution per minute (rpm) and package diameter from the master controller (301) and data related to turns per minute of a twisted yarn (704) from the counter (504) for calculating turns per meter (TPM) on real time basis.
2. A method for real time monitoring of yarn twisting using the said apparatus comprising steps of:
detecting interruption of an infrared (IR) beam from the infrared (IR) transmitter (105) using the infrared (IR) receiver (106);
filtering of an output signal from the infrared (IR) receiver (106) using the filter (104) for noise reduction;
strengthening this filtered signal using the signal conditioner (103) and presenting this conditioned signal to an amplitude demodulator within the signal conditioner (103) to extract presence of the twisted yarn (704) under observation in the shape of pulses for subsequent processing purpose defining presence of the twisted yarn (704) within or outside the transmitted infrared (IR) beam in digital form named as digital signal;
feeding this digital signal to the controller (101) which presents a resultant count value for presence the twisted yarn (704) within transmitted infrared (IR) beam for the unit time wherein the processor (501) of the controller employs an embedded software as per the method (600) within the program memory (502) which is applied for data processing on this count value to derive actual revolution of the twisted yarn in a unit time on continuous basis which is then stored in the data memory (503);
comparing these values of actual revolution of the twisted yarn in a unit time with an input threshold value given via the keypad (403) and displaying it on a display (400) of the standard HMI display keypad device (201);
extracting data related to real time twisting machine spindle revolution per minute (rpm) and package diameter from the master controller (301) using the processor (501) of the controller employing an embedded software as per the method (600) within the program memory (502);
calculating linear velocity of the twisted yarn at which it is winding on the package (709) using data related to real time twisting machine spindle revolution per minute (rpm) and package diameter;
utilizing data related to linear velocity of the twisted yarn and actual revolution of the twisted yarn in a unit time for calculating the turns per meter (TPM) to which twisted yarn is subjected to;
updating and storing these values of turns per meter (TPM) of the twisted yarn are in the data memory (503);
comparing these stored values of actual turn per meter (TPM) of the twisted yarn with the input threshold value of the turns per meter (TPM) given via the keypad (403) and displaying on the display (400) of the standard HMI display keypad device (201);
utilizing these stored data related to actual revolution of the twisted yarn in a unit time and actual turns per meter (TPM) of the twisted yarn for evaluating soundness of the quality of twisted yarn (704) under observation/production to be monitored and verified on real time basis;
3. The method for real time monitoring of yarn twisting using the said apparatus as claimed in claim 2, wherein the condition of continuous receipt of transmitted infrared (IR) rays without any interruption by the infrared (IR) receiver (106) is utilized by the controller (101) for detection of the twisted yarn (704) breakage or absence and generating an alert signal for the respective standard HMI display keypad device (201) as well as for the master controller (301) for avoiding wastage of raw yarns and preventing production of undesired – unsuitable yarn guarantying soundness of quality of the yarn package (709).