Description:FIELD OF THE INVENTION
This invention relates to a device for detecting breakage or absence of a primary yarn or inadequate twisting of primary yarn that can be installed on a twisting or cabling machine for on-line primary yarn breakage indication in real time during production of yarn package for quality check. For simplicity, we refer here for twisting machine.
Device and method for detecting soundness of quality of twisted yarn sense and predict breakage or absence of one or more primary yarns by measuring tension in the delivered yarn and comparing it with set threshold tension and, prevent formation of defective twisted yarn with one or more primary yarn missing in it guarantying quality soundness of the twisted yarn on final yarn package. The device activates a cutter to cut all other primary yarns on sensing of breakage or absence or inadequate twisting of one or more primary yarn or yarns and gives an alarm or an alert signal for taking corrective action in multi-yarn twisting. The device is having a provision for storing production statistic and generation of production reports using the statistic.
Almost all manufacturers of twisted yarn in textile industry are concern with output quality of twisted yarn package more specifically quality of multi-ply or multi-primary yarn twisted yarn package production. It is always beneficial if quality check is done in real time during the production phase itself to prevent wastage of resources, material and time.
BACKGROUND OF THE INVENTION
Two ply or multi ply twisting and cabling machine are very common in textile industry. These machines allow two or multiple (i.e. more than two) primary yarns combined together and wound on a single package. The primary yarns itself may be a twisted yarn or a plain yarn. The main problem in such machines is detection of breakage of one or more input primary yarn or yarns. In absence of detection of breakage of one or more primary yarn or yarns, package will continue to wind with remaining primary yarn or yarns and hence missing one or more input primary yarn in the final twisted yarn package. This results into supply of the defective final twisted yarn package with one or more primary yarn missing in it to the customers or users.
It is extremely difficult or impossible to detect such defect (i.e. absence of one or more primary yarn in the final yarn package) as post production activity. Further, the yarn package rejection based on post-production quality check results into wastage of resources.
Hence, for twisting or cabling machine combining two or multiple (i.e. more than two) primary yarns together and winding on a single package for twisting or cabling, there is demand and necessity to have a device and method for real time detection of missing primary yarn during multi-primary yarn twisting and winding operation.
DESCRIPTION OF THE RELATED ART
Appropriate means for monitoring and sensing of breakage of the yarn on twisting machine having sensor working on mechanical, inductive or optical principle are disclosed in prior art.
FR2267399A1 presented measurement of rotation frequency of the twisted yarn in an eyelet. As per disclosure in the said document, a signal representative of the rotation frequency of the ball of wire is obtained at the control station. The exploration is carried out not only on the wire itself but preferably inside the wire guide eyelet which determines the highest point of the balloon. When in such a process, in the event of a wire break, the depleting balloon end drags the wire on the spool, this driven wire is pulled through the control zone with a completely different rotation speed from that of the ball of wire, that is to say at a rotation frequency which no longer corresponds to that of the ball of wire.
CN101864629A discloses a yarn break automatic stop device adopted on a twisting machine in the textile industry. The device comprises a pressing roll-roller pair for convening plied yarns and also comprises a lever mechanism consisting of a probe rod, a fulcrum and a guide block. The fulcrum is at the mass center of the lever mechanism, and the lever mechanism is fixed on a base through the fulcrum, wherein the base is connected with the twisting machine to form a whole; acting forces on the probe rod and the guide block on two sides of the fulcrum are twisting tension and gravity of a pressing roll respectively; and an eccentricity is formed between the centers of the pressing roll and a roller. During normal production, a torque produced by the twisting tension is greater than that produced by the gravity of the pressing roll, and the lever mechanism inclines left; and when the plied yarns are broken, the twisting tension disappears, the lever mechanism turns right under the gravity action of the pressing roll and rolls to a brake along the guide block so as to break automatic stop. The device has the advantages that a force system is formed by using the yarn twisting tension and the pressing roll gravity according to the mechanics principle, the yarn break automatic stop is realized by changing the torque, and the device has a simple structure, quick response and accurate and reliable motion.
CN111519294B discloses a yarn breakage early warning monitoring method, a system, a device and a readable storage medium, wherein the method comprises the following steps: data acquisition: acquiring production data of various types of spinning equipment, wherein the production parameters comprise but are not limited to yarn breakage confirmation information, yarn thickness and yarn pressure borne by a yarn feeding roller; data processing: processing and classifying the acquired production data according to a general mathematical processing method, and performing rationality judgment on the processed and classified data according to a preset judgment engine; and (3) data analysis: classifying and judging the data judged to be reasonable according to a preset mathematical model to obtain result data; and (3) result feedback: and feeding back the obtained result data to a controller of the spinning equipment, wherein the result data comprises but is not limited to normal parameter instructions, stop instructions, alarm signals, early warning signals and trigger signals for controlling the wiring robot to be in place. The invention can early warn the broken wire condition and effectively prevent the broken wire.
As per disclosure in prior art, individual sensors are required for each primary yarns during production of twisted yarn package. Further sensors as per disclosure in prior art are not capable of giving indication about poor quality of the twisted yarn. In twisted yarn, primary yarn may be with inadequate number of twist.
OBJECT OF THE INVENTION
Principal objective of the present invention is to provide a device and a method that senses breakage or absence of one or more primary yarn in a final twisted yarn on a real time bases.
Another object of the present invention is to provide a device and a method that sense the breakage or absence or inadequate twisting of one or more primary yarn in a final twisted yarn on a real time bases by measuring tension in the final twisted yarn.
Another object of the present invention is to provide a device and a method that activate a yarn cutter for cutting of all or remaining primary yarn or yarns on sensing of breakage or absence of one or more input primary yarns.
Another object of the present invention is to provide a device and a method that is versatile and can be implemented on any exiting yarn twisting machine without major modifications.
Another object of the present invention is to prevent wastage of primary yarns and ensure soundness of quality of the final twisted yarn package by real time monitoring and sensing of breakage or absence or inadequate twisting of one or more primary yarn and initiating preventive measures.
Another object of the present invention is to provide a device and a method that can be installed in multiple depending on the number of spindles on the existing twisting machine and can be configured to communicate with a master controller of the said machine.
In the context to the formation of cabling - twisted yarn with plurality of primary yarns, quality is of great concern. The importance given by manufacturer in this area has to be attended by this invention.
This issue can be ascertained to some extent by the use of mechanical spring tension or optical devices measuring yarn shadow may be suitable for sensing the plurality of final package but have limitation of setting the parameters and / or effected by surrounding ambient light, vibration etc. Such devices are found with a limitation that this are not found adequate to provide information on quality.
In accordance with above, this invention provides method for detecting soundness of quality of cabling / twisted yarn formation, violation of final twisted yarn tension against set threshold value of the yarn tension, avoiding formation of missing ply yarn and lastly guarantee the soundness of twisted yarn quality on final yarn package there by alert / cut signal used in the integrated system. Optionally, integrated system can generate production statics / reports if it has been program to do so.
SUMMARY OF THE INVENTION
Present invention provides a device and a method for online monitoring of primary yarns during production of twisted yarn package or cable on twisting or cabling machine by combining two or more primary yarns. For the purpose, the device is provided with a primary yarn breakage or absence detection sensor. The device can be deployed for monitoring twisting or cabling of two primary yarns or more than two primary yarns wherein number of primary yarns are limited only by twisting or cabling machine specification. It is being considered that minimum two primary yarns are combined or twisted together by unwinding upward from primary yarn packages. The device cut all primary yarns automatically on detection of breakage or absence of one or more primary yarns and alert a master controller of the twisting machine. Device is also capable of determining twisted yarn production with one of the primary yarn with adequate number of twist. The device is discussed in detail description based on twisted yarn package production from two primary yarn twisting or cabling on two ply twisting or cabling machine. The device is independent of number of primary yarns and primary yarn structure and hence can be implemented for multi filament complex artificial or natural fibres.
The device for online primary yarn breakage or absence detection according to the principles of present invention is consisting of a primary yarn breakage or absence sensor in electronic communication with a master controller of the twisting machine on which it is installed, a Human Machine Interface (HMI) display in electronic communication with a master controller of the twisting machine and a cutter control in electronic communication with the primary yarn breakage or absence sensor.
The online primary yarn breakage or absence sensor along with the cutter control as per present invention is consisting of a spring lever, a strain gauge and a controller. The strain gauge is mounted on the spring lever and is configured to measure strain in the spring lever. The controller in electronic communication with the strain gauge and the cutter control and is configured to compare the measured strain in the spring lever with the set threshold strain value and activate the cutter control. The controller is connected to the strain gauge via a bridge circuit, a signal conditioner and a serial analogue to digital convertor. The controller is connected to the master controller via a MOD bus interface.
The cutter control is in electronic communication with a yarn cutter and configured to operate the yarn cutter on receipt of activation signal from the controller. When measured strain in the spring lever is less than the set threshold strain value, the controller activate the cutter control and hence the yarn cutter.
The controller of the online primary yarn breakage or absence sensor is consisting of a processor in electronic communication with a program memory, a data memory, counters, timers, a communication device and a pulse generator. The processor executes a program stored in the program memory. The data memory stores interim calculation results, input data values and, final data values. The timers are used for time interval calculations and triggering the processor at the end of a time event. The digital input-output device reads the serial analogue to digital convertor at set time interval and generate activation signal for the cutter control on primary yarn breakage or absence detection. The digital input-output device is configured to communicate with the processor from external peripheral devices. The communication device is used to connect the Master controller. The Human Machine Interface (HMI) display is consisting of a key pad and a graphical display. The Human Machine Interface (HMI) display is connected to the master controller using MOD bus interfaces.
The program is embedded in the program memory of the processor of the primary yarn breakage or absence sensor. The program is described in detail description using a flow chart. The spring lever is attached to a final twisted yarn in motion. At regular interval, the serial analogue to digital convertor in association with the spring arm and the strain gauge, detect the presence of yarn by sensing the tension produced on the spring lever and hence on the strain gauge by the yarn. After sensing the stain value in the spring lever using the strain gauge because of presence of the yarn, the resultant yarn tension is then compared against the threshold set value of the yarn tension received from the master controller and communicated to the controller of the primary yarn breakage sensor. If the measured value of the yarn tension is less than the threshold set value of yarn tension, then the controller activate the cutter control and hence the cutter for cutting the remaining primary yarn or yarns and also sends alert details to master controller and to the data memory for recording purpose and to the Human Machine Interface (HMI) display via the master controller wherein an alert signal or an alarm is used to alert the operator for corrective action on particular spindle of the twisting machine. Multiple number of the device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality is installed wherein number of the device depends on the number of spindles of the twisting machine on which it is installed. In case of installation of multiple number of the device for detecting breakage or absence of primary yarn on the twisting machine, all the said devices are in electronic communication with the master controller of the twisting machine.
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 showing an online primary yarn breakage or absence detector along with a cutter controller as per present invention.
FIG. 2 is a schematic block diagram showing Human Machine Interface (HMI) display system according to the principles of present invention.
FIG. 3 is a schematic block diagram showing an integrated device (300) for online primary yarn breakage or absence detection according to the principles of present invention.
FIG. 4 is a schematic block diagram showing architecture of a central processing unit (CPU) of an online primary yarn breakage or absence detector according to the principles of invention.
FIG. 5 is a flow chart showing working of a device for online primary yarn breakage or absence detection as per present invention.
FIG. 6 is a schematic block diagram showing implementation of a method and a device for online primary yarn breakage or absence detection on the twisting machine.
List of designations/ reference numbers in figure
100 a primary yarn breakage or absence sensor
101 a controller
102 a MOD bus interface
103 a serial analogue to digital convertor (Digitizer)
104 a signal conditioner
105 a bridge circuit
106 a spring lever
107 a strain gauge
108 a cutter control
200 a Human Machine Interface (HMI) display
201 a graphical display
202 a key pad
203 a MOD bus interfaces
204 a MOD bus interfaces
300 an integrated system for online primary yarn breakage or absence detection
301 a master controller of the twisting machine on which it is installed,
501 a processor
502 a program memory
503 a data memory
504 counters
505 timers
506 a communication device
507 a pulse generator
508 digital input-output device
600 a program (600) stored in the program memory
701 input primary yarn feed package
702 input primary yarn feed package
703 a primary yarn
704 a primary yarn
705 a yarn guide
706 a yarn guide
707 a combiner yarn guide
708 a final twisted yarn
709 a yarn cutter
710 an overfeed roller
711 a final twisted yarn package
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.
A device that can be installed on a twisting machine for detecting breakage or absence of primary yarn in real time during production and a method for online primary yarn breakage or absence detection in real time and preventing the wastage of resources by cutting the other primary yarns and giving an alarm or an alert signal to an operator using the said device for taking corrective action is described.
The device for online primary yarn breakage or absence is to be used in twisting or cabling machine where two or more primary yarns are processed for twisting or cabling together.
FIG. 3 shows a schematic block diagram of an integrated device (300) for online primary yarn breakage or absence detection according to the principles of present invention. As shown in FIG. 3, the said device (300) is consisting of a primary yarn breakage or absence sensor (100) in electronic communication with a master controller (301) of the twisting machine on which it is installed, a Human Machine Interface (HMI) display (200) in electronic communication with a master controller (301) of the twisting machine and a cutter control (108) in electronic communication with the primary yarn breakage or absence sensor (100).
FIG. 1 shows a schematic block diagram of the online primary yarn breakage or absence sensor (100) along with the cutter control (108) as per present invention. As shown in FIG. 1, the primary yarn breakage or absence sensor (100) is consisting of a spring lever (106), a strain gauge (107) and a controller (101). The strain gauge (107) is mounted on the spring lever (106) and is configured to measure strain in the spring lever (106). As shown in FIG. 1, the controller (101) in electronic communication with the strain gauge (107) and the cutter control (108) and is configured to compare the measured strain in the spring lever (106) with the set threshold strain value and activate the cutter control (108). The controller (101) is connected to the strain gauge (107) via a bridge circuit (105), a signal conditioner (104) and a serial analogue to digital convertor (103). The controller (101) is connected to the master controller (301) via a MOD bus interface (102).
As shown in FIG. 6, the cutter control (108) is in electronic communication with a yarn cutter (709) and configured to operate the yarn cutter (709) on receipt of activation signal from the controller (101). When measured strain in the spring lever (106) is less than the set threshold strain value, the controller (101) activate the cutter control (108) and hence the yarn cutter (709).
As shown in FIG. 4, the controller (101) of the online primary yarn breakage or absence sensor (100) is consisting of a processor (501) in electronic communication with a program memory (502), a data memory (503), counters (504), timers (505), a communication device (506) and a pulse generator (507).
The processor (501) executes a program (600) stored in the program memory (502). The data memory (503) stores interim calculation results, input data values and, final data values. The timers (505) are used for time interval calculations and triggering the processor (501) at the end of a time event. The digital input-output device (508) reads the serial analogue to digital convertor (103) at set time interval and generate activation signal for the cutter control (108) on primary yarn breakage or absence detection. The digital input-output device (508) is configured to communicate with the processor (501) from external peripheral devices. The communication device (506) is used to connect the Master controller (301).
As shown in FIG. 2, the Human Machine Interface (HMI) display (200) is consisting of a key pad (202) and a graphical display (201). The Human Machine Interface (HMI) display (200) is connected to the master controller (301) using MOD bus interfaces (203, 204).
FIG. 5 is a flow chart showing working of a device for online primary yarn breakage or absence detection as per present invention. It is an illustrative diagram showing the flow chart for the program (600) embedded in the program memory (502) of the processor (501) of the primary yarn breakage or absence sensor (100). As shown in FIG. 1, the spring lever (106) is attached to a final twisted yarn (708) in motion. The twisted yarn in motion is shown in FIG. 6. At regular interval, the serial analogue to digital convertor (103) in association with the spring arm (106) and the strain gauge (107), detect the absence or breakage or inadequate twisting of primary yarn or yarns by sensing the tension produced on the spring lever (106) and hence on the strain gauge (107) by the final twisted yarn (708). After sensing the stain value in the spring lever (106) using the strain gauge (107) because of presence of the yarn, resultant tension in the final twisted yarn (708) is then compared against the threshold set value of the yarn tension received from the master controller (301) and communicated to the controller (101) of the primary yarn breakage or absence sensor (100). If the measured value of the tension in the final twisted yarn (708) is less than the threshold set value of yarn tension, then the controller (101) activate the cutter control (108) and hence the cutter (709) for cutting the all or remaining primary yarn or yarns and also sends alert details to master controller (301) and to the data memory (503) for recording purpose and to the Human Machine Interface (HMI) display (200) via the master controller (301) wherein an alert signal or an alarm is used to alert the operator for corrective action on particular spindle of the twisting machine.
Multiple number of the device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality is installed wherein number of the device depends on the number of spindles of the twisting machine on which it is installed. In case of installation of multiple number of the device for detecting breakage or absence of primary yarn on the twisting machine, all the said devices are in electronic communication with the master controller (301) of the twisting machine.
BEST METHOD OF WORKING THE INVENTION
FIG. 6 is a schematic block diagram showing implementation of a method and a device for online primary yarn breakage or absence detection on the twisting machine. Parts which are not necessary to understand the invention has been omitted for clarity from FIG. 6. Other than the primary yarn breakage or absence sensor (100) are the standard parts of the cabling / twisting machine and are shown for explanation purpose. These parts can have alteration / variation from manufacturer to manufacturer. The input primary yarn feed packages (701, 702) optionally may be supported within the twisting spindle basket. The central axis for these input primary yarn feed packages (701, 702) are centered on yarn guides (705, 706). Primary yarns (703, 704) are unwound with upward delivery of the input primary yarn feed packages (701, 702) respectively. The primary yarns (703, 704) are passing through yarn guides (705, 706) respectively and then combined jointly by inserting in a combiner yarn guide (707). An overfeed roller (710) pulls the final twisted yarn (708) at constant set speed set in the master controller (301). The primary yarn breakage or absence sensor (100) is installed between the combiner yarn guide (707) and the overfeed roller (710). As the overfeed roller (710) pulls the final twisted yarn (708) at set speed, it produces tension in the final twisted yarn based on the pulling speed of the final twisted yarn (708), denier of the input primary yarns (703, 704) and number of primary yarns. Tension in the final twisted yarn (708) is measured by the online primary yarn breakage or absence sensor (100) at regular interval as per the program (600) stored in the program memory (502).
Then after this yarn tension value of the final twisted yarn (708) is compared with the threshold value set by the master controller (301). In the event of breakage or absence of any of the primary yarn (703, 704) or inadequate twisting of one or more of the primary yarn (703, 704), the yarn tension produced in the final twisted yarn (708) after the combiner yarn guide (707) drops drastically. This sudden drop in tension in the final twisted yarn (708) is being detected by the online primary yarn breakage or absence sensor (100). Because of breakage of or absence of any one of the primary yarns (703, 704) or inadequate twisting of one or more of the primary yarn (703, 704), this value of tension in the final twisted yarn (708) will be well below the set threshold value of yarn tension as per the master controller (301). In this situation, the controller (101) activates the cutter control (108) and the cutter (709) for cutting all or remaining input primary yarn (708 or 709) and also gives signal to the master controller (301) about this event. This will ensure that final twisted yarn with primary yarns as required wound on the package and prevent production of defective twisted yarn package. ,
Claims:We Claim:
1. A device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality comprising of:
a primary yarn breakage or absence sensor (100) in electronic communication with a master controller (301) installed on a twisting and/or cabling machine;
a Human Machine Interface (HMI) display (200) in electronic communication with the master controller (301) and;
a cutter control (108) is in electronic controlled by the primary yarn breakage or absence sensor (100);
characterized in that
the primary yarn breakage or absence sensor (100) is consisting of
• a spring lever (106),
• a strain gauge (107) mounted on the spring lever (106) and configured to measure strain in the spring lever (106) and,
• a controller (101) in electronic communication with the strain gauge (107), the cutter control (108) and the mater controller (301),
wherein
the controller (101) is consisting of a processor (501) in electronic communication with a program memory (502), a data memory (503), counters (504), timers (505), a communication device (506) and a pulse generator (507),
the controller (101) is connected to the strain gauge (107) via a bridge circuit (105), a signal conditioner (104) and a serial analogue to digital convertor (103),
the controller (101) is connected to the master controller (301) via a MOD bus interface (102),
the Human Machine Interface (HMI) display (200) is consisting of a key pad (202) and a graphical display (201) wherein the Human Machine Interface (HMI) display (200) is connected to the master controller (301) using MOD bus interfaces (203, 204),
the cutter control (108) is in electronic communication with a yarn cutter (709) and configured to operate the yarn cutter (709),
the spring lever (106) is attached to a final twisted yarn (708) and the controller (101) is configured to compare the measured strain in the spring lever (106) because of the final twisted yarn feeding with the set threshold strain value and activate the cutter control (108) for cutting of all or other remaining primary yarns at measured strain value in the spring lever (106) lesser than the set threshold strain value wherein strain in the spring lever (106) drops below the set threshold strain value in event of breakage or absence or inadequate twisting of one or more of the primary yarn and,
at measured strain value in the spring lever (106) lesser than the set threshold strain value the controller (101) also sends alert details to master controller (301) and to the data memory (503) for recording purpose and to the Human Machine Interface (HMI) display (200) via the master controller (301) wherein an alert signal or an alarm is used to alert the operator for corrective action on particular spindle of the twisting machine.
2. The device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality as claimed in claim 1, the processor (501) is configured to executes a program (600) stored in the program memory (502).
3. The device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality as claimed in claim 1, wherein the data memory (503) is configured to store interim calculation results, input data values and, final data values.
4. The device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality as claimed in claim 1, wherein the timers (505) are configured for time interval calculations and triggering the processor (501) at the end of a time event.
5. The device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality as claimed in claim 1, wherein the digital input-output device (508) is configured to read the serial analogue to digital convertor (103) at set time interval and generate activation signal for the cutter control (108) on primary yarn breakage or absence detection and communicate with the processor (501) to external peripheral devices.
6. The device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality as claimed in claim 1, wherein the communication device (506) is used to communicate with the Master Controller (301).
7. The device for detecting breakage or absence of primary yarn for real time monitoring of final yarn package quality as claimed in claim 1, wherein multiple number of the said device for real time monitoring of final yarn package quality is installed on single twisting machine depending on the number of spindles of the twisting machine with all the said devices are in electronic communication with the master controller (301) of the twisting machine.