MANAGEMENT DEVICE FOR SPINNING MACHINE AND SPINNING
MACHINE WITH MANAGEMENT DEVICE
BACKGROUND OF THE INVENTION
5 1. Field of the Invention
The present invention mainly relates to a
management device for a spinning machine that forms and
winds a yarn.
10 2. Description of the Related Art
Conventionally, a spinning machine for forming a
yarn from a raw material and winding the yarn has been
known. JP S62-22908 B (Patent Document 1) and JP 2015-
183338 A (Patent Document 2) respectively disclose a
15 spinning machine and a yarn winding machine, which are
spinning machines of this type.
In the spinning machine of Patent Document 1, when
a yarn breakage occurs during winding of a yarn, a worker
performs yarn joining. The spinning machine of Patent
20 Document 1 is configured to monitor this yarn breakage
and calculate a production loss (corresponding to a yarn
waste quantity) caused by the yarn breakage.
The yarn winding machine of Patent Document 2
includes a yarn waste storage box that collects yarn
3
waste generated in a yarn joining operation. When a
worker collects the yarn waste from the yarn waste
storage box, a weight of the collected yarn waste has
been measured in some cases by a measuring instrument to
5 manage the production loss. However, since it is
troublesome to measure with the measuring instrument
every time, and the measurement is forgotten sometimes,
there is room for improvement in accuracy of production
loss management. The measurement work of the yarn waste
10 by the worker has been performed after some time in some
cases, which causes a time lag in the production loss
management.
In spinning machines, in addition to generation of
yarn waste due to a yarn joining operation and the like,
15 fiber waste is generated during a yarn formation process,
which also causes a raw material loss. In order to
manage the raw material loss in yarn production, there
is an increasing demand for calculating a quantity of
fiber waste generated during formation of the yarn.
20
BRIEF SUMMARY OF THE INVENTION
An object of the present invention is to provide
a management device and a spinning machine that can
efficiently and accurately calculate a generation
4
quantity of fiber waste.
A management device for a spinning machine
including a spinning device configured to form a yarn,
and a fiber waste collecting device configured to collect
5 fiber waste generated during yarn formation, the
management device comprises: a control device configured
to calculate a fiber waste generation quantity of the
spinning machine, based on a feature quantity that
changes in accordance with a quantity of the fiber waste
10 collected by and accumulated in the fiber waste
collecting device.
A spinning machine with a management device
comprises the management device; and the spinning
machine configured to be managed by the management device,
15 wherein the spinning device included in the spinning
machine is an air jet spinning device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic front view illustrating an
20 overall configuration of a spinning machine according to
one embodiment of the present invention;
FIG. 2 is a side view of a spinning unit and a yarn
joining cart;
FIGS. 3A and 3B are schematic views illustrating
5
an internal structure of a fiber waste collecting box;
and
FIG. 4 is a view illustrating a configuration of
a fiber waste collecting device of a spinning machine
5 according to an alternative embodiment.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A spinning machine 100 according to one embodiment
of the present invention will be described below with
10 reference to the drawings. Hereinafter, the terms
"upstream" and "downstream" regarding a spinning
operation of the spinning machine 100 refer to upstream
and downstream in a travelling direction of a sliver
(raw material) S, a fiber bundle F, and a spun yarn
15 (yarn) Y, when winding the spun yarn Y. The terms
"upstream" and "downstream" regarding suction of fiber
waste or yarn waste in the spinning machine 100 refer to
upstream and downstream in a direction in which a suction
airflow flows.
20 The spinning machine 100 of a first embodiment
illustrated in FIG. 1 includes a blower box 80, a motor
box 70, spinning units 1, and a yarn joining cart 6. A
plurality of the spinning units 1 are arranged in one
line.
6
In the blower box 80, a negative pressure source
81, a collecting device 82, and the like are provided.
The negative pressure source 81 generates a negative
pressure. The collecting device 82 collects fiber waste
5 and yarn waste generated in each spinning unit 1.
In the present specification, the fiber waste
refers to waste in a state where fibers are not twisted,
and is typically generated during a formation process of
the spun yarn Y. The yarn waste refers to waste in a
10 state where spinning is completed and the spun yarn Y is
obtained. The fiber waste can be called soft waste, and
the yarn waste can be called hard waste.
As illustrated in FIG. 1, the negative pressure
source 81 includes a main blower (blower) 81a, a main
15 motor 81b, an additional blower 81c, and an additional
motor 81d.
The main blower 81a is connected to a fiber waste
collecting device 83, which will be described later,
included in the collecting device 82. The main blower
20 81a is driven by the main motor 81b formed by an electric
motor, and generates a negative pressure (in other words,
a suction airflow) in the fiber waste collecting device
83.
The additional blower 81c is connected to a yarn
7
waste collecting device 84, which will be described later,
included in the collecting device 82. The additional
blower 81c is driven by the additional motor 81d formed
by an electric motor, and generates a negative pressure
5 (in other words, a suction airflow) in the yarn waste
collecting device 84.
As illustrated in FIG. 1, the collecting device 82
includes the fiber waste collecting device 83 configured
to collect fiber waste, and the yarn waste collecting
10 device 84 configured to collect yarn waste. The fiber
waste collecting device 83 includes a fiber waste
collecting box 85 and a main suction duct 86. The yarn
waste collecting device 84 includes a yarn waste
collecting box 87 and an additional suction duct 88.
15 The fiber waste collecting box 85 is provided
between the main blower 81a and the main suction duct
86. The fiber waste collecting box 85 uses a filter (a
main filter 73 and an additional filter 74 described
later and illustrated in FIGS. 3A and 3B) provided in a
20 passage through which the suction airflow flows, and
captures and collects fiber waste flowing along with the
suction airflow in the main suction duct 86.
As illustrated in FIGS. 3A and 3B, in the fiber
waste collecting box 85, a main passage 71 and a bypass
8
passage 72 through which the suction airflow flows are
formed. The main passage 71 is provided with the main
filter 73, and the bypass passage 72 is provided with
the additional filter 74. Both the main filter 73 and
5 the additional filter 74 include a mesh capable of
capturing fiber waste.
In a normal state of the spinning machine 100, as
illustrated in FIG. 3A, the suction airflow flows so as
to pass through the main passage 71 in the fiber waste
10 collecting box 85. Therefore, the fiber waste having
flowed into the fiber waste collecting box 85 along with
the suction airflow is captured by the main filter 73
arranged in the main passage 71.
The fiber waste collecting box 85 is provided with
15 a plurality of movable members, and positions can be
changed as illustrated in FIG. 3B. The positions of the
movable members can be switched by an appropriate
actuator (not illustrated). This makes it possible to
discharge the fiber waste accumulated in the fiber waste
20 collecting box 85 while continuing spinning in each
spinning unit 1 in the spinning machine 100.
In a state of FIG. 3B, the suction airflow flows
so as to pass through the bypass passage 72 in the fiber
waste collecting box 85. In the state of FIG. 3B, a
9
bottom portion of the main passage 71 near a portion
provided with the main filter 73 is opened. Therefore,
the fiber waste captured by the main filter 73 falls due
to its own weight and is discharged to the outside of
5 the fiber waste collecting box 85. In this way, the
fiber waste can be automatically discharged from the
fiber waste collecting box 85. The discharged fiber
waste is sent to an appropriate place by a conveyor (not
illustrated) or the like, and is collected for reuse,
10 for example.
In the state of FIG. 3B, the fiber waste having
flowed into the fiber waste collecting box 85 along with
the suction airflow is captured by the additional filter
74 arranged in the bypass passage 72. After a while,
15 the fiber waste collecting box 85 returns from a
discharge state of FIG. 3B to the normal state of FIG.
3A. Since the suction airflow no longer passes through
the bypass passage 72, the fiber waste captured by the
additional filter 74 falls downward. This fiber waste
20 flows along with the suction airflow passing through the
main passage 71 and is captured by the main filter 73.
The main suction duct 86 is formed elongated in a
direction in which the spinning units 1 are arranged,
and is provided over the plurality of spinning units 1.
10
The suction airflow generated inside the fiber waste
collecting device 83 by rotation of the main blower 81a
is supplied through the main suction duct 86 to a draft
device 2 and a spinning device 3, which will be described
5 later, included in each spinning unit 1.
As illustrated in FIG. 1, the yarn waste collecting
box 87 is provided between the additional blower 81c and
the additional suction duct 88. The yarn waste
collecting box 87 uses a filter (not illustrated)
10 provided in a passage through which the suction airflow
flows, and captures and collects yarn waste having flowed
along with the suction airflow in the additional suction
duct 88.
When discharging the yarn waste stored in the yarn
15 waste collecting box 87, an operator closes a passage of
the suction airflow in the yarn waste collecting box 87
by pressing a yarn waste discharging button (not
illustrated). After that, the yarn waste stored in the
yarn waste collecting box 87 is collected by a manual
20 operation and the like of the operator. However, for
example, the yarn waste collecting box 87 can be
configured substantially similarly to the fiber waste
collecting box 85 to realize automatic discharge of the
yarn waste.
11
The additional suction duct 88 is formed elongated
in the direction in which the spinning units 1 are
arranged, and is provided over the plurality of spinning
units 1. The suction airflow generated inside the yarn
5 waste collecting device 84 by rotation of the additional
blower 81c is supplied through the additional suction
duct 88 to the yarn joining cart 6, a doffing cart (not
illustrated), and the like that travel to each spinning
unit 1, as well as a suction port (such as a yarn trap
10 and/or a yarn suction device 28 described later) provided
in each spinning unit 1.
As illustrated in FIG. 1, the motor box 70 is
provided with a management device 9. This realizes a
spinning machine with a management device. The
15 management device 9 is configured to be able to
communicate with a unit control section (not
illustrated) included in each spinning unit 1. The unit
control section may be provided not for each spinning
unit 1 but for each predetermined number of spinning
20 units 1. The management device 9 can also communicate
with a cart control section (not illustrated) included
in each of the yarn joining cart 6 and the doffing cart.
The management device 9 can centrally manage information
about each spinning unit 1, the yarn joining cart 6, the
12
doffing cart, and the like by communicating with each
unit control section and the cart control section.
The management device 9 includes a control device
90, a display (display section) 91, and an input device
5 92.
The control device 90 is configured as a known
computer. The control device 90 includes a central
processing unit (CPU), a read only memory (ROM), a random
access memory (RAM), a hard disk drive (HDD), and the
10 like, which are not illustrated.
The display 91 displays various kinds of
information regarding an operating status of each
spinning unit 1, yarn quality, a raw material loss
quantity (a fiber waste total generation quantity, a
15 yarn waste total generation quantity), and the like.
The input device 92 includes a plurality of input
keys. By operating the input device 92, the operator
can select information to be displayed on the display
91, and set a spinning condition and the like of the
20 spinning machine 100. The spinning condition of the
spinning machine 100 include at least one of a thickness
(a yarn count, a fiber quantity) of the spun yarn Y, a
yarn speed that is a travelling speed of the spun yarn
Y, and a draft condition of the draft device 2 included
13
in the spinning unit 1. When the display 91 is a touch
panel display (touch screen), the display 91 and the
input device 92 may be integrally configured.
As illustrated in FIG. 1, each spinning unit 1
5 mainly includes the draft device 2, the spinning device
3, and a yarn winding device 4, which are sequentially
provided from upstream to downstream.
The draft device 2 is provided near an upper end
of a frame 10 of the spinning machine 100. As
10 illustrated in FIG. 2, the draft device 2 includes four
pairs of draft rollers, which are a pair of back rollers
21, a pair of third rollers 22, a pair of middle rollers
23, and a pair of front rollers 24, provided from the
upstream side. To the pair of middle rollers 23, an
15 apron belt 25 is provided for each roller.
The draft device 2 stretches (drafts) the sliver S
supplied from a sliver case (not illustrated) to a
predetermined fiber quantity (or thickness) by conveying
while sandwiching between opposing rollers included in
20 the pair of draft rollers, to form the fiber bundle F.
The fiber bundle F formed by the draft device 2 is
supplied to the spinning device 3.
As illustrated in FIG. 2, a first fiber waste
suction/removal device 26 is provided immediately
14
downstream of the draft device 2 (below the pair of front
rollers 24). The first fiber waste suction/removal
device 26 includes an elongated hollow member connected
to the main suction duct 86. Therefore, a suction
5 airflow is generated at a distal end portion and an
inside of the first fiber waste suction/removal device
26.
Around the draft device 2, various kinds of fiber
waste are generated. For example, when the sliver S is
10 stretched in the draft device 2, fibers fall out from
the fiber bundle F, and the fallen fibers become fiber
waste. The draft device 2 is provided with a cleaning
device (not illustrated) that is for cleaning, and this
cleaning results in generating fiber waste. Further, as
15 will be described later, a cleaning operation of the
spinning device 3 causes fiber waste adhering inside the
spinning device 3 to be blown to the surroundings. The
first fiber waste suction/removal device 26 suctions and
removes these fiber wastes. The fiber waste suctioned
20 by the first fiber waste suction/removal device 26 is
carried on the suction airflow in the first fiber waste
suction/removal device 26 and flows into the fiber waste
collecting box 85 through the main suction duct 86.
The fiber waste generated in the draft device 2
15
may be removed by another suction/removal device instead
of or in addition to the first fiber waste
suction/removal device 26. Examples of the other
suction/removal device include a suction device
5 configured to face a pair of draft rollers and suction
an outer peripheral surface thereof. The other
suction/removal device may be a suction device specially
provided for removing fiber waste generated as a result
of cleaning by the cleaning device.
10 The spinning device 3 is formed by, for example,
an air jet spinning device. The spinning device 3
includes a spinning nozzle (not illustrated). The
spinning device 3 generates a whirling airflow by
injecting compressed air from the spinning nozzle into
15 an inner side of the spinning device 3. The fiber bundle
F supplied from the draft device 2 is twisted by this
whirling airflow to form the spun yarn Y.
The configuration of the spinning device 3 is known,
and thus will be briefly described below. Although not
20 illustrated, the spinning device 3 includes a nozzle
block and a hollow guide shaft body. The nozzle block
includes a fiber guiding section, a spinning nozzle, and
a spinning chamber. The hollow guide shaft body includes
a yarn passage and a second nozzle.
16
The fiber guiding section included in the nozzle
block is a member that guides the drafted fiber bundle
F into the spinning device 3 (the spinning chamber).
The spinning device 3 injects air from the spinning
5 nozzle into the spinning chamber, and causes a whirling
airflow to act on the fiber bundle F in the spinning
chamber. By receiving the action of the whirling airflow,
each fiber end of a plurality of fibers that form the
fiber bundle F is reversed and whirled.
10 The hollow guide shaft body is a cylindrical member,
and the yarn passage is formed inside thereof. The
hollow guide shaft body guides the spun yarn Y from
inside the spinning chamber to outside the spinning
device 3.
15 To start spinning, it is necessary to introduce
the fiber bundle F from the draft device 2 into the
spinning device 3. Therefore, the spinning device 3
injects air into the yarn passage by using the second
nozzle, to generate a whirling airflow flowing from
20 upstream to downstream in the yarn passage. The
direction of the whirling airflow generated in the yarn
passage is opposite to the direction of the whirling
airflow in the spinning chamber.
The spinning machine 100 (each spinning unit 1)
17
includes a second fiber waste suction/removal device 27.
The second fiber waste suction/removal device 27
includes an elongated hollow member. The second fiber
waste suction/removal device 27 is provided so as to
5 connect the spinning chamber of the spinning device 3
(or an exhaust passage provided downstream of the
spinning chamber) and the main suction duct 86.
Therefore, a suction airflow is generated inside the
second fiber waste suction/removal device 27.
10 Some fibers of the fiber bundle F supplied to the
spinning device 3 fall off without being twisted into
the spun yarn Y during the spinning operation. In this
way, fiber waste is generated in the spinning chamber.
The second fiber waste suction/removal device 27 can
15 remove this fiber waste. The fiber waste suctioned by
the second fiber waste suction/removal device 27 is
carried on the suction airflow in the second fiber waste
suction/removal device 27 and flows into the fiber waste
collecting box 85 through the main suction duct 86.
20 After the spinning operation of the spinning device
3 is stopped or before the spinning operation is
restarted (started), a cleaning operation of the
spinning device 3 is performed. The cleaning operation
will be described. First, the hollow guide shaft body
18
of the spinning device 3 is separated from the nozzle
block, to open the spinning chamber toward outside. Next,
in this state, air is injected from the spinning nozzle
for a predetermined time. This enables fiber waste
5 remaining in the spinning chamber in the previous
spinning operation to be blown off toward outside and
removed from the spinning device 3. However, the above
cleaning operation is an example, and the fiber waste
can be cleaned by other operation. The fiber waste is
10 suctioned and removed by the first fiber waste
suction/removal device 26 or the second fiber waste
suction/removal device 27.
The yarn winding device 4 includes a cradle arm 41,
a winding drum 42, and a traverse guide 43. The cradle
15 arm 41 can rotatably support a bobbin 46 (that is, a
package 45) that is for winding the spun yarn Y. The
cradle arm 41 is supported to be swingable about a
supporting shaft 44. The winding drum 42 rotates while
being in contact with an outer peripheral surface of the
20 bobbin 46 or the package 45, to rotationally drive the
package 45 in a winding direction. The yarn winding
device 4 drives the winding drum 42 by an electric motor
(not illustrated) while reciprocating the traverse guide
43 by driving means (not illustrated). This causes the
19
spun yarn Y to be wound into the package 45 while being
traversed.
In each spinning unit 1, a yarn accumulating device
11 and a yarn monitoring device 12 are provided between
5 the spinning device 3 and the yarn winding device 4.
The yarn accumulating device 11 is provided
downstream of the spinning device 3. As illustrated in
FIG. 2, the yarn accumulating device 11 includes a yarn
accumulating roller 11a and a motor 11b that rotationally
10 drives the yarn accumulating roller 11a.
The yarn accumulating roller 11a winds and
temporarily stores the spun yarn Y of a predetermined
quantity around an outer peripheral surface. By
rotating at a predetermined rotation speed with the spun
15 yarn Y being wound around the outer peripheral surface,
the yarn accumulating roller 11a pulls out the spun yarn
Y from the spinning device 3 at a predetermined speed
and conveys the spun yarn Y to the downstream side.
As illustrated in FIG. 2, the yarn suction device
20 28 is provided near the yarn accumulating roller 11a.
The yarn suction device 28 is formed by a hollow pipe.
This pipe is connected to the additional suction duct
88. Therefore, a suction airflow is generated at a
distal end portion and an inside of the yarn suction
20
device 28.
During winding of the spun yarn Y, when a yarn
breakage occurs for some reason, and the spun yarn Y
remains on the yarn accumulating roller 11a, the yarn
5 suction device 28 can suction and capture to remove the
residual yarn wound around the yarn accumulating roller
11a, with the suction airflow generated at the distal
end portion and the inside thereof. The yarn breakage
includes at least one of an event in which the spun yarn
10 Y is cut due to an excessive tension applied to the spun
yarn Y, or an event in which the yarn monitoring device
12 detects a yarn defect and the spun yarn Y is cut.
The residual yarn (yarn waste) suctioned and
removed by the yarn suction device 28 is carried on the
15 suction airflow in the yarn suction device 28, and flows
into the yarn waste collecting box 87 through the
additional suction duct 88. The removal of the residual
yarn by the yarn suction device 28 is performed, for
example, before starting the yarn joining operation,
20 described later, performed by the yarn joining cart 6.
The yarn monitoring device 12 is provided between
the spinning device 3 and the yarn accumulating device
11. The spun yarn Y generated by the spinning device 3
passes through the yarn monitoring device 12 before being
21
wound by the yarn accumulating device 11.
The yarn monitoring device 12 monitors quality (a
thickness or the like) of the travelling spun yarn Y by
a light transmissive sensor, and detects a yarn defect
5 (such as a portion with abnormality in a thickness of
the spun yarn Y, or foreign substance) contained in the
spun yarn Y. Without being limited to the light
transmissive sensor, the yarn monitoring device 12 can
also monitor the spun yarn Y by using, for example, an
10 electrostatic capacitance sensor. The yarn monitoring
device 12 may be configured to detect a tension of the
spun yarn Y as the quality of the spun yarn Y.
When the yarn monitoring device 12 detects a yarn
defect, the spun yarn Y is cut. There are various
15 methods for cutting the spun yarn Y. For example, the
spun yarn Y can be cut by stopping the spinning in the
spinning device 3. The spinning unit 1 and the like may
be configured to include a cutter, and the spun yarn Y
may be cut by this cutter.
20 As illustrated in FIG. 1, the yarn joining cart 6
includes travelling wheels 61, a yarn joining device 62,
a suction pipe 63, and a suction mouth 64.
The travelling wheels 61 are configured to be
rotationally driven by a motor (not illustrated).
22
Driving the travelling wheels 61 allows the yarn joining
cart 6 to travel for the plurality of spinning units 1.
The suction pipe 63 is connected to the additional
suction duct 88. The suction pipe 63 can suction and
5 capture the spun yarn Y fed from the spinning device 3,
by generating a suction airflow at a distal end thereof.
The suction mouth 64 is connected to the additional
suction duct 88. The suction mouth 64 can suction and
capture the spun yarn Y from the package 45 supported by
10 the yarn winding device 4, by generating a suction
airflow at a distal end thereof. The suction pipe 63
and the suction mouth 64 rotate with the captured spun
yarn Y, to guide the spun yarn Y to a position where the
spun yarn Y can be introduced into the yarn joining
15 device 62.
The yarn joining device 62 joins the spun yarn Y
guided by the suction pipe 63 from the spinning device
3 and the spun yarn Y guided by the suction mouth 64
from the package 45. In the present embodiment, the
20 yarn joining device 62 is a splicer device adapted to
twist yarn ends by a whirling airflow. The yarn joining
device 62 is not limited to the splicer device, and a
piecer, a knotter that mechanically joins the spun yarn
Y, or the like may be adopted In order to form a yarn end for yarn joining, the
yarn joining device 62 cuts each of the spun yarn Y
suctioned by the suction pipe 63 and the spun yarn Y
suctioned by the suction mouth 64. Yarn waste generated
5 by this is respectively suctioned and removed by the
suction pipe 63 and the suction mouth 64. The yarn waste
suctioned and removed by the suction pipe 63 is carried
on the suction airflow in the suction pipe 63, and flows
into the yarn waste collecting box 87 through the
10 additional suction duct 88. The yarn waste suctioned
and removed by the suction mouth 64 is carried on the
suction airflow inside the suction mouth 64, and flows
into the yarn waste collecting box 87 through the
additional suction duct 88.
15 In the present embodiment, the management device 9
of the spinning machine 100 can calculate a raw material
loss quantity generated in a process of forming the spun
yarn Y and forming the package 45, for each predetermined
yarn production quantity. The management device 9
20 stores the calculated raw material loss quantity in a
storage section 95. The calculated raw material loss
quantity is appropriately monitored, and an irregular
change in the raw material loss quantity is detected as
an abnormality, if any.
24
The calculated raw material loss quantity is used
to obtain a quantity of the sliver S (a raw material
quantity) required to form and wind the spun yarn Y of
a predetermined yarn production quantity, under a
5 spinning condition specified by the operator using the
input device 92. This makes it possible to accurately
predict the required raw material quantity, which
facilitates stock management of the raw material, for
example.
10 The raw material loss quantity can be obtained by
adding a fiber waste total collection quantity by the
fiber waste collecting device 83 and a yarn waste total
collection quantity by the yarn waste collecting device
84, within a period in which the spun yarn Y of the
15 predetermined yarn production quantity is formed and
wound. At least most of the fiber waste generated in
the spinning machine 100 is collected by the fiber waste
collecting device 83, and at least most of the yarn waste
is collected by the yarn waste collecting device 84.
20 Therefore, a collection quantity (a total collection
quantity) of the fiber waste can be regarded as a
generation quantity (a total generation quantity) of the
fiber waste in the spinning machine 100. Similarly, a
collection quantity (a total collection quantity) of the
25
yarn waste can be regarded as a generation quantity (a
total generation quantity) of the yarn waste.
Next, calculation of the fiber waste total
collection quantity will be described in detail. The
5 predetermined yarn production quantity is a quantity of
the spun yarn Y required to be produced as a whole by
the spinning machine 100, and is preset by the operator.
The predetermined yarn production quantity can be
expressed, for example, by a total weight or the number
10 of the packages 45. The predetermined yarn production
quantity is appropriately set on the basis of a model of
the spinning machine 100, a type of the spun yarn Y to
be produced, and the like.
In the fiber waste collecting box 85, the main
15 filter 73 that captures the fiber waste is provided in
the passage through which the suction airflow flows, as
illustrated in FIGS. 3A and 3B. Therefore, as the fiber
waste accumulates on the main filter 73, resistance to
the suction airflow flowing through the main filter 73
20 increases. A loss of dynamic pressure due to this
resistance appears as a phenomenon in which a static
pressure in the passage upstream of the main filter 73
decreases due to Bernoulli's principle.
In this way, the static pressure (a feature
26
quantity) in the fiber waste collecting box 85 located
upstream of the main filter 73 decreases as the fiber
waste collection quantity increases. By using this
relationship, the quantity of fiber waste accumulated in
5 the fiber waste collecting box 85 can be acquired.
The spinning machine 100 of the present embodiment
is provided with a first static pressure detection device
(a static pressure detection device) 93. The first
static pressure detection device 93 is provided in the
10 bypass passage 72 formed in the fiber waste collecting
box 85, for example, as illustrated in FIGS. 3A and 3B.
The first static pressure detection device 93 detects a
static pressure in the fiber waste collecting box 85
located upstream of the main filter 73 in the main
15 passage 71.
The first static pressure detection device 93 is
preferably provided downstream of the additional filter
74 in the bypass passage 72 illustrated in FIGS. 3A and
3B. This allows the first static pressure detection
20 device 93 to accurately detect the static pressure in
the fiber waste collecting box 85 without being affected
by fiber waste or the like.
The first static pressure detection device 93 is
formed by, for example, a fine differential pressure
27
sensor. The first static pressure detection device 93
outputs the detected static pressure in the fiber waste
collecting box 85, to the control device 90.
The control device 90 uses the storage section 95
5 including the ROM, RAM, and HDD described above, to store
the static pressure detected by the first static pressure
detection device 93. The storage section 95 stores
static pressure-fiber waste collection quantity data
indicating a correspondence relationship between a
10 static pressure in the fiber waste collecting device 83
and a collection quantity of fiber waste collected by
the fiber waste collecting box 85.
The relationship between the static pressure and
the fiber waste collection quantity is variously
15 different on the basis of, for example, a type of the
spun yarn Y to be produced by the spinning machine 100,
a set spinning condition, and the like. In consideration
of this fact, the static pressure-fiber waste collection
quantity data is stored in association with the type of
20 the spun yarn Y and the spinning condition. The static
pressure-fiber waste collection quantity data may be
stored in the storage section 95 in a form of a table,
or may be stored in the storage section 95 in a form of
a parameter of a calculation formula.
28
This allows the control device 90 to easily
calculate the quantity of fiber waste accumulated in the
fiber waste collecting box 85 on the basis of the static
pressure detected by the first static pressure detection
5 device 93.
The control device 90 monitors the static pressure
in the fiber waste collecting device 83 by using the
first static pressure detection device 93. Specifically,
when the static pressure detected by the first static
10 pressure detection device 93 becomes equal to or lower
than a predetermined threshold value, the control device
90 outputs a fiber waste discharging instruction to the
fiber waste collecting device 83, to automatically
discharge the fiber waste in the fiber waste collecting
15 box 85. The fiber waste collecting device 83 performs
the above-described automatic discharge in accordance
with the fiber waste discharging instruction from the
control device 90.
The control device 90 calculates a quantity of
20 fiber waste discharged from the fiber waste collecting
device 83 as a fiber waste discharge quantity Q, every
time the automatic discharge is performed. The fiber
waste discharge quantity Q corresponds to a quantity of
fiber waste collected in the fiber waste collecting box
29
85 until immediately before the automatic discharge.
Therefore, the fiber waste discharge quantity Q
corresponds to the fiber waste generation quantity
generated in a period between two adjacent automatic
5 discharges. The fiber waste discharge quantity Q is
calculated on the basis of a static pressure detected by
the first static pressure detection device 93
immediately before the automatic discharge is performed,
with reference to the above static pressure-fiber waste
10 collection quantity data. The calculated fiber waste
discharge quantity Q is stored in the storage section
95.
It takes some time for the production quantity of
the spun yarn Y in the spinning machine 100 to reach the
15 predetermined yarn production quantity. Hereinafter, a
yarn formation period corresponding to the predetermined
yarn production quantity is referred to as a specific
period P. The specific period P may become longer or
shorter due to uncertain factors (for example, the number
20 of times a yarn defect is actually detected by the yarn
monitoring device 12, and the like) even if the type of
the spun yarn Y and the spinning condition are the same.
The specific period P is not limited to the above, but
may be set per one shift time unit, for example.
30
In this specific period P, the automatic discharge
of the fiber waste may be performed for a plurality of
times in the fiber waste collecting device 83. In this
case, the control device 90 of the present embodiment
5 calculates the fiber waste discharge quantity Q every
time the automatic discharge of the fiber waste is
performed, and obtains a total sum of the plurality of
calculated fiber waste discharge quantities Q. This
makes it possible to calculate the total collection
10 quantity of fiber waste collected by the fiber waste
collecting device 83 within the specific period P. The
fiber waste total collection quantity corresponds to the
fiber waste generation quantity generated within the
specific period P.
15 In most cases, ending of the specific period P does
not coincide with the automatic discharge timing of the
fiber waste in the fiber waste collecting device 83. In
consideration of this fact, at a time when the specific
period P is completed, the control device 90 preferably
20 calculate the quantity of fiber waste accumulated in the
fiber waste collecting box 85 on the basis of the static
pressure detected by the first static pressure detection
device 93. In this case, the control device 90 adds the
calculated fiber waste generation quantity to a total
31
sum of the fiber waste discharge quantity Q calculated
up to that point within the specific period P, to
calculate the fiber waste total collection quantity.
Forcible automatic discharge of the fiber waste at
5 the end of the specific period P enables easy and
accurate calculation of the total collection quantity in
the next specific period P. The operator may clean the
fiber waste collecting device 83 at any timing during
the specific period P. In this case, the control device
10 90 calculates the quantity of fiber waste accumulated in
the fiber waste collecting box 85 on the basis of a
static pressure detected by the first static pressure
detection device 93 immediately before the cleaning, and
uses the calculation result to calculate the fiber waste
15 total collection quantity within the specific period P.
For some reason (for example, maintenance of the
machine and the like), when the specific period P is
interrupted and the operator cleans the fiber waste
collecting device 83, or when the specific period P is
20 cancelled by an operation of the operator, the control
device 90 may once cancel the calculation process up to
that point and newly start a series of calculations when
the specific period P is restarted or started.
Next, calculation of a yarn waste total collection
32
quantity by the spinning machine 100 of the present
embodiment will be described in detail. In the present
embodiment, the control device 90 of the management
device 9 calculates a yarn waste total collection
5 quantity by adding a calculated yarn joining yarn waste
quantity and a doffing yarn waste quantity, in the
specific period P.
The yarn joining yarn waste quantity is calculated
as follows, for example. That is, by counting the number
10 of times of yarn joining performed by the yarn joining
cart 6 within the specific period P, and multiplying the
obtained number of times of yarn joining by a unit yarn
joining yarn waste quantity to be generated in one yarn
joining, the control device 90 calculates the yarn
15 joining yarn waste quantity. The unit yarn joining yarn
waste quantity is a parameter preset in the control
device 90. The unit yarn joining yarn waste quantity
can be obtained, for example, by actually measuring the
yarn joining yarn waste quantity actually generated in
20 a trial operation or an actual operation, and obtaining
an average value of the measured values.
The unit yarn joining yarn waste quantity is not
limited to a fixed value. For example, the yarn joining
yarn waste quantity can be obtained by counting the
33
number of times of the yarn joining separately for each
of a long yarn defect and a short yarn defect,
multiplying each counted number of times with each of
the unit yarn joining yarn waste quantity for the long
5 yarn defect and the unit yarn joining yarn waste quantity
for the short yarn defect, and adding the multiplication
results.
The doffing yarn waste quantity is calculated, for
example, by multiplying the number of doffing operations
10 calculated by a predetermined yarn production quantity
planned to be wound within the specific period P, a yarn
type, a yarn thickness, a shape of the package 45, and
the like, by a unit doffing yarn waste quantity to be
generated in one doffing operation calculated on the
15 basis of a yarn travelling speed and the like.
Similarly to the calculation of the fiber waste
total collection quantity, when the specific period P is
interrupted for some reason (for example, machine
maintenance or the like), or when the specific period P
20 is cancelled by an operation of the operator, the control
device 90 may once cancel the calculation process up to
that point and newly start a series of calculations when
the specific period P is restarted or started.
However, the present embodiment is not limited to
34
such an example, and the doffing yarn waste quantity may
be calculated, for example, similarly to the calculation
of the yarn joining yarn waste quantity, by counting the
number of times the doffing operation is actually
5 performed within the specific period P.
The yarn joining operation and the doffing
operation are not always successful, and errors may occur.
When an error occurs, the yarn waste quantity increases
accordingly. In consideration of this fact, the yarn
10 joining yarn waste quantity and the doffing yarn waste
quantity calculated as described above may be corrected
on the basis of, for example, the number of yarn joining
operation errors and doffing operation errors,
respectively.
15 In the spinning machine 100 of the present
embodiment, the control device 90 calculates a raw
material loss quantity by adding the fiber waste total
collection quantity (the total generation quantity) and
the yarn waste total collection quantity (the total
20 generation quantity) calculated as described above. The
raw material loss quantity calculated by the control
device 90 is stored in the storage section 95. The
storage section 95 stores the obtained raw material loss
quantity in association with the type of the spun yarn
35
Y formed within the specific period P corresponding to
the raw material loss quantity, the set spinning
condition, and the like.
By dividing the raw material loss quantity by the
5 predetermined yarn production quantity, which is the
total quantity of the spun yarn Y wound within the
specific period P, a raw material loss rate can be
obtained. The control device 90 calculates the raw
material loss rate and stores in the storage section 95.
10 The raw material loss rate is stored in the storage
section 95 in association with the type of the spun yarn
Y formed within the specific period P and the set
spinning condition.
In the spinning machine 100 of the present
15 embodiment, the control device 90 determines whether or
not an abnormality (an abnormality regarding the raw
material loss) is occurring in the spinning machine 100,
on the basis of the calculated raw material loss quantity
within the specific period P. The control device 90 may
20 detect an abnormality of the sliver S itself, which is
the raw material, as the abnormality related to the raw
material loss.
Specifically, after winding the spun yarn Y of the
predetermined yarn production quantity, the control
36
device 90 calculates the raw material loss quantity
within the specific period P as described above. The
control device 90 calculates a loss quantity deviation
that is a deviation between a current raw material loss
5 quantity, which is a raw material loss quantity
calculated for a most recent specific period P, and a
past raw material loss quantity, which is a raw material
loss quantity calculated for the past specific period P
under the same spinning condition stored by the storage
10 section 95.
When an absolute value of the loss quantity
deviation is equal to or larger than a preset threshold
value, that is, when the raw material loss quantity in
the current specific period P deviates from the raw
15 material loss quantity of the past specific period P by
a predetermined quantity or more, the control device 90
determines that an abnormality is occurring regarding
the raw material loss quantity, and notifies the operator
of the fact. There are various methods of notifying the
20 operator of this abnormality. For example, a warning
may be displayed on the display 91.
When an absolute value of the loss quantity
deviation is smaller than the threshold value, the
control device 90 updates the past raw material loss
37
quantity stored in the storage section 95 with the raw
material loss quantity in the specific period P obtained
this time, in correspondence with the same spun yarn Y
type and the same spinning condition. This makes it
5 possible to detect an abnormality of the raw material
loss quantity while allowing a gradual change of the raw
material loss quantity due to a change over time and the
like of the spinning machine 100.
In the spinning machine 100 of the present
10 embodiment, when the past raw material loss quantity is
not stored in the storage section 95, the control device
90 makes the above determination by using a past raw
material loss quantity that is similarly calculated and
stored by a different management device that manages
15 another spinning machine that is different spinning
machine. The control device 90 is configured to be able
to communicate with the different management device, and
can obtain the past raw material loss quantity through
known communication. As a result, for example, even
20 when spinning a spun yarn Y of an unknown type, acquiring
information from the different management device makes
it possible to perform abnormality determination
regarding the raw material loss quantity without
problems.
38
As described above, the management device 9 of the
present embodiment is a management device for the
spinning machine 100 including the spinning device 3 and
the fiber waste collecting device 83. The spinning
5 device 3 forms the spun yarn Y. The fiber waste
collecting device 83 collects fiber waste generated
during the formation of the spun yarn Y. The management
device 9 includes the control device 90. The control
device 90 calculates a fiber waste generation quantity
10 of the spinning machine 100 on the basis of a feature
quantity (for example, a static pressure inside the fiber
waste collecting device 83) that changes in accordance
with a quantity of the fiber waste collected by and
accumulated in the fiber waste collecting device 83.
15 This enables quick and accurate calculation of the
fiber waste generation quantity.
In the present embodiment, the fiber waste
collecting device 83 gathers and collects the fiber waste
via a suction airflow caused by a negative pressure.
20 The management device 9 includes the first static
pressure detection device 93. The first static pressure
detection device 93 detects a static pressure inside the
fiber waste collecting device 83. The control device 90
calculates the fiber waste generation quantity on the
39
basis of the static pressure that is the feature quantity
and is detected by the first static pressure detection
device 93.
This enables calculation of the fiber waste
5 generation quantity with simple processing using a
detected value of the static pressure inside the fiber
waste collecting device 83.
In the present embodiment, when the static pressure
detected by the first static pressure detection device
10 93 becomes equal to or lower than a threshold value, the
control device 90 outputs a fiber waste discharging
instruction for discharging the fiber waste accumulated
in the fiber waste collecting device 83.
This allows the static pressure in the fiber waste
15 collecting device 83 to be favorably maintained within
an appropriate range. Therefore, in the spinning
machine 100 that forms the spun yarn Y by using the
suction airflow, it is possible to avoid deterioration
of quality of the spun yarn Y to be formed. Further,
20 the collected fiber waste can be discharged at an
appropriate timing.
In the present embodiment, the fiber waste
collecting device 83 automatically discharges the
accumulated fiber waste in accordance with the fiber
40
waste discharging instruction inputted from the control
device 90.
This makes it possible to save labor in discharging
fiber waste. Further, since the fiber waste can be
5 reliably discharged, it is possible to avoid
deterioration of quality of the spun yarn Y formed in
the spinning machine 100 that forms the spun yarn Y by
using a suction airflow.
The spinning machine 100 managed by the management
10 device 9 of the present embodiment includes the yarn
winding device 4 and the yarn joining device 62. The
yarn winding device 4 winds the spun yarn Y formed by
the spinning device 3. The yarn joining device 62
performs yarn joining when a yarn breakage occurs in a
15 process of winding the formed spun yarn Y. The control
device 90 calculates a fiber waste generation quantity
as a fiber waste total generation quantity in the
specific period P in which the spun yarn Y of a
predetermined yarn production quantity is formed and
20 wound. The control device 90 calculates a yarn waste
total generation quantity within the specific period P,
on the basis of the number of times and/or a period of
time of yarn joining performed by the yarn joining device
62 within the specific period P. The control device 90
41
calculates a raw material loss quantity by adding the
calculated fiber waste total generation quantity and
yarn waste total generation quantity.
This enables calculation of the raw material loss
5 quantity within the specific period P from the viewpoint
of both fiber waste and yarn waste, and thus the raw
material loss quantity can be managed more accurately.
In the present embodiment, the control device 90
determines a ratio of the raw material loss quantity to
10 the predetermined yarn production quantity as a raw
material loss rate.
This makes it possible to easily manage at what
rate the raw material is lost in the production of the
spun yarn Y.
15 The management device 9 of the present embodiment
includes the display 91. The display 91 displays a raw
material loss quantity calculated by the control device
90.
This allows a production manager and/or an operator
20 to easily check the raw material loss quantity of the
spinning machine 100.
In the present embodiment, the control device 90
includes the storage section 95. The storage section 95
stores a raw material loss quantity calculated by the
42
control device 90. The control device 90 calculates the
raw material loss quantity for each predetermined yarn
production quantity of the spun yarn Y wound by the
spinning machine 100. The control device 90 calculates
5 a loss quantity deviation that is a deviation between a
current raw material loss quantity and a past raw
material loss quantity. The current raw material loss
quantity is a raw material loss quantity calculated for
a most recent specific period P in which the spun yarn
10 Y of the predetermined yarn production quantity is formed
and wound. The past raw material loss quantity is the
raw material loss quantity determined to have no
abnormality, among the raw material loss quantities
stored in the storage section 95 and calculated for the
15 past specific period P in which the spun yarn Y of the
predetermined yarn production quantity has been formed
and wound. When an absolute value of the calculated
loss quantity deviation is equal to or larger than a
threshold value, the control device 90 determines that
20 an abnormality is occurring in the raw material loss
quantity and displays the abnormality on the display 91.
This allows production management to be favorably
performed by monitoring a change in the raw material
loss quantity. Further, the operator can notice an
43
abnormality or the like occurring in the spinning machine
100 at an early stage.
In the management device 9 of the present
embodiment, when an absolute value of the loss quantity
5 deviation is smaller than the threshold value, the past
raw material loss quantity stored in the storage section
95 is updated to the current raw material loss quantity.
This makes it possible to determine an abnormality
of the raw material loss quantity while allowing a
10 gradual change of the raw material loss quantity due to
a change over time and the like of the spinning machine
100.
In the present embodiment, the control device 90
can communicate with a different management device that
15 manages a spinning machine different from the spinning
machine 100. The control device 90 acquires the past
raw material loss quantity from the different management
device through communication.
This enables an abnormality in the raw material
20 loss quantity to be favorably determined by sharing
information.
In the present embodiment, the control device 90
includes the storage section 95. The storage section 95
stores the calculated raw material loss quantity in
44
association with a type of a yarn to be formed and a
spinning condition. The control device 90 calculates,
on the basis of the raw material loss quantity stored in
the storage section 95, a raw material quantity required
5 to form and wind the spun yarn Y of the predetermined
yarn production quantity with a specified yarn type and
spinning condition.
This enables accurate prediction of the raw
material quantity required for production of the spun
10 yarn Y.
Next, a second embodiment will be described. In
the description of the present embodiment, same
reference numerals are given in the drawings for the
members same as or similar to those in the above15 described embodiment, and the description thereof may be
omitted.
In a spinning machine 100 of the present embodiment,
on the basis of a preset reference fiber waste quantity
and the number of times of automatic discharge of fiber
20 waste performed by a fiber waste collecting box 85 within
a specific period P, a management device 9 calculates a
fiber waste total collection quantity.
The reference fiber waste quantity refers to a
quantity of fiber waste automatically discharged from
45
the fiber waste collecting box 85 per time. The
reference fiber waste quantity can be obtained as an
average value, for example, by dividing a total quantity
of fiber waste actually discharged in a trial operation
5 or an actual operation by the number of times of the
automatic discharge. The reference fiber waste quantity
is inputted to the management device 9 by an operator
operating an input device 92.
A control device 90 of the management device 9
10 counts the number of times of the automatic discharge of
the fiber waste performed by the fiber waste collecting
box 85 within the specific period P. The control device
90 multiplies the obtained number of times of the
automatic discharge by the reference fiber waste
15 quantity, to calculate the fiber waste total collection
quantity (in other words, a total generation quantity).
This enables easy calculation of the fiber waste total
generation quantity.
As described above, the management device 9 of the
20 present embodiment includes the input device 92 that
allows input of the reference fiber waste quantity that
serves as a reference for calculating a generation
quantity of fiber waste.
This enables easy calculation of the fiber waste
46
total generation quantity.
Next, an alternative embodiment of the abovedescribed embodiment will be described. FIG. 4 is a
view illustrating a configuration of a fiber waste
5 collecting device 83 of a spinning machine 100 of the
alternative embodiment. Note that, in the description
of this alternative embodiment, same reference numerals
are given in the drawing for the members same as or
similar to those in the above-described embodiment, and
10 the description thereof may be omitted.
In the spinning machine 100 of this alternative
embodiment, a rotation speed of a main blower 81a is
controlled so that a static pressure in the fiber waste
collecting device 83 is constantly maintained within a
15 predetermined range. Specifically, when a static
pressure detected by a first static pressure detection
device 93 falls below a lower limit value of the above
range, a control device 90 increases a rotation speed of
the main blower 81a. Hereinafter, the rotation speed of
20 the main blower 81a may be simply referred to as a blower
rotation speed. As a quantity of fiber waste accumulated
in a fiber waste collecting box 85 increases, the blower
rotation speed increases.
In a management device 9 of the present embodiment,
47
a storage section 95 stores rotation speed-fiber waste
collection quantity data indicating a correspondence
relationship between a rotation speed of the main blower
81a and a collection quantity of fiber waste collected
5 by the fiber waste collecting box 85.
In the spinning machine 100 of the present
embodiment, as illustrated in FIG. 4, a blower rotation
speed sensor (a blower rotation speed acquiring device)
94 configured to detect a rotation speed of the main
10 blower 81a is provided. The blower rotation speed sensor
94 is formed by, for example, a photoelectric rotation
sensor, a magnetic rotation sensor, or the like. The
blower rotation speed sensor 94 outputs the detected
rotation speed of the main blower 81a to the control
15 device 90.
The management device 9 of the present embodiment
calculates a quantity of fiber waste on the basis of the
rotation speed (a feature quantity) of the main blower
81a detected by the blower rotation speed sensor 94,
20 instead of the static pressure in the above-described
first embodiment. This enables accurate calculation of
a quantity of fiber waste accumulated in the fiber waste
collecting box 85.
The management device 9 of the present embodiment
48
monitors a static pressure in the fiber waste collecting
device 83 by using the first static pressure detection
device 93. The management device 9 also uses the blower
rotation speed sensor 94 to monitor the collection
5 quantity of fiber waste accumulated in the fiber waste
collecting box 85.
When the rotation speed of the main blower 81a
detected by the blower rotation speed sensor 94 becomes
equal to or higher than a predetermined threshold value,
10 the control device 90 outputs a fiber waste discharging
instruction to the fiber waste collecting device 83.
The control device 90 calculates a fiber waste discharge
quantity Q on the basis of a rotation speed of the main
blower 81a detected immediately before starting of
15 automatic discharge of the fiber waste.
Instead of a configuration of detecting the blower
rotation speed by the sensor, the control device 90 can
acquire the blower rotation speed on the basis of a
rotation speed command value outputted to a main motor
20 81b. In this case, the control device 90 substantially
functions as a blower rotation speed acquiring device.
As described above, the management device 9 of the
present embodiment includes the blower rotation speed
sensor 94. The blower rotation speed sensor 94 acquires
49
a rotation speed of the main blower 81a that supplies a
negative pressure to the fiber waste collecting device
83. The control device 90 calculates a fiber waste
generation quantity on the basis of the rotation speed
5 acquired by the blower rotation speed sensor 94.
As a result, when the blower rotation speed is
controlled in accordance with a quantity of the fiber
waste accumulated in the fiber waste collecting device
83, the fiber waste generation quantity can be calculated
10 with simple processing using the blower rotation speed.
In the management device 9 of the present
embodiment, when the rotation speed detected by the
blower rotation speed sensor 94 exceeds a threshold value,
the control device 90 outputs the fiber waste discharging
15 instruction for discharging the fiber waste collected by
the fiber waste collecting device 83.
As a result, when performing control to increase
the blower rotation speed as the fiber waste accumulates
in the fiber waste collecting device 83, the collected
20 fiber waste can be discharged at an appropriate timing.
Therefore, in the spinning machine 100 that forms a spun
yarn Y by using a suction airflow, it is possible to
avoid deterioration of quality of the spun yarn Y to be
formed.
50
The preferred embodiments and the alternative
embodiments of the present invention have been described
above, but the above-described configurations may be
modified as below. The above-described embodiments and
5 alternative embodiments, and the following modifications
can be appropriately combined.
The first static pressure detection device 93 may
be provided in the main suction duct 86 or may be
provided in a passage downstream of the main filter 73.
10 The control device 90 may not necessarily calculate
the fiber waste discharge quantity Q every time the
automatic discharge of fiber waste is performed. For
example, after winding a yarn of the predetermined yarn
production quantity (that is, after the specific period
15 P has elapsed), the control device 90 may collectively
calculate the fiber waste discharge quantity Q in the
specific period P on the basis of a transition of
increase and/or decrease of a static pressure in the
specific period P.
20 The yarn waste total collection quantity may be
calculated in the same manner as the fiber waste total
collection quantity. Specifically, in the yarn waste
collecting box 87, a second static pressure detection
device (not illustrated) is provided close to and
51
upstream of the filter (not illustrated) that captures
the yarn waste. Within the specific period P, every
time the yarn waste discharging operation is performed,
by calculating the yarn waste collection quantity on the
5 basis of the detected static pressure in the yarn waste
collecting box 87 and adding each yarn waste collection
quantity at the end of the specific period P, the yarn
waste total collection quantity can be obtained.
The control device 90 may be configured to be able
10 to transmit a raw material loss quantity calculated for
each specific period P to a separately provided
management system (not illustrated). In this case, the
management system can use each raw material loss quantity
received from the control device 90 for performance
15 analysis, determination of maintenance time, and the
like of the spinning machine 100.
The control device 90 may store the raw material
loss quantity calculated for each specific period P for
a plurality of past times. In this case, a loss quantity
20 deviation can be obtained, for example, as a deviation
between a current raw material loss quantity with respect
to an average value of past raw material loss quantities
for the plurality of times.
When an abnormal raw material loss quantity is
52
detected, the control device 90 may determine whether
the fiber waste total generation quantity is abnormal,
the yarn waste total generation quantity is abnormal, or
both are abnormal, and display the determination result
5 on the display 91. In this case, it becomes easy to
identify a cause of the abnormality.
Not all the fiber waste generated in the spinning
machine 100 is collected by the fiber waste collecting
device 83. Not all the yarn waste generated in the
10 spinning machine 100 is collected by the yarn waste
collecting device 84. In consideration of this fact,
the control device 90 may perform correction considering
a collection rate, instead of calculating the collection
quantity of the fiber waste and the yarn waste as it is
15 as the generation quantity.
In each spinning unit 1, each device may be
provided so that the spun yarn Y supplied from a lower
side is wound at an upper side in a height direction.
Instead of the yarn joining cart 6, the yarn
20 joining device 62, the suction pipe 63, and the suction
mouth 64 may be provided in each spinning unit 1.
Instead of the configuration of performing yarn
joining by splicing or knotting as described above, the
spinning unit 1 may bring the divided spun yarn Y into
53
a continuous state by feeding back the spun yarn Y from
the package 45 to the spinning device 3, and then
restarting the draft by the draft device 2 and the
spinning by the spinning device 3 (piecing). In this
5 case, for example, the yarn end of the spun yarn Y may
be cut before the spun yarn Y is fed back to the spinning
device 3, and the cut yarn end corresponds to yarn waste.
The number of draft rollers in the draft device 2
is not limited to four, but can be changed to two, three,
10 and five or more.
The management device 9 may calculate a generation
quantity of an accumulated yarn waste on the basis of a
cumulative period of time in which the motor 11b has
rotated the yarn accumulating roller 11a in order to
15 remove a residual yarn of the yarn accumulating roller
11a, and add to the yarn waste total generation quantity
described above.
The management device 9 of the spinning machine
100 may be configured to exclusively control the
20 collecting device 82, and a generation quantity of fiber
waste and/or yarn waste may be calculated by a management
device provided separately from the spinning machine 100
(for example, a portable terminal, or a computer provided
in a textile factory in which the spinning machine 100
54
is installed). In this case, this management device
receives necessary data from the management device 9 of
the spinning machine 100.
The spinning unit 1 may be configured to pull out
5 the spun yarn Y from the spinning device 3 by a pair of
known delivery rollers instead of the yarn accumulating
roller 11a. In this case, at least one of the yarn
accumulating device 11, a slack tube using a suction
airflow, or a mechanical compensator may be arranged
10 downstream of the pair of delivery rollers.
The spinning machine 100 may be an open-end
spinning machine instead of the air jet spinning machine.
According to a first aspect of the present
invention, a management device having the following
15 configuration is provided. That is, this management
device is a management device for a spinning machine
including a spinning device and a fiber waste collecting
device. The spinning device forms a yarn. The fiber
waste collecting device collects fiber waste generated
20 during the formation of the yarn. The management device
includes a control device. The control device
calculates a fiber waste generation quantity of the
spinning machine on the basis of a feature quantity that
changes in accordance with a quantity of the fiber waste
55
collected by and accumulated in the fiber waste
collecting device.
This enables quick and accurate calculation of the
fiber waste generation quantity.
5 The management device may have the following
configuration. That is, the fiber waste collecting
device gathers and collects the fiber waste via a suction
airflow caused by a negative pressure. The management
device includes a static pressure detection device that
10 detects a static pressure inside the fiber waste
collecting device. The control device calculates the
fiber waste generation quantity on the basis of the
static pressure that is the feature quantity and is
detected by the static pressure detection device.
15 This enables calculation of the fiber waste
generation quantity with simple processing using a
detected value of the static pressure inside the fiber
waste collecting device.
The management device may have the following
20 configuration. That is, the fiber waste collecting
device gathers and collects the fiber waste via a suction
airflow caused by a negative pressure. The management
device includes a blower rotation speed acquiring device.
The blower rotation speed acquiring device acquires a
56
blower rotation speed of a blower that supplies a
negative pressure to the fiber waste collecting device.
The control device calculates the fiber waste generation
quantity on the basis of the blower rotation speed that
5 is the feature quantity and is acquired by the blower
rotation speed acquiring device.
As a result, when the blower rotation speed is
controlled in accordance with a quantity of the fiber
waste accumulated in the fiber waste collecting device,
10 the fiber waste generation quantity can be calculated
with simple processing using the blower rotation speed.
In the management device, when the static pressure
detected by the static pressure detection device becomes
equal to or lower than a threshold value, the control
15 device preferably outputs a fiber waste discharging
instruction for discharging the fiber waste accumulated
in the fiber waste collecting device.
This allows the static pressure in the fiber waste
collecting device to be favorably maintained within a
20 predetermined range. Therefore, in the spinning machine
that uses a suction airflow to form a yarn, it is
possible to avoid deterioration of quality of the yarn
to be formed. Further, the collected fiber waste can be
discharged at an appropriate timing.
57
In the management device, when the blower rotation
speed detected by the blower rotation speed acquiring
device becomes equal to or higher than a threshold value,
the control device preferably outputs a fiber waste
5 discharging instruction for discharging the fiber waste
accumulated in the fiber waste collecting device.
As a result, when performing control to increase
the blower rotation speed as the fiber waste is
accumulated in the fiber waste collecting device, it is
10 possible to discharge the collected fiber waste at an
appropriate timing. Therefore, in the spinning machine
that uses a suction airflow to form a yarn, it is
possible to avoid deterioration of quality of the yarn
to be formed.
15 In the management device, it is preferable that
the fiber waste collecting device automatically
discharges the accumulated fiber waste in accordance
with the fiber waste discharging instruction inputted
from the control device.
20 This makes it possible to save labor in discharging
fiber waste. Further, since the fiber waste can be
reliably discharged, it is possible to avoid
deterioration of quality of the formed yarn in the
spinning machine that forms the yarn by using a suction
58
airflow.
The management device preferably includes an input
device that allows input of a reference fiber waste
quantity that serves as a reference for calculating the
5 fiber waste generation quantity.
This enables easy calculation of the fiber waste
generation quantity.
The management device preferably has the following
configuration. That is, the spinning machine includes a
10 yarn winding device and a yarn joining device. The yarn
winding device winds a yarn formed by the spinning device.
The yarn joining device performs yarn joining when a
yarn breakage occurs in a process of winding the formed
yarn. The control device calculates the fiber waste
15 generation quantity as a fiber waste total generation
quantity in a yarn formation period in which a yarn of
a predetermined yarn production quantity is formed and
wound. The control device calculates a yarn waste total
generation quantity within the yarn formation period, on
20 the basis of the number of times and/or a period of time
of yarn joining performed by the yarn joining device
within the yarn formation period. The control device
calculates a raw material loss quantity by adding the
calculated fiber waste total generation quantity and
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yarn waste total generation quantity.
This enables calculation of the raw material loss
quantity within the yarn formation period from the
viewpoint of both fiber waste and yarn waste, and thus
5 the raw material loss quantity can be managed more
accurately.
In the management device, the control device
preferably obtains a ratio of the raw material loss
quantity to the predetermined yarn production quantity.
10 This makes it possible to easily estimate at what
rate the raw material is lost in yarn production.
The management device preferably includes a
display section configured to display the raw material
loss quantity calculated by the control device.
15 This allows a production manager and/or an operator
to easily check the raw material loss quantity of the
spinning machine.
The management device preferably has the following
configuration. That is, the control device includes a
20 storage section that stores the calculated raw material
loss quantity. The control device calculates the raw
material loss quantity for each of the predetermined
yarn production quantities of a yarn wound by the
spinning machine. The control device calculates a loss
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quantity deviation that is a deviation between a current
raw material loss quantity and a past raw material loss
quantity. The current raw material loss quantity is the
raw material loss quantity calculated for the yarn
5 formation period that is most recent in which a yarn of
the predetermined yarn production quantity is formed and
wound. The past raw material loss quantity is the raw
material loss quantity that is stored in the storage
section and determined to have no abnormality, among the
10 raw material loss quantities calculated for the yarn
formation period of the past in which the yarn of the
predetermined yarn production quantity has been formed
and wound. When an absolute value of the calculated
loss quantity deviation is equal to or larger than a
15 threshold value, the raw material loss quantity is
determined to have an abnormality, and the abnormality
is displayed on the display section.
This allows production management to be favorably
performed by monitoring a change in the raw material
20 loss quantity. Further, the operator can notice an
abnormality or the like occurring in the spinning machine
at an early stage.
In the management device, when an absolute value
of the loss quantity deviation is smaller than the
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threshold value, it is preferable that the past raw
material loss quantity stored in the storage section is
updated to the current raw material loss quantity.
This makes it possible to determine an abnormality
5 of the raw material loss quantity while allowing a
gradual change of the raw material loss quantity due to
a change over time and the like of the spinning machine.
The management device preferably has the following
configuration. That is, the control device is
10 configured to be able to communicate with a different
management device that manages a spinning machine
different from the spinning machine. The control device
acquires the past raw material loss quantity from the
different management device through communication.
15 This enables an abnormality in the raw material
loss quantity to be favorably determined by sharing
information among a plurality of devices.
The management device preferably has the following
configuration. That is, the control device includes a
20 storage section that stores the calculated raw material
loss quantity in association with a type of a yarn to be
formed and a spinning condition. The control device
calculates, on the basis of the raw material loss
quantity stored in the storage section, a raw material
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quantity required to form and wind a yarn of a
predetermined yarn production quantity with a specified
yarn type and the spinning condition.
This enables accurate prediction of the raw
5 material quantity required for yarn production.
According to a second aspect of the present
invention, there is provided a spinning machine with a
management device having the following configuration.
That is, this spinning machine includes the above10 described management device and spinning machine. The
spinning machine is managed by the management device.
The spinning device included in the spinning machine is
an air jet spinning device.
This makes it possible to quickly and accurately
15 calculate a quantity of fiber waste that is generated
along with the yarn formation by the air jet.

WE CLAIM
1. A management device (9) for a spinning machine
(100) including a spinning device (3) configured to form
a yarn (Y), and a fiber waste collecting device (83)
5 configured to collect fiber waste generated during yarn
formation, the management device (9) comprising:
a control device (90) configured to calculate a
fiber waste generation quantity of the spinning machine
(100), based on a feature quantity that changes in
10 accordance with a quantity of the fiber waste collected
by and accumulated in the fiber waste collecting device
(83).
2. The management device (9) as claimed in claim
15 1, wherein
the fiber waste collecting device (83) is
configured to gather and collect the fiber waste via a
suction airflow caused by a negative pressure,
the management device (9) comprises a static
20 pressure detection device (93) configured to detect a
static pressure inside the fiber waste collecting device
(83), and
the control device (90) is configured to calculate
the fiber waste generation quantity, based on the static
64
pressure that is the feature quantity and is detected by
the static pressure detection device (93).
3. The management device (9) as claimed in claim
5 1, wherein
the fiber waste collecting device (83) is
configured to gather and collect the fiber waste via a
suction airflow caused by a negative pressure,
the management device (9) comprises a blower
10 rotation speed acquiring device (94) configured to
acquire a blower rotation speed of a blower (81a) that
supplies a negative pressure to the fiber waste
collecting device (83), and
the control device (90) is configured to calculate
15 the fiber waste generation quantity, based on the blower
rotation speed that is the feature quantity and is
acquired by the blower rotation speed acquiring device
(94).
20 4. The management device (9) as claimed in claim
2, wherein when the static pressure detected by the
static pressure detection device (93) becomes equal to
or lower than a threshold value, the control device (90)
outputs a fiber waste discharging instruction for
65
discharging the fiber waste accumulated in the fiber
waste collecting device (83).
5. The management device (9) as claimed in claim
5 3, wherein when the blower rotation speed detected by
the blower rotation speed acquiring device (94) becomes
equal to or higher than a threshold value, the control
device (90) outputs a fiber waste discharging
instruction for discharging the fiber waste accumulated
10 in the fiber waste collecting device (83).
6. The management device (9) as claimed in claim
4 or 5, wherein the fiber waste collecting device (83)
is configured to automatically discharge the accumulated
15 fiber waste in accordance with the fiber waste
discharging instruction inputted from the control device
(90).
7. The management device (9) as claimed in any
20 one of claims 1 to 6, comprising:
an input device (92) configured to allow input of
a reference fiber waste quantity that serves as a
reference for calculating the fiber waste generation
quantity.
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8. The management device (9) as claimed in any
one of claims 1 to 7, wherein
the spinning machine (100) comprises:
5 a yarn winding device (4) configured to wind
a yarn (Y) formed by the spinning device (3); and
a yarn joining device (62) configured to
perform yarn joining when a yarn breakage occurs in a
process of winding the formed yarn (Y),
10 the control device (90) is configured to
calculate the fiber waste generation
quantity as a fiber waste total generation quantity in
a yarn formation period in which a yarn (Y) of a
predetermined yarn production quantity is formed and
15 wound,
calculate a yarn waste total generation
quantity within the yarn formation period, based on a
number of times and/or a period of time of yarn joining
performed by the yarn joining device (62) within the
20 yarn formation period, and
add the calculated fiber waste total
generation quantity and yarn waste total generation
quantity, to calculate a raw material loss quantity.
67
9. The management device (9) as claimed in claim
8, wherein the control device (90) is configured to
obtain a ratio of the raw material loss quantity to the
predetermined yarn production quantity.
5
10. The management device (9) as claimed in claim
8 or 9, comprising:
a display section (91) configured to display the
raw material loss quantity calculated by the control
10 device (90).
11. The management device (9) as claimed in claim
10, wherein
the control device (90) includes a storage section
15 (95) configured to store the calculated raw material
loss quantity,
the control device (90) is configured to calculate
the raw material loss quantity for each of the
predetermined yarn production quantities of the yarn (Y)
20 wound by the spinning machine (100),
the control device (90) is configured to calculate
a loss quantity deviation that is a deviation between
a current raw material loss quantity that is
the raw material loss quantity calculated for the yarn
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formation period that is most recent in which the yarn
(Y) of the predetermined yarn production quantity is
formed and wound, and
a past raw material loss quantity that is
5 the raw material loss quantity that is stored in the
storage section (95) and determined to have no
abnormality, among the raw material loss quantities
calculated for the yarn formation period of past in which
the yarn (Y) of the predetermined yarn production
10 quantity has been formed and wound, and
when an absolute value of the calculated loss
quantity deviation is equal to or larger than a threshold
value, the raw material loss quantity is determined to
have an abnormality, and the abnormality is displayed on
15 the display section (91).
12. The management device (9) as claimed in claim
11, wherein when an absolute value of the loss quantity
deviation is smaller than the threshold value, the past
20 raw material loss quantity stored in the storage section
(95) is updated to the current raw material loss quantity.
13. The management device (9) as claimed in claim
11 or 12, wherein
69
the control device (90) is configured to be able
to communicate with a different management device (9)
that manages a spinning machine (100) different from the
spinning machine (100), and
5 the control device (90) is configured to acquire
the past raw material loss quantity from the different
management device (9) through communication.
14. The management device (9) as claimed in any
10 one of claims 9 to 13, wherein
the control device (90) includes a storage section
(95) configured to store the calculated raw material
loss quantity in association with a type of a yarn (Y)
to be formed and a spinning condition, and
15 the control device (90) is configured to calculate,
based on the raw material loss quantity stored in the
storage section (95), a raw material quantity required
to form and wind a yarn (Y) of a predetermined yarn
production quantity with a specified yarn type and the
20 spinning condition.
15. A spinning machine (100) with a management
device (9), comprising:
the management device (9) as claimed in any one of
70
claims 1 to 14; and
the spinning machine (100) configured to be managed
by the management device (9),
wherein the spinning device (3) included in the
5 spinning machine (100) is an air jet spinning device (3).