The present disclosure relates to a textile machinery
management system.
BACKGROUND
[0002] A management device for collecting and analyzing information
hom textile machinery has been utilized to easily grasp the states of a
plurality of units of textile machinery on the whole and help early
detection of errors. For example, Patent Literatures 1 to 3 disclose
management devices of this type.
[0003] Patent Literature 1 (Japanese Unexamined Patent Publication
No. H6-127828) discloses a system for diagnosing a failure in machines
in textile machinery having a plurality of units. The machine includes
a control device. The control device is connected to a host
management device through a transmission line. The management
device is configured to receive operating state information on each
winding unit of the machine. The management device is connected
with a diagnosis device. The diagnosis device receives the operating
state information horn the management device, diagnoses the content of
an error, if any, and displays it on the screen. The system described in
Patent Literature 1 is configured as described above to easily diagnose
the cause of a failure.
[0004] Patent Literature 2 (Japanese Unexamined Patent Publication
No. 2002-137867) discloses a management system for a spun yarn
winding machine including an induction motor for driving a bobbin
holder. The management system collects slip information about slip of
the induction motors in a number of winding machines to conduct
statistical processing. Patent Literature 2 also discloses a configuration
in which setting computers installed in plants are connected to the
Internet. The setting computer in each plant transmits slip information
on an induction motor to a server computer connected to the Internet
likewise. The server computer then conducts statistical processing on
the slip information and sends back the result to the setting computer.
The management system described in Patent Literature 2 thus enables
maintenance and management of the winding machines on a large scale.
[0005] Patent Literature 3 (Japanese Unexamined Patent Publication
No. H8-269825) discloses a method of monitoring a spinning machine
unit. Each spinning machine having 200 spinning units includes a
spinning machine calculator. Each spinning machine calculator
transfers a signal of a sensor in the spinning machine to a process
control calculator through a signal transmission network. The process
control calculator is configured to view a state of the spinning room.
The method of monitoring a spinning machine or a spinning machine
unit in Patent Literature 3 thus can clarify the source of a failure and
prevent increase of the risk of failures.
SUMMARY
[0006] In order to effectively assist maintenance activities for textile
machinery, it is preferable that the work actually conducted by a
maintenance administrator be input as response information to a host
device so that the result of this is reflected in an analysis result. It is,
however, extremely difficult to input response information to the host
device and have it reflected in the analysis result. This is because the
host device and the textile machinery are often disposed at physically
separate locations, such that, for example, the host device is installed in
a quality control building while the textile machinery is installed in a
production building. In such a situation, intercommunication between
the host device and the textile machinery is difficult. Since the host
device collects information on a large number of units of textile
machinery, inputting response information for individual textile
processing units to the host device requires a great deal of time and is
not practical.
[0007] An object of an embodiment of the present disclosure is
therefore to provide a textile machinery management system capable of
assisting maintenance activities for textile machinery more effectively.
This object is obtained by a textile machinery management
system according to claim 1.
[0008] A textile machinery management system includes textile
machinery having a control device and a management device configured
to manage the textile machinery. The control device is configured to
acquire operating state information on the textile machinery. The
management device includes a first acquisition unit configured to
acquire the operating state information on the textile machinery that is
acquired by the control device, an analyzer configured to analyze the
operating state information acquired by the first acquisition unit, and a
first output unit configured to output a result of analysis performed by
the analyzer. The control device includes a second acquisition unit
configured to acquire the result of analysis output by the first output
unit, a second output unit configured to output the result of analysis
acquired by the second acquisition unit, and a maintenance information
input unit configured to accept input of response information for the
result of analysis output by the second output unit. The first
acquisition unit also acquires the response information accepted by the
maintenance information input unit. In a case where the response
information is input to the maintenance information input unit, the
analyzer updates the result of analysis based on the response
information acquired through the first acquisition unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is configuration diagram of a textile machinery
management system according to an embodiment.
FIG. 2 is a functional block diagram showing a functional
configuration of the textile machinery management system in FIG. 1.
FIG. 3 shows an exemplary maintenance information reference
screen.
FIG. 4 shows an exemplary transmission setting screen.
FIG. 5 shows an exemplary automatic transmission setting
screen.
FIG. 6A shows an exemplary new notification screen.
FIG. 6B shows an exemplary new notification screen.
FIG. 6C shows an exemplary new notification screen.
FIG. 7 shows an exemplary message display screen.
FIG. 8 shows an exemplary notification information list screen.
FIG 9A shows exemplary display of an unread notice.
FIG. 9B shows exemplary display of an unread notice.
FIG. 9C shows exemplary display of an unread notice.
FIG. 10 shows an exemplary machine-specific status list screen.
FIG. 11 shows an exemplary status information list screen.
FIG. 12 is a flowchart illustrating an exemplary method of
determining maintenance information.
FIG. 13 shows an exemplary maintenance information reference
screen.
FIG. 14 is a diagram illustrating an example of updating of
maintenance information.
FIG. 15 is a diagram illustrating an example of updating of
maintenance information.
FIG. 16 shows an example of legends for the determination
results of maintenance information displayed in the maintenance
information reference screen.
DETAILED DESCRIPTION
[0010] An embodiment will be described below with reference to the
drawings. In the description of the drawings, the same elements are
denoted with the same reference signs and an overlapping description is
omitted.
[0011] A textile machinery management system 1 according to an
embodiment will be described. The textile machinery management
system 1 is a system that collectively manages a plurality of units of
textile machinery 10. As shown in FIG. 1, the textile machinery
management system 1 includes the plurality of units of textile
machinery 10 and a management device 20. The management device
20 is manipulated through a general personal computer 30 connected to
the management device 20. The personal computer 30 is a' desktop
personal computer and includes a display 31A, a keyboard 31B, a
mouse 3 lC, and a local area network (LAN) interface 3 ID. The LAN
interface 31D is connected to a second communication unit 22H
described later through a LAN 3. Not only a personal computer 30 but
also, for example, a notebook personal computer, a tablet, and/or a
smartphone may be connected to the management device 20.
(00121 The textile machinery 10 to be managed by the textile
machinery management system 1 of the present embodiment will now
be described. Examples of the textile machinery include an automatic
winder. The automatic winder is a machine that unwinds yarn from a
yarn feeding bobbin having yarn spun by a spinning machine and winds
the yarn on a take up tube to form a package of wound yarn of a
predetermined length. The textile machinery 10 includes a machine
control device (control device) 11 and a plurality of textile processing
units 13 arranged side by side. Other examples of the textile
machinery include a pneumatic spinning frame, a roving frame, a
spinning frame, a weaving machine, a knitting machine, a spun yarn
winding machine, and a draw texturing machine.
[0013] The individual textile processing unit 13 includes a unit
controller 13A. The unit controller 13A includes a not-shown central
processing unit (CPU), a read only memory (ROM), a random access
memory (RAM), and an input/output port. The ROM stores a program
for controlling the configuration of the textile processing unit 13. The
CPU reads out a winding program stored in the ROM to the RAM for
execution to enable control on the configuration of the textile processing
unit 13.
5 [0014] The inputloutput port of each unit controller 13A is connected to
the machine control device 11 to transmitlreceive information. The
machine control device 11 thus can centrally manage the plurality of
textile processing units 13 of the textile machinery 10.
[0015] The machine control device 11 is configured as a
10 microcomputer and includes a display 11E, an input key 11F, and a
LAN interface 1 ID. The LAN interface 11D of the individual machine
control device 11 is connected to the LAN 3, which is a network
constructed in a plant. The textile machinery 10 also includes a tower
lamp 11H for notifying, for example, the operator of a situation that
15 requires attention.
[OO 161 As shown in FIG. 2, the machine control device 11 includes a
CPU 11A, a RAM 11B, a ROM 11 C, and an inputloutput port 11G.
The ROM 11C stores a control program for controlling the textile
processing unit 13. The CPU 11A reads out the control program stored
20 in the ROM 11C to the RAM 11B for execution to allow the textile
processing unit 13 to control each part.
[OO 171 The inputloutput port 11 G of the machine control device 11 is
connected to the inputloutput port (not shown) of the unit controller 13A
in each textile processing unit 13 through an appropriate communication
25 line. This configuration allows the machine control device 11 to
transmit various control conditions to the unit controller 13A of the
individual textile processing unit 13 and set the various control
conditions. The machine control device 11 is configured to obtain
information about the current operating state (hereinafter referred to as
"operating state information") in the individual processing unit 13 from
the unit controller 13A of the textile processing unit 13.
[OO 181 The control conditions for spinning machines include, for
example, items concerning spinning settings such as spinning speed and
settings for a yam fault-removing device. The operating state
information for spinning machines includes, for example, operation data
10 such as production eff~ciency and spun yarn quality data such as fault
counts. Similarly, the control conditions for automatic winders include,
for example, items concerning yarn winding conditions such as winding
speed, yarn count, take up tension, winding volume of winding
packages, package weight, and yarn faults. The operating state
information for automatic winders includes, for example, yam winding
state information such as current package diameter, current winding
speed, occurrence of yarn breakage, and detection of yam faults.
[0019] Specifically, for example, the operator can display a control
condition setting menu on the display 11E of the machine control device
11 through appropriate manipulation and set control conditions by
inputting numeric values with the input key 11F. The setting values
related to the control conditions may be transmitted to each individual
specified textile processing unit 13 or may be transmitted collectively to
all of the textile processing units 13.
[0020] The machine control device 11 is configured to display the
operating state information, which changes every moment, real-time on
the display 11E. The machine control device 11 is also configured to
store past history of operating state information and, for example,
display a graph representing the yam fault frequency plotted on the time
axis on the display 11E.
[0021] In this manner, for example, the operator can collectively set the
control conditions for the plurality of textile processing units 13 with
the machine control device 11 and can view the operating state
information on the plurality of textile processing units 13 all together
with the machine control device 11. The textile machinery 10
therefore can be managed efficiently. The operating state information
and the control conditions are transmitted to the management device 20
described later to undergo a variety of analyses in order to take effective
management activities. The information transmitted from the textile
machinery 10 to the management device 20 is not limited to the
operating state information and the control conditions. For example,
the operating state information alone may be transmitted, or other
information may be included in addition to the operating state
information and the control conditions.
[0022] The textile machinery management system 1 including the
textile machinery 10 and the management device 20 will now be
described in details. The textile machinery management system 1
includes the management device (host management device) 20 that
centrally manages the plurality of units of textile machinery 10. The
management device 20 is mainly manipulated by the administrator who
manages maintenance activities and production efficiency.
[0023] The LAN 3 constructed in the plant is connected to the
respective machine control devices 11 of the plurality of units of textile
machinery 10 (textile machinery lox, 10y) as shown in FIG. 1. The
LAN 3 is in turn connected to the host device 20. This configuration
enables exchange of a variety of information between the machine
5 control devices 11 and the management device 20.
[0024] First of all, an electrical configuration of the management device
20 will be described. In the present embodiment, the management
device 20 is configured as a control unit and includes, as shown in FIG.
2, a CPU 21A, a RAM 21B, a storage device (for example, such as a
10 solid state drive (SSD) and mSATA) 21C, and a LAN interface 21D,
which are housed in a casing. The storage device 21C stores a
management program for centrally managing the machine control
devices 11 of the plurality of units of textile machinery 10. The LAN
interface 2 1D is connected to the LAN 3.
15 [0025] The hardware as described above cooperates with software to
allow the management device 20 to fimction as, for example, a frst
communication unit 22A, an information acquiring unit (first
acquisition unit) 22B, an information accumulating unit 22C, an
analyzer 22D, a transmitter (first output unit) 22E, a message input unit
20 22F, an image converter 22G, and a second communication unit 22H.
[0026] The first communication unit 22A is configured to communicate
with the machine control device 11 of the textile machinery 10 through
the LAN 3.
[0027] The information acquiring unit 22B acquires the operating state
25 information on the textile machinery 10 acquired by the machine control
device 11. More specifically, the information acquiring unit 22B
receives the operating state information and the control conditions from
the machine control device 11 of the textile machinery 10. The
information acquiring unit 22B also receives information input from a
status information list screen 77 described later, that is, response
information for a textile processing unit 13.
[0028] In the present embodiment, the information acquiring unit 22B
receives the operating state information from the machine control
device 11 of the textile machinery 10 through the first communication
unit 22A. In place of this configuration, for example, the operating
state information may be output to a removable storage device (for
example, a USB memory or a memory card) connected to the machine
control device 11, and then the removal storage device may be
connected to the management device 20, so that the first acquisition unit
acquires the operating state information from the removable storage
device. In the present embodiment, the receiver 12D receives the
result of analysis conducted by the management device 20 from the
management device 20 through the communication unit 12A. In place
of this configuration, for example, the result of analysis may be output
to a removable storage device (for example, a USB memory or a
memory card) connected to the management device 20, and then the
removable storage device may be connected to the machine control
device 11, so that the second acquisition unit acquires the result of
analysis from the removable storage device.
[0029] The information accumulating unit 22C is formed with, for
example, the storage device 21C and stores the operating state
information and the control conditions input to the information
acquiring unit 22B for a predetermined period. Alternatively, the
information accumulating unit 22C may be a hard disc drive (HDD) or
may be a storage device such as a server connectable through a network.
[0030] The analyzer 22D analyzes the operating state information
acquired by the information acquiring unit 22B. More specifically, the
analyzer 22D performs a predetermined analysis work (computation)
based on the operating state information and the control conditions input
by the information acquisition unit 22B and stored in the information
accumulating unit 22C to obtain an analysis result (maintenance
information). When the textile machinery 10 is a spinning machine,
the analyzer 22D can analyze, for example, operation data of each unit,
quality data, and occurrence frequency of alarms. When the textile
machinery 10 is an automatic winder, the winding efficiency of the
textile processing unit 13 and the frequency of occurrence of faults by a
clearer can be highly analyzed, for example, using standard deviations.
The analyzer 22D can also generate an image (for example, a list or a
graph image) graphically representing the analysis result in a manner
easy to understand for users of the management device 20. Details of
the analysis result of the analyzer 22D will be described later.
[0031] For example, the analyzer 22D analyzes the operating state
information at a second timing different from a first timing at which the
transmitter 22E periodically transmits the analysis result. The second
timing is a periodical timing shorter than the first timing.
[0032] The transmitter 22E outputs the result of analysis performed by
the analyzer 22D. More specifically, the transmitter 22E transmits the
result of analysis performed by the analyzer 22D to the machine control
device 11 of the textile machinery 10 through the first communication
unit 22A. When receiving a message input by the message input unit
22F described later, the transmitter 22E transmits the content of the
input message (a message image created by the image converter 22G
described later) together with the result of analysis to the machine
control device 11 of the textile machinery 10. The transmitter 22E can
further transmit a command related to the operation of the textile
machinery 10 when the user of the management device 20 gives an
instruction.
[0033] When transmitting the result of analysis and the message
(hereinafter also referred to as "notification information") to the
machine control device 11, the transmitter 22E can set the target
machine control device, the degree of importance and the distribution
time of the notification information to be transmitted, whether to display
a pop-up on the display 11E of the machine control device 11 to indicate
that the notification information is given, and whether to display a
screen saver to indicate that the notification information is given.
Details of this function will be described later.
[0034] The message input unit 22F allows the user of the management
device 20 to input a message (character string) that the user wishes to
convey to, for example, the operator of the textile machinery 10. The
message (character string) is input, for example, through the keyboard
3 1B of the personal computer 30 connected through the LAN 3.
[0035] The image converter 22G converts the character string input
hom the message input unit 22F into an image (message image)
representing the message.
[0036] The second comunication unit 22H is configured to
communicate with the personal computer 30 through the LAN 3.
[0037] In this manner, the management device 20 acquires the
operating state information on the textile machinery 10, analyzes the
acquired operating state information, and transmits the analysis result to
the machine control device 11, and in a case where response
information is received, updates the analysis result based on the
response information. That is, the management device 20 is a circuit
configured to execute acquisition of the operating state information on
the textile machinery 10, analysis of the acquired operating state
information, transmission of the analysis result to the machine control
device 11, and in a case where response information is received,
updating of the analysis result based on the response information.
[0038] An electrical configuration of the machine control device 11 of
the textile machinery 10 will now be described. That is, in the
individual textile machinery 10, the ROM 11C of the machine control
device 11 stores a transmission/reception program for communicating
with the management device 20, in addition to the aforementioned
control program. The hardware such as the CPU 11A, the RAM 11B,
and the ROM 11C and the software such as the transmission/reception
program cooperate together to allow the machine control device 11 to
fbnction as a communication unit 12A, an information storage unit 12B,
a transmitter (third output unit) 12C, a receiver (second acquisition unit)
12D, a notification information management unit (second output unit)
12E, a maintenance information input unit 12F, a lamp controller 12G;
an operation controller 12H, and other units.
[0039] The communication unit 12A is configured to communicate with
the management device 20 through the LAN 3.
[0040] The information storage unit 12B is configured with a
nonvolatile storage unit (for example, EEPROM) to store the operating
state information and the control conditions of the textile machinery 10
for a predetermined period. The storage capacity of the information
storage unit 12B is generally smaller than that of the storage device 21C
of the management device 20. The storage device 21C thus can store
the operating state information and the control conditions for a longer
period and can store more kinds of information.
[0041] The transmitter 12C transmits the operating state information on
the textile machinery 10 to the management device 20 through the
communication unit 12A. The transmitter 12C also outputs the
response information accepted by the maintenance information input
unit 12F described later. More specifically, the transmitter 12C
transmits information input from the status information list screen 77
(see FIG. 11) described later, that is, response information for the textile
processing unit 13 to the management device 20 through the
communication unit 12A.
[0042] The receiver 12D acquires the analysis result output by the
information acquisition unit 22B. More specifically, the receiver 12D
receives the result of analysis conducted by the management device 20
in connection with the operating state information and the control
conditions, from the management device 20 through the communication
unit 12A. The received analysis result appears on the display 11E
through manipulation of the input key 1 IF as appropriate, for example,
by the operator. When the receiver 12D receives data of a message
together with the analysis result, the message also appears on the
display 11E through manipulation of the input key 11F as appropriate,
for example, by the operator.
[0043] The notification information management unit 12E manages the
notification information transmitted fiom the management device 20.
For each message received by the receiver 12D, the notification
information management unit 12E stores whether the message has
appeared on the display 11E (in other words, whether, for example, the
operator performs manipulation for displaying the message). The
readunread state of such a message is transmitted to the management
device 20 through the communication unit 12A. As a result, the
readunread state of the message can be viewed, for example, in a list
form on the display 31A of the personal computer 30 connected to the
management device 20. The user of the management device 20 thus
can easily check whether, for example, the operator of the individual
textile machinery 10 has viewed the message.
[0044] When transmitting the notification information, the management
device 20 specifies the target (operators, maintenance workers, or all)
intended to receive the notification information. The notification
information management unit 12E provides the function of displaying
the target to whom the information given from the management device
20 is addressed, in a visually distinguishable manner, as shown in FIGS.
6A, 6B, and 6C. This function will be detailed later.
[0045] The notification information management unit 12E outputs the
analysis result acquired by the receiver 12D. More specifically, the
notification information management unit 12E further provides: the
function of displaying maintenance information (analysis result)
transmitted from the management device 20, for each machine, that is,
for example, as shown in FIG. 10, the maintenance information in units
of textile machinery 10 connected to the management device 20,
including other textile machinery 10; and the function of displaying the
maintenance information for each of the textile processing units 13
belonging to the machinery itself, for example, as shown in FIG.ll.
These functions will be detailed later.
[0046] The maintenance information input unit 12F accepts input of
response information for the analysis result output by the notification
information management unit 12E. More specifically, the maintenance
information input unit 12F has the function of inputting the response
result, based on the maintenance information transmitted from the
management device 20. For example, as shown in FIG. 11, the
provided function accepts input of information indicating, for example,
whether the response such as repair is done or no measures are taken
although the maintenance information is recognized for the maintenance
information transmitted from the management device 20. This
function will be detailed later.
[0047] The lamp controller 12G allows the tower lamp 11H provided
on the textile machinery 10 to illuminate or flash on and off when the
receiver 12D receives an analysis result or a message transmitted from
the management device 20. This can, for example, prompt the
operator or any other person to check the analysis result or the message.
[0048] When receiving a command related to the operation of the
textile machinery 10 ffom the management device 20 through the
receiver 12D, the operation controller 12H controls the textile
machinery 10 so as to operate in accordance with the command. This
enables the management device 20 to remotely control the operation of
the textile machinery 10.
[0049] Referring to FIG. 3 to FIG 16, the function of transmitting
maintenance information from the management device 20 to the textile
machinery 10 and the function of collecting response information
corresponding to maintenance information will now be described. The
maintenance information refers to information about a defective textile
processing unit analyzed based on the operating state information and
the control conditions stored in the information accumulating unit 22C,
and information about the history of measures taken for a defective
textile processing unit.
[0050] The analyzer 22D of the management device 20 determines a
textile processing unit 13 that newly develops a defect (error)
(hereinafter referred to as "initial unit"), based on the operating state
information and the control conditions stored in the information
accumulating unit 22C. The analyzer 22D also determines a textile
processing unit 13 that develops a recurring defect (hereinafter referred
to as "recurrent unit") and a textile processing unit 13 on which no
measures have been taken, based on the history of measures taken for
the textile processing units 13 that develop defects. Furthermore, the
analyzer 22D determines whether the textile processing unit 13 on
which no measures have been taken is a textile processing unit 13
(hereinafter referred to as "left unit") on which no measures have been
taken intentionally, or a textile processing unit 13 (hereinafter referred
to as "not-handled unit") on which no measures have been taken
because of a failure to view maintenance information (no input through
the status information list screen 77 described later).
[0051] The management device 20 can display the result of analysis
performed by the analyzer 22D on the display 31A of the personal
computer 30. The result of analysis performed by the analyzer 22D
appears in the form of a maintenance information reference screen 5 1 as
shown in FIG. 3. The maintenance information reference screen 51
displays a maintenance information display area 51A, an OK button
51B, and a sendbutton SIC.
[0052] The maintenance information display area 51A shows the
respective numbers of initial units, recurrent units, left units, and
not-handled units in single textile machinery (machine) 10. In the
maintenance information display area 51A, as shown in FIG. 3, the
initial unit, the recurrent unit, the left unit, and the not-handled unit each
are denoted by symbols "x", "A", "X", and "On, respectively. The
symbols representing the initial unit, the recurrent unit, the left unit, and
the not-handled unit are not limited to "X ", "A", "X", and "O", and
those units may be displayed with, for example, a red circle, a green
circle, a yellow circle, and a blue circle. The characters for the initial
unit, the recurrent unit, the left unit, and the not-handled unit may be
displayed.
[0053] The OK button 51B is a button for going back to the menu
screen. The send button 5 1C is a button for transmitting maintenance
information to the textile machinery 10 through the transmitter 22E
described later.
[0054] In this manner, the machine control device 11 acquires the
analysis result from the management device 20 and displays (outputs)
the analysis result, and accepts input of response information for the
analysis result. That is, the machine control device 11 is a circuit
configured to execute acquisition of the analysis result from the
management device 20, display (output) of the analysis result, and
acceptance of input of response information for the analysis result.
[0055] Referring to FIG 4 and FIG. 5, the function of attaching a
message to maintenance information that is transmitted from the
management device 20 to the textile machinery 10 will now be
described. FIG. 4 shows a transmission setting screen 53 in which
settings are made when the maintenance information generated by the
management device 20 is transmitted to the textile machinery 10. The
transmission setting screen 53 can be displayed on the display 11E of
the personal computer 30 connected to the management device 20.
The display of the transmission setting screen 53 is implemented by the
management program installed in the management device 20.
[0056] The transmission setting screen 53 displays a text box 53A for
inputting a recipient of notification information, a text box 53B for
inputting the title of notification information, a pull-down menu 53C for
choosing a recipient category, a pull-down menu 53D for choosing the
kind (category) of notification information to be transmitted, a
pull-down menu 53E for choosing a machine as a transmission
destination, a pull-down menu 53F for choosing the degree of
importance of the notification information to be transmitted to the
machine control device 11, a pull-down menu 53G for choosing
ONIOFF of the screen saver hnction on the display 11E in the machine
control device 11 as a notification destination, a pull-down menu 53H
for choosing ONlOFF of the pop-up hnction on the display 11E in the
5 machine control device 11 as a notification destination, a text box 531
for inputting a message, a clear button 53J for deleting the content input
to the text box 531, a save button 53K for temporarily saving the
contents input to the entries (53A to 53I), a print button 53L for printing
the contents input to the entries (53A to 53I), and a send button 53M for
10 executing transmission in accordance with the contents input to the
entries (53A to 531).
[0057] In the text box 53A, a person's name, a group's name, or the like
can be input as desired. That is, for example, a recipient not registered
in the pull-down menu 53C for choosing a recipient category can be
15 input as desired. In the text box 53B, about 20 characters can be input
as desired. In the pull-down menu 53C, one of job categories
(maintenance workers, operators, or all) registered in advance can be
chosen. In the pull-down menu 53D, one of the kinds of comments
(notification information) registered in advance can be chosen. The
20 kinds of comments include, for example, "periodical maintenance
instruction", which is an instruction on periodical check such as
lubrication, "maintenance work instruction", which is an instruction on
maintenance work for malfunction textile processing units based on
maintenance information, "yarn type change instruction", which is an
25 instruction on produced yarn type change, and "business operations
instruction", which is an instruction on general business operations
other than maintenance and production change. In the pull-down
menu 53E, one of the machines registered in advance can be chosen.
Individual machines, all machines, and registered groups can be chosen
as the machine.
[0058] The user of the management device 20 confirms the
transmission setting screen 53 as shown in FIG. 4 on the display 31A
and then clicks the send button 53M by manipulating the mouse 3 1C or
the like. The data of maintenance information is then transmitted from
the management device 20 to the machine control device 11 of the
textile machinery 10 set in the transmission setting screen 53.
[0059] The image converter 22G converts the character string in the
text box 531 into an image when the maintenance information is
transmitted to the machine control device 11 of the textile machinery 10.
For conversion from a character string into an image, the management
program to be executed in the management device 20 includes font data
in advance for rendering a character string. The transmitter 22E
transmits the resulting message image together with the maintenance
information to the machine control device 11 of the textile machinery 10.
The data of the maintenance information and the data of the message
image may be transmitted from the transmitter 22E to the textile
machinery 10 (machine control device 11) in the form of consolidated
data or may be transmitted individually.
[0060] Although the notification information is transmitted manually
(second output mode) in the example described above, an automatic
transmission fimction may be provided to automatically transmit the
notification information, for example, at 8:00 every morning (first
output mode). To implement such an automatic transmission function,
the transmitter 22E is configured to display, for example, an automatic
transmission setting screen 55 as shown in FIG. 5 on the display 3 1A.
[0061] The automatic transmission setting screen 55 displays a
pull-down menu 55A for choosing automatic transmission or manual
transmission and a pull-down menu 55B for setting a transmission time.
The user of the management device 20 can input the transmission mode
and the transmission time, for example, through at least one of the
keyboard 31B and the mouse 31C.
[0062] The reception of the notification information sent from the
management device 20 by the machine control device 11 of the textile
machinery 10 will now be described. When the machine control
device 11 receives the notification information, a new notification
screen 60 appears on the display 11E to indicate the reception of the
notification information, as shown in FIG. 6A to FIG. 6C. Even when
an operating state screen or other screens are displayed on the display
1 lE, the new notification screen 60 appears if maintenance information
is received. The new notification screen 60 displays marks (graphics)
6 1 A, 6 lB, 6 1C indicating the targets of the notification information and
a list 62 of latest notification information. Here, the The lamp
controller 12G of the textile machinery 10 may draw the attention of the
operator or any other person by allowing the tower lamp 11H of the
textile machinery 10 to illuminate or flash on and off.
[0063] The notification information management unit 12E provides the
fimction of displaying the information given from the management
device 20 in such a manner that visually distinguishes who is the target
recipient (operators, maintenance workers, or all). Specifically, as
shown in FIG. 6A to FIG. 6C, the background colors and the marks are
different. For example, the notification addressed to operators has a
"green" background color and a pictograph of "person", the notification
5 addressed to maintenance workers includes an "orange" background
color and a pictograph of "tool", and the notification addressed to all
includes a "blue" background color and a pictograph of "mail". The
notification is not limited to the above-described content as long as the
three categories are distinguishable. The function provided by the
10 notification information management unit 12E can notify the target
recipient of notification information that notification information has
arrived.
[0064] The notification information management unit 12E allows a
message display screen 65 as shown in FIG. 7 to pop up on the display
15 11E when detecting touch on the display 11E, in the display 11E
showing the new notification screen 60. The message display screen
65 displays a message display area 65A, a details button 65B, an OK
button 65C, and a target identification 65D.
[0065] The message display area 65A is an area in which a message
20 input by the management device 20 appears. As described above, the
image information, which is an image converted from the character
information, appears in this area. The details button 65B is a button
for displaying the maintenance information transmitted from the
management device 20 (machine-specific status list screen 75 (see FIG.
25 10) and the status information list screen 77 (see FIG. 11)). The
display of the maintenance information will be detailed later. The OK
button 65C is a button for closing the message display screen 65. The
notification information management unit 12E displays a notification
information list screen 71 as shown in FIG. 8 to display a list of
notification information on the display 1 lE, when clicking on the OK
button 65C is detected. The target identification 65D is a display
section for easily identifying a target recipient in such a manner that the
notifications addressed to operators, maintenance workers, and all are
distinguishable from each other, as in the new notification screen 60.
[0066] In the example described above, when a touch on the display
11E is detected in a state in which the new notification screen 60
appears, the message display screen 65 corresponding to the newest
notification information pops up. However, the message display
screen 65 corresponding to the notification information selected
(tapped) in the list 62 of the latest notification information may pop up.
[0067] Alternatively, the notification information management unit 12E
may display the new notification screen 60 on the display 11E in the
form of a screen saver. In the absence of manipulation on the display
11E or the like for a predetermined time, the screen saver switches on
from a screen showing the operating state or the like. This fimction
provided by the notification information management unit 12E can
notify the target recipient of the notification information that the
notification information has arrived, even when the new notification
screen 60 disappears due to manipulation by a person other than the
target recipient.
[0068] The notification information list screen 71 displayed by the
notification information management unit 12E as shown in FIG 8 will
now be described. The notification information list screen 71 displays
a display area 71A showing the latest notification information and an
unread notice 72 indicating the unread state. The display area 71A
shows the degree of importance (level) of notification information, the
5 notification destination, the title of notification information, and the
notification time. When the row of the notification information to be
viewed is touched (tapped) in the display area 71A, the message display
screen 65 as shown in FIG. 7 corresponding to the notification
information appears, or maintenance information (the machine-specific
10 status list screen 75 (see FIG. 10) or the status information list screen 77
(see FIG. 11)) appears.
[0069] The unread notice 72 notifies the operator, the maintenance
worker, or all that there is unread notice information, if any, in the
notification information given fiom the management device 20. When
15 the notification information addressed to a maintenance worker is
unread, the notification information management unit 12E allows the
unread notice 72 to flash on and off in the same background color (for
example, green) 72A as when the notification addressed to operators is
given in the new notification screen 60, as shown in FIG. 9A.
20 Similarly, the unread notice 72 flashes on and off in the same
background color (for example, orange) 72B as when the notification
addressed to maintenance workers is given in the new notification
screen 60, as shown in FIG. 9B. Similarly, the unread notice 72 flashes
on and off in the same background color (for example, blue) 72C as
25 when the notification addressed to all is given in the new notification
screen 60, as shown in FIG. 9C. This function provided by the
notification information management unit 12E can notify the target
recipient of the notification information that the notification information
has arrived, even when the new notification screen 60 disappears due to
manipulation by a person other than the target recipient.
[0070] The machine-specific status list screen 75 shown in FIG. 10
shows the maintenance information distributed from the management
device 20. The machine-specific status list screen 75 displays a
display area 75A showing the maintenance information for each textile
machinery 10 (for each machine) and a back button 75B. The display
area 75A shows the identification number (machine No.) of the textile
machinery 10, the total of defective units, and the respective subtotals of
initial units, recurrent units, left units, and not-handled units. A
numeric value in the figure shows the number of units. The back
button 75B is a button for going back to the notification information list
screen 7 1 shown in FIG. 8.
[0071] The status information list screen 77 shown in FIG. 11 is a
screen for inputting response information for the maintenance
information distributed from the management device 20. The status
information list screen 77 shows detailed malfunction information for
each textile processing unit 13 of the textile machinery 10. The
response information may be configured to enable input of information
related to the textile processing units 13 managed by the machine
control device 11 alone or may be configured to enable input of
information related to the textile processing units 13 managed by
another machine control device 11.
[0072] The status information list screen 77 shown in FIG. 11 includes a
display section 77A showing the identification number (machine No.) of
the textile machinery 10, a display area 78 showing the cause of the
defect, status information, the message from the management device 20,
and a response entry field, and a back button 77B. The response entry
field includes check boxes 78A to be ticked if a response is made to the
defect cause provided by the management device 20, and check boxes
78B to be ticked if the defect cause provided by the management device
20 is intentionally left.
[0073] The back button 77B is a button for going back to the
notification information list screen 71 shown in FIG. 8. When the
maintenance information is distributed from the management device 20,
the maintenance worker inputs the content of the response, that is,
whether the defect cause has been handled, or the defect cause is
intentionally left, through the status information list screen 77. The
meaning "intentionally left" includes, for example, a case where the
defect cause is unable to be handled due to parts on back-order and a
case where appropriate response is unknown. Although the defect
cause is denoted by a code in the illustrated example, the specifics
thereof may be directly displayed. The status information refers to a
defect determination made by the management device 20 (initial unit,
recurrent unit, left unit, and not-handled unit).
[0074] The transmitter 12C transmits the response content (ticks in the
check box 78A and the check box 78B) input on the status information
list screen 77, together with the operating state information on the
textile machinery 10, to the management device 20 through the
communication unit 12A. The analyzer 22D updates the maintenance
information (defect determination) based on the content of the response
input on the status information list screen 77. The updating of the
maintenance information will be detailed later.
[0075] Referring to FIG. 12, a defect determination method in the
5 analyzer 22D of the management device 20 will now be described.
The analyzer 22D conducts a defect determination for individual textile
processing units 13, based on the operating state information transmitted
horn the management device 20, that is, based on the information
accumulated in the information accumulating unit 22C.
10 [0076] The analyzer 22D determines a defect for each textile processing
unit 13, based on the information accumulated in the information
accumulating unit 22C (start). It is then determined whether the same
defect determination is stored in the information accumulating unit 22C
(step Sl). As used herein, the storing refers to storing of information
15 as to whether the defect as described above is still ongoing at present
(whether the defect has been eliminated). Therefore, when the
specifications are designed to record the history of defect, it is
determined whether the defect still continues at present. If the same
defect determination is not stored in the information accumulating unit
20 22C (NO in Sl), the analyzer 22D determines that the defect is of an
"initial unit" that newly develops a defect. If the same defect
determination is stored in the information accumulating unit 22C (YES
in Sl), the analyzer 22D determines whether the maintenance
information indicating the defect (the determination result) has been
25 transmitted to the machine control device 11 (step S2).
[0077] If the maintenance information has not been transmitted to the
machine control device 11 (NO in S2), the analyzer 22D keeps the
existing determination result, that is, the previous determination result.
If the maintenance information has been transmitted to the machine
control device 11 (YES in S2), the analyzer 22D determines whether the
5 response information for the determination result has been received
from the machine control device 11 (whether response information has
been input to the status information list screen 77) (step S3). If the
response information has not been received (NO in S3), the analyzer
22D determines that the defect is of a "not-handled unit" on which no
10 measures have been taken due to a failure to view (no input on the status
information list screen 77), although the maintenance information has
been transmitted to the machine control device 11.
[0078] If the determination result shows that response information has
been received (YES in S3), the analyzer 22D determines whether the
15 defect is of a recurrent unit that develops a recurring defect or a left unit
on which no measures have been taken intentionally, based on the
content of the response information. That is, if the check box 78B,
which is to be ticked when the defect cause provided by the
management device 20 is intentionally left, is ticked (NO in S4), the
20 analyzer 22D determines that the defect is of a "left unit" on which no
measures are taken intentionally. In a case where the check box 78A,
which is to be ticked when the defect cause provided by the
management device 20 is handled, is ticked (YES in S4), the analyzer
22D determines that the defect is of a "recurrent unit" that develops a
25 recurring defect.
[0079] The maintenance information reference screen 51 displayed
when the analyzer 22D updates the maintenance information based on
the defect determination method shown in FIG. 12 will now be
described. That is, after the result of analysis by the analyzer 22D, that
is, the maintenance information is transmitted to the machine control
5 device 11, the maintenance information reference screen 5 1 is updated
as shown in FIG. 13. The maintenance information reference screen
5 1 does not differ from the one shown in FIG. 3 in that the maintenance
information display area 51A shows the respective numbers of initial
units, recurrent units, left units, and not-handled units in single textile
10 machinery (machine) 10, but differs in that "the maintenance
information displayed in the maintenance information reference screen
5 1 has already been transmitted to the machine control device 11 ".
[0080] As shown in FIG 13, "the maintenance information displayed in
the maintenance information reference screen 51 has already been
15 transmitted to the machine control device 11" can be identified by the
under bars under the symbols " x ", "A", "X", and "0". Shown at the
rightmost column in the maintenance information display area 51A is
the number of textile processing units 13 (hereinafter referred to as
handled units) of which information has been input on the status
20 information list screen 77. In place of the symbols " X ", "A", "Xu,
"OM, and "Q", the initial unit, the recurrent unit, the left unit, the
not-handled unit, and the handled unit may be denoted by, for example,
a red double circle, a green double circle, a yellow double circle, a blue
double circle, and a black double circle, or may be denoted by
25 characters "initial unit", "recurrent unit", "left unit", "not-handled unit",
and "handled unit".
[008 11 In the maintenance information reference screen 5 1, "before
sending" and "after sending" of the maintenance information to the
machine control device 11 may be distinguished fiom each other. That
is, after transmitting the maintenance information to the machine control
device 11 of the textile machinery 10, the color of the characters
representing "machine No." may be changed. For example, in the
maintenance information reference screen 51 shown in FIG. 3 and FIG
13, the character color of "machine No.", which is red before
transmitting the maintenance information, may be changed to blue after
transmitting the maintenance information.
[0082] In the maintenance information reference screen 51, "before
sending" in a case where the maintenance information is unsent may be
distinguished fiom "before sending" in a case where the maintenance
information has been transmitted by the transmitter 22E but fails to be
received due to some reasons (for example, communication error,
power-off of the textile machinery 10) (error transmission). In this
case, for example, the character color of "machine No." in the latter case
may be changed to a character color other than "red" or "blue", or the
characters may be underlined so as to be distinguishable. In this case,
for example, when the transmission timings vary among machines and
the information "before sending" and the information "after sending" are
displayed routinely, such as in the case of automatic transmission, the
administrator can easily grasp occurrence of error transmission.
[0083] Referring to FIG. 14 and FIG 15, the updating of maintenance
information for one textile processing unit 13 based on the defect
determination method shown in FIG. 12 will now be described using
case studies below. That is, the updating of the display content in the
maintenance information display area 51A shown in FIG. 13 will be
described using case studies illustrated below.
[0084] For example, three days from February 1 to February 3 and a
plant operating in three shifts per day are simulated. Also assume that
the maintenance work is carried out for a predetermined time from a
fixed time (for example, 8:30 am) every day. The maintenance
information to be transmitted by the management device 20 to the
machine control device 11 is transmitted at a fixed time (for example,
8:00 am) every day in order to enable the worker in charge of the
maintenance work to view the maintenance information simultaneously
with the start of the work. The maintenance information is transmitted
by the transmitter 22E. The legends of the symbols shown in FIG. 14
and FIG. 15 are provided in the table shown in FIG. 16.
[0085] CASE 1 will now be described. In CASE 1, it is assumed that
the analyzer 22D of the management device 20 determines no defect as
of February 1, and the analyzer 22D determines a defect in the second
shift on February 2. The analyzer 22D confirms that no record of a
defect determination in the textile processing unit 13 is stored in the
information accumulating unit 22C, and then determines that the defect
is "initial". The analyzer 22D determines a defect again as of the third
shift but keeps the determination "initial", because the previous
determination has not been transmitted as maintenance information to
the machine control device 11.
COO861 The maintenance information related to the textile processing
unit 13 is then transmitted to the machine control device 11 in
accordance with the settings for routine transmission. At this point of
time, the analyzer 22D processes the previous determination as being
sent. Next, the analyzer 22D determines a defect in the second shift on
February 3. At this point of time, the analyzer 22D performs an update
with "recurrence (not-handled)" in which no information has been input
hom the status information list screen 77 in a certain time since the
previous maintenance information transmission.
[0087] The maintenance information related to the textile processing
unit 13 is then manually transmitted to the machine control device 11.
At this point of time, the analyzer 22D processes the previous
determination as being sent. The analyzer 22D then determines a
defect again as of the third shift. At this point of time, the analyzer
22D performs an update with "recurrence (not-handled)" in which no
information has been input from the status information list screen 77 in
a certain time since the previous maintenance information transmission.
[0088] CASE 2 will now be described. In CASE 2, it is assumed that
the analyzer 22D determines a defect in the second shift on February 1.
The analyzer 22D confirms that no record of a defect determination in
the textile processing unit 13 is stored in the information accumulating
unit 22C at this point of time, and then determines that the defect is
"initial". The analyzer 22D determines a defect again as of the end of
the third shift but keeps the determination "initial", because the previous
determination has not been transmitted as maintenance information to
the machine control device 11.
[0089]The maintenance information related to the textile processing unit
13 is then transmitted to the machine control device 11 in accordance
with the settings for routine transmission. At this point of time, the
analyzer 22D processes the previous determination as being sent. If
the analyzer 22D does not determine a single defect until the next
maintenance information transmission, it is determined that the defect
has been eliminated, and the record "initial" is deleted f?om the
information accumulating unit 22C.
[0090] When determining a defect as of the second shift on February 3,
the analyzer 22D confirms that no history of a defect of the unit is
stored in the information accumulating unit 22C, and then determines
that the defect is "initial". The maintenance information related to the
textile processing unit 13 is then manually transmitted to the machine
control device 11. At this point of time, the analyzer 22D processes
the previous determination as being sent.
[0091] CASE 3 will now be described. In CASE 3, it is assumed that
the analyzer 22D determines a defect as of the second shift on February
1. The analyzer 22D confirms that no record of a defect determination
in the textile processing unit 13 is stored in the information
accumulating unit 22C, and then determines that the defect is "initial".
[0092] The maintenance information related to the textile processing
unit 13 is then transmitted to the machine control device 11 in
accordance with the settings for routine transmission. At this point of
time, the analyzer 22D processes the previous determination as being
sent. The analyzer 22D then determines a defect again as of the end of
the second shift. At this point of time, the analyzer 22D performs an
update with "recurrence (not-handled)" for the unit of which
information has not been input on the status information list screen 77 in
a certain time after the previous maintenance information transmission.
[0093] The maintenance information related to the textile processing
unit 13 is then transmitted to the machine control device 11 in
accordance with the settings for routine transmission. At this point of
time, the analyzer 22D processes the previous determination as being
sent. The maintenance information related to the textile processing
unit 13 is then manually transmitted to the machine control device 11.
The analyzer 22D keeps "recurrence (not-handled)". The analyzer
22D then determines a defect as of the start of the third shift. At this
point of time, the analyzer 22D performs an update with "recurrence
(not-handled)" for the unit of which information has not been input on
the status information list screen 77 in a certain time after the previous
maintenance information transmission.
[0094] CASE 4 will now be described. In CASE 4, it is assumed that
the analyzer 22D determines a defect as of the second shift on February
1. The analyzer 22D confirms that no record of a defect determination
in the textile processing unit 13 is stored in the information
accumulating unit 22C at this point of time, and then determines that the
defect is "initial".
[0095] The maintenance information related to the textile processing
unit 13 is then transmitted to the machine control device 11 in
accordance with the settings for routine transmission. At this point of
time, the analyzer 22D processes the previous determination as being
sent. It is assumed that, for example, information that a defect
determination has been made but measures to be taken are unknown, or
that the defect is intentionally left due to parts on back-order, is input on
the status information list screen 77 as of the end of the first shift. The
analyzer 22D performs an update, assuming that some measures have
been taken for the unit at this point of time.
[0096] If the analyzer 22D does not determine a single defect until the
next maintenance information transmission, it is determined that the
defect has been eliminated, and the record "initial" is deleted from the
information accumulating unit 22C. When determining a defect as of
the second shift on February 3, the analyzer 22D confirms that no
history of a defect of the unit is stored in the information accumulating
unit 22C, and then determines that the defect is "initial". The
maintenance information related to the textile processing unit 13 is then
manually transmitted to the machine control device 11. At this point
of time, the analyzer 22D processes the previous determination as being
sent.
[0097] CASE 5 will now be described. It is assumed that the analyzer
22D determines a defect as of the second shift on February 1. The
analyzer 22D confirms that no record of a defect determination in the
textile processing unit 13 is stored in the information accumulating unit
22C at this point of time, and then determines that the defect is "initial".
The maintenance information related to the textile processing unit 13 is
then transmitted to the machine control device 11 in accordance with the
settings for routine transmission. At this point of time, the analyzer
22D processes the previous determination as being sent. It is assumed
that the information "handled" is input on the status information list
screen 77 as of the end of the first shift. The analyzer 22D performs an
update, assuming that some measures have been taken on the unit at this
point of time.
[0098] It is assumed that the analyzer 22D determines a defect as of the
second shift. The analyzer 22D confirms that a record "handled" in the
textile processing unit 13 is stored in the information accumulating unit
22C at this point of time, and then performs an update with "recurrence
(handled)". The maintenance information related to the textile
processing unit 13 is then transmitted to the machine control device 11
in accordance with the settings for routine transmission. At this point
of time, the analyzer 22D processes the previous determination as being
sent.
[0099] It is assumed that the analyzer 22D determines a defect as of the
start of the second shift. At this point of time, the analyzer 22D
performs an update with "recurrence (not-handled)" for the unit of
which information has not been input on the status information list
screen 77 in a certain time after the previous maintenance information
transmission. It is then assumed that information that a defect
determination has been made but measures to be taken are unknown, or
that the defect is intentionally left due to parts on back-order, is input on
the status information list screen 77 as of the second shift. The
analyzer 22D performs an update, assuming that some measures have
been taken on the unit at this point of time. The maintenance
information related to the textile processing unit 13 is then manually
transmitted to the machine control device 11. At this point of time, the
analyzer 22D updates the previous determination with "recurrence
(left)" in which malfunction is continuously determined in the unit
intentionally left due to measures unknown or parts on back-order.
[0100] It is assumed that the analyzer 22D determines a defect as of the
start of the third shift. At this point of time, the analyzer 22D performs
an update with "recurrence (not-handled)" in which no information has
been input on the status information list screen 77 in a certain time since
the previous maintenance information transmission.
[0101] CASE 6 will now be described. In CASE 6, it is assumed that
the "initial" determination has been kept since the previous day and this
determination is processed as being sent. Here, it is assumed that the
analyzer 22D determines a defect as of the third shift on February 1.
At this point of time, the analyzer 22D performs an update with
"recurrence (not-handled)" in which no information has been input on
the status information list screen 77 in a certain time since the previous
maintenance information transmission.
[0102] The maintenance information related to the textile processing
unit 13 is then transmitted to the machine control device 11 in
accordance with the settings for routine transmission. At this point of
time, the analyzer 22D processes the previous determination as being
sent. It is assumed that information that a defect determination has
been made but measures to be taken are unknown, or that the defect is
intentionally left due to parts on back-order, is input on the status
information list screen 77 as of the first shift. At this point of time, the
analyzer 22D performs an update, assuming that some measures have
been taken on the unit.
[0103] It is assumed that the analyzer 22D determines a defect in the
first shift on February 3. At this point of time, the analyzer 22D
performs an update with "recurrence (left)" in which a malfunction
determination is kept in the unit intentionally left due to measures
unknown or parts on back-order. The maintenance information related
to the textile processing unit 13 is then transmitted to the machine
control device 11 in accordance with the settings for routine
transmission. At this point of time, the analyzer 22D processes the
previous determination as being sent.
[0104] The maintenance information related to the textile processing
unit 13 is then manually transmitted to the machine control device 11.
At this point of time, the analyzer 22D processes the previous
determination as being sent. The analyzer 22D then determines a
defect again as of the third shift. At this point of time, the analyzer
22D performs an update with "recurrence (not-handled)" in which no
information has been input on the status information list screen 77 in a
certain time since the previous maintenance information transmission.
[0105] CASE 7 will now be described. In CASE 7, it is assumed that
some measures (handled) have been taken since the previous day.
Here, it is assumed that the analyzer 22D determines a defect in the
third shift on February 1. The analyzer 22D confirms that a record
"handled" in the textile processing unit 13 is stored in the information
accumulating unit 22C at this point of time, and then performs an
update with "recurrence (handled)". The maintenance information
related to the textile processing unit 13 is then transmitted to the
machine control device 11 in accordance with the settings for routine
transmission. At this point of time, the analyzer 220 processes the
previous determination as being sent. If the analyzer 22D does not
determine a single defect until the next maintenance information
transmission, the record of a defect determination is deleted from the
information accumulating unit 22C, assuming that the defect has been
eliminated.
[0106] When determining a defect as of the second shift on February 3,
the analyzer 22D confirms that no history of a defect of the unit is
stored in the information accumulating unit 22C, and then determines
that the defect is "initial". The maintenance information related to the
textile processing unit 13 is then manually transmitted to the machine
control device 11. At this point of time, the analyzer 22D processes
the previous determination as being sent.
[0107] CASE 8 will now be described. In CASE 8, it is assumed that
some measures (left) have been taken since the previous day. Here, it
is assumed that the analyzer 22D determines a defect as of the third shift
on February 1. At this point of time, the analyzer 22D performs an
update with "recurrence (left)" in which a malfunction determination
continues in the unit intentionally left due to measures unknown or parts
on back-order. The maintenance information related to the textile
processing unit 13 is then transmitted to the machine control device 11
in accordance with the settings for routine transmission. At this point
of time, the analyzer 22D processes the previous determination as being
sent.
[0108] The analyzer 22D then determines a defect again as of the end
of the second shift. At this point of time, the analyzer 22D updates the
previous determination with "recurrence (left)" in which a malfunction
determination continues in the unit intentionally left due to measures
unknown or parts on back-order. The maintenance information related
to the textile processing unit 13 is then transmitted to the machine
control device 11 in accordance with the settings for routine
transmission. At this point of time, the analyzer 22D processes the
previous determination as being sent. The maintenance information
related to the textile processing unit 13 is then manually transmitted to
the machine control device 11. The analyzer 22D continuously
processes the previous determination as being sent.
[0109] As described above, in the textile machinery management
system 1 in the present embodiment, the machine control device 11
acquires not only the operating state information on the textile
machinery 10 but also the response information for the analysis result
output from the management device 20, and transmits the response
information to the management device 20 through the information
acquiring unit 22B. Thus, the response information for the analysis
result can be easily acquired and easily collected in the management
device 20. This makes response information easy to acquire, which is
conventionally difficult to collect, and enables the management device
20 to conduct analysis based on the response information. As a result,
the maintenance activities for the textile machinery 10 can be assisted
effectively.
[0110] In the textile machinery management system 1 in the present
embodiment, the machine control device 11 is configured to have the
analysis fimction similar to the analyzer 22D of the management device
20 and is configured to analyze the operating state information stored in
the information storage unit 12B and display the analysis result on the
display 11E. The analysis in such a machine control device 11
determines a malfunction real-time or for a relatively short span based
on information from, for example, a sensor installed in the textile
processing unit, whereas the analysis in the management device 20
determines a malfunction in a relatively long span based on, for
example, the operating state information stored in the information
accumulating unit 22C. In this manner, the analysis by logic different
between the machine control device 11 and the management device 20
is performed to provide layered malhction information.
[Olll] In the management device 20 of the present embodiment, the
information acquiring unit 22B inputs the operating state information on
the textile machinery 10 through the first communication unit 22A. It
is thus possible to easily input the operating state information to the
management device 20.
[0112] The management device 20 of the present embodiment is
configured as a host management device for a plurality of machine
control devices 11. An efficient configuration is thus implemented, in
which the management device 20 serving as a host management device
analyzes the operating state information on the textile machinery 10,
and the management device 20 distributes a message together with the
analysis result to the individual machine control devices 11.
[0113] In the management device 20 of the present embodiment, the
information acquiring unit 22B inputs the control conditions of the
textile machinery 10 in addition to the operating state information.
The analyzer 22D analyzes the operating state information and the
control conditions. The analysis from more multiple points of views
thus can be presented.
[0114] In the management device 20 of the present embodiment, the
transmitter 22E can transmit a command to give an instruction on the
operation of the textile machinery 10 to the machine control device 11
through the first communication unit 22A. This enables the textile
machinery 10 as a destination to perform some operation, in addition to
transmission of the analysis result and the message. For example, this
creates a state in which the operator of the textile machinery 10 easily
conducts work in accordance with the message.
[0115] In the foregoing embodiment, the machine control device 11 of
the textile machinery 10 is configured to allow the tower lamp 11H
provided on the textile machinery 10 to illuminate or flash on and off
without a specific command, when receiving a message. However,
when transmitting the analysis result to the machine control device 11,
the management device 20 may additionally transmit a command
(notice command) to allow the tower lamp 11H to illuminate or flash on
and off, so that the machine control device 11 of the textile machinery
10 allows the tower lamp 11H to illuminate or flash on and off based on
the command. In this case, the illumination or the flashing on and off
of the tower lamp 11H can appropriately prompt, for example, the
operator of the textile machinery 10 to view the analysis result.
[0116] For example, the machine control device 11 receiving the
maintenance information from the management device 20 can display at
least one of a specific instruction and information related to the items to
work on (check, inspection, and repair methods) in accordance with the
maintenance information, that is, the contents of the defective textile
processing unit information. For example, the machine front LED of
the malfunction textile processing unit may illuminate or flash on and
off based on the contents of defective textile processing unit information
in the maintenance information. In this case, for example, the
maintenance worker can recognize a defective part efficiently.
[0117] As described above, the user of the management device 20 can
freely input the content of the message (through the text box 531). For
example, the content of the message may be supplementary remarks on
the analysis result or an operation instruction to the operator. When
compared with transmission of the maintenance information alone as
shown in FIG. 10 and FIG. 11, flexible and productive information can
be distributed from the user of the management device 20. In addition,
since the analysis result and the message can be transmitted
simultaneously to the plurality of units of textile machinery 10,
information from the user of the management device 20 can be
distributed accurately and efficiently even in a large-scale plant
including a number of units of textile machinery 10.
[O 11 81 The management device 20 of the present embodiment includes
the image converter 22G that converts a message of a character string
input from the message input unit 22F into an image. The transmitter
22E transmits the message converted into an image by the image
converter 22G to the machine control device 11. This eliminates the
need for preparing font data for rendering character strings in individual
machine control devices 11 for displaying messages, thereby
implementing a simple configuration as a whole.
[0119] Even in a case where multilingual messages are supported, the
font data for multiple languages for rendering message character strings
is prepared only on the management device 20, and the individual
machine control devices 11 need not have font data, which often
requires much data volume. A message in various languages thus can
be displayed on the display 11E with a simple configuration of the
machine control device 11.
[0120] In the machine control device 11 of the present embodiment, the
analysis result and the message appear on the display 11E capable of
displaying information. The message thus can be distributed to, for
example, the operator of the textile machinery 10 by a simple method.
[0121] The machine control device 11 of the present embodiment
includes the operation controller 12H that controls the operation of the
textile machinery 10. When receiving a command to give an
instruction on the operation of the textile machinery 10 from the
management device 20, the operation controller 12H allows the textile
machinery 10 to operate in accordance with the command. This
enables the textile machinery 10 to perform some operation in
accordance with the command, in addition to displaying a message on
the display 11E. For example, this creates a state in which, for
example, the operator of the textile machinery 10 easily conducts work
in accordance with the message from the management device 20.
[0122] In the textile machinery management system 1 of the present
embodiment, the management device 20 includes the information
accumulating unit 22C that stores the operating state information input
through the information acquiring unit 22B. The machine control
device 11 of the textile machinery 10 includes the information storage
unit 12B that stores the operating state information on the machinery
itself. The information accumulating unit 22C is configured to store
the operating state information for a period longer than the information
storage unit 12B. It is thus possible to obtain the analysis result of the
operating state information for a long period at the management device
20, without increasing the capacity of the information storage unit 12B
of the individual textile machinery 10. This can simplify the
configuration of the textile machinery 10.
[0123] Although an embodiment has been described above, the present
disclosure is not limited to the foregoing embodiment.
[0124] In the foregoing embodiment, the textile machinery
management system 1 including the machine control device 11 and the
management device 20 has been described. However, the machine
control device 11 or the management device 20 as an embodiment of the
present disclosure may singly achieve the same effects as in the
foregoing embodiment. That is, the management device 20 that
manages the textile machinery 10 having the machine control device 11
includes the information acquiring unit 22B that acquires the operating
state from the machine control device 11 acquiring the operating state
information on the textile machmery 10, the analyzer 22D that analyzes
the operating state information acquired by the information acquiring
unit 22B, and the transmitter 22E that transmits the result of analysis by
the analyzer 22D to the control device. The analyzer 22D updates the
analysis result based on the response information for the analysis result
acquired £?om the machine control device 11 through the information
acquiring unit 22B. This management device 20 also achieves the
same effects as in the foregoing embodiment.
[0125] Alternatively, the machine control device 11 of the textile
machinery 10 managed by the management device 20 and connected to
the management device 20 includes the receiver 12D that acquires the
result of analysis of the operating state information in the textile
machinery 10 from the management device 20, the notification
information management unit 12E that outputs the analysis result, and
the maintenance information input unit 12F that accepts input of
response information for the analysis result. The response information
accepted by the maintenance information input unit 12F is output to the
management device 20. This machine control device 11 also achieves
the same effects as in the foregoing embodiment.
[O 1261 The machine control device 11 of the textile machinery 10 and
the management device 20 can connect (access) to each other through
any other network rather than the LAN 3. The network is not limited
to a wired network but may be a wireless network.
[0127] The management device 20 may manage any number of units of
textile machinery 10, that is, one or two or more textile machinery 10.
[0128] In the example described in the foregoing embodiment, a
message is transmitted together with maintenance information from the
management device 20. However, the maintenance information alone
may be transmitted, or a message alone may be displayed.
[0129] Although the management device 20 is configured as a control
unit, for example, it may be configured as a desktop personal computer.
The management device 20 is not limited to this example but may be
configured, for example, as an easy-to-carry tablet computer. In this
case, a message can be input using the touch panel in place of the
keyboard.
[0130] In the foregoing embodiment and modifications, the
management device 20 is configured as a control unit or a computer
separate from the machine control device 11. However, the
configuration may be modified such that one of the machine control
devices 11 of the plurality of units of textile machinery 10 fulfills the
hction of the management device.
[0131] In the foregoing embodiment, the message input through the
message input unit 22F is transmitted from the management device 20
to the textile machinery 10 (machine control device 11) in the form
converted into an image. However, the message may be transmitted in
the form of character string data. In this case, the volume of data
transferred can be reduced.
(01321 In the foregoing embodiment, in the maintenance information
reference screen 51 after the management device 20 transmits the
maintenance information to the machine control device 11, "the
maintenance information displayed in the maintenance information
reference screen 5 1 has already been transmitted to the machine control
device 11" can be identified by the under bars under the symbols " X ",
"A", "X1', and "OMa,nd the number of units on which some measures
have been taken in response to the transmitted maintenance information
is denoted by "0". In place of or in addition to this, the determination
results successively determined and updated in time series as shown in
FIG. 13 and FIG. 14 may be displayed real-time.
[0133] In the status information list screen 77, two items (handled and
left) are input as response information. However, information as to
specifically what response has been made (for example, parts
replacement, adjustment of default values) may be input. In this case,
preferably, a pull-down menu may be used to save time and efforts of
input. The management device 20 may be configured to allow such
information not only to be viewed but also to be reflected in the
maintenance information.
[0134] A notification of reception of the analysis result and the message
may be given, for example, acoustically with a buzzer, rather than
visually with the tower lamp 11H.
[0135] In the foregoing embodiment or modifications, one unit
controller 13A is provided for each textile processing unit 13.
However, in place of this, one unit controller 13A may be provided for
the plurality of (for example, four) textile processing units 13, so that
the unit controller 13A controls the textile processing units 13.
[0136] At least part of the embodiment and modifications described
above may be combined as appropriate.
[0137] The management device according to an embodiment of the
present disclosure that manages textile machinery having a control
device capable of acquiring operating state information on the textile
machinery includes: a first acquisition unit configured to acquire the
operating state from the control device acquiring the operating state
information on the textile machinery; an analyzer configured to analyze
the operating state information acquired by the first acquisition unit: and
a first output unit configured to output the result of analysis by the
analyzer. The analyzer updates the analysis result based on the
response information for the analysis result acquired from the control
device through the first acquisition unit.
[0138] In the management device configured as described above, not
only the operating state information on the textile machinery but also
the response information for the analysis result output from the
management device can be acquired. This enables response
information, which is conventionally difficult to collect, to be easily
collected in an electronic data format and enables the management
device to conduct analysis based on the response information. As a
result, the maintenance activities for the textile machinery can be
assisted more effectively.
[0139] The control device according to an embodiment of the present
disclosure is included in textile machinery managed by a management
device and connected to the management device and can acquire
operating state information on the textile machinery. The control
device includes: a second acquisition unit configured to acquire the
result of analysis of the operating state information in the textile
machinery from the management device; a second output unit
configured to output the analysis result acquired by the second
acquisition unit; and a maintenance information input unit configured to
accept input of response information for the analysis result output by the
second output unit. The response information accepted by the
maintenance information input unit is output to the management device.
[0140] In the control device configured as described above, not only the
operating state information on the textile machinery but also the
response information for the analysis result output from the
management device can be input. This enables response information,
which is conventionally difficult to collect, to be easily collected in an
electronic data format and enables the management device to conduct
analysis based on the response information. As a result, the
maintenance activities for the textile machinery can be assisted more
effectively.
[0141] The control device according to an embodiment of the present
disclosure is a textile machinery management system including textile
machinery having a control device and a management device that
manages the textile machinery. The management device includes: an
information input unit configured to acquire operating state information
on the textile machinery; an analyzer configured to analyze the
operating state information acquired by the information input unit; and a
transmitter configured to transmit the result of analysis by the analyzer
to the control device. The control device of the textile machinery
includes: a receiver configured to acquire the analysis result related to
the operating state information from the management device; an output
unit configured to output the analysis result acquired from the
management device; and a maintenance information input unit
configured to accept input of response information for the analysis
result. In a case where the response information is input to the
maintenance information input unit, the analyzer updates the analysis
result based on the response information acquired through the
information input unit.
[0142] A textile machinery management system includes textile
machinery having a control device and a management device configured
to manage the textile machinery. The control device is capable of
acquiring operating state information on the textile machinery. The
management device includes a first acquisition unit configured to
acquire the operating state information on the textile machinery that is
acquired by the control device, an analyzer configured to analyze the
operating state information acquired by the first acquisition unit, and a
first output unit configured to output a result of analysis by the analyzer.
The control device includes a second acquisition unit configured to
acquire the result of analysis output by the first output unit, a second
output unit configured to output the result of analysis acquired by the
second acquisition unit, and a maintenance information input unit
configured to accept input of response information for the result of
analysis output by the second output unit. The first acquisition unit
also acquires the response information accepted by the maintenance
information input unit. In a case where the response information is
input to the maintenance information input unit, the analyzer updates
the result of analysis based on the response information acquired
through the first acquisition unit.
[0143] In the textile machinery management system configured as
described above, the control device not only acquires the operating state
information on the textile machinery but also acquires the response
information for the analysis result output fkom the management device.
Since the response information is acquired by the management device
through the first acquisition unit, the response information can be easily
collected in the management device. This makes response information
easy to acquire, which is conventionally difficult to collect, and enables
the management device to conduct analysis based on the response
information. As a result, the textile machinery management system is
capable of assisting the maintenance activities for the textile machinery
more effectively.
[0144] In an aspect of the present disclosure, the maintenance
information input unit lnay accept one of a plurality of selectable pieces
of information prepared in advance, as the response information. In
the textile machinery management system configured as described
above, the operator only has to selectively input the minimum required
information through the maintenance information input unit, thereby
eliminating an increase in burden on the operator. This can prompt the
operator to input response information and can ensure acquisition of
necessary information.
[0145] In an aspect of the present disclosure, the plurality of selectable
pieces of information prepared in advance may include "handled",
"actively left", and "accidentally left". Here, "handled" indicates that
the operator takes some measures, "actively left" indicates that the
operator selects nothing to be done on purpose, and "accidentally left"
indicates that the operator does not know the measures to be taken and
thus does nothing, or the operator fails to input and eventually does
nothing. The operator has only to selectively input the minimum
required simple information through the maintenance information input
unit, thereby eliminating an increase in burden on the operator. This
can prompt the operator to input response information and can ensure
acquisition of necessary information.
[0146] In an aspect of the present disclosure, the maintenance
information input unit may accept specific information among the
plurality of selectable pieces of information prepared in advance, as the
response information, when nothing is input as the response information
for a predetermined time or longer. In the textile machinery
management system configured as described above, the operating state
including a case where the operator inputs nothing can be analyzed.
[0147] In an aspect of the present disclosure, the maintenance
information input unit may accept the "accidentally left" as the response
information when nothing is input as the response information for a
predetermined time or longer. In the textile machinery management
system configured as described above, the operating state including a
case where the operator inputs nothing can be analyzed appropriately.
[0148] In an aspect of the present disclosure, the analyzer may analyze
whether an error occurs in the textile machinery based on the operating
state information and the response information and determine which of
"initial", "recurrence after being handled", and "recurrence after being
left" the error is. The term "initial" indicates an error that has no
history of occurrence in the past and occurs for the frst time, the term
"recurrence after being handled" indicates an error that occurs again
although some actions have been taken, and the term "recurrence after
being left" indicates that an error occurs again as a result of being left
without taking actions at the time of error occurrence, or that an error
continuously occurs. In the textile machinery management system
configured as described above, the administrator can easily grasp the
error recurrence state. Accordingly, for example, in the case of
"recurrence after being handled", it is determined that the measures
taken have no effect, and the next response such as reviewing the work
can be examined. For example, in the case of "recurrence after being
left", it is found that the operator needs operational guidance and
education.
to1491 In an aspect of the present disclosure, the management device
may be connected to a display device configured to display the result of
analysis output by the second output unit. In the textile machinery
management system configured as described above, for example, the
operator can be notified of the analysis result effectively.
[0150] In an aspect of the present disclosure, the control device may
further include a third output unit configured to output the response
information accepted by the maintenance information input unit. The
first acquisition unit may acquire , at any time the response information
output by the third output unit. The response information for the
operating state information may be updated at any time and displayed
on the display device. In the textile machinery management system
configured as described above, the administrator can grasp the
operator's response state real-time in connection with the operating state
information.
[0151] In an aspect of the present disclosure, the analyzer may analyze
the operating state information at a second timing different from a first
timing at which the first output unit periodically outputs the result of
analysis, the second timing being a periodical timing shorter than the
first timing. In the textile machinery management system configured
as described above, the administrator can analyze the operating state
information so as to follow the operator's response information updated
at any time and can grasp the operating state at present.
[0152] In an aspect of the present disclosure, the operating state
information may be displayed on the display device, in a state in which
error recurrence states are sorted according to each unit of the textile
machinery. In the textile machinery management system configured as
described above, the administrator can easily grasp the error recurrence
state in the entire plant.
[0153] In an aspect of the present disclosure, the first output unit may
have a fxst output mode and a second output mode, as a mode for
deciding on a timing for outputting the result of analysis to the control
device. In the first output mode, the result of analysis may be
automatically output periodically at a preset timing. In the second
output mode, the result of analysis may be output at a timing manually
set. In the textile machinery management system configured as
described above, the administrator can output the analysis result
periodically or at any timing.
[0154] In view of advantageous aspects of the invention, the
maintenance activities of the textile machinery can be assisted more
effectively.

We claim
1. A textile machinery management system (1) comprising:
textile machinery (10) having a control device (11); and
a management device (20) configured to manage the textile
machinery, the control device being configured to acquire operating
state information on the textile machinery, wherein
the management device comprises:
a first acquisition unit (22B) configured to acquire the operating
state information on the textile machinery that is acquired by the control
device;
an analyzer (22D) configured to analyze the operating state
information acquired by the first acquisition unit; and
a first output unit (22E) configured to output a result of analysis
by the analyzer, wherein
the control device comprises:
a second acquisition unit (12D) configured to acquire the result
of analysis output by the first output unit;
a second output unit (12E) configured to output the result of
analysis acquired by the second acquisition unit; and
a maintenance information input unit (12F) configured to accept
input of response information for the result of analysis output by the
second output unit, and wherein
the first acquisition unit is also configured to acquire the
response information accepted by the maintenance information input
unit, and
the analyzer is further configured to, in a case where the
response information is input to the maintenance information input unit,
update the result of analysis based on the response information acquired
through the first acquisition unit.
2. The textile machinery management system according to claim 1,
wherein the maintenance information input unit is configured to accept
one of a plurality of selectable pieces of information prepared in
advance, as the response information.
3. The textile machinery management system according to claim 2,
wherein the plurality of selectable pieces of information prepared in
advance include "handled", "actively left", and "accidentally left".
4. The textile machinery management system according to claim 3,
wherein the maintenance information input unit is configured to accept
specific information among the plurality of selectable pieces of
information prepared in advance, as the response information, when
nothing is input as the response information for a predetermined time or
longer.
5. The textile machinery management system according to claim 3,
wherein the maintenance information input unit is configured to accept
the "accidentally left" as the response information when nothing is input
as the response information for a predetermined time or longer.
6. The textile machinery management system according to any one
of claims 2 to 5, wherein the analyzer is configured to analyze whether
an error occurs in the textile machinery based on the operating state
information and the response information and to determine which of
"initial", "recurrence after being handled", and "recurrence after being
left" the error is.
7. The textile machinery management system according to any one
of claims 1 to 6, wherein the management device is connected to a
display device (3 1A) configured to display the result of analysis output
by the second output unit.
8. The textile machinery management system according to claim 7,
wherein
the control device further comprises a third output unit (12C)
configured to output the response information accepted by the
maintenance information input unit, wherein
the first acquisition unit is configured to acquire, at any time, the
response information output by the third output unit, and wherein
the response information for the operating state information is
updated at any time and displayed on the display device.
9. The textile machinery management system according to claim 8,
wherein the analyzer is configured to analyze the operating state
information at a second timing different from a first timing at which the
first output unit periodically outputs the result of analysis, the second
timing being a periodical timing shorter than the first timing.
10. The textile machinery management system according to any one
of claims 7 to 9, wherein the operating state information is displayed on
the display device, in a state in which error recurrence states are sorted
according to each unit of the textile machinery.
11. The textile machinery management system according to any one
of claims 1 to 10, wherein
the first output unit has a first output mode and a second output
mode, as a mode for deciding on a timing for outputting the result of
analysis to the control device,
in the first output mode, the result of analysis is automatically
output periodically at a preset timing, and
in the second output mode, the result of analysis is output at a
timing manually set.