TECHNICAL FIELD
[0001] The present disclosure relates to a textile processing method, a
textile processing system, and a recording medium.
BACKGROUND
[0002] As a technology concerning a conventional textile processing
method, the method described in Japanese Unexamined Patent
10 Publication No. H4-7269 has been known. In the method described in
Japanese Unexamined Patent Publication No. H4-7269, in a textile mill
where yarn is produced via a carding process, a drawing process, and a
break spinning process (an open-end or air-jet spinning process), each
process, each machine, and each spindle are assigned with respective
15 identification code. When doffing a product and supplying said
product to a subsequent process, a machine number of a machine that
performs doffing, a lot number of the product, and the machine number
of the supply destination are stored. As a result, locational and
temporal history of an intermediate product or a final product can be
20 traced.
SUMMARY
[0003] In the above-described conventional technology, even if the yarn
finally obtained is defective, correlation between the fact that the yarn is
defective and the raw material and each process cannot be found, and
25 thus it may be not possible to learn an abnormality of the raw material
and of the machine of each process (a carding machine, a drawing
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frame, and an air spinning frame). In this case, the action to resolve
the abnormality may be delayed.
[0004] Thus, an object of the present disclosure is to provide a textile
processing method, a textile processing system, and a recording medium
5 in which an abnormality of raw material, a carding machine, a drawing
frame, and an air spinning frame can be learnt.
[0005] A textile processing method according to one aspect of the
present disclosure includes a carding process in which a fiber bundle is
produced from raw material by using one or more of carding machines,
10 a drawing process in which the fiber bundle produced in the carding
process is drawn by using one or more of drawing frames, a break
spinning process in which yarn is produced by spinning the fiber bundle
drawn in the drawing process by using one or more of air spinning
frames, a first acquisition process in which first quality data concerning
15 quality of the fiber bundle produced in the carding process is acquired, a
second acquisition process in which second quality data concerning
quality of the fiber bundle drawn in the drawing process is acquired, a
third acquisition process in which third quality data concerning quality
of the yarn produced in the break spinning process is acquired, and an
20 abnormality identifying process in which when the yarn produced in the
air spinning frame is defective, at least from among the raw material,
the carding machines, the drawing frames, and the air spinning frames,
in which an abnormality has occurred is identified, based on the first
quality data, the second quality data, and the third quality data.
25 [0006] As for the abnormality of the raw material and of the
machine of each process, correlation is found with a relation of the
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quality data that is acquired in association with each process. Thus,
when the yarn produced in the air spinning frame is defective, based on
the first quality data, the second quality data, and the third quality data,
the raw material and the machine in each process having the
5 abnormality are identified. Accordingly, the abnormality of the raw
material, the carding machine, the drawing frame, and the air spinning
frame can be learnt.
[0007] In the textile processing method according to one aspect of the
present disclosure, in the abnormality identifying process, when the
10 yarn produced in the air spinning frame is defective, at least one from
among the raw material of said yarn, one or more of the air spinning
frames that produced said yarn, one or more of the drawing frames that
drew the fiber bundle supplied to said air spinning frame, and one or
more of the carding machines that produced the fiber bundle supplied to
15 said drawing frame, in which the abnormality has occurred may be
identified based on the first quality data, the second quality data, and the
third quality data. Accordingly, it is possible to learn the abnormality of
the raw material, the carding machine, the drawing frame, and the air
spinning frame in a processing route involved with the production of the
20 defective yarn.
[0008] In the textile processing method according to one aspect of the
present disclosure, in the abnormality identifying process, when the
yarn produced in the air spinning frame is defective, at least one from
among the raw material of said yarn, one air spinning frame that
25 produced said yarn, one drawing frame that drew the fiber bundle
supplied to said air spinning frame, and one carding machine that
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produced the fiber bundle supplied to said drawing frame, in which the
abnormality has occurred may be identified , based on the first quality
data, the second quality data, and the third quality data. In this case,
because the number of machines involved with the production of the
5 defective yarn is small, it is possible to accurately learn the abnormality
of the raw material, the carding machine, the drawing frame, and the air
spinning frame in the processing route involved with the production of
the defective yarn.
[0009] In the textile processing method according to one aspect of the
10 present disclosure, in the abnormality identifying process, when the
yarn produced in the air spinning frame is defective, a cause of the
occurred abnormality may be estimated based on the first quality data,
the second quality data, and the third quality data. In this case, it is
also possible to learn a specific cause of the abnormality in the raw
15 material, the carding machine, the drawing frame, and the air spinning
frame.
[0010] In the textile processing method according to one aspect of the
present disclosure, the first quality data may be data concerning at least
either one of the number of neps contained in the fiber bundle and a
20 thickness of the fiber bundle, the second quality data may be data
concerning the thickness of the fiber bundle, and the third quality data
may be data concerning at least either one of a defect of and a thickness
of the yarn. In this case, it is possible to accurately learn the
abnormality of the raw material, the carding machine, the drawing
25 frame, and the air spinning frame.
[0011] In the textile processing method according to one aspect of the
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present disclosure, in the abnormality identifying process, when the
yarn produced in the air spinning frame is defective, at least one from
among the raw material, the carding machine, the drawing frame, and
the air spinning frame, in which the abnormality has occurred may be
5 identified also based on setting data of the carding machine and setting
data of the drawing frame. As for the abnormality of the raw material
and of the machine of each process, correlation is also found with a
relation of each setting data of the carding machine and the drawing
frame, in addition to the relation of the quality data acquired in
10 association with each process. Accordingly, by being further based on
the setting data of the carding machine and the setting data of the
drawing frame, it is possible to accurately learn the abnormality of the
raw material, the carding machine, the drawing frame, and the air
spinning frame.
15 [0012] In the textile processing method according to one aspect of the
present disclosure, the setting data of the carding machine may be data
concerning setting of at least either one of a production speed of the
fiber bundle and a removal amount of neps from the fiber bundle, and
the setting data of the drawing frame may be data concerning setting of
20 at least either one of an auto-leveler and a drawing speed of the fiber
bundle of the drawing frame. In this case, it is possible to accurately
learn the abnormality of the raw material, the carding machine, the
drawing frame, and the air spinning frame.
[0013] The textile processing method according to one aspect of the
25 present disclosure may further include a notification process in which,
depending on a identification result identified in the abnormality
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identifying process, notification prompting setting adjustment of or
maintenance of at least one of the carding machine, the drawing frame,
and the air spinning frame is made. This makes it possible for the
operator to act promptly for the abnormality of the raw material, the
5 carding machine, the drawing frame, and the air spinning frame, for
example.
[0014] In the textile processing method according to one aspect of the
present disclosure, in the notification process, a display prompting the
setting adjustment of or the maintenance of at least one of the carding
10 machine, the drawing frame, and the air spinning frame may be
displayed on a display unit. This makes it possible for the operator to
check the specific content of the notification prompting the setting
adjustment or the maintenance.
[0015] The textile processing method according to one aspect of the
15 present disclosure may include a first process of setting a first threshold
value and a second threshold value, the first threshold value being a
control limit value of fluctuation in the third quality data, and the
second threshold value being smaller than the first threshold value, a
second process of changing, after the first process, setting data of at
20 least either one of the carding machine and the drawing frame, and a
third process, after the second process, of returning to the second
process when the third quality data is greater than the first threshold
value, of returning the setting data of at least either one of the carding
machine and the drawing frame to the setting data that was valid before
25 the latest second process when the third quality data is smaller than or
equal to the first threshold value and is greater than the second threshold
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value, and of returning the setting data of at least either one of the
carding machine and the drawing frame to the setting data that was valid
before an initial second process when the third quality data is smaller
than or equal to the second threshold value. Accordingly, it is possible
5 to investigate the desirable setting data of at least either one of the
carding machine and the drawing frame, with the fluctuation in the
quality of the yarn produced in the air spinning frame as an indicator.
[0016] In the textile processing method according to one aspect of the
present disclosure, the abnormality identifying process may be
10 performed by a control device of the air spinning frame. By
performing the abnormality identification by the control device of the
air spinning frame arranged downstream in the process, it is easy to
confirm the setting adjustment or the maintenance by retracing the
process.
15 [0017] A textile processing system according to one aspect of the
present disclosure includes one or more of carding machines configured
to produce a fiber bundle, one or more of drawing frames configured to
draw the fiber bundle produced in the carding machine, one or more of
air spinning frames configured to produce yarn by spinning the fiber
20 bundle drawn in the drawing frame, a first quality data acquisition unit
configured to acquire first quality data concerning quality of the
produced fiber bundle, a second quality data acquisition unit configured
to acquire second quality data concerning quality of the drawn fiber
bundle, a third quality data acquisition unit configured to acquire third
25 quality data concerning quality of the produced yarn, and an
abnormality identifying unit configured to identify, when the yarn
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produced in the air spinning frame is defective, at least one from among
raw material, the carding machines, the drawing frames, and the air
spinning frames, in which an abnormality has occurred, based on the
first quality data, the second quality data, and the third quality data.
5 [0018] In this textile processing system also, as with the
above-described textile processing method, when the yarn produced in
the air spinning frame is defective, the raw material and the machine of
each process having the abnormality are identified based on the first
quality data, the second quality data, and the third quality data.
10 Accordingly, it is possible to learn the abnormality of the raw material,
the carding machine, the drawing frame, and the air spinning frame.
[0019] A recording medium according to one aspect of the present
disclosure is a computer readable recording medium storing therein a
textile processing program that causes a computer to execute, in a textile
15 processing system including one or more of carding machines
configured to produce a fiber bundle, one or more of drawing frames
configured to draw the fiber bundle produced in the carding machine,
one or more of air spinning frames configured to produce yarn by
spinning the fiber bundle drawn in the drawing frame, a first quality
20 data acquisition unit configured to acquire first quality data concerning
quality of the produced fiber bundle, a second quality data acquisition
unit configured to acquire second quality data concerning quality of the
drawn fiber bundle, and a third quality data acquisition unit configured
to acquire third quality data concerning quality of the produced yam, to
25 perform an abnormality identifying process in which when the yarn
produced in the air spinning frame is defective, at least one from among
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raw material, the carding machines, the drawing frames, and the air
spinning frames, in which an abnormality has occurred is identified,
based on the first quality data, the second quality data, and the third
quality data.
5 [0020] In this recording medium, with the textile processing program,
as with the above-described textile processing method, when the yarn
produced in the air spinning frame is defective, the raw material and the
machine of each process having the abnormality are identified, based on
the first quality data, the second quality data, and the third quality data.
10 This makes it possible to learn the abnormality of the raw material, the
carding machine, the drawing frame, and the air spinning frame.
[0021] According to the present disclosure, it is possible to provide a
textile processing method, a textile processing system, and a recording
medium in which the abnormality of raw material, a carding machine, a
15 drawing frame, and an air spinning frame can be learnt.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a block diagram illustrating a configuration of a textile
processing system according to one embodiment.
[0023] FIG. 2 is a block diagram illustrating a principal portion of FIG.
20 1.
[0024] FIG. 3 is a diagram illustrating a textile processing program
according to one embodiment.
[0025] FIG. 4 is a table illustrating a map for abnormality identification.
[0026] FIG 5 is a graph illustrating a correlation between a number of
25 neps and time.
DETAILED DESCRIPTION
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[0027] With reference to the accompanying drawings, an exemplary
embodiment according to the present disclosure will be described in
detail. In the description of the drawings, identical or equivalent
constituent elements are denoted by identical reference signs, and
5 redundant explanations are omitted.
[0028] As illustrated in FIG. 1, a textile processing system 1 according
to one embodiment includes a plurality of carding machines 10, a
plurality of drawing frames 30, aplurality of air spinning frames 50, and
a controller 70.
10 [0029] The carding machine 10 cards a lap produced by an opening and
blowing machine in a preceding process (upstream process) of a carding
process, and produces a fiber bundle. For example, the carding
machine 10 separates fibers by combing the sheet-shaped lap, and
removes dust, short fibers, and the like that are contained in the lap.
15 Thereafter, the carding machine 10 collects the fibers remained after
removing the dust and the short fibers by arranging the fibers in parallel,
and produces a rope-like fiber bundle (carded slivers). The carding
machine 10 includes a drafting device. The drafting device is provided
on the downstream side of the carding machine 10 and drafts (draws)
20 the produced fiber bundle. The drafting device separates fibers of the
fiber bundle and improves the parallelism of the fiber bundle. The
carding machine 10 accommodates the fiber bundle drafted in the
drafting device into a can (for example, a cylindrical container). The
fiber bundle drafted in the drafting device of the carding machine 10 is,
25 in a state of being accommodated into the can, transported to a
subsequent process.
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[0030] The drawing frame 30 draws the fiber bundle produced in the
carding machine 10. For example, the drawing frame 30 drafts six or
eight fiber bundles together by six-times or eight-times, and eliminates
unevenness of thickness in the fiber bundles by straightening the fibers.
5 The drawing frame 30 accommodates the drawn fiber bundle into a can.
The fiber bundle drawn in the drawing frame 30 is, in a state of being
accommodated into the can, transported to a subsequent process.
[0031] The air spinning frame 50 produces yarn by spinning the fiber
bundle drawn in the drawing frame 30. The air spinning frame 50
10 produces yarn by twisting the fiber bundle drawn in the drawing frame
30 and forms a package by winding the yarn. The air spinning frame
50 is an air-jet spinning machine or an open-end spinning machine, for
example. The air-jet spinning machine produces yarn by twisting a
fiber bundle by a swirl airflow. The air spinning frame 50 may draft
15 the fiber bundle by a drafting unit having a plurality of drafting roller
pairs. The open-end spinning machine separates fibers of a fiber
bundle by a combing roller or an airflow, and thereafter produces yarn
by twisting the fibers while collecting the fibers again.
[0032] The controller 70 is a computer including a processor (for
20 example, a central processing unit (CPU)) that executes an operating
system, application programs, and the like, a storage unit 72 (see FIG. 3)
composed of a read only memory (ROM), a random-access memory
(RAM), a hard disk, and the like, and a communication controller
composed of a network card or a wireless communications module. In
25 the storage unit 72, data or a database needed for processing is stored.
[0033] The controller 70 is a host controller configured to manage or
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control the entire textile processing system 1. For example, the
controller 70 is a central management computer of a textile mill in
which the textile processing system 1 is disposed. The controller 70
performs communication with the carding machines 10, the drawing
5 frames 30, and the air spinning frames 50, and manages or controls the
carding machines 10, the drawing frames 30, and the air spinning
frames 50. The controller 70 may be composed of a single device or
may be composed of a plurality of devices. When the controller 70 is
made up of multiple devices, a single controller 70 is logically
10 constructed as the multiple devices are connected via a communication
network such as the Internet or an intranet.
[0034] In such a textile processing system 1, performed is a textile
processing method including a carding process of producing a fiber
bundle from raw material by using the carding machine 10, a drawing
15 process of drawing the fiber bundle produced in the carding process by
using the drawing frame 30, and a break spinning process of producing
yarn by spinning the fiber bundle drawn in the drawing process by using
the air spinning frame 50.
[0035] In the textile processing system 1, the fiber bundle that is
20 produced in the carding machine 10 and supplied to the air spinning
frame 50 passes through the drawing frame 30 only once (a single pass).
In the textile processing system 1, the fiber bundles produced in two
carding machines 10 are supplied to a single drawing frame 30, and the
fiber bundles drawn in the single drawing frame 30 are supplied to two
25 air spinning frames 50.
[0036] The textile processing system 1 may include a sliver lap
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machine that performs a sliver lap process and a comber that performs a
combing process. In this case, the textile processing method includes
the sliver lap process and the combing process. In the sliver lap
process, a sliver lap is produced by winding 18 to 24 rope-like fiber
5 bundles produced in the carding machine 10 into a single sheet shape.
In the combing process, by combing the sliver lap produced in the sliver
lap machine, dusts and short fibers are removed, and by arranging fibers
remaining after removal in parallel, an even (uniform) fiber bundle is
produced. The fiber bundle produced in the combing process is
10 supplied to the drawing frame 30.
[0037] The textile processing system 1 may include, in place of the air
spinning frame 50, a roving frame that performs a roving process, a ring
spinning frame that performs a spinning process, and an automatic
winder that performs a rewinding process. In this case, the textile
15 processing method includes the roving process, the spinning process,
and the rewinding process, in place of the break spinning process. In
the roving process, by using the roving frame, roved yarn is produced
from the fiber bundle drawn in the drawing process. In the spinning
process, by using the ring spinning frame, yarn is produced from the
20 roved yarn produced in the roving process. In the rewinding process, a
package is formed by winding the yarn produced in the spinning process
by the automatic winder.
[0038] In the textile processing system 1, although the carding machine
10 includes the drafting device, the carding machine 10 may include no
25 drafting device. The textile processing system 1 is of a one-pass
configuration for which the fiber bundle passes through the drawing
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frame 30 only once, but it may be of a two-pass configuration for which
the fiber bundle passes through the drawing frame 30 twice, or may be
of a three or more pass configuration for which the fiber bundle passes
through the drawing frame 30 three or more times.
5 [0039] Next, a principal portion of the textile processing system 1 will
be described with reference to FIG. 2.
[0040] The textile processing system 1 includes a first quality data
acquisition unit 11 configured to acquire first quality data concerning
the quality of the produced fiber bundle. The first quality data
10 includes data concerning a number of neps contained in a fiber bundle
and data concerning the thickness of the fiber bundle. For example,
the first quality data acquisition unit 11 is a sensor provided on the
downstream side of the carding machine 10. As the first quality data
acquisition unit 11, various known sensors can be used. The first
15 quality data acquisition unit 11 needs to acquire only one of the data
concerning the nep of the fiber bundle or the data concerning the
thickness of the fiber bundle.
[0041] The textile processing system 1 includes a second
quality data acquisition unit 31 configured to acquire second quality
20 data concerning the quality of the drawn fiber bundle. The second
quality data includes data concerning the thickness of the fiber bundle.
For example, the second quality data acquisition unit 31 is a sensor
provided on the downstream side of the drawing frame 30. As the
second quality data acquisition unit 31, various known sensors can be
25 used.
[0042] The textile processing system 1 includes a third quality data
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acquisition unit 51 configured to acquire third quality data concerning
the quality of the produced yarn. The third quality data includes data
concerning a defect (a slub and/or a nep) of the yarn and data
concerning the thickness of the yarn. For example, the third quality
5 data acquisition unit 51 is a sensor provided between an air spinning
device and a yarn pull-out device (a yarn storage roller or a delivery
roller pair) in the air spinning frame 50. As the third quality data
acquisition unit 51, various known sensors can be used.
[0043] The controller 70 includes, as a functional configuration, an
10 abnormality identifying unit 71. The abnormality identifying unit 71
performs an abnormality identifying process. In the abnormality
identifying process, it is first determined whether the yarn produced in
the air spinning frame 50 is defective. Whether the yarn produced in
the air spinning frame 50 is defective can be determined from the third
15 quality data acquired by the third quality data acquisition unit 51 of the
air spinning frame 50. For example, in the abnormality identifying
process, in a case of at least either of a case where the number of small
defects of the yarn produced in the air spinning frame 50 has increased
and a case where the fluctuation in the thickness of the yarn produced in
20 the air spinning frame 50 has occurred, it is determined that said yarn is
defective.
[0044] In the abnormality identifying process, when the yarn produced
in the air spinning frame 50 is defective, at least one from among, the
raw material, the carding machines 10, the drawing frames 30, and the
25 air spinning frames 50, in which the abnormality has occurred is
identified, based on the first quality data, the second quality data, and
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the third quality data. In the abnormality identifying process, when the
yarn produced in the air spinning frame 50 is defective, at least one
from among the raw material, the carding machine 10, the drawing
frame 30, and the air spinning frame 50, in which the abnormality has
5 occurred is identified, also based on the setting data of the carding
machine 10 and the setting data of the drawing frame 30.
[0045] The raw material is the raw material of the yarn that the textile
processing system 1 produces. For example, the raw material is raw
cotton (not limited to cotton) that has been press-packed and conveyed.
10 The setting data concerning the setting of the carding machine 10
includes data concerning the setting of a fabrication speed (a production
speed) of the fiber bundle and data concerning the setting of a removal
amount of neps (snags). The setting data concerning the setting of the
carding machine 10 can be acquired from said carding machine 10.
15 The setting data concerning the setting of the drawing frame 30 includes
data concerning the setting of an auto-leveler of the drawing frame 30
and data concerning a drawing speed (a production speed) of the fiber
bundle of the drawing frame 30. The setting data concerning the
setting of the drawing frame 30 can be acquired from said drawing
20 frame 30.
[0046] The auto-leveler is a system that adjusts the drafting speed in the
drawing frame 30. Specifically, one roller of a most upstream drafting
roller pair of the drawing frame 30 is provided so as to move with
respect to the other roller of the drafting roller pair depending on the
25 thickness of the fiber bundle. The thickness of the fiber bundle is
detected based on the amount of this displacement. When a thick fiber
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bundle is inserted, the speed of the most upstream drafting rollers is
made fast. When a thin fiber bundle is inserted, the speed of the most
upstream drafting rollers is made slow.
[0047] In the abnormality identifying process, when the yarn produced
5 in the air spinning frame 50 is defective, a cause of the abnormality that
has occurred is estimated, based on the first quality data, the second
quality data, and the third quality data. In the abnormality identifying
process, when the yarn produced in the air spinning frame 50 is
defective, the cause of the abnormality that has occurred is estimated,
10 also based on the setting data of the carding machine 10 and the setting
data of the drawing frame 30.
[0048] In the abnormality identifying process of the present
embodiment, as will be described later, when the yarn produced in the
air spinning frame 50 is defective, an abnormal region and an estimated
15 cause of the abnormality are identified, by using a map M for
abnormality identification (see FIG. 4). The map M for abnormality
identification is stored in the storage unit 72 of the controller 70.
[0049] The controller 70 performs a notification process. In the
notification process, depending on a identification result identified in
20 the abnormality identification, notification prompting setting adjustment
of or maintenance of at least one of the carding machines 10, the
drawing frames 30, and the air spinning frames 50 is made. The
notification is a notice prompting the setting adjustment or the
maintenance for eliminating the cause of the abnormality estimated in
25 the abnormality identifying process. Examples of the notification
include lighting or flashing of a notifying lamp of at least one of the
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carding machine 10, the drawing frame 30, and the air spinning frame
50 having the cause of the abnormality. In the notification process, a
display prompting the setting adjustment of or the maintenance of at
least one of the carding machine 10, the drawing frame 30, and the air
5 spinning frame 50 is displayed on a display unit 90. The display unit
90 is a monitor of a mobile terminal such as a tablet, for example. The
display unit 90 is capable of performing communication with the
controller 70.
[0050] In the controller 70, a first threshold value that is a control limit
10 value of fluctuation in the third quality data and a second threshold
value smaller (stricter) than the first threshold value are set. The
controller 70, when an operator changed the setting data of the carding
machine 10, allows inputting of changing the setting data of the carding
machine 10 again if the third quality data is greater than the first
15 threshold value, returns the setting data of the carding machine 10 to the
setting data that was valid before the latest change if the third quality
data is smaller than or equal to the first threshold value and is greater
than the second threshold value, and returns the setting data of the
carding machine 10 to the setting data that was valid before the initial
20 change if the third quality data is smaller than or equal to the second
threshold value (detail will be described later).
[0051] In the textile processing system 1, two carding machines 10, a
single drawing frame, and two air spinning frames 50 construct a single
route group U for which a processing route of the fiber is the same.
25 When the yarn produced in one air spinning frame 50 is defective, the
abnormality identifying process is performed on the route group U to
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which said air spinning frame 50 belongs. In this case, the abnormality
identification on another air spinning frame 50 may be omitted.
[0052] Specifically, when the yarn produced in one air spinning frame
50 is defective, based on the first to the third quality data and the setting
5 data of the carding machines 10 and the drawing frame 30 in the route
group U to which said air spinning frame 50 belongs, at least one from
among the raw material of the yarn, the air spinning frames 50, the
drawing frame 30, and the carding machines 10 in the route group U to
which said air spinning frame 50 belongs, in which the abnormality has
10 occurred is identified. That is, when the yarn is defective, at least one
from among the raw material of said yarn, the air spinning frame 50 that
produced said yarn, the drawing frame 30 that drew the fiber bundle
supplied to said air spinning frame 50, and the carding machine 10 that
produced the fiber bundle supplied to said drawing frame 30, in which
15 the abnormality has occurred is identified. The information on the
route group U (correspondence relation of the carding machines 10, the
drawing frame 30, and the air spinning frames 50) for which the
processing route of fiber is the same is predetermined and stored in the
storage unit 72 (see FIG. 3) of the controller 70. The controller 70 may
20 perform the above-described abnormality identification, also based on
the setting data of the air spinning frames 50.
[0053] As illustrated in FIG. 3, in the storage unit 72 of the controller
70, a textile processing program P is stored. The storage unit 72 is a
non-transitory computer readable recording medium storing therein the
25 textile processing program P. The controller 70 implements the textile
processing method by making the processor load and execute the textile
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processing program P. The textile processing program P includes an
abnormality identifying module PL The abnormality identifying
module PI makes the controller 70 execute abnormality identifying
processing of the above-described abnormality identifying process.
5 The textile processing program P may be provided by being
permanently recorded on a tangible recording medium such as a
CD-ROM, a DVD-ROM, and a semiconductor memory, for example.
Alternatively, the textile processing program P may be provided via a
communication network as a data signal.
10 [0054] Next, one example of the textile processing method executed in
the textile processing system 1 will be described.
[0055] In the textile processing method, as in the foregoing, a fiber
bundle is produced from raw material by using the carding machine 10
(a carding process). The produced fiber bundle is drawn by using the
15 drawing frame 30 (a drawing process). Yarn is produced by spinning
the drawn fiber bundle by using the air spinning frame 50 (a break
spinning process). The first quality data is acquired by the first quality
data acquisition unit 11 (a first acquisition process). The second
quality data is acquired by the second quality data acquisition unit 31 (a
20 second acquisition process). The third quality data is acquired by the
third quality data acquisition unit 51 (a third acquisition process).
[0056] In the textile processing method, when the yarn produced in the
air spinning frame 50 is defective, by referring to the map M illustrated
in FIG. 4, based on the setting data of the carding machine 10, the
25 setting data of the drawing frame 30, the first quality data, the second
quality data, and the third quality data, an abnormal region in the
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processing route that said defective yarn passes through is identified (an
abnormality identifying process). In the abnormality identifying
process, an abnormality cause may further be estimated.
[0057] The setting data of the carding machine 10 is the setting data of
5 the carding machine 10 in the processing route that said defective yarn
has passed through. The setting data of the drawing frame 30 is the
setting data of the drawing frame 30 in the processing route that said
defective yarn has passed through. The first quality data is the quality
data of the fiber bundle produced by the carding machine 10 in the
10 processing route that said defective yarn has passed through. The
second quality data is the quality data of the fiber bundle drawn by the
drawing frame 30 in the processing route that said defective yarn has
passed through. The third quality data is the quality data of said
defective yarn.
15 [0058] In the map M, the setting data of the carding machine 10
includes the production speed of a fiber bundle and a removal amount of
neps from the fiber bundle. The first quality data includes the number
of neps contained in a fiber bundle and the fluctuation in the thickness
of the fiber bundle that are detected by the sensor of the carding
20 machine 10. The setting data of the drawing frame 30 includes a
drawing speed of the fiber bundle and information on presence or
absence of change in the setting of the auto-leveler. In addition to or in
lieu of the information on the presence or the absence of the change in
the setting of the auto-leveler, the setting data of the drawing frame 30
25 may also include a gauge of drafting rollers (a distance between a
plurality of drafting rollers in the drafting direction) and/or a drafting
21
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ratio (a ratio of circumferential speed of the drafting rollers in the
drafting direction). The second quality data includes the fluctuation in
the thickness of the fiber bundle detected by the sensor of the drawing
frame 30. The third quality data includes the number of small defects
5 of the yarn and the fluctuation in the thickness of the yarn that are
detected by the sensor of the air spinning frame 50.
[0059] In the map M, "increase" and "changed" mean change of a value
equal to or greater than a prescribed value that is predetermined. In the
map M,"-" means that there is no change (no fluctuation with respect to
10 a prescribed value that is predetermined). In the setting of the carding
machine 10, "changed to reduction setting" of the nep removal amount
means at least one of widening the distance between a main cylinder
and a top flat of the carding machine 10, widening the distance between
the main cylinder and a stationary flat, and adjusting the angle of a mote
15 knife (narrowing the size of a suction opening).
[0060] The wire (teeth) of the carding machine 10 is a large number of
pyramid-shaped portions for which the distal end is sharp and which are
provided on the outer circumferential surface of the main cylinder. A
doffer unit of the carding machine 10 is a device that guides the fiber
20 bundle from the main cylinder toward the drafting device or a can. A
state of the drafting device of the drawing frame 30 being inappropriate
is a state in which the drafting ratio and/or the gauge of drafting rollers
are inappropriate. Overall drafting unit abnormality of the air spinning
frame 50 means that there is abnormality somewhere in the overall
25 drafting unit excluding a front top roller (the gauge of drafting rollers
and/or deposition of fluff, for example).
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[0061] As illustrated in FIG. 4, in the abnormality identifying process,
when the number of neps contained in the fiber bundle detected by the
sensor of the carding machine 10 increases, the fluctuation in the
number of small defects of and the thickness of the yarn that are
5 detected by the sensor of the air spinning frame 50 occurs, and there is
no fluctuation in the data other than the foregoing, it is identified that
the abnormal region is the raw material, and the cause of the
abnormality is estimated to be the deterioration in raw material quality.
Specifically, it is the abnormality in the raw material of the fiber bundle
10 before being processed in the carding machine 10, or even when there is
no abnormality in the raw material of said fiber bundle, it is the
abnormality in management of the temperature and/or the humidity of
said fiber bundle, for example. Alternatively, when the number of
neps contained in the fiber bundle detected by the sensor of the carding
15 machine 10 increases, the fluctuation in the number of small defects of
and the thickness of the yarn that are detected by the sensor of the air
spinning frame 50 occurs, and there is no fluctuation in the data other
than the foregoing, it is identified that the abnormal region is the
carding machine 10, and the cause of the abnormality is estimated to be
20 the abrasion of the wire. In this case, in the notification process which
will be described later, an abnormality lamp provided near the main
cylinder in which the abrasion of the wire has occurred may be
controlled to light or flash, or a message that prompts the maintenance
of the wire (polishing or replacing by the operator) may be displayed on
25 the display unit 90. Alternatively, when the carding machine 10 is
provided with a wire polishing device, the wire may be polished by the
23
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polishing device.
[0062] In the abnormality identifying process, when the fluctuation in
the thickness of the fiber bundle detected by the sensor of the carding
machine 10 occurs, the fluctuation in the thickness of the fiber bundle
5 detected by the sensor of the drawing frame 30 occurs, the thickness of
the yarn that is detected by the sensor of the air spinning frame 50
increases, and there is no fluctuation in the data other than the
foregoing, it is identified that the abnormal region is the carding
machine 10, and the cause of the abnormality is estimated to be the
10 abnormality of the doffer unit.
[0063] In the abnormality identifying process, when the fluctuation in
the thickness of the fiber bundle detected by the sensor of the drawing
frame 30 occurs, the fluctuation in the thickness of the yarn that is
detected by the sensor of the air spinning frame 50 occurs, and there is
15 no fluctuation in the data other than the foregoing, it is identified that
the abnormal region is the drawing frame 30, and the cause of the
abnormality is estimated to be the abnormality of the drafting unit. In
this case, in the later-described notification process, an abnormality
lamp provided to the drafting unit of the drawing frame 30 may be
20 controlled to light or flash, or a message that prompts, for example, the
maintenance of the drafting unit (cleaning or the like by the operator) or
the adjustment of the drafting ratio and/or the gauge may be displayed
on the display unit 90.
[0064] In the abnormality identifying process, when the setting of the
25 production speed of the carding machine 10 is changed to be faster, the
number of neps contained in.the fiber bundle detected by the sensor of
24
FP19-0123-00IN-MRT
the carding machine 10 increases, the fluctuation in the number of small
defects of and the thickness of the yam that are detected by the sensor of
the air spinning frame 50 occurs, and there is no fluctuation in the data
other than the foregoing, it is identified that the abnormal region is the
5 carding machine 10, and the cause of the abnormality is estimated to be
the reduction of the nep removal.
[0065] In the abnormality identifying process, when the setting of the
production speed of the carding machine 10 is changed to be faster, the
fluctuation in the thickness of the fiber bundle detected by the sensor of
10 the carding machine 10 occurs, the fluctuation in the thickness of the
fiber bundle detected by the sensor of the drawing frame 30 occurs, the
number of small defects of the yam that are detected by the sensor of
the air spinning frame 50 increases, and there is no fluctuation in the
data other than the foregoing, it is identified that the abnormal region is
15 the carding machine 10, and the cause of the abnormality is estimated to
be the abnormality of the drafting device. In this case, in the
later-described notification process, a message that prompts returning
the drafting speed of the drafting device of the carding machine 10 to
the previous setting may be displayed on the display unit 90.
20 [0066] In the abnormality identifying process, when the setting of the
nep removal amount of the carding machine 10 is changed to the
reduction setting, the number of neps contained in the fiber bundle
detected by the sensor of the carding machine 10 increases, the
fluctuation in the number of small defects of and the thickness of the
25 yarn that are detected by the sensor of the air spinning frame 50 occurs,
and there is no fluctuation in the data other than the foregoing, it is
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FP19-0123-00IN-MRT
identified that the abnormal region is the carding machine 10, and the
cause of the abnormality is estimated to be the reduction of the nep
removal amount. In this case, in the later-described notification
process, the display unit 90 may be controlled to display a message that
5 prompts at least one of changing the setting to increase the production
speed, widening the distance between the main cylinder and the top flat
of the carding machine 10, widening the distance between the main
cylinder and the stationary flat, and adjusting the angle of the mote
knife.
10 [0067] In the abnormality identifying process, when the setting of the
drawing speed of the drawing frame 30 is changed to be faster, the
fluctuation in the thickness of the yarn that is detected by the sensor of
the air spinning frame 50 occurs, and there is no fluctuation in the data
other than the foregoing, it is identified that the abnormal region is the
15 drawing frame 30, and the cause of the abnormality is estimated to be
the drafting device of the drawing frame 30 being inappropriate. In
this case, in the later-described notification process, the display unit 90
is controlled to display a message that prompts changing the drafting
ratio and/or the gauge of the drafting rollers.
20 [0068] In the abnormality identifying process, when the setting of the
auto-leveler of the drawing frame 30 is changed, the fluctuation in the
thickness of the yarn that is detected by the sensor of the air spinning
frame 50 occurs, and there is no fluctuation in the data other than the
foregoing, it is identified that the abnormal region is the drawing frame
25 30, and the cause of the abnormality is estimated to be the drafting
device of the drawing frame 30 being inappropriate. In this case, in
26
FP19-0123-00IN-MRT
the later-described notification process, the display unit 90 is controlled
to display a message that prompts the adjustment of the setting of the
auto-leveler.
[0069] In the abnormality identifying process, when the fluctuation in
5 the number of small defects of and the thickness of the yarn that are
detected by the sensor of the air spinning frame 50 occurs and there is
no fluctuation in the data other than that, it is identified that the
abnormal region is the air spinning frame 50, and the cause of
abnormality is estimated to be the abnormality of the overall drafting
10 unit of the air spinning frame 50. In this case, in the later-described
notification process, the fact that there is abnormality somewhere in the
overall drafting unit excluding the front top roller (the gauge of the
drafting rollers and/or deposition of fluff, for example) may be
displayed on the display unit 90. More specifically, a message that
15 prompts the cleaning of the drafting unit may be displayed on the
display unit 90.
[0070] In the abnormality identifying process, when the number of
small defects of the yarn that are detected by the sensor of the air
spinning frame 50 increases and there is no fluctuation in the data other
20 than that, it is identified that the abnormal region is the air spinning
frame 50, and the cause of the abnormality is estimated to be the
abnormality of the front top roller of the air spinning frame 50. In this
case, in the later-described notification process, a message that prompts
the maintenance (polishing of the front top roller by the operator) of or
25 the replacement of the front top roller may be displayed on the display
unit 90.
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[0071] In the abnormality identifying process, when the fluctuation in
the yarn that is detected by the sensor of the air spinning frame 50
occurs and there is no fluctuation in the data other than that, it is
identified that the abnormal region is the air spinning frame 50, and the
5 cause of abnormality is estimated to be the abnormality of the overall
drafting unit of the air spinning frame 50. In this case, in the
later-described notification process, the fact that there is abnormality
somewhere in the overall drafting unit excluding the front top roller (the
gauge of the drafting rollers and/or deposition of fluff, for example)
10 may be displayed on the display unit 90. More specifically, a message
that prompts the cleaning of the drafting unit may be displayed on the
display unit 90.
[0072] In the textile processing method, depending on a identification
result of the abnormality identifying process, the notification that
15 prompts the setting adjustment of or the maintenance of at least one of
the carding machine 10, the drawing frame 30, and the air spinning
frame 50 is made (a notification process). In the notification process,
the controller 70 controls the display unit 90 to display various pieces of
information prompting the setting adjustment or the maintenance.
20 [0073] In the textile processing method, with the changes in the post
process (downstream process) as an indicator, the optimal setting of the
preceding process (upstream process) may be investigated. That is, the
operator first sets, via an operation input unit of the controller 70, the
first threshold value that is a control limit value of fluctuation in the
25 third quality data, and the second threshold value that is smaller than the
first threshold value (a first process). The operator changes, via the
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FP19-0123-00IN-MRT
operation input unit of the carding machine 10 or the controller 70, the
setting data of the carding machine 10 (a second process).
[0074] When the third quality data is greater than the first threshold
value, the processing is returned to the second process. When the third
5 quality data is smaller than or equal to the first threshold value and is
greater than or equal to the second threshold value, the controller 70
returns the setting data of the carding machine 10 to the setting data that
was valid before the latest second process. When the third quality data
is smaller than or equal to the second threshold value, the controller 70
10 returns the setting data of the carding machine 10 to the setting data that
was valid before the initial second process (a third process).
[0075] In such a first process, a second process, and a third process in
which the setting of the preceding process is investigated with the
changes in the post process as an indicator, the operator may perform all
15 of the processing manually, or the controller 70 may perform all of the
processing automatically. The operator may perform a part of the
processing of the first process, the second process, and the third process
manually and the controller 70 may perform the other of the processing
of the. first process, the second process, and the third process
20 automatically.
[0076] In the present embodiment, when the number of neps contained
in the fiber bundle detected by the sensor of the carding machine 10
increases, the fluctuation in the number of small defects of and the
thickness of the yarn that are detected by the sensor of the air spinning
25 frame 50 occurs, and there is no fluctuation in the data other than the
foregoing, it has been identified that the abnormal region is the raw
29
FP19-0123-00IN-MRT
material and the cause of the abnormality has been estimated to be the
deterioration in raw material quality, or it has been identified that the
abnormal region is the carding machine 10 and the cause of the
abnormality has been estimated to be the abrasion of the wire. These
5 identification results may be easily distinguished, by being based on the
maintenance history of the carding machine 10 and the past fluctuation
trend of the number of neps.
[0077] Specifically, as illustrated in FIG. 5, in the fluctuation trend DO
of the number of neps, the number of neps increases in accordance with
10 the maintenance period of the carding machine 10. Because the data
Dl substantially lies along the fluctuation trend DO of the number of
neps, there is no problem with the raw material quality, and it can be
identified that the abrasion of the wire of the carding machine 10 is the
cause. Because the data D2 is drastically deviated from the fluctuation
15 trend DO, it can be identified that the raw material itself has a problem.
[0078] As in the foregoing, in the textile processing method, the textile
processing system 1, and the textile processing program P, when the
yarn produced in the air spinning frame 50 is defective, the raw material
and the machine of each process (the carding process, the drawing
20 process, and break spinning process) having abnormality are accurately
identified, based on the first quality data, the second quality data, and
the third quality data. As for the abnormality of the raw material and
of the machine of each process, this is because the correlation is found
with the relation of the quality data that is acquired in association with
25 each process. Accordingly, in the textile processing method, the textile
processing system 1, and the textile processing program P, it is possible
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FP19-0123-00IN-MRT
to learn the abnormality of the raw material, the carding machine 10, the
drawing frame 30, and the air spinning frame 50.
[0079] In the textile processing method, the textile processing
system 1, and the textile processing program P, when the yarn produced
5 in the air spinning frame 50 is defective, at least one from among the
raw material of said yarn, the air spinning frame 50 that produced said
yarn, the drawing frame 30 that drew the fiber bundle supplied to said
air spinning frame 50, and the carding machine 10 that produced the
fiber bundle supplied to said drawing frame 30, in which the
10 abnormality has occurred is identified. Accordingly, it is possible to
learn the abnormality of the raw material, the carding machine 10, the
drawing frame 30, and the air spinning frame 50 in the processing route
involved with the production of the defective yarn.
[0080] In the textile processing method, the textile processing system 1,
15 and the textile processing program P, when the yarn produced in the air
spinning frame 50 is defective, a cause of the abnormality that, occurred
is estimated, based on the first quality data, the second quality data, and
the third quality data. In this case, it is also possible to learn the
specific cause of the. abnormality in the raw material, the carding
20 machine 10, the drawing frame 30, and the air spinning frame 50.
[0081] In the textile processing method, the textile processing system 1,
and the textile processing program P, the first quality data is the data
concerning the number of neps contained in the fiber bundle and the
thickness of the fiber bundle, the second quality data is the data
25 concerning the thickness of the fiber bundle, and the third quality data is
the data concerning the defect of and the thickness of the yarn. In this
31
FP19-0123-00IN-MRT
case, it is possible to accurately learn the abnormality of the raw
material, the carding machine 10, the drawing frame 30, and the air
spinning frame 50. The first quality data needs to be the data
concerning at least only one of the number of neps contained in the fiber
5 bundle or the thickness of the fiber bundle. The third quality data
needs to be the data concerning at least only one of the defect of or the
thickness of the yarn.
[0082] In the textile processing method, the textile processing system 1,
and the textile processing program P, when the yarn produced in the air
10 spinning frame 50 is defective, at least one from among the raw
material, the carding machine 10, the drawing frame 30, and the air
spinning frame 50, in which the abnormality has occurred is identified,
also based on the setting data of the carding machine 10 and the setting
data of the drawing frame 30. As for the abnormality of the raw
15 material and of the machine of each process, the correlation is found
with the relation of each setting data of the carding machine 10 and the
drawing frame 30, in addition to the relation of the quality data acquired
in association with each process. Accordingly, by being further based
on the setting data of the carding machine 10 and the setting data of the
20 drawing frame 30, it is possible to accurately learn the abnormality of
the raw material, the carding machine 10, the drawing frame 30, and the
air spinning frame 50.
[0083] In the textile processing method, the textile processing system 1,
and the textile processing program P, the setting data of the carding
25 machine 10 is the data concerning the setting of the production speed of
the fiber bundle and the removal amount of neps from the fiber bundle.
32
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The setting data of the drawing frame 30 is the data concerning the
setting of the auto-leveler and the drawing speed of the fiber bundle of
the drawing frame 30. In this case, it is possible to learn the
abnormality of the raw material, the carding machine 10, the drawing
5 frame 30, and the air spinning frame 50. For example, it is possible to
learn the abnormality due to the production speed of the fiber bundle in
the carding machine 10 being too fast, the abnormality due to the
removal amount of neps in the carding machine 10 being too small, the
abnormality in the detection of thickness of the fiber bundle by the
10 auto-leveler of the drawing frame 30, and the abnormality due to the
drawing speed in the drawing frame 30 being not appropriate. The
setting data of the carding machine 10 needs to be the data concerning
at least only one of the production speed of the fiber bundle or the
removal amount of neps from the fiber bundle. The setting data of the
15 drawing frame 30 needs to be the data concerning the setting of at least
only one of the auto-leveler of the drawing frame 30 or the drawing
speed of the fiber bundle of the drawing frame 30.
[0084] In the textile processing method, the textile processing system 1,
and the textile processing program P, depending on the identification
20 result that has been identified, the notification that prompts the setting
adjustment of or the maintenance of at least one of the carding machine
10, the drawing frame 30, and the air spinning frame 50 is made,
Accordingly, the operator can act promptly for the abnormality of the
raw material, the carding machine 10, the drawing frame 30, and the air
25 spinning frame 50, for example.
[0085] In the textile processing method, the textile processing system 1,
33
FP19-0123-00IN-MRT
and the textile processing program P, a display prompting the setting
adjustment of or the maintenance of at least one of the carding machine
10, the drawing frame 30, and the air spinning frame 50 is displayed on
the display unit 90. Accordingly, the operator can confirm the specific
5 content of the notification prompting the setting adjustment or the
maintenance.
[0086] The textile processing method includes the first process of
setting the first threshold value and the second threshold value, the
second process of changing, after the first process, the setting data of the
10 carding machine 10, and the third process, after the second process, of
returning to the second process when the third quality data is greater
than the first threshold value, of returning the setting data of the carding
machine 10 to the setting data that was valid before the latest second
process when the third quality data is smaller than or equal to the first
15 threshold value and is greater than the second threshold value, and of
returning the setting data of the carding machine 10 to the setting data
that was valid before the initial second process when the third quality
data is smaller than or equal to the second threshold value.
Accordingly, the desirable setting data of the carding machine 10 can be
20 investigated with the fluctuation in the quality of the yarn produced in
the air spinning frame 50 as an indicator.
[0087] In the second process and the third process, the setting data of
the drawing frame 30 may be changed, in lieu of or in addition to the
setting data of the carding machine 10. When considering the entire
25 textile mill in which the textile processing system 1 is arranged, if the
production speed of the carding machine 10 is increased, the fiber
34
FP19-0123-00IN-MRT
bundles (carded slivers) waiting for processing in the drawing frame 30
may arise, unless the production speed of the drawing frame 30 is also
increased. On this point, if the occurrence of such fiber bundles is
acceptable, only the production speed of the carding machine 10 may be
5 adjusted or only the production speed of the drawing frame 30 may be
adjusted.
[0088] As in the foregoing, one embodiment and modifications
according to the present disclosure have been described, but the present
disclosure is not limited to the above-described embodiment and the
10 modifications. For example, the material and the shape of each
constituent element are not limited to the above-described material and
the shape, and various materials and shapes may be employed. The
present disclosure may be modified without altering the scope described
in each of the claims. The above-described embodiment and the
15 modifications may be combined as appropriate. At least a part of the
above-described embodiment and of the modifications may be
combined in any desired manner.
[0089] In the above-described embodiment, the controller 70 was a
central management computer of the textile mill, but the controller 70
20 may be the control device of the air spinning frame 50, the control
device of the drawing frame 30, the control device of the carding
machine 10, or a control device of a mobile terminal such as a tablet.
[0090] In the above-described embodiment, a single carding machine
10, a single drawing frame, and a single air spinning frame may
25 construct a single route group U for which the processing route of the
fiber is the same. In this case, in the textile processing method, the
35
FP19-0123-00IN-MRT
textile processing system 1, and the textile processing program P, when
the yarn produced in the air spinning frame 50 is defective, at least one
from among the raw material of said yarn, the single air spinning frame
50 that produced said yarn, the single drawing frame 30 that drew the
5 fiber bundle supplied to said air spinning frame 50, and the single
carding machine 10 that produced the fiber bundle supplied to said
drawing frame 30, in which the abnormality has occurred is identified.
Accordingly, because the number of machines involved with the
production of the defective yarn is small, it is possible to accurately
10 learn the abnormality of the raw material, the carding machine 10, the
drawing frame 30, and the air spinning frame 50 in the processing route
involved with the production of the defective yarn.
[0091] In the above-described embodiment, the information on the
route group U for which the processing route of the fiber is the same is
15 stored in the storage unit 72 of the controller 70, and the machine of
each process in the same processing route is identified based on said
stored information. However, the identification of the machine of each
process in the same processing route is not limited to said example, and
it only needs to be possible to identify the fiber passed which machine
20 in each process. For example, by using an ID tag or a barcode attached
to a can, the cause of the abnormality may be identified. At the time
point at which the carding machine 10 fully filled a single can with the
fiber bundle, the first quality information may be associated with said
can and transmitted to the controller 70 to be managed by the controller
25 70. At the time point at which the drawing frame 30 fully filled a
single can with the fiber bundle, the second quality information may be
36
FP19-0123-00IN-MRT
associated with said can and transmitted to the controller 70 to be
managed by the controller 70.
[0092] In the above-described embodiment, the third quality data may
be average quality data of a plurality of spinning units of the air
5 spinning frame 50, or may be the quality data for each spinning unit
(unit of a spindle). When the third quality data is the quality data of
each spinning unit, in the abnormality identifying process, at least one
from among a spinning unit, one or more of the drawing frames 30 that
drew the fiber bundle supplied to said spinning unit, and one or more of
10 the carding machines 10 that produced the fiber bundle supplied to said
drawing frames 30, in which the abnormality has occurred may be
identified.
[0093] In the above-described embodiment, in the abnormality
identifying process, a single one from among the raw material, the
15 carding machine 10, the drawing frame 30, and the air spinning frame
50, in which the abnormality has occurred may be identified, or two or
more from among the foregoing, in which the abnormality has occurred
may be identified. In the above-described embodiment, a display that
prompts the setting adjustment or the maintenance as the notification
20 has been displayed on the display unit 90, but in lieu of or in addition to
the display on the display unit 90, it may be displayed on at least one of
the display devices that the machines in each process have or on a
portable display device. Alternatively, paper on which information on
said notification is described may be printed. In the above-described
25 embodiment, the quality (the first quality data) of the fiber bundle
produced in the carding process may be acquired between the carding
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process and the drawing process by using a measuring instrument.
[0094] In the above-described embodiment, the carding machine 10
may be one or more. The drawing frame 30 may be one or more.
The air spinning frame 50 may be one or more. In the abnormality
5 identifying process executed by the abnormality identifying unit 71, it
only needs to identify at least one from among the raw material, one or
more of the carding machines 10, one or more of the drawing frames 30,
and one or more of the air spinning frames 50, in which the abnormality
has occurred.
10 [0095] In the above-described embodiment, the controller 70 was the
central management computer, but the controller 70 may be the control
device of the air spinning frame 50. In this case, the abnormality
identifying unit 71 is included in the control device of the air spinning
frame 50, and the abnormality identifying process is executed by the
15 control device of the air spinning frame 50. By performing the
abnormality identification by the control device of the air spinning
frame 50 arranged downstream of the process, it is easy to confirm the
setting adjustment or the maintenance by retracing the process.

We claim:
1. A textile processing method comprising:
a carding process in which a fiber bundle is produced from raw
material by using one or more of carding machines (10);
5 a drawing process in which the fiber bundle produced in the
carding process is drawn by using one or more of drawing frames (30);
a break spinning process in which yarn is produced by spinning
the fiber bundle drawn in the drawing process by using one or more of
air spinning frames (50);
10 a first acquisition process in which first quality data concerning
quality of the fiber bundle produced in the carding process is acquired;
a second acquisition process in which second quality data
concerning quality of the fiber bundle drawn in the drawing process is
acquired;
15 a third acquisition process in which third quality data concerning
quality of the yarn produced in the break spinning process is acquired;
and
an abnormality identifying process in which when the yarn
produced in the air spinning frame (50) is defective, at least one from
20 among the raw material, the carding machines (10), the drawing frames
(30), and the air spinning frames (50), in which an abnormality has
occurred is identified, based on the first quality data, the second quality
data, and the third quality data.
25 2. The textile processing method according to claim 1, wherein in
the abnormality identifying process, when the yarn produced in the air
39
FP19-0123-00IN-MRT
spinning frame (50) is defective, at least one from among the raw
material of said yarn, one or more of the air spinning frames (50) that
produced said yarn, one or more of the drawing frames (30) that drew
the fiber bundle supplied to said air spinning frame (50), and one or
5 more of the carding machines (10)that produced the fiber bundle
supplied to said drawing frame (30), in which the abnormality has
occurred is identified, based on the first quality data, the second quality
data, and the third quality data.
3. The textile processing method according to claim 2, wherein in
10 the abnormality identifying process, when the yarn produced in the air
spinning frame (50) is defective, at least one from among the raw
material of said yarn, one air spinning frame (50) that produced said
yarn, one drawing frame (30) that drew the fiber bundle supplied to said
air spinning frame (50), and one carding machine (10) that produced the
15 fiber bundle supplied to the relevant drawing frame (30), in which the
abnormality has occurred is identified, based on the first quality data,
the second quality data, and the third quality data.
4. The textile processing method according to any one of claims 1
to 3, wherein in the abnormality identifying process, when the yarn
20 produced in the air spinning frame (50) is defective, a cause of the
abnormality that has occurred is estimated based on the first quality
data, the second quality data, and the third quality data.
5. The textile processing method according to any one of claims 1
to 4, wherein
25 the first quality data is data concerning at least either one of
number of neps contained in the fiber bundle and a thickness of the fiber
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bundle,
the second quality data is data concerning the thickness of the
fiber bundle, and
the third quality data is data concerning at least either one of a
5 defect of and a thickness of the yarn.
6. The textile processing method according to any one of claims 1
to 5, wherein in the abnormality identifying process, when the yarn
produced in the air spinning frame (50) is defective, at least one from
among the raw material, the carding machine (10), the drawing frame
10 (30), and the air spinning frame (50), in which the abnormality has
occurred is identified, also based on setting data of the carding machine
(10) and setting data of the drawing frame (30).
7. The textile processing method according to claim 6, wherein
the setting data of the carding machine (10) is data concerning
15 setting of at least either one of a production speed of the fiber bundle
and a removal amount of neps from the fiber bundle, and
the setting data of the drawing frame (30) is data concerning
setting of at least either one of an auto-leveler of the drawing frame (30)
and a drawing speed of the fiber bundle of the drawing frame (30).
20 8. The textile processing method according to any one of claims 1
to 7, further comprising a notification process in which, depending on a
identification result identified in the abnormality identifying process,
notification prompting setting adjustment of or maintenance of at least
one of the carding machine (10), the drawing frame (30), and the air
25 spinning frame (50) is made.
9. The textile processing method according to claim 8, wherein, in
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the notification process, a display prompting the setting adjustment of or
the maintenance of at least one of the carding machine (10), the drawing
frame (30), and the air spinning frame (50) is displayed on a display unit
(90).
5 10. The textile processing method according to any one of claims 1
to 9, further comprising:
a first process of setting a first threshold value and a second
threshold value, the first threshold value being a control limit value of
fluctuation in the third quality data, and the second threshold value
10 being smaller than the first threshold value;
a second process of changing, after the first process, setting data
of at least either one of the carding machine (10) and the drawing frame
(30); and
a third process, after the second process,
15 of returning to the second process when the third quality
data is greater than the first threshold value,
of returning the setting data of at least either one of the
carding machine (10) and the drawing frame (30) to the setting data that
was valid before a latest second process when the third quality data is
20 smaller than or equal to the first threshold value and is greater than the
second threshold value, and
of returning the setting data of at least either one of the
carding machine (10) and the drawing frame (30) to the setting data that
was valid before an initial second process when the third quality data is
25 smaller than or equal to the second threshold value.
11. The textile processing method according to any one of claims 1
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to 10, wherein the abnormality identifying process is performed in a
control device of the air spinning frame (50).
12. The textile processing method according to any one of claims 1
to 11, wherein in the abnormality identifying process, when the yarn
5 produced in the air spinning frame (50) is defective, at least one from
among the raw material, the carding machine (10), the drawing frame
(30), and the air spinning frame (50), in which the abnormality has
occurred is identified, by using a map (M) for abnormality identification
stored in a storage unit (70).
10 13. A textile processing system (1) comprising:
one or more of carding machines (10) configured to produce a
fiber bundle;
one or more of drawing frames (30) configured to draw the fiber
bundle produced in the carding machine (10);
15 one or more of air spinning frames (50) configured to produce
yarn by spinning the fiber bundle drawn in the drawing frame (30);
a first quality data acquisition unit (11) configured to acquire
first quality data concerning quality of the produced fiber bundle;
a second quality data acquisition unit (31) configured to acquire
20 second quality data concerning quality of the drawn fiber bundle;
a third quality data acquisition unit (51) configured to acquire
third quality data concerning quality of the produced yarn; and
an abnormality identifying unit (71) configured to identify, when
the yarn produced in the air spinning frame (50) is defective, at least one
25 from among raw material, the carding machines (10), the drawing
frames (30), and the air spinning frames (50) based on the first quality
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data, the second quality data, and the third quality data.
14. A recording medium storing therein a textile processing program
that causes a computer to execute, in a textile processing system (1)
5 including one or more of carding machines (10) configured to produce a
fiber bundle, one or more of drawing frames (30) configured to draw the
fiber bundle produced in the carding machine (10), one or more of air
spinning frames (50) configured to produce yarn by spinning the fiber
bundle drawn in the drawing frame (30), a first quality data acquisition
10 unit (11) configured to acquire first quality data concerning quality of
the produced fiber bundle, a second quality data acquisition unit (31)
configured to acquire second quality data concerning quality of the
drawn fiber bundle, and a third quality data acquisition unit (51)
configured to acquire third quality data concerning quality of the
15 produced yarn, to perform
an abnormality identifying process in which when the yarn
produced in the air spinning frame (50) is defective, at least one from
among raw material, the carding machines (10) , the drawing frames
(30) , and the air spinning frames (50), in which an abnormality has
20 occurred is identified, based on the first quality data, the second quality
data, and the third quality data.