System for monitoring looms in weaving mill

A loom monitoring system includes loom computers and a host computer connected to the loom computers through a network. Each loom computer acquires a temporary IP address from a DHCP server when a fixed IP address is not set for the loom computer and requests the host computer to transmit a fixed IP address using the temporary IP address. The host computer assigns a fixed IP address to the loom computer that transmitted the assignment request signal and correlates the fixed IP address with a loom layout map. The loom computers each transmit an acquisition completion signal to the host computer using the fixed IP address in a designated order based on the loom layout map. The host computer correlates the fixed IP address of each loom computer with the loom layout map in accordance with the designated order.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2013-176171, filed on Aug. 28, 2013, the entire contents of which are incorporated herein by reference.

FIELD

The present invention relates to a system for monitoring looms in a weaving mill.

BACKGROUND

Japanese Laid-Open Patent Publication No. 2005-301916 discloses a manufacturing system that includes a central control computer, which is located in a central control room, and loom computers connected to the central control computer through a network. The loom computers and the central control computer each include a central processing unit (CPU), a memory, an input unit, a display, and external memory, a storage medium drive, a network interface.

The network may be a local area network (LAN), for example. The loom computers and the central control computer communicate through the network to transmit and receive control data and operation data. To communicate through the network, communication addresses are assigned to the loom computers and the central control computer.

Although not described in detail in the '916 publication, when the system uses a TCP/IP network, a unique IP address serving as a communication address has to be assigned and set to each loom computer. Thus, when the network is formed in a weaving mill, a unique IP address has to be set to each of the looms installed in the weaving mill. Setting the IP addresses in the weaving mill is performed manually by an operator. For example, an operator manually inputs and sets an IP address to each of the loom computers while referring to a printout of an IP address list obtained from the central control computer.

The central control computer is configured to generate and store a loom layout map indicating the layout of the looms in the weaving mill. To accurately transfer data between the central control computer and the loom computers, the operator needs to correlate the IP address set for each loom computer with the loom layout map stored in the central control computer.

In the manufacturing system disclosed in the '916 publication, the operator needs to manually and accurately input the IP address for each loom computer while referring to the IP address list. The operator also needs to correctly correlate the IP address of each loom with the loom layout map of the central control computer. The operator refers to the printed IP address list to check the IP address that is to be input and correctly input the IP address to each loom computer. When there are many looms, such a task consumes time and manpower. Further, when an IP address is erroneously input, the operator would have to correct the error.

SUMMARY

It is an object of the present invention to provide a system that facilitates the setting of fixed IP addresses for loom computers and allows the fixed IP addresses to be easily correlated with a loom layout map of a host computer.

One aspect of the present invention is a loom monitoring system including loom computers respectively coupled to looms installed in a weaving mill and a host computer connected to the loom computers through a network. The host computer is configured to communicate with the loom computers to manage the loom computers. A dynamic host configuration protocol (DHCP) server is arranged in the network. The host computer is configured to manage fixed IP addresses to be assigned to the loom computers and store a loom layout map indicating where the looms are located in the weaving mill. Each of the loom computers is configured to transmit, when a fixed IP address is not set for the loom computer, a temporary IP address acquisition request signal to the DHCP server to acquire a temporary IP address from the DHCP server, and transmit a fixed IP address assignment request signal to the host computer using the acquired temporary IP address. The host computer is configured to assign fixed IP addresses to the loom computers that transmitted the assignment request signal, and shift to a correlating mode when the assignment of the fixed IP addresses to the loom computers that transmitted the assignment request signal is completed. The host computer in the correlating mode correlates the fixed IP addresses assigned to the loom computers that transmitted the assignment request signal with the loom layout map. The host computer is configured to request each of the loom computers that transmitted the assignment request signal to transmit an acquisition completion signal so that the acquisition signal is transmitted from the loom computers in a designated order based on the loom layout map. Each loom computer is configured to register the assigned fixed IP address in lieu of the temporary IP address, transmit the acquisition completion signal to the host computer using the fixed IP address when the acquisition completion switch of the loom computer is operated in the designated order based on the loom layout map. The host computer is configured to, when receiving the acquisition completion signals, store and correlate the fixed IP addresses of the loom computers with the loom layout map in accordance with the designated order.

The aspect of the present invention eliminates the need to manually and directly input IP addresses to the host computer and the loom computers in a weaving mill, facilitates the setting of fixed IP addresses for the loom computers, and allows the fixed IP addresses to be easily correlated with the loom layout map of the host computer. Thus, for example, an operator who does not have sophisticated knowledge of the network system may easily correlate the fixed IP address of each loom with the loom layout map.

DETAILED DESCRIPTION OF THE EMBODIMENTS

A first embodiment will now be described with reference toFIGS. 1 to 3.FIG. 1shows a monitoring system2that is used in a weaving mill1. In the weaving mill1shown inFIG. 1, for example, a rectangular array of a total of forty looms R01to R40are arranged in five rows with eight looms in each row. A host computer (hereafter referred to as the host PC)3is located in, for example, a central control room of the weaving mill1. A loom computer (hereafter referred to as the loom PC)4is coupled to each of the looms R01to R40. Each loom PC4is configured to control and manage the operation of the corresponding loom. Each of the host PC3and the loom PCs4may include, for example, a central processing unit (CPU), a memory, an input/output unit, and a network interface. The host PC may include a display5(refer toFIG. 2). Each loom PC4may include a display6(refer toFIG. 3).

The host PC3and each loom PC4are wire-connected or wireless-connected to form a network7. A dynamic host configuration protocol (DHCP) server8is arranged in the network7. The DHCP server8is configured to automatically issue temporary IP addresses to the loom PCs4connected to the network7. In the illustrated embodiment, the DHCP server8is a discrete node separate from the host PC3but may be incorporated in the host PC3in other embodiments. In the illustrated embodiment, the network7is a TCP/IP network, and a unique IP address is set for the host PC3.

The host PC3stores and manages fixed IP addresses. The host PC3is configured to assign a single fixed IP address to a single loom PC4upon request. The host PC3is configured to generate and store a loom layout map9(refer toFIG. 2). The loom layout map9shows where the looms R01to R40are located in the weaving mill1on the display5using loom identification numbers (e.g., R01to R40). The host PC3formats the loom layout map9so that it can be shown on the display5. Each of the looms R01to R40may be indicated by a graphical icon provided with the loom identification number on the display5.

A process for assigning a unique IP address to each of the looms R01to R40will now be described. The looms R01to R40are installed in the weaving mill1. When the installation of the looms R01to R40is completed, an operator pushes a power button (not shown) of one of the looms R01to R40(e.g., loom R01). Each loom PC4is initialized when the corresponding loom is installed in the weaving mill1, and a unique IP address is not set for each loom PC4. Accordingly, when the power goes on, the loom PC4of the loom R01transmits a temporary IP address acquisition request signal to the DHCP server8, automatically acquires a temporary IP address from the DHCP server8, and sets the temporary IP address to the loom PC4of the loom R01. In some embodiments, the loom PC4may be configured to transmit the temporary IP address acquisition request signal when a switch is operated after the power button is pushed. Upon acquisition of the temporary IP address, the loom PC4becomes capable of communicating over the network7. The temporary IP address assigned by the DHCP server8is valid for only a certain time. For example, the temporary IP address acquired by a loom PC4is automatically deleted or invalidated when the power goes off in the corresponding loom.

The loom PC4of the loom R01uses the acquired temporary IP address to communicate with the host PC3over the network7. The loom PC4transmits a fixed IP address assignment request signal. Then, the host PC3assigns and transmits a fixed IP address to the loom PC4of the loom R01, which transmitted the assignment request signal. The loom PC4of the loom R01receives the assigned fixed IP address and registers the fixed IP address. The temporary IP address set for the loom PC4may be replaced by the fixed IP address. The fixed IP address is set to the loom PC4as a unique IP address managed by the host PC3.

In the same manner as the loom PC4of the loom R01, the loom PC4of each of the looms R02to R40acquires a temporary IP address from the DHCP server8when the corresponding power button is pushed. Further, the loom PC4of each of the looms R02to R40acquires a fixed IP address from the host PC using the temporary IP address. Then, the loom PC4registers the fixed IP address.

The host PC3stores a loom layout map9, which is generated in advance. After the host PC3completes the assignment of the fixed IP addresses to the loom PC4of every one of the looms R01to R40, in response to a mode shifting operation performed by the operator, the host PC3shifts to a correlating mode to correlate the fixed IP address of each loom PC4with the loom layout map9. The host PC requests each loom PC4that transmitted a fixed IP address assignment request signal to transmit a fixed IP address acquisition completion signal. In a certain embodiment, the host PC3requests the acquisition completion signal to be transmitted from the loom PCs4of the looms R01to R40in an order designated by the loom layout map9, for example, in an order starting from the loom R01and proceeding in the order of the loom R02, the loom R03, and so on until reaching the loom R40.

Based on the shift to the correlating mode of the host PC3and a request for transmitting a fixed IP address acquisition completion signal provided from the host PC3to the loom PCs4of the looms R01to R40, a screen image11including an acquisition completion switch10illustrated inFIG. 3is simultaneously shown on the displays6of the loom PCs4of the looms R01to R40. A designated transmission order for the acquisition completion signals of the fixed IP addresses may be indicated on a printout of the loom layout map9obtained from the host PC3or be indicated in the loom layout map9that is shown on a tablet terminal.

In accordance with the designated order shown on the loom layout map9, the operator operates the acquisition completion switch10, which is shown on the display6of each of the looms R01to R40in the weaving mill1. For example, when the operator operates the acquisition completion switch10in the screen image11shown on the display6of the loom R01that is first designated, the loom PC4of the loom R01communicates using the fixed IP address set for the loom R01and transmits an acquisition completion signal to the host PC3.

The host PC3receives the acquisition completion signal from the loom R01and correlates the fixed IP address of the loom R01with the loom R01in the loom layout map9shown inFIG. 2. Then, the host PC stores the fixed IP address. In the same manner, upon receipt of the acquisition completion signal from each of the looms R02to R40in accordance with the designated order, the host PC3correlates the fixed IP addresses of the looms R02to R40with the looms R01to R40in the loom layout map9and stores the fixed IP addresses. The process correlating the fixed IP addresses of the looms R01to R40with the loom layout map9allows the host PC3to control the looms R01to R40and manage operation data of the looms R01to R40.

In some embodiments, the host PC3may store a layout-address table that correlates the fixed IP addresses of the looms R01to R40that transmitted the acquisition completion signal with the corresponding looms R01to R40(identification numbers and/or graphical icons) in the loom layout map9.

When completing the process correlating the fixed IP addresses of the looms R01to R40with the loom layout map9, the operator shifts the host PC3to a correlation test mode to test whether or not the correlating process was correctly performed. In the correlation test, when the operator sequentially designates the looms R01to R40in the loom layout map9, the host PC3transmits a test signal to the corresponding loom PCs4. The test signal includes an instruction that instructs each of the looms R01to R40, which received the test signal, to continuously illuminate a tower lamp as an affirmative response indication. For example, when the operator designates the loom R01in the loom layout map9and the tower lamp of the corresponding loom R01is continuously illuminated, the operator can determine that the fixed IP address of the loom R01was correctly correlated with the loom layout map9. The affirmative response indication of the looms R01to R40is not restricted to the continuous illumination of the tower lamp and may be intermittent illumination of the tower lamp, continuous illumination of the tower lamp in a certain color, a graphic indication on the display6of the loom PC4, or a combination of these indications.

In the first embodiment, the operator can set the fixed IP addresses of the looms R01to R40and correlate the fixed IP addresses with the loom layout map9in the host PC3without directly or manually inputting the IP addresses.

In a certain embodiment, after correlating fixed IP addresses with the loom layout map9, the host PC3is configured to receive an input designating a single loom (e.g., R01) in the loom layout map9and, in response to the input, transmit a test signal to the corresponding loom PC4of the designated loom (e.g., R01). The test signal includes an instruction that instructs the loom (e.g., R01) that received the test signal to generate an affirmative response indication (continuous lamp illumination). In this configuration, the operator may designate a loom (e.g., R01) in the loom layout map9to determine whether the loom (e.g., identification number and/or graphical icon) in the loom layout map9shown on the host PC3has been correctly correlated with a loom actually installed in the weaving mill1.

In a certain embodiment, when requested for the transmission of the acquisition completion signal by the host PC3, each loom PC4shows the acquisition completion switch10on the display6. In this configuration, when correlating the looms R01to R40in the weaving mill1with the loom layout map9of the host PC3, the acquisition completion switch10is shown on each loom PC4. This allows the operator to easily find the acquisition completion switch10.

In a certain embodiment, when assignment of the fixed IP address to the loom layout map9has not been completed in a loom (e.g., R01), the loom PC4of the loom R01or the host PC3is configured to indicate that assignment has not been completed for the loom R01. In this configuration, the operator can visually recognize the presence of a loom of which the fixed IP address has not been correlated with the loom layout map9. This prompts the operator to complete the correlation process.

A second embodiment will now be described with reference toFIG. 4focusing on differences from the first embodiment.

The looms R01to R40are installed and operated in the weaving mill1. However, some of the looms R01to R40may be replaced. Further, the control board of a loom PC4may be replaced. For example, when the loom PC4of the loom R07becomes defective, the control board of the loom PC4may be replaced. Alternatively, the loom R07may be replaced by a new loom. In such cases, the loom R07would not have a fixed IP address that is managed by the host PC3. Thus, the loom R07cannot communicate with the host PC3.

The second embodiment is directed to a system configured to facilitate the setting of the fixed IP address and the process for correlating the fixed IP address with the loom layout map9when any one of the looms R01to R40is changed. The second embodiment will be described using the loom R07(refer toFIG. 1) in the weaving mill1that is correlated with the loom R07in the loom layout map9shown inFIG. 4. The loom R07may be referred to as a correlated subject loom.

When the loom R07stops operating and the power is cut off, the control board of the loom PC4is replaced by a new control board or the loom R07is replaced by a new loom. In any of these cases, the loom PC4does not have a fixed IP address. If the new loom was operated in another mill, the loom PC4of the new loom may have an IP address used for communication in the other mill. In this case, the IP address is deleted.

The host PC3shows the loom layout map9on the display5, shifts to the correlating mode, and marks the loom R07on the loom layout map9by coloring or intermittently illuminating the loom R07to indicate the correlated subject loom. In the loom R07, the power button (not shown) is pushed to activate the loom PC4and a temporary IP address is acquired from the DHCP server8through the same procedures as the first embodiment. Then, the temporary ID address is used to transmit a fixed IP address assignment request signal to the host PC3. The host PC3receives the assignment request signal, assigns a fixed IP address managed by the host PC3to the loom R07, and transmits the fixed IP address to the loom PC4.

The loom PC4of the loom R07registers and sets the acquired fixed IP address in lieu of the temporary IP address. Then, the fixed IP address acquisition completion switch10is shown on the display6of the loom PC4of the correlated subject loom. For example, among a plurality of switches of the loom PC4, the acquisition completion switch10may be shown solely emphasized on the display6. Alternatively, only the acquisition completion switch10may be selectively shown on the display6. When the operator operates the acquisition completion switch10, the loom PC4transmits an acquisition completion signal to the host PC3. The loom R07is marked on the loom layout map9of the host PC3, and the host PC3is waiting for the acquisition completion signal from the loom R07. Upon receipt of the acquisition completion signal, the host PC3correlates the fixed IP address of the loom R07that transmitted the acquisition completion signal with the loom R07in the loom layout map9and stores the fixed IP address.

When the process for correlating the fixed IP address is completed, the host PC3cancels the marking of the loom R07in the loom layout map9. It is preferred that when, for one reason or another, the loom R07cannot complete the acquisition of the fixed IP address or correlate the fixed IP address with the loom layout map9, the host PC3keeps the loom R07marked in the loom layout map9and indicates on the display6of the loom PC4of the loom R07that the correlation has not been completed.

In the second embodiment, when one or more of the looms R01to R40is changed from the status quo, a fixed IP address is acquired only for the changed loom, and the fixed IP address is correlated with the loom layout map9. This facilitates the task for setting the fixed IP address. The operator, for example, performs operations related to only the changed loom but does not perform any operation on looms that remain unchanged. This allows the operator to complete the task for setting the fixed IP address within a short period of time.

(1) In the first embodiment, when one of the looms R01to R40, for example, the loom R10is replaced with another loom or the loom PC4of the loom R10is initiated, the correlation of the fixed IP address of the loom R10and the loom layout map9is cancelled or invalidated. This disables the management of the loom R10with the host PC3. In such a case, it is preferred that the display6of the loom PC4of the loom R10or the loom layout map9of the host PC3indicates that the correlation of the loom R10and the loom layout map9is incomplete.

(2) In the second embodiment, the task for selecting and marking the changed loom in the loom layout map9does not have to be performed on the display5of the host PC3and may be performed using a tablet terminal or the display5of the loom PC4of a loom adjacent to the changed loom. This would improve convenience since settings such as the correlating process may be performed near the changed loom.