Patent Abstract:
A control system for a group of fiber processing machines includes a superordinated control console; and separate machine-specific control consoles connected to each respective fiber processing machine. The superordinated control console and the machine-specific control consoles are connected to one another by control and regulating devices via a network. The superordinated control console includes a stationary unit having arrangements for supplying current, for communicating with said network, for storing and administering data, and a computer. The superordinated control console further includes a mobile unit having an operating and displaying unit.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of application Ser. No. 09/986,203 filed Nov. 7, 2001. 
    
    
     This application claims the priority of German Application No. 100 55 026.6 filed Nov. 7, 2000, which is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     This invention relates to a system and a method for controlling a group of fiber processing machines, such as carding machines and/or draw frames. The system has at least one superordinated control console, and each machine has a machine-specific control console. All control consoles are connected with one another by control and regulating devices (computers) via a network. 
     In practice, up-to-date textile machines have high- performance controls, by means of which a plurality of functions may be performed and controlled. This applies particularly to the machine control by operating personnel. Such a control has become increasingly more complex and more difficult to overview and to manipulate because of the increasing number of choices as concerns input and setting. Also, more and more information, data and details are available which have to be prepared and made visible for the operating or maintenance personnel. To meet these requirements, complex and expensive control consoles or visual indicating devices are being used. Such devices are computers with monitor screens, keyboards and/or touch screens. It is a significant disadvantage of such an arrangement that the equipment is, as a rule, very expensive. The expenses are often several times the cost of conventional equipment and such a cost applies to each and every machine. Particularly high costs are encountered in case a large number of machines are used which may be desirable from a technological or manufacturing point of view. In addition, the numerous functions of these devices are, as a rule, utilized only relatively rarely, that is, only in certain situations. 
     International patent document WO 92/13121, to which corresponds U.S. Pat. No. 5,517,404, describes a process control system which has a master computer and a network having a computer of a machine control arrangement of, for example, a pre-yarn transport system. Each computer has a dedicated memory and drive. The drivers determine the necessary interfaces for the communication of the computers with their user interfaces, designated as display devices, controls and printers. The system is programmed and configured in such a manner that the master computer may perform machine control support via the user interface of the respective machine; that is, the master computer may send control commands over the network and the machine controls may receive and obey such control commands so that the condition of the user interface is determined by the master computer via the respective control. Such a system is very complex and expensive. It is a particular drawback that the operation of the machines is controlled from the master computer. The disadvantage resides in the manipulation of complex control consoles for merely a few desired inputs for the manufacturing operation of the respective individual machines, such as on and off switching, coiler can replacement, and indicator displays. 
     SUMMARY OF THE INVENTION 
     It is an object of the invention to provide an improved system and method of the above-outlined type, from which the discussed disadvantages are eliminated and which is structurally significantly simpler and further ensures a simplified machine control and display for the personnel. 
     This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the control system for a group of fiber processing machines includes a superordinated control console; and separate machine-specific control consoles connected to each respective fiber processing machine. The superordinated control console and the machine-specific control consoles are connected to one another by control and regulating devices via a network. The superordinated control console includes a stationary unit having arrangements for supplying current, for communicating with said network, for storing and administering data, and a computer. The superordinated control console further includes a mobile unit having an operating and displaying unit. 
     The measures according to the invention provide for a significant system-wise simplification as well as a simplified machine control and display. Particularly from the technological point of view it is feasible to perform certain setting and parametering steps directly at the machine, combined with complex numeric or graphical indications which go beyond the purely production-specific machine handling. For an effective and economical realization the central control console is a two-part construction. The first part is stationary and essentially contains a current supply, a system for communicating with the network, a data storage and administrating system as well as a computer. On the other hand, the control and indicating part is constructed such that it is separate from the stationary part and may be used as a mobile terminal. Thus, all the machines are adapted, on the one hand, to mechanically receive the mobile control and indicating part of the central control console at a suitable location and, on the other hand, to couple the mobile part electrically with the machine computer which is also connected to the stationary part of the central control console via the available network. No significant handling difficulties appear by virtue of the possibility of performing, when needed, all machine settings, parameter settings and inquiries with corresponding graphical support which are directly required at the machine. This is particularly so, because, as a rule, these tasks are performed as deliberate steps, and occur relatively seldom in normal operation. Also, it is almost impossible that they are performed simultaneously at several machines. It is a further advantage that because of the reduced number of more complex structural groups, the risk of outage as well as the required spare part acquisition are significantly diminished. Overall, the system according to the invention makes possible a practical and cost-effective solution without the need of taking into account substantial technical or technological limitations. Also, it is almost impossible that they are performed simultaneously at several machines. It is a further advantage that because of the reduced number of more complex structural groups, the risk of outage as well as the required spare part acquisition are significantly diminished. Overall, the system according to the invention makes possible a practical and cost-effective solution without the need of taking into account substantial technical or technological limitations. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a schematic perspective view of a system composed of eight carding machines and three draw frames which are connected by a data network with a central handling and displaying apparatus (central control console). 
     FIG. 2 is a schematic view of a system formed of four carding machines each having a machine-specific control console which are connected with the central control console by a data network. 
     FIG. 3 is a diagram showing the several control and display functions assigned to the control consoles. 
     FIG. 4 is a diagram showing the central control console, having a stationary and a mobile part. 
     FIG. 5 a  is a diagram illustrating the several control and display functions assigned to the control consoles, and a mobile terminal coupled to the stationary part of the superordinated control console. 
     FIG. 5 b  is a diagram illustrating the several control and display functions assigned to the control consoles, and a mobile terminal coupled to a machine control apparatus. 
     FIG. 6 is a diagram illustrating the connection of a modem to the central control console and the connection with a mobile telephone equipment via a wireless station. 
     FIG. 7 is a schematic side elevational view of a carding machine with a block diagram for controlling and regulating the carding machine. 
     FIG. 8 is a schematic side elevational view of a draw frame with block diagram for controlling and regulating the draw frame. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     FIG. 1 shows a spinning preparation system composed of eight carding machines  1   a - 1   h  and three draw frames  2   a ,  2   b  and  2   c . The carding machines  1   a - 1   h  are connected by a data network  3  to a superordinated control console  4  which comprises, among others, a monitor screen  5  and a keyboard  6  and may further include a printer  7 . The carding machines may be high-production DK 903 models, the draw frames may be high-production HSR 1000 models and the data network may be a TEXNET model, all manufactured by Trutzschler GmbH &amp; Co. KG, Monchengladbach, Germany. 
     As shown in FIG. 2, four carding machines  1   a - 1   d  are each connected with a respective, machine-specific control console  8   a - 8   d , each having a respective keyboard  9   a - 9   d  and a monitor screen  10   a - 10   d . Each control console  8   a - 8   d  is connected with a respective electronic machine control and regulating device  11   a - 11   d , for example, a microcomputer. 
     As illustrated in FIGS. 1 and 2, all the carding machines and draw frames of the system are connected with a communication network  3  and can exchange data with one another or with other devices. The central control console  4  has a monitor screen  5 , a touch screen, a keyboard  6  as well as capabilities to store data in large quantities over a long period of time. Based on this arrangement, it is feasible to centrally perform all complex machine-setting, parameter-setting and inputting steps. In addition, numerous data of the individual machines may be displayed, visualized, stored, exchanged and monitored. 
     Each machine (such as the cards  1   a - 1   d  according to FIG. 2) has a relatively simple and inexpensive respective terminal  9   a - 9   d , by means of which only those inputting steps are performed which are necessary for the normal manufacturing operation. Likewise, the displays  10   a - 10   d  belonging to the respective terminals  9   a - 9   d  cover only such a working field. According to FIG. 3, a clear division is effected between a first group composed of control and display pertaining to the normal manufacturing operation and a second group required for the machine-setting, parameter-setting, and visualizing steps as well as error detection. The first group is exclusively feasible via the respective, machine-specific control consoles  8   a - 8   d  (simple machine terminals  9   a - 9   d ), while the second group is possible only by means of the elements of the central control console  4  which is shown as a one-part, stationary apparatus. 
     Thus, for example, as concerns the three draw frames  2   a ,  2   b  and  2   c , the following division of control and display functions between the superordinated control console  4  and the machine-specific control consoles  31  (only one shown in FIG. 8) may be effected: 
     Only the following data are indicated at the display apparatus  5  of the central control console  4 : as operating data: the initial tensions, the useful effect and the standstill periods; in connection with the quality of the drafting limits: the sliver fineness limits, the thickened portions in the sliver, spectrograms, coiler can-related quality data; in connection with monitoring: regulating parameters, drafting limits, sliver fineness limits, thickened locations in the sliver, CV values and electronic functions. 
     Only at the display devices  33  of the machine-specific control consoles  31  the following are shown: start/stop, error acknowledgement, coiler can replacement. 
     At the display device  5  of the central control console  4  and at the display devices  33  of the machine-specific control consoles  31  the following are shown: in connection with the operational data: delivery speed, production, drafts, rpm&#39;s, reasons for standstill; in connection with quality: CV values; and in connection with monitoring: safety devices. 
     The following are inputted only at the inputting device  6  of the central control console  4 : draft, delivery speed, sliver fineness and quality limit values. 
     The following are inputted only at the inputting devices  32  (only one shown in FIG. 8) of the machine-specific control consoles  31 : start/stop, coiler can replacement. 
     Because of technological reasons, certain machine-setting and parameter-setting steps must be combined with complex numeric or graphic indications which stem from the purely production-specific control and must be performed directly at the machine. For an effective and economical solution of this task, the central control console  4  is constructed in two parts as shown in FIG.  4 . The first part  4   a  is stationary and contains mainly a current supply  12 , the device  13  maintaining communication with the network  3 , the memory  14 , data administration as well as a computer  15 . The control and display portion  4   b  is a mobile terminal separated from the stationary part  4   a . Thus, all the machines have the possibility, on the one hand, to receive mechanically at a suitable location the mobile control and display part  4   b  of the central control console  4  and, on the other hand, to couple the mobile part  4   b  electrically with the machine computers  11   a - 11   d  (FIG.  2 ),  11  (FIG.  7 ),  30  (FIG. 8) which are also connected with the stationary part  4   a  of the central control console  4  via the network  3 . 
     As shown in FIG. 5 a , the “not production-specific control” is performed by the superordinated control console  4 , but, in contrast to FIG. 4, in such a manner that the mobile terminal  4   b , disconnected from the stationary part  4   a , is associated with one of the machines. 
     FIG. 5 b  shows an embodiment in which a mobile terminal  4   b  is associated with a machine and takes care of the “not production-specific control” via a high performance machine computer  11 . 
     The above-outlined arrangements result in the following advantages: 
     a. Each machine disposes of all devices, but only of such devices, which are necessary for a “normal” production-specific machine control. The control console  8  required for this purpose may be relatively simple and economical. 
     b. The machine control is optimally coordinated with the machine operator and his/her tasks based on the display  10  and the overall control. In particular, the displays and information should be available independently from language, if possible, and only those keys should be available which are required for the respective control step. 
     c. At the superordinated control console  4  (central station) predetermined settings may be done effectively and in a simple manner. This applies, for example, to the inputting of the same preliminary data for several machines (machine group), to a take-over of parameters and settings from the machines, to a comparison of data and results, etc. By virtue of the fact that the control console  4 , as a rule, may be used for a large number of machines, the technical outlay may be overall somewhat higher and may be optimally adapted to requirements. 
     d. By virtue of the possibility to nevertheless perform, if necessary, all machine-settings, parameter-settings and data recall required directly at the machine, with the aid of the mobile terminal  4   b  together with a corresponding graphic support, no appreciable disadvantages in the control are experienced. This is particularly so, because, as a rule, these tasks are performed deliberately and occur relatively seldom as related to the “normal operation”. Further, it is almost impossible that these tasks are performed simultaneously at several machines. 
     e. By virtue of the small number of utilized complex structural groups, the risk of outage as well as the required spare part acquisition are significantly reduced. 
     f. Overall, by virtue of the system according to the invention, a practical and substantially cost-optimal solution is found without significant technical or technological limitations. 
     g. If very large manufacturing systems are required or are present, more than one mobile control console  4   a  may be used; in an extreme situation a separate one may be used for every machine. 
     h. The central control console  4  is a personal computer for industrial use, having a mobile control component. In this manner it is possible to perform all tasks for which corresponding devices and special instruments are required, such as, for example, the parameter-setting of digital driving components. 
     i. The control console  4  is further connected via a suitable device, such as a modem  16  (FIG. 6) with a telephone or other communication network  17  to make it possible to call for external information concerning the machines or to transfer data thereto (telephone service for problem searching, technical support, updates, and the like). 
     j. With an appropriately equipped central station  4  and/or the computers  11 ,  11   a - 11   d  and  30  it is possible, for example, to effect via the Internet a direct access to the machine control or assistance, or to gain access to externally stored drawings, graphs, and the like. It is advantageous to make available, maintain and store such information centrally, and then make them available for worldwide locations. 
     k. The central control console  4  is constructed such that it is capable of transmitting reports via the ordinary telephone network  17  or other communication networks to one or several arbitrarily designated communication devices in case of errors or other problems. As shown in FIG. 6, this applies particularly in case of handheld remote controls  18  (for example, by means of SMS), with which the maintenance personnel may be equipped for being contacted under predefined conditions via a transmitter  19 . Thus, such an arrangement may also assume the function of an automatic personal paging system. A transmitter station is designated at  19 . 
     l. In addition, the central control console  4  may control one or more signaling lamps or acoustic signaling devices. In case of a malfunction, the signal transmitters acoustically or visibly may indicate the existence of a problem and alert the maintenance personnel. A plant plan on the monitor of the central control console  4  or its mobile terminal  4   b  may point to the particular machine which experiences difficulties. 
     m. The central control console  4  may also be coupled to further networks to thus provide the possibility to establish communication with additional desired machines and devices. 
     n. To avoid an unnecessary burdening of the machine computer, the machine controls  11 ,  11   a - 11   d  and  30  may be designed such that the mobile terminal  4   b  has, when in use at the machine, a direct connection with the network which interconnects the machines. 
     o. The mobile part  4   b  of the central handling and indicating station  4  is coupled with the stationary part  4   a  by means of a serial communication (for example, CANopen, Ethernet, and the like). In this manner, it may also be coupled to the individual machine controls  11 ,  11   a - 11   d  and  30 . 
     p. The mobile terminal  4   b  as well as the input at the machines are designed such that upon coupling the mobile terminal to the machine, the required electric connections are automatically established (for example, by means of a special, integrated plug-in unit). 
     q. The mobile terminal  4   b  is designed such that it has all the usual attributes of a personal computer for industrial use. 
     r. The control console  4  and the mobile terminals  4   b  communicate with one another by wireless or by infrared transmission. As a result, the terminal may be used even without a direct electrical connection practically at any desired location of the plant. 
     s. The standard machine terminal  8  (which is stationary at each machine) provides for the possibility for an operator to summon maintenance personnel (for example, by the handheld control unit  18 ) from this position, via the central control console  4  and its connection to the telephone network  17 . 
     t. It is of particular advantage to provide that the central control console  4  and the machines connected via the network  3  have approximately the same hardware conditions and the used operating system is the same. In this manner a very simple and problem-free data exchange may be ensured. 
     FIG. 7 illustrates a carding machine  1  having a feed roller  20  connected to an electronic tachogenerator  21  as measured value receiver. The tachogenerator  21  is connected to an analog-digital converter  22  which, in turn, is coupled with an electronic control device  11  (microcomputer) including a microprocessor with memory. The analog/digital converter  22  is controlled by the microcomputer  11  coupled to a nominal value inputter  23 . The microcomputer  11  is further connected to a first digital/analog power converter  24  connected with a regulating motor  25  which drives the feed roller  20 . The carding machine  1  further has a doffer  29  coupled to an electric tachogenerator  26  which functions as a measured value receiver and which is connected with the analog/digital converter  22  coupled to the microcomputer  11 . The latter is also connected to a second digital/analog power converter  27  coupled to a regulating motor  28  driving the doffer  29 . In operation the rpm signals of the feed roller  20  and the doffer  29  are converted into analog electric signals by the tachogenerators  21  and  26 , respectively. These analog signals are converted into digital electric signals by the analog/digital converter  22  and constitute the input signals in the microcomputer  11 . The microprocessor of the microcomputer  11  forms digital electric output signals from the input signals and the stored program data. These digital signals are reconverted into analog electric signals by the successive digital/analog power converters  24  and  27 , respectively, and are applied thereafter to the regulating motors  25  and  28 . The inputting device  9  and the monitor  10 , comprised in the machine-specific control console  8  (FIG.  2 ), are connected to the electronic machine control and regulating device  11 . One of the functions of the inputting device  9  is to switch the carding machine  1  on and off. The control console  8  of the carding machine  1  is connected by the data cable  3  to the central control console  4 . 
     FIG. 8 schematically shows a draw frame  2  in which the slivers  35  are withdrawn from non-illustrated coiler cans and enter a sliver guide  36  and pass by a measuring member  39  as they are pulled by calender rolls  37 ,  38  in the working direction A. The draw unit of the draw frame  2  is a 4-over-3 construction, that is, it has a lower output roll I, a lower mid roll II and a lower input roll III as well as four upper rolls  40 ,  41 ,  42  and  43 . In the draw unit a drafting of the slivers is taking place, and the drafted slivers are introduced at the outlet of the draw unit into a sliver guide  44  and are, by means of calender rolls  45  and  46 , pulled through a sliver trumpet  47  in which the slivers are combined into a single sliver  48  which is subsequently deposited into a non-illustrated coiler can. 
     The calender rolls  37 ,  38 , the lower input roll III and the lower mid roll II which are mechanically coupled to one another, for example, by means of a tooth belt, are driven by a regulating motor  49  as a function of an inputted nominal (desired) value. The upper rolls  40  and  41  are driven by friction from the respective lower rolls. The lower output roll I and the calender rolls  45 ,  46  are driven by a principal motor SO. The regulating motor  49  and the principal motor  50  have a respective regulator  51  and  52 . The rpm regulation is effected by a closed regulating circuit in which the regulator  51  is connected with a tachogenerator  53  and the principal motor  50  is connected with a tachogenerator  54 . At the inlet of the draw unit a mass-proportionate magnitude, for example, the cross section of the slivers  35  is sensed by the measuring organ  39 . At the outlet of the draw unit the cross section of the exiting sliver is obtained by a measuring organ  55  integrated in the sliver trumpet  47 . A central control and regulating device  30  such as a microcomputer with a microprocessor transmits to the regulator  51  a setting of the desired magnitude for the regulating motor  49 . The measured magnitudes of the two measuring organs  39  and  55  are, during the sliver drafting step, applied to the central computer unit  30 . From the measured magnitude of the inlet measuring organ  39  and from the desired value for the cross section of the discharged sliver, the desired value for the regulating motor  49  is determined in the central computer  30 . The measured magnitudes sensed by the outlet measuring organ  55  serve for monitoring the outputted sliver. By means of this regulating system fluctuations in the cross section of the slivers  35  may be compensated for by a suitable regulation of the drafting process, that is, an evening of the sliver may be achieved. A machine-specific control console  31  which encompasses an inputting device  32  and a monitor screen  33  is connected to the electronic machine control and regulating device  30 . One of the functions of the inputting device  32  is to switch the draw frame  2  on and off. The machine-specific control console  31  of the draw frame  2  is connected to the central control console  4  by means of the data cable  3 . 
     The invention was described in an exemplary manner in connection with a system formed of carding machines  1  and/or draw frames  2 . It is to be understood that the invention may be utilized in a system formed of other spinning room machines, for example, flyers, spinning machines, spooling frames and the like. 
     The term “superordinated” characterizing the central control console  4  encompasses a functional super-ordination such that the central functions (FIGS. 3,  5   a ,  5   b ) of the superordinated (central) control console  4  for the plurality of associated machines  1 ,  2 ,  1   a - 1   h  and  2   a - 2   c  are the same. The term “superordinated” for central control console  4  further encompasses a structural super-ordination such that only one control console  4  or only one mobile control console  4   b  is present for the plurality of associated machines  1 ,  2 ,  1   a - 1   h  and  2   a - 2   c . In this arrangement, the mobile control console  4   b  cooperates either with the stationary control console  4   a  (and its computer unit  15 ) or with the electronic machine control and regulating apparatus  11 ,  11   a - 11   d  and  30  of a machine  1 ,  2 ,  1   a - 1   h  and  2   a - 2   c.    
     It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.

Technology Classification (CPC): 3