WO2017081605A1

WO2017081605A1 - System for monitoring operating parameters of components of a weaving loom

Info

Publication number: WO2017081605A1
Application number: PCT/IB2016/056714
Authority: WO
Inventors: Cristian LOCATELLI
Original assignee: Camozzi Digital S.R.L.
Priority date: 2015-11-12
Filing date: 2016-11-08
Publication date: 2017-05-18
Also published as: JP6931348B2; CN108291338B; ITUB20155502A1; JP2018537597A; CN108291338A

Abstract

A comprehensive monitoring system for weaving looms comprises a local monitoring system (400), placed in a weaving mill (500), associated with a respective loom (1), main transmission means (670) connected with the local monitoring system (400), main storage means located remotely with respect to the weaving mill (500), and main processing means located remotely with respect to the weaving mill (500), suitable to process a high volume of parameters to identify a deviation of the operation of the loom (1) from a reference operation.

Description

"System for monitoring operating parameters of components of a weaving loom"

DESCRIPTION

[0001] The present invention relates to a system for monitoring operating parameters of components of a weaving loom.

[0002] As is known, it is essential for a machine of high cost, such as a weaving loom, to work continuously without interruptions due to failures, for the investment to be worthwhile .

[0003] However, the repairs needed to restore the operation of a loom often entail production downtime for a period which varies depending on the extent of the failure and intervention times.

[0004] It is therefore extremely important to intervene on the machine in time, performing scheduled maintenance or maintenance piloted by the monitoring system, before a breakage or a failure occurs. This approach to maintenance management is known as "predictive maintenance".

[0005] To effectively implement a predictive maintenance system is however extremely complex because the predictions of breakage or failure, on the basis of which to perform intervention, may be relied upon only if based on the lessons learned from a large number of cases, that is, by a large number of machines, a large number of working hours and a large archive of application and operating conditions.

[0006] The purpose of the present invention is to provide a reliable system for monitoring the operating parameters of components of a weaving loom so as to detect in time deviations of machine operation from nominal optimal operation .

[0007] Such purpose is achieved by a system made according to claim 1 below.

[0008] The characteristics and advantages of the monitoring device according to the present invention will be evident from the description given below, by way of a non-limiting example, according to the appended drawings, wherein: - figure 1 illustrates schematically some components of a weaving loom to which a local monitoring system is applied according to the present invention;

figure 2 shows a diagram of an air transfer mechanism of the weft;

- figure 3 shows a diagram of a projectile transfer mechanism of the weft;

figure 4 shows a diagram of a pincer transfer mechanism of the weft;

figure 5 shows a diagram of a support structure of the weaving loom;

figure 6 illustrates a local monitoring system according to one embodiment of the present invention; figure 7 illustrates a comprehensive system according to the present invention.

[0009] A loom 1 is installed in a weaving mill 500. The term "weaving mill" means the industrial plant where processing takes place, consisting of the sequence of operations required to transform yarns into fabric. Preferably a plurality of looms 1 are installed in the weaving mill.

[0010] The loom 1 comprises an unwinder roller 2, which bears a beam 4 consisting of a winding of yarn destined to form the warp 6 of a fabric 8 and an unwinder roller electric motor 10 connected to the unwinder roller 2 to place it in rotation upon command.

[0011] A local monitoring system 400 according to the invention comprises, preferably, a temperature sensor 12 operatively coupled to the unwinder roller motor 10 to measure the temperature T10 of the motor; in addition, for the unwinder roller motor 10 at least one status parameter is available, such as the value of the current absorbed 110.

[0012] In addition, the unwinder roller 2 is supported in rotation by unwinder roller bearings and the local monitoring system 400 comprises a temperature sensor 13 for detecting the temperature T2 of said bearings.

[0013] The local monitoring system 400 further comprises a load cell 15 for measuring the tension S2 of the warp yarns being unwound from the unwinder roller 2.

[0014] In addition, the loom 1 comprises a backrest roll 14 on which the warp yarn 6 passes to be properly diverted, drop wire stops 16 to detect rupture of the warp, shafts 18 provided with heddles and a reed 20 moved by a fold 22.

[0015] Downstream of the reed 20, transverse to the direction of advancement of the warp yarn 6, a weft yarn 50 is inserted which goes to make the weave of the fabric 8.

[0016] The fold 22, with a reciprocating rotary motion, is driven by a fold shaft, typically by means of a conversion mechanism suitable to transform a continuous rotary motion in said reciprocating rotary motion (for example, a connecting rod-crank mechanism or a cam mechanism) .

[0017] The fold shaft is supported by in rotation by fold shaft bearings and the local monitoring system 400 comprises a temperature sensor 23 for detecting the temperature T22 of said bearings.

[0018] In addition, the loom comprises an electric fold drive shaft 37, operated by means of a current 137, provided with a temperature sensor 39 for measuring the temperature T37 of said motor.

[0019] In addition, preferably, the conversion mechanism is housed in a box in an oil bath and the local monitoring system 400 comprises a temperature sensor for measuring the temperature T25 of the oil in said box.

[0020] The fabric 8 is pulled by a pulling roller 24 placed in rotation by an electric pulling roller motor 26 coupled to a temperature sensor 28 for measuring the temperature T26, absorbing a current that generates a current value 126.

[0021] In addition, the pulling roller 24 is supported in rotation by pulling roller bearings and the local monitoring system 400 comprises a temperature sensor 29 for detecting the temperature T24 of said bearings.

[0022] In addition, the monitoring system comprises a load cell 27 for measuring the tension S24 of the fabric pulled by the pulling cylinder 24.

[0023] By means of a number of return rollers, the fabric 8 is lastly wound on a beam 30 placed on a winder roller 32, placed in rotation by an electric winder roller motor 34. Said motor 34 is coupled to a temperature sensor 36 for measuring the temperature T34 and absorbs a current that generates a current value 134.

[0024] In addition, the winder roller 32 is supported in rotation by winder roller bearings and the local monitoring system 400 comprises a temperature sensor 33 for detecting the temperature T32 of said bearings.

[0025] In addition, the monitoring system comprises a load cell 31 for measuring the tension S32 of the fabric wound on the winder roller 32.

[0026] The loom 1 is further provided with a mechanism for transferring the weft for the insertion of the weft between the warp threads and the transfer from one side to the other of the machine.

[0027] According to a first embodiment (figure 2) the transfer mechanism of the weft is an air jet.

[0028] According to this embodiment, the weft is transported from one side to the other of the warp using a flow of compressed air that crosses a channel made transversally in the reed 20.

[0029] The air is blown both from a main nozzle 39, which the weft initially wound on a reel 52 is inserted in, and from a plurality of secondary nozzles 41, called runners, which blow according to specially synchronised sequences and times.

[0030] The nozzles 39, 41 are fed with pressurised air via solenoid valves connected to a tank of pressurised air.

[0031] Preferably, the local monitoring system 400 comprises a pressure transducer 40 coupled to said tank of pressurised air to measure the pressure value p40 in said tank .

[0032] According to a further embodiment, the transfer mechanism of the weft is a jet of water.

[0033] According to this embodiment, the transportation of the weft is via a high pressure water jet issued by a nozzle .

[0034] According to yet a further embodiment, the transfer mechanism is called "projectile" (figure 3) .

[0035] According to such embodiment, the weft 50, wound on a reel 52, is fastened to a projectile 54 by means of a pincer placed at the tail of said projectile.

[0036] The transfer mechanism further comprises a mechanical launching device 56 fitted with a torsion bar 58, suitable to free the potential mechanical energy stored in the torsion bar 58 towards the projectile 54, launching it from the side of the reel 52 to the other side of the machine, going along a path formed of aligned hooks 60.

[0037] The torsion bar 58, fixed at one end, is supported in rotation by bar bearings and the local monitoring system 400 comprises a temperature sensor 62 for measuring the temperature T58 of said bearings.

[0038] In addition, the torsion bar 58, at the opposite end to the fixed end, is rotationally engaged with a bar load shaft, typically by means of a toothed groove, in turn moved in rotation to twist the bar 58 by means of a toggle and cam mechanism.

[0039] The load shaft bar is supported in rotation by load shaft bearings and the local monitoring system 400 comprises a temperature sensor 64 for measuring the temperature T64 of said bearings.

[0040] In addition, the toggle and cam mechanism comprises an oil damper and the local monitoring system 400 provides a temperature sensor 66 for measuring the temperature T66 said oil damper.

[0041] The transfer mechanism further comprises a braking device 62 placed on the other side of the machine to engage and brake the projectile, and a return mechanism, such as a chain, to bring the projectiles 54 back to the side of the reel.

[0042] According to yet a further embodiment, the transfer mechanism is a pincer mechanism (figure 4) .

[0043] In this embodiment, the weft 50, wound in the reel 52, is coupled by clamps of a first pincer 70, moved by a conveyor 72 to the centre of the loom 1. A second pincer 74, coming from the opposite side moves to the centre of the loom, moved by a second conveyor 76, takes the weft carried by the first pincer 70 and brings it to the opposite side, completing the insertion.

[0044] The conveyors 72, 76 are moved by a respective cogwheel 78, called dentarella , set on a dentarella shaft, supported in rotation by dentarella bearings. The local monitoring system 400 comprises a temperature sensor 80 for measuring the temperature T78 of said bearings.

[0045] According to a first variation of such embodiment, the transfer system is a negative pincer system i.e. the passage of the weft between the pincers is not positively controlled but the second pincer co-penetrates the first pincer and unhooks the end of the weft from the first pincer .

[0046] According to a further variation of such embodiment, the transfer system is a "positive pincer" system i.e. the passage of the weft from the first pincer to the second pincer occurs through the controlled opening and closing of the clamps.

[0047] The loom 1 further comprises a lubrication system with oil under pressure, comprising an oil pump, an oil tank and a distribution circuit for the lubrication of the key components, such as those mentioned above.

[0048] The local monitoring system 400 comprises a temperature sensor 90 for measuring the temperature T90 of the lubrication oil.

[0049] Moreover, the local monitoring system 400 comprises a pressure transducer 92 for measuring the pressure value P92 of the oil in the oil distribution circuit.

[0050] According to a preferred embodiment of the present invention, the loom 1 comprises a dobby for controlling the raising of the shafts according to a predetermined pattern. Said dobby is moved by a dobby shaft supported in rotation by bearings. The local monitoring system 400 comprises a temperature sensor 97 for measuring the temperature T97 of said bearings.

[0051] In addition, the loom 1 comprises an electric dobby motor 81 to move the dobby shaft. The local monitoring system 400 comprises a temperature sensor 83 for measuring the temperature T81 of said motor. The dobby motor 81 is powered by a current 181.

[0052] According to a further embodiment, the loom 1 is of the Jacquard type (mechanical or electronic) . In the case of a mechanical jacquard loom, the loom 1 comprises a plurality of hooks for the command of the shafts, moved by a jacquard shaft supported in rotation by bearings. The local monitoring system 400 comprises a temperature sensor 99 for measuring the temperature T99 of said bearings.

[0053] In addition, the loom 1 comprises an electric jacquard motor 85 to move the jacquard shaft. The local monitoring system 400 comprises a temperature sensor 87 for measuring the temperature T85 of said motor. The jacquard motor 85 is powered by a current 185.

[0054] In addition, the loom 1 comprises a support structure 100 (figure 5), which typically comprises a pair of shoulders 102a, 102b, usually made of cast iron, spaced crosswise and suitable to support the machine components.

[0055] The local monitoring system 400 preferably comprises a vibration sensor 104 for measuring the vibrations V100 of the support structure 100.

[0056] Lastly, preferably, the local monitoring system 400 comprises image acquisition means 110, such as a webcam for the capture of images WHO related to the loom as a whole or its organs.

[0057] The loom 1 is also equipped with a local management device 120, for example an electronic card, a PLC or a microprocessor, for the management of the machining, which in itself measures (and possibly stores) loom status data, for example the speed of one or more organs, the absorbed power, current absorbed by the motors, temperature of certain organs, etc.

[0058] The local monitoring system 400 further comprises transmission means 130, for example operating through wireless technology (Wi-Fi type) , suitable to transmit the values of the parameters measured and the status parameters of the loom 1 outside the weaving mill.

[0059] Preferably, the local monitoring system 400 further comprises means of local storage 140, connected with the transmission means 130 and / or with the components of the machine for the storage of the parameters measured and / or with the local management device 120 for storing status parameters .

[0060] Preferably, moreover, the local monitoring system 400 comprises processing and local display means 150, for example comprising a computer, operatively connected with the transmission means 130 and / or with the components of the machine for storing the measured parameters and / or with the local management device 120 and / or the means of local storage 140, for processing the measured parameters and status parameters and displaying the results of the processing .

[0061] According to the invention, a comprehensive monitoring system comprises the local monitoring systems 400 of each loom 1, main means of storage 660 for storing the measured parameters and the status parameters of each loom 1, and main transmission means 670, for example consisting of components for an Internet connection, operatively connected to the transmission means 130 of the local monitoring systems 400.

[0062] The main means of storage 660 are situated in a control room 700 remote with respect to the weaving mills 500.

[0063] Preferably, the information collected locally, and the images possibly captured are transmitted to the main means of storage 660 remotely with continuity over time ( "real time" mode) ; according to further embodiments, such information is transmitted at a predefined frequency, such as daily or weekly (batch mode) ; according to yet a further embodiment, such information is transmitted upon occurrence of a predefined event, such as in the case of machine downtime, or the approach of a planned intervention ("event based" mode) .

[0064] Additionally, the comprehensive monitoring system comprises processing means 680, such as a PC, operatively connected to the Internet and/or main storage means 660, for processing the information from each weaving mill 500.

[0065] Innovatively, the comprehensive monitoring system according to the present invention allows the implementation of efficient maintenance, since, through special calculation algorithms, it warns the operator of a deviation of functioning of the loom from the reference functioning, considered optimal.

[0066] Said comprehensive monitoring system enables the signalling in particular of the need to perform preventive maintenance, as it makes it possible to collect, store and analyse a huge amount of data (Big Data, namely data collection so extensive in terms of volume, speed and variety as to require specific technologies and analytical methods for the extraction of a value) , coming from a large number of machines in one or more weaving mills.

[0067] Advantageously, moreover, the system according to the invention makes it possible to collect and store a large amount of data for very long periods of time, thereby allowing detection of deviation phenomena, or statistical phenomena, which are often symptoms of malfunction or slow deterioration of the operating conditions, usually not recognisable or identifiable.

[0068] According to a further advantageous aspect, the system according to the invention has the ability to collect and store different parameters of a machine, identifying interrelationships among these, for example between speed, power consumption and temperature. In addition, the system makes it possible to analyse the data collected in the frequency domain to identify periodic phenomena on a single parameter or on the result of the aforesaid correlations.

[0069] Analysing the correlation between parameters means, for example, identifying the trend of generic parameters PI and P2 as a function of another generic parameter X and correlating them with each other via a correlation function Φ{Ρ1, P2 (X) (X) } or the trend of a generic parameter PI as a function of time t.

[0070] The architecture thus identified, given the flexibility, the ability to accumulate large amounts of information and data (Big Data) , to develop processing and calculation functions on a single central system which has the historical trends of the operating parameters of the looms enables a progressive and continuous identification, development and evolution of the correlation functions and prediction algorithms.

[0071] For example, the system according to the invention makes it possible to measure, by means of vibration sensors, the vibrations of the support structure of the loom, to perform analysis in the frequency domain and correlate certain frequencies with stopping episodes of the loom (for example due to breakage, technological problems, mechanical failures) . It is thus possible to define which frequencies are related to operating problems and to schedule predictive maintenance operations. [0072] Advantageously, moreover, it is possible to measure the operating and status parameters of the loom in the absence of a fabric being produced, thus defining a condition of empty running, and comparing the reference condition of empty running with empty running in a given moment, detecting any deviations.

[0073] In addition, advantageously, the monitoring system according to the present invention enables an online support service by virtue of the remote detection of anomalous operation, deviation of a quantity or any other abnormality .

[0074] According to a further advantageous aspect, the monitoring system according to the present invention makes it possible to remotely update the machine management software, without the need for local intervention.

[0075] It is clear that a person skilled in the art may make modifications to the monitoring system described above so as to satisfy contingent requirements while remaining within the sphere of protection of the following claims.

Claims

1. Method of identification of malfunctions or degradation of the operation of a weaving loom (1), comprising the steps of:

- providing, in a weaving mill (500), at least one loom (1), a local monitoring system (400) applied to said loom (1) for the collection of operating parameters of the components of the loom and status parameters of the loom, and transmission means (130) for transmitting said parameters;

providing main transmission means (670) operatively connected with the transmission means (130) of the local monitoring system (400);

- providing main storage means (660) located remotely with respect to the weaving mill (500), operatively connected with the main transmission means (670) and suitable to store a high volume of local monitoring system parameters (400) ;

providing main processing means (680), operatively connected with the main transmission means (670) and/or with the main storage means (660) located remotely with respect to the weaving mill (500), suitable to process a high volume of parameters;

-identifying the trend of the general parameters (PI, P2) on the basis of a further general parameter (X) , transforming said trends in the frequency domain and correlating them with each other using a correlation function to identify a deviation of the operation of the loom (1) from a reference operation on the basis of an enormous amount of data (Big Data) .

2. Method of identification of malfunctions or degradation of the operation of a weaving loom (1), comprising the steps of:

- providing, in a plurality of weaving mills (500), at least one loom (1) per mill, a local monitoring system (400) applied to said loom (1) for the collection of operating parameters of the components of the loom and status parameters of the loom, and transmission means (130) for transmitting said parameters;

providing main transmission means (670) operatively connected with the transmission means (130) of the local monitoring systems (400);

- providing main storage means (660) located remotely with respect to the weaving mills (500), operatively connected with the main transmission means (670) and suitable to store a high volume of local monitoring system parameters (400) ;

providing main processing means (680), operatively connected with the main transmission means (670) and/or with the main storage means (660) located remotely with respect to the weaving mills (500), suitable to process a high volume of parameters;

- identifying the trend of the general parameters (PI, P2) of each loom (1) on the basis of a further general parameter (X) , transforming said trends in the frequency domain and correlating them with each other using a correlation function to identify a deviation of the operation of the loom (1) from a reference operation on the basis of an enormous amount of data (Big Data) .

3 . Comprehensive monitoring system for weaving looms, comprising :

- at least one local monitoring system (400), placed in a weaving mill (500), associated with a respective loom (1) and comprising sensors for measuring operating parameters of the components of the loom, a local management device (120) to provide status parameters of the loom (1), and remote transmission means (130) of said parameters; - main transmission means (670) operatively connected with the transmission means (130) of the local monitoring system (400) ;

- main storage means (660) located remotely with respect to the weaving mill (500), operatively connected with the main transmission means (670) and suitable to store a high volume of local monitoring system parameters (400);

- main processing means (680), operatively connected with the main transmission means (670) and/or with the main storage means (660) located remotely with respect to the weaving mill (500), suitable to process a high volume of parameters to identify a deviation of the operation of the loom (1) from a reference operation.

4. Comprehensive monitoring system according to claim 3, wherein the main transmission means (670) comprise components for an Internet connection.

5. Comprehensive monitoring system according to claim 3 or 4, wherein said sensors comprise at least one temperature sensor (12,39,28,36,83,87) for measuring the temperature of electric motors (10,37,26,34,81,85) or for measuring the temperature of the support bearings of rotating organs of the loom or for measuring the temperature of lubrication oil .

6. Comprehensive monitoring system according to any of the claims from 3 to 5 wherein said sensors comprise at least one pressure transducer for measuring the pressure in a pressure plenum or in a pressurised oil distribution circuit .

7. Comprehensive monitoring system according to any of the claims from 3 to 6, wherein said sensors comprise at least one load cell (15,27,31) for measuring the tension (S2) of the warp yarns being unwound from an unwinder roller (2) or for measuring the tension (S24) of the fabric pulled by a pulling roller (24) or for measuring the tension (S32) of the fabric wound on a winding roller (32) .

8. Comprehensive monitoring system according to any of the claims from 3 to 7, wherein said sensors comprise at least one vibration sensor (104) for measuring the vibrations (V100) of a support structure (100) of the loom (1) .

9 . Comprehensive monitoring system according to any of the claims from 3 to 8, comprising image acquisition means

(110) for the capture of images (WHO) related to the loom

(1) as a whole or its organs.