Method and system for managing and controlling the feeding of at least one thread to a textile machine as a function of the operating step of the latter

Abstract

Method and system for managing and controlling feeding of at least one thread to a textile machine as a function of the machine operating step in product production or thread processing, such production or processing providing for a succession of steps corresponding to obtaining product parts or treating thread. The thread fed to the machine by a feeder at constant tension and/or speed and/or controlled by a sensor which monitors sliding or inherent characteristic thereof such as tension, speed, diameter, quantity and color. The sensor and/or feeder controlled by a setting controller. The setting controller receiving synchronization signals from the machine and detectingaccording to the latterthe operating steps and thus product or production status. The operation setting programmed as a function of operating steps. The machine generates a unique synchronization signal, for each operating step, independently from step length.

Claims

1. A method for managing and controlling feeding a thread-containing feedstock selected from a thread or yarn or a plurality of threads at constant tension and/or speed to an operating machine selected from a textile machine, a knitting machine, a stocking machine, a loom or a machine for preparing the yarn, the method comprising: carrying out said feeding during: production of a product from the thread-containing feedstock or processing of the thread-containing feedstock, wherein such production or processing comprises a succession of operating steps or operating areas defining a complete production cycle of the operating machine with respect to production of the product or processing of the thread-containing feedstock, wherein every single operating step or single operating area produces a product macro-area from the thread-containing feedstock or performs a single complete treatment of a plurality of treatments of the thread-containing feedstock, wherein said feeding of each thread-containing feedstock to said operating machine is by a corresponding feeder device, wherein said feeding is performed with at least one feature selected from: the thread-containing feedstock being at constant tension, the thread-containing feedstock being at constant speed, and controlling the feeding by a sensor device which monitors the feeding or at least one characteristic of the thread-containing feedstock selected from thread tension, thread speed, thread diameter, fed thread quantity, thread color, and thread setting; detecting said single operating step of the production cycle or said operating area of the operating machine or progress status of the production of the product through a synchronization signal generated by the operating machine, wherein the synchronization signal uniquely identifies the single operating step or single operating area through generation of a unique synchronization signal by the operating machine at a start or at an end of production of the product macro-area or the single complete treatment of the thread-containing feedstock; associating particular set values of said at least one characteristic of the thread-containing feedstock fed by each feeder device to each of such operating steps or operating areas, said at least one characteristic being selected from the group consisting of thread tension, thread speed, thread diameter, fed thread quantity, and thread color, said set values being recorded in a table; memorizing said particular set values in a setting and control means to which the feeder device and/or the sensor device is connected; and said setting and control means intervening on operation of the feeder device and/or the sensor device to define operating values of said at least one characteristic being selected from the group consisting of thread tension, the thread speed, the thread diameter, the fed thread quantity, and the thread color of the thread-containing feedstock corresponding to the particular set values memorized for producing said product macro-area of the product or for implementing the single complete treatment of the plurality of treatments to be carried out during processing of the thread-containing feedstock, said unique synchronization signal being used by said setting and control means for said intervening on operation of the feeder device and/or the sensor device to control and/or feed the thread with the operating characteristics suitable to implement said single operating step or said single operating area to obtain, respectively, said product macro-area or to carry out said single complete treatment of the plurality of treatments to be carried out during processing of the thread-containing feedstock, said setting and control means uniquely identifying said single operating step or said single operating area according to the unique synchronization signal received from the operating machine, wherein the single operating step or the single operating area to obtain the product macro-area or the single treatment, respectively, is carried out according to the particular set values of said at least one characteristic of the thread for each of the single operating steps or the single operating areas.

2. The method according to claim 1, wherein said setting and control means detects corresponding current actual values of the characteristic of the thread fed to the textile machine by each feeder device, and compares said current actual values with the particular set values, generating a warning to the operator, stopping the textile machine, or requiring intervention on each feeder device, should there be detected a difference between actual or current values and the set values.

3. The method according to claim 1, associating data regarding the characteristics of the thread-containing feedstock fed to the operating machine to the synchronization signal, which uniquely identifies the operating step or single operating area, the setting and control means acting on said feeder device and/or sensor device to adapt every controlled characteristic of the thread to every single operating step or single operating area based on the synchronization signal and data associated to the respective synchronization signal.

4. The method according to claim 1, wherein the unique synchronization signal corresponds to a particular operating step or a particular operating area to which a plurality of data regarding feeding and/or control of the thread and the characteristics is associated.

5. The method according to claim 1, wherein the unique synchronization signal is defined by a logic level, or one or more pulses, or one or more digital signals, or a variable duty cycle signal, or an analogue signal or a serial communication.

6. The method according to claim 1, wherein, besides the unique synchronization signal defining each single operating step or single operating area, the textile machine may transmit to the control and setting means a further synchronization signal that is dependent on a position of an operating member of the textile machine during the particular single operating step or single operating area.

7. The method according to claim 6, wherein said setting and control means alternatively use the further synchronization signal or a time programmable range in each single operating step or single operating area to manage an automatic tension ramp or a delay of the control step of one of the characteristics of the thread.

8. The system for managing and controlling the feeding of a thread-containing feedstock selected from a thread or yarn or a plurality of threads with constant tension and/or speed to an operating machine selected from a textile machine, a knitting machine, a stocking machine, loom or a machine for preparing the yarn, said system operating according to the method according to claim 1, said feeding being carried out during production of a product from the thread-containing feedstock or processing of the thread-containing feedstock, such production or processing comprising a succession of operating steps or operating areas defining a complete production cycle of the operating machine with respect to production of the product or processing of the thread-containing feedstock, wherein every single operating step or single operating area produces a product macro-area from the thread-containing feedstock or performs a single complete treatment of a plurality of treatments of the thread-containing feedstock, the system comprising a feeder device feeding a corresponding said thread-containing feedstock to said operating machine with at least one feature selected from: the thread-containing feedstock being at constant tension, the thread-containing feedstock being at constant speed, and a sensor device being provided to monitor the feeding or at least one characteristic selected from thread tension, thread speed, thread diameter, fed thread quantity, thread color, and thread setting, a setting and control means connected to such feeder device and/or sensor device being provided to set and control the operation thereof, said setting and control means receiving synchronization signals from the operating machine, wherein the synchronization signals correspond to the start and end of each operating cycle or operating area, said synchronization signals being suitable to allow the production of a product macro-area or the obtainment of a single complete treatment of a plurality of treatments to which the thread should be subjected, each single synchronization signal uniquely corresponding to each of a plurality of operating steps or operating areas of the operating machine to produce a product macro-area or implement said single complete treatment of the thread, the sum of such operating steps corresponding to the production of a complete product or the implementation of a complete treatment of the thread-containing feedstock, the setting and control means being suitable to act on said feeder device and/or sensor device according to each of said synchronization signals received from the machine so that such feeder device or sensor device feeds and/or controls the respective thread-containing feedstock with predefined and peculiar tension and/or speed of each of such operating steps or operating areas, values of the at least one characteristic of the fed thread-containing feedstock by each feeder device being set for each aforementioned operating step or operating area, said characteristic comprising at least one characteristic selected from thread tension, thread speed, thread diameter, thread quantity, and thread color, said set values of each characteristic of the fed thread-containing feedstock being memorized in said setting and control means.

9. The system according to claim 8, wherein the setting and control means are a drive and control interface unit interposed between each feeder device and/or sensor device and the textile machine, said drive and control interface unit being programmable.

10. The system according to claim 9, wherein each of the feeder devices and/or sensor devices is connected to the drive and control interface unit alternatively through one of the following methods: serial communication, electrical signals adapted to recognize hardware controls generated by the drive and control interface unit.

11. The system according to claim 9, wherein said drive and control interface unit is part of a device for feeding the plurality of feeder devices.

12. The system according to claim 8, wherein said feeder devices are configured for feeding the thread with constant tension, also comprising accumulation feeders with fixed or rotary drum, yarn feeding detector devices, devices for controlling tension or speed or quantity of the thread fed to the textile machine, and/or devices for acting on the thread such as cutters or operator members of the textile machine.

13. The system according to claim 8, wherein the synchronization signal is alternatively a signal characterized by a logic level, or by one or more pulses, or by one or more binary code digital signals or by a variable duty cycle signal, or by an analogue signal, or by a serial communication.

14. Method according to claim 1, wherein said characteristic being selected from among said characteristics thereof, said particular set values being recorded in the table.

15. The method according to claim 1, wherein, besides the unique synchronization signal defining each operating step or operating area, the textile machine transmits to the control and setting means a further synchronization signal in the single operating step or single operating area, the further synchronization signal being dependent on a position of an operating member of the textile machine selected from at least one of a rotary cylinder of a circular machine or a transmission shaft of a machine for preparing the yarn.

16. The system according to claim 8, wherein each single feeder device and/or sensor device is connected to the interface and control unit alternatively through one of the following methods: serial communication, electrical signals adapted to recognize hardware controls generated by the aforementioned unit selected from INC, DEC, and enabling/disabling the signals.

17. The method according to claim 1, wherein said feeding is performed with at least one feature selected from: the thread-containing feedstock being at constant tension and the thread-containing feedstock being at constant speed.

18. The method according to claim 1, wherein the feeding is controlling by a sensor device which monitors the feeding or at least one characteristic of the thread-containing feedstock selected from thread tension, thread speed, thread diameter, fed thread quantity, thread color, and thread setting.

19. The system according to claim 8, wherein the sensor device is provided to monitor the feeding or at least one characteristic selected from thread tension, thread speed, thread diameter, thread quantity, thread color, and thread setting.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) For a better understanding of the present invention, the following drawings are attached hereto, by way of non-limiting example, wherein:

(2) FIG. 1 shows a diagram of a system obtained according to the invention:

(3) FIG. 2 shows a table indicating a possible operating mode of the system according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(4) With reference to the aforementioned FIG. 1, it shows various devices 1 for feeding the threads (not shown) to a textile machine 2, such devices possibly being identical or different from each other. FIG. 1 also shows sensors 100 adapted to control at least one characteristic of each fed thread such as the tension, speed, diameter, quantity and color thereof or the like.

(5) The textile machine is of the type adapted to manufacture a product. However, the invention can also be applied to machines for preparing the yarn where each single thread is subjected to an operating cycle (for example, twisting, texturizing, plying, intertwining) which still comprises operating areas or operating steps for obtaining product macro-areas or single complete treatments of a plurality of treatments to which the thread is subjected, distinct from each other, in the production cycle: for example, for the production of a spool, the production areas or steps could be binding, winding with layers having different operating tensions, doffing or repetitive or random fancy patterns obtained during the production of the spool.

(6) All the devices 1 and 100 in FIG. 1 are connected to the control and interface unit 3, preferably of the microprocessor type. Such interface unit 3 may have or be connected through a connection 10 (of every type, electrical or serial), to the a display 11 and/or a keypad 5 through which an operator can enter or select different operating modes of the unit 3 and programming the operation of each device (feeder or sensor) connected to the latter.

(7) The control and interface unit 3 is adapted to program and manage the devices as a function of the various operating modes of the machine. As mentioned, such devices can be of the same type or type different from each other (feeder of the thread at constant tension, feeder of the thread at constant speed, sliding control sensors, sensors for controlling the quality of the thread etc.) The management and programming of said devices preferably occurs through a serial line 4 which is connected to the unit 3, so as to simplify and thus reduce the system wiring costs, in particular when the number of devices 1 and 100 is particularly high (such as for example in case of medium and large diameter circular machines).

(8) The invention (method and system) is based on the fact that in almost all textile production processes, for example in small and medium diameter circular machines, the production process can be divided into a series of repetitive production cycles, where a production process corresponds to the production of a single garment (for example a stocking).

(9) A plurality of operating steps for obtaining complete parts with macro-areas of the product, for example, in the case of a stocking i.e. the heel, leg, foot, etc., can be identified in every production cycle. Thus, production sub-processes adapted to obtain single parts of each macro-area or single sections of the product which, together with similar and consecutive sections, define the latter can be identified in each of said operating steps that lead to obtaining a product macro-area. In the light of this consideration, it is provided for that the unit 3 operates receivingfrom the textile machine 2, through electrical or serial connection lines 7 and 8at least synchronization signal that uniquely identifies each operating step adapted to define at least one product macro-area, this always allowing such unit 3 to absolutely and uniquely identify the process progress state of the textile machine.

(10) Such synchronization signal may be obtained through any electrical signal, a frequency modulated signal, an amplitude modulated signal, a variable duty cycle signal, a pulse sequence, a logic signal or an analogue signal. However, it is such to identify the start (or end) of a specific operating step of the machine (area) to which said signal is correlated so as to define the start (or end) of the production step of a macro-area of the product.

(11) The machine 2 is thus predisposed to generate, through a usual programmable control unit thereof in which the steps for processing a product are memorized, said synchronism signal each time a single macro-area of the product or a single operating step of the machine that produces such macro-area starts (or ends). This applies to every garment or product obtained.

(12) Thus, continuing to generate said unique synchronization signal for every step for producing a macro-area of the product, the textile machine signals the repetition of the steps required for the complete production of a single product and thus the repetition of the production of several products to the control and interface unit 3.

(13) More in particular, the unit 3 receivesthrough at least one connection line (electrical or serial) 10data regarding the processing area (or what is indicated with MACHINE PROGRAM in FIG. 2 in column A), given that they are combined to the OPERATING PROGRAM (shown in column B of FIG. 2) associated to the article being produced or the regarding the specific programs or activations for each device; such data was previously saved in a memory present in the unit. As mentioned, such product actually provides for macro-areas (clearly identifiable portions of the product) obtained using different threads or with the same thread, but fed to the textile machine with different tension and/or speed so as to obtain said macro-areas with characteristics (for example resistance, compactness or aesthetic characteristics) peculiar of the adjacent macro-areas or product portions.

(14) The programming of such data or operating program allows the unit 3 to set and control the operation of each single device 1 or 100 through specific methods which are as a function of the type of device and a function of the manufactured product, the production step thereof and the thread used for the production thereof. Such loading, for example occurs through a PC connected to the unit 3, through a USB flash drive, SDI cards, Ethernet connection, Wi-Fi connection or similar devices (identifiedby way of exampleby a block 11 in the figure).

(15) The operating program provides for a table of the type indicated in FIG. 2. It is provided by an operator and provides for the division of the single production cycle of a product in different operating steps for the obtainment of different macro-areas of the product (for example a stocking: cuff, leg, ankle, heel, foot, tip) and the programming/activation of each device is defined for every operating macro-area. In the case in question, see FIG. 2, operating areas (ZERO, CUFF, LEG, HEEL, FOOT AND TIP) are provided corresponding to the aforementioned macro-areas of the product, two feeder devices (FEEDER_1 and FEEDER_2) and two sensors for controlling the presence of the yarn (SENSOR_1 and SENSOR_2). It should be observed that in the table of FIG. 2, to every operating area there corresponds a signal (generated by the machine) which, in the example, is a unique number for each operating area (shown in the MACHINE CODE column). For example, it is generated by four digital outfeeds (binary code), thus allowing the capacity to manage up to sixteen areas and an unlimited number of feeder devices 1 and sensors 100.

(16) According to such division, the operating mode is defined for each device, i.e. each characteristic of each fed thread is defined, such as the operating tension, the speed thereof, as well as the enabling or disabling of each feeder 1 and the control parameters thereof, . . . .

(17) Thus, the unit 3 drives and controls every device 1 as a function of the selected operating area of the machine (MACHINE CODE of table 2) according to the programming table.

(18) Thus, the invention allows the operator to manage every device 1 or a plurality of devices in an extremely simple manner: actually, it is sufficient to fill the table of FIG. 2, specifying the behavior of the single device or a group of devices upon the variation of the operating areas indicated in column A of such figure. thus the unit 3 will program and manage the devices: for example, in the case of a feeder with constant tension, the control algorithm present in the unit 3 will manage the possible passage from one tension (and/or speed) to another exploiting the maximum resolution (or the minimum programmable tension) of the device to be managed.

(19) The operator shall simply specify the need to pass, for example, from a 2 to 5 grams tension and it will be the control algorithm instead to decide the passage ramp from the first to the second tension depending on the type of controlled device. By using a unit 3 operating according to what is described, it becomes extremely simple for the operator to even intervene and modify the final result when defining the article. It will not be necessary to act on the machine program (column 2A of FIG. 2), but solely on the data of column 2B of such figure, memorized in the unit 3 and associated to the article being manufactured.

(20) Thus, the unit 3 operates according to a method that provides for dividing the operating mode to obtain every product in a series of production steps corresponding to every product macro-area, said production steps being identified through unique synchronism or synchronization signals corresponding to each operating step of the machine or any area of the product being manufactured.

(21) In other words, during the production of every macro-area or product portion (or operating area) corresponding to a specific operating step (or operating area) of the machine, the machine generates a corresponding synchronism or synchronization signal (shown in FIG. 2, column A through a MACHINE CODE 0-5). Such signal is received by the unit 3 which activates/deactivates each device by associating it to the corresponding process of the program (FIG. 2, column B).

(22) Such operating condition for each device lasts until the machine generates another synchronism signal, corresponding to the production of a different product macro-area (or different operating area). This succession of steps continues until the product is completely obtained and then resumes from the step for obtaining the first product macro-area or first operating area, the one indicated with ZERO in the table of FIG. 2 and thus corresponds with start/end of a production cycle.

(23) Thus, according to the invention, a unique synchronism signal that leads to programming and/or activating or deactivating every device 1 is detected for every specific operating step corresponding to a different macro-area of the product. Thus, the unit 3 sets and controls the operation of the latter and the mode of intervention thereof on the thread; thus, the unit 3 can manage every product production macro-area in a differentiated manner.

(24) Thus, in the light of the above it is clear that the unit 3, operating according to the methods corresponding to the data contained in the table regarding every operating area, and knowing the operating step of the machine by analyzing the received synchronism signals, is capable of modifying the operating methods of each device as a function of the process progress status; as a matter of fact, the control unit 3 shall be solely be required to modify the operating methods thereof (for example by setting the operating tension for a feeder with constant tension) at each of such signals, for each connected device 1 or 100. If the modification is not possible, the unit 3 generates an alarm for the operator and stops the textile machine.

(25) Given that the operating program (see the table of FIG. 2, column B) is the result of the data set in the unit 3 in a manner unconstrained from the textile machine 2 and the type of connected feeder 1 and/or sensor 100, it is clear that the operating data of the unit 3 can be set in a differentiated manner as a function of each type of device 1 or 100 or possible hardware/software version of the connected feeder device, thus allowing the yarn to continue developing the products thereof independently from the need to maintain compatibility with the particular textile machine to which they should be coupled or with other feeder devices connected to such machine.

(26) In a more advanced version of the implementation of this method, besides generating a unique signal of each product macro-area, the machine can generate another synchronism signal (PRX) as a function of the position of an operating member of the machine textile machine such as, for example, of the cylinder of a circular machine or of the transmission shaft of a machine for preparing the yarn, in the operating step for the production of such macro-area. The algorithm could possibly use this information for managing a tension ramp or a tension modification mode/speed. For example, in the table of FIG. 2, column B, a request to pass from 2.0 grams (the tension present in the previous area) to 5.0 grams within 10 rotations of the cylinder is indicated by the operator in the CUFF area of FEEDER 1. Instead of being generated by the machine, the additional synchronism signal PRX could instead be retrieved from the machine through a proximity sensor capable of intercepting the rotation of the cylinder.

(27) In any case, given that the steps not affected by the sizes of the article (or the cylinder rotations on a stocking manufacturing machine, for example) given that the synchronism or synchronization signals are each generated at the start (or at the end) of each product operating area (and they can even last over the entire work cycle), the feeding system and the method remain unvaried for every size of product obtained, where the transition of the operating step of each device 1 occurs for example as regards the tension with time ramps that may even be adjusted and programmed in each operating area (see FEEDER_2 in the LEG line of the table of FIG. 2) or with ramps as a function of the process progress state in the operating area through synchronism signals (PRX).

(28) In particular, such devices may be of different type, same case applying to feeders with constant tension, of the positive or accumulation type, with fixed or rotary drum, feeders with constant sped, yarn detection sensors and quality control sensors. Such devices may also be one or more members that activate an operating function of the machine such as a solenoid valve, a waxing device, a cutter, an intertwining device.

(29) In addition, in the operating area of each device (corresponding to an operating area of the machine) and for every operating step of the machine, besides the tension and/or thread feed speed there may also be associated the activation of special functions, such as for example the function of identifying any broken thread. Thus, in this case the broken thread function would be automatically enabled and disabled by the unit 3, at the operating area of the device 1, thus identifying the absence or breakage of the thread or utilization thereof in an undesired area.

(30) The table of FIG. 2, column B, also shows the programming of a sensor for controlling the presence of the yarn, in which the sensitivity to be used for controlling the thread and whether the control should be active is selected as a function of the operating steps or areas of the machine.

(31) The operative program can be optimized in terms of space (occupation of the memory), for example by indicatingfor each operating areathe operations alone with respect to the previous operating area, or making each column (FEEDER 1) correspond not to a single device, but a group of devices that perform the same activity.

(32) In a further alternative solution, the table for setting the tensions as a function of the process progress status could be contained in the memory of each device 1 and the synchronism signals could reach the device 1 directly or through the unit 3.

(33) In another variant, the display and/or keypad 5 serves as control unit 3 and it is directly interfaced with the feeder devices 1 and receives the synchronism signals of the machine 2.

(34) In a further variant of the invention, the display and/or keypad 5 is outside the control unit 3 or it is not there at all.

(35) Lastly, according to a further variant, a first device 1 of the plurality of devices contains the unit 3, the other devices 1 of such plurality receiving the setting of such first device 1. In the mode in which the unit 3 also controls the operation of the of each feeder device, if it is contained in the first device 1 mentioned above, the latter drives and controls the operation of all the other feeder devices mounted on the machine.

(36) The invention allows controlling the feeding of a thread to an operating machine obtained with a greater abstraction level with respect to that of the prior art and in particular that of WO2013/114174 and independent from the length of each operating area of the machine, thus allowing having a single Table for controlling such feeding upon the variation of the sizes, thus simplifying the programming of the devices.

(37) The invention does not require knowing the length of each product macro-area and the corresponding operating area of the machine for the obtainment thereof for each size, due to the fact that the change from the operating area as a function of the macro-area occurs automatically as a function of the code of the operating area activated by the program of the machine. Thus, the change of size occurs automatically without requiring any selection by the operator, hence eliminating any risk of error.

(38) Thus, in the machine program of any model/manufacturer, the operator shall solely be required to program a unique signal for every macro-area identical for any type of stocking/product and size.

(39) Lastly, the memory consumption of the control means is considerably low.

(40) The description regards an embodiment of the invention applied to a textile machine which operates on several threads fed by corresponding devices 1 and 100. However the invention also applies to the case of a machine that operates on only one thread which is processed using various methods in a production step such as of a twisting machine or any yarn preparation machine.

(41) These variants shall also be deemed to fall within the scope of protection of the claims that follow.