A NEW INDUSTRIAL WASHING SYSTEM

Abstract

Disclosed is a system into which barcode software, SCADA, operator monitoring software and the interfaces are integrated, for the industrial textile washing systems having at least one washing machine. In particularly, a system and a method are disclosed which allow the operation to be realized upon approval of an operator by displaying the washing recipes defined based on a product on a screen and minimized the work load of the operator.

Claims

1. A system comprising at least one washing machine, at least one user display connected to said washing machine, and a PLC which controls both said washing machine and the operation and is located in said washing machine, wherein the system comprises: a PLC system having the Profinet and TCP Modbus communication protocols which control the washing machine and the operation; at least one electronic device connected to said PLC (2) system and the washing machine, which manages said washing machine during the check (approval) of an employee; at least one user display on which the outputs, such as a recipe, a written warning, etc., are displayed, wherein the user display is connected to said electronic device and the PLC system; at least one wired or wireless fixed server which sends and receives information to/from said washing machine; at least one central server connected to said fixed server; at least one database in which the recipe and operation information is stored, in said fixed server and thus, in the central server; and at least one main screen connected to said central server.

2. A system according to claim 1, wherein the washing machine is a textile machine, or a machine tool and a workbench.

3. An industrial washing method comprising the following steps: turning on a machine and enabling an electronic device, turning on a WiFi module, making a wireless network connection and requesting scanning of a card from an operator, scanning the card by the operator and sending card information to a server, scanning a barcode of a product and sending product information to a server, approving a recipe, loading the products and starting the washing process, loading chemicals, and unloading the products.

4. A method according to claim 3, wherein the method comprises the steps of turning on the machine and enabling the electronic device in the steps of turning on the machine and enabling the electronic device.

5. A method according to claim 3, wherein the method comprises the step of making the system ready for performing the functions, such as sending/receiving data to/from the system, by turning on the WiFi module during the step of turning on the WiFi module.

6. A method according to claim 3, wherein the method comprises the steps of making the wireless connection and requesting scanning of the card through the Rfid reader module from the operator, during the steps of making the wireless network connection and requesting scanning of the card from the operator.

7. A method according to claim 3, wherein the method comprises the steps of scanning the card through the Rfid reader module by the operator and sending the card information to a fixed server and then to a central server, during the steps of scanning the card by the operator and sending the card information to the server.

8. A method according to claim 3, wherein the method comprises the steps of scanning the barcode on the label through the barcode reader, sending the product information to the fixed server and then to the central server via the wifi module and performing the scanning process by the communication protocols via the device, during the steps of scanning the barcode of the products and sending the product information to the server.

9. A method according to claim 3, wherein the method comprises the steps of displaying the washing recipes on a user display and approving the washing recipes by the operator during the step of approving the recipe after the steps of scanning the barcode of the products and sending the product information to the server.

10. A method according to claim 9, wherein the method comprises the steps of selecting a different recipe or entering the data by the operator, during the step of approving the recipe.

11. A method according to claim 3, comprising the steps of opening the door, loading the products and starting the washing process by the operator according to the guidance recipes displayed on a user display, during the steps of loading the products and starting the washing process after the step of approving the recipe.

12. A method according to claim 3, wherein the method comprises the steps of displaying information on the required chemical substance and the amount of that substance to be used on a user display, loading the chemical substance by the operator according to the recipe on the user display and performing the approval process, during the step of loading chemicals.

13. A method according to claim 3, wherein the method comprises the steps of falling over the washing machine after the washing process is performed according to the recipe defined for the product, displaying a warning note on a user display before the machine falls over that the machine will fall over, approving the warning note by the operator, falling over the washing machine, unloading the products by the operator, displaying a warning note on the user display that the machine will return to the previous position after unloading the products, and returning the washing machine back to the previous position before falling over upon the approval of the operator, during the step of unloading the products.

Description

DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 is a scheme showing the main components of the system according to the invention.

[0027] FIG. 2 is a drawing showing the components of the electronic device in the system according to the invention.

[0028] FIG. 3 is a flow chart demonstrating the work flow in the system according to the invention.

REFERENCE NUMERALS OF THE SECTIONS, PARTS AND FLOW FOR DESCRIBING THE INVENTION

[0029] 1Washing machine [0030] 2PLC [0031] 3Fixed server [0032] 4Central server [0033] 5aUser display [0034] 5bMain display [0035] 6Electronic device [0036] 7Regulator [0037] 8Power jack (DC Power Jack) [0038] 9Condenser [0039] 10RFID antenna socket [0040] 11RFID reader module [0041] 12Programming jumper [0042] 13Programming socket [0043] 14Wifi module [0044] 15Buzzer sound alarm [0045] 16Reset button [0046] 17Programming button [0047] 18Automatic reset jumper [0048] 19Power led [0049] 20Wifi connection led [0050] 21Status led

Process Flow Chart to Help Describing the Invention

[0051] 100Turning on the machine and enabling the electronic device, [0052] 110Turning on the WiFi module, [0053] 120Making the wireless network connection and requesting scanning of the card from the operator, [0054] 130Scanning the card by the operator and sending the card information to the server, [0055] 140Scanning the barcode of the product and sending the product information to the server, [0056] 150Approving the recipe, [0057] 160Loading the products and starting the washing process, [0058] 170Loading the chemicals, [0059] 180Unloading the products.

Detailed Description of the Invention

[0060] The system of the invention is intended to be a system in which the textile washing machines are monitored instantly and the analyses performed by the personnel are reported by the machines due to the machine learning. In particularly, the invention allows the washing recipes defined for the product to be automatically displayed on the user display (5a) and the operation to be performed upon the approval of the operator, thereby minimizing the work load of the operator. To this end, the processes which are required to be controlled and observed in the production plant are determined, and the system is controlled by the PLC member in the washing machines and the interface software developed. The electronic and software system of the invention may be applied to all areas of textiles, including the production plants for denim trousers, or to the non-textile areas. Although the system of the invention is described as a washing machine (1) and a washing system, it generally includes the textile machines, or a machine tool or workbench.

[0061] FIG. 1 shows a scheme depicting the components of the system according to the invention. Accordingly, the invention generally comprises at least one washing machine (1), a PLC (2) system which controls both said washing machine (1) and the operation and is located in said washing machine (1), at least one electronic device (6) connected to said PLC (2) system and the washing machine (1), which manages said washing machine (1) during the check (approval) of an employee, at least one user screen (5a) on which the outputs, such as a recipe, a written warning, etc., are displayed, wherein the user screen is connected to said electronic device (6) and the PLC (2) system, at least one wired or wireless fixed server (3) which sends and receives information to/from said washing machine (1), at least one central server (4) connected to said fixed server (3), at least one database in which the recipe and operation information, including the engine speed, operation time, temperature, driver errors, step information, etc., is stored, in said fixed server (3) and thus, in the central server (4), and at least one main screen (5b) connected to said central server (4).

[0062] FIG. 1 shows a system comprising three washing machines. However, it should be known that this is not limiting. The electronic and software system of the invention may be applied to all systems comprising at least one washing machine (1). In the system, there exist an IP (Internet Protocol) number for each washing machine, as well as a PLC (2) and the user displays (5a), which have those IP (Internet Protocol) numbers. Said PLC (2) system comprises a MODBUS TCP or PROFINET communication protocol. The central server (4) may be omitted for the application of the system according to the invention in small businesses, and in this case only a fixed server (3) may be present. The fixed server (3) may be connected to the cloud system.

[0063] The system of the invention comprises at least one electronic device (6) which manages the washing machine (1) under the control (approval) of an employee. FIG. 2 shows said electronic device (6) and the components thereof. Accordingly, said electronic device (6) comprises at least one regulator (7) which provides protection against overheating; at least one power jack (8) which provides the necessary power input to the card; at least one condenser (9) which actuates said regulator (7) integrations and also minimizes the voltage fluctuations and the noises in the circuit; at least one RFID reader module (11) which reads the RFID cards; at least one RFID antenna socket (10) which connects the RFID reader antenna of the RFID reader circuit and so, allows the position of the antenna to be adjusted; at least one wifi module (14) which controls the card and makes the wifi connection by programming the microcontroller therein, wherein the wifi module sends/receives data to/from the Internet; at least one programming jumper (12) which, when said wifi module (14) is programmed, disconnects the serial communication therebetween with the RFID reader module (11) and itself; at least one programming socket (13) by means of which the programmer necessary for programming said wifi module (14) is attached to the card; at least one buzzer sound alarm (15) which informs a user of a successful scanning process by providing a sound when the card is scanned; at least one reset button (16) which resets said wifi module (14) and operates the system again; at least one programming button (17) which enables said wifi module (14) to enter the programming mode; at least one automatic reset jumper (18) which provides the connection necessary for awaking said wifi module (14) again when it enters the sleep mode for power save; at least one power led (19) which informs a user of the power provided to the system; at least one wifi connection led (20) which informs a user of the connection of said wifi module (14) to the designated wifi network; and at least one status led (21) which informs a user of a successful scanning process of the RFID card and the operating status of the system. The locations and numbers of the components indicated in FIG. 2 may vary. In this sense, it should be known that the figure is not limiting. For example, there are more than one regulator (7) in FIG. 2. Preferably, at least two regulators (7) are used in the system of the invention. One of the regulators (7) is preferably a linear regulator of 3.3V/800 mA. It has a tolerance of 0.2%. It limits the voltage applied to the input to 3.3 Volts, and an input of maximum 12V is provided. The second regulator (7) is preferably a linear regulator of 5V/1A. It has a tolerance of 2%. It limits the voltage applied to the input to 5 Volts, and an input of maximum 35V is provided. Similarly, there are four condensers (9) in the preferred embodiment. The condensers (9) used are preferably filter condensers of 220 pF/50V, 100 pF/50V, 100 pF/25V and 47 pF/25V. Said power jack (8) is preferably a DC Power Jack of 2.1 mm.

[0064] In case of the electronic and software system of the invention, a work flow is performed according to the flow chart shown in FIG. 3. Accordingly, the invention comprises the following process steps when considered as an industrial washing method: [0065] 100Turning on the machine and enabling the electronic device, [0066] 110Turning on the WiFi module, [0067] 120Making the wireless network connection and requesting scanning of the card from the operator, [0068] 130Scanning the card by the operator and sending the card information to the server, [0069] 140Scanning the barcode of the product and sending the product information to the server, [0070] 150Approving the recipe, [0071] 160Loading the products and starting the washing process, [0072] 170Loading the chemicals, [0073] 180Unloading the products.

[0074] The process details of the general scheme above are provided below.

[0075] Step of Turning on the Machine and Enabling the Electronic Device (100)

[0076] In this step, the machine is turned on, and the electronic device (6) is enabled. Herein, the machine is a washing machine (1), but may vary depending on the sector or field of manufacture to which the system is applied.

[0077] Step of Turning on the WiFi Module (110)

[0078] The wifi module (14) is turned on, and the system is made ready for the functions such as sending/receiving information to/from the system, updating, etc.

[0079] Step of Making the Wireless Network Connection and Requesting Scanning of the Card from the Operator (120)

[0080] In this step, a wireless connection is made, and the operator is asked to scan the card through the Rfid reader module (11) in order to the record the operator who performs the operation.

[0081] Step of Scanning the Card by the Operator and Sending the Card Information to the Server (130)

[0082] In this step, after the operator scans the card through the Rfid reader module (11), the card information is sent to the fixed server (3) and then, to the central server (4). Thus, the information of the operator who conducts the operation is obtained.

[0083] Step of Scanning the Barcode of the Product and Sending the Product Information to the Server (140)

[0084] Information is identified in the barcode, such as order number, lot number, etc. of the product. In this step, the barcode on the label is scanned through the barcode reader, and the product information is sent to the fixed server (3) and then, to the central server (4) via the wifi module (14). The scanning process is carried out by the communication protocols via the device. The barcode reader does not need to be shown in the drawings. Preferably, it is positioned near the washing machine.

[0085] Step of Approving the Recipe (150)

[0086] The washing recipe is displayed on the user display (5a) after the steps of scanning the barcode of the products and sending the product information to the server (140). Upon approval of the washing recipe by the operator, the guidance instructions, such as open the door, load the products, etc., are displayed on the user display (5a). In this step, the operator does not approve the recipe and may select a different recipe, or may enter data.

[0087] Step of Loading the Products and Starting the Washing Process (160)

[0088] After approval of the recipe (150), the operator opens the door and loads the products according to the guidance instruction displayed on the user display (5a), so that the washing process is started.

[0089] Step of Loading Chemicals (170)

[0090] In this step, information on the chemical substance required for the washing process and the amount of that substance is displayed on the user display (5a). The operator will load and approve the chemical according to the instruction on the user display (5a).

[0091] Step of Unloading the Products (180)

[0092] After the washing process is performed according to the recipe defined for the product, the washing machine (1) will fall over. Before falling over, a warning note will be displayed on the user display (5a) that the machine will fall over. This warning is important for the safety of the employees working near the machine. The operator who has seen and approved the warning note will unload the products upon falling over of the washing machine (1). After the products are unloaded, a warning note will be displayed on the user display (5a) that the machine will return back to the previous position thereof, and the washing machine (1) will return back to its previous position prior to falling over upon the approval of the operator.

INDUSTRIAL APPLICABILITY OF THE INVENTION

[0093] The industrial washing system of the invention has been already designed to be integrated into the production line of the textile companies, or to generate a new production line. The production lines will be integrated into the existing system in line with the modernized production purposes within the Industry 4.0 revolution, and the existing system will be made smart, efficient, modern and monitorable from a center. The system may be applied in other sectors, as well as all areas of textile.