Ring Data in Textile Manufacturing

Ring Data in Textile Manufacturing

Ring data is an online monitoring system that assesses the performance of ring frames on the machine itself with the help of sensors and embedded electronics. This system enables to locating the faulty package and material. It is a powerful analysis tool that allow instant identification of performing machine and spindles, resulting in faster reaction to problems and an increased efficiency and quality level with minimum effort.

By considering the need of online control most manufacturer provides an embedded online monitoring system in ring frames itself like RIETER, LMW, KTTM, and others. The machine display provides information about the production, end breakages, stop time, overall performance, and power consumption of the machine.  

Need of Ring data:

Offline quality control:  

In the olden days quality control was the offline type. That is sampling the material from different spindles or machines or countries and then testing of it is carried out. Then by comparing testing result either with norms or customer requirement machine setting or other decision is taken. All this process of sampling, testing, analyzing, and correcting action consumes more time with human error. All this is happening away from the machine’s so-called offline monitoring system. Quality monitoring by trial and error is outdated as is quality assurance and control from the laboratory. So modern system approaches online monitoring on ring frame which will overcome the drawbacks of offline monitoring. 

Modern and efficient is linked online with the production process; continuous monitoring and optimization of the production process are desired factors for consistent quality. Complete quality monitoring provides information on raw material and machine parameters. 

Drawbacks of Offline Control 

1. Required extra laboratory equipped with a modern testing instrument increases cost. 

2. Sampling and testing are time-consuming and may add human error.

3. Corrective action is taken by observing results that may be wrong. 

4. Saving of testing results which may be difficult due to paperwork. 

5. Calibration of the testing instrument in a specific time should do which increase the cost. 

Functions of Ring data in Textile Manufacturing

Ring data has sensors which placed at the front roller and at the spindle. They can perform several  tasks as follows, 

1. Detaching and signaling ends down. 

2. Detaching and reciprocating ends down. 

3. Detaching and recording ends down. 

4. Detaching and analyzing ends down. 

5. Recording stoppages 

6. Recording output 

7. Calculating efficiency 

8. Roving stop motion in the events of end down. 

These data are fed as input to machine or monitoring software. Software is made such that  they compare the input with the standard result or customer requirement if any match is not found machine give the signal to the operator or by adjusting automatic machine setting error get corrected  as well as production, which extremely helpful to the mill for, 

1. Assessing the spinning behavior of the raw material. 

2. Assessing the production behavior of the machine. 

3. Establishing causes of faults, overall and per spindle. 

4. Assessing climatic influence. 

5. Operator guidance by proper signaling. 

6. Workplace loading. 

7. Personnel rating. 

8. Cost calculation. 

Types of ring data in Textile Manufacturing :  

There are two types of ring data monitoring system as follow, 

1. Machine monitoring system (MMS)

In this system, the traveling sensor runs continuously back and forth at the height of the ring rail of each side of the machine on a single machine or all machines. This generates a  magnetic field that is affected by the rapidly rotating traveler. If yarn breaks occur, the traveler ceases to rotate and the sensor displays the resulting impulse as an ends down, downtime, and repair time. 

Fig: Machine Monitoring System 

Another sensor fitted on front roller records delivery speed and machine stoppages and  number of doffing and duration. All the information collected is transmitted to the computer  with monitor and printer which performs the necessary analysis and stores data for preset  periods. Report from printer contains data per machine, blends or installation. Following data  are given in reports,  

Machine number, date, time, production period, spindle speed, yarn twist, output in kg or  kg/spindle, efficiency, downtime, doffing time, ends down/1000 spindle hours and a number  of the spindle with ends down exceeding this limit. 

2. Individual spindle monitoring system (IMS):  

In this system optical sensor on the ring frame at each spinning position, which is assessing the motion of the traveller. Each spindle has an individual sensor which provides more  control than MMS (MACHINE MONITORING SYSTEM). More and more spinning  operations want to monitor the individual ring spindle for yarn breaks and spindle speed.

IMS, based on an individual optical sensor for each spindle, detects run/stop and speed,  monitors the ends down level and reports slipping spindles. 

Ring dataFig. 2 Individual spindle monitoring system 

One mouse click on a particular ring data frame allows the user to select any detailed  report, such as spindles with the highest breakage level, slipping spindles per machine, yarn  breaks as function of the bobbin build up, and during up and down movement of the ring rail,  Stops are always assigned to the right spindle, regardless the length of the machine. Ends  down levels, slipping spindles, and frame and spindle efficiency are reported by doffing, as  well as by shift, day, week and month. Trend reports highlight recurring problem spindles.

The advantage of IMS ON MMS  

a. No moving parts in the system. 

b. No maintenance due to less moving parts. 

c. Continuous monitoring of all spindles. 

d. Each and every spindle is under in supervision and control. 

The architecture of system at the machine 

At one side of ring frame machine, the station is there; at other side power module is present  as shown in the figure. Power module contains motor supply and gearing is available. Ring 

frame has spindle sensor and draft sensor they are internally connected in machine station.  The software takes it as input and display on machine display unit. According to problems,  bulb signal is provided which will helpful to the operator. End breakages and draft error  signal were given on machine. Machine station is connected to co-coordinator. At each co 

coordinator, 15 to 20 machines are connected. From machine production, number of  breakages, efficiency, twist, spindle speed, yarn length on bobbin, count, twist variation, draft  setting, maintenance setting, air pressure, roller speed, ring-rail speed, bobbin build-up  doffing cycle, doffing time number of doff and power consumption all data given to co 

coordinator through wire connections or wireless connections. 

Fig. 3 The architecture of system at ring frame

Fig. 4 The architecture of system at ring frame 

Co-ordinate has data of 15-20 ring frame, it collects data from machine and store for some  time and then given to network router. The network router is the main component in the  system it stores data, display data, give data to server PC, client PC. Network router has a  display to show all parameter. Client PC and supervisor PC has only displayed no any  corrective action. The only owner as well as manager only can adjust parameter. Server PC  connects to owner mobile, email to online storage data. All connections are either wireless or  wired connections. All pcs are connected to printer from each report are printed according to  time, shift, day, count, lot wise and client wise. All production parameter, machine setting,  client order, twist setting and draft setting are stored on PC and server it can withdraw at any  time.  

The RIETER spiderweb system  

Spider web is modern user oriented windows based data system figure 6.6 shows the  corresponding data flow the mill in schematic form within the mill this data flow is based on  Ethernet. This both simplifies data management and enables data loss to be prevented  efficiency. Data are stored in 3 locations for this purpose.

a. On the machine, until is they are written onto the customer’s PC. 

b. On the hard disc of the host PC, until are written into Spiderweb database for  up to one-year external backup. 

c. In the spider web database for up to one year. External backup of this database  is possible. 

These systems mostly feature a three or four-level structure, starting at the lowest  level, i.e. the level at which sensitive sensors are installed directly at special control points on  the machines. They pick up the incoming figures and transmit them to the second level, the  machine level. At the machine level, simple computers collect, transform and evaluate the  signals arriving from the sensors. The summarized result is often indicated in a simple  manner on a panel at the machine, informing the personnel responsible and enabling them to  react immediately. 

Fig. 6 Rieter SpiderWeb System 

The third level is the level of the PC workstation, where the data collected at the machine  level is selectively evaluated and informatively displayed in the supervisor‘s office, often also  in graphic form. The top level of the MIS is usually a commercial host computer. Here again,  all information arriving from the third (or perhaps second) level is collected in a condensed  and compatible form by a local network and selectively evaluated in an easy-to-use form, The 

detailed analysis of the second, third and fourth level enables immediate action to be taken if  the slightest deviation occurs.

 

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