AN APPARATUS AND A METHOD FOR PROCESS IDENTIFICATION IN SPINNING MACHINES

FIELD OF THE INVENTION

This invention relates in general to textile machines. Particularly the present invention relates to a method and apparatus to avoid process/product mix-up through an improved process identification system for spinning preparatory machines. Still particularly, the present invention relates to an apparatus and method for process identification and an loT enebled wireless network communication system to monitor the process through online.

BACKGROUND OF THE INVENTION

The spinning preparatory machines such as carding, lap formers, combing machines, draw frames and speed frames are involved in a process to remove the short fibres and impurities present in the raw cotton, parallelise and converting the fibres in the form of thin strand of fibres so called. sliver or roving. The sliver materials are filled in the containers for a predetermined length for example 100 to 5000 metres. The container is preferably a 'Can'. Once the predetermined length of material is reached, the filled Can is replaced by an empty Can either by manually or by using an automatic can changing system. The delivered containers with material are stored in a particular place and then fed into another machines for further processes.

Normally, various types of materials are processed with different raw materials, different fineness and density with various process parameters in an everyday operation of spinning mills. The raw material such as natural and synthetic fibres or in a combination of both used for yarn manufacturing. The natural raw material most commonly used in spinning mills is Cotton which has various changing phenomenon like colour, staple length, short fibre content fineness, strength etc,. The synthetic staple fibres such as Polyester and Viscose are most commonly used in spinning mills either individually, blended together or blended with cotton fibres. The process parameters such as linear density, short fibre removalpercentage and process speeds are varied depending upon the end product required. Therefore, in a spinning mill, different types of materials are processed in different machines at the same time.

In the existing art, "Colour coding system" is the most commonly used method for identifying the different materials. For example, from raw material to finished product, same colour of containers are used to identify a particular process. For this method, more number of containers in different colours are required in each department. This will increase the inventory cost and also more space is required to store the containers which is disadvantageous.

Alternatively, colour bands and labels are used as identification means in the plain containers especially cans with white in colour in spinning preparatory machines. The major disadvantage in this system is, the colour bands and labels may fall down or cut while handling. Also, there are huge chances for mix- up due to operator error such as forgetting to replace the bands after processing.

The conventional colour coding system requires manual operations, extreme care, high investment and more storage space. Also, the existing methods are not suitable for the operators with colour blindness. Although the drawbacks are recognised by various machine manufacturers, no fool proof system for process identification has so far been introduced which would satisfy all the requirements by the mills.

Various efforts have been to overcome the disadvantage of the existing art. For example, Germany patent application 4015826, filed on May 17, 1990 describes a sliver can identification system with memory at cans and an electronic scanner to code and decode material container.The invention aimed to make a specific record of its contents which can be accessed electronically or manually. But the method of operating the coding and decoding process is not explained in the application. Also, the communication between machines are processed with wired connections which has practical limitations.

Patent application GB2483987 filed on Sep 20, 2011describes an apparatus for contactless recognition of variable machine or system constituents in textile machines and systems, especially in spinning preparation. The transponders may be read automatically and at regular, adjustable intervals. The reading devices may be capable of writing information to memories of the transponders. The transponder information may be fed via a network to a super-ordinate system to be available centrally. The transponder may be associated with spinning preparation machine components such as a motor belt wheel, a motor, or stationary card flats. This is for maintaining the inventory of spare parts and this system does not involve any inventive step where it lacks the novelty also.

To overcome the drawbacks present in the existing art, the present invention describes a method and an apparatus to avoid process/product mix-up through an electronic identification system for spinning preparatory machines.

OBJECTS OF THE INVENTION

It is an object of the present invention to overcome the above mentioned disadvantages of the existing process management system in the spinning preparatory machines.

It is an object of the present invention to provide an electronic process identification system for the spinning preparatory machines It is another object of the present invention to provide an apparatus and method for providing a process identification system in spinning preparatory machines.

It is yet another object of the present invention to provide transponders to the containers for materials in spinning preparatory machines.

It is yet another object of the present invention to provide a driving arrangement to enable the decoding/encoding process on the containers.

It is still another object of the present invention to provide electronic receivers in the creel zone of spinning preparatory machines to monitor the containers and thereby the process.

It is still further object of the present invention to provide an Internet of things (loT) enabled wireless communication network system to monitor the process in spinning preparatory department.

The object of the present inventions are achieved by providing an apparatus and driving arrangement in the spinning preparatory machines. Said apparatus comprises encoder/decoder, control unitand plurality of sensing means to encode/decode the electronic data in the transponders providedin the containers such as Can. The apparatusencodes the necessary data in the transponders such as Radio frequency(RFID), electromagnetic or any other electronic format suitable for identification of process, material, machine, product etc.The driving arrangement is provided in the spinning preparatory machines to rotate the containers and to place the transponders in the required position.

Said preparatory machines are also provided with sensing means such as electronic receivers to monitor the containers. Said sensing devices are mounted at the creel portion of the machines. When the containers with encoded transponders are moved near to the machines, the sensing means scans the data and verify the correct process code. Thereby, mix-up of feed material are avoided.

SUMMARY OF THE INVENTION

The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the present invention. It is not intended to identify the key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form as a prelude to a more detailed description of the invention presented later.

According to the main aspect of the present invention, the process identification apparatus for spinning preparatory machines comprising a decoding and encoding arrangement, a driving arrangement, said decoding/encoding device comprises a control unit, plurality of sensing means, decoding /encoding device with a driving means and said control units are connected with wireless communication network system. Said Encoding/decoding device is rigidly mounted in the driving means and said driving means is preferably a piston which shall be operated either by the pneumatic or hydraulic system. The entire arrangement process identification apparatus is mounted in a box and said box is mounted on a pillar rod. Said process identification apparatus, is mounted in the delivery zone of the spinning preparatory machines.

According to another aspect of the invention, the driving arrangement comprises platform, a circular base plate, and a driving means, said driving means is preferably a motor and it consists a gear arrangement and a drive pulley. Said driving arrangement comprises a drive motor, driving wheels, driving pulley, driving belt and a cover. According to another aspect of the invention, said encoding/decoding apparatus shall be mounted in the can changer mechanism and said apparatus can be directly controlled by the main control unit mounted in the spinning preparatory machines.

According to yet another aspect of the invention the container shall be a spool and a transponder is provided in the inner portion of said spool. An encoding/decoding device is mounted in the front portion of the main head and said device is connected with the main control unit mounted in the lap forming machine.

According to another aspect of the invention, Electronic receivers are mounted in the creel portion of the each spinning preparatory machines and said receiver comprises an alarm system such as buzzer or signal lamp.

The method of working of the electronic process identification system comprises the following steps. The sensing means senses the entry of empty can and send signal to the control unit. The control unit activates the drive motor and thereby rotates the empty can through the driving the circular base plate through the driving arrangement. When the motor is energised, the sensing means is also energised and senses the presence of transponder and when the Transponder is sensed, it gives signal to the control unit. The control unit stops the drive motor and activates the piston and moves the decoding/encoding device towards the transponder. To carry out the decoding and encoding process on the transponders. Once the data is decoded, the encoder encodes the necessary data is into the transponder. .

An Internet of things (loT) enabled wireless communication network system is used to transfer the data from each control units to server. The Internet of things (ΙοΤ) enabled wireless communication network system inter connects the control units and the Electronic receivers mounted in each of spinning preparatory machines which comprise at least an loT enabled Integrated chips and wireless devices such as Wi-Fi, ZigBee or Bluetooth devices.

The control units and the Electronic receivers also comprise Field programmable or multi service gateway approach system to communicate between the machines. The server is connected with communicating devices such as mobile phone, tablets and personal computers. The process identification system uses the Electronic transponders such as RFID (Radio Frequency Infrared), NFC (Near Field communication) tags or Bluetooth enabled radio transmitters such as Beacon.

These and other advantages of the present invention will become readily apparent from the following detailed description read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The above and other aspects, features, and advantages ofcertain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:

Figure 1 a to Ifdepict spinning preparatory process sequence known in the existing art.

Figure 2 depicts a delivery zone of the spinning preparatory machines known in the existing art.

Figure 3a and 3b depict the containers used in the spinning preparatory machines in accordance with the existing art and present invention. Figure 4a and 4bdepict the delivery zone of the spinning preparatory machines along with a process identification apparatus in accordance with the present invention.

Figure 5a and 5b depict the exploded view of ^■ electronic process identification apparatus in accordance with the present invention.

Figure 6aand 6bdepicts the driving arrangement of process identification apparatus in accordance with the present invention.

Figure 7 is a block diagram and Figure 8 is Flow chart which depicts the working method ofprocess identification apparatus in accordance with the present invention.

Figure 9a and 9b depicts the driving arrangement of process identification apparatus in accordance with another aspect of the present invention.

Figure 10a and l Obdepicts the coding and decoding device for the process identification system in accordance with another embodiment of the present invention.

Figure 11 depicts a spool used for winding the fibre material in lap form especially used in lap forming spinning preparatory machines.

Figure 12 depicts a coding and decoding device for the process identification apparatus for lap forming machines in accordance with another embodiment of the present invention. Figure 13 depicts a process identification apparatus mounted on the back portion of spinning preparatory machines in accordance with the present invention.

Figure 14 depicts a chart which describes the wireless communication system to send the status of process flow through Internet of things.

Figure 15 describes the material flow and process monitoring system display on the monitor in accordance with the present invention.

Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure.Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.

DETAILED DESCRIPTION OF THE INVENTION

The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary.

The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

Features that are described and/or illustrated with respect to one embodiment may beused in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

Figure 1 describes the spinning preparatory machine sequence in accordance with the existing art. The raw material for example cotton is available in the form of bales. The bales are opened and the impurities like seed, leaf bits are removed in opening and cleaning machines at Blow room and the cleaned cotton fibres are sent to spinning preparatory department. The preparatory department consists Carding (1a), drawing (1 b), lap forming (1 c), combing (1d) and roving (1f) machines. The raw material such as cotton fibres fed into the carding (1 a) machines are opened, cleaned, parallelized and converted into a rope form so called 'sliver'at the delivery zone (101 ) and stored into the containers (102). Plurality of carded slivers are fed into the drawing (1 b) machines for parallelizing and blending. The delivered sliver is stored in the cans(202) through the delivery zone (201 ). The drawing cans are fed into the lap forming machines (1 c). Plurality of drawing slivers are combined and formed as a lap (302) and wound on a spool. After a predetermined length is reached, the lap is replaced with an empty spool. The laps are fed into the combing machines

(1d) and short fibres are removed by combing. The delivery zone (401) in the combing machines helps to store the combed sliver into the cans (402). In the draw frames (1 e), at least 6 combed slivers are fed and converted as a single sliver. The delivery zone (501). in the drawing machines fills the sliver material into the cans (502) and the cans are supplied to roving machines. In roving machines (1f). the sliver material is thinned down and converted as Roving by applying twist on the fibre strand. The roving machines contain at least 120 spindles per machine. Said roving machines requires at least one sliver can per one spindle and the sliver cans (502) are placed at the back portion (601) of the roving frames. The roving material is wound as bobbins (602) at the front portion of the machine through the aid of flyers (603). Once the predetermined length of the bobbins are reached, it is replaced by the empty bobbins and the full bobbins are supplied to the spinning department for further process.

Figure 2 depicts a delivery zone (101 , 201 , 401 and 501 ) of the various spinning preparatory machines known in the existing art. The delivery zone comprises a coiler unit (103), can feeding zone (104) and can delivery zone (105). In feeding zone (104), the empty containers for example Cans (106) are placed over the conveyor rail (107). The sliver material delivered from the coiler unit is stored in the Cans. An automatic can changing mechanism (108) is provided in the delivery zone of the machine. When a predetermined length of sliver material is reached, the can is moved to delivery zone (105) and the reserve can (106) is moved to running position through the aid of automatic ¹ can changing mechanism (108).

Figure3a and 3b depict the containers used in the spinning preparatory machines. Figure 3a particularly describes the process identification method used in the existing system. The identification bands (109) are most commonly used in the cans (106) to identify the different processes. Said identification bands are made up of polymer materials and available in various colours. The operator select a particular colour band (109) and uses the same colour bands for the cans used in various spinning preparatory machines. Figure 3b particularly describes the process identification method used in accordance with the present invention. The cans (106) are provided with transponders for example RFID tags (30). The process data are stored in the tags in electronic form. The data can be encoded or decoded in the tags (30) using the process identification apparatus (1 1) provided in the spinning preparatory, machines in accordance with present invention.

Figure4a and 4bdescribes a delivery zone of the spinning preparatory machines (101 , 201 , 401 and 501 ) along with theprocess identification apparatus (1 1 ) in accordance with the present invention. The process identification apparatus (1 1 ) is mounted in the spinning preparatory machines preferably at delivery zone. The empty container (106) is placed on the feeding area as reserve can. The existing data in the transponders are decoded and the new data is encoded on the tags provided in the containers through the encoding/decoding arrangement (12) and the driving arrangement (31) provided in the process identification apparatus (11 ).

Figure 5a and 5b depict the exploded view of electronic process identification apparatus(1 1 ) in accordance with the present invention. Said process identification apparatus (1 1 ) consistsa decoding and encoding arrangement (12) and a driving arrangement (31 ). Said decoding and encoding arrangement(12) consists a control unit (13), plurality of sensing means (14, 15), decoding/encoding device (16) with a driving means (17) and the entire arrangement is mounted in a box (18) and said box is mounted on a pillar rod

(19). The control unit (13) is preferably a microprocessor and said control unit is mounted in the front portionof the box (18). Said box is divided into two portion using a plate (20). The driving means (17) is preferably a piston and said piston is mounted in the wall plate (20) of the box (18). Encoding/decoding device (16) is rigidly mounted in the piston rod (21 ) which is movable to and fro. The piston rod (21 ) shall be operated either by the pneumatic or hydraulic system. In the present invention, the pneumatic system is considered for description. The airline pipes(22, 23) are connected with the piston rod (21 ) and arranged in the inner portion of the pillar rod (19). The bottom portion of the pillar rod is mounted on the base plate through the support (22). The back portion of the box (18) consists a cover (24) with slots wherein the slot (25) is used for encoding/decoding device (17) and other slot (26) is used for mounting the sensing means (14). Said sensing means (14) is connected with the control unit (13) and used to sense the presence of transponders such as RFID tags. The sensing means (15) is used to sense the presence of empty container (Can). Said sensor (15) is also mounted on the slot (27) and connected with the control unit (13).

Figure 6a and 6b depicts the driving arrangement (31 ) of process identification apparatus (1 1) in accordance with the present invention.The driving arrangement (31) shall be used as an external driving element in the existing spinning preparatory machines. Referring more specific to Fig 6b, the driving arrangement comprises platform (32), a circular base plate (33), and a driving means (34). Said driving means is preferably a motor and it consists a gear arrangement and a drive pulley (35). The platform (32) is placed on the feeding area of the delivery zone (101 , 201 , 401 and 501). The base plate. (33) is rotatably mounted in the centre portion of the platform (32). The base plate consists a shaft (not shown) which is rigidly mounted at the bottom portion. At the bottom plate (37), a bearing (38) is mounted and the shaft is mounted inside the bearing (38). A driven pulley (36) is mounted in the shaft between the bearing and base plate and said pulley is driven by the drive pulley (35) through the driving means (39). The driving means is preferably a belt, timing belt, chain or V-Belt. When the container (106) is entered, the sensing means (15) gives signal to the control unit (13), and said control unit activates the motor (34).

Figure 7describes the working method of the electronic process identification system (1 1) in accordance with the present invention. The block diagram shows anelectronic process identification system (1 1 ) which comprises plurality of sensing means (14, 15), adecoding/encoding device (16) and driving means

(34)which are connected with the control unit (13). Alternatively, the control unit (13) shall be connected with Main control unit of spinning preparatory machines if required.

The flow chart as shown in Figure 8 describes working method of an electronic process identification system (11) in accordance with the present invention. The sensing means (15) senses the entry of empty can (106) and send signal to the control unit (13). The control unit (13) activates the drive motor (34) and thereby rotates the empty can (106) through the driving the circular base plate (33) through the driving arrangement. When the motor (34) is energised, the sensing means (14) is also energised at the same time. The sensing means (14) senses the presence of transponder (30) and when the Transponder (30) is sensed, it gives signal to the control unit (13). The control unit (13) stops the drive motor (34) and activates the piston (17) and moves the decoding/encoding device (16) towards the transponder (30). During the decoding process, it decodes the electronic data stored in the transponders (30). Once the data is decoded, the encoder (15) is energised and necessary data is encoded into the transponder in electronic format. The necessary data such as process code, material, date, machine number etc., are entered in the Control unit (13) or the data shall be collected from main control unit of the spinning machine. Once the data is stored into the transponder (30), the can is ready for collecting the material.

Figure 9a and 9b describes the driving arrangement of process identification apparatus in accordance with yet another aspect of the present invention.The driving arrangement (31 ) of the present invention shall be replaced with an alternative driving arrangement (51 ). Said driving arrangement (51) shall be used as replacement of baseplate can driving arrangement. The driving arrangement (51) comprises a drive motor (52) at least two driving wheels (53,

54), a driving pulley (55), driving belt (56) and a cover (57). When the Can is entered in to the reserve position, the sensor (15) activates the drive motor (52) and when the drive motor (52) is operated, the drive wheels (53, 54) are driven and said drive wheels rotate the Can as a result of friction. When the sensor senses the transponder, the motor is stopped and the decoding/encoding process takes place.

Figure 10a and 10b describes the encoding/decoding apparatus (61) for the process identification system in accordance with another embodiment of the present invention. The encoding/decoding apparatus (61 ) is mounted in the can changer mechanism (108). Said apparatus (61 ) is directly controlled by the main control unit mounted in the spinning preparatory machines. A slot (62) is provided in the can changer pillar (108). A piston (63) is mounted inside the slot. The encoding/decodingdevice (65) is mounted at the piston rod (64). The piston is operated through the airline connections (66, 67). A sensing means (68) is mounted to sense the presence of transponders (30). Said sensing means (68) is mounted slot (70) provided in the front cover (69). When, the container is filled with predetermined material, the doffing process is enabled and the full container is replaced by an empty container. Once the new container is placed, the decoding/encoding process will be enabled. This embodiment of the present invention shall be used as an inbuilt mechanism in the new spinning machines.

Figure 11 describes a spool (71 ) used for winding the fibre material in lap form especially used in lap forming spinning preparatory machines. According to the present invention, the transponder (72) for example, RFID tags are provided in the inner portion of the spool (71 ). In the outer portion, an identification symbol (73) is marked to show the position of the Transponder.

Figure 12 describes theencoding and decoding device for the process identification apparatus for lap forming machines (81 )in accordance with another embodiment of the present invention. The lap forming machines comprises a creel portion (82), Main head (83) and delivery portion (84). Plurality of sliver materials are fed through the creel and converted as a lap form in the main head part. The lap material is wound on the spools (71 ), The empty spools are stored in the reserve hood (85). According to the present invention, the encoding and decoding device (86) is mounted in the front portion of the main head (83). Said device is connected with the main control unit (87) mounted in the lap forming machine. At the outer portion of the decoding and encoding device, a circular frame (88) is mounted. Said frame is used to hold the spool (71 ) while coding and decoding process. There is a mark (89) made in the frame (88) to identify the position of device (86). Once mark (73) in the spool (71 ) and the mark (89) in the frame is matched, the decoding and encoding process will be enabled.

Figure 13 describes an Identification apparatus mounted on the back portion of spinning preparatory machines in accordance with the present invention. The Fig 13 depicts the spinning preparatory machine so called roving frame (91) in accordance with the present invention. The roving frame consists three main zones such as Creel zone (92), drafting zone (93) and winding zone (94). The feed material such as cans (106) from draw frames are stored in the creel zones.The sliver material (95) from the cans are fed to the drafting zone (93) for thinning down as fibre strand. Said fibre strand is then twisted and wound on the tubes to convert as bobbins (96) in the winding zone (94). According to the present invention, Electronic receivers (97a, 97b) are mounted in the creel portion of the roving frames. The required data can be stored in the receiver (97) to identify the right product. Said receiver comprises an alarm system for indication and warning.

Figure 14describes the wireless communication network system (1 1 1 ) to send the status of process flow through Internet of things (loT). The control units and the Electronic receivers mounted in the each of spinning preparatory machines comprise at least an loT enabled Integrated chips to communicate the process details to the main server (1 12) through wireless devices such as ZigBee. Said control units and the Electronic receivers also comprise Field programmable or multi service gateway approach system to communicate between the machines. The number of containers encoded and decoded are considered as main factors of process monitoring. The difference in number of containers encoded and decoded are monitored continuously and the details are collected and send to the cloud server (112) unit to monitor the status of process in each stage of spinning preparatory machines. This network system is used to adopt the Industrial loT to monitor the material flow and to eliminate the material mix-up.

The data sent from control units and the Electronic receivers of each machines are combined and updated frequently and the data will be displayed in communicating devices such as mobile phone (1 13), tablets (114) and personal computers (115). The data from control units and the Electronic receivers are sent in the form of Application Programmable Interface (API) such as XML (Extended machine language) or JSON format. The compiled data is transferred to communicating devices in SAAS, IAAS or PAAS format. The data collected from various machines are used to monitor the process and the intelligent system in the server (1 12) supports to evaluate the status of a particular process and advice the concerned person to necessary plan changes.

Figure 15 describes the material flow and process monitoring system display on the monitor in accordance with the present invention.The preparatory department consists Carding (1 ), Lap forming (2), Combing (3), Drawing (4) and Roving (5) machines as described in Figure 1. The process flow is shown in display of the communicating devices as shown in Figure 15. The different processes are represented in different colours and the changes of containers and material flow will be displayed with continuous updates.

According to the aforesaid invention, the Transponders (30) provided in the containers (106) are encoded with the necessary data such as process details, machine number or process code. The delivered cans with encoded transponders are stored in the feeding zone of the spinning preparatory machines. When the containers are moved near to the electronic receiver (47), said receiver senses the stored data in the transponders (30) and compare the values stored in the receiver. If the data are matched, it shows a positive signalsuch as green light. When the data does not matches with the stored data, the receiver produces alarm sound which means that the cans are not to be processed in this machine. Thus the process mix-ups shall be avoided. When the alarm is activated, the information will be communicated to the server through the network.

Advantageously, the process identification system can be mounted in any of the textile machines. The present invention can be mounted in any part of the machine. for example feeding or delivery zone. The process identification system is made up of using Electronic transponders such as RFID (Radio Frequency Infrared), NFC (Near Field communication) tags. Alternatively, the process monitoring system shall be enabled with Bluetooth enabledradio transmitters such as Beacon.

In view of the present disclosure which describes preferred and best modes for providing process identification apparatus in textile machines, modifications and variations would present themselves to those skilled in the art without departing from the scope and spirit of this invention. Any modifications and variations coming within the meaning and range of equivalency are considered within the scope.