CENTRALIZED APPAREL PRESS CONTROLLER BACKGROUND OF THE INVENTION Field of the Invention The invention relates generally to an interactive textile finishing machine control system. More particularly, the invention relates to an interactive textile finishing machine control system for a plurality of finishing machines.

Description of the Related Art In fabric and garment manufacturing, it is customary to employ multiple finishing machines. Some examples of finishing equipment including well known components, such as heads, bucks, valve controllers, etc. , are disclosed in U. S.

Patent Numbers 3, 593, 440 ; 3, 715, 818 ; and 3, 797, 142. It is also known to use pneumatic cylinders that are controlled by solenoid valves.

In one attempt to modernize the operation of multiple finishing machines, a programmable logic chip (PLC) was used to directly control the electrical system of a plurality of finishing machines and bypass the standard mechanical timers. In another modernization attempt, some manufacturers offer a leg press finishing machine with an optional microprocessor that controls the electrical operations of that press. In certain configurations, two presses may be controlled by the same microprocessor.

Although the prior efforts demonstrated the benefits of multiple machine control systems, there remains a need to centrally and precisely control varied function cycles in a plural finishing machine. In addition to controlling the cycles, there is a need for collecting data from each machine. This creates a need for bidirectional communication between a central control system and an individual finishing machine. Finally, there is a desire for a central control system that can be used with both new and existing finishing systems.

SUMMARY OF THE INVENTION The present invention provides an interactive textile machine control system that individually monitors and controls multiple machines even when the various machines are performing under different operating conditions.

BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 shows a system architecture for a control system according to the present invention ; Fig. 2 is an expanded view of a master monitor and controller according to the present invention ; Fig. 3 shows a finishing machine monitor and controller architecture according to the present invention ; Fig. 4 is an expanded view of a machine monitor and controller for a finishing machine according to the present invention ; Fig. 5 is a flow chart for a sequence of events in accordance with the present invention ; and Fig. 6 is a timing diagram for the events in the flow chart of Fig. 5.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The invention is described with reference to the drawing figures wherein like numerals represent like elements throughout. Referring to Fig. 1, an interactive textile finishing machine control system according to the present invention includes a plurality of commonly available textile finishing machines 10,11, 12, and 13. Each finishing machine is functionally a separate unit that is monitored and controlled by a respective unit monitor and controller 14,15, 16, or 17. The central processor 19, which includes the master monitor and controller 18, is connected to a respective finishing machine monitor and controller unit 14,15, 16, or 17 through a bidirectional data communication link, lines w and x. Although only four finishing machines are illustrated, a presently preferred

embodiment of the present invention comprising one master monitor and controller unit 18 is capable of bidirectional communication with up to two hundred fifty-five (255) unit monitor and controllers.

Referring to Fig. 2, master monitor and controller unit 18 has a user interface 30 that includes a data display, such as a four-line liquid crystal display, and a data input device, such as a keyboard. The master monitor and controller unit 18 may be a dedicated terminal of a larger computer system or a separate personal computer. The user interface 30 allows a single operator control of all operations for each of the individual finishing machines.

The machine operations may be commonly programmed at fixed settings, or individually programmed for each finishing machine. The user interface 30 is connected to a central control board 22 which includes a memory chip 24, such as a microprocessor chip, and the necessary bidirectional communication components based on the number of finishing machines within a network. In the preferred embodiment, the memory chip 24 of the central control board 22 has a predetermined database of control and style settings variables that may be selected through the user interface 30 and downloaded to a selected machine monitor and controller unit 18 on the network. The database stored on memory chip 24 contains known variables in the settings used in an individual press controller to control automatic operations of the press. The system allows for a central control of different functions. Different style settings are necessary because of pressability of different fibers, the cure characteristics of chemical additives applied to the textiles, production requirements, and quality requirements.

These settings are numeric timer values matched by the press functions according to a style number. A current example of a style setting would be : Head down 20. 0 (sec), Top steam Delay 01. 0 (sec), Amount of top steam - 08. 0 (sec), bottom steam delay 05. 0 (sec), bottom steam 05. 0 (sec) Vacuum delay 15. 0 (sec), Pre Vacuum 05. 0 (sec), Release 01. 0 (sec), Post

Vacuum 0. 5. 0 (sec), High temperature alarm Value 500 (F), Low Temp alarm Value 200 (F). These are assigned a style number and stored in the central controller memory 24. The style number is recalled by the operator and selected for downloading to an individual controller or group of controllers according to the style needed for that machine.

After downloading the style to the press, the controller will operate all automatic functions according to the assigne style independently of other machines. Preferably the database of styles is stored only in the central controller and can be modified only from the central controller. The stored database allows quick operator selection of a control function for a particular item without the need for individualized programming and avoids potential selection errors.

With reference to Fig. 1, the master monitor and controller unit 18 is in two way communication with the finishing machines and provides, via communication lines w, control variables for each finishing machine. The master monitor and controller unit collects data from each individual finishing machine, via communication lines y, and compares the respective machine data to the desired standard. The data may include, but is not limited to, temperature, production rates, and cycle times.

Representative controlled functions for a press are : 1. Head down time - the length of time the head is closed on the fabric before the head is released to the up position.

2. Top steam delay - the length of time before steam from the top head of the press is turned on by the controller.

3. Amount of top steam - the length of time the top steam is turned and injecting steam into the fabric under a closed head.

4. Vacuum delay - The length of time the pre vacuum is delayed before being turned on by the controller.

5. Amount of pre vacuum - The length of time vacuum is applied during the head down cycle and before the head is released.

6. Bottom steam delay - The length of time before the bottom steam is turned on.

7. Amount of bottom steam - The length of time the bottom steam is on before the head down cycle is complete.

8. High or low temperature alarm - When the press microprocessor signals the central controller to indicate a high or low temperature at the press, an alarm is tripped by the central controller.

9. Temperature calibration function - Although not a style setting, calibration is used for accurate temperature readings at individual presses. The temperature reading, taken by hand at each press, is compared with the reading for the press at the central controller.

The temperature calibration is entered into the computer as a multiplying factor to correct any erroneous reading.

As illustrated, the master monitor and controller unit communicates with each finishing machine monitor and controller unit via a series of parallel data communication links w, x, y, z, connected between the plurality of machine monitors and controllers. The master monitor and controller transmits control signals to the respective machine controller, for controlling the operation of the respectively associated finishing machine, via communication w lines, and monitors operations from each of the respective machines as reported to the master monitor and controller, - via communication lines x. This communication link can be achieved with a Radio Shack@ RS485 interface using a token- based messaging scheme. The master monitor and controller unit can communicate with up to 255 machine monitor and controller units through this interface.

As illustrated in Fig. 4, each machine monitor and controller unit has a central board 26 that includes a memory chip 28. The memory chip, typically a

microprocessor, stores the down loaded variables for the sequence of operations.

Each machine monitor and controller unit measures and stores various signals. The machine monitor and controller units send data to the master monitor and controller unit so that the master monitor and controller unit can control finishing machine changes or adjustments to maintain performance within certain acceptable conditions or limits defined by the operator. The controller units send data such as current style settings, current total production counts current temperature readings to the central controller. Some are sent automatically, such as temperature readings, while others, such as current style settings, are sent on request of the operator. However, the controller does not actually change any settings or make adjustment according to preset conditions or limits. All changes are made by operator input. This is to keep all machines at a preset standard. In the prior systems, individual timers were set on each press. These timers permitted operator changes but all timers did not work the same. The present invention allows for all presses to be set uniformly by style. Independent operation permits the individual machines to operate under separately downloaded instructions. If the central controller is off line, such as due to a hardware failure, the individual presses will continue to operate under the last downloaded style settings. Data collections will continue at the press and it will up loaded when the central controller is back on line.

With reference to Fig. 3, a typical machine monitor and control unit will be described. Each machine monitor and controller unit has a small amount of nonvolatile memory, preferably at least 32 bytes, for holding operational parameters, such as, identification and delay times. Each machine monitor and controller unit communicates with the master monitor and controller unit. The machine monitor and controller unit is powered by power supply 30. Information

to and from each machine monitor and controller unit is transferred over communication driver 31. Head open sensor 33 detects when the head is open. Head close sensor 34 detects when the head is closed. Temperature sensor 35 detects temperature of the finishing machine at the head.

Temperature sensor data is forwarded to machine monitor and controller 14 via an analog digital converter 36. Data from head open sensor 33, head close sensor 34, and temperature sensor 35 are transmitted to the machine monitor and controller unit via communication lines y. In the current embodiment four valves, top steam valve 37, bottom steam valve 38, vacuum valve 39, and release valve 40 are controlled via drivers 32a, 32b, 32c, and 32d, and communication lines z. Some additional signals monitored by the press control unit via communication lines y are identity, current parameters setting, steam temperature, and count production. Count production typically is good process-count, the number of times the head is in an open position under normal conditions, this can be incremented at the end of a process cycle, and bad process count, the number of times the head is open prematurely, control cycle times, operator hours earned, and labor efficiency. This data may be communicated to the master monitor and controller unit via communication lines x and downloaded to a personal computer for monitoring, printing, or storing.

This data may also be used to activate signal indicator device 20 to alert an operator to an event or a condition that is out of tolerance for a given finishing machine.

Optionally, the machine monitor and controller unit can collect and store a small number of temperature measurements. For example, 64 points of measurements for diagnostic purposes maybe stored. Based on the results of these measurements, the master monitor and controller unit can send commands to a machine monitor and controller so that the machine monitor and controller can directly and thereafter, independently control the operation of valves.

An exemplary sequence of finishing machine events is illustrated in the flow chart of Fig. 5 and described below.

The process begins when all valves are in the OFF state and a head-down signal is. detected. Fig. 6 is a timing diagram for the subsequent events in Fig. 5. The process will start only if all timing parameters are correct and valid. If a mistake is made in entering data, the software has a set of rules that all data entries must meet. For example - the head down time is the largest numerical value of the settings. If an entered setting exceeds the maximum head down time, an error message is generated ; if the sum of the vacuum delay and pre vacuum cycles entered exceeds the setting for head down time, an error message will occur. At the end of the style data entry, all variables must be within the predetermined values. Delay timers, T0, the pre- vacuum delay; T1, the delay time in turning on the top steam line after head down is detected ; T2, the delay time in turning on the bottom steam line after head down is detected ; and T3, the length of time the head is down ; are activated upon detection of head down signal. Top steam is activated when T1 expires after which TD1 timer, the dwell time for the top steam application, is initiated, bottom steam is activated when T2 expires after which TD2 timer, the dwell time for the bottom steam application is activated. The length of time the top steam is on is determined by the value of TD1 and the amount of time the bottom steam is on is determined by the value of TD2. Top steam is disabled when the initial value of TD1 equals zero (0). Similarly, bottom steam is disabled if the initial value of TD2 equals zero (0). The vacuum is turned on after the expiration of T0, vacuum delay, and then timer TV1, the dwell time for the vacuum, is activated.

The release valve is activated after TV1 expires and the vacuum is turned off. The length of time the release valve is activated is determined by timer T4. At the end of T4, the vacuum is activated again for a post vacuum period of TV2, the post vacuum dwell time. The production count is

incremented at the end of the post vacuum dwell time. A temperature measurement is made at the end of the dwell time of the top head steam.

The position of the head, the head down signal, and the steam temperature with respect to the upper and lower limits set by the user, are monitored continuously during the entire process. The head down signal must be present at all times during the steaming process. If the head-down signal is not detected during the process, an EXCEPTION event is triggered. An exception event will cause the following sequence of events to take place. (1) A signal is generated, (2) the steam valves are deactivated, (3) a sequence of head release and vacuum activation/deactivation are triggered, (4) a penalty time is activated during which the release valve is activated to prevent the head from closing again, (5) the process is restarted after the penalty timer expires, and (6) the process good count is not changed and the process bad-count is incremented. The present invention provides both an operating control system and a post operation system. Because the production count and temperature data can be downloaded, they can be used in making productivity comparisons on machines or operators.

This data is important because many operators are paid on production. These data can be exported to PC database programs, such as Microsoft Excel or Lotus 123 for charting and analysis. Opened and closed data is actually the production count expressed as good or bad. A good count is one where the head is down for the entire length of the head down cycle. A bad count is one where a head does not stay down for the full cycle. A bad count is only by operator interruption of the cycle. If an operator can short cycle a machine cycle, the operator can cheat the system and cause problems of poor or defective quality that is visually difficult to detect. Thus, the present system also provides a very important quality control tool.

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