AŞKIN MUSTAFA VEHBI (TR)
| WO2003029546A1 | 2003-04-10 |
| US20170146989A1 | 2017-05-25 | |||
| US20060144457A1 | 2006-07-06 |
| ❖ This invention is a data tracking and analysis system (1) comprising a stenter machine (2), which adjusts the gr/moisture ratio per linear meter by giving the necessary chemicals to the fabric; that is, data tracking and analysis system (1) produces a fabric in the desired length/width and with the desired amount of moisture, and ❖ a controller (3), which collects the analog data of the stenter machine (2), provides the control and monitoring of the stenter machine (2) via the operator screen, and has an internal OPC UA server on the controller (3), that collects and records the working values of textile factories, analyzes these values, enables instantaneous remote monitoring of the data collected from the stenter machine (2) and sensors, reduces alarm, idle time and downtime and increases productivity, prevents the failure of the stenter machine (2), prevents the production from being interrupted, prevents personnel errors and encourages performance work, by following the maintenance information of the stenter machine (2), wherein; comprising, ❖ a machine reading module (4) that works in integration with ERP systems, receives the data collected by the controller (3) over the local network with the OPC UA protocol, and enables the work order forms to be sent directly to the stenter machine (2) by integrating with the information systems currently used in the factory, ❖ a local server (5), which is SQL-based and allows the data read by the machine reading module (4) to be recorded in the local network, ❖ a remote server (6) that saves the data together with the data’s fixed IPs so that the data read by the machine reading module (4) can be opened to the internet, ❖ a local web application (7) which is a responsive web interface developed in an ASP.NET environment, working on the local server (5), integrated with ERP systems, used for instant viewing of data and obtaining retrospective reports and statistics, and enables the stenter machine (2) to be operated with the most appropriate values for each fabric type, ❖ a remote web application (8) which works over the internet, on the remote server (6) side, integrated with ERP systems, used for instant viewing of data and obtaining retrospective reports and statistics, and enables the stenter machine (2) to be operated with the most appropriate values for each fabric type, ❖ a mobile application (9) which is uploaded to the mobile devices, uses web services, works on the remote server (6) side, is integrated with ERP systems, is used for instant viewing of data and obtaining retrospective reports and statistics, and enables the stenter machine (2) to be operated with the most appropriate values for each fabric type. |
Technical Field
This invention relates to a data tracking and analysis system that collects and records the working values of textile factories, analyzes these values, enables instantaneous remote monitoring of the data collected from the stenter machine and sensors, reduces alarm, idle time, and downtime, and increases productivity, prevents the failure of the stenter machine, prevents the production from being interrupted, prevents personnel errors and encourages performance work, by following the maintenance information of the stenter machine.
Prior Art
Today, no local or international solutions are offered to monitor and analyze the parameters and instant operating data of the machines in the finishing department of textile factories. The purpose of using the stenter machines in textile factories is to adjust the gr/moisture ratio per linear meter by applying the necessary chemicals to the fabric. In other words, the stenter machine produces fabrics with the desired width and the desired amount of moisture. Currently, there are no applications that read the data of stenter machines and record and analyze this data, at least on a local server. Following the market research and as a result of the consultations carried out with the well-esteemed consultants and technologists in the sector, it was found that there was no study that analyzes the reading of data and increasing productivity and that the machines primarily work under operator control. In the bilateral discussions with the factory managers, the need and demand for an application where machine data can be monitored instantly and various analyzes can be made were expressed.
In a machine that is entirely under operator control, for example, the operator can hold the machine on stand-by via heating it. This process is entirely at the operator's initiative and can be controlled by the operator. In this process, there is a waste of electricity and natural gas consumption, as well as a loss of production and time for planning. On the other hand, different quantities of the same type and the same process of fabric can be produced in different periods or under different operator control. According to the information obtained from bilateral meetings with factory managers and consultants, there is no research study within the factory regarding which parameters increase productivity. No method is used other than using the values whose efficiency has been experienced for the works done in the past for the current works as well.
However, there are studies that collect data from some other machines in the factory and analyze their efficiency. Many studies have been done on both weaving looms and dyeing machines in Turkey and abroad. One of the patented works developed in Turkey is used, for example, on weaving looms of textile factories. This study focuses on some parameters that affect the machine operation and does not follow all the values of the machine. However, in the said study, since PLC control is not completely achieved, it is not possible to reach all the data in technical terms.
Information systems are used within the institution to keep the information of previous work orders and to follow the process stages in a controlled manner from the initial state of the fabric to its final shape. However, since the stenter machines cannot be communicated with these information systems, the process values kept in the information systems and the parameters entered into the device may differ. As they are not digitized, work orders sent to operators are carried on paper. This reduces machine efficiency and leads to operator errors. This process, which is challenging to follow, not only depends on the operator's way of doing his work, performance, and experience but also directly affects the machine's efficiency.
On the other hand, the lack of retrospective records makes it difficult to prevent errors that cause production losses and to make production planning. In this sector, where the production speed is high and the control of machine parameters is valuable, the importance of creating added value for the enterprises and our country by reducing the efficiency of the operators is evident.
In the patent application document, TR2020/09377, encountered in the prior art of the technique, the method and the related system for optimizing and adjusting an operating parameter of an industrial machine are explained. However, the said system does not provide a solution that collects and records the working values of textile factories and analyzes these values. As a result, due to the above-mentioned inadequacy of the existing solutions, an improvement that fulfill the needs in the technical field has been required.
The Purpose of Invention
The invention is inspired by the existing circumstances and aims to solve the above- mentioned drawbacks.
The purpose of the invention is to introduce a system that collects and records the working values of textile factories and analyzes these values.
Another purpose of the invention is to present a system that enables instant remote monitoring of the data collected from the machine and sensors. Another purpose of the invention is to introduce a system that increases productivity by reducing alarm, idle, and downtime durations.
Another purpose of the invention is to put forward a system that prevents machine failures and production from being interrupted by tracking machine maintenance information. Another purpose of the invention is to provide a system that prevents staff errors and encourages performance work.
The structural and characteristic features and all advantages of the invention outlined in the figure below and in the detailed description made by referring to that figure will be understood clearly; therefore, the evaluation should be made by taking that figure and detailed explanations into consideration.
Brief Description of the Figures
Figure 1 is the schematic representation of the system of the invention.
Reference Numbers
1. System 2. Stenter Machine
3. Controller
4. Machine reading module
5. Local server
6. Remote server 7. Local web application
8. Remote web application
9. Mobile application
Detailed Description of the Invention
In this detailed description, the preferred structures of the system (1) of the invention are described only for a better understanding of the subject.
This invention relates to a data tracking and analysis system (1) that collects and records the working values of textile factories, analyzes these values, enables instantaneous remote monitoring of the data collected from the stenter machine (2) and sensors, reduces alarm, idle time and downtime and increases productivity, prevents the failure of the stenter machine (2), prevents the production from being interrupted, prevents personnel errors and encourages performance work, by following the maintenance information of the stenter machine (2).
The system (1) of the invention, whose schematic representation is presented in Figure 1 , comprises,
❖ a stenter machine (2), which adjusts the gr/moisture ratio per linear meter by giving the necessary chemicals to the fabric; that is, it produces a fabric in the desired length/width and with the desired amount of moisture,
❖ a controller (3), which collects the analog data of the stenter machine (2), provides the control and monitoring of the stenter machine (2) via the operator screen, and has an internal OPC UA server on it,
❖ a machine reading module (4) that works in integration with ERP systems, receives the data collected by the controller (3) over the local network with the OPC UA protocol, and enables the work order forms to be sent directly to the stenter machine (2) by integrating with the information systems currently used in the factory,
❖ a local server (5), which is SQL-based and allows the data read by the machine reading module (4) to be recorded in the local network,
❖ a remote server (6) that saves the data together with its fixed IPs so that the data read by the machine reading module (4) can be opened to the internet, ❖ a local web application (7) which is a responsive web interface developed in an ASP.NET environment, working on the local server (5), integrated with ERP systems, used for instant viewing of data and obtaining retrospective reports and statistics, and enables the stenter machine (2) to be operated with the most appropriate values for each fabric type,
❖ a remote web application (8) which works over the internet, on the remote server (6) side, integrated with ERP systems, used for instant viewing of data and obtaining retrospective reports and statistics, and enables the stenter machine (2) to be operated with the most appropriate values for each fabric type,
❖ a mobile application (9) which is uploaded to the mobile devices, uses web services, works on the remote server (6) side, is integrated with ERP systems, is used for instant viewing of data and obtaining retrospective reports and statistics, and enables the stenter machine (2) to be operated with the most appropriate values for each fabric type
The data tracking and analysis system (1) developed within the scope of the study can initially be used in the stenter machines (2) in the finishing departments of textile factories. The data provided by the system (1) can be closely monitored in the production, purchasing, accounting, and human resources departments of enterprises. The system (1) does what needs to be done in the production department to increase the efficiency of the stenter machine (2) and ensures that the maintenance of the stenter machine (2) can be done on time. In this way, while enhancing the life of the stenter machine (2), the amount of future production can also be planned. The human resources department, on the other hand, has more information about the competence and the abilities of the staff and can better work on the training of the team and the employment of new staff. The purchasing department, on the other hand, updates the amount of raw materials and intermediate products to be procured in the light of new data and may consider allocating a budget for additional technological investments (such as electricity, gas, and humidity sensors).
The purpose of the developed system (1) of the invention is to increase the performance and efficiency of the stenter machines (2) (hence the employees) and reduce energy costs by collecting and analyzing the data on the stenter machines (2) used in the finishing department in the textile industry. Data storage, data analysis, optimization, and machine learning techniques are used to achieve this purpose. The developed system (1) of the invention can work integrated with systems used throughout the enterprise. With the developed system (1) of the invention, it is aimed that the stenter machines (2) can work autonomously and with the most optimized values. Thus, the advanced technological solutions required by Industry 4.0 and the Internet of Things era are being used more in production. Enterprises that use the system (1) can closely monitor the stenter machines (2) and their personnel, receive retrospective statistics, and view predicted scenarios for the future, become more powerful in terms of planning the future and making strategic decisions. By using the system (1), these enterprises will be able to activate data-based decision mechanisms rather than intuitive ones.
Within the scope of the study, study data, parameter data, and all other data can be recorded in order to obtain comparative statistics and to apply machine learning techniques. With comparative statistics, the customer can experience different scenarios by retrieving all efficiency statistics, including stenter machine (2) operating times, production and energy consumption data for the historical daily, weekly, monthly and yearly periods or for two date ranges through the system (1) according to operator, shift and product type differences.
There is currently no study either on how to operate the stenter machines (2) with which parameters will result in more efficient production. Within the scope of the study, it is also planned to increase the efficiency of the stenter machine (2) by using optimization algorithms. Another unique contribution of the study is that it works integrated with the existing information systems within the institution, thus preventing errors or performance losses caused by the operator.
With the artificial intelligence that is planned to be developed using the data collected from the stenter machines (2), the expertise of the experienced personnel can be discovered and included in the knowledge capital of the institution. Thus, it is ensured that the work that needs to be carried out with intensive mental activities can be done more smoothly.
In this context, approximately 200 types of stenter machine (2) data are monitored and it is aimed to increase production efficiency by storing, reporting, optimization and analysis of this data. In the system (1), processes such as creating work order forms, sending the process values to the stenter machine (2), and tracking and analyzing the work order forms can also be operated. In addition, in the system (1), it is ensured that all stenter machine (2) data and processes can be monitored through the local web application (7), remote web application (8), and mobile application (9), and OEE analyzes are periodically performed.
The user can access the system (1) screen via the local web application (7), remote web application (8), and mobile application (9). The user displays the status (running, idle, alarm, and stopping) and speed values (current, set, and capacity) of all stenter machines (2) connected to the system (1) via the screen with updates of 10 seconds (the page is automatically refreshed). In addition, the time period (last hour, shift, day, month, and year) can be selected with the drop-down list in the upper right corner of the screen, and statistics and OEE analyses for the working hours for this period are presented. According to the stenter machine (2) status, the readability of the data has been increased by coloring the texts in the box (green: running, orange: idle, red: alarm, and black: stopping).
Shift information (operator, time until the end of the shift, etc.), work order form information on related shift (customer, fabric type, etc.), and productivity values (produced fabric and consumed electricity/natural gas quantities) are displayed on the screen. The user screen also provides statistics, OEE analyses, and system (1) records of working hours on the basis of shifts, work orders, and stenter machine (2). In addition, the time period (last hour, shift, day, month, and year) can be selected with the drop-down list located in the upper right corner, and work statistics and OEE analysis are presented for this period. According to the stenter machine (2) status, the readability of the data has been increased by coloring the texts in the box (green: running, orange: idle, red: alarm, and black: stopping). The data on this page is updated every hour.
On a different screen of the system (1), the working times and production/consumption values of the stenter machine (2) for the last day starting from midnight are graphically displayed.
On a different screen of the system (1), the instantaneous process values (actual, set, and status) of the selected ram machine (2) are updated and displayed at 10-second intervals. The Cabin values tab displays the cabin temperatures (set and actual value) and their status for each cabin, as well as the speed and status values for the upper and lower fans. On this screen, instant process values are also displayed for Fabric Widths, Exhausts, Fixtures, and Moisture Controllers.
On a different screen of the system (1), the information regarding the work order form that is run on the selected stenter machine (2) is displayed. For this purpose, integration is made with the existing information system within the factory, if any.
On a different screen of the system (1), the statistics of working times and production/consumption values of the stenter machine (2) can be accessed according to the selected criteria (shift, fabric type, personnel, and the stenter machine (2)). The time selection in these statistics can be made for two date ranges or for periods (month and shift). Statistics accessed via this screen can also be printed out in ".xlsx" format, or statistics can be sent via e-mail.
On a different screen of the system (1), it is displayed how many operating hours the selected stenter machine (2) will alert and alarm after each maintenance type. When the maintenance periods defined in the system (1) are exceeded, warning/alarm e-mails are sent to the factory managers.
On a different screen of the system (1), the information regarding the OEM, end user, and SuperViser and similar information on the company are displayed.
In the Maintenance Settings Screen under the Settings menu, a new maintenance type can be defined as well as updating and deleting operations related to the maintenance type definition. Moreover, with the “Reset” button on this screen, the system (1) where the maintenance of the related ram machine (2) is currently being performed is processed, and the remaining warning and alarm times are reset.
A new system (1) user can be added via the User Settings Screen under the Settings menu, as well as updating and deleting operations for existing users. Through this screen, the access permissions of users to the screens located in the system (1) are also defined. In addition, users can select which notifications they will receive for the maintenance of the stenter machine (2) on this screen.
Finally, the stenter machine (2) information (Name, IP Address, Number of Cabinet, Number of Encoder, Number of Exhaust, Number of Foulards, Number of Fixtures, Number of Humidity Controllers, Capacity, and Shift Information) can be updated with the Machine Settings Screen under the Settings menu. The ram machine (2) consists of 4 main parts: the foulard section (where chemicals are applied to the fabric), the entrance section, the cabinets (generally 8-10 cabinets), and the exit section.
The control of the stenter machine (2) is provided by a PLC, and all signals are collected in the PLC. With these signals, the process set values and actual process values of the stenter machine (2) are recorded in the PLC. According to these values, the operator can control the stenter machine (2).
In the textile finishing department, the most crucial process values are the temperature, chimney speed, fan speed, and fabric width values, particularly for the stenter machine (2). Depending on these values, the operator sets the engine speed values. Thus, according to the fabric type, the speed increase/decrease is made to some motors, and the amount of moisture and fabric per linear meter is adjusted. In addition, fixed moisture values and chimney moisture values are also important for fabric moisture rate. Their control is also necessary for high-quality and efficient production.
Next Patent: A CONSTRUCTION BLOCK