[0001] The present invention relates to a method and apparatus for monitoring the yarn tension
of a continuously advancing yarn, such as at each of the operating positions of a
false twist crimping machine.
[0002] U.S. Patent No. 4,720,702 to Martens discloses a method for continuously monitoring
the yarn tension at each of a plurality of yarn processing stations, and which involves
continuously determining the mean value of the monitored tension at each station,
and continuously determining the differential between the monitored value and the
mean value. An alarm signal is generated whenever the mean value leaves a predetermined
tolerance range, and also whenever the differential value leaves a second predetermined
tolerance range.
[0003] In the above described method, the upper limiting value of a mean value and the lower
limiting value of a mean value are set so far apart from each other for the control
of the entire false twist texturing machine, as to ensure that the mean values of
all working positions are within these centrally set values. Consequently, the mean
value of the individual positions is able to fluctuate within a relatively wide range,
which adversely affects the accuracy of the method.
[0004] It is accordingly the object of the present invention to provide a method and apparatus
for monitoring the yarn tension at each of a plurality of yarn processing stations
of a yarn processing machine, and wherein it is possible to respond to relatively
small fluctuations of the mean value at each position.
[0005] The above and other objects and advantages of the present invention are achieved
in the embodiment illustrated herein by the provision of a method and apparatus for
monitoring the tension of an advancing yarn and which includes the steps of continuously
monitoring the value U of the tension of the advancing yarn at each of the yarn processing
stations, while continuously determining the mean value MU of the monitored tension
of each of the yarns. A mean value signal SM is generated which is representative
of an average of the mean value signals MU of all of the stations on the machine,
and at each of the yarn processing stations on the machine, the mean value signal
SM is compared with the actual mean value signal MU of the position to generate a
difference signal D. An alarm signal is generated whenever the difference signal D
exceeds a predetermined tolerance limit LD.
[0006] In one embodiment, the step of generating a mean value signal SM comprises continuously
summing the mean value signals MU from all of said stations on said machine, and continuously
dividing the sum by the number of the stations. In another embodiment, the step of
generating the mean value signal SM comprises determining a desired mean value signal,
and generating such signal as a constant value.
[0007] The method also preferably includes the step of continuously determining the differential
DU between the monitored value and the mean value for each of the yarns, and generating
a first alarm signal whenever the mean value MU for one of the advancing yarns leaves
a predetermined tolerance range, or whenever the differential value for one of the
advancing yarns leaves a second predetermined tolerance range.
[0008] The present method makes it possible with simple means to monitor not only the quality
of the individual working stations, but also of the entire machine. This is of significance
in the operation of a multi-position machine, such as a false twist crimping machine
which has, for example, 216 working stations, inasmuch as the present method permits
a uniform quality level to be achieved for a plurality of working stations. The mean
value of the stations is determined for a plurality of working stations of the false
twist crimping machine. To this end, it is possible to form the mean value of the
stations from mean values which are simultaneously present, or from measured values
which are simultaneously present on individual, selected stations. However, it is
also possible to determine the mean value of the stations on a different machine,
which serves as a pilot machine. It is further possible to determine the mean value
of the stations one time based on a representative determination of a limited duration.
Finally, it is possible to input the mean value of the stations by means of a continuous
evaluation of the measured values or respectively mean values of individual, selected
stations. Even when the mean value of the stations is not input constant in time,
short-time fluctuations of the mean value are preferably filtered out, so as to limit
the rate of change of the overall mean value.
[0009] The present invention provides for two basic measures, namely:
(a) An alarm signal is emitted at each position, whose continuous mean value signal
MU exceeds the upper limit of a group average value USM, which remains constant during
the operation or the lower limit of a group average value LSM, which remains constant
during the operation. This measure allows to eliminate, i.e., discontinue the operation
of positions, whose continuous mean value is considerably outside of the tolerance
range LD provided for the group average value, upon the occurrence of a certain number
of errors. This ensures that only those positions are operated, which are within a
certain, narrow tolerance range. As aforesaid, positions outside of this tolerance
range are shut down, or the packages produced thereon are assigned an inferior class
of quality.
(b) An alarm signal is generated at all positions, for which a common group average
value is continuously produced from the continuously measured values or continuous
mean values, when the group average value leaves the tolerance range LD. In taking
this measure, all positions are evaluated, for which a common group average value
is determined. When the group average value of these positions leaves the tolerance
range, an error signal is emitted, which leads to a lesser quality classification
or even to a shutdown of the positions, when a certain number is exceeded.
(c) The upper limit UMU and the lower limit LMU for the mean value of the individual
positions are not input constant, but formed after the mean value of a group of positions.
In so doing, the upper limit and the lower limit follow the continuous average value
of the group at a certain, predetermined interval, thus taking into account a possible
scattering of the mean values of the individual positions. It is made possible to
establish a quite narrow tolerance range between the upper limit UMU and the lower
limit LMU. This measure is applicable in addition or as an alternative to the measures
described under (a) and (b) above.
[0010] The invention will be described below with reference to diagrams and the circuit
diagram of a preferred embodiment.
[0011] Some of the objects and advantages of the present invention having been stated, others
will become apparent as the description proceeds, when taken in conjunction with the
accompanying drawings, in which:
Figure 1 is a diagram illustrating yarn tension versus time for three operating yarn
processing stations;
Figure 2 is a schematic diagram illustrating an apparatus and electrical control circuit
in accordance with the present invention;
Figure 3 is a diagram illustrating the yarn tension M1 of an individual station and
the group average value SM versus time, and further illustrating upper and lower group
average mean value limits;
Figure 4 is a diagram illustrating the mean value SM versus time, and further illustrating
upper and lower limits thereof; and
Figure 5 is a diagram illustrating the yarn tension M1 of an individual station and
the group average value SM versus time, and further illustrating established upper
and lower limits for the mean value.
[0012] Referring more particularly to the drawings, Figure 1 illustrates a recording of
the values measured at three working stations of a multi-position yarn processing
machine. The ordinate represents the magnitude of the measured value U, and the abscissa
the time. As is shown, the recording of the measured values U1, U2, U3 is different
over time. In the example, the mean value SM of the positions is formed from the different
measured values. This mean value of the positions may be constantly recorded for the
entire machine. This means that the upper limit and the lower limit vary with the
mean value of the positions, however, with the width of the tolerance range remaining
constant between the upper and the lower limiting value.
[0013] It is possible to average the mean value of the positions itself over a certain evaluation
time, and to form a constant mean value of the positions in this manner. In this event,
the upper and the lower limiting value will also remain constant.
[0014] Likewise, it is possible to determine the mean value of the positions only on one
representative machine, for example, a well adjusted machine, and to input the mean
value obtained therefrom on other machines, which process the same lot. Also in this
instance, it is possible to continuously record this representative mean value of
the positions, or, however, to average same for a certain time and to finally input
same as a constant value.
[0015] Figure 2 is a schematic diagram illustrating a yarn processing station and associated
control circuitry in accordance with the present invention. The left hand portion
of the diagram illustrates one yarn processing station of a multi-position false twist
machine, and wherein a yarn 10 is withdrawn from a supply roll or other source (not
shown) by delivery roll 11. The yarn advances past a conventional yarn cutter 12,
and then it is guided across and in contact with a heater 13, through a false twister
14, and past a yarn sensor 15. The yarn is withdrawn from the false twisting zone
by delivery roll 16 and wound onto a package 17 by means of a conventional winder.
[0016] The output signal U of the sensor 15 is transmitted to a circuit 20, which is illustrated
within the dash-dot line of Figure 2. Circuit 20 is associated with each position
of the multi-position false twist machine, and with the yarn sensor 15 of such position.
The circuit 20 receives predetermined tolerance values from a set limit value memory
22 which is described below in more detail. Memory 22 is associated with a group of
stations of the multi-position texturing machine. Circuit 20 produces one output signal
to the yarn cutter 12 and another output signal to a general alarm unit 23 which is
also associated with a group of stations. Circuit 20, furthermore, produces output
signals to alarm units 25, 26, 27, 28 which will be described below in more detail.
These alarm units are correlated to the associated processing station.
[0017] The output signal of yarn sensor 15 is fed to amplifier 30 and then to filter 32.
The filter is a circuit containing an induction coil and a capacitor, the circuit
having a delay time constant of for example one to three seconds. The output signal
of the amplifier 30 is a voltage U which may be fed to a central microprocessor for
further processing and calculation via line 34. The output of filter 32 is the mean
value MU which may also be fed to a general microprocessor via line 35 for further
processing and calculation. On the other side, signal U and signal MU are fed to differential
amplifier 38 producing an output signal DU which represents the difference of the
input signals U and MU. The output signal DU of the differential amplifier 38 may
be fed via line 36 to the central microprocessor for further processing and calculation.
[0018] The output signal MU of the filter 32 is furthermore used to produce alarm signals
A1 and A2, if the mean value MU leaves the predetermined range of tolerance. The predetermined
range of tolerance is defined by the upper limit of the mean value UMU and by the
lower limit of the mean value LMU, both of which are stored in the limit value memory
22 and fed to circuit 20 via respective lines. The circuit 20 for this purpose contains
triggers 40 and 41. Trigger 40 is fed by the mean value MU and the upper limit of
the mean value UMU, and it is designed to produce an output signal A1, if the mean
value exceeds the set upper limit of the mean value. Trigger 41 is designed to receive
the mean value MU and set lower limit of the mean value LMU as an input signal and
to produce an output signal A2, if the mean value Mu is lower than the set lower limit
of the mean value.
[0019] The circuit 20 also produces alarm signals A3, A4, if the differential signal DU
exceeds the predetermined range which is defined by a set upper limit of the differential
value UDU and the set lower value of the differential value LDU. The predetermined
upper and lower limits are stored in the limit value memory 22 and fed as input signals
to triggers 42 and 43, respectively, of the circuit 20. The other input signal to
the triggers 42 and 43 is the differential signal DU which is the output of differential
amplifier 38 as described above. If the differential signal DU is greater than the
set upper limit UDU, trigger 42 produces alarm signal A3. If differential value DU
is smaller than the set lower limit LDU, trigger 43 produces alarm signal A4. Each
of the alarm signals Al, A2, A3, A4 is fed to either one of the alarm units 25-28
which are associated with this position and which are, e.g., designed as a light emitting
diode integrated into the circuit 20. Furthermore, alarm signals A1 to A4 are fed
to OR gate 44, delay time unit 45, memory 46 and amplifier 47. The OR gate 44 produces
an output signal, if any one of the alarm signals A1 to A4 is present. The delay time
unit has a delay constant of about 10 msec, and is designed to prevent an output signal
from a transient and irrelevant disturbance of the yarn texturing process, and which
could result in the yarn 10 being cut by yarn cutter 12. The memory 46 ensures that
a general alarm unit 23, which is associated with a group of stations or with the
entire machine, will be able to generate a permanent signal to show that the production
is disturbed and/or terminated.
[0020] The output signal of the memory 46 is also fed to an amplifier 47 and from there
to OR gate 48, which receives another signal to be more fully described below. The
output signal of the amplifier 47 produces an output signal of the OR gate 48, which
in turn is fed to the yarn cutter 12 to cause cutting of the yarn and interruption
of the texturizing or draw-texturizing process, as the case may be. The other input
signal to OR gate 48 is produced by trigger 49 via delay time unit 50 and amplifier
51. Trigger 49 is fed by the value U representing the measured yarn tension and by
a second set value LU stored in set limit value memory 22 and representing the lowest
accepted value of the yarn tension. It should be noted that this value LU is preferably
set at zero. Trigger 49 produces an output signal, if the measured value U is lower
than or equal to the set value LU. The delay time constant of unit 50 may be about
10 msec. The output signal of trigger 49 is, as mentioned above, fed to OR gate 48
and causes yarn cutter 12 to cut the yarn upstream of delivery roll 11, if and when
the yarn tension is below a set value or in case of a yarn break between delivery
rolls 11 and 16.
[0021] The above described circuit generally corresponds to that disclosed in U.S. Patent
No. 4,720,702 to Martens. In accordance with the present invention, the mean values
MU of a certain number of positions which all correspond to the one as shown in Figure
2 and which all have the same circuit as shown in Figure 2, are fed to a device 80
for summing all of the mean values, so that the sum of the mean values of these positions
is determined continuously. The output signal SM of summing means 80 equals the actual
sum divided by the number of positions, in this case six positions. It should be mentioned
that this summing means is common to the given number of positions. At each position,
however, the output signal SM of the summing means 80 is fed to a trigger 81 together
with the actual mean value MU of that position. Trigger 81 forms the difference D
between the overall mean value of the set number of positions and the mean value derived
at the given position. This difference D is fed to another trigger 82 together with
a limit difference value LD which is taken from the set limit values memory 22. Trigger
82 gives an output signal, whenever the absolute value of the difference D is greater
than the absolute value of the difference limit value LD. The output signal is fed
to the general alarm unit 23 or may also be used for marking the package or classifying
the quality of the package as described in the European patent application, Serial
No. 90112524.5 /0406736, entitled Method and Apparatus for Monitoring the Tension
and Quality of an Advancing Yarn (EP-l726).
[0022] The difference limit value LD represents the upper limit and the lower limit of the
overall mean value SM of the given number of stations in that it gives the tolerance
by which the mean value MU of each station has to correspond to the overall mean value
SM of all stations.
[0023] The diagram of Figure 3 shows a recording of measured values with the mean value
M1 of an individual position of a group and the group average value SM, which is continuously
formed from the measured values or mean values of all measuring points associated
to the group. A positive interval from the mean value of the group SM and a negative
interval are established. These intervals result in an upper limit line UMU or a lower
limit line LMU for the mean values of all measuring points associated to the group.
When now the mean value of one position, for example, M1 of a measuring point under
review, leaves the tolerance range LD between the upper limit UMU and the lower limit
LMU, a first alarm signal will be emitted with a time delay. This alarm signal is
repeated at regular time intervals as long as the described faulty condition continues.
Marked on the time axis are the faulty conditions with the individual alarm signals.
[0024] Figure 4 represents as a diagram the portion of a recording with the mean value SM
of a group of measuring points. The group average value SM is determined from the
continuously measured values of the individual positions or from the continuous mean
values of the individual positions. A tolerance range is established for the group
average value SM between an upper limit line USM and a lower limit line LSM. An alarm
signal is emitted at all positions associated to the group with a time delay, when
the average value of the group leaves its tolerance range. This alarm signal is repeated
at regular time intervals as long as the described faulty condition continues. The
respective faulty condition is again plotted on the time axis with the emitted alarm
signals.
[0025] As an alternative of Figure 3, the diagram of Figure 5 is a recording of the mean
value M1 of a certain position as well as the group average value SM of all measuring
points associated to the group. Again, a tolerance range is established for the group
average value with an upper limit line USM and a lower limit line LSM.
[0026] An alarm signal is emitted with a time delay at each measuring point, whose mean
value, for example, M1, leaves the tolerance range of the group average value between
the upper limit line USM and the lower limit line LSM. Likewise, as was described
already with reference to Figure 4, an alarm signal is emitted with a time delay at
all positions associated to the group, when the mean value of the group SM leaves
its tolerance range between the upper limit line USM and the lower limit line LSM.
The alarm signals are each repeated at regular time intervals as long as the described
faulty conditions last.
[0027] The emitted alarm signals can be only optical or acoustical signals. The alarm signals
can be also used to shut down one position or a group of positions of the machine.
Further, the alarm signals can be used to classify the quality of the produced yarns
and packages. In this instance the number of the errors will determine the class of
quality.
[0028] In the drawings and specification, there has been set forth a preferred embodiment
of the invention, and although specific terms are employed, they are used in a generic
and descriptive sense only and not for purposes of limitation.
1. A method of monitoring the tension of an advancing yarn at each of a plurality of
monitored yarn processing stations of a yarn processing machine,
characterized by the steps of
continuously monitoring the value (U) of the tension of the advancing yarn at each
of the yarn processing stations, while continuously determining the mean value (MU)
of the monitored tension of each of the yarns,
generating a mean value signal (SM) representative of an average of the mean value
signals (MU) of a group of said stations, and
at each of said yarn processing stations on the machine, comparing the mean value
signal (SM) with the actual mean value signal (MU) of the position to generate a difference
signal (D), and generating an alarm signal whenever the difference signal (D) exceeds
a predetermined tolerance limit (LD).
2. The method as defined in Claim 1,
characterized by the fact that
the step of generating a mean value signal (SM) comprises continuously summing the
mean value signals (MU) from all of said stations of the group, and continuously dividing
the sum by the number of said stations.
3. The method as defined in Claim 1,
characterized by the fact that
the step of generating a mean value signal (SM) comprises continuously summing the
actual tension value signals (U) from all of the stations of the group, forming the
mean value of the sum, and continuously dividing the mean value of the sum by the
number of said stations.
4. The method as defined in Claim 1,
characterized by the fact that
the step of generating a mean value signal (SM) comprises determining a desired mean
value signal, and generating such signal as a constant value.
5. A method of monitoring the tension of an advancing yarn at each of a group of monitored
yarn processing stations of a yarn processing machine,
characterized by the steps of
continuously monitoring the value (U) of the tension of the advancing yarn at each
of the yarn processing stations, while continuously determining the mean value (MU)
of the monitored tension of each of the yarns,
generating a mean value signal (SM) representative of an average of the mean value
signals (MU) of all of said stations of said group, and
generating an alarm signal at each of said yarn processing stations whenever the
mean value signal (SM) exceeds a predetermined tolerance limit (LD).
6. A method of monitoring the tension of an advancing yarn at each of a plurality of
monitored yarn processing stations of a yarn processing machine,
characterized by the steps of
continuously monitoring the value (U) of the tension of the advancing yarn at each
of the yarn processing stations, while continuously determining the mean value (MU)
of the monitored tension of each of the yarns,
generating a mean value signal (SM) representative of an average of the mean value
signals (MU) of a group of said stations,
setting a constant positive negative tolerance limit (LD) relative to said mean
value limit of the group to thereby define an upper limiting line (UMU) and a lower
limiting line (LMU) for the mean value of each position, and
at each of said yarn processing stations of the group, comparing the mean value
signal (SM) of the group with the actual mean value signal (MU) of the position to
generate a difference signal (D), and generating an alarm signal whenever the difference
signal (D) exceeds a predetermined tolerance limit (LD).
7. A method of monitoring the tension of an advancing yarn at each of a plurality of
monitored yarn processing stations of a yarn processing machine,
characterized by the steps of
continuously monitoring the value (U) of the tension of the advancing yarn at each
of the yarn processing stations, while continuously determining the mean value (MU)
of the monitored tension of each of the yarns, and while also continuously determining
the differential (DU) between the monitored value and the mean value for each of the
yarns,
generating a first alarm signal whenever the mean value (MU) for one of the advancing
yarns leaves a predetermined tolerance range (UMU;LMU), or whenever the differential
value (DU) for one of the advancing yarns leaves a second predetermined tolerance
range (UDU;LDU),
generating a mean value signal (SM) representative of an average of the mean value
signals (MU) of all of said stations on the machine, and
at each of said yarn processing stations on the machine, comparing the mean value
signal (SM) with the actual mean value signal (MU) of the station to generate a difference
signal (D), and generating a second alarm signal whenever the difference signal (D)
exceeds a predetermined tolerance limit (LD).
8. The method as defined in Claim 6,
characterized by the fact that
the step of generating a mean value signal (SM) comprises continuously summing the
mean value signals (MU) from all of said stations on said machine, and continuously
dividing the sum by the number of said stations.
9. The method as defined in Claim 6,
characterized by the fact that
the step of generating a mean value signal (SM) comprises determining a desired mean
value signal, and generating such signal as a constant value.
10. The method as defined in Claim 6,
characterized by the fact that
the step of generating a first alarm signal includes generating an alarm signal which
is correlated to the associated yarn processing station upon the occurrence of either
of the stated contingencies.
11. The method as defined in Claim 6,
characterized by the fact that
the step of generating the second alarm signal includes generating an alarm signal
which is correlated to the associated yarn processing station upon the occurrence
of the stated contingency.
12. The method as defined in Claim 6,
characterized by the fact that
the step of generating a first alarm signal includes severing the yarn being processed
at the associated yarn processing station upon the occurrence of either of the stated
contingencies.
13. The method as defined in Claim 11,
characterized by the fact that
the step of severing the yarn includes passing the first alarm signal through a time
delay circuit having a predetermined time constant so as to prevent the severing of
the yarn in the event of the presence of a short and irrelevant alarm signal.
14. The method as defined in Claim 12,
characterized by the fact that
the step of severing the yarn includes generating a general alarm signal which is
associated with a group of yarn processing stations of the machine to indicate the
yarn production at at least one of the associated stations has been terminated.
15. A yarn processing machine having a plurality of stations for processing an advancing
yarn,
characterized by
sensor means at each of the yarn processing stations for continuously monitoring
the value (U) of the tension of the advancing yarn,
first circuit means at each of the yarn processing stations and operatively connected
to said sensor means for continuously determining the mean value (MU) of the monitored
tension of each of the yarns,
second circuit means for generating a mean value signal (SM) representative of
an average of the mean value signals (MU) of all of said stations on the machine,
and
third circuit means at each of said yarn processing stations for comparing the
mean value signal (SM) with the actual mean value signal (MU) of the station to generate
a difference signal (D), and for generating an alarm signal whenever the difference
signal (D) exceeds a predetermined tolerance limit (LD).
16. The yarn processing machine as defined in Claim 14,
characterized by the fact that
said first circuit means further comprises means for continuously determining the
differential (DU) between the monitored value (U) and the mean value (MU) for each
of the yarns, and means for generating an alarm signal whenever the mean value (MU)
for one of the advancing yarns leaves a predetermined tolerance range (UMU; LMU),
or whenever the differential value for one of the advancing yarns leaves a second
predetermined tolerance range (UDU; LDU).
17. The yarn processing machine as defined in Claim 14,
characterized by the fact that
each of said processing stations includes a false twist unit for imparting false twist
to the advancing yarn, and yarn delivery means positioned downstream of said false
twist unit,
and that said sensor means is positioned between said false twist unit and said delivery
means.