BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a method for displaying operational information
of a loom on a display device, such as a CRT, in association with step numbers of
a weaving pattern. The operational information is obtained from stoppage information
of the loom.
2. Description of the Related Art
[0002] Japanese Unexamined Patent Application Publication No.
2004-100061 describes a method for displaying operational information of a loom. According to
this method, when the loom stops during operation, stoppage information including
a stop time, details of stoppage (cause of stoppage), and a step number of a weaving
pattern is stored. Then, the stoppage information is displayed as the stoppage history
in time series in the form of a list. The meaning of the weaving pattern, the step
number, and a weaving cycle described below, will be explained in the description
of the preferred embodiments section.
[0003] According to the display method described in Japanese Unexamined Patent Application
Publication No.
2004-100061, the stoppage information is simply displayed in time series. Therefore, as the number
of stoppages increases, the size of the stoppage information to be displayed in the
form of a list increases accordingly. The stoppage of the loom does not always occur
at a weaving cycle (weaving step) corresponding to a specific step number. Therefore,
if the stoppage information is simply displayed as the stoppage history in the form
of a list, as the size of the stoppage information increases, it becomes difficult
for an operator to recognize the relationship between the weaving step and the occurrence
of stoppage. More specifically, there may be a case where the loom frequently stops
at a certain weaving step but the occurrences of stoppage are temporally dispersed.
In such a case, according to the above-described method of the related art, a certain
step number will be intermittently displayed and it is difficult to check the number
of stoppages in association with the weaving cycle.
[0004] If the operator becomes aware of the fact that the loom frequently stops at a certain
weaving step, the operator can determine that there is a problem in the weaving operation
in that weaving step, for example, in the settings of the operation timing of heald
frames and the like for that weaving step. Unless the problem is solved soon, the
operating rate will be reduced or the quality of the woven cloth will be degraded.
[0005] Japanese Unexamined Patent Application Publication No.
9-195145 describes another method for displaying operational information of a loom. According
to this method, data regarding the stoppage of the loom (stoppage information) is
successively stored. When a display request is issued, the stoppage information obtained
in a period designated by the display request is aggregated, the period starting at
a start time point and ending at a current time. Then, the result of the aggregation
is displayed as the operational information.
[0006] However, according to the display method described in Japanese Unexamined Patent
Application Publication No.
9-195145, the number of stoppages is simply aggregated, or is aggregated for each cause of
stoppage. Therefore, the relationship between the weaving step and the number of stoppages
cannot be checked.
SUMMARY OF THE INVENTION
[0007] In view of the above-described situation, an object of the present invention is to
provide a method for allowing an operator to quickly check the number of stoppages
in association with weaving steps.
[0008] The present invention is applied to a loom which performs a weaving operation by
operating weaving elements in accordance with a weaving pattern having a plurality
of weaving cycles successively numbered with step numbers, which stores stoppage information
including a step number each time the loom stops due to a weaving failure during the
weaving operation, and which displays an aggregation result on a display device as
the operational information. The aggregation result is obtained by aggregating the
stoppage information stored in a designated period from a start time point to a current
time point, and the designated period is designated at the time when a display request
is issued.
[0009] According to the present invention, the number of stoppages of the loom is aggregated
for each of the step numbers to obtain aggregation results for the respective step
numbers, and the thus-obtained aggregation results are displayed on the display device
in association with the respective step numbers.
[0010] According to the present invention, the number of stoppages can be easily checked
in association with the weaving step (step number) from the contents displayed on
the display device. Therefore, an adjustment of the weaving elements operated in each
weaving step can be quickly made as necessary. As a result, the operating rate can
be increased and the quality of the woven cloth can be improved.
[0011] Although the aggregation results may be simply displayed, the aggregation results
may also be displayed in a certain manner. For example, preferably, the aggregation
results are displayed on the display device such that the aggregation results are
arranged in the order from the aggregation result for the step number corresponding
to the largest number of stoppages.
[0012] In such a case, since the step numbers are displayed in the order from the step number
corresponding to the largest number of stoppages, the weaving steps corresponding
to large numbers of stoppages can be more easily checked and the adjustment can be
efficiently made.
[0013] In addition to classifying the stoppage information by the step numbers, the stoppage
information may further be classified by other elements. For example, preferably,
the stoppage information is aggregated for each cause of stoppage, and the aggregation
results for each cause of stoppage are displayed in association with the respective
step numbers.
[0014] In such a case, the weaving steps corresponding to large numbers of stoppages can
be checked for each cause of stoppage. Therefore, the adjustment can be made by mainly
checking the weaving elements relating to the cause of stoppage.
[0015] The period for which the number of stoppages is aggregated starts at the start time
point of the period designated by the display request. However, an arbitrary time
point may be set as an additional start time point so that aggregation results for
a period that starts at a time point other than the start time point of the designated
period can be displayed. For example, preferably, an arbitrary time point is settable
as a start time point of an aggregation period for which the number of stoppages is
aggregated, and the aggregation results for a period from the arbitrary time point
to the current time point can be displayed on the display device. The aggregation
results for a period from the start time point of the designated period to the arbitrary
time point and the aggregation results for the period from the arbitrary time point
to the current time point may be displayed next to each other on the display device.
[0016] In such a case, the aggregation results for the periods before and after the arbitrary
time point can be compared with each other. Therefore, it can be easily determined
whether or not the adjustment has succeeded.
[0017] Although the display may be set such that only aggregation results in a fixed period
can be displayed, the display may also be set such that aggregation results for a
plurality of periods can be selectively displayed. For example, preferably, the display
device is capable of selectively displaying a plurality of unit reports corresponding
to different periods, and displays the aggregation results for a period corresponding
to the unit report selected by the display request.
[0018] In such a case, the aggregation results of the desired unit report can be checked.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019]
Fig. 1 is a diagram illustrating display contents displayed on a display device of
a loom;
Fig. 2 is a diagram illustrating the schematic structure of the loom; and
Fig. 3 is a diagram illustrating the display device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] Referring to Figs. 2 and 3, a loom according to an embodiment of the present invention
is an air jet loom. The loom has a main shaft 1, which is connected to an encoder
2 that detects a rotational angle (crank angle) of the main shaft 1 and outputs a
crank shaft signal to a main controller 3. The crank angle signal is used to generate
a timing signal for the loom or to drive predetermined actuators.
[0021] The main controller 3 transmits and receives data to and from a display device 4.
In addition, the main controller 3 outputs drive command signals and the like to a
weft insertion device shown in Fig. 2, and to other weaving elements, such as a drive
motor, a brake device, a shedding device, another weft insertion device, a take-up
device, and a warp let-off device, which are not shown in the figure. Thus, the main
controller 3 causes the above-mentioned weaving elements to execute a weaving operation.
[0022] In the weft insertion device shown in Fig. 2, a weft yarn 6 is supplied from a weft
supply package 5 and is wound around a length measuring drum 8 in a measuring-and-storing
device 7 by a predetermined length. The measuring-and-storing device 7 includes the
length measuring drum 8, a retaining pin 9, and a solenoid 11 for driving the retaining
pin 9, all of which are controlled by the main controller 3. In a weft insertion operation,
the retaining pin 9 is moved forward and backward at predetermined crank angles so
that the weft yarn 6 wound around the length measuring drum 8 is released by a length
corresponding to a single pick.
[0023] The weft yarn 6 is inserted into a warp shed (not shown) through a main nozzle 12
and is caused to flow through the warp shed by air supplied from sub-nozzles 14 disposed
so as to face a reed 13. Solenoid valves 15 are provided between the main nozzle 12
and a pressure source corresponding thereto and between the sub-nozzles 14 and a pressure
source corresponding thereto.
[0024] The solenoid valves 15 receive drive signals output from the main controller 3 at
predetermined crank angles. Accordingly, the solenoid valves 15 open and close to
control the ON-OFF states of the air ejected from the nozzles 12 and 14. As a result,
the weft yarn 6 released from the measuring-and-storing device 7 is reliably inserted
into the warp shed and conveyed therethrough by the air ejected from the nozzles 12
and 14.
[0025] H1 and H2 feeler heads 16 and 17 are disposed with a gap therebetween so as to face
the reed 13 at a weft-arrival-side end of the reed 13. Outputs from the feeler heads
16 and 17 are input to the main controller 3 through a feeler 18. The feeler heads
16 and 17 are sensors that detect the presence or absence of the weft yarn 6. When
it is determined that the weft yarn 6 is present, a yarn signal is output to the feeler
18. The H1 feeler head 16 is used to determine whether or not the weft yarn 6 has
been successfully inserted at the end of the weft insertion operation. The H2 feeler
head 17 is used to determine whether or not breakage of the weft yarn 6 has occurred
in the weft insertion operation.
[0026] A catch cord 19 is placed between the H1 and H2 feeler heads 16 and 17. The catch
cord 19 is used to catch the weft yarn 6 at the leading end thereof. Tension applying
means (not shown) and a yarn breakage sensor 21 are disposed at a base end of the
catch cord 19 in a warp direction. The yarn breakage sensor 21 outputs a yarn breakage
signal to the main controller 3. Warp breakage detectors (droppers) 22 and yarn breakage
detectors (not shown) for selvage devices 23 respectively detect breakage of warp
yarns (not shown) and selvage yarns 24 and output yarn breakage signals to the main
controller 3.
[0027] The display device 4, which is connected to the main controller 3, includes a display
unit 27, such as a CRT or a liquid crystal panel, a setting unit 28 including a keyboard
or the like for making various settings, a CPU 29 for performing calculations based
on the settings made by the setting unit 28 and controlling the contents displayed
by the display unit 27, a memory 31 for storing the calculation results obtained by
the CPU 29, and a time-signal generator (not shown). In the display device 4, the
display unit 27 may have a touch panel that functions as the setting unit 28. In addition,
operation buttons 26 for issuing commands for starting or stopping the loom, operating
the loom in the reverse direction, executing an inching operation, etc., are connected
to the main controller 3.
[0028] If a cause of stoppage occurs while the loom is in operation (weaving operation),
a sensor corresponding to the cause of stoppage detects the cause of stoppage and
outputs a detection signal. The detection signal is supplied to the CPU 29 in the
display device 4 through the main controller 3. The CPU 29 stores stoppage information
based on the detection signal in the memory 31, calculates operational information
of the loom on the basis of the stored stoppage information, and stores the operational
information in the memory 31. When a display request is issued, the CPU 29 displays
the operational information on the display unit 27.
[0029] The stoppage information is the information based on which the operational information
is obtained and includes, for example, the time of occurrence of stoppage and the
cause of stoppage. According to the present invention, the stoppage information includes
the step number at the time when the cause of stoppage has occurred. The cause of
stoppage can be generally classified into weft stoppage and warp stoppage. The weft
stoppage is caused by, for example, weft insertion failure such as short pick and
bent pick detected by the H1 feeler head 16 (H1 stoppage), weft insertion failure
such as weft breakage and long pick detected by the H2 feeler head 17 (H2 stoppage),
or failure such as weft breakage at a position upstream of the main nozzle 12. The
warp stoppage is caused by, for example, ground warp breakage detected by the droppers
22, catch cord breakage detected by the yarn breakage sensor 21, or selvage yarn breakage
detected by the yarn breakage detectors for the selvage devices 23.
[0030] The operational information includes various values, such as the number of stoppages
and the stop time, calculated from the stoppage information. In the example shown
in Fig. 1, the number of stoppages is displayed in two kinds of forms. More specifically,
in a lower section of a display screen on the display unit 27, numbers of stoppages
aggregated for each cause of stoppage are displayed. In addition, in a display area
27a in an upper section of the display screen, numbers of stoppages aggregated for
each step number in accordance with the present invention are displayed. In the display
area 27a, causes of stoppage are indicated at the top as "WEFT" for the weft stoppage
and "WARP" for the warp stoppage. In each of left and right display sections indicated
as "WEFT" and "WARP", step numbers of the weaving pattern are shown in the left column
and numbers of stoppages are shown in the right column. Thus, the result of aggregation
of the number of stoppages in a designated time period backing from the current time
point is displayed. In general, the operational information is not limited to the
information calculated from the stoppage information as described above, and also
includes, for example, the operating rate of the loom, the rotational speed of the
loom, and the weaving length. Also in the present invention, the operational information
may also include information other than those calculated from the stoppage information
as described above.
[0031] The period for which the number of stoppages is aggregated (aggregation period) is
basically a period which starts at a specific time point (start time point) in the
past and ends at a current time point. This is because the display request is normally
issued to check the operational information of the loom at the current time point.
However, the aggregation period may also include a specific period in the past. In
other words, the display request may be issued not only when the operational information
of the loom at the current time point is to be checked but also when the operational
information of the loom in a specific period in the past is to be checked. The above-mentioned
specific time point in the past is determined from a period which is set in advance
and of which the operational information is to be displayed to check the operational
information of the loom.
[0032] The period which is set in advance and of which the operational information is to
be displayed to check the operational information of the loom is a period corresponding
to, for example, an operation unit (in the case of three-shift operation, 8 hours
as calculated by dividing one day (24 hours) by 3), a unit of hours (for, example,
24 hours backing from the current time point), or a unit of days. In the present invention,
the operational information of each unit is generically called a unit report. The
unit reports for the above-mentioned units are called a shift report, an hour report,
and a day report in the mentioned order.
[0033] More specifically, the shift report is the operational information of the loom for
the current shift. The hour report is the operational information of the loom for
a period backing from the current time point by A hours (A is a set value). The day
report is the operational information of the loom for the current day. The above-described
specific time point in the past corresponds to the start time point of each unit report.
In the loom according to the present invention, the display device 4 may be capable
of selectively displaying any one of a plurality of unit reports. Alternatively, the
display device 4 may also be capable of displaying only one of the unit reports.
[0034] The weaving pattern shows operational states of the weaving elements for forming
a single repeat of a weave structure. The operational states of the weaving elements
are set for each of a plurality of weaving cycles in the weaving pattern. The weaving
cycles are the unit of the weaving operation which is repeated every time the main
shaft 1 of the loom rotates one turn. In the weaving pattern, the weaving cycles are
numbered in the order of execution, and these numbers correspond to the step numbers.
[0035] The weaving pattern is set in the main controller 3 by a setting device (not shown)
connected to the main controller 3. The main controller 3 operates the weaving elements
in accordance with the order of step numbers in the weaving pattern. More specifically,
when the operation of the loom is started, the main controller 3 starts counting the
number of turns of the main shaft 1 in response to an output from the encoder 2. The
main controller 3 controls the operations of the weaving elements in accordance with
the operational states set in the weaving pattern for the weaving cycle designated
by the step number corresponding to the number of counts. When the number of counts
reaches the total number of weaving cycles (steps) set in the weaving pattern, the
main controller 3 clears the number of counts and controls the weaving elements in
accordance with the settings for the first weaving cycle. Then, the above-described
steps are repeated.
[0036] In the above-described loom, the method for displaying the operational information
according to the present invention is performed as described below.
[0037] First, when a cause of stoppage occurs while the loom is in operation, a sensor corresponding
to the cause of stoppage detects the cause of stoppage and outputs a detection signal
to the main controller 3. Then, the main controller 3 sets a loom operation signal
to an OFF state to stop the loom. The detection signal output from the sensor is also
input to the CPU 29 in the display device 4 through the main controller 3. Then, the
CPU 29 reads the stoppage information including the step number and the cause of stoppage
(kind of sensor) and information regarding the unit report (the time and date of occurrence
of the stoppage and shift information) from the main controller 3 and the time-signal
generator. The CPU 29 stores the thus obtained information in association with each
other in the memory 31. The CPU 29 also starts measuring the stop time on the basis
of the input of the detection signal as necessary.
[0038] Then, when the operator presses an operation button of the loom after performing
a repairing operation corresponding to the cause of stoppage or when a repairing-operation
completion signal is output to the main controller 3 after the repairing operation
corresponding to the cause of stoppage is performed by an automatic repairing device
(not shown), the main controller 3 sets the loom operation signal to an ON state to
restart the operation of the loom. The above-described measurement of the stop time
is finished when the loom operation signal is switched to the ON state, and is stored
in the memory 31 in association with other elements of the stoppage information.
[0039] The above-described operation is repeated each time the loom stops, and the stoppage
information is accumulated in the memory 31 in time series so as to form a database.
If the amount of the stoppage information exceeds the capacity of the memory 31, the
stoppage information is deleted in the order from the oldest information.
[0040] During the above-described operation of the loom, if the operator wishes to check
the operational state of the loom and performs an operation for displaying a desired
unit report (for example, a shift report), a display command for displaying the unit
report (shift report) is input to the CPU 29. The display command is output to the
CPU 29 when the operator operates the setting unit 28. In this case, the display command
corresponds to the display request according to the present invention. The display
command (display request) is not limited to the command generated in response to the
operation performed by the operator as described above. For example, the display command
(display request) also includes a command that is automatically and periodically generated
at set intervals (time period or number of picks) while a certain unit report is continuously
displayed on the display unit 27. More specifically, in the case where a certain unit
report is continuously displayed, the display contents may be automatically updated
at set intervals. In such a case, a command signal issued to update the display contents
serve as the display command (display request).
[0041] When the above-described display command is issued, the CPU 29 refers to the database
in which the stoppage information is accumulated and extracts the information obtained
in the aggregation period for the current shift report on the basis of the information
regarding the unit report. More specifically, the CPU 29 extracts the stoppage information
obtained in the period from the start time point of the current shift to the current
time point. Then, the CPU 29 checks each set of extracted stoppage information and
determines whether the cause of stoppage is the warp stoppage or the weft stoppage.
Thus, the CPU 29 classifies the stoppage information by the cause of stoppage. Then,
the CPU 29 further classifies the stoppage information for each cause of stoppage
by the step number, and counts the number of sets of stoppage information corresponding
to each step number as the number of stoppages for each step number.
[0042] Then, the CPU 29 creates record data including the aggregated numbers of stoppages
in association with the causes of stoppage for each step number and forms an additional
database in which the record data for each step number is accumulated. The CPU 29
stores the new database in the memory 31, and extracts from the database the top N
records (N is a set value (N=3 in Fig. 1)) in the order from the record with the largest
number of stoppages as aggregation results. The thus obtained aggregation results
are displayed in the display area 27a of the display unit 27 as a part of the operational
information in the shift report. In addition, the CPU 29 also calculates the operating
rate, the stop time, etc., by the respective methods and displays the calculation
results as other parts of the operational information.
[0043] The operational information to be displayed on the display unit 27 is not limited
to the shift report shown in Fig. 1, and other unit reports, such as the above-described
hour report and day report, may also be displayed. In such a case, the aggregation
period for which the number of stoppages is aggregated starts at a start time point
that is determined as follows. That is, when the hour report is to be displayed, the
start time point is set to a time point that is A hours (A is a set value) earlier
than the current time point. When the day report is to be displayed, the start time
point is set to a time point at which the operation of the loom was started in the
current day (0 AM of the current day if the loom is continuously operated from the
previous day). The CPU 29 determines the stoppage information necessary for obtaining
the operational information to be included in the desired unit report on the basis
of the information regarding the unit report, and extracts the necessary stoppage
information from the database.
[0044] The unit report for displaying the above-described operational information is not
limited to the shift report, the hour report, and the day report. For example, the
unit report may also be made for every warp beam, every unit length of woven cloth,
every take-up beam (every period from when winding of the woven cloth around a take-up
beam is started to when the woven cloth is cut), or every weaving pattern (every period
in which the weaving operation is performed in accordance with a constant weaving
pattern). In such a case, information regarding the warp beam, the take-up beam, the
weaving pattern, etc., is included in the stoppage information to be accumulated in
the database. At least one of the unit reports corresponds to the period designated
at the time when the display request is issued according to the present invention.
[0045] In the above-described example, when the database is created, the stoppage information
is accumulated in time series in accordance with the time of occurrence of the cause
of stoppage. However, the database may also be created by the following two methods.
[0046] According to the first method, each time a cause of stoppage occurs, the CPU 29 temporarily
stores the step number, the cause of stoppage, and the information regarding the unit
report in the memory 31. Then, the CPU 29 determines whether or not there is a set
of stoppage information with the same step number and the same cause of stoppage in
the database stored in another area of the memory 31, that is, whether or not the
information is new. If the information is new, the new set of stoppage information
is registered in the database and a count number therefor is set to 1. If the information
is already registered, the CPU 29 increments the count number for the corresponding
set of stoppage information by 1. Then, when a display request is issued, the CPU
29 extracts from the database the sets of stoppage information corresponding to the
request on the basis of the information regarding the unit report. In this manner,
the aggregation results are displayed on the display unit 27. In this case, the database
can be structured to have different tables for each of the causes of stoppage (warp
stoppage and weft stoppage) instead of a single table.
[0047] According to the second method, the database is structured in the form of a matrix
table in which all of the step numbers in the weaving pattern are registered. In the
table, the step numbers are assigned to the rows and the two causes of stoppage (warp
stoppage and weft stoppage) are assigned to respective columns, or vice versa. Each
time a cause of stoppage occurs, the count number in the corresponding cell in the
table is incremented by 1. When a display request is issued, the aggregation results
are displayed on the display unit 27 in a manner similar to the above-described first
method on the basis of the count numbers in the cells corresponding to the display
request. The aggregation period of the database may be set not only to the operation
unit for the shift report but also to other units.
[0048] It is not necessary that the aggregation results be shown on the display unit 27
for each cause of stoppage, as shown in Fig. 1. For example, the aggregation results
may also be obtained simply for each of the step numbers irrespective of the cause
of stoppage. Conversely, the aggregation results displayed on the display unit 27
may also be classified into more detailed causes of stoppage. For example, the weft
stoppage can be classified into the H1 stoppage, the H2 stoppage, and the feed yarn
breakage, and the warp stoppage can be classified into the ground warp breakage, the
catch cord breakage, and the selvage yarn breakage.
[0049] In addition, it is not necessary that the aggregation results be displayed on the
display unit 27 in the order from the aggregation result with the largest number of
stoppages (total number of times). For example, a list in which the numbers of stoppages
are shown in the order of the step number may also be displayed. In such a case, if
the total number of weaving cycles in the weaving pattern is large, there may be a
case where the aggregation results cannot be displayed on the screen at the same time.
Therefore, a list including only the aggregation results corresponding to a certain
number of stoppages or more may be displayed on the display unit 27.
[0050] In the above-described example, the aggregation period in which the number of stoppages
is aggregated starts at the start time point corresponding to the unit report for
displaying the aggregation results. Then, only the aggregation results for the aggregation
period from the start time point to the current time point are displayed. However,
the operator can also set an arbitrary time point during the operation of the loom
to define an aggregation period ending at the arbitrary time point and an aggregation
period starting at the arbitrary time point. In such a case, the display device 4
preferably displays the aggregation results obtained in the periods before and after
the arbitrary time point next to each other on the display unit 27 so that the aggregation
results can be compared with each other. To perform the above-described setting process
and the displaying process, the display device 4 is provided with a dedicated setting
switch and a display switch on the setting unit 28. In addition, memory areas for
storing the aggregation results obtained in the periods before and after the arbitrary
time point are prepared. The above-described setting process and the displaying process
are performed in, for example, the following case.
[0051] That is, in the case where the operational information is displayed as a shift report,
there is a possibility that the operator will become aware of the fact that the loom
frequently stops at a certain step number (weaving cycle) from the displayed aggregation
results. In such a case, it can be determined that there is a problem in the operations
of the weaving elements in that weaving cycle. Therefore, the operator stops the weaving
operation and makes an adjustment (change the settings). Then, to determine whether
or not the abnormality has been eliminated by the adjustments, the operator performs
the following operation and the display device 4 performs the following processes
in response to the operation performed by the operator.
[0052] That is, the operator presses a dedicated setting switch at the time when the operator
makes an adjustment. The CPU 29 receives an operation signal from the dedicated setting
switch and stores the aggregation results obtained in the period from the start time
point of the current shift to the current time in a dedicated memory area, and then
clears the aggregation results. After the adjustment, the CPU 29 restarts the aggregation
when the operation of the loom is restarted. Then, when the operator presses a dedicated
display switch or when a predetermined time interval elapses, the CPU 29 reads out
the previous aggregation results stored in the dedicated memory area and displays
the previous and current aggregation results, that is, the aggregation results obtained
in the periods before and after the adjustment such that the previous and current
aggregation results are shown next to each other on the display unit 27.
[0053] As a result, the operator can easily compare the previous and current aggregation
results on the display unit 27 to determine whether or not the abnormality has been
eliminated. The previous and current aggregation results may be alternatively displayed
by switching the display screen instead of being shown next to each other.
[0054] The present invention is not limited to the above-described embodiments, and various
modifications are possible within the scope of the invention.