- 1 1. Introduction To Ring Frame Data Monitoring Systems –
- 2 2. Ring-Frame Management
- 3 3. Elements of Ring Frame monitoring systems
- 4 4. Working on Different Monitoring systems.
- 5 5. Commercial Benefits/ Techno-economic Viability
- 6 6. Conclusion
- 7 7. References
Ring Frame Data Interpretation is nothing but monitoring system to analyze the various problems occuring during various operations on machines. By the interpretation of this data problems can be overcomed easily in least time.
In the times when the profit margins for spinning mills are diminishing the online and offline monitoring systems are evitable dear ones for the spinners. Monitoring each and every individual spindle is now possible. Along with monitoring the production and quality these systems also help the maintenance department to perform total productive maintenance.
The monitoring systems generate data in a systematic way, which helps the spinner in many ways. By identification of the rogue spindles, quality of the yarn is checked along with reducing the workload on ring frame sides by troubleshooting the rogue spindles which was almost impossible in the olden times.
1. Introduction To Ring Frame Data Monitoring Systems –
The ever shrinking profit margins in the textile industry call for 100% control over the production and quality at all stages of yarn production. This is specifically important at ring spinning stage since ring spinning is investment intensive and a major contributor to power and wages cost. This requires a system to monitor all the production points round the clock so that bottlenecks and deviation could be promptly identified and corrected.
To sustain the extremely competitive spinning market and still make profits, it is very important for a spinner to produce dimensioned quality at the lowest possible conversion costs, which comes out to be as the skill for the spinner. Both Over and under dimensioned qualities are fatal for spinners because over dimensioned quality will bring down the profits whereas under-dimensioned quality may result in the rejection of the entire lots, thus continuous monitoring of the process is necessary.
1.1. Sending module: the function of this module is to sense the various machine and material parameters like speeds, settings, hank/ count, Neps etc. Sensors convert mechanical interference to usable electrical signal and given to electronic module for processing, sensing devices include limit switches, proximity switch and various transducers.
1.2. Electronic circuits: They process the data transmitted by the sensors and generates necessary resultant action based on the signals and transmits to the action points.
1.3. Visual display units: The function of the display module is to display the information about the actions taken by signals generated by electronic module in digitally readable form.
1.4. Data storage units: Enormous data has to be made available for the sake of controlling the production and quality particulars.
2. Ring-Frame Management
Managing the Ring-frame department comes with its own challenges, due to which it needs to be dealt with a systematic approach, the managerial setup hence has to be Segmented, which can be broadly defined as follows, this approach may change as per the product portfolio and working conditions in the mill.
The Different segments of the Ring-frame management are as follows:
1. Scheduling and order follow up
- Real-time graphical plan board.
- Order status reporting.
- Yarn requirement calculation.
2. Quality Control
- Statistical quality control (SQC).
- Data import from lab equipment.
- Quality management reporting.
Table. Characteristics of Online and offline monitoring
|Sample Testing||100% Monitoring|
|High Reproductivity||Detection and elimination of seldom Accruing events|
|High Accuracy||Enormous amount of data|
|Interlaboratory compression||Sound statistical platform|
|Compression with benchmark||Trend analysis|
3. Spindle Monitoring
- Spindle by spindle monitoring.
- Real-time yarn breakage detection.
- Yarn breakage classification.
- Energy monitoring.
- Climate monitoring.
4. Reporting of the data
- Real-time data collection.
- Report and formula generator.
- Key Performance Indicators (OEE).
- From raw material to finished yarn.
- Traceback and forward.
6. ERP interfaces
- Download from orders and style data.
- Upload order progress.
- Upload production information.
Herewith, the production plan/schedule is stringently followed by the managers, alongside the quality is continuously monitored both by online and offline means, this is done with the help of data and monitoring systems which continuously report the data with the help of ERP interfaces which enables the managers to trace the entire process and various process parameters. This data recording generates reports which are later discussed, these reports facilitate the manager to practice direct process control method.
3. Elements of Ring Frame monitoring systems
These systems are available from various manufacturers on local, domestic as well as international level. Some manufacturers that are very popular in this sectors which have these systems developed in-house are ISM by Rieter, End2end monitoring Marzoli which are centrally integrated with the monitoring systems such as the SPIDERweb and YarNET software respectively. Zinser has FILAGuard, whereas, Uster AG provides a solution for the entire spinning industry by its various testing instruments and central control software namely Assistant Q.
Whereas, there are also some external developers which solely develop the monitoring system solutions for the mills like Spinnova, Pinter, Ultimo, BMS vision, Intex, Premier Etc.
The combination of online and offline quality monitoring systems help in optimization of the 3 basic fundamental elements of a spinning mill. I.e. Quality, production and costs. The monitoring systems do the work of detection and recording the data elements which can be thereafter analyzed by the spinner to determine the suitable control measures.
3.1. Quality monitoring:
For the purpose of quality monitoring, the following parameters are considered and monitored in the systems,
- Ends down: Ends down at any instance obtain through systems PC.
- End Breaks Rate: No motion of ring traveler recorded as end breaks of particular spindle position. It may obtain End breaks per 1000 Spindles Per hours for a particular ring frame. End breakages classified into three types:
a. Start-up Breaks (STU): Breaks recorded at the start of the machine after doffing within a preselected time.
b.Normal Breaks (EB): Breaks recorded after start-up till doff is over.
c. Other Breaks (PRT): Breaks other than STU & EB, normally idle spindles.
3. End mending time (EM): Mean duration of normal end breaks in minutes. This indicates operator efficiency.
4. Momentary Stops Positions (MSP): Momentary stops positions at any instance.
5. Idle spindles: Spindles which do not produce anything for a “set of time” are listed as idle spindles. Usually, spindles stopped for more than 30 Minutes are consider as idle spindles.
6. Rogue Spindles: Enables the user to detect spindles which end breaks rate lies significantly above the machine average.
7. Worst Spinning Positions: This report shows a maximum of 10 spindles with spindle number/machine number with the higher number of breaks. 8. Actual Spindle Speed: Rotational speed of each & every traveler is measured by the traveling sensor and the mean RPM of the machine stored in the system. 9. TPM / TPI: Twist per meter / twist per inch. 10.Slip Spindles %: The individual traveler speed is compared with the “Mean RPM” of the machine. A spindle will be recorded as a slip spindle if it’s traveler speed observed less than the limit set (i.e. 3 – 5%) for more than the number of times set.
8. Actual Spindle Speed: Rotational speed of each & every traveler is measured by the traveling sensor and the mean RPM of the machine stored in the system. 9. TPM / TPI: Twist per meter / twist per inch. 10.Slip Spindles %: The individual traveler speed is compared with the “Mean RPM” of the machine. A spindle will be recorded as a slip spindle if it’s traveler speed observed less than the limit set (i.e. 3 – 5%) for more than the number of times set.
9. TPM / TPI: Twist per meter / twist per inch.
10. Slip Spindles %: The individual traveler speed is compared with the “Mean RPM” of the machine. A spindle will be recorded as a slip spindle if it’s traveler speed observed less than the limit set (i.e. 3 – 5%) for more than the number of times set.
3.2. Production monitoring systems
- Front Roll Speed: Actual front roll delivery speed in RPM.
- Delivery speeds: Yarn delivery speed in meters per minutes calculated from front roll speed.
- Total Ring frame production: Total ring frame production at any instance and for defined shift duration in Kg. /Hrs or Kgs.
- Gms/Spindle/shift: Shift wise GPSS for count-wise, group-wise & ring frame wise.
- Total Downtimes (STM): Total downtime minutes since the beginning of the shift.
- Efficiency: AEF % i.e. Actual efficiency, PEF % i.e. production efficiency, through a system.
- No. of Doffs in a shift: Total No. of doffs since the beginning of the shift. This report helps to monitor doffing load of ring frame doffers.
- Doffing time (DFM): Total doffing time in minutes since the beginning of the shift. This report helps to monitor the ring frame doffing team efficiency.
For the systematic presentation of the data recorded various types of reports are generated by the system. These specific reports help in the easy interpretation of data and thus facilitates the process control operation for a spinning mill. These are as follows:
- Instantaneous value Report: Shows the status of the machine(s) at the moment of call-up (i.e. instantaneous). No period is applicable for this report.
- Shift Reports: Automatic shift report may obtain at the end of shift with defined parameters.
- Stoppage Reports: the Overall analysis based on stop causes possible with or without reference to the machine number. Reports may obtain in form of Stop summary, stop history & stop diagram.
- Long term Reports: Long term reports for a fixed interval i.e. on weekly basis or monthly basis may obtain.
- Article Wise: In this report machines processing the same count/material are listed together.
- Operator / Supervisor section wise: This report provided an overview of the machine data as per work assignment allotted to Operator / Supervisor section.
- Group Report: Any number of machines can be put together into as many groups as possible.
3.3. Maintenance monitoring systems
- Machine status.
- Machine alarms.
- Pressures/lubrication levels.
- Temperatures of drive and electric cabinet.
- Wearing level of critical components.
- Energy consumption.
3.4. Cost monitoring
The cost monitoring can be understood as the benefits that are achieved by controlling the various process parameters that we regulate by the monitoring systems. As everything is ultimately measured in terms of profits it is necessary to understand the economic benefits of these factors, the relation of cost benefit can indirectly be associated with the monitoring of energy consumption, improvement of the machine efficiency and production speeds.
4. Working on Different Monitoring systems.
4.1. Individual spindle monitoring systems (ISM)
Only by monitoring each individual spindle can the production process be systematically optimized on the basis of clear and precise facts.
ISM is based on optical scanning of the traveler. If the traveler is no longer rotating on the ring, the control system detects an end down and indicates this by illuminating the spindle LED directly at the spinning position.
Since the traveler speed is continuously monitored, slipper spindles (spindles running at less than their rated speed for a defined period of time) can also be precisely identified and indicated.
4.2. Remote Maintenance.
This unique and innovative remote maintenance facility provided by the standard machine manufacturers like Marzoli has its own advantages to offer, this feature of remote maintenance produces relevant and reliable information in order to effectively undertake maintenance operations. As the customer learns how long the maintenance cycles should be, he can better plan maintenance activities, reduce operating costs and always obtain the highest machinery performances. Here, inside the machines there are measuring sensors that monitor the most significant physical parameters here, inside the machines there are measuring sensors that monitor the most significant physical parameters so that rotating components, transmission systems, and electric motors are constantly under control. In addition to that, the integrated electronic automation system allows collecting all the data related to the working conditions of the machines.
- Machine status.
- Machine alarms.
- Pressures/lubrication levels.
- Temperatures of drive and electric cabinet.
- Wearing level of critical components.
- Energy consumption.
By doing this, a detailed picture of the mechanical/ electrical behavior of the machine can be taken at a regular interval of times. This can detect the premature aging of machine components throughout the lifespan of the machine.
5. Commercial Benefits/ Techno-economic Viability
5.1. Prioritization of patrolling paths:
Using the machine display unit and light indications on spindles, the operator can prioritize the machines based on breaks and can optimize the patrolling path effectively. By this way, stress level on operators can be reduced to a large extent. Also, efficiency loss due to breaks is reduced and thereby a significant increase in production is achieved.
Operator Guidance in the case of end breaks:
- Signal lamps at both ends of the machine indicate when an ends down limit has been exceeded.
- A LED for each 24 spindles indicates that an end is down in this section.
- A LED at each spinning position indicates an end down or a slipper spindle.
5.2. Control your slip spindles:
Slip spindles are identified and indicated in the single spindle light indication itself. The user can set two levels for identifying slip spindles. A normal slip which will be usually about 3-5 per cent, which is due mostly due to a worn out tape or old spindle wharves. There are few spindles which are slipping due to the tapes running out of the spindle where or jockey pulleys. The slip levels in those spindles will be very high in a range of 10-20 percent. The yarns from these spindles possess lower twist and weak in strength and elongation. These yarns create more breakages in further processing. Cops from these spindles can be even removed by the operator and thus producing poor quality yarn can be avoided. Ultimo indicates a simple green light indication for normally slipping spindles and if slip is abnormal and above the user defined limits, then the green and red light toggles in the spindle light indication alarming the user that the slip is abnormal.
5.3. Changing the work culture:
Till date, without a spindle monitoring system, the workers could not be able to recognize their skills in terms of work effectiveness. With the help of various tools like status boards, machine display units operator can tangibly estimate see their performances in terms of a number of breaks in each Ring frame and end mending time. Even the working method of the operator itself can be changed effectively. An operator has to compulsorily patrol inside all the Ring frame sides if there is no spindle monitoring system available. Now they can decide whether to enter into a Ring frame side or not based on the individual spindle light indications and machine display unit information. An effective change and easiness in work culture will fetch direct benefits at the workplace and also to the management.
5.4. Reduce the rogues:
Practical experience shows that attending and correcting 5 per cent of rogue spindles reduces 30 percent of breaks in a spinning mill. Rogue spindle identification by Ultimo helps the foreman to identify poorly performing spindles easily and hence they can attend the same immediately. A unique report shows repeated rogue spindles also with which the maintenance persons can prioritize on attending the rogue spindles.
5.5. Smart management:
With smart technology tools like automated SMS, automated emails and smartphone applications mills can monitor the production of ring frames lively and can have an effective control over the same. There is no necessity to seek for information, everything is available on hands.
5.6. Working with targets:
Keeping targets and working towards the same plays a vital role in achieving production in ring frames. Ultimo provides target deviation report which highlights the Ring frame.
With the introduction of electronic textile laboratory systems a few decades ago most of the spinning mills have started to systematically take samples In the production area with this method quality managers could establish a quality management system with which the influence of the raw material, the spinning machinery, the environmental condition could be analyzed.
The Data Unit on the machine detects delivery speed and automatic stops such as doffing and hand stop. Additional information, such as manual stop declarations, operator log on/off and other administrative data is entered via the Data Unit keyboard. On the color-coded layout of the mill, the frames are pictured in certain colors, each color indicating the current machine status. The user selects the type of information to be displayed: production data, speeds, stop rates, efficiencies.
User definable “filter sets” allow the user to display only these machines that correspond to a certain condition, for example all machines with an efficiency less than 90%, all machines waiting for an intervention, Every user, even without having any programming knowledge, can define his own calculations and reports both in tabular and graphic format by means of a built-in report and formula generator. Through a graphical user interface, Users are constantly informed about the actual situation in the spinning mill. Powerful analysis tools allow instant identification of poor performing machines and spindles, resulting in a faster reaction to problems and an increased efficiency and quality level Machine.
- Trade brochure of the spinmaster by BMSvision.
- Uster Quality management, Measure to control spindle outliers.
- Ultimo, Indian textile Journal.
- Premier Ring data system.
- Marzoli remote maintenance.
- Individual spindle monitoring by rieter.
- M. Quad, Managing a spinning mill with quality in mind, 33rd international cotton conference, Bremen, Mar 16-18. 8. G. Goyal et. al, Online Quality Monitoring in Spinning