EP1475470B1 - Data acquisition and processing system for controlling and operating a set of industrial sewing machines and method for controlling and operating this set with a data acquisition and processing system - Google Patents

Abstract

An installation (2) of industrial sewing machines (3) has a central computer (11) and memory (18). A communication device (7) is connected to each machine controller (4) with a standard interface by a first signal path (6) and to the central computer (11) by a second signal path (12) through a local network (9). The communication device (7) can deal with processing conditions, machine control, operator details and servicing requirements in the form of data packets. An independent claim is also included for the control and monitoring of industrial sewing machines by collecting data from individual machines (3) and transmitting it to a communication device (7). It is then transmitted to a central computer (11) where it is monitored and processed. Control data can be initially determined from a sample sewing machine (14) and then evaluated statistically from plant data.

Description

The invention relates to a data acquisition and processing system for monitoring and controlling a composite of industrial sewing machines and a method for monitoring and controlling such a network with a data acquisition and processing system.

From the US Pat. No. 5,970,894 discloses a data acquisition and processing system for monitoring and controlling an assembly of industrial sewing machines, in which a plurality of industrial sewing machines are each separately connected to a central monitoring and control computer which provides sewing process data to the sewing machines and repair relevant data unique to each industrial sewing machine are stored, interrogated. For connecting a single industrial sewing machine to the control and monitoring computer, a number of special solutions are proposed, in particular the connection via a local network. The storage of repair-relevant data in storage media of the individual sewing machines then presents a problem if the sewing machine fails in such a way that access to the internal memory of the sewing machine via the central control and monitoring computer is no longer possible. Older sewing machine types also have no interfaces for connecting to the currently used local networks. The adaptation of each individual sewing machine to a currently used local network is again too costly.

From the EP 0 356 181 A1 an automated working composite of industrial sewing machines with a central control computer is known, which is on the one hand with a central data storage and on the other hand via an interface with the sewing machines of the network in data connection.

The US 4,932,342 discloses a sewing machine network, wherein the individual sewing machines can be connected to a central control computer via a Local Area Network (LAN).

The US 4,369,722 describes a further automated sewing machine combination.

It is an object of the present invention, a data acquisition and processing system of the type mentioned in such a way that it is flexible and reliable for a sewing machine network can be used, which includes older sewing machines.

This object is achieved by a data acquisition and processing system with the features specified in claim 1.

According to the invention, it has been recognized that instead of the complex connection of each individual older sewing machine to a local area network via, for example, an RS232 interface and a so-called gateway, it is possible to use a single data communication device to connect a plurality of sewing machines of the network. This considerably reduces the expenditure on equipment when connecting the sewing machines to the local network. Through such a connection to the local network, the possibility is created for all sewing machines of the network, So even for older types of sewing machines, make separate from the respective sewing machine storage of the working data of the sewing machine. Work data can here be sewing process data, that is, data on the sewing tasks of the individual sewing machine, and operating data of the sewing machine. In particular, a transmission of qualified error messages from the respective sewing machine to the central monitoring and control computer is possible via the local network, which ensures efficient service of the sewing machines. Also, a documentation of the entire operation of the sewing machine network is possible. The remote from the respective sewing machine storage of the working data can be done in the data communication device, in a server of the local network or in the central data memory of the central monitoring and control computer. The interfaces via which the sewing machines are connected to the data communication device depend on the respective sewing machine type. Older sewing machines usually have an RS232 interface or an RS485 interface. For older types of sewing machines, it may additionally be necessary to exchange processor components of the respective machine control with the data communication device in order to realize the data exchange. This is possible with little effort. Depending on the configuration of the monitoring and control software of the central monitoring and control computer, an operation of the data acquisition and processing system tailored to the respective sewing application is possible. The central data storage ensures fast access to all data collected during monitoring and control. The input interface increases the flexibility of the data acquisition and processing system. The already existing in most sewing machines data input device can in this way in the system, for example, for the registration of operators, to adapt sewing process data or repair information or used for a service request. Alternatively, it is possible to provide a special data input device tailored to the data acquisition and processing system in each sewing machine of the network. A division of the data packets into a function address and a function number is particularly clear. The local area networks, such as a LAN or a field bus, are reliable and provide a data transfer rate sufficient to operate the data acquisition and processing system.

Data packets according to claim 2 can be both Nähprozess- and operating data packets. Such data packets can be easily transmitted via standard interfaces.

Coded entries according to claim 3 reduce the amount of data to be exchanged during operation of the data acquisition and processing system between the sewing machines and the central monitoring and control computer.

A data communication device according to claim 4 can be adapted to different types of industrial sewing machines.

A buffer of the data communication device according to claim 5 allows a retrieval of the cached data there at longer intervals, for example daily.

An internal clock of the data communication device according to claim 6 allows data storage with associated real-time information. It is then possible to automatically record the exact time of the creation of the respective stored working date, which is especially true is advantageous for the monitoring and for a statistical analysis of the working data.

An evaluation module according to claim 7 provides the ability to selectively detect certain types of errors or frequencies or other significant information during operation of the industrial sewing machine network. This makes it possible to make corrections to the concept of the industrial sewing machine network in addition to the repair of errors occurring in order to avoid particularly frequent errors.

Another object of the invention is to provide a method for monitoring and controlling an industrial sewing machine network with the data acquisition and processing system according to the invention.

This object is achieved by a method according to claim 8.

With such a method, in particular an operation monitoring of all industrial sewing machines is possible without the individual industrial sewing machines have to be converted consuming. Due to the transfer of the data packets with function addresses and function numbers, it is possible, for example, to search for specific function addresses or function numbers in order to detect the occurrence of specific individual processes.

Further advantages of the method according to the invention will become apparent from the above discussion of the data acquisition and processing system according to the invention.

When inputting work data via the data input device, if a bidirectional data transfer via the data input device is given, an acknowledgment, for example of a service request, is also possible. The data input device can in particular also be designed such that a voice message is possible.

The connection of a pattern sewing machine according to claim 10 allows a precisely tailored to the respective sewing situation specification of Nähprozessdaten by the central monitoring and control computer.

Caching according to claim 12 reduces the requirements for the local network. As an alternative to such caching, online monitoring is also possible.

The presentation of the data according to claim 15 may also include the possibility of sorting the data according to certain sorting algorithms or a search function for certain transmitted work data.

Fig. 1

schematisch die Datenkommunikation innerhalb eines Datenerfas- sungs- und -verarbeitungssystems zur Überwachung und Steuerung eines Verbundes von Industrienähmaschinen;

Fig. 2

schematisch den internen Aufbau eines Datenkommunikationsgeräts des Datenerfassungs- und -verarbeitungssystems von Fig. 1;

Fig. 3

ein Ablaufdiagramm eines Verfahrens zur Überwachung und Steue- rung eines Verbundes von Industrienähmaschinen mit dem Datener- fassungs- und -verarbeitungssystems der Fig. 1 und 2; und

Fig. 4

ein Datenpaket, mit dem Daten innerhalb des Datenerfassungs- und -verarbeitungssystems der Fig. 1 transferiert werden.

An embodiment of the invention will be explained in more detail with reference to the drawing. In this show:

Fig. 1

schematically the data communication within a data acquisition and processing system for monitoring and controlling an assembly of industrial sewing machines;

Fig. 2

schematically the internal structure of a data communication device of the data acquisition and processing system of Fig. 1 ;

Fig. 3

a flowchart of a method for monitoring and control of a combination of industrial sewing machines with the data acquisition and processing system of the Fig. 1 and 2 ; and

Fig. 4

a data packet containing the data within the data acquisition and processing system of the Fig. 1 be transferred.

An in Fig. 1 Overall, designated by the reference numeral 1 data acquisition and processing system is used to monitor and control a composite 2 of industrial sewing machines 3. Each industrial sewing machine 3 has its own machine control 4 and running as a terminal 5 Data input device. Each terminal 5 has a control panel and a display.

Via a first bidirectional signal path 6, each machine control 4 is connected to a data communication device 7. The signal path 6 may be, for example, a signal line that communicates with the machine controller 4 via an RS232 interface. Other types of signal connections and interfaces can also be used - depending on the type of sewing machine 3 to be connected - in the signal path 6. This may include a wireless signal connection.

When in Fig. 1 1, a single data communication device 7 is provided for data communication with all industrial sewing machines 3 of the composite 2. In an alternative data acquisition and processing system 1, a plurality of data communication devices 7 may be provided. However, the number of the data communication devices 7 is less than or equal to that of the industrial sewing machines 3.

Via a bidirectional signal connection 8, the data communication device 7 is connected to a local network 9. The latter is connected via a further bidirectional signal connection 10 with a central monitoring and control computer 11 of the data acquisition and processing system 1 in connection.

The two signal connections 8, 10, which may be formed in accordance with the first signal path 6, together with the local network 9, constitute a second signal path 12 for connecting the data communication device 7 to the central monitoring and control computer 11.

Via a further bidirectional signal connection 13, the central monitoring and control computer 11 is also connected via the network 9 with a pattern sewing machine 14 with machine control 15 and terminal 16.

Another bidirectional signal connection 17 represents a data connection between the central monitoring and control computer 11 and a central data memory 18. The latter comprises a plurality of, in Fig. 1 a total of six, data storage modules 19.

The internal structure of the data communication device 7 is shown schematically Fig. 2 , A microprocessor 20 of the data communication device 7 is connected via a first section 21 of an internal bus system 22 with a RAM 23 as a storage unit, a flash ROM 24 and an internal real-time clock 25. Via a second section 26 of the internal bus system 22, the microprocessor 20 is provided with a flash card interface 27, a Universal Asynchronous Receiver / Transmitter (UART) 28, an Ethernet interface 29, a Profibus / CAN bus interface 30, a Universal Serial Bus (USB) interface 31, a multi-port input / output device (multiport I / O) 32 and a terminal interface 33 in conjunction. The UART 28 in turn is connected via data lines 34 to a total of sixteen RS232 interfaces 35 and via a data line 36 to an RS485 interface 37. For the electrical supply of the data communication device 7 is a power supply 38th

The various interface variants 27 to 37 of the data communication device 7 can each be used to connect the data communication device 7 with the industrial sewing machines 3 and the local network 9 are used. In the data acquisition and processing system 1 of the embodiment of FIGS Fig. 1 to 3 the connection of the data communication device 7 with the industrial sewing machines 3 via the RS232 interfaces 35. In this embodiment, the connection of the data communication device 7 takes place with the local network 9 via the Ethernet interface 29th

In Fig. 4 a data packet 39 is shown. In the form of such data packets 39, working data is transferred within the data acquisition and processing system 1. The working data can be sewing process data or operating data or service requirements of industrial sewing machines 3. Each data packet 39 is assigned to a specific process or operating situation of the industrial sewing machines 3 and comprises a function address 40 and a function number 41.

The function address 40 refers to a stored in the central monitoring and control computer 11 general function and may for example be a four-digit decimal number. The function number 41 serves to individualize the function to which the function address refers, and may be, for example, an eight-digit decimal number. The data packets 39 is assigned a real-time information in the data communication device 7 yet. For this purpose, the microprocessor 20 queries the internal real-time clock 25. The establishment of a function address 40 and a function number 41 has the advantage that an open system is thereby provided, the functionality of which can be set individually by each user of the data acquisition and processing system 1.

A method for monitoring and controlling the network 2 with the data acquisition and processing system 1 is as follows:

First, a Nähdatenprogrammierung, which can be omitted if the same sewing program always runs on the industrial sewing machines 3. In sewing data programming, sewing process data are first predefined in a predefined step. For this purpose, 14 pattern seams are sewn using the pattern mower until all parameters and boundary conditions for the applied with the industrial sewing machines 3 seams are set. The mode of operation of the pattern sewing machine 14 can be influenced by the central monitoring and control computer 11 via the bidirectional signal connection 13. After completion of the pattern sewing operation, the sewing process data thus determined are transmitted from the pattern sewing machine 14 to the central monitoring and control computer 11 via the signal connection 13. The latter then controls the filing and cataloging of the sewing process data in the data storage modules 19 of the central data memory 18 in a filing step 43.

In a first forwarding step 44, the central monitoring and control computer 11 forwards the sewing process data via the second signal path 12 to the data communication device 7. The sewing process data arrive at the Ethernet interface 29 of the data communication device 7 and are directed to the UART 28 under the control of the microprocessor 20. If necessary, the sewing process data can also be stored in the memory unit 23 of the data communication device 7. This caching takes place in a buffer step 45. The cached sewing process data can be retrieved, if necessary, from the machine controls 4 from the data communication device 7 via the RS232 interfaces 35. The UART 28 distributes the sewing process data over the data lines 34 and the RS232 interfaces 35 and the first signal paths 6 to the machine controls 4 of the industrial sewing machines 3. This is done in a second forwarding step 46th

This concludes the procedure for sewing data programming. The sewing process data, which can be stored as a data set or as parameters in the machine controls 4, can alternatively also be programmed via the terminals 5 of the industrial sewing machines 3 or be changed by the operator depending on the sewing sequence. Both by hand and with the aid of the method described for sewing data programming, a plurality of seam patterns can be programmed into the machine controls 4 and retrieved depending on the article to be sewn.

With the aid of the described sewing data programming specification of the sewing process data by the central monitoring and control computer 11, a complete seam documentation during the operation of the composite 2 is possible.

Furthermore, the monitoring and control of the composite 2 with the aid of the data acquisition and processing system 1 also includes management and evaluation of the working data of the individual industrial sewing machines 3 of the composite 2. For this purpose, operating data of the sewing machine 3 are detected in a detection step 47 with the aid of corresponding sensors and encoders , The following data may belong to this operating data: Actual speed, Power ON state, Drive running, Seam end, Free seam active, Counted seam active, Sewing foot lift active, Interlock active, Thread trimmer active and Error status. Further data that are acquired are the sewing process data present in the respective machine controller 4. After all Work data can also be entered in the course of an input step 48 via the terminal 5 by hand in the machine control 4. The acquired or entered data are then transmitted in a further forwarding step 49 from the machine controls 4 via the first signal paths 6 to the data communication device 7 and arrive there via the RS232 interfaces 35. The data is then forwarded via the UART 28 and, under the control of the microprocessor 20, to the Ethernet interface 29. Alternatively or additionally, the acquired data, controlled by the microprocessor 20, stored in the memory unit 23 in a buffering step 50 and retrieved as needed. Instead of buffering the working data in the intermediate storage steps 45 and 50, the working data can also be forwarded online, for example every 500 ms. Via the Ethernet interface 29, the acquired data then pass via the second signal path 12 to the central monitoring and control computer 11. This takes place in a second forwarding step 51. Subsequently, the acquired working data are controlled by the central monitoring and control computer 11 in FIG stored central data memory 18. This is done in a storage step 52. The storage of the acquired work data in the central data memory 18 takes place in a conventional database format, for example in the format DBASE.

The work data recorded, for example, during a production day are then evaluated by the central monitoring and control computer 11 in an evaluation step 53. The evaluation can take place, for example, with the aid of one of the known database programs. The evaluation in the evaluation step 53 takes place in an evaluation module 53 a of the central monitoring and control computer 11.

In the context of the input step 48, the respective industrial sewing machine 3 can for example be assigned a serial number. For this purpose, the operator, who has installed the industrial sewing machine 3, enters a data packet 39 via the terminal 5 of the industrial sewing machine 3. First of all, the input of the function address 40, which stands for the input of the serial number, takes place. Then enter the serial number of the machine as function number 41. With the input step 48, the registration of an operator at the beginning of commissioning of the industrial sewing machine 3 can also take place. For this purpose, a data packet 39 is also entered. First, the entry of the standing for the entry of a personnel number function address 40. Subsequently, the personnel number of the operator is entered as function number 41. In the same way, by entering appropriate data packets 39, a mechanic can be registered. Also, for example, the completion of a service process can be entered by entering a corresponding data packet 39. For this purpose, the type of service or repair work is entered as function number 41 in addition to a function address representing the service end.

With the help of the input step 48, a service request can also be made. For this purpose, the operator inputs a data packet 39 with a function address 40 representing a service request and a function number relating to the specific service content. Such a function number 41 can stand, for example, for the service request "replace thread bobbin." The receipt of such service requests can be acknowledged via the central monitoring and control computer 11. The service request can then be processed further. This may be, for example, an automatic request for information to a service mechanic by means of telephone call, email, SMS.

For inputting longer sequences of data packets 39, for example when preselecting sewing process data, 48 software input masks are used in the input step.

For example, in the statistical evaluation in evaluation step 53, the total number of repairs during a certain period or the number of repairs of an industrial machine 3 during a certain period of time or the number of all repaired parts during a certain period of time can be compiled. Corresponding compilations are also possible with the transferred service requests.

The evaluated work data are then displayed in a presentation step 54 on a screen of the central monitoring and control computer 11. Depending on the selection of the user, this representation takes place, for example, in tabular form, wherein a column selection and a sorting specification can be specified. The illustrated table may include, for example, the industrial sewing machines 3 used in the production with manufacturer and type information and serial number and each to be produced sewing order. Also, for example, the currently operating operators or the currently active mechanics or the currently performed service work or the currently unprocessed service requests can be displayed. The work data can also be sorted in time by the associated real-time information of the data packets 39 during the presentation step 54. Search functions, for example for specific function addresses 40 or function numbers 41, are also possible in the frame of the evaluation step 53. The in the presentation step 54 shown labor data can be deleted, changed or re-entered if desired.

The operating data can also be evaluated and displayed accordingly, in particular also graphically.

Claims (15)

1. Data acquisition and processing system (1) for monitoring and controlling a set (2) of industrial sewing machines (3), the system (1) comprising

   - a central monitoring and control computer (11) which is connected to a central data memory (18);

   - at least one data communication device (7) which

   -- is connectable to machine control systems (4) of a multitude of the sewing machines (3) of the set (2) via a first signal path (6);

   -- is connected, via a second signal path (12), to the central monitoring and control computer (11) at least temporarily via a local network (9); and

   -- wherein the data communication device (7) comprises a standard interface (27 to 37) for connection with the respective machine control system (4),

   characterized in that

   - wherein the local network (9) is a LAN or a fieldbus;

   - the data communication device (7) is designed in such a way as to transmit service inquiries by the sewing machines (3) in the form of data packages (39) provided with a function address (40) and a function number (41);

   - the data communication device (7) comprises an input interface (33) in the form of a terminal interface for connection with a data input device (5) in the form of a terminal at the respective sewing machine (3).
2. Data acquisition and processing system according to claim 1, characterized in that the data communication device (7) is designed in such a way as to transmit operational data such as operating data, program data of the control system or of the drive, inspection data, personnel data (service person / operator), hour meter data of the sewing machines (3) in the form of data packages (39).
3. Data acquisition and processing system according to claim 2, characterized in that the data packages (39) contain coded entries (40, 41) which are assigned to particular process or operating situations, wherein the data packages (39) in particular contain a function address (40) which refers to a general function stored in the central monitoring and control computer (11) and in particular a function number (41) for individualizing the function.
4. Data acquisition and processing system according to one of claims 1 to 3, characterized in that the data communication device (7) comprises several network interfaces (29 to 32) for connection to different types of local networks and/or several communication interfaces (27, 35, 37) for connection to different types of sewing machines (3).
5. Data acquisition and processing system according to one of claims 1 to 4, characterized in that the data communication device (7) comprises a rewritable intermediate memory (23, 24) for storing operational data of the sewing machines (3) connected to the data communication device (7).
6. Data acquisition and processing system according to one of claims 1 to 5, characterized in that the data communication device (7) comprises an internal clock (25).
7. Data acquisition and processing system according to one of claims 1 to 6, characterized in that the central monitoring and control computer (11) comprises an evaluation module (53a) for statistical evaluation of the operational data received from the data communication device (7).
8. Method for monitoring and controlling a set (2) of industrial sewing machines (3) using a data acquisition and processing system (1) according to one of claims 1 to 7, the method comprising the following steps:

   - recording (47) operational data of the sewing machines (3) in the form of service inquiries in the form of data packages (39) having a function address (40) and a function number (41) by means of the respective machine control system (4);

   - transmitting (49) the operational data from the respective machine control system (4) to the data communication device (7);

   - transmitting (51) the operational data from the data communication device (7) to the central monitoring and control computer (11), the data communication device (7) comprising an input interface (33) in the form of a terminal interface;

   - monitoring (53, 54) the operational data by means of the central monitoring and control computer (11),

   - wherein the operational data are entered (48) via a data input device (5) in the form of a terminal at the respective sewing machine (3).
9. Method according to claim 8, characterized by the following steps:

   - defining (42) sewing process data for at least one of the sewing machines (3);

   - transmitting (44) the sewing process data from the central monitoring and control computer (11) to the data communication device (7);

   - transmitting (46) the sewing process data from the data communication device (7) to the respective machine control system (4).
10. Method according to claim 9, characterized in that the sewing process data are defined via a model sewing machine (14) which is connected to the central monitoring and control computer (11) via the local network (9).
11. Method according to claim 9 or 10, characterized in that the sewing process data are stored (43) in the central data memory (18).
12. Method according to one of claims 8 to 11, characterized by an intermediate storage (45, 50) of the operational data in the data communication device (7) until the operational data are accessed.
13. Method according to one of claims 8 to 12, characterized by a statistical evaluation (53) of the operational data received from the data communication device (7) in the central monitoring and control computer (11).
14. Method according to one of claims 8 to 13, characterized by a storage (52) of the operational data in a data base format.
15. Method according to one of claims 8 to 14, characterized by a display (54) of the operational data.

Images