Distributed Spinning Frame Monitor System Based on DSP and PROFIBUS

Chun-ying WU Li-yan ZHANG Institute of Information Science & Engineering Hebei University of Science and Technology.

HeBei ShiJiaZhuang , CHINA, 050011 Chunying_1965@163.com

Lie CAO ShiJiaZhuang Vocational College of Foreign Language

Translation HeBei ShiJiaZhuang, CHINA ,050011

Abstract—In order to improve the management level, promote informationization and automation in textile enterprise, a spinning’s monitor management system based on DSP and PROFIBUS is discussed in this article. By using field monitory system, production management system and server system to form three layers network architecture, connecting all computers from workshops (detect real-time computer) with computers from offices (monitor computer) through intranet, it can realize monitoring real-time and auto-control to the production process, trace dynamicly to the parameters. For illustration, there gives the detail design for the monitor system, discuss the architecture of network, the whole software design of the system and the key to design database. Empirical results show that it gives an approach for the textile enterprise to realize information and modernization.

Keywords-textile, spinning, PROFIBUS; DSP; monitor; database; network)

I. INTRODUCTION

Conventional spinning has traditionally consisted of a series of operations performed by individual machines and has involved a great deal of hand labor. Although continuous spinning and some automation have come into use, spinning is still a long and expensive process. Spinning process is the last process to spinning fiber into yarn.

With the development of advanced manufacture technique, many advanced spinning machines are used, such as FA series type spinning machine(FA502 ,FA503FA506,etc.). But meanwhile many textile enterprises still manage production by manual such as single machine monitoring, recording all information of production by hand. There shows a striking contrast between advanced technique and old management. It’s an availability approach for the textile enterprise to realize modernization management by

using of computer and network. Management informationize is the development direction for textile industry..

In recent years, although there are some reports occasionally about spinning frame production monitor and information management system, but most of those are only about single machine, it can only finish the function of production data monitoring, querying, statistic, and table printing. A spinning workshop production monitoring and management system based on computer and network is designed in this paper, it can implement information collection real-time, multi-thread monitoring online in distance. It can improve the informationization level of spinning.

II. ARCHITECTURE OF NETWORK

The whole network architecture is divided into three layers: field monitor system, production management system and sever system. [1] They are connected through intranet. The structure of monitor management system consists of upper machinery (main computers in spinning workshop) and lower machinery (spinning monitor).They are connected by PROFIBUS to form the second distributed computer system. It can implement distribute collection for production data and management centralization. By using of intranet, the upper machinery and other computer from office form client/server structure system. The upper machinery collects production information from spinning monitor real-time and then transmits it to server. The client computer can also query, static and analyze production data real-time from data server. See Figure 1.

III. ARCHITECTURE OF SOFTWARE SYSTEM

According to the actual situation of workshop, the functions of software system include:

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• Spinning monitor should real-time collect data information of yarn breakage, speed of front roller, time of stoppage, frequency of doffing, name of labor and shift information, etc, for each spinning frame. It can also store data information of each shift [2].

• Monitoring dynamicly the spinning frame with distribute position ichnography, showing production data information of each shift in table.

• Spinning frames management. It can record information for each spinning frame, such as the rate of running, the maintenance cycle, numbers of spindle, etc.

• Production processing parameters management. According to the kind of yarn, it can calculate the main processing parameter, such as speed of front rollers, speed of winding, twist level of yarn, times of yarn drawing and so on.

• Good adaptability. It’s convenient to maintain, extend and networking.

• It has function of failure diagnosis, alarming and

searching for troubles • Data security. In order to ensure data security,

different operation stuffs have different access right. Such as only the technician has right to modify the production processing parameters. See Figure 2

A. System Management

System management include: logging on, password setting, access right setting, initial setting, client user management, and database backup as well as data recovery. In order to ensure data security, data sever has additional function to identify client’s IP address, if it finds the client’s IP isn’t in the list, the accessing to data sever will be rejected.

B. Monitor Real-time System

First, upper machinery communicate to monitor, then if communication is successful it will send production processing parameters to monitor, and meanwhile it can receive the message (speed of front roller, speed of winding, etc.) from monitor to analyze the behavior of spinning

Distributed spinning frame computer monitor system

System management

Production processing parameter

Machinery management

Monitor real-time system

Quality control system

Stuff management

Figure 2 Architecture of software system

Spinning monitor 1

Spinning monitor 2

Spinning monitor N

……

……

……

……

PROFIBUS Upper computer

Data exchange

Intranet of textile enterprise

Collection real time

Spinning workshop

Upper computer

Database server

Web server Utility server

Data exchange

Figure 1 Architecture of network

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frames. The upper computer can calculate the times of drawing, twist level of yarns, production of each shift, and production efficiency, etc. All those informations are shown in table so as to being managed conveniently.

C. Production Processing Parameters

Main function of parameters system include: port setting for each entity, working out shift sheet, grouping setting for all spinning machines, printing and showing the process parameters sheet.

D. Machinery Management System

• Numbering each entity, grouping all machines according to the kind of yarn.

• Monitoring each machine, it can diagnose failure and give alarm signal.

• Re-grouping all machines when new kind of yarn is produced.

E. Production Management System

• Querying, statistic, analyzing the production data information.

• Indexing production plan monthly and daily through the API of ERP system so as to give basis data information to calculate the parameters of spinning machine.

• Input the information of failure machine, such as time and reason of stoppage.

• Printing production sheet monthly and daily. It can realize second edit by using of Excel.

F. Quality Management System

The model of quality management can input, query and statistic the information of equipment utility rate, empty spindle rate, breaking rate.

IV. SOFTWARE DESIGN FOR UPPER SYSTEM

Because the software for upper system relates to data’s communication, handle and shared, so Visual Basic 6.0 is used to develop the user interface, it’s easy to communicate with lower system by WinAC Computing control.[3] The principle to design the software should be simple and

practical .The main function should include showing signal real-time, adjusting parameter, storing the important history data, showing graphics, alarming and printing tables.

V. THE HARDWARE OF SPINNING FRAME FIELDMONITOR

A. Spinning Frame Monitor

The field structure of spinning frame monitor is shown as Figure 3. It is consisted of:

• FA506 spinning frame with SIEMENS MDV inverter • PROFIBUS(Process Field Bus) with CP5611 card,

CPU226+EM277 and PROFIBUS network cable[4]. • Siemens industry personal computer(IPC) : SIMATIC

RACK PC • Siemens pc based automation component : WINAC. WINAC has a software controller called

WINLC(Windows Logic Controler embedded in. PROFIBUS( CP5611, CP5613) is used as main site ,it can drive directly to external attachment site through software. See Figure 4.

VI. DATABASE DESIGN

SQL Server 2000 is used to develop the database. Database designing is the foundation for system to store, analyze, query and statistic data. Because the quantity of data information is larger, kinds are plenty of, frequency of accessing is higher, database design must be done according to the rule of relational database model. Meanwhile, all kinds of tables should obey the relationship of 3NF so as to reduce the storage redundancy.[5]

In order to optimize database, the following three points should be considered:

• The relationship data items should be store in the same or adjoin physical block so as to improve the query efficiency

• Using triggers to ensure the data consistency in database.

• Application program doesn’t access directly the database. Instead, by running storage procedure to capture data.

Figure 3 Field structure of spinning frame monitor

PROFIBUS

• PC based control software WINAC• Main site with CP5611 card • Database and monitor software

Spinning workshop

Repeaters

Spinning frame FA506

Figure 4 Software structure of Upper machine

WINLC

CP5611

EM277 WINLC DP others

WINCC STEP

STEP7

ACTIVE X Third party

software

PROFIBUS-DP

PC

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The most important production database tables are designed dynamic or static. The dynamic table stores temporality the real-time data, on the other hand, the static table stores history data which can be retrieved by time and shift.

VII. NETWORK MANAGEMENT

The architecture of this system is client/server, so all distance clients share the same database with server. In order to ensure clients can query, input, print and download distance through intranet, the network management is an important technical key that must to think about. The solution is to establish account number, register IP, assignment accessing rights for each client by using the

management software installed in main computer. Every client has an trust levels and limited connection time.

VIII. SUMMARY

The system realizes information collection and monitors the status of the spinning machine real-time for the textile workshop by using of DSP microprocessor and PROFIBUS. It has advantage of simple structure, maintaining and extending easily, excellent anti-disturb ability under the condition of high rate of communication. Practice has proved that it’s benefit to the textile enterprise .The management and productive control reach a good grade by using of this system .It supplies a good foundation for the mill to realize digitization and modernization.

REFERENCES

[1] Q.B. Liu Design of network supervise system of rapier loom based on the DSP and CAN field bus. [Paper of the Master Degree of Engineering, ZheJiang University]. 2004:26-46.

[2] J.F. Shao, L.S.Qin. Design of loom monitoring and management system based on C/S model. Journal of Textile Research, 2006, 27(7): 75-78

[3] L.Y. Mou. The process of constructing a primary module based on DSP and CAN-bus for an electronic aero-engine controller . [Paper of the Master Degree of engineering. NanJing University of aeronautics and astronautics.]. 2004:12-16.

[4] J. Liu. The computer monitor system of spinning machine . Journal of Wuhan University of Science and Engineering , 2006 ,19 (3) :16 - 19.

[5] ZH.G. Bao, X.J. Gu, H.H.Xu, et al. Reconfigurative customer relationship management system for textile machinery industry . Journal of Textile Research ,2006 ,2(12) :117 - 120.

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