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Weaving machine as cyber-physical production system: Multi-objective self-optimization of the weaving process

Real (physical) objects melt together with information-processing (virtual) objects. These blends are called Cyber-Physical Production Systems (CPPS). The German government identifies this technological revolution as the fourth step of industrialization (Industry 4.0). Through embedding of intelligent, self-optimizing CPPS in process chains, productivity of manufacturing companies and quality of goods can be increased. Textile producers especially in high-wage countries have to cope with the trend towards smaller lot sizes in combination with the demand for increasing product variations. One possibility to cope with these changing market trends consists in manufacturing with CPPS and cognitive machinery. This paper focuses on woven fabric production and presents a method for multi-objective self-optimization of the weaving process. Multi-objective self-optimization assists the operator in setting weaving machine parameters according to the objective functions warp tension, energy consumption and fabric quality. Individual preferences of customers and plant management are integrated into the optimization routine. The implementation of desirability functions together with Nelder/Mead algorithm in a software-based Programmable Logic Controller (soft-PLC) is presented. The self-optimization routine enables a weaving machine to calculate the optimal parameter settings autonomously. Set-up time is reduced by 75 % and objective functions are improved by at least 14 % compared to manual machine settings.