A replacement device for heating and driving controller of spinning hot roller

Abstract

The present invention discloses a replacement device for a spinning hot roller heating and driving controller, comprising a process setting computer and a main control board, wherein the process setting computer and the main control board are electrically connected, and further comprising a first controller for simulating communication between a frequency converter and the main control board and a second controller for simulating communication between a temperature controller and the main control board, wherein the second controller is electrically connected to the main control board, and the first controller is electrically connected to the process setting computer and the main control board respectively. The present invention provides a low-cost and easy-to-maintain replacement device for a spinning hot roller heating and driving controller.

Description

Technical Field

[0001] The invention relates to the technical field of chemical fiber processing, and in particular to a replacement device for a heating and driving controller of a spinning hot roller. Background Art

[0002] There is a polyester yarn production line imported from abroad that is specially used for spinning polyester yarn. Each part of the production line contains two hot rollers, two spindle rollers and a traverse roller. The five rollers are driven by five special inverters respectively, and the temperature of the two hot rollers is controlled by two special temperature controllers. Figure 1 As shown. The setting parameters of these inverters and temperature controllers are input from the process setting computer, transmitted to the main control board of each part through the communication line, and then transmitted by the main control board. Five of the inverters are connected to a communication port of the main control board of the part, and two temperature controllers are connected to the main control board of the part through another communication port. The actual operation data of the inverter and temperature controller are also fed back to the computer through these two communication ports. When spinning polyester yarn on these production lines, the tows are heated by two hot rollers before winding. The polyester yarn production line can be used to spin nylon yarn after modification. According to the existing technology, two of the production lines can meet the production requirements without heating by hot rollers because of the products they are spun. Considering energy saving and cost saving, the hot rollers and corresponding inverters and temperature controllers of these two lines were removed. However, after removing the inverter and temperature controller, it was found that the computer kept displaying information about communication failure of the hot roller inverter and temperature controller. Since the original program in the process setting computer does not save the old alarm information, the alarm interface of the computer displays almost all the communication fault information of the hot roller inverter and temperature controller of each part. Other electromechanical fault information is covered by these two communication fault information, which is very unfavorable for equipment maintenance. For the above reasons, even if the hot rollers of these two production lines are removed, each winding head still needs to retain two imported hot roller inverters and two hot roller temperature controllers to communicate with the main control board. The above situation has the following problems during use:

[0003] 1. A large number of hot roller inverters and temperature controllers do not participate in actual control but must be retained, which increases the usage of inverters and temperature controllers and increases equipment costs.

[0004] Second, due to the presence of oil mist in the environment around the electrical control cabinet, these hot roller inverters and temperature controllers may fail due to oil mist or other reasons, thereby increasing the workload of electrical instrument maintenance workers. Summary of the invention

[0005] The technical problem to be solved by the present invention is to overcome the defects of the above-mentioned prior art and provide a low-cost and easy-to-maintain alternative device for heating and driving a spinning hot roller controller.

[0006] In order to achieve the above object, the technical solution of the present invention is:

[0007] A replacement device for a spinning hot roller heating and driving controller comprises a process setting computer and a main control board, wherein the process setting computer is electrically connected to the main control board. The invention also comprises a first controller for simulating communication between a frequency converter and the main control board and a second controller for simulating communication between a temperature controller and the main control board, wherein the second controller is electrically connected to the main control board, and the first controller is electrically connected to the process setting computer and the main control board respectively.

[0008] After adopting the above structure, the present invention has the following advantages compared with the prior art: a first controller is provided for simulating the communication between the frequency converter and the main control board, and a second controller is provided for simulating the communication between the temperature controller and the main control board, so that the frequency converter and the temperature controller can be removed, which is beneficial to production. By reducing the frequency converters and temperature controllers in use, the electrical failure rate can be reduced, thereby reducing the impact of electrical failures on production; it is beneficial to the maintenance of the front-end spinning electrical instruments: on the one hand, the decrease in the failure rate of the electrical appliances in use can reduce the workload of electrical instrument maintenance; on the other hand, due to the increase in spare frequency converters and temperature controllers, electrical instrument technicians can have sufficient time to repair faulty electrical appliances, thereby improving the maintenance quality.

[0009] Preferably, the first controller includes a first control chip, a first communication chip and a second communication chip. The main control board, the first communication chip, the first control chip and the second communication chip are electrically connected end to end to form a closed loop. The set speed signal is sent from the process setting computer and is sequentially sent to the first control chip through the main control board and the first communication chip. The feedback speed signal is sent from the first control chip and is sequentially sent to the process setting computer through the second communication chip and the main control board, which facilitates communication between the analog inverter and the main control board.

[0010] Preferably, it also includes a third communication chip, and the third communication chip is electrically connected to the process setting computer and the first control chip, and has high reliability.

[0011] Preferably, it also includes a USB / 485 communication converter, the process setting computer and the third communication chip are connected via the USB / 485 communication converter, a new monitoring and recording program is compiled on the process setting computer, the replacement device and the replacement devices in other parts form a network, and then the frequencies of the traverse and spindle inverters of each part are sent to the process setting computer through a USB / 485 communication converter to facilitate inspection and tracing by process and management personnel.

[0012] Preferably, it also includes a third communication interface, and the third communication chip and the USB / 485 communication converter are connected via the third communication interface, which has high reliability.

[0013] Preferably, it also includes a first communication interface, and the first communication chip and the second communication chip are both connected to the main control board via the first communication interface to facilitate communication.

[0014] Preferably, the second controller includes a second control chip, a fourth communication chip and a fifth communication chip. The main control board, the fourth communication chip, the second control chip and the fifth communication chip are electrically connected end to end to form a closed loop. The set temperature signal is sent from the process setting computer and is sequentially sent to the second control chip through the main control board and the fourth communication chip. The feedback temperature signal is sent from the second control chip and is sent to the process setting computer through the fifth communication chip and the main control board, which is convenient for simulation.

[0015] Preferably, it also includes a second communication interface, and the fourth communication chip and the fifth communication chip are both connected to the main control board via the second communication interface to facilitate communication.

[0016] Preferably, it also includes a housing, and the first controller and the second controller are arranged on the same PCB board and integrated in the housing, thereby reducing space and facilitating integration. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a circuit schematic diagram of a polyester yarn production line in the prior art;

[0018] Figure 2 It is a circuit schematic diagram of a device for replacing a heating and driving controller for a spinning hot roller according to the present invention;

[0019] Figure 3 It is a program flow chart of the communication between the thermostat and the main control board of a substitute device for the heating and driving controller of a spinning hot roller of the present invention;

[0020] Figure 4 It is a replacement device for the heating and driving controller of a spinning hot roller of the present invention, and the internal wiring diagram of the first controller and the second controller;

[0021] Figure 5 The invention discloses a program flow chart of a replacement device for a spinning hot roller heating and driving controller, which simulates the communication between a frequency converter and a main control panel and a process setting computer.

[0022] Among them, 1. process setting computer, 2. main control board, 5. third communication chip, 6. first control chip, 7. first communication chip, 8. second communication chip, 9. USB / 485 communication converter, 10. third communication interface, 11. first communication interface, 12. second control chip, 13. fourth communication chip, 14. fifth communication chip, 15. second communication interface, 16. shell. DETAILED DESCRIPTION

[0023] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.

[0024] like Figure 2 As shown, the present invention provides an alternative device for the heating and driving controller of a spinning hot roller, comprising a process setting computer 1 and a main control board 2, wherein the process setting computer 1 is electrically connected to the main control board 2, and further comprises a first controller for simulating communication between a frequency converter and the main control board 2 and a second controller for simulating communication between a temperature controller and the main control board 2, wherein the second controller is electrically connected to the main control board 2, and the first controller is electrically connected to the process setting computer 1 and the main control board 2 respectively. The advantage of the present invention is that a first controller is provided for simulating communication between the frequency converter and the main control board 2, and a second controller is provided for simulating communication between the temperature controller and the main control board 2, so that the frequency converter and the temperature controller can be removed, which is beneficial to production. By reducing the frequency converters and temperature controllers in use, the electrical failure rate can be reduced, thereby reducing the impact of electrical failures on production; it is beneficial to the maintenance of the front spinning electrical instrument: on the one hand, the reduction in the failure rate of the electrical equipment in use can reduce the workload of electrical instrument maintenance; on the other hand, due to the increase in the number of spare frequency converters and temperature controllers, electrical instrument technicians can have sufficient time to repair faulty electrical appliances, thereby improving the maintenance quality.

[0025] The first controller includes a first control chip 6, a first communication chip 7 and a second communication chip 8. The main control board 2, the first communication chip 7, the first control chip 6 and the second communication chip 8 are electrically connected end to end to form a closed loop. The set speed signal is sent from the process setting computer 1 and sequentially passes through the main control board 2 and the first communication chip 7 to reach the first control chip 6. The feedback speed signal is sent from the first control chip 6 and sequentially passes through the second communication chip 8 and the main control board 2 to reach the process setting computer 1, which facilitates communication between the analog inverter and the main control board.

[0026] It also includes a third communication chip 5 , and the third communication chip 5 is electrically connected to the process setting computer 1 and the first control chip 6 .

[0027] It also includes a USB / 485 communication converter 9. The process setting computer 1 and the third communication chip 5 are connected via the USB / 485 communication converter 9. A new monitoring and recording program is compiled on the process setting computer 1. The replacement device and the replacement devices in other parts form a network. The frequencies of the traverse and spindle inverters of each part are sent to the process setting computer 1 through a USB / 485 communication converter 9 to facilitate the inspection and tracing of process and management personnel. By expanding and developing the replacement devices and compiling monitoring and recording programs in the process setting computer 1, the efficiency of solving product quality problems is improved, and it is also beneficial to the production workshop's management of the production process.

[0028] It also includes a third communication interface 10, through which the third communication chip 5 and the USB / 485 communication converter 9 are connected, and the third communication interface 10 is an RS485 interface.

[0029] It also includes a first communication interface 11, and the first communication chip 7 and the second communication chip 8 are both connected to the main control board 2 through the first communication interface 11 to facilitate communication.

[0030] The second controller includes a second control chip 12, a fourth communication chip 13 and a fifth communication chip 14. The main control board 2, the fourth communication chip 13, the second control chip 12 and the fifth communication chip 14 are electrically connected end to end to form a closed loop. The set temperature signal is sent from the process setting computer 1 and is sequentially sent to the second control chip 12 through the main control board 2 and the fourth communication chip 13. The feedback temperature signal is sent from the second control chip 12 and is sent to the process setting computer 1 through the fifth communication chip 14 and the main control board 2, which is convenient for simulation.

[0031] It also includes a second communication interface 15, and the fourth communication chip 13 and the fifth communication chip 14 are both connected to the main control board 2 through the second communication interface 15 to facilitate communication.

[0032] It also includes a housing 16. The first controller and the second controller are arranged on the same PCB board and assembled in the housing 16, which reduces space and facilitates integration. In order to reduce the number of controllers, the first controller and the second controller are integrated together, so a new device with dual control chips and interface terminals is made. The integrated new device is connected to the communication ports of the remaining three inverters and the main control board through the communication port of the first control chip 6 to complete the response function of the two hot roller inverters; the second control chip 12 completes the response function of the two temperature controllers. After testing, the new device replaces the two hot roller inverters and the two temperature controllers and communicates normally with the main control board. In this way, two inverters and two temperature controllers can be removed from each spinning production site. There are 16 sites in the two production lines, and 16 new devices are made to replace 32 inverters and 32 temperature controllers. After the transformation, it has been running stably.

[0033] Write a program to simulate the two hot roller inverters responding to the main control board 2. The purpose is to replace the two hot roller inverters with the first controller. The communication process between the first controller and the main control board 2 is as shown in the attached figure. Figure 5The specific communication process is as follows: After the first controller is powered on, it first initializes the serial port communication, interruption and flag bits, and then uses the serial port interruption subroutine to receive information from the main control board, and sets the corresponding flag bit according to the first byte code of each group of information. While the main program continuously feeds the watchdog, it replies specific information or frequency signals to the main control board according to the flag bit, and clears the corresponding flag bit after sending the information. When sending information, it is required to perform odd check on each byte, and accumulate the hexadecimal numbers corresponding to each byte in the group of bytes sent, and then convert the two numbers in the accumulated sum into ASCII code to obtain two bytes. These two bytes are used as the check code of the group of bytes sent previously, and are also sent to the main control board 2 in sequence, so that continuous communication with the main control board 2 can be carried out.

[0034] Design the second controller and write the temperature controller response program. In the program, fix the temperature value of the hot roller to 25°C. Then use the second controller to replace the two hot roller temperature controllers to connect and communicate with the main control board 2. The communication process between the second controller and the main control board 2 is as follows: Figure 3 , the process is similar to the communication process between the first controller and the main control board 2, but the communication baud rate in the program, the content sent to the main control board 2, and the format are different from those in the program in the first controller. The temperature value of the hot roller returned is fixed at 25°C, which saves two temperature measuring components. Specifically, the different communication baud rates refer to the baud rate of 19200 in the inverter response program and 9600 in the thermostat response program; the content and number of bytes sent in each group are different. The data corresponding to the inverter is the frequency value (after replacement, the frequency is always zero, because the hot rollers are removed and the inverter does not need to be started), the number of bytes is 9, and the communication value is 5 bytes; the data group corresponding to the thermostat is the temperature value, the number of bytes is 6, and the communication value is 4 bytes.

[0035] This production line in the prior art uses imported special inverters and temperature controllers, which are expensive, costing about RMB 20,000 per inverter. After the transformation, there is no need to purchase spare parts for the hot roller inverters and temperature controllers of these two lines, and the 32 replaced inverters and 32 temperature controllers can be used as spare parts for the same type of inverters and temperature controllers in other production lines, thus saving a lot of spare parts costs for the company.

[0036] From the attached Figure 1It can be seen that each part of the production line contains a transverse roller and two spindle rollers, each driven by a dedicated inverter, and the operating frequency of the inverter is determined by the process setting value and the speed feedback value from the corresponding roller. According to the production process personnel: in the past production process, some product quality abnormalities may be caused by the abnormal speed of a certain roller, but because the process computer does not record and save the speed values ​​of each roller, it is impossible to verify the corresponding relationship between the problem product and the abnormal speed of the running roller.

[0037] By the attached Figure 2 It can be seen that the first communication interface 11 of the new device is connected to the communication line of the traverse and spindle inverters. When these three inverters send operating frequency signals to the main control board 2, the new device can receive these signals through the program. So we modified the communication program of the analog inverter so that it can replace the two hot roller inverters to communicate with the main control board, and can also obtain the frequency signals when the traverse and spindle inverters send information to the main control board 2, and temporarily store these signals in the first control chip 6. In addition, we also improved the 16 new devices, adding a communication chip to each new device, which is connected to the second communication terminal of the first control chip 6 to form the third communication interface 10 in the new device. Finally, we connected the third communication interfaces 10 of the 16 new devices with a network cable, and connected them to the process setting computer 1 through a USB / 485 converter; according to the requirements of the production workshop, we developed a new monitoring and recording program in the process setting computer 1, which can read and display the temporarily stored frequency signals of the traverse and spindle inverters in the 16 new devices, and record and save these signals in the form of curves. Because the frequency signal of the inverter can indirectly reflect the speed of the controlled roller, when a product quality problem occurs, the corresponding frequency curve can be checked to determine whether it is caused by the abnormal speed of the roller, thereby improving the efficiency of solving the problem product; in the normal production process, one of the spindle rollers in each winding head that is winding the silk cake is moving, and the corresponding inverter frequency is not zero; the other roller is stopped, and the corresponding inverter frequency is zero. When the winding process reaches the preset full-roll weight time, the two spindle rollers automatically switch, that is, the roller that was originally stopped becomes moving, and the roller that was originally moving becomes stopped. If a fault occurs during the winding process, the two spindle rollers will also be manually switched. We record the time of the two rollers switching as the current time of the computer, and compare the time difference between the two switches before and after with the preset weight time of each level, so that we can judge whether the silk cakes produced in each batch are full rolls, medium rolls, small rolls or waste. This is very beneficial to the workshop's management of production.

[0038] The control chip mentioned above is a single-chip microcomputer device, and the communication chip is a communication conversion device.

[0039] Specifically, Figure 4, the first controller and the second controller are controllers with two communication serial ports and control terminals, the first communication interface 11 and the second communication interface 15 are both RS422 communication ports, the first control chip 6 and the second control chip 12 are both IAP 15F2k61S2, the first communication chip 7, the second communication chip 8, the third communication chip 5, the fourth communication chip 13 and the fifth communication chip 14 are all ADM2483. That is to say, the 3rd pin of the communication chip ADM2483 is the receiving pin, the 6th pin is the sending pin, the 12th and 13th pins are differential input / output pins, the 4th pin is the receiving enable pin, and the 5th pin is the sending enable pin. The 4th and 5th pins of the first, second, fourth and fifth communication chips are short-circuited together, wherein the enable pins of the second and fifth sending chips are connected to a high level, and the enable pins of the first and fourth receiving chips are connected to a low level. Pins 4 and 5 of the third communication chip are controlled by the program via pins 1 and 2 of the first control chip respectively; pins 18 / 19 of the first control chip IAP15F2K61S2 are the receiving / transmitting pins of communication serial port 1, and pins 4 / 5 are the receiving / transmitting pins of communication serial port 2; the first controller and the second controller are both mounted on a PCB board and protected by a plastic shell.

[0040] like Figure 5 The first control chip receives the information of the main control board and the process computer and the frequency of the traverse and spindle inverters through the two interrupt subroutines of serial ports 1 and 2 respectively, and marks the corresponding flag bit or saves the frequency of the corresponding inverter. In the main program, the information is sent to the main control board and the process computer through serial ports 1 and 2 respectively.

[0041] Specifically, the principle of the present invention is to provide a first controller for simulating communication between the frequency converter and the main control board 2, and to provide a second controller for simulating communication between the temperature controller and the main control board 2, so that the frequency converter and the temperature controller can be removed, which is beneficial to production. By reducing the frequency converters and temperature controllers in use, the electrical failure rate can be reduced, thereby reducing the impact of electrical failures on production; it is beneficial to the maintenance of pre-spinning electrical instruments: on the one hand, the decrease in the failure rate of electrical appliances in use can reduce the workload of electrical instrument maintenance; on the other hand, due to the increase in spare frequency converters and temperature controllers, electrical instrument technicians can have sufficient time to repair faulty electrical appliances, thereby improving the quality of maintenance.

[0042] Based on the above scheme, if various changes or modifications to the present invention do not depart from the spirit and scope of the present invention, and if these changes and modifications fall within the scope of the claims and equivalent technologies of the present invention, the present invention is also intended to include these changes and modifications.

Claims

1. A replacement device for a spinning hot roller heating and driving controller, comprising a process setting computer (1) and a main control board (2), wherein the process setting computer (1) and the main control board (2) are electrically connected, and characterized in that: It also includes a first controller for simulating communication between a frequency converter and a main control board (2) and a second controller for simulating communication between a temperature controller and the main control board (2), the second controller being electrically connected to the main control board (2), and the first controller being electrically connected to the process setting computer (1) and the main control board (2) respectively; The first controller comprises a first control chip (6), a first communication chip (7) and a second communication chip (8); the main control board (2), the first communication chip (7), the first control chip (6) and the second communication chip (8) are electrically connected end to end to form a closed loop; a set speed signal is sent from the process setting computer (1) and sequentially passes through the main control board (2) and the first communication chip (7) to the first control chip (6); a feedback speed signal is sent from the first control chip (6) and sequentially passes through the second communication chip (8) and the main control board (2) to the process setting computer (1); It also includes a third communication chip (5), wherein the third communication chip (5) is electrically connected to the process setting computer (1) and the first control chip (6); It also includes a USB / 485 communication converter (9), and the process setting computer (1) and the third communication chip (5) are connected via the USB / 485 communication converter (9); The second controller comprises a second control chip (12), a fourth communication chip (13) and a fifth communication chip (14); the main control board (2), the fourth communication chip (13), the second control chip (12) and the fifth communication chip (14) are electrically connected end to end to form a closed loop; a set temperature signal is sent from the process setting computer (1) and sequentially passes through the main control board (2) and the fourth communication chip (13) to the second control chip (12); a feedback temperature signal is sent from the second control chip (12) and passes through the fifth communication chip (14) and the main control board (2) to the process setting computer (1).

2. The alternative device for heating and driving controller of a spinning hot roller according to claim 1, characterized in that: It also includes a third communication interface (10), and the third communication chip (5) and the USB / 485 communication converter (9) are connected via the third communication interface (10).

3. The alternative device for heating and driving controller of a spinning hot roller according to claim 1, characterized in that: It also includes a first communication interface (11), and the first communication chip (7) and the second communication chip (8) are both connected to the main control board (2) via the first communication interface (11).

4. A replacement device for the heating and driving controller of a spinning hot roller according to claim 1, characterized in that: It also includes a second communication interface (15), and the fourth communication chip (13) and the fifth communication chip (14) are both connected to the main control board (2) via the second communication interface (15).

5. A replacement device for the heating and driving controller of a spinning hot roller according to claim 1, characterized in that: It also includes a housing (16), and the first controller and the second controller are arranged on the same PCB board and integrated in the housing (16).

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