A method, system and device for real-time control of fabric density

Abstract

The present invention belongs to the field of textile printing and dyeing technology, and specifically relates to a real-time fabric density control method, system, and device. The method includes the following steps: determining an overfeed amount and maintaining a constant overfeed amount; determining a fabric density on the fabric feed side of an upper overfeed roller and configuring the fabric density to a constant value P1; and adjusting the fabric density on the fabric feed side of the upper overfeed roller in real time to reach the constant value P1. The real-time adjustment method includes collecting the real-time fabric density P1′ on the fabric feed side of the upper overfeed roller; if P1′ is less than P1, increasing the fabric feed speed on the fabric feed side of the upper overfeed roller; and if P1′ is greater than P1, decreasing the fabric feed speed on the fabric feed side of the upper overfeed roller until P1′ is equal to P1 or the difference between the two is within an error range. The present invention can adjust the fabric density on the fabric feed side of the upper overfeed roller in real time, accurately, and automatically, so that the density of the fabric after shaping reaches or does not exceed the process density requirement, thereby improving the overall level of the textile industry and enhancing the industry's competitiveness.

Description

Technical Field

[0001] The present invention belongs to the technical field of textile printing and dyeing, and in particular relates to a method, system and device for real-time control of fabric density. Background Art

[0002] Heat setting can improve the thermal stability of fabric size and quality, effectively eliminate wrinkles on the fabric, and improve the feel. By controlling parameters such as the heating temperature, machine speed, and overfeed amount in the heat setting machine, fabric quality, such as fabric surface density, can be controlled. The main manipulated variable for controlling surface density is the overfeed amount. Increased overfeeding causes an increase in fiber density, resulting in an increase in fabric density. The essence of overfeeding is to adjust the speed at which the upper overfeed roller feeds the fabric to overcome the unstable state of the fabric during the heat setting process, where the fabric stretches and narrows due to tension. This ensures that the finished product size and fabric surface density of the textile are stable and consistent after setting, meeting but not exceeding customer requirements. Therefore, precise control of the overfeed amount is particularly important, as it is the basis for achieving precise control of fabric surface density.

[0003] In the current textile industry, some fabric areal density control processes still rely on manual labor. The overfeed rate of the heat setting machine is adjusted based on the difference between the average of multiple sampling measurements and the density specified by the customer order. Repeated adjustments maintain the overfeed parameter within the required density range. Clearly, manual monitoring and control schemes are time-consuming and inefficient, preventing continuous measurement throughout the fabric production process. To ensure that fabric density meets requirements during production, repeated sampling and monitoring of density changes are necessary, which is labor-intensive and can severely damage fabric integrity. The varying degrees of stretching applied to the fabric during manual sampling reduces measurement accuracy, and overfeed ratios are set arbitrarily based on experience by different operators. This effectively creates a subjective, lacking data standardization. Operators only recognize the inaccuracy of the overfeed control scheme and implement adjustments when product quality issues become apparent. This not only results in significant control lag but also wastes resources and energy. Furthermore, when machine speeds fluctuate or external disturbances occur, the previously set overfeed rate no longer adapts, directly leading to fabric quality degradation and failure, a significant challenge for manufacturers.

[0004] As we all know, the weaving process often results in large deviations in weight at the head and tail due to the loom. Fabrics of the same specifications and varieties woven on different looms often have large density deviations. Furthermore, uneven tension during fabric processing often results in density errors.

[0005] Chinese patent ZL202020018193.4 discloses a real-time control device for the density of heat-set fabrics, including a heat-setting machine, an upper superfeeding roller, and an electric controller. A fabric speed detection mechanism and an industrial camera are provided before the upper superfeeding roller. The industrial camera obtains a fabric image and transmits it to the electric controller. The electric controller processes the obtained fabric image to obtain the real-time density P1 of the fabric before the fabric enters the upper superfeeding roller, and regulates it accordingly. The electric controller calculates the fabric running speed Vsc that meets the process density P0 based on the real-time density P1, the running speed V0, and the process density P0; the electric controller adjusts the motor speed of the upper superfeeding roller based on Vsc so that the fabric running speed reaches Vsc, thereby ensuring that the density of the fabric before setting can reach the process density. This patent has the following problems in specific working conditions:

[0006] (1) This patent sets a fabric speed detection mechanism and an industrial camera before the upper overfeed roller to detect the change of fabric density before the upper overfeed roller in real time. This cannot well reflect the real fabric density at the needle clip on the fabric, because the fabric between the upper overfeed roller and the lower overfeed roller is usually in a stretched state. In addition to the stretching elastic force Fn and its own gravity FMg, the fabric is also affected by the static friction of the roller on the fabric at each contact position between the fabric and the upper and lower overfeed rollers, the rotational inertia of the upper overfeed roller, the angular acceleration of the upper and lower overfeed rollers when running at a higher or lower speed, the elastic deformation of the fabric, etc., which will have a great impact on the fabric density measured by this patent. Therefore, this patent may not be able to accurately and automatically control the overfeed amount of the upper overfeed roller.

[0007] (2) The fabric running path between the fabric density sampling point and the upper superfeeding roller in this patent is relatively long. On the one hand, the error position cannot be accurately determined, resulting in inaccurate correction and inaccurate control. On the other hand, the density error at the junction of the head and tail of the fabric varies greatly, and the existing technology cannot guarantee rapid correction within a short distance. In addition, there are factors such as the resistance distance of the guide roller and the elastic elongation of the fabric. The required running speed of the fabric is obviously not the calculated Vsc, which will affect the control accuracy of the fabric density in actual production.

[0008] (3) The control of the existing technology is open-loop control, and the detection signal is used to control the rotation speed of the upper superfeed roller. Once an abnormal phenomenon such as slippage occurs between the upper superfeed roller and the fabric, it directly leads to a large error in the actual fabric density control accuracy.

[0009] (4) The existing technology controls the fabric density to be constant by adjusting the relative speed between the upper overfeed roller and the chain (adjusting the overfeed amount). However, due to the large changes in fabric density before shaping, the overfeed amount often fluctuates greatly, and serious abnormal phenomena such as fabric falling, hanging or rolling up may occur at the fabric outlet, seriously affecting the normal production of the shaping machine.

[0010] (5) The fabric density at the seam joint will fluctuate greatly. Since the path is too long, the existing technology cannot make real-time and rapid adjustments, resulting in a large error between the fabric density at the seam and the standard density, which seriously affects the quality of the product.

[0011] In view of this, it is necessary to solve the problem of fabric density control during fabric shaping in existing working conditions. Summary of the Invention

[0012] The purpose of the present invention is to solve the problem of low fabric density control accuracy during fabric stretching and shaping in the prior art, and to provide a method, system and device for real-time fabric density control.

[0013] To achieve the above object, the technical solution adopted by the present invention is: a real-time control method for fabric density, used in a setting machine, the setting machine including an upper overfeed roller and a chain equipped with a needle plate or cloth clip, the fabric is transferred to the needle plate or cloth clip on the chain by the upper overfeed roller, the control method comprising:

[0014] The fabric inlet side of the upper superfeeding roller is provided with at least one active adjusting roller and a density detection unit, and the active adjusting roller and the density detection unit cooperate to adjust the fabric density on the fabric inlet side of the upper superfeeding roller in real time to reach a constant value P1.

[0015] Preferably, the real-time adjustment method includes collecting the real-time density P1′ of the fabric on the cloth feeding side of the upper superfeeding roller, and if P1′ is less than P1, controlling to increase the cloth feeding speed on the cloth feeding side of the upper superfeeding roller; if P1′ is greater than P1, controlling to reduce the cloth feeding speed on the cloth feeding side of the upper superfeeding roller until P1′ is equal to P1.

[0016] Alternatively, the real-time adjustment method includes collecting the real-time density P1′ of the fabric at the fabric feeding side of the upper superfeeding roller, and controlling the difference between P1′ and P1 within an error range.

[0017] Preferably, the real-time density P1′ of the fabric is collected from between the fabric feeding side of the upper overfeed roller and the active adjusting roller.

[0018] Preferably, the fabric setting process density P0 is obtained. If the fabric density at the drop location cannot reach the process density P0, the overfeed amount is adjusted until the fabric density at the drop location reaches the process density P0, and then the current overfeed amount is kept constant.

[0019] Alternatively, obtain the target weight G0 of the fabric heat setting. If the fabric weight at the drop location cannot reach the target weight G0, adjust the overfeed amount until the fabric weight at the drop location reaches the target weight G0, and then keep the current overfeed amount constant.

[0020] Preferably, if the fabric tension on the cloth feeding side of the upper superfeeding roller exceeds the set tension range, the constant value P1 is re-corrected to obtain a corrected constant value P10 until the fabric tension on the cloth feeding side of the upper superfeeding roller meets the set tension range.

[0021] A fabric density real-time control system, used in the above fabric density real-time control method, comprising:

[0022] The adjustment module is used to adjust the fabric density on the fabric feeding side of the upper overfeed roller in real time to reach the constant value P1.

[0023] Preferably, the adjustment module includes:

[0024] A collecting unit, used for collecting the real-time density P1′ of the fabric at the feeding side of the upper superfeed roller;

[0025] a control unit for adjusting the real-time density P1′ of the fabric on the fabric feeding side of the upper superfeed roller; if P1′ is less than P1, the fabric feeding speed on the upper superfeed feeding side is increased; if P1′ is greater than P1, the fabric feeding speed on the upper superfeed feeding side is decreased until P1′ is equal to P1;

[0026] Alternatively, the difference between P1′ and P1 is controlled within an error range.

[0027] A fabric density real-time control device is used for a setting machine, wherein the setting machine includes an upper overfeed roller and a chain equipped with a needle plate or cloth clips, and the fabric is transferred to the needle plate or cloth clips on the chain through the upper overfeed roller, and further includes:

[0028] At least one active adjusting roller, the active adjusting roller being located at the cloth feeding side of the upper overfeed roller, the linear speed of the upper overfeed roller and the chain being relatively constant;

[0029] A density detection unit is provided on the cloth feeding side of the upper superfeed roller and is used to collect fabric density information and transmit it to the controller;

[0030] A controller is provided, wherein the controller controls the active adjustment roller to adjust the fabric density on the fabric feeding side of the upper overfeed roller in real time to a constant value according to the fabric density information.

[0031] Preferably, the density detection unit is located between the upper overfeed roller and the active adjustment roller.

[0032] Preferably, the controller is a controller of the shaping machine or an independently arranged controller.

[0033] After adopting the above technical solution, the method, system and device for real-time control of fabric density provided by the present invention have the following beneficial effects:

[0034] 1) The present invention detects changes in fabric density on the fabric inlet side of the upper overfeed roller in real time and provides at least one active adjustment roller to adjust the fabric running speed, thereby adjusting the fabric density on the fabric inlet side of the upper overfeed roller in real time. This achieves the purpose of accurately and automatically controlling the overfeed amount of the upper overfeed roller according to the process density, and can ensure that the density of the fabric after shaping is consistent with the process density, thereby ensuring the high quality of the fabric.

[0035] 2) The present invention collects the real-time fabric density P1′ between the upper overfeed roller and an active regulating roller located no more than three meters away from the upper overfeed roller, compares it with the fabric density P1, and adjusts the linear speed of the active regulating roller in real time. This design avoids the problem of a long fabric travel path between the sampling point and the upper overfeed roller, which affects control accuracy, further ensuring high fabric quality.

[0036] 3) The present invention can avoid the problem of fabric slipping at the upper superfeed roller by actively adjusting the linear speed of the roller to be lower than the linear speed of the upper superfeed roller. The control design of the fabric tension on the fabric inlet side of the upper superfeed roller can avoid the influence of the fabric tension on the real-time density of the fabric on the fabric inlet side of the upper superfeed roller, thereby further ensuring the control accuracy.

[0037] 4) The present invention can prevent and predict the fluctuation of fabric density in advance, and effectively achieve stable control of fabric density;

[0038] 5) The present invention can accurately control the setting density of the fabric because the present invention directly detects and controls the fabric on the fabric feeding side of the upper superfeed roller, and then the upper superfeed roller and the setting machine maintain a constant running speed. This overcomes the technical problem of the prior art that adjustment is only made after a long path after detection. It also overcomes the problem of uncertain control error caused by the inability to determine whether the fabric density is adjusted correctly under open-loop control in the prior art. The present invention greatly improves control accuracy.

[0039] 6) The present invention can quickly adjust the fabric setting density and enable rapid adjustment and response to improve product quality. This is because the present invention directly detects and controls the fabric on the fabric feeding side of the upper superfeed roller, and then the upper superfeed roller and the setting machine maintain a constant operating speed. This effectively solves the technical problem of slow correction speed caused by adjusting after a long path after detection in the prior art, especially the problem of difficulty in properly correcting areas with large fabric density variations, such as seam ends.

[0040] 7) The present invention realizes intelligent monitoring of fabric density and reduces labor costs;

[0041] 8) The present invention is easy to implement, helps to improve the overall level of the textile industry and enhance the industry's competitiveness. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1A schematic flow chart of a method for real-time control of fabric density according to the present invention;

[0043] Figure 2 Another schematic flow chart of a method for real-time control of fabric density according to the present invention;

[0044] Figure 3 This is a structural block diagram of a real-time control system for fabric density according to the present invention;

[0045] Figure 4 This is a structural schematic diagram of a real-time fabric density control device of the present invention.

[0046] Among them: forming machine 1, upper superfeeding roller 2, active adjusting roller 3, industrial camera 4, lighting source 5, external speed measuring device 6, cloth guide roller 7, tensioning roller 8, swing arm 9, cylinder 10, fabric 11. DETAILED DESCRIPTION

[0047] The present invention will be further described clearly and completely below in conjunction with the accompanying drawings and specific embodiments. It should be understood that the embodiments described are only some, not all, of the embodiments of the present invention. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention, its application, or use. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are intended to fall within the scope of protection of the present invention.

[0048] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0049] Unless otherwise specifically stated, the relative arrangement of the parts and steps, the numerical expressions and the numerical values set forth in these embodiments do not limit the scope of the present invention. At the same time, it should be understood that, for ease of description, the sizes of the various parts shown in the drawings are not drawn according to the actual proportional relationship. The techniques, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but where appropriate, the techniques, methods and equipment should be considered as part of the authorization specification. In all examples shown and discussed here, any specific values should be interpreted as being merely exemplary and not as limiting. Therefore, other examples of the exemplary embodiments may have different values. It should be noted that similar numbers and letters represent similar items in the following figures, and therefore, once an item is defined in one figure, it does not need to be further discussed in subsequent figures.

[0050] In the description of the present invention, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, perpendicular, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention; the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.

[0051] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0052] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0053] The present invention provides a real-time fabric density control method for a setting machine, which belongs to dyeing and finishing equipment. The setting machine can also be a setting machine, a drying machine or a stenter setting machine. The setting machine includes an upper superfeeding roller and a chain equipped with a needle plate or a cloth clip. The fabric is conveyed to the needle plate or cloth clip on the chain by the upper superfeeding roller for setting treatment. In order to enable the fabric reaching the needle plate or cloth clip on the chain to reach the fabric setting process density P0, the prior art usually adjusts the density of the fabric fed into the needle plate or cloth clip by adjusting the upper superfeeding roller. This fabric density control method has many technical problems as described in the background technology. Therefore, this embodiment proposes a real-time fabric density control method, which no longer adjusts the upper superfeeding roller, but adjusts the fabric density on the cloth feeding side of the upper superfeeding roller. Specifically, the control method includes:

[0054] At least one active adjusting roller and a density detection unit are provided on the fabric feeding side of the upper overfeed roller. The active adjusting roller and the density detection unit are then used to cooperate with each other to adjust the fabric density on the fabric feeding side of the upper overfeed roller in real time so as to reach a constant value P1. That is, the linear speed of the active adjusting roller is controlled in real time according to the detection result of the density detection unit so that the fabric density on the fabric feeding side of the upper overfeed roller reaches a constant value P1. In this way, it is only necessary to ensure that the upper overfeed amount can reach the fabric shaping process density P0 and then keep the current overfeed amount constant without adjusting the upper overfeed roller.

[0055] It is well known to those skilled in the art that overfeeding refers to providing a specific ratio required according to the requirements of the next step. The specific ratio includes positive overfeeding, negative overfeeding or zero overfeeding. The required amount can be reflected in speed, quantity, quality, etc. In this embodiment, the method for determining the overfeeding amount can be adopted in various ways, for example, the overfeeding amount can be determined by experience, historical data or experimental data.

[0056] According to one embodiment of the method for determining the overfeed amount of the present invention, the fabric setting process density P0 is obtained. If the fabric density at the drop does not reach the process density P0, the overfeed amount is adjusted until the fabric density at the drop reaches the process density P0. The fabric density at the drop can be measured manually or detected online.

[0057] According to another embodiment of the method for determining an overfeed amount of the present invention, a target fabric heat-setting weight G0 is obtained. If the fabric weight at the drop does not reach the target weight G0, the overfeed amount is adjusted until the fabric weight at the drop reaches the target weight G0. The fabric weight at the drop can be measured manually or detected online.

[0058] In this embodiment, the constant value P1 can be determined according to the following method: after determining the overfeed amount, the average value of the density of any section of the fabric to be shaped is obtained, and the constant value P1 of the fabric density on the cloth feeding side of the upper overfeed roller is determined based on the average value. The constant value P1 of this embodiment can be determined by manual visual inspection, historical data, experimental data or actual measured data from on-site operation.

[0059] Preferably, if the fabric tension on the cloth-feeding side of the upper superfeeding roller exceeds the set tension range (the preferred tension range is 0-150N), the constant value P1 is re-corrected to obtain a corrected constant value P10 until the fabric tension on the cloth-feeding side of the upper superfeeding roller meets the set tension range. This ensures that the linear speed of the actively adjusted roller is less than the linear speed of the upper superfeeding roller, and can avoid the problem of fabric slipping at the upper superfeeding roller. Through the control design of the fabric tension on the cloth-feeding side of the upper superfeeding roller, the influence of the fabric tension on the real-time density of the fabric on the cloth-feeding side of the upper superfeeding roller can be avoided, thereby further ensuring the control accuracy.

[0060] According to one embodiment of the present invention, the method for real-time adjusting the fabric density on the cloth-feeding side of the upper superfeeding roller to reach the constant value P1 includes: real-time collection of the real-time fabric density P1′ on the cloth-feeding side of the upper superfeeding roller; if P1′<P1, controlling to increase the cloth-feeding speed on the cloth-feeding side of the upper superfeeding roller; if P1′>P1, controlling to reduce the cloth-feeding speed on the cloth-feeding side of the upper superfeeding roller until P1′ is equal to P1; or, controlling the difference between P1′ and P1 within an error range, preferably, the error range is within 5%.

[0061] It should be noted that the density of the fabric to be set will change during the loading process. In this embodiment, the real-time adjustment of the real-time density of the fabric on the cloth feeding side of the upper superfeed roller refers to the real-time adjustment of the cloth feeding speed of the upper superfeed roller on the cloth feeding side by the controller, thereby adjusting the real-time density of the fabric on the cloth feeding side of the upper superfeed roller to ensure that the density of the fabric to be set during the loading process is equal to the target fabric density or the difference between the two is controlled within an error range, and the error range is preferably within 5%.

[0062] Furthermore, the real-time density P1′ of the fabric is collected from between the upper overfeed roller and the real-time adjustment position. The distance between the upper overfeed roller and the real-time adjustment position is not greater than 3M, preferably not greater than 1.5M. Such a design can avoid the problem of the fabric running path between the sampling point and the upper overfeed roller being too long, which affects the control accuracy, thereby ensuring the high quality of the fabric.

[0063] like Figure 1 As shown, the fabric density real-time control method of the present invention can be performed according to the following steps:

[0064] S1: Determine the overfeeding amount and keep it constant;

[0065] S2: Determine the constant value P1 of the fabric density on the fabric feeding side of the upper overfeed roller;

[0066] S3: Real-time adjustment of the fabric density on the fabric feeding side of the upper overfeed roller to a constant value P1.

[0067] like Figure 2 As shown, the above process can of course be changed and performed in the following manner:

[0068] Sa: Determine the constant value P1 of the fabric density on the feeding side of the upper superfeed roller;

[0069] Sb: Adjust the overfeed amount according to the constant value P1 until the fabric density at the drop reaches the process density P0 or the fabric weight at the drop reaches the target weight G0;

[0070] Sc: Real-time adjustment of the fabric density on the feeding side of the upper overfeed roller to a constant value P1.

[0071] From the above content, it can be seen that the key point of the present invention is to adjust the fabric density on the fabric feeding side of the upper overfeed roller in real time to reach a constant value P1. Once the upper overfeed amount is determined, there is no need to actively adjust the upper overfeed roller, thereby achieving the purpose of accurately and automatically controlling the overfeed amount of the upper overfeed roller according to the process density, and being able to keep the density of the fabric after shaping consistent with the process density, thereby ensuring the high quality of the fabric.

[0072] Example 2:

[0073] like Figure 3 As shown, this embodiment provides a fabric density real-time control system for use in the above fabric density real-time control method, comprising:

[0074] The adjustment module is used to adjust the fabric density on the fabric feeding side of the upper overfeed roller in real time to reach the constant value P1.

[0075] Furthermore, the adjustment module includes:

[0076] A collecting unit, used for collecting the real-time density P1′ of the fabric at the feeding side of the upper superfeed roller;

[0077] The control unit is used to adjust the real-time density P1′ of the fabric on the fabric feeding side of the upper superfeed roller. If P1′ is less than P1, the fabric feeding speed on the upper superfeed feeding side is increased; if P1′ is greater than P1, the fabric feeding speed on the upper superfeed feeding side is reduced until P1′ is equal to P1 or the difference between the two is controlled within an error range, and the error range is preferably within 5%.

[0078] Example 3:

[0079] like Figure 4As shown, this embodiment provides a real-time control device for fabric density, which is used for a setting machine. The setting machine belongs to dyeing and finishing equipment. The setting machine can also be a setting machine, a drying machine or a stenter setting machine. The setting machine includes an upper overfeed roller 2 and a chain equipped with a needle plate or a cloth clip. The fabric 11 is transmitted to the needle plate or the cloth clip on the chain through the upper overfeed roller 2. The real-time control device for fabric density of this embodiment also includes at least one active adjustment roller, a density detection unit and a controller.

[0080] The active adjusting roller of this embodiment is located on the fabric inlet side of the upper overfeed roller 2 and is used to adjust the fabric density on the fabric inlet side of the upper overfeed roller 2 in real time. The upper overfeed roller 2 and the active adjusting roller 3 are respectively controlled by a controller. Of course, the controller can be the controller of the setting machine 1 or an independent controller. In the present invention, the controller is preferably a commercially available industrial controller or industrial computer. The controller drives the motor through a motor driver, such as a variable frequency drive, a variable frequency motor, or a servo driver, a servo motor.

[0081] The density detection unit of this embodiment is arranged on the cloth feeding side of the upper superfeed roller 2, and is used to collect the density of the fabric and transmit the information to the controller. The density detection unit includes but is not limited to an intelligent camera, an industrial camera image detection and a photoelectric detection. If the density detection unit is an intelligent camera, it can process the acquired image and obtain data by itself, and then transmit the data to the controller; or if the density detection unit is an industrial camera, the industrial camera directly transmits the acquired image to the controller, and the controller processes the image and then obtains the data; or photoelectric detection is used to obtain the fabric density and then transmit the information to the controller.

[0082] Preferably, the density detection unit is arranged between the upper overfeed roller 2 and the active adjustment roller 3 close to the upper overfeed roller 2, and the distance between the upper overfeed roller 2 and the active adjustment roller 3 can generally be controlled within a range of no more than 3m, preferably within a range of no more than 1.5m.

[0083] Furthermore, the density detection unit includes an industrial camera 4 and an illumination light source 5 arranged on one side or both sides of the fabric. The industrial camera 4 is a linear array or area array industrial camera, and the illumination light source 5 includes a front light source and / or a back light source.

[0084] The controller of this embodiment controls the active adjusting roller to adjust the fabric density on the cloth feeding side of the upper overfeed roller in real time to a constant value according to the fabric density information. The constant value is a standard value or a range value. Furthermore, the controller needs to collect the speed signals of the upper overfeed roller 2 and the active adjusting roller 3 during the control process. The speed signal includes the speed output signal of the driver or the speed output signal of the external speed measuring device.

[0085] For example, an external speed measuring device 6 is used to collect the rotational speed output signal. The external speed measuring device 6 can be a roller encoder. After the controller receives the roller encoder data, it can convert it into the linear speed of the upper superfeed roller, that is, the running speed of the fabric passing through the feed roller assembly; or it can be an infrared speed meter installed on the fabric at the periphery of the upper superfeed roller for measuring the linear speed of the upper superfeed roller; or it can be a motor encoder installed on the upper superfeed roller. Since the diameter of the upper superfeed roller is known, the controller can convert the motor encoder data received by the controller into the linear speed of the upper superfeed roller, etc.

[0086] Furthermore, a fabric adjustment module for adjusting the tension and position of the fabric is provided before the upper overfeed roller, so as to enable the forming machine to obtain fabric with appropriate tension and centering. The fabric adjustment module includes a tension detection unit and a cloth guide unit. The tension detection unit detects the fabric tension before the upper overfeed roller, and the controller receives the detection data of the fabric tension detection unit and adjusts the fabric tension through the cloth guide unit; specifically, the cloth guide unit includes a plurality of cloth guide rollers 7, and the driving motor of the cloth guide roller 7 is electrically connected to the controller. The tension detection unit includes a tensioning roller 8 arranged between the cloth guide rollers 7, and the tensioning roller 8 is rotatably connected to the frame through a swing arm 9, and a cylinder 10 is provided between the swing arm 9 and the frame. The swing arm 9 is also provided with a sensor electrically connected to the controller. When working, the sensor senses the swing angle of the swing arm to detect the fabric tension, and the controller changes the speed of the cloth guide roller driving motor in real time according to the detection signal to adjust the fabric tension.

[0087] It should be noted that the tension detection unit may also adopt other structures, such as using two spaced-apart cloth guide rollers and a fabric tension sensor, detecting the fabric tension by the fabric tension sensor, and adjusting the fabric tension by changing the cloth feeding speed of the two cloth guide rollers in real time according to the detection signal. Those skilled in the art may make various modifications, which are not specifically limited here.

[0088] When the fabric density real-time control device of the present invention is used, the fabric heat setting process density P0 / target gram weight G0 is obtained, the overfeed amount is set according to the density of the fabric before setting, and then the output fabric density / fabric gram weight is calculated. If the output fabric density reaches the process density P0 or the output fabric gram weight reaches the target gram weight G0, the overfeed amount is determined and kept constant. After determining the overfeed amount, the average value of the density of any section of the fabric to be set is obtained, and the target fabric density P1 on the cloth feeding side of the upper overfeed roller is determined according to the average value. For example, the fabric to be set is taken as 10 meters of fabric are measured, and then density detection is performed to calculate the average value. The constant fabric density value P1 on the fabric feeding side of the upper superfeeding roller is determined based on the average value. The density detection unit collects fabric density information on the fabric feeding side of the upper superfeeding roller and transmits it to the controller. The controller makes a judgment and control based on the acquired real-time density P1′ of the fabric. If P1′ is less than P1, the linear speed of the active adjusting roller is increased. If P1′ is greater than P1, the linear speed of the active adjusting roller is decreased until P1′ is equal to P1 or the difference between the two is controlled within an error range, and the error range is preferably within 5%.

[0089] It should be noted that, the constant value P1 of the fabric density on the fabric feeding side of the upper overfeed roller may be determined first and then the upper overfeed amount may be determined.

[0090] After trial, the present invention can quickly, accurately and automatically adjust the fabric density on the cloth feeding side of the upper superfeed roller, so that the density of the fabric after shaping meets the process density requirements well, ensuring the high quality of the fabric, greatly improving the one-time success rate, and is easy to implement and low in cost, which helps to achieve high-quality development of the textile printing and dyeing industry and enhance the international competitiveness of my country's textile printing and dyeing industry.

[0091] The above description is only a preferred specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A method for real-time control of fabric density, for use in a setting machine, wherein the setting machine comprises an upper overfeed roller and a chain equipped with a needle plate or cloth clips, wherein the fabric is transferred to the needle plate or cloth clips on the chain by the upper overfeed roller, and wherein: The control method includes: At least one active adjusting roller is provided on the fabric inlet side of the upper superfeeding roller, the distance therefrom being no more than 3m, and a density detection unit for detecting the real-time density of the fabric between the active adjusting roller and the upper superfeeding roller. The active adjusting roller adjusts its rotation speed according to the real-time density of the fabric to achieve a constant fabric density P1 on the fabric inlet side of the upper superfeeding roller, and the linear speed of the active adjusting roller is less than the linear speed of the upper superfeeding roller.

2. A fabric density real-time control method according to claim 1, characterized in that: The real-time control method includes collecting the real-time density P1′ of the fabric on the fabric feeding side of the upper superfeeding roller, and if P1′ is less than P1, controlling to increase the fabric feeding speed on the fabric feeding side of the upper superfeeding roller; if P1′ is greater than P1, controlling to reduce the fabric feeding speed on the fabric feeding side of the upper superfeeding roller until P1′ is equal to P1; Alternatively, the real-time control method includes collecting the real-time density P1′ of the fabric at the fabric feeding side of the upper superfeeding roller, and controlling the difference between P1′ and P1 within an error range.

3. A fabric density real-time control method according to claim 2, characterized in that: The real-time density P1′ of the fabric is collected from the fabric feeding side of the upper overfeed roller and between the active adjusting roller.

4. A fabric density real-time control method according to claim 1, characterized in that: Obtain the fabric shaping process density P0. If the fabric density at the drop location cannot reach the process density P0, adjust the overfeed amount until the fabric density at the drop location reaches the process density P0, and then keep the current overfeed amount constant. Alternatively, obtain the target weight G0 of the fabric heat setting. If the fabric weight at the drop location cannot reach the target weight G0, adjust the overfeed amount until the fabric weight at the drop location reaches the target weight G0, and then keep the current overfeed amount constant.

5. The method for real-time control of fabric density according to claim 1, characterized in that: If the fabric tension on the cloth feeding side of the upper superfeeding roller exceeds the set tension range, the constant value P1 is re-corrected to obtain a corrected constant value P10 until the fabric tension on the cloth feeding side of the upper superfeeding roller meets the set tension range.

6. A fabric density real-time control system, used in the fabric density real-time control method according to any one of claims 1 to 5, characterized in that: include: The adjustment module is used to adjust the fabric density on the fabric feeding side of the upper overfeed roller in real time to reach the constant value P1.

7. The fabric density real-time control system according to claim 6, characterized in that: The adjustment module includes: A collecting unit, used for collecting the real-time density P1′ of the fabric at the feeding side of the upper superfeed roller; a control unit for adjusting the real-time density P1′ of the fabric on the fabric feeding side of the upper superfeed roller; if P1′ is less than P1, the fabric feeding speed on the upper superfeed feeding side is increased; if P1′ is greater than P1, the fabric feeding speed on the upper superfeed feeding side is decreased until P1′ is equal to P1; Alternatively, the difference between P1′ and P1 is controlled within an error range.

8. A fabric density real-time control device using the fabric density real-time control method according to claim 1, used in a setting machine, wherein the setting machine comprises an upper overfeed roller and a chain equipped with a needle plate or cloth clips, and the fabric is transferred to the needle plate or cloth clips on the chain by the upper overfeed roller, characterized in that: Also includes: At least one active adjusting roller, located at the cloth feeding side of the upper overfeed roller, for adjusting the fabric density at the cloth feeding side of the upper overfeed roller in real time; A density detection unit is provided on the cloth feeding side of the upper superfeed roller and is used to collect fabric density information and transmit it to the controller; A controller is provided, wherein the controller controls the active adjustment roller to adjust the fabric density on the fabric feeding side of the upper overfeed roller in real time to a constant value according to the fabric density information.

9. The fabric density real-time control device according to claim 8, characterized in that: The density detection unit is located between the upper overfeed roller and the active adjustment roller.

10. The fabric density real-time control device according to claim 8, characterized in that: The controller is a controller of the shaping machine or an independently arranged controller.

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