Yarn constant tension electrical control system and control method

Abstract

The present invention discloses an electrical control system and method for constant yarn tension. A tension sensing module collects real-time yarn tension and transmits it to a control module via an analog-to-digital converter module. After receiving tension control instructions from a host computer, the control module uses an adaptive fuzzy controller to determine the motor control current based on the real-time yarn tension. The motor is then controlled via a motor module to achieve constant yarn tension control. The present invention optimizes the drive motor current through an adaptive fuzzy controller, assigning different drive motor currents based on the real-time state of the yarn, thereby achieving constant yarn tension control. This system can operate stably and effectively for long periods of time in an environment where large-capacity creels are simultaneously weaving.

Description

Technical Field

[0001] The invention belongs to the field of tension control, and in particular relates to a yarn constant tension electrical control system and a control method. Background Art

[0002] With the continuous progress of the textile industry, various woven three-dimensional fabrics have higher and higher requirements for warp tension control. Traditional unstable tension control can no longer meet the requirements of warp tension, and constant tension control has also become an important indicator of weaving technology.

[0003] The tension control systems in the existing technology usually adopt mechanical and motor types. The advantage of the spring type is low cost, but the tension cannot be adjusted over a large range and cannot meet the weaving requirements of some fabrics; the motor type is constant force control and cannot provide feedback based on the set value and tension to control the motor torque, speed and direction. Summary of the Invention

[0004] In response to the above problems, the purpose of the present invention is to provide a yarn constant tension electrical control system and control method, which can adjust the motor operating state according to the memory output value before stopping when powered on, ensure that the tension after weaving stops is consistent with that before stopping, and optimize the motor control current through fuzzy control to achieve constant tension control of the yarn.

[0005] The specific technical solutions for achieving the purpose of the present invention are as follows:

[0006] A yarn constant tension electrical control system, comprising a control module, a tension sensing module, a motor module, a host computer module and a power supply module;

[0007] The tension sensing module is used to collect yarn tension in real time and transmit the collected yarn tension to the control module;

[0008] The host computer module is used to control the yarn tension in real time and send tension control instructions;

[0009] The control module is used to receive the tension control instruction sent by the host computer, and determine the real-time adjustment current value of the motor in combination with the real-time yarn tension transmitted by the tension sensing module, and output it to the motor module;

[0010] The motor module is used to receive the control instructions output by the control module, adjust the motor current, and complete the corresponding yarn constant tension control;

[0011] The power supply module is used to supply power to each module in the system.

[0012] Furthermore, the tension sensing module includes a tension sensor and an AD conversion module;

[0013] The tension sensor is set on the yarn to collect the real-time tension of the yarn, and converts the collected yarn tension into numerical information through the AD conversion module and transmits it to the control module:

[0014]

[0015] Among them, A represents the collected current, A0 represents the minimum value of the standard electrical signal, and A m Indicates the maximum value of the standard electrical signal, D m It represents the maximum value after conversion, and D0 represents the minimum value after conversion.

[0016] Furthermore, the control module is specifically configured as follows based on the tension setting value sent by the host computer and the real-time tension determined by the tension sensing module:

[0017] First, determine the initial control current of the motor module based on the tension setting value sent by the host computer:

[0018] Then, according to the real-time yarn tension collected by the tension sensing module, the real-time control current of the motor is determined based on the adaptive fuzzy controller.

[0019] Furthermore, the initial current of the motor module is:

[0020]

[0021] Among them, S represents the tension setting value determined by the host computer, K d It represents the coefficient of the weight calibration tension value, U represents the motor voltage, I represents the initial current of the motor module, n represents the efficiency of the brushless DC motor, and N represents the set initial motor speed.

[0022] Furthermore, the real-time control current of the motor is determined based on the adaptive fuzzy controller, specifically:

[0023] Based on the adaptive fuzzy controller u D , determine the output current value:

[0024] x (n) =f(S…S 2 )+bu

[0025] y=S

[0026] u=u D (S|θ)

[0027] u D (S|θ)=θ T ξ(S)

[0028] Let e = y m -y, and:

[0029]

[0030] K=(k n -k1) T

[0031] but:

[0032] e (n) +k1e (n-1) +…+k n e=0

[0033] u D (S|θ)=θ T ξ(S)

[0034] Among them, S represents the tension setting value determined by the host computer, y m represents the real-time control current of the motor, ξ(S) is dimensional vector, n and k are constants, θ represents the set of adjustable parameters, and b is an element in the domain;

[0035] By substituting the required tension and setting the initial parameters, the real-time control current value is obtained according to the fuzzy rules.

[0036] Furthermore, the motor module includes a motor unit, a motor drive unit and a motor encoding unit;

[0037] The motor drive unit and the motor encoding unit are respectively connected to the control module, and receive the motor control current sent by the control module to control the direction, speed and torque of the motor unit.

[0038] The yarn constant tension electrical control method based on the above system includes the following steps:

[0039] Step 1: Power on each device in the system and determine whether there is a tension value set by the host computer before shutdown. If yes, control the motor to restore to the last tension state. If not, keep in standby mode.

[0040] Step 2: Determine the initial control current of the motor according to the tension value set by the host computer;

[0041] Step 3: The tension sensing module collects the real-time tension of the yarn and transmits it to the control module. The control module combines the tension value set by the host computer and determines the real-time control current of the motor based on the adaptive fuzzy controller;

[0042] Step 4: Detect the yarn status in real time to determine whether the tension is abnormal. If abnormal, shut down the system and perform troubleshooting.

[0043] Compared with the prior art, the present invention has the following beneficial effects:

[0044] (1) The technical solution of the present invention optimizes the driving motor current through an adaptive fuzzy controller, and gives different driving motor currents according to the real-time state of the yarn, thereby achieving constant tension control of the yarn, and can operate stably and effectively for a long time in an environment where a large capacity creel is simultaneously weaving;

[0045] (2) The technical solution of the present invention can determine whether there is a tension value set last time each time the machine is turned on, and adjust the motor operating state accordingly to ensure that the tension after weaving stops is consistent with the tension before and after weaving stops. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 This is a schematic diagram of the framework of the yarn constant tension electrical control system of the present invention.

[0047] Figure 2 The figure is a flow chart of the steps of the yarn constant tension electrical control method of the present invention.

[0048] Figure 3 This is a tension memory recovery flow chart in the yarn constant tension electrical control method of the present invention.

[0049] Figure 4 This is a constant tension control flow chart of the yarn constant tension electrical control method of the present invention. DETAILED DESCRIPTION

[0050] Example

[0051] Combine Figure 1 , a yarn constant tension electrical control system, including a control module, a tension sensing module, a motor module, a host computer module and a power module;

[0052] The tension sensing module is arranged on the yarn and is used to collect the yarn tension in real time and transmit the collected yarn tension to the control module;

[0053] The host computer module is used to control the yarn tension in real time and send tension control instructions;

[0054] The control module is used to receive the tension control instruction sent by the host computer, and determine the real-time adjustment current value of the motor in combination with the real-time yarn tension transmitted by the tension sensing module, and output it to the motor module;

[0055] The motor module is connected to the yarn weaving machine and is used to receive the control instructions output by the control module, adjust the motor current, and complete the corresponding yarn constant tension control;

[0056] The power supply module is used to supply power to each module in the system.

[0057] The host computer and the control module are connected via Ethernet.

[0058] Furthermore, the tension sensing module includes a tension sensor and an AD conversion module;

[0059] The tension sensor is set on the yarn to collect the real-time tension of the yarn, and converts the collected yarn tension into numerical information through the AD conversion module and transmits it to the control module:

[0060]

[0061] Among them, A represents the collected current, A0 represents the minimum value of the standard electrical signal, and A m Indicates the maximum value of the standard electrical signal, D m It represents the maximum value after conversion, and D0 represents the minimum value after conversion.

[0062] Furthermore, the control module is specifically configured as follows based on the tension setting value sent by the host computer and the real-time tension determined by the tension sensing module:

[0063] First, determine the initial control current of the motor module based on the tension setting value sent by the host computer:

[0064] Then, according to the real-time yarn tension collected by the tension sensing module, the real-time control current of the motor is determined based on the adaptive fuzzy controller.

[0065] Furthermore, the initial current of the motor module is:

[0066]

[0067] Among them, S represents the tension setting value determined by the host computer, K d It represents the coefficient of the weight calibration tension value, U represents the motor voltage, I represents the initial current of the motor module, n represents the efficiency of the brushless DC motor, and N represents the set initial motor speed.

[0068] Furthermore, the real-time control current of the motor is determined based on the adaptive fuzzy controller, specifically:

[0069] Based on the adaptive fuzzy controller u D , determine the output current value:

[0070] x (n) =f(S…S 2 )+bu

[0071] y=S

[0072] u=u D (S|θ)

[0073] u D (S|θ)=θ T ξ(S)

[0074] Let e = y m -y, and:

[0075]

[0076] K=(k n -k1) T

[0077] but:

[0078] e (n) +k1e (n-1) +…+k n e=0

[0079] u D (S|θ)=θ T ξ(S)

[0080] Among them, S represents the tension setting value determined by the host computer, y m represents the real-time control current of the motor, ξ(S) is dimensional vector, n and k are constants, θ represents the set of adjustable parameters, and b is an element in the domain;

[0081] By substituting the required tension and setting the initial parameters, the real-time control current value is obtained according to the fuzzy rules.

[0082] Furthermore, the motor module includes a motor unit, a motor drive unit and a motor encoding unit;

[0083] The motor drive unit and the motor encoding unit are respectively connected to the control module, and receive the motor control current sent by the control module to control the direction, speed and torque of the motor unit.

[0084] The speed and torque of the motor unit are controlled by the magnitude of the motor control current, and the direction of the motor unit is controlled by changing the direction of the current;

[0085] Here, the direction of rotation of the motor unit is adjusted according to the needs during the constant tension control of the yarn.

[0086] Combine Figures 2 to 4 The yarn constant tension electrical control method based on the above system is characterized by comprising the following steps:

[0087] Step 1: Power on each device in the system and determine whether there is a tension value set by the host computer before shutdown. If yes, control the motor to restore to the last tension state; if not, keep in standby mode;

[0088] This step can ensure the consistency of tension before and after shutdown;

[0089] Step 2: Determine the initial control current of the motor according to the tension value set by the host computer. Specifically:

[0090]

[0091] Among them, S represents the tension setting value determined by the host computer, K d It represents the coefficient of the weight calibration tension value, U represents the motor voltage, I represents the initial current of the motor module, n represents the efficiency of the brushless DC motor, and N represents the set initial motor speed.

[0092] Step 3: The tension sensing module collects the real-time tension of the yarn and transmits it to the control module. The control module combines the tension value set by the host computer and determines the real-time control current of the motor based on the adaptive fuzzy controller. Specifically:

[0093] Based on the adaptive fuzzy controller u D , determine the output current value:

[0094] x (n) =f(S…S 2 )+bu

[0095] y=S

[0096] u=u D (S|θ)

[0097] u D (S|θ)=θ T ξ(S)

[0098] Let e = y m -y, and:

[0099]

[0100] K=(k n -k1) T

[0101] but:

[0102] e (n) +k1e (n-1) +…+k n e=0

[0103] u D (S|θ)=θ T ξ(S)

[0104] Among them, S represents the tension setting value determined by the host computer, y m represents the real-time control current of the motor, ξ(S) is dimensional vector, n and k are constants, θ represents the set of adjustable parameters, and b is an element in the domain;

[0105] By substituting the required tension and setting the initial parameters, the real-time control current value is obtained according to the fuzzy rules.

[0106] Step 4: Real-time detection of yarn status to determine whether the tension is abnormal. If abnormal, the system will be shut down and troubleshooting will be carried out. Specifically:

[0107] (1) When the yarn is loose, the motor keeps rotating clockwise. When the motor rotates clockwise to the set number of turns, it is judged that the tension is abnormal;

[0108] (2) The tension sensing module detects the real-time tension of the yarn. If the tension value exceeds the set threshold, it is determined that the tension is abnormal.

[0109] This step can be used to confirm in real time whether there are any loose or slipping parts in the yarn manufacturing process. The real-time sensing of the tension sensing module can quickly and accurately alarm and easily locate the fault area.

[0110] The technical solution of the present invention can optimize the driving motor current through an adaptive fuzzy controller, and give different driving motor currents according to the real-time state of the yarn, thereby completing the constant tension control of the yarn. It can operate stably and effectively for a long time in an environment where large-capacity yarn frames are weaving at the same time.

[0111] The above embodiments illustrate and describe the basic principles and main features of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention, and such changes and modifications fall within the scope of the invention as claimed.

Claims

1. A yarn constant tension electrical control system, characterized in that: Including control module, tension sensor module, motor module, host computer module and power module; The tension sensing module is used to collect yarn tension in real time and transmit the collected yarn tension to the control module; The tension sensor is set on the yarn to collect the real-time tension of the yarn, and converts the collected yarn tension into numerical information through the AD conversion module and transmits it to the control module: Among them, A represents the collected current, A0 represents the minimum value of the standard electrical signal, and A m Indicates the maximum value of the standard electrical signal, D m Indicates the maximum value after conversion, and D0 indicates the minimum value after conversion; The host computer module is used to control the yarn tension in real time and send tension control instructions; The control module is used to receive the tension control instruction sent by the host computer, and determine the real-time adjustment current value of the motor in combination with the real-time yarn tension transmitted by the tension sensing module, and output it to the motor module; First, determine the initial control current of the motor module based on the tension setting value sent by the host computer: Then, according to the real-time yarn tension collected by the tension sensing module, the real-time control current of the motor is determined based on the adaptive fuzzy controller; The motor module is used to receive the control instructions output by the control module, adjust the motor current, and complete the corresponding yarn constant tension control; The power supply module is used to supply power to each module in the system; The initial current of the motor module is: Among them, S represents the tension setting value determined by the host computer, K d Indicates the coefficient of the weight calibration tension value, U indicates the motor voltage, I indicates the initial current of the motor module, n indicates the efficiency of the brushless DC motor, and N indicates the set initial motor speed; The real-time control current of the motor is determined based on the adaptive fuzzy controller, specifically: Based on the adaptive fuzzy controller u D , determine the output current value: x (n) =f(S…S 2 )+bu y=S in=in D (S|θ) you D (S|θ)=θ T ξ(S) Let e = y m -y, and: K=(k n -k1) T but: have been (n) +k1e (n-1) +…+k n e=0 you D (S|θ)=θ T ξ(S) Among them, S represents the tension setting value determined by the host computer, y m represents the real-time control current of the motor, ξ(S) is dimensional vector, n and k are constants, θ represents the set of adjustable parameters, and b is an element in the domain; By substituting the required tension and setting the initial parameters, the real-time control current value is obtained according to the fuzzy rules.

2. The yarn constant tension electrical control system according to claim 1, characterized in that: The motor module includes a motor unit, a motor drive unit and a motor encoding unit; The motor drive unit and the motor encoding unit are respectively connected to the control module, and receive the motor control current sent by the control module to control the direction, speed and torque of the motor unit.

3. A yarn constant tension electrical control method based on the system according to any one of claims 1-2, characterized in that: The following steps are involved: Step 1: Power on each device in the system and determine whether there is a tension value set by the host computer before shutdown. If yes, control the motor to restore to the last tension state. If not, keep in standby mode. Step 2: Determine the initial control current of the motor according to the tension value set by the host computer; Step 3: The tension sensing module collects the real-time tension of the yarn and transmits it to the control module. The control module combines the tension value set by the host computer and determines the real-time control current of the motor based on the adaptive fuzzy controller; Step 4: Detect the yarn status in real time to determine whether the tension is abnormal. If abnormal, shut down the system and perform troubleshooting.

4. The yarn constant tension electrical control method according to claim 3, characterized in that: The initial control current of the motor is determined in step 2, specifically: Among them, S represents the tension setting value determined by the host computer, K d It represents the coefficient of the weight calibration tension value, U represents the motor voltage, I represents the initial current of the motor module, n represents the efficiency of the brushless DC motor, and N represents the set initial motor speed.

5. The yarn constant tension electrical control method according to claim 3, characterized in that: The step 3 of determining the real-time control current of the motor based on the adaptive fuzzy controller is specifically as follows: Based on the adaptive fuzzy controller u D , determine the output current value: x (n) =f(S…S 2 )+bu y=S in=in D (S|θ) you D (S|θ)=θ T ξ(S) Let e = y m -y, and: K=(k n -k1) T but: have been (n) +k1e (n-1) +…+k n e=0 you D (S|θ)=θ T ξ(S) Among them, S represents the tension setting value determined by the host computer, y m represents the real-time control current of the motor, ξ(S) is dimensional vector, n and k are constants, θ represents the set of adjustable parameters, and b is an element in the domain; By substituting the required tension and setting the initial parameters, the real-time control current value is obtained according to the fuzzy rules.

6. The yarn constant tension electrical control method according to claim 3, characterized in that: The determination of whether the tension is abnormal in step 4 is specifically as follows: (1) When the yarn is loose, the motor keeps rotating clockwise. When the motor rotates clockwise to the set number of turns, it is judged that the tension is abnormal; (2) The tension sensing module detects the real-time tension of the yarn. If the tension value exceeds the set threshold, it is determined that the tension is abnormal.

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