A method, apparatus, equipment and storage medium for detecting encoder faults in a fabric rolling machine.

Abstract

This invention provides a method, apparatus, device, and storage medium for encoder fault detection in a fabric winding machine, relating to the field of textile machinery technology. The method includes: real-time acquisition of motion information of the main shaft of a circular knitting machine collected by a main encoder, wherein the main encoder is configured on the main shaft and can rotate with it; acquisition of a counting signal from the large disc of the circular knitting machine collected by a counter or auxiliary encoder; generation of a real-time pulse deviation based on the motion information and the counting signal; acquisition of a pulse deviation expectation value; and determination of the encoder's state based on the pulse deviation expectation value and the real-time pulse deviation. This invention aims to solve the problem that most existing electronic fabric winding systems on the market cannot automatically determine and notify the main circular knitting machine to stop operation when an encoder malfunctions, leading to the gradual accumulation of fabric, resulting in fabric overflow and subsequent large-scale damage to the knitting needles, causing significant losses to the user.

Description

Technical Field

[0001] This invention relates to the field of textile machinery technology, specifically to a method, device, equipment, and storage medium for detecting encoder faults on a fabric rolling machine. Background Technology

[0002] The circular knitting machine electronic fabric winding machine, also known as the circular knitting weft knitting machine electronic fabric winding machine, is a common textile auxiliary equipment. Currently, most commonly used electronic fabric winding systems on the market cannot automatically detect and notify the main circular knitting machine to stop operating when an encoder malfunctions. In this situation, the main circular knitting machine continues to unload the fabric, but because the fabric winding machine lacks an encoder signal, it cannot follow the main machine in winding the fabric. This leads to the gradual accumulation of fabric, causing fabric overflow (floating fabric). At this point, the fabric may get caught in the needle cylinder, causing extensive damage to the knitting needles and resulting in significant losses for the user.

[0003] In view of the above, this application is hereby submitted. Summary of the Invention

[0004] In view of this, the purpose of the present invention is to provide a method, device, equipment and storage medium for detecting encoder faults in a fabric rolling machine, which can effectively solve the problem that in the prior art, when an encoder malfunction occurs, most electronic fabric rolling systems cannot automatically make a judgment and notify the main unit of the circular knitting machine to stop running, which leads to the gradual accumulation of produced fabric, causing fabric overflow, and in turn, large-scale damage to the knitting needles, resulting in a large amount of losses for the user.

[0005] This invention discloses a method for detecting encoder faults in a fabric rolling machine, comprising:

[0006] The motion information of the main shaft of the circular knitting machine, collected by the main encoder, is acquired in real time. The main encoder is configured on the main shaft and can follow the rotation of the main shaft of the circular knitting machine.

[0007] Acquire the counting signal of the large circular knitting machine disc collected by the counter or auxiliary encoder;

[0008] A real-time pulse deviation is generated based on the motion information and the counting signal;

[0009] Obtain the expected value of the pulse deviation, and determine the state of the main encoder based on the expected value of the pulse deviation and the real-time pulse deviation.

[0010] Preferably, after acquiring the counting signal of the large circular knitting machine disc collected by the counter, the method further includes:

[0011] The counting signals are recorded in a preset order.

[0012] Preferably, the motion information includes the operating speed pulse signal and angle pulse signal of the fabric winding machine spindle.

[0013] Preferably, a real-time pulse deviation is generated based on the motion information and the counting signal, specifically as follows:

[0014] Based on the recorded value of the counting signal, the motion information is calculated to generate a main shaft pulse difference, which is then recorded.

[0015] Multiple sets of spindle pulse differences are obtained and subtracted to generate real-time pulse deviation.

[0016] Preferably, the motion information is calculated based on the recorded value of the counting signal to generate a main shaft pulse difference, specifically as follows:

[0017] When the recorded value of the counting signal is determined to be the first preset value, the actual pulse value collected by the encoder is directly recorded.

[0018] When the recorded value of the counting signal is determined to be the second preset value, it is calculated according to the formula ΔP1=P2-P1, where P2 is the actual pulse value collected by the encoder this time, P1 is the pulse value recorded when the counter signal is the first preset value, and ΔP1 is the first pulse difference calculated when the counter signal is the second preset value.

[0019] When the recorded value of the counting signal is determined to be the third preset value, it is calculated according to the formula ΔP2=P3-P2, where P3 is the actual pulse value, P2 is the pulse value recorded when the counter signal is the second preset value, and ΔP2 is the second pulse difference calculated when the counter signal is the third preset value.

[0020] When the recorded value of the counting signal is determined to be the fourth preset value, the calculation is performed according to the formula ΔP=|ΔP2-ΔP1|, where ΔP2 is the second pulse difference calculated when the counter signal is the third preset value, ΔP1 is the first pulse difference calculated when the counter signal is the second preset value, and ΔP is the real-time pulse deviation absolute value calculated by subtracting the first pulse difference from the second pulse difference when the counter signal is the fourth preset value, thus generating the spindle pulse difference.

[0021] Preferably, the expected pulse deviation value is obtained, and the encoder state is determined based on the expected pulse deviation value and the real-time pulse deviation, specifically as follows:

[0022] The real-time pulse deviation is compared with the expected value of the pulse deviation to generate a comparison result;

[0023] Based on the comparison results, the encoder status signal is output.

[0024] Preferably, the real-time pulse deviation is compared with a preset expected pulse deviation value to generate a comparison result, specifically as follows:

[0025] Determine whether the real-time pulse deviation is greater than the expected value of the pulse deviation;

[0026] If so, generate comparison results;

[0027] If not, continue to acquire the next real-time pulse deviation and compare it.

[0028] The present invention also discloses a fault detection device for a fabric rolling machine encoder, comprising:

[0029] A motion information acquisition unit is used to acquire motion information of the main shaft of the large circular knitting machine in real time, which is collected by the main encoder. The main encoder is configured on the main shaft and can follow the rotation of the main shaft of the large circular knitting machine.

[0030] The counting signal acquisition unit is used to acquire the counting signal of the large circular knitting machine disc collected by the counter or auxiliary encoder;

[0031] A real-time pulse deviation generation unit is used to generate a real-time pulse deviation based on the motion information and the counting signal;

[0032] The state determination unit is used to obtain the expected value of pulse deviation and determine the state of the main encoder based on the expected value of pulse deviation and the real-time pulse deviation.

[0033] The present invention also discloses a fabric rolling machine encoder fault detection device, including a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor. When the processor executes the computer program, it implements a fabric rolling machine encoder fault detection method as described above.

[0034] The present invention also discloses a readable storage medium storing a computer program, which can be executed by the processor of the device where the storage medium is located to implement a fabric rolling machine encoder fault detection method as described in any of the above claims.

[0035] In summary, this embodiment provides a method, device, equipment, and storage medium for detecting encoder faults in a fabric winding machine. It acquires the motion information of the main shaft of a circular knitting machine and the counting signal of the large disc in real time. Based on the motion information and the counting signal, it generates a real-time pulse deviation. This real-time pulse deviation is compared with a preset expected pulse deviation value to determine the encoder's state. This prevents the electronic fabric winding machine from failing to follow or fully follow the main shaft due to encoder failure, leading to fabric spillage, damage to knitting needles, and significant losses for the machine user. It also solves the problem in existing electronic fabric winding systems where, when an encoder malfunctions, the system often fails to automatically determine and notify the main circular knitting machine to stop operating, resulting in fabric accumulation, spillage, and extensive damage to knitting needles, causing substantial losses to the user. Attached Figure Description

[0036] Figure 1 This is a flowchart illustrating a method for detecting encoder faults in a fabric rolling machine, as provided in an embodiment of the present invention.

[0037] Figure 2 This is a schematic diagram of the fabric rolling machine provided in an embodiment of the present invention.

[0038] Figure 3 This is a schematic diagram of a module for a fabric rolling machine encoder fault detection device provided in an embodiment of the present invention. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to represent selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0040] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0041] Please see Figures 1 to 2 The first embodiment of the present invention provides a method for detecting encoder faults in a fabric rolling machine, which can be executed by a fault detection device (hereinafter referred to as the detection device), specifically by one or more processors within the detection device, to achieve the following steps:

[0042] S101, real-time acquisition of motion information of the main shaft of the circular knitting machine collected by the main encoder, wherein the main encoder is configured on the main shaft and can follow the rotation of the main shaft of the circular knitting machine;

[0043] It should be noted that the detection device can be a PLC controller or a microcontroller controller, which can communicate with the counter and encoder via wired or wireless means. In this embodiment, a host computer can also be configured to issue instructions to the controller. For example, the host computer can provide the controller with the expected value of the pulse deviation.

[0044] In one possible embodiment of the present invention, the motion information includes the operating speed pulse signal and angle pulse signal of the fabric winding machine spindle.

[0045] Specifically, in this embodiment, the detection device acquires motion information sent by the encoder of the fabric winding machine in real time. The encoder of the fabric winding machine converts the rotation speed and angle of the main shaft of the large circular knitting machine into pulse signals and then feeds them back to the detection device.

[0046] S102, acquire the counting signal of the large circular knitting machine disc collected by the counter or auxiliary encoder;

[0047] In one possible embodiment of the present invention, after acquiring the counting signal of the large circular knitting machine disk collected by the counter, the method further includes: recording the counting signal in a preset order.

[0048] Specifically, in this embodiment, the detection device can obtain the counting signal sent by the large disc counter of the large circular knitting machine through wiring, and the user can monitor whether the counting signal is real and reliable through a touch screen; wherein, the counter is mainly used to calculate the number of rotations of the spindle. After obtaining the counting signal, the detection device will determine the quantity of the counting signal and record it sequentially in the order of 1, 2, 3, 0.

[0049] In this embodiment, when the counter malfunctions and cannot properly read the counting signal from the large circular knitting machine's main dial, an auxiliary encoder can be used to acquire the current counting signal from the large circular knitting machine's main dial to ensure the normal calculation of the pulse deviation of the main encoder. Simply put, the auxiliary encoder is mainly used to replace the counter in acquiring the counting signal from the large circular knitting machine's main dial when the counting signal cannot be received, in order to calculate the pulse deviation of the main encoder.

[0050] S103, generate a real-time pulse deviation based on the motion information and the counting signal;

[0051] Specifically, step S103 includes: calculating the motion information based on the recorded value of the counting signal, generating a main shaft pulse difference, and recording it;

[0052] Multiple sets of spindle pulse differences are obtained and subtracted to generate real-time pulse deviation.

[0053] Specifically, based on the recorded value of the counting signal, the motion information is calculated to generate the main axis pulse difference, as follows:

[0054] When the recorded value of the counting signal is determined to be the first preset value, the actual pulse value collected by the encoder is directly recorded.

[0055] When the recorded value of the counting signal is determined to be the second preset value, it is calculated according to the formula ΔP1=P2-P1, where P2 is the actual pulse value collected by the encoder this time, P1 is the pulse value recorded when the counter signal is the first preset value, and ΔP1 is the first pulse difference calculated when the counter signal is the second preset value.

[0056] When the recorded value of the counting signal is determined to be the third preset value, it is calculated according to the formula ΔP2=P3-P2, where P3 is the actual pulse value, P2 is the pulse value recorded when the counter signal is the second preset value, and ΔP2 is the second pulse difference calculated when the counter signal is the third preset value.

[0057] When the recorded value of the counting signal is determined to be the fourth preset value, the calculation is performed according to the formula ΔP=|ΔP2-ΔP1|, where ΔP2 is the second pulse difference calculated when the counter signal is the third preset value, ΔP1 is the first pulse difference calculated when the counter signal is the second preset value, and ΔP is the absolute value of the real-time pulse deviation calculated by subtracting the first pulse difference from the second pulse difference when the counter signal is the fourth preset value, thus generating the spindle pulse difference.

[0058] Specifically, in this embodiment, if the received count signal is 1, the encoder pulse value received by the detection device is recorded; if the received count signal is 2, the encoder pulse value received by the detection device is recorded and the pulse value recorded when the count signal is 1 is subtracted; if the received count signal is 3, the encoder pulse value received by the detection device is recorded and the pulse value recorded when the count signal is 2 is subtracted; if the received count signal is 0, the pulse difference 2 is subtracted from the pulse difference 1, and the absolute value is calculated. The final absolute value is the real-time pulse deviation calculated in this instance. In short, the detection device calculates the spindle pulse difference between two count signals and performs subtraction on the two calculated spindle pulse differences to obtain the real-time pulse deviation. Simultaneously, the user can monitor whether this value is reasonable via a touchscreen.

[0059] S104, obtain the expected value of pulse deviation, and determine the state of the main encoder based on the expected value of pulse deviation and the real-time pulse deviation.

[0060] Specifically, step S104 includes: comparing the real-time pulse deviation with the expected value of the pulse deviation to generate a comparison result;

[0061] Based on the comparison results, the encoder status signal is output.

[0062] Specifically, the real-time pulse deviation is compared with a preset expected pulse deviation value to generate a comparison result, as follows:

[0063] Determine whether the real-time pulse deviation is greater than the expected value of the pulse deviation;

[0064] If so, generate comparison results;

[0065] If not, continue to acquire the next real-time pulse deviation and compare it.

[0066] Specifically, in this embodiment, the user can input the desired pulse deviation value to the controller of the fabric rolling machine via the touch screen; the real-time pulse deviation is compared with the expected pulse deviation value set via the touch screen. If the real-time pulse deviation exceeds the pulse deviation setting value, the encoder is considered to be faulty. At this time, the detection device will issue an alarm signal to remind the user to check.

[0067] In summary, the fabric winding machine encoder converts the rotation speed and angle of the main shaft of the circular knitting machine into pulse signals and feeds them back to the detection device. The detection device obtains the counter signal of the large disc of the circular knitting machine through wiring. The detection device calculates the main shaft pulse difference between the two counter signals and subtracts the two pulse differences to obtain the real-time pulse deviation. Finally, the real-time pulse deviation is compared with the expected pulse deviation value set on the touch screen. If the real-time pulse deviation exceeds the pulse deviation setting value, the encoder is considered to be faulty, and the detection device issues an alarm signal. That is, the fabric winding machine encoder fault detection method is to set an encoder fault detection function in the fabric winding machine controller. This function can not only reduce the defect rate caused by encoder failure, but also reduce the damage to knitting needles and economic losses caused by fabric overflow.

[0068] Please see Figure 3 The second embodiment of the present invention provides a fabric winding machine encoder fault detection device, comprising:

[0069] The motion information acquisition unit 201 is used to acquire motion information of the main shaft of the large circular knitting machine collected by the main encoder in real time, wherein the main encoder is configured on the main shaft and can follow the operation of the main shaft of the large circular knitting machine.

[0070] The counting signal acquisition unit 202 is used to acquire the counting signal of the large circular knitting machine disk collected by the counter or auxiliary encoder;

[0071] The real-time pulse deviation generation unit 203 is used to generate a real-time pulse deviation based on the motion information and the counting signal.

[0072] The state determination unit 204 is used to obtain the expected value of the pulse deviation and determine the state of the main encoder based on the expected value of the pulse deviation and the real-time pulse deviation.

[0073] A third embodiment of the present invention provides a fabric winding machine encoder fault detection device, including a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor. When the processor executes the computer program, it implements a fabric winding machine encoder fault detection method as described in any of the above embodiments.

[0074] The fourth embodiment of the present invention provides a readable storage medium storing a computer program, which can be executed by the processor of the device where the storage medium is located to implement a fabric rolling machine encoder fault detection method as described in any of the above embodiments.

[0075] Exemplary examples show that the computer program described in the third and fourth embodiments of the present invention can be divided into one or more modules, which are stored in the memory and executed by the processor to complete the present invention. The one or more modules can be a series of computer program instruction segments capable of performing specific functions, which describe the execution process of the computer program in implementing a fabric roll encoder fault detection device. For example, the apparatus described in the second embodiment of the present invention.

[0076] The processor referred to can be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor. The processor is the control center of the fabric winding machine encoder fault detection method, connecting various parts of the method via various interfaces and lines.

[0077] The memory can be used to store the computer program and / or modules. The processor, by running or executing the computer program and / or modules stored in the memory and calling the data stored in the memory, implements various functions of a fabric rolling machine encoder fault detection method. The memory may mainly include a program storage area and a data storage area. The program storage area may store the operating system, at least one application program required for a function (such as sound playback function, text conversion function, etc.), etc.; the data storage area may store data created according to the use of the mobile phone (such as audio data, text message data, etc.). In addition, the memory may include high-speed random access memory, and may also include non-volatile memory, such as hard disk, memory, plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, at least one disk storage device, flash memory device, or other volatile solid-state storage device.

[0078] If the implemented module is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the above embodiments of the present invention can also be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include: any entity or device capable of carrying the computer program code, recording media, USB flash drives, portable hard drives, magnetic disks, optical disks, computer memory, read-only memory (ROM), random access memory (RAM), electrical carrier signals, telecommunication signals, and software distribution media, etc. It should be noted that the content included in the computer-readable medium can be appropriately added or removed according to the requirements of legislation and patent practice in the jurisdiction. For example, in some jurisdictions, according to legislation and patent practice, computer-readable media do not include electrical carrier signals and telecommunication signals.

[0079] It should be noted that the device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate, and the components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Furthermore, in the accompanying drawings of the device embodiments provided by this invention, the connection relationships between modules indicate that they have communication connections, which can be specifically implemented as one or more communication buses or signal lines. Those skilled in the art can understand and implement this without any creative effort.

[0080] The above are merely preferred embodiments of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions that fall within the scope of the present invention are within the scope of protection of the present invention.

Claims

1. A method for detecting encoder faults in a fabric rolling machine, characterized in that, include: The motion information of the main shaft of the circular knitting machine, collected by the main encoder, is acquired in real time. The main encoder is configured on the main shaft and can follow the rotation of the main shaft of the circular knitting machine. Acquire the counting signal of the large circular knitting machine disc collected by the counter or auxiliary encoder; A real-time pulse deviation is generated based on the motion information and the counting signal, specifically as follows: Based on the recorded value of the counting signal, the motion information is calculated to generate a main shaft pulse difference, which is then recorded. Specifically: When the recorded value of the counting signal is determined to be the first preset value, the actual pulse value collected by the encoder is directly recorded. When the recorded value of the counting signal is determined to be the second preset value, according to the formula... The calculation is performed, where P2 is the actual pulse value acquired by the encoder, P1 is the pulse value recorded when the counter signal is the first preset value, and ΔP1 is the first pulse difference calculated when the counter signal is the second preset value. When the recorded value of the counting signal is determined to be the third preset value, according to the formula... The calculation is performed, where P3 is the actual pulse value, P2 is the pulse value recorded when the counter signal is the second preset value, and △P2 is the second pulse difference calculated when the counter signal is the third preset value. When the recorded value of the counting signal is determined to be the fourth preset value, according to the formula... The calculation is performed, where △P2 is the second pulse difference calculated when the counter signal is the third preset value, △P1 is the first pulse difference calculated when the counter signal is the second preset value, and △P is the real-time pulse deviation absolute value calculated by subtracting the first pulse difference from the second pulse difference when the counter signal is the fourth preset value, thus generating the spindle pulse difference. Multiple sets of spindle pulse differences are obtained and subtracted to generate real-time pulse deviation; Obtain the expected pulse deviation value, and determine the state of the main encoder based on the expected pulse deviation value and the real-time pulse deviation, specifically as follows: The real-time pulse deviation is compared with the expected value of the pulse deviation to generate a comparison result, specifically as follows: Determine whether the real-time pulse deviation is greater than the expected value of the pulse deviation; If so, generate comparison results; If not, continue to acquire the next real-time pulse deviation and compare it; Based on the comparison results, the encoder status signal is output.

2. The method for detecting encoder faults in a fabric winding machine according to claim 1, characterized in that, After acquiring the counting signal of the large circular knitting machine disk collected by the counter, the process also includes: The counting signals are recorded in a preset order.

3. The method for detecting encoder faults in a fabric winding machine according to claim 1, characterized in that, The motion information includes the operating speed pulse signal and angle pulse signal of the fabric rolling machine spindle.

4. A fabric winding machine encoder fault detection device, characterized in that, The device is used to implement the encoder fault detection method for a fabric rolling machine as described in any one of claims 1 to 3, comprising: A motion information acquisition unit is used to acquire motion information of the main shaft of the large circular knitting machine in real time, which is collected by the main encoder. The main encoder is configured on the main shaft and can follow the rotation of the main shaft of the large circular knitting machine. The counting signal acquisition unit is used to acquire the counting signal of the large circular knitting machine disc collected by the counter or auxiliary encoder; A real-time pulse deviation generation unit is used to generate a real-time pulse deviation based on the motion information and the counting signal; The state determination unit is used to obtain the expected value of pulse deviation and determine the state of the main encoder based on the expected value of pulse deviation and the real-time pulse deviation.

5. A fabric winding machine encoder fault detection device, characterized in that, The method includes a processor, a memory, and a computer program stored in the memory and configured to be executed by the processor, wherein the processor executes the computer program to implement a fabric winding machine encoder fault detection method as described in any one of claims 1 to 3.

6. A readable storage medium, characterized in that, The device contains a computer program that can be executed by a processor of the device where the storage medium is located, to implement a fabric rolling machine encoder fault detection method as described in any one of claims 1 to 3.

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