An online measurement device and method for warp density distribution

Abstract

The present invention discloses an online measurement device and method for warp beam density distribution, which belongs to the technical field of textile equipment. The present invention combines Hooke's law and can directly calculate the warp beam unwinding density in real time by measuring the warp beam unwinding tension and radius, adopting a completely different idea from the prior art. The detection device of the present invention includes a tension measuring device and a radius measuring device. The tension measuring device can realize three-degree-of-freedom movement and can accurately record the angle of each measurement to ensure the consistency of yarn measurement. The design of the magnetic base of the device of the present invention makes the device easy to install. The present invention can accurately detect the warp beam density distribution online in real time, has practical feasibility in industrial production, and can provide accurate data support for online regulation of warping, sizing and weaving processes, which helps to improve the uniformity of the winding density of the warp beam or weaving beam, thereby ensuring the sizing quality, reducing the weaving breakage rate, and improving the quality of the fabric.

Description

Technical Field

[0001] The invention relates to an online measurement device and method for warp density distribution, belonging to the technical field of textile equipment. Background Art

[0002] In the textile industry, warping and sizing are two key processes that directly affect fabric quality. During warping, the warp beam winding density is usually required to be uniform to ensure the roundness, surface flatness, and consistency of the internal and external density of the warp beam during winding. The yarn elasticity should be maintained as much as possible to facilitate the subsequent sizing and weaving processes. During sizing, the yarn sheets of multiple warp beams are unwound simultaneously for sizing. It is necessary to ensure that the unwinding tension of these yarns remains consistent to achieve uniformity and consistency in sizing, thereby improving yarn performance to meet weaving requirements. It should be emphasized that the winding density distribution of the warp beam during warping is one of the key factors affecting the uniformity of the warp beam unwinding tension during sizing. The uniformity of the sizing warp beam unwinding tension has a significant impact on the quality of the weaving beam package. The quality of the weaving beam package determines the uniformity of the fabric surface during weaving. Therefore, the density of the warp beam or weaving beam is an extremely important process parameter in the warping, sizing, and weaving processes.

[0003] Currently, textile mills only control the winding density during warping, ignoring its impact on the unwinding tension during sizing and the uniformity of the fabric surface during weaving. Warping winding density is typically controlled by setting corresponding winding density parameters in the control program and relying on workers' experience to ensure uniformity. However, this method cannot monitor changes in winding density in real time, making it difficult to promptly correct production problems. Furthermore, traditional measurement methods may require production line downtime or suspension for measurement, impacting production efficiency. Furthermore, after warping or sizing, the warp or weaving beams are typically left idle for a period of time before further production. During this period, the winding density distribution of the warp or weaving beams will inevitably vary due to factors such as centripetal force and the temperature and humidity environment. The sizing process typically utilizes a constant tension control scheme that uniformly regulates multiple warp beams. Inconsistent winding density distribution further increases the inconsistency of the unwinding tensions during sizing, further impacting the package quality of the weaving beams and the fabric surface.

[0004] In order to solve the above problems, patent CN106093453B "Device and method for detecting the density of warp beams in warping machines" proposes to detect and calculate the warp beam winding density through speed measuring and distance measuring devices, so as to strictly control the uniformity of density distribution on the warp beam during warping. However, this device and calculation method have the following disadvantages: (1) In actual measurement, it is difficult for the measuring light of the distance measuring device to be vertically aligned with the axis of the warp beam, and there is an error between the measurement result and the true value. If the result is not corrected, the calculated winding density will inevitably have an error; (2) The winding density is calculated as the ratio of yarn volume to yarn length. The calculated density can only indirectly reflect the warp beam winding density and cannot obtain the actual true value. Summary of the Invention

[0005] In order to solve one or more existing problems, the present invention provides an online measurement device and method for warp density distribution, and the technical solution is as follows:

[0006] The present invention provides an online measurement device for warp beam density distribution, comprising a tension measuring sub-device and a radius measuring sub-device. The tension measuring sub-device is used to obtain the unwinding tension of a single warp yarn roll in real time; the radius measuring sub-device is used to obtain the real-time unwinding radius of the warp beam roll.

[0007] The tension measuring sub-device includes a tension sensor and a tension sensor fixing device. The tension sensor fixing device includes a magnetic base, a vertical fixing plate, a horizontal fixing plate, a handle screw, a magnet and a T-nut. The magnet is sucked on the bottom of the magnetic base; a vertical U-shaped hole is provided on the vertical fixing plate, and rulers are provided on both sides of the hole. The vertical fixing plate is fixed on the magnetic base; a U-shaped hole is provided on the horizontal fixing plate, and rulers are provided on both sides of the hole. The horizontal fixing plate is fixed to the vertical fixing plate by a handle screw and a T-nut that cooperates with it; the tension sensor is fixed on the horizontal fixing plate; during measurement, the fixing device is adsorbed and fixed at any position by the magnet at the bottom of the magnetic base. Through the cooperation of the handle screw and the T-nut, the horizontal fixing plate can move up and down, left and right, and rotate to achieve three degrees of freedom of movement. The measurement position and measurement angle of the tension sensor are recorded each time according to the rulers on the two fixing plates to ensure consistency during yarn measurement.

[0008] The radius measurement sub-device includes a distance sensor and a distance sensor fixing device. During measurement, the distance sensor is fixed on the distance sensor fixing device; the bottom of the fixing device is a magnetic base that can be adsorbed on the surface of a magnetic object.

[0009] In one embodiment, there are six groups of magnets evenly distributed on the bottom of the magnetic base.

[0010] In one embodiment, the distance sensor fixing device is a magnetic crab claw mount.

[0011] In one embodiment, the distance measuring sensor is an ultrasonic distance measuring sensor.

[0012] In one embodiment, when the distance measuring sensor is installed and fixed, it is ensured that the distance between the distance measuring sensor and the warp axis is within the sensor test range and is aligned with the axis center of the warp axis to be measured.

[0013] The present invention provides an online measurement method for warp density distribution during unwinding, comprising the following specific steps:

[0014] Step 1: Obtain the unwinding tension of a single warp yarn roll;

[0015] Step 2: Obtain the warp beam unwinding radius after correction and the radius after unwinding one circle;

[0016] Method for obtaining the corrected warp beam unwinding radius:

[0017] Obtain the axis radius of the warp beam, the full axis radius and the difference between the measured initial distance and the final distance of the warp beam, and correct the measured warp beam radius based on these three values.

[0018] The formula for warp beam unwinding radius correction is:

[0019]

[0020] Wherein, L0 is the distance from the distance sensor to the warp beam surface measured by the radius measuring device when the warp beam is not unwound; L1 is the distance from the distance sensor to the warp beam surface measured by the radius measuring device after the yarn is unwound; D m =|L0-L1|; r is the radius of the warp axis; R m L is the actual full-axis radius of the warp beam obtained by artificial measurement; t is the distance from the distance measuring sensor to the warp beam surface detected in real time; R(t) is the warp beam unwinding radius detected in real time after correction.

[0021] Step 3: Calculate the warp beam density distribution of the yarn during unwinding based on the tension, the warp beam unwinding radius, and the radius after unwinding one circle.

[0022] The density distribution calculation formula is:

[0023]

[0024] Where, ρ(t) is the density of the warp beam; n is the total number of yarns on the warp beam; is the winding tension of a single warp yarn; E is the elastic modulus of the yarn; A is the cross-sectional area of ​​the yarn; L is the distance between the warp beam and the guide roller; Tex i is the tex of the yarn when no external force is applied; Δh=|R i+1 (t)-Ri (t)|, where R i (t) is the warp beam unwinding radius after correction; R i+1 (t) is the radius of the warp beam after unwinding one circle after correction.

[0025] The beneficial effects of the present invention are:

[0026] (1) The present invention is different from the existing detection method of indirectly calculating the warp density by the ratio of yarn volume to length. Instead, it combines Hooke's law and directly calculates the warp unwinding density by the warp unwinding tension and radius, adopting a completely different approach from the existing technology.

[0027] (2) The detection device and calculation method of the present invention can calculate the winding density distribution of the warp beam or weaving beam in real time when the warp beam is unwound.

[0028] (3) The correction algorithm proposed in the present invention makes the calculation results more accurate. The tension measuring device of the present invention can realize three-degree-of-freedom movement and can accurately record the angle of each measurement to ensure the consistency of yarn measurement. The design of the magnetic base makes the measuring device easy to install, making it practical in industrial production. It can provide accurate data support for online control of warping, sizing and weaving processes, and help to improve the uniformity of the winding density of the warp beam or weaving beam, thereby ensuring the sizing quality, reducing the weaving breakage rate, and improving the fabric quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0030] Figure 1 This is a schematic diagram of the overall structure of the on-line measurement device for density distribution during warp beam winding according to the present invention;

[0031] Figure 2 This is a schematic diagram of the overall structure of the on-line measurement device for density distribution during warp beam unwinding according to the patent of the present invention;

[0032] Figure 3 This is a schematic diagram of the structure of the unwinding tension measuring device of the patent of this invention;

[0033] Figure 4 This is a schematic diagram of the structure of the unwinding radius measuring device of the patent of this invention;

[0034] Among them, 1. Tension sensor; 2. Tension sensor fixing device; 3. Yarn; 4. Warp beam; 5. Distance sensor; 6. Distance sensor fixing device; 7. Guide roller; 201. Magnetic base; 202. Vertical fixing plate; 203. Horizontal fixing plate; 204. Handle screw; 205. Magnet; 206. T-nut; 207. Ruler. DETAILED DESCRIPTION

[0035] To make the objectives, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.

[0036] Example 1:

[0037] An online measuring device for warp density distribution of the present invention is as follows Figure 1 and Figure 2 As shown, it includes a tension measuring device and a radius measuring device. The tension measuring device is used to obtain the unwinding tension of a single warp yarn in real time. and the unwinding tension T(t) of the warp beam 4, where n is the total number of yarns on the warp beam; the radius measuring device is used to obtain the real-time warp beam unwinding radius R(t).

[0038] like Figure 3 As shown, the tension measurement device includes a tension sensor 1 and a tension sensor fixture 2. The tension sensor fixture 2 comprises a magnetic base 201, a vertical fixing plate 202, a horizontal fixing plate 203, a handle screw 204, magnets 205, and T-nuts 206. Six sets of magnets 205 are evenly distributed on the bottom of the magnetic base 201. The vertical fixing plate 202 has a vertical U-shaped hole with scales 207 on either side of the hole. The vertical fixing plate 202 is fixed to the magnetic base 201. The horizontal fixing plate 203 has a U-shaped hole with scales 207 on either side of the hole. The horizontal fixing plate 203 is fixed to the vertical fixing plate 202 via a handle screw 204 and a matching T-nut 206. The tension sensor 1 is fixed to the horizontal fixing plate 203. During measurement, the six sets of magnets 205 on the bottom of the magnetic base 201 can be used to secure the tension sensor fixture at any position. The handle screw 204 and T-nut 206 allow the horizontal fixing plate 203 to move up and down, left and right, and rotate, achieving three degrees of freedom. The scales 207 on the two fixing plates record the tension sensor 1's measurement position and angle each time, ensuring consistency during yarn measurement. Angles are measured by comparing the left and right scale values ​​on the vertical fixing plate 202.

[0039] like Figure 4As shown, the radius measuring device includes a distance sensor 5 and a distance sensor fixing device 6. The distance sensor fixing device 6 is a magnetic crab clamp table holder, and the distance sensor 5 is fixed on the distance sensor fixing device 6. When installing and fixing, ensure that the distance between the sensor and the warp axis is within the sensor test range and is aligned with the axis center of the measured warp axis.

[0040] Example 2:

[0041] refer to Figure 1 、 Figure 3 and Figure 4 In this embodiment, a method for online measurement of warp beam density distribution is described in detail by taking warping beam winding as an example.

[0042] A method for online measurement of warp beam density distribution during warping and winding, using the online measurement device for warp beam density distribution described in Example 1, the method comprising the following specific steps:

[0043] S1: Correction of warp beam winding radius

[0044] Get the warp beam's axis radius, i.e., the radius of the warp beam's axis around which the yarn is wound; get the warp beam's full axis radius, i.e., the radius when the warp beam is fully wound with yarn; and get the distance from the distance sensor 5 to the warp beam. The warp beam winding radius correction formula is:

[0045]

[0046] Wherein, L0 is the distance from the distance sensor 5 to the warp beam surface measured by the radius measuring device when the warp beam is not wound; L1 is the distance from the distance sensor 5 to the warp beam surface measured by the radius measuring device after the yarn winding is completed; D m =|L0-L1|; r is the radius of the warp axis; R m L is the actual full-axis radius of the warp beam obtained by artificial measurement; t is the distance from the distance measuring sensor 5 to the warp beam surface detected in real time; R(t) is the warp beam unwinding radius detected in real time after correction.

[0047] S2: Calculate the density distribution of the warp beam

[0048] The tension measuring device is used to measure the winding tension of a single warp yarn; the radius measuring device is used to measure the real-time winding radius of the warp beam and the radius after one winding;

[0049] Calculation method:

[0050] 1) Assume that the winding tension of a single warp yarn is The elastic modulus of the yarn is E, the cross-sectional area of ​​the yarn is A, and the distance between the warp beam and the guide roller is L. According to Hooke's law, the deformation of the yarn before and after stretching ΔL can be obtained:

[0051]

[0052] 2) Let Tex be the value of the yarn before stretching i , you can get Tex of the stretched yarn i+1 :

[0053]

[0054] 3) Let the warp beam winding radius after correction be R i (t), the radius of the warp beam after winding one circle is R i+1 (t), the thickness of each warp yarn Δh can be obtained:

[0055] Δh=R i+1 (t)-R i (t) (5)

[0056] 4) Assuming the total number of yarns on the warp beam is n and the lateral area of ​​a single layer of yarn is S, the winding density of the warp beam ρ(t) is:

[0057]

[0058] The measurement data of the above various sensors are read, displayed and stored in real time on the host computer using the MODBUS communication protocol. After obtaining the above data, the warp density distribution is obtained by calculation.

[0059] The yarn type is 14.8tex pure cotton yarn, E=2.11×10 9 N / m 2 , A=1.59×10 -8 m 2 , L=0.7m,n=450,R m =0.315m, r=0.15m, D m = |L1-L0| = |0.152-0.310| = 0.158m. Based on the measurement results of tension and radius at a certain moment and correcting the radius measurement results, the warp density distribution can be calculated as shown in Table 1.

[0060] Table 1

[0061]

[0062] Example 3:

[0063] refer to Figure 2 、 Figure 3 and Figure 4 This embodiment takes the unwinding of the sizing warp beam as an example to describe in detail an online measurement method for the density distribution of the warp beam. The specific calculation steps are the same as those in Example 2, except that R i+1 (t) is the radius after unwinding one circle, Dm =L1-L0,

[0064] The yarn type is 14.6tex pure cotton yarn, E=1.86×10 9 N / m 2 , A=1.56×10 -8 m 2 , L = 1m, n = 500, R m =0.364m, r=0.15m, D m = |L1-L0| = |0.316-0.096| = 0.22 m. Based on the tension and radius measurements at a certain moment and by correcting the radius measurements, the warp density distribution ρ(t) can be calculated as shown in Table 2.

[0065] Table 2

[0066]

[0067]

[0068] Some steps in the embodiments of the present invention may be implemented using software, and the corresponding software program may be stored in a readable storage medium, such as a CD or a hard disk.

[0069] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An online measuring device for warp density distribution, characterized in that: The online measurement device for warp beam density distribution includes a tension measuring sub-device and a radius measuring sub-device. The tension measuring sub-device is used to obtain the unwinding tension of a single warp yarn roll in real time; the radius measuring sub-device is used to obtain the real-time corrected unwinding radius of the warp beam roll. The tension measurement sub-device includes a tension sensor and a tension sensor fixing device. The tension sensor fixing device includes a magnetic base, a vertical fixing plate, a horizontal fixing plate, a handle screw, a magnet, and a T-nut. The magnet is attracted to the bottom of the magnetic base. The vertical fixing plate is provided with a vertical U-shaped hole with scales on both sides of the hole. The vertical fixing plate is fixed to the magnetic base. The horizontal fixing plate is provided with a U-shaped hole with scales on both sides of the hole. The horizontal fixing plate is fixed to the vertical fixing plate by a handle screw and a T-nut that cooperates with it. The tension sensor is fixed to the horizontal fixing plate. The radius measurement sub-device includes a distance sensor and a distance sensor fixing device, the distance sensor is fixed on the distance sensor fixing device; the bottom of the fixing device is a magnetic base that can be adsorbed on the surface of a magnetic object.

2. The online measuring device for warp density distribution according to claim 1, characterized in that: There are six groups of magnets evenly distributed on the bottom of the magnetic base.

3. The online measuring device for warp density distribution according to claim 1, characterized in that: The distance sensor fixing device is a magnetic crab clamp meter stand.

4. The online measuring device for warp density distribution according to claim 1, characterized in that: The distance measuring sensor is an ultrasonic distance measuring sensor.

5. The online measuring device for warp density distribution according to claim 1, characterized in that: When installing and fixing the distance measuring sensor, ensure that the distance between the distance measuring sensor and the warp axis is within the sensor test range and is aligned with the axis center of the warp axis being measured.

6. An online measurement method for warp density distribution, characterized in that: The method is implemented based on the online measurement device for warp density distribution according to any one of claims 1 to 5, and the method comprises: Step 1: Obtain the warp beam unwinding radius after correction; Step 2: Calculate the density distribution of the warp beam according to the corrected warp beam unwinding radius obtained in step 1; In step 1: By obtaining the axis radius of the warp beam, the full beam radius and the difference between the measured initial distance and the final distance of the warp beam, the real-time corrected warp beam unwinding radius is obtained; The expression of the corrected warp beam unwinding radius is: Wherein, L0 is the distance from the distance sensor to the warp beam surface measured by the radius measuring device when the warp beam is not unwound; L1 is the distance from the distance sensor to the warp beam surface measured by the radius measuring device after the yarn is unwound; D m =|L0-L1|; r is the radius of the warp axis; R m L is the actual full-axis radius of the warp beam obtained by artificial measurement; t is the distance from the distance measuring sensor to the warp beam surface detected in real time; R(t) is the warp beam unwinding radius detected in real time after correction; In step 2: The warp beam density distribution of the yarn during unwinding is calculated according to the unwinding tension of the single warp yarn, the warp beam unwinding radius after correction and the radius after one round of unwinding after correction; The density distribution calculation formula is: Where, ρ(t) is the density of the warp beam; n is the total number of yarns on the warp beam; is the winding tension of a single warp yarn; E is the elastic modulus of the yarn; A is the cross-sectional area of ​​the yarn; L is the distance between the warp beam and the guide roller; Tex i is the tex of the yarn when no external force is applied; Δh=|R i+1 (t)-R i (t)|, where R i (t) is the warp beam unwinding radius after correction; R i+1 (t) is the radius of the warp beam after unwinding one circle after correction.

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