Tension detection-based automatic trimming compensation method and system for a winder

Abstract

The application provides a winding machine automatic trimming compensation method and system based on tension detection, comprising: sampling tension tracking results under different line speeds, curve fitting the samples obtained by sampling to obtain a relationship curve; according to Hooke's law and the curve fitting result, obtaining diameter estimation values of sections at various positions of a yarn surface. The estimated diameters of sections at various positions of the yarn surface in one round trip are checked, whether the estimated diameter of the edge of the yarn surface is abnormally increased is checked, and the abnormal lifting condition of the edge of the yarn surface is determined. According to the severity of the lifting condition, the amplitude of soft edge correction is determined, the edge of the yarn surface is leveled, and the condition that the edge of the yarn surface exceeds the edge of the bobbin is solved. The soft edge correction condition is counted, the increase and decrease of the reference position of the edge of the yarn surface are confirmed according to the frequency and amplitude of the occurrence, the uneven speed of the edge of the yarn surface is accelerated, the number of soft edge correction is reduced, and the condition that the edge of the yarn surface cannot reach the edge of the bobbin is solved.

Description

Technical Field

[0001] This invention relates to the technical field of textile machinery, and more specifically, to an automatic trimming compensation method and system for winding machines based on tension detection. Background Technology

[0002] Winding is a crucial step in the spinning process, its task being to process the yarn from the previous process into bobbins that meet specific requirements. In simple terms, winding involves drawing yarn from one or more bobbins onto another to fulfill certain technological requirements. The machines that perform the winding process are collectively called winding machines. Generally, a bobbin-type winding machine consists of a winding spindle, a yarn-laying structure, and a tensioning component. A bobbin-type winding machine uses a bobbin with an edge as the container for processing the yarn.

[0003] Traditional edge-tube winding machines use a parallel winding method, where the processed yarn is wound parallel to the winding drum at a very small winding angle, and a tensioning device applies a target tension to achieve the winding process. Because the winding angle is very small in parallel winding, the yarn at both ends of the yarn surface is prone to slippage and even edge collapse. Therefore, edge-tube winding spindles have retaining edges on both sides to prevent yarn slippage and edge collapse at the yarn ends.

[0004] However, the introduction of the aforementioned edge guards makes the yarn processed by edge-tube winding machines prone to errors in its actual position at both ends during the yarn arrangement process due to mechanical aging and inconsistencies in the edge tubes. This results in the finished bobbin exhibiting edge curling or concavity. Traditional edge-tube winding machines have employed various edge determination methods to address this issue, but the results have not been entirely satisfactory. These methods include improving the precision of the machinery and the bobbin, and adding edge-finding equipment to locate the edge of the bobbin bobbin while stationary.

[0005] These methods have the following drawbacks:

[0006] 1. High precision requirements in machining lead to high equipment costs, extended machine production cycles, and reduced mass production speed.

[0007] 2. When equipment or pipes age, timely maintenance is required, which can result in significant ongoing costs.

[0008] 3. If the yarn develops curled or concave edges, the production requirements of subsequent processes cannot be met, resulting in waste yarn products.

[0009] Automatic edge trimming compensation in edge tube winding machines employs certain methods to automatically locate the edge of the edge tube during operation, detect warped or concave edges, and correct them in real time, thereby resolving the aforementioned defects and improving product quality.

[0010] Compared to traditional edge determination methods, automatic edge trimming compensation differs in that traditional methods rely on mechanical precision and additional positioning equipment, performing correction only when the machine is stationary and remaining inactive during operation—essentially an open-loop system. Automatic edge trimming compensation, on the other hand, is implemented through software algorithms, providing real-time correction during machine operation—making it a closed-loop system.

[0011] Compared to traditional edge determination methods for pipes with sidewalls, the advantages of automatic edge trimming and compensation are:

[0012] 1. The precision requirements for machining and bobbin tubes are greatly reduced, equipment and operating costs are significantly reduced, and machine production efficiency is improved;

[0013] 2. No additional positioning equipment is required, thus eliminating a potential for malfunction and uncertainty;

[0014] 3. Closed-loop real-time adjustment and edge trimming throughout the entire process ensure product quality;

[0015] 4. When mechanical parts wear out, they can self-correct, reducing the cost and manpower required for later maintenance.

[0016] The current challenges of automatic edge trimming and compensation:

[0017] Selecting the appropriate assessment object is challenging: Without additional positioning equipment, the system must locate the edge of the tube based on its operating parameters and estimate and evaluate the warping and indentation of the edge. This assessment cannot be directly obtained from a single parameter. Furthermore, the system's operating parameters often exhibit significant uncertainty, such as fluctuations in rotational speed, tension, and unevenness of the yarn surface, all of which can affect the assessment of edge conditions.

[0018] Determining the appropriate threshold is difficult: Currently, textile orders are increasingly demanding customization, requiring the same machine model to handle a wider variety of yarn types. For the same machine, it's challenging to find a suitable threshold applicable to different yarn types, thus affecting the stability of automatic trimming compensation.

[0019] Therefore, a new technical solution is needed to improve the above-mentioned technical problems. Summary of the Invention

[0020] To address the shortcomings of existing technologies, the purpose of this invention is to provide an automatic trimming compensation method and system for winding machines based on tension detection.

[0021] An automatic trimming compensation method for a winding machine based on tension detection, provided by the present invention, includes the following steps:

[0022] Average draw ratio statistics under tension closed loop: Using statistical methods, during the acceleration and deceleration process of the winding machine, the tension tracking results, i.e. draw ratio, at different linear speeds are sampled with the tension tracking speed; then, the sampled samples are curve fitted to obtain the relationship curve between linear speed and draw ratio under the current target tension closed loop control condition.

[0023] Tension-based real-time diameter estimation: Based on Hooke's law and curve fitting results, using the current winding speed, current linear speed, feed linear speed, and real-time draw ratio as input conditions, the estimated diameter of the cross section at each position on the yarn surface under the current real-time working conditions is obtained.

[0024] Silk edge diameter consistency judgment and soft edge correction: Check the estimated diameter of the cross section of the yarn at each position during a round trip, and check whether the estimated diameter of the silk edge is abnormally increased, thereby determining the abnormal curling of the silk edge; determine the extent of soft edge correction based on the severity of the curling, and then smooth the curled silk edge.

[0025] Statistics and correction of the reference position of the silk edge: Statistics on the soft edge correction, based on the frequency and magnitude of its occurrence, to confirm the increase or decrease of the current reference position of the silk edge, and to perform edge trimming compensation.

[0026] Preferably, the average draw ratio statistics under the tension closed loop include the following steps:

[0027] Statistical analysis of yarn draw ratio: Under closed-loop tension conditions, the yarn draw ratio corresponding to different linear speeds was statistically analyzed.

[0028]

[0029] Fitting the "linear velocity-thread draw ratio" curve: Sample the thread draw ratio at each linear velocity and fit it using the least squares method:

[0030] Thread draw ratio = k1 × linear velocity + b1

[0031]

[0032]

[0033] Preferably, the tension-based real-time diameter estimation includes the following steps:

[0034] Obtain the theoretical wire draw ratio: Based on the current linear speed and the "linear speed-wire draw ratio" curve, the theoretical wire draw ratio is obtained;

[0035] To obtain the current draw ratio of the yarn: Calculate the current draw ratio of the yarn using Hooke's Law, current tension, target tension, and theoretical draw ratio of the yarn.

[0036]

[0037] Estimated real-time observation diameter: The real-time observation diameter is estimated based on the current draw ratio of the yarn, the feed rate, and the winding speed.

[0038]

[0039] Preferably, the determination of the consistency of the wire edge diameter and the correction of the soft edge include the following steps:

[0040] The winding machine has a reference value for edge warping of the tube: the real-time observed diameter is estimated once every millisecond, and the maximum value of the real-time observed diameter is taken when the wire is within 2 mm of both sides of the winding drum;

[0041] The winding machine has a side tube bridge for judgment: when the wire is within 1 mm of both sides of the winding drum, the deviation of the real-time observed diameter from the above maximum value is judged;

[0042] Soft edge judgment and execution: If the deviation is greater than 0.4 mm, an automatic soft edge of 4 mm distance is executed once; if the deviation is greater than 0.2 mm and less than 0.4 mm, an automatic soft edge of 2 mm distance is executed once.

[0043] Preferably, the statistical correction of the reference position of the silk surface edge includes the following steps:

[0044] Statistics on soft edge frequency and amplitude: The system determines whether the total stroke needs to be corrected based on the number of times the soft edge is triggered and the distance of the trigger, so that the stroke of the wire on the bobbin gradually approaches the actual stroke range of the tube with edge.

[0045] Total travel correction: If no automatic soft edge is triggered within 15 round trips of the winding motion, the target winding travel distance is increased by 0.2 mm; if an automatic soft edge of 4 mm is triggered within 3 round trips of the winding motion, the target winding travel distance is shortened by 0.2 mm; if an automatic soft edge of 2 mm is triggered within 3 round trips of the winding motion, the target winding travel distance is shortened by 0.1 mm; if an automatic soft edge of 4 mm is triggered within 7 round trips of the winding motion, the target winding travel distance is shortened by 0.1 mm; if an automatic soft edge of 2 mm is triggered within 7 round trips of the winding motion, the target winding travel distance is shortened by 0.05 mm; otherwise, the target winding travel distance remains unchanged. Following the above steps, the winding travel distance and soft edge amplitude are automatically adjusted for automatic edge tracking on winding machines with edge tubes.

[0046] The present invention also provides an automatic trimming compensation system for a winding machine based on tension detection, the system comprising the following modules:

[0047] Average draw ratio statistics under tension closed loop: Using a statistical system, during the acceleration and deceleration process of the winding machine, the tension tracking results, i.e. the draw ratio, at different linear speeds are sampled based on the tension tracking speed; then, the sampled data are curve fitted to obtain the relationship curve between linear speed and draw ratio under the current target tension closed loop control condition.

[0048] Tension-based real-time diameter estimation: Based on Hooke's law and curve fitting results, using the current winding speed, current linear speed, feed linear speed, and real-time draw ratio as input conditions, the estimated diameter of the cross section at each position on the yarn surface under the current real-time working conditions is obtained.

[0049] Silk edge diameter consistency judgment and soft edge correction: Check the estimated diameter of the cross section of the yarn at each position during a round trip, and check whether the estimated diameter of the silk edge is abnormally increased, thereby determining the abnormal curling of the silk edge; determine the extent of soft edge correction based on the severity of the curling, and then smooth the curled silk edge.

[0050] Statistics and correction of the reference position of the silk edge: Statistics on the soft edge correction, based on the frequency and magnitude of its occurrence, to confirm the increase or decrease of the current reference position of the silk edge, and to perform edge trimming compensation.

[0051] Preferably, the average draw ratio statistics under the tension closed loop include the following modules:

[0052] Statistical analysis of yarn draw ratio: Under closed-loop tension conditions, the yarn draw ratio corresponding to different linear speeds was statistically analyzed.

[0053]

[0054] Fitting the "linear velocity-thread draw ratio" curve: Sample the thread draw ratio at each linear velocity and fit it using the least squares method:

[0055] Thread draw ratio = k1 × linear velocity + b1

[0056]

[0057]

[0058] Preferably, the tension-based real-time diameter estimation includes the following modules:

[0059] Obtain the theoretical wire draw ratio: Based on the current linear speed and the "linear speed-wire draw ratio" curve, the theoretical wire draw ratio is obtained;

[0060] To obtain the current draw ratio of the yarn: Calculate the current draw ratio of the yarn using Hooke's Law, current tension, target tension, and theoretical draw ratio of the yarn.

[0061]

[0062] Estimated real-time observation diameter: The real-time observation diameter is estimated based on the current draw ratio of the yarn, the feed rate, and the winding speed.

[0063]

[0064] Preferably, the determination of the consistency of the silk surface edge diameter and the correction of the soft edge include the following modules:

[0065] The winding machine has a reference value for edge warping of the tube: the real-time observed diameter is estimated once every millisecond, and the maximum value of the real-time observed diameter is taken when the wire is within 2 mm of both sides of the winding drum;

[0066] The winding machine has a side tube bridge for judgment: when the wire is within 1 mm of both sides of the winding drum, the deviation of the real-time observed diameter from the above maximum value is judged;

[0067] Soft edge judgment and execution: If the deviation is greater than 0.4 mm, an automatic soft edge of 4 mm distance is executed once; if the deviation is greater than 0.2 mm and less than 0.4 mm, an automatic soft edge of 2 mm distance is executed once.

[0068] Preferably, the statistical correction of the reference position of the silk surface edge includes the following modules:

[0069] Statistics on soft edge frequency and amplitude: The system determines whether the total stroke needs to be corrected based on the number of times the soft edge is triggered and the distance of the trigger, so that the stroke of the wire on the bobbin gradually approaches the actual stroke range of the tube with edge.

[0070] Total travel correction: If no automatic soft edge is triggered within 15 round trips of the winding motion, the target winding travel distance is increased by 0.2 mm; if an automatic soft edge of 4 mm is triggered within 3 round trips of the winding motion, the target winding travel distance is shortened by 0.2 mm; if an automatic soft edge of 2 mm is triggered within 3 round trips of the winding motion, the target winding travel distance is shortened by 0.1 mm; if an automatic soft edge of 4 mm is triggered within 7 round trips of the winding motion, the target winding travel distance is shortened by 0.1 mm; if an automatic soft edge of 2 mm is triggered within 7 round trips of the winding motion, the target winding travel distance is shortened by 0.05 mm; otherwise, the target winding travel distance remains unchanged. Following the above module, the winding travel distance and soft edge amplitude are automatically adjusted for automatic edge tracking on winding machines with edge tubes.

[0071] Compared with the prior art, the present invention has the following beneficial effects:

[0072] 1. The winding stroke control of the winding machine of the present invention does not depend on an external edge finder, but comes directly from the result of algorithm calculation;

[0073] 2. This invention can dynamically adjust the wire laying stroke during the entire wire processing process, thereby ensuring a higher quality of edge tube wire forming;

[0074] 3. This invention can not only reduce the requirements for machining precision in equipment production, but also achieve an adaptive effect to aging or wear after the machinery has been used.

[0075] 4. The algorithm of this invention is based on the estimation of the real-time winding diameter. After the wire is processed, the quality of its forming effect is also reflected in the consistency of the diameter throughout the entire stroke range of the edge tube. Therefore, its criteria are convenient, the threshold is easy to determine, and it can be compatible with various wire types. Attached Figure Description

[0076] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0077] Figure 1 This is a flowchart illustrating the steps of an automatic trimming compensation method for yarn tension detection on a winding machine according to the present invention.

[0078] Figure 2 This is a schematic diagram of the mechanical structure of the edge tube winding machine of the present invention. Detailed Implementation

[0079] The present invention will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present invention, but do not limit the invention in any way. It should be noted that those skilled in the art can make several changes and improvements without departing from the concept of the present invention. These all fall within the protection scope of the present invention.

[0080] Example 1:

[0081] Reference Figure 1 and Figure 2 According to the present invention, an automatic trimming compensation method for a winding machine based on tension detection is provided, the method comprising the following steps:

[0082] Average draw ratio statistics under tension closed loop: Using statistical methods, during the acceleration and deceleration process of the winding machine, the tension tracking results, i.e. draw ratio, at different linear speeds are sampled with the tension tracking speed; then, the sampled samples are curve fitted to obtain the relationship curve between linear speed and draw ratio under the current target tension closed loop control condition.

[0083] Statistical analysis of yarn draw ratio: Under closed-loop tension conditions, the yarn draw ratio corresponding to different linear speeds was statistically analyzed.

[0084]

[0085] Fitting the "linear velocity-thread draw ratio" curve: Sample the thread draw ratio at each linear velocity and fit it using the least squares method:

[0086] Thread draw ratio = k1 × linear velocity + b1

[0087]

[0088]

[0089] Tension-based real-time diameter estimation: Based on Hooke's law and curve fitting results, using the current winding speed, current linear speed, feed linear speed, and real-time draw ratio as input conditions, the estimated diameter of the cross section at each position on the yarn surface under the current real-time working conditions is obtained.

[0090] Obtain the theoretical wire draw ratio: Based on the current linear speed and the "linear speed-wire draw ratio" curve, the theoretical wire draw ratio is obtained;

[0091] To obtain the current draw ratio of the yarn: Calculate the current draw ratio of the yarn using Hooke's Law, current tension, target tension, and theoretical draw ratio of the yarn.

[0092]

[0093] Estimated real-time observation diameter: The real-time observation diameter is estimated based on the current draw ratio of the yarn, the feed rate, and the winding speed.

[0094]

[0095] Silk edge diameter consistency judgment and soft edge correction: Check the estimated diameter of the cross section of the yarn at each position during a round trip, and check whether the estimated diameter of the silk edge is abnormally increased, thereby determining the abnormal curling of the silk edge; determine the extent of soft edge correction based on the severity of the curling, and then smooth the curled silk edge.

[0096] The winding machine has a reference value for edge warping of the tube: the real-time observed diameter is estimated once every millisecond, and the maximum value of the real-time observed diameter is taken when the wire is within 2 mm of both sides of the winding drum;

[0097] The winding machine has a side tube bridge for judgment: when the wire is within 1 mm of both sides of the winding drum, the deviation of the real-time observed diameter from the above maximum value is judged;

[0098] Soft edge judgment and execution: If the deviation is greater than 0.4 mm, an automatic soft edge of 4 mm distance is executed once; if the deviation is greater than 0.2 mm and less than 0.4 mm, an automatic soft edge of 2 mm distance is executed once.

[0099] Statistics and correction of the reference position of the silk edge: Statistics on the soft edge correction, based on the frequency and magnitude of its occurrence, to confirm the increase or decrease of the current reference position of the silk edge, and to perform edge trimming compensation;

[0100] Statistics on soft edge frequency and amplitude: The system determines whether the total stroke needs to be corrected based on the number of times the soft edge is triggered and the distance of the trigger, so that the stroke of the wire on the bobbin gradually approaches the actual stroke range of the tube with edge.

[0101] Total travel correction: If no automatic soft edge is triggered within 15 round trips of the winding motion, the target winding travel distance is increased by 0.2 mm; if an automatic soft edge of 4 mm is triggered within 3 round trips of the winding motion, the target winding travel distance is shortened by 0.2 mm; if an automatic soft edge of 2 mm is triggered within 3 round trips of the winding motion, the target winding travel distance is shortened by 0.1 mm; if an automatic soft edge of 4 mm is triggered within 7 round trips of the winding motion, the target winding travel distance is shortened by 0.1 mm; if an automatic soft edge of 2 mm is triggered within 7 round trips of the winding motion, the target winding travel distance is shortened by 0.05 mm; otherwise, the target winding travel distance remains unchanged. Following the above steps, the winding travel distance and soft edge amplitude are automatically adjusted for automatic edge tracking on winding machines with edge tubes.

[0102] The present invention also provides an automatic trimming compensation system for a winding machine based on tension detection. The automatic trimming compensation system for a winding machine based on tension detection can be implemented by executing the process steps of the automatic trimming compensation method for a winding machine based on tension detection. That is, those skilled in the art can understand the automatic trimming compensation method for a winding machine based on tension detection as a preferred embodiment of the automatic trimming compensation system for a winding machine based on tension detection.

[0103] Example 2:

[0104] The present invention also provides an automatic trimming compensation system for a winding machine based on tension detection, the system comprising the following modules:

[0105] Average draw ratio statistics under tension closed loop: Using a statistical system, during the acceleration and deceleration process of the winding machine, the tension tracking results, i.e. the draw ratio, at different linear speeds are sampled based on the tension tracking speed; then, the sampled data are curve fitted to obtain the relationship curve between linear speed and draw ratio under the current target tension closed loop control condition.

[0106] Statistical analysis of yarn draw ratio: Under closed-loop tension conditions, the yarn draw ratio corresponding to different linear speeds was statistically analyzed.

[0107]

[0108] Fitting the "linear velocity-thread draw ratio" curve: Sample the thread draw ratio at each linear velocity and fit it using the least squares method:

[0109] Thread draw ratio = k1 × linear velocity + b1

[0110]

[0111]

[0112] Tension-based real-time diameter estimation: Based on Hooke's law and curve fitting results, using the current winding speed, current linear speed, feed linear speed, and real-time draw ratio as input conditions, the estimated diameter of the cross section at each position on the yarn surface under the current real-time working conditions is obtained.

[0113] Obtain the theoretical wire draw ratio: Based on the current linear speed and the "linear speed-wire draw ratio" curve, the theoretical wire draw ratio is obtained;

[0114] To obtain the current draw ratio of the yarn: Calculate the current draw ratio of the yarn using Hooke's Law, current tension, target tension, and theoretical draw ratio of the yarn.

[0115]

[0116] Estimated real-time observation diameter: The real-time observation diameter is estimated based on the current draw ratio of the yarn, the feed rate, and the winding speed.

[0117]

[0118] Silk edge diameter consistency judgment and soft edge correction: Check the estimated diameter of the cross section of the yarn at each position during a round trip, and check whether the estimated diameter of the silk edge is abnormally increased, thereby determining the abnormal curling of the silk edge; determine the extent of soft edge correction based on the severity of the curling, and then smooth the curled silk edge.

[0119] The winding machine has a reference value for edge warping of the tube: the real-time observed diameter is estimated once every millisecond, and the maximum value of the real-time observed diameter is taken when the wire is within 2 mm of both sides of the winding drum;

[0120] The winding machine has a side tube bridge for judgment: when the wire is within 1 mm of both sides of the winding drum, the deviation of the real-time observed diameter from the above maximum value is judged;

[0121] Soft edge judgment and execution: If the deviation is greater than 0.4 mm, an automatic soft edge of 4 mm distance is executed once; if the deviation is greater than 0.2 mm and less than 0.4 mm, an automatic soft edge of 2 mm distance is executed once.

[0122] Statistics and correction of the reference position of the silk edge: Statistics on the soft edge correction, based on the frequency and magnitude of its occurrence, to confirm the increase or decrease of the current reference position of the silk edge, and to perform edge trimming compensation;

[0123] Statistics on soft edge frequency and amplitude: The system determines whether the total stroke needs to be corrected based on the number of times the soft edge is triggered and the distance of the trigger, so that the stroke of the wire on the bobbin gradually approaches the actual stroke range of the tube with edge.

[0124] Total travel correction: If no automatic soft edge is triggered within 15 round trips of the winding motion, the target winding travel distance is increased by 0.2 mm; if an automatic soft edge of 4 mm is triggered within 3 round trips of the winding motion, the target winding travel distance is shortened by 0.2 mm; if an automatic soft edge of 2 mm is triggered within 3 round trips of the winding motion, the target winding travel distance is shortened by 0.1 mm; if an automatic soft edge of 4 mm is triggered within 7 round trips of the winding motion, the target winding travel distance is shortened by 0.1 mm; if an automatic soft edge of 2 mm is triggered within 7 round trips of the winding motion, the target winding travel distance is shortened by 0.05 mm; otherwise, the target winding travel distance remains unchanged. Following the above module, the winding travel distance and soft edge amplitude are automatically adjusted for automatic edge tracking on winding machines with edge tubes.

[0125] Example 3:

[0126] like Figure 1 This invention provides an automatic trimming compensation method for winding machines based on tension detection, comprising:

[0127] Average draw ratio statistics under tension closed-loop control: Using a statistical method, during the acceleration and deceleration process of the winding machine, at a relatively fast tension tracking speed, the tension tracking results, i.e., the draw ratio, are sampled at different linear velocities. Then, curve fitting is performed on the sampled data to obtain the relationship curve between linear velocity and draw ratio under the current target tension closed-loop control condition.

[0128] Tension-based real-time diameter estimation: Based on Hooke's law and curve fitting results, using the current winding speed, feed line speed, and real-time draw ratio as input conditions, the estimated diameter of the cross-section at each position of the yarn surface under the current real-time working conditions is obtained.

[0129] Yarn edge diameter consistency assessment and soft edge correction: Check the estimated diameter of the cross-section at each position of the yarn surface during a round trip, and check whether the estimated diameter of the yarn edge is abnormally increased, thereby determining the abnormal curling of the yarn edge. Based on the severity of the curling, determine the extent of soft edge correction, and then smooth out the curled yarn edge to resolve the situation where the yarn edge exceeds the spindle tube edge.

[0130] Statistics and correction of the reference position of the wire surface edge: Statistics on the soft edge correction situation, based on the frequency and magnitude of its occurrence, confirm the increase or decrease of the current reference position of the wire surface edge, thereby accelerating the unevenness of the wire surface edge, reducing the number of soft edge corrections, and solving the problem that the wire surface edge cannot reach the edge of the spindle tube.

[0131] Preferably, the average draw ratio statistical step under the tension closed loop includes:

[0132] Average draw ratio statistics under tension closed-loop control: Using a statistical method, during the acceleration and deceleration process of the winding machine, at a relatively fast tension tracking speed, the tension tracking results, i.e., the draw ratio, are sampled at different linear velocities. Then, curve fitting is performed on the sampled data to obtain the relationship curve between linear velocity and draw ratio under the current target tension closed-loop control condition.

[0133] The purpose of average draw ratio statistics is to determine the amount of stretch corresponding to the target tension of the processed yarn, i.e., the draw ratio. Definition of draw ratio:

[0134]

[0135] During the winding process, the yarn travels along the yarn path, which is the route the yarn takes from the raw material drum to the winding drum. The presence of mechanical parts and yarn contact along this path causes the yarn draw ratio to vary at different linear speeds in order to achieve the same tension. This variation is essentially linear. Therefore, when calculating the average draw ratio, linear speed is used as the calculation value, resulting in a linear speed-yarn draw ratio curve.

[0136] Thread draw ratio = k1 × linear velocity + b1

[0137] The wire draw ratios at various linear velocities were sampled, and the values ​​of k1 and b1 were calculated using the least squares method for fitting. The least squares calculation method is as follows:

[0138]

[0139]

[0140] Tension-based real-time diameter estimation: Based on Hooke's law and curve fitting results, using the current winding speed, current linear speed, feed linear speed, and real-time draw ratio as input conditions, the estimated diameter of the cross-section at each position of the yarn surface under the current real-time working conditions is obtained.

[0141] First, based on the current linear velocity and the "linear velocity - wire draw ratio" curve, the theoretical wire draw ratio is obtained:

[0142] Theoretical wire draw ratio = k1 × linear velocity + b1

[0143] According to Hooke's Law, the relationship between draw ratio and tension is:

[0144] Tension = Hooke's coefficient × Yarn path length (1 - 1 / Yarn draft ratio)

[0145] Therefore, the current draw ratio of the yarn can be calculated using the current tension, target tension, and theoretical draw ratio of the yarn:

[0146] Current draw ratio of the yarn

[0147]

[0148] Based on the definition of draw ratio, the real-time observed diameter of the yarn at the current draw ratio can be estimated:

[0149]

[0150] Yarn edge diameter consistency assessment and soft edge correction: Check the estimated diameter of the cross-section at each position of the yarn surface during a round trip, and check whether the estimated diameter of the yarn edge is abnormally increased, thereby determining the abnormal curling of the yarn edge. Based on the severity of the curling, determine the extent of soft edge correction, and then smooth out the curled yarn edge to resolve the situation where the yarn edge exceeds the spindle tube edge.

[0151] The system estimates the real-time observed diameter every millisecond and performs different processing based on the position of the yarn on the winding drum:

[0152] When the wire is within 2 millimeters of both sides of the winding drum, take out the maximum value of the real-time observed diameter.

[0153] When the wire is within 1 mm of both sides of the winding drum, determine the deviation between the real-time observed diameter and the above maximum value.

[0154] If the deviation is greater than the threshold, a soft edge is implemented. Wherein,

[0155] If the deviation is greater than 0.4 mm, an automatic soft edge of 4 mm distance is achieved in one operation.

[0156] If the deviation is greater than 0.2 mm and less than 0.4 mm, then an automatic soft edge with a distance of 2 mm is achieved in one operation.

[0157] Statistics and correction of the reference position of the wire surface edge: Statistics on the soft edge correction situation, based on the frequency and magnitude of its occurrence, confirm the increase or decrease of the current reference position of the wire surface edge, thereby accelerating the unevenness of the wire surface edge, reducing the number of soft edge corrections, and solving the problem that the wire surface edge cannot reach the edge of the spindle tube.

[0158] The system determines whether the total stroke needs adjustment based on the number of soft edge triggers and the distance of the triggers, thus gradually bringing the wire's stroke on the bobbin closer to the actual stroke range of the bobbin with the edge. The determination method is as follows:

[0159] If no automatic soft edge is triggered within 15 round trips of the ribbon cable movement, then the target ribbon cable movement will be increased by 0.2 mm.

[0160] If an automatic soft edge of 4 mm is triggered within the time of 3 round trips of the ribbon cable movement, then the target ribbon cable movement will be shortened by 0.2 mm.

[0161] If an automatic soft edge of 2 mm is triggered within the time of 3 round trips of the ribbon cable movement, then the target ribbon cable movement will be shortened by 0.1 mm.

[0162] If an automatic soft edge with a distance of 4 mm is triggered within 7 round trips of the ribbon cable movement, then the target ribbon cable movement will be shortened by 0.1 mm.

[0163] If an automatic soft edge with a distance of 2 mm is triggered within 7 round trips of the ribbon cable movement, then the target ribbon cable movement will be shortened by 0.05 mm.

[0164] In other cases, the target wiring remains unchanged.

[0165] Following the steps above, the system can automatically adjust the wire laying stroke and soft edge amplitude, ultimately achieving automatic edge tracking function for winding tubes on the winding machine.

[0166] According to the computer-readable storage medium storing a computer program provided by the present invention, when the computer program is executed by a processor, it implements the steps of the yarn electronic forming position closed-loop control method.

[0167] The electronic device provided by the present invention includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the computer program is executed by the processor, it implements the steps of the yarn electronic forming position closed-loop control method.

[0168] Those skilled in the art can understand this embodiment as a more specific description of Embodiment 1 and Embodiment 2.

[0169] Those skilled in the art will understand that, besides implementing the system and its various devices, modules, and units provided by this invention in the form of purely computer-readable program code, the same functions can be achieved entirely through logical programming of the method steps, making the system and its various devices, modules, and units of this invention function in the form of logic gates, switches, application-specific integrated circuits, programmable logic controllers, and embedded microcontrollers. Therefore, the system and its various devices, modules, and units provided by this invention can be considered as a hardware component, and the devices, modules, and units included therein for implementing various functions can also be considered as structures within the hardware component; alternatively, the devices, modules, and units for implementing various functions can be considered as both software modules implementing the method and structures within the hardware component.

[0170] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various changes or modifications within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. An automatic trimming compensation method for a winding machine based on tension detection, characterized in that, The method includes the following steps: Average draw ratio statistics under tension closed loop: Using statistical methods, during the acceleration and deceleration process of the winding machine, the tension tracking results, i.e. draw ratio, at different linear speeds are sampled with the tension tracking speed; then, the sampled samples are curve fitted to obtain the relationship curve between linear speed and draw ratio under the current target tension closed loop control condition. Tension-based real-time diameter estimation: Based on Hooke's law and curve fitting results, using the current winding speed, current linear speed, feed linear speed, and real-time draw ratio as input conditions, the estimated diameter of the cross section at each position on the yarn surface under the current real-time working conditions is obtained. Silk edge diameter consistency judgment and soft edge correction: Check the estimated diameter of the cross section of the yarn at each position during a round trip, and check whether the estimated diameter of the silk edge is abnormally increased, thereby determining the abnormal curling of the silk edge; determine the extent of soft edge correction based on the severity of the curling, and then smooth the curled silk edge. Statistics and correction of the reference position of the silk edge: Statistics on the soft edge correction, based on the frequency and magnitude of its occurrence, to confirm the increase or decrease of the current reference position of the silk edge, and to perform edge trimming compensation; The statistical analysis of the average draw ratio under the tension closed loop includes the following steps: Statistical analysis of yarn draw ratio: Under closed-loop tension conditions, the yarn draw ratio corresponding to different linear speeds was statistically analyzed. Fitting the "linear velocity-thread draw ratio" curve: Sample the thread draw ratio at each linear velocity and fit it using the least squares method: ； The tension-based real-time diameter estimation includes the following steps: Obtain the theoretical wire draw ratio: Based on the current linear speed and the "linear speed-wire draw ratio" curve, the theoretical wire draw ratio is obtained; To obtain the current draw ratio of the yarn: Calculate the current draw ratio of the yarn using Hooke's Law, current tension, target tension, and theoretical draw ratio of the yarn. Estimated real-time observation diameter: The real-time observation diameter is estimated based on the current draw ratio of the yarn, the feed rate, and the winding speed. ； The determination of the consistency of the wire surface edge diameter and the correction of the soft edge include the following steps: The winding machine has a reference value for edge warping of the tube: the real-time observed diameter is estimated once every millisecond, and the maximum value of the real-time observed diameter is taken when the wire is within 2 mm of both sides of the winding drum; The winding machine has a side tube warping determination: when the wire is within 1 mm of both sides of the winding drum, the deviation of the real-time observed diameter from the above maximum value is determined; Soft edge judgment and execution: If the deviation is greater than 0.4 mm, an automatic soft edge of 4 mm distance is executed in one operation; if the deviation is greater than 0.2 mm and less than 0.4 mm, an automatic soft edge of 2 mm distance is executed in one operation. The statistical analysis and correction of the reference position of the silk surface edge includes the following steps: Statistics on soft edge frequency and amplitude: The system determines whether the total stroke needs to be corrected based on the number of times the soft edge is triggered and the distance of the trigger, so that the stroke of the wire on the bobbin gradually approaches the actual stroke range of the tube with edge. Total travel correction: If no automatic soft edge is triggered within 15 round trips of the ribbon cable movement, then the target ribbon cable travel will be increased by 0.2 mm. If an automatic soft edge of 4 mm is triggered within 3 round trips of the winding motion, the target winding motion is shortened by 0.2 mm; if an automatic soft edge of 2 mm is triggered within 3 round trips of the winding motion, the target winding motion is shortened by 0.1 mm; if an automatic soft edge of 4 mm is triggered within 7 round trips of the winding motion, the target winding motion is shortened by 0.1 mm; if an automatic soft edge of 2 mm is triggered within 7 round trips of the winding motion, the target winding motion is shortened by 0.05 mm; otherwise, the target winding motion remains unchanged. Following the above steps, the winding motion and soft edge amplitude are automatically adjusted to automatically track the edge of the winding machine when the winding machine has edge tubes.

2. An automatic trimming compensation system for a winding machine based on tension detection, characterized in that, The system includes the following modules: Average draw ratio statistics under tension closed loop: Using a statistical system, during the acceleration and deceleration process of the winding machine, the tension tracking results, i.e. the draw ratio, at different linear speeds are sampled based on the tension tracking speed; then, the sampled data are curve fitted to obtain the relationship curve between linear speed and draw ratio under the current target tension closed loop control condition. Tension-based real-time diameter estimation: Based on Hooke's law and curve fitting results, using the current winding speed, current linear speed, feed linear speed, and real-time draw ratio as input conditions, the estimated diameter of the cross section at each position on the yarn surface under the current real-time working conditions is obtained. Silk edge diameter consistency judgment and soft edge correction: Check the estimated diameter of the cross section of the yarn at each position during a round trip, and check whether the estimated diameter of the silk edge is abnormally increased, thereby determining the abnormal curling of the silk edge; determine the extent of soft edge correction based on the severity of the curling, and then smooth the curled silk edge. Statistics and correction of the reference position of the silk edge: Statistics on the soft edge correction, based on the frequency and magnitude of its occurrence, to confirm the increase or decrease of the current reference position of the silk edge, and to perform edge trimming compensation; The average draw ratio statistics under the tension closed loop include the following modules: Statistical analysis of yarn draw ratio: Under closed-loop tension conditions, the yarn draw ratio corresponding to different linear speeds was statistically analyzed. Fitting the "linear velocity-thread draw ratio" curve: Sample the thread draw ratio at each linear velocity and fit it using the least squares method: ； The tension-based real-time diameter estimation includes the following modules: Obtain the theoretical wire draw ratio: Based on the current linear speed and the "linear speed-wire draw ratio" curve, the theoretical wire draw ratio is obtained; To obtain the current draw ratio of the yarn: Calculate the current draw ratio of the yarn using Hooke's Law, current tension, target tension, and theoretical draw ratio of the yarn. Estimated real-time observation diameter: The real-time observation diameter is estimated based on the current draw ratio of the yarn, the feed rate, and the winding speed. ； The consistency determination of the silk surface edge diameter and soft edge correction includes the following modules: The winding machine has a reference value for edge warping of the tube: the real-time observed diameter is estimated once every millisecond, and the maximum value of the real-time observed diameter is taken when the wire is within 2 mm of both sides of the winding drum; The winding machine has a side tube warping determination: when the wire is within 1 mm of both sides of the winding drum, the deviation of the real-time observed diameter from the above maximum value is determined; Soft edge judgment and execution: If the deviation is greater than 0.4 mm, an automatic soft edge of 4 mm distance is executed in one operation; if the deviation is greater than 0.2 mm and less than 0.4 mm, an automatic soft edge of 2 mm distance is executed in one operation. The statistical correction of the reference position of the silk surface edge includes the following modules: Statistics on soft edge frequency and amplitude: The system determines whether the total stroke needs to be corrected based on the number of times the soft edge is triggered and the distance of the trigger, so that the stroke of the wire on the bobbin gradually approaches the actual stroke range of the tube with edge. Total travel correction: If no automatic soft edge is triggered within 15 round trips of the ribbon cable movement, then the target ribbon cable travel will be increased by 0.2 mm. If an automatic soft edge of 4 mm is triggered within 3 round trips of the winding motion, the target winding motion is shortened by 0.2 mm; if an automatic soft edge of 2 mm is triggered within 3 round trips of the winding motion, the target winding motion is shortened by 0.1 mm; if an automatic soft edge of 4 mm is triggered within 7 round trips of the winding motion, the target winding motion is shortened by 0.1 mm; if an automatic soft edge of 2 mm is triggered within 7 round trips of the winding motion, the target winding motion is shortened by 0.05 mm; otherwise, the target winding motion remains unchanged. According to the above module, the winding motion and soft edge amplitude are automatically adjusted to automatically track the edge of the winding machine with edge tube winding.

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