Rotary screen printing machine control system and rotary screen printing machine

Abstract

The present invention discloses a rotary screen printing machine control system and a rotary screen printing machine, relating to the technical field of printing machines. The rotary screen printing machine control system includes a frequency conversion control module, a speed detection module, a motion control module, a visual acquisition module, and a main control processing module. The frequency conversion control module is connected to the guide belt motor of the rotary screen printing machine and is used to control the speed of the guide belt motor. The speed detection module is used to detect the guide belt speed of the rotary screen printing machine. The motion control module is respectively connected to the speed detection module and the printing roller servo motor of the rotary screen printing machine and is used to control the speed of the printing roller servo motor according to the guide belt speed. The visual acquisition module is used to capture a printed image of the fabric. The main control processing module is connected to the frequency conversion control module and is used to determine the printing quality based on the printed image of the fabric and send a frequency conversion control instruction to the frequency conversion control module based on the printing quality. The present invention can improve the printing accuracy, production efficiency, and automation level of the rotary screen printing machine.

Description

Technical Field

[0001] The present invention relates to the technical field of printing machines, and in particular to a rotary screen printing machine control system and a rotary screen printing machine. Background Art

[0002] A rotary screen printer is a highly efficient textile printing and dyeing machine. It transfers color paste evenly to the fabric by contacting the patterned portion of the rotary screen (printing roller) with the fabric, enabling continuous, high-volume printing. This machine is widely used in the printing production of clothing, home textiles, and industrial textiles, and is favored by the market for its high speed and diverse pattern design capabilities.

[0003] Traditional rotary screen printing machine control systems typically use mechanical transmission and relay logic circuits to implement basic motor start / stop and speed regulation. However, due to deficiencies in real-time monitoring and precise control, these control systems have limitations in printing accuracy, production efficiency, and automation, making them difficult to meet the demands of modern high-speed, high-quality production. Summary of the Invention

[0004] In view of the above technical problems and defects, the purpose of the present invention is to provide a rotary screen printing machine control system and a rotary screen printing machine, which can improve the printing accuracy, production efficiency and automation level of the rotary screen printing machine.

[0005] To achieve the above-mentioned objectives, in a first aspect, the present invention provides a rotary screen printing machine control system, comprising a frequency conversion control module, a speed detection module, a motion control module, a visual acquisition module and a main control processing module; the frequency conversion control module is connected to the guide belt motor of the rotary screen printing machine and is used to control the speed of the guide belt motor; the speed detection module is used to detect the guide belt speed of the rotary screen printing machine; the motion control module is respectively connected to the speed detection module and the printing roller servo motor of the rotary screen printing machine, and is used to control the speed of the printing roller servo motor according to the guide belt speed; the visual acquisition module is used to capture the fabric print image; the main control processing module is connected to the frequency conversion control module, and is used to determine the print quality according to the fabric print image, and send a frequency conversion control instruction to the frequency conversion control module according to the print quality.

[0006] By monitoring and analyzing key parameters during the printing process in real time, the embodiments of the present invention achieve precise control of the guide belt speed and the printing roller speed, thereby ensuring high accuracy and consistency of the printed pattern. The intelligent image processing and quality assessment functions of the main control processing unit further improve the automation level of the production process and reduce human interference. In addition, the high flexibility and adaptability of the control system enable it to quickly respond to different production conditions and design requirements, significantly improving production efficiency and the quality of printed products. This reduces operational complexity, maintenance costs and downtime, and overall improves the intelligence and reliability of the production process.

[0007] In combination with some embodiments of the first aspect, in some embodiments, the main control processing module is specifically used to: determine the printing quality and the complexity of the printing pattern based on the fabric printing image; determine the guide belt adjustment speed based on the printing quality and the complexity of the printing pattern; generate a frequency conversion control instruction based on the guide belt adjustment speed; and send the frequency conversion control instruction to the frequency conversion control module.

[0008] The technical solutions of the above-mentioned embodiments of the present invention enable precise assessment of print quality and pattern complexity through intelligent analysis of fabric print images by the main control processing module. This assessment not only improves the automation level of the printing process but also optimizes the printing effect by dynamically adjusting the belt speed, ensuring efficient production for different patterns and quality requirements.

[0009] In combination with some embodiments of the first aspect, in some embodiments, the main control processing module is specifically used to: extract the print color complexity and pattern detail richness from the fabric print image; and determine the print pattern complexity based on the print color complexity and pattern detail richness.

[0010] By employing the technical solutions of the above-described embodiments of the present invention, the system can more accurately determine pattern complexity through quantitative analysis of print color complexity and pattern detail richness. This enables the printer to automatically adjust process parameters when processing highly complex patterns, ensuring print quality and production efficiency.

[0011] In combination with some embodiments of the first aspect, in some embodiments, the main control processing module is specifically used to: extract print color uniformity and print pattern clarity from the fabric print image; and determine the print quality based on the print color uniformity and print pattern clarity.

[0012] Using the technical solutions of the above-mentioned embodiments of the present invention, the system can accurately determine print quality by evaluating print color uniformity and pattern clarity. This evaluation mechanism enables the printer to adjust the printing process in a timely manner, avoiding quality defects and improving product quality.

[0013] In conjunction with some embodiments of the first aspect, in some embodiments, the main control processing module is specifically configured to: calculate the conduction tape adjustment speed according to the conduction tape speed adjustment formula, where the mathematical form of the conduction tape speed adjustment formula is:

[0014] V(t)=V0·e -k·F·A(t) ;

[0015] Among them, V0 is the preset reference guide belt speed, A(t) is the dynamic adjustment factor, and F is the comprehensive index of printing difficulty. The comprehensive index of printing difficulty is determined based on the printing color uniformity, printing pattern clarity, printing color complexity and pattern detail richness.

[0016] By applying the above-mentioned technical solution and a belt speed adjustment formula, the system can dynamically adjust the belt speed based on a comprehensive, real-time printing difficulty indicator. This intelligent speed control strategy improves the adaptability and flexibility of the printing process, ensuring optimal printing results under varying production conditions.

[0017] In combination with some embodiments of the first aspect, in some embodiments, the main control processing module is specifically used to: calculate the printing difficulty comprehensive index according to the printing difficulty comprehensive index formula, and the mathematical form of the printing difficulty comprehensive index formula is:

[0018]

[0019] Among them, U, C, Co, and D are the standardized scoring values ​​of printing color uniformity, printing pattern clarity, printing color complexity, and pattern detail richness, respectively. U 、w C 、w Co 、w D are weight parameters respectively.

[0020] By employing the technical solutions of the above-mentioned embodiments of the present invention and applying a comprehensive printing difficulty indicator formula, the system can comprehensively consider multiple printing quality factors and make more reasonable belt speed adjustments. This approach improves the printer's adaptability to different printing tasks, thereby enhancing production efficiency and product quality.

[0021] In combination with some embodiments of the first aspect, in some embodiments, the mathematical expression of the dynamic adjustment factor is A(t) = a0 + a1·sin(ωt) + a2·cos(ωt), where a0, a1, and a2 are adjustment parameters, and ω is the time-varying frequency.

[0022] By implementing the technical solutions of the above-mentioned embodiments of the present invention and introducing dynamic adjustment factors, the system can adjust the operating parameters of the printing machine in real time based on time changes and production needs. This dynamic adjustment mechanism improves the system's response speed and production adaptability, optimizing the production process.

[0023] In combination with some embodiments of the first aspect, in some embodiments, the rotary screen printing machine control system also includes a connected color paste detection module and a paste pump motor, the color paste detection module is used to detect the remaining amount of color paste in the printing roller, and the paste pump motor is used to drive the corresponding paste pump to replenish the color paste to the printing roller according to the remaining amount of color paste.

[0024] The technical solutions of the above-mentioned embodiments of the present invention, through the cooperation of the colorant detection module and the slurry pump motor, achieve automatic management of the colorant supply during the printing process. This automated colorant replenishment mechanism ensures the continuity and uniformity of the colorant during the printing process, avoiding printing quality problems caused by insufficient or uneven colorant.

[0025] In combination with some embodiments of the first aspect, in some embodiments, the rotary screen printing machine control system also includes a first user interaction end and a second user interaction end, the second user interaction end is connected to the main control processing module, and the main control processing module is connected to the slurry pump motor; the first user interaction end is connected to the motion control module for receiving control instructions input by the user.

[0026] By adopting the technical solution of the above embodiment of the present invention, by providing the first and second user interaction terminals, the operator can more conveniently interact with the control system, achieving precise control and monitoring of the printing machine. This user-friendly interactive interface improves the convenience of operation and the ease of use of the system.

[0027] In a second aspect, the present invention provides a rotary screen printing machine, comprising a rotary screen printing machine body and the above-mentioned rotary screen printing machine control system, wherein the rotary screen printing machine body and the rotary screen printing machine control system are connected.

[0028] It is understandable that the rotary screen printing machine provided in the second aspect includes the rotary screen printing machine control system provided in the first aspect. Therefore, the beneficial effects that can be achieved can refer to the beneficial effects of the rotary screen printing machine control system provided in the first aspect, and will not be repeated here.

[0029] One or more technical solutions provided by the present invention have at least the following technical effects or advantages:

[0030] 1. Improved printing precision and quality: The system precisely controls the speed of the guide belt through its integrated frequency conversion control module and speed detection module. The motion control module also precisely adjusts the speed of the printing roller servo motor, ensuring precise pattern alignment and color uniformity during the printing process. Furthermore, the main control processing module utilizes images captured by the visual acquisition module to intelligently analyze print quality and adjust production parameters in a timely manner, significantly improving the quality of printed products.

[0031] 2. Enhanced automation and intelligence in the production process: The system utilizes advanced image processing technology and intelligent algorithms to automatically assess the complexity and quality of printed patterns, enabling intelligent control of the production process. The main control processing module dynamically adjusts the belt speed based on real-time feedback and preset mathematical models, reducing manual intervention and improving the automation level of the printing process. It also enables the printer to adapt to different production conditions and design requirements.

[0032] 3. Optimizing production efficiency and operational convenience: Through the intuitive user interface, operators can easily monitor system status, input control commands, and make necessary manual adjustments. Furthermore, the system's highly integrated design and automated processes reduce production downtime and improve production efficiency. The colorant detection module and the pump motor work together to automate the management of colorant supply, avoiding colorant issues during the printing process and further improving production continuity and operational convenience. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The accompanying drawings are incorporated into and constitute a part of the specification, illustrate embodiments consistent with the present invention, and together with the specification, are used to explain the principles of the present invention. Obviously, the drawings described below are only some embodiments of the present invention, and those skilled in the art can derive other drawings based on these drawings without inventive effort. In the drawings:

[0034] Figure 1 This is an architectural diagram of a rotary screen printing machine control system according to an embodiment of the present invention;

[0035] Figure 2 1 is a schematic diagram of a conductive band connection relationship in an embodiment of the present invention;

[0036] Figure 3 is a schematic diagram of the positions of the first user interaction terminal and the second user interaction terminal in an embodiment of the present invention;

[0037] Figure 4 This is a schematic diagram of the main operation screen of the main control processing module in an embodiment of the present invention;

[0038] Figure 5 This is a schematic diagram of a fan control screen of a main control processing module in an embodiment of the present invention;

[0039] Figure 6 1 is a schematic diagram of a unit selection and setting interface of a main control processing module in an embodiment of the present invention;

[0040] Figure 7 1 is a schematic diagram of a parameter setting interface of a main control processing module in an embodiment of the present invention;

[0041] Figure 8 Schematic diagram of a monitoring screen of a main control processing module in an embodiment of the present invention;

[0042] Figure 9 2 is a schematic diagram of virtual spindle control in an embodiment of the present invention. DETAILED DESCRIPTION

[0043] The terms used in the following embodiments of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. As used in the specification of the present invention, the singular expressions "a," "an," "above," "the," and "this" are intended to include the plural expressions as well, unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used in the present invention refers to any and all possible combinations of one or more of the listed items.

[0044] Hereinafter, the terms "first" and "second" are used for descriptive purposes only and should not be construed as implying relative importance or implicitly indicating the quantity of the technical features indicated. Thus, a feature designated "first" or "second" may explicitly or implicitly include one or more of such features. In the description of the embodiments of the present invention, unless otherwise specified, "plurality" means two or more.

[0045] It should also be noted that, unless otherwise clearly specified and limited, in the embodiments of the present invention, terms such as "setting" and "connection" should be understood in a broad sense. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, or it can be the internal connection of two components; it can be a wired communication connection or a wireless communication connection. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances. The embodiments of the present invention are described in detail below.

[0046] Example 1:

[0047] The embodiment of the present invention provides a rotary screen printing machine control system, such as Figure 1 As shown, it includes a frequency conversion control module 1, a speed detection module 2, a motion control module 3, a visual acquisition module 4 and a main control processing module 5; the frequency conversion control module 1 is connected to the guide belt motor of the rotary screen printing machine to control the speed of the guide belt motor; the speed detection module 2 is used to detect the guide belt speed of the rotary screen printing machine; the motion control module 3 is respectively connected to the speed detection module 2 and the printing roller servo motor of the rotary screen printing machine to control the speed of the printing roller servo motor according to the guide belt speed; the visual acquisition module 4 is used to capture the fabric printing image; the main control processing module 5 is connected to the frequency conversion control module 1 to determine the printing quality according to the fabric printing image, and send a frequency conversion control instruction to the frequency conversion control module 1 according to the printing quality.

[0048] The working process of the rotary screen printing machine control system (hereinafter referred to as the system or control system) of this embodiment is as follows:

[0049] First, the frequency conversion control module 1 automatically adjusts the speed of the guide belt motor to accommodate varying printing speed requirements. The speed detection module 2 monitors the guide belt speed in real time and feeds this data back to the motion control module 3. This module uses this feedback to precisely control the speed of the servo motors used in the printing rollers, ensuring synchronization during the printing process. The visual acquisition module 4 captures the printed image of the fabric. The main control processing module 5 uses image analysis technology to assess the print quality and, based on this information, sends frequency conversion control instructions to the frequency conversion control module 1, dynamically optimizing the guide belt speed for efficient and accurate printing. The entire process is highly automated, improving both printing quality and production efficiency.

[0050] This embodiment achieves precise control of the guide belt speed and the printing roller speed by real-time monitoring and analysis of key parameters in the printing process, thereby ensuring high accuracy and consistency of the printed pattern. The intelligent image processing and quality assessment functions of the main control processing unit further improve the automation level of the production process and reduce interference from human factors. In addition, the high flexibility and adaptability of the control system enable it to quickly respond to different production conditions and design requirements, significantly improving production efficiency and the quality of printed products. It reduces operational complexity, maintenance costs and downtime, and overall improves the intelligence and reliability of the production process.

[0051] In some embodiments, the guide belt includes a cloth feeding guide belt, a printing guide belt, a first drying room guide belt, a second drying room guide belt and a cloth discharge guide belt. Figure 2 As shown, the fabric passes through the inlet guide, printing guide, first drying chamber guide, second drying chamber guide, and outlet guide in sequence. The speeds of these guides are linearly proportional, ensuring stable tension between them. Each guide has a corresponding guide motor to control its speed, including the inlet guide motor, printing guide motor, first drying chamber guide motor, second drying chamber guide motor, and outlet guide motor.

[0052] The main control processing module 5 first starts the circulating fan and the temperature control system, and waits until the temperature in the oven reaches the required process value. After the required printing rollers are installed, the rotary screen printing machine (low speed) will be started, and the cloth will be introduced from the cloth inlet guide belt to the printing guide belt, and then pass through each printing roller, and then introduce the cloth into the first drying room guide belt after exiting the printing guide belt, and then pass through the second drying room guide belt, and after drying, the cloth will be discharged from the cloth outlet guide belt. Among them, the main control processing module 5 performs temperature control monitoring and controls the operation of the circulating fan and the exhaust fan in the drying room. The main control processing module 5 controls the opening of the air valve and the speed of each circulating fan. The exhaust fan discharges the exhaust gas to ensure the air quality of the workshop.

[0053] Among them, two drying room guide belts are set, which can increase the drying distance of the fabric, and the first drying room guide belt is located above the second drying room guide belt. The upper and lower two-layer design can make the fabric drying effect better.

[0054] In this embodiment, the main control processing module 5 uses a high-performance industrial-grade computer as the core processing unit, which has sufficient data processing capabilities and high-speed computing speed. This module integrates advanced image processing algorithms and intelligent control strategies, and can receive and process data from the speed detection module 2 and the print images captured by the visual acquisition module 4 in real time. By applying machine learning and pattern recognition technology, the main control processing module 5 can accurately evaluate the quality of the print, automatically generate control instructions for optimizing the printing process, and convey these instructions to the frequency conversion control module 1 to achieve dynamic adjustment of the guide belt speed. The design of the main control processing module 5 in this embodiment reflects a high degree of integration and intelligence, providing a powerful, flexible and responsive control center for the rotary screen printing machine.

[0055] For example, the main control processing module 5 can utilize a CT MH72 servo controller for motor control. This controller utilizes an EtherCAT (Ethernet Control Automation Technology) architecture for real-time control, offering high-speed real-time performance and robust synchronization mechanisms. The module also boasts a minimum EtherCAT communication speed of 125 μs. The main control processing module 5 can also connect to the motion control module 3 to send control commands to it.

[0056] The speed detection module 2 may include an encoder that can be installed on the bottom roller of the guide belt and is responsible for real-time monitoring of the running status of the guide belt. The encoder adopts a high-resolution design with a resolution of up to 5000P / R, and can provide 5000 pulses per revolution, ensuring accurate measurement of the movement of the guide belt. Through precise pulse counting, the encoder converts position and speed information into electrical signals and transmits them to the motion control module 3. This information is not only used in the closed-loop control system to adjust the servo motor in real time to ensure the synchronization and accuracy of the printing process, but is also crucial for fault diagnosis and predictive maintenance of the system. The high reliability and stability of the encoder ensure accuracy over long periods of operation, reduce errors and scrap rates in production, and thus improve the performance and efficiency of the entire printing machine control system.

[0057] Motion control module 3 includes an XMC-E32C controller that supports the standard EtherCAT network. It can control up to 32 real axes, 4 imaginary axes, and 4 remote I / O stations, with two-channel encoder input. This module can be based on the PLCopen motion control specification. Specifically, motion control module 3 communicates with the servo controller of the printing roller servo motor (hereinafter referred to as the printing roller servo or rotary screen servo) via the EtherCAT bus. Motion control module 3 includes a programmable CPU and remote I / O stations (including digital and analog signals) to implement programmable logic control.

[0058] The variable frequency control module 1 utilizes a CT NE300 series inverter, featuring an excellent software control platform, a unique vector control algorithm, and true current vector control. It can control both asynchronous and permanent magnet synchronous motors. It has a strong overload capacity, capable of increasing current by 180% for 20 seconds. It controls the printing guide motor, drying room guide motor, fabric infeed motor, fabric outfeed motor, printing guide guide guide motor, drying room exhaust fan, and circulation fan.

[0059] In this embodiment, an encoder is mounted on a roller at the bottom of the guide belt to detect the actual linear velocity of the guide belt. The encoder signal is then transmitted to the motion control module 3. The motion control module 3 receives the encoder signal and enables the servo to track the encoder signal in real time, ensuring that the servo of each printing roller is synchronized with the position of the guide belt. The motion control module primarily controls the servo of the printing roller, and its internal programming implements all the movements of the printing roller servo.

[0060] In some embodiments, the rotary screen printing machine control system may further include one or more of a first user interaction terminal 6 , a second user interaction terminal 7 , a color paste detection module 8 , and a paste pump motor 9 .

[0061] The first user interaction terminal 6 is connected to the motion control module 3 and is used to receive control instructions input by the user.

[0062] In this way, the user can input control instructions through the first user interaction terminal 6 according to the on-site situation and his own correct experience, and the motion control module 3 automatically adjusts the speed of the servo motor of the printing roller according to the user instructions and real-time data.

[0063] Exemplarily, there may be 12 printing rollers, i.e., 12 axes (rotary screen servos) synchronously following the printing. The 12 printing rollers need to be synchronized with the speed of the printing guide belt, which is controlled by a frequency converter driving a motor through a reduction gear box. The rotary screen printing machine is a 12-axis printing machine or a few axes are selected for printing. The 12-axis rotary screen needs to be synchronized in position and color registration. During the acceleration and deceleration of the guide belt, the 12-axis printing rollers need to follow accurately and synchronously. When the color registration is offset, the user can perform manual control operations through the first user interaction terminal 6 to perform fine-tuning and correction. The correction process is divided into fast forward, fast reverse, slow forward, and slow reverse.

[0064] 1 printing roller is controlled by a servo motor, such as Figure 3 As shown, the first user interaction terminal 6 and the second user interaction terminal 7 can be respectively arranged at the two ends of each printing roller, so as to realize the individual control and adjustment of the servo motor of each printing roller.

[0065] Specifically, the first user interface terminal 6 and the motion control module 3 utilize an RS485 communication connection, enabling event triggering and rapid response. The servo controllers of each printing roller servo motor are connected to the motion controller via an EtherCat network cable, enabling isochronous control, rapid response, and precise signal synchronization. During normal printing, each servo controller tracks the encoder on the guide belt motor in real time to achieve position synchronization, ensuring synchronization of each cylinder screen with the guide belt and alignment of the pattern. Using the alignment button on the control interface of each first user interface terminal 6, the corresponding cylinder screen axis can be fine-tuned to independently adjust the pattern position.

[0066] In this embodiment, the color paste detection module 8 is connected to the pulp pump motor 9. The color paste detection module 8 is used to detect the remaining amount of color paste in the printing roller. The pulp pump motor 9 is used to drive the corresponding pulp pump to replenish the color paste to the printing roller according to the remaining amount of color paste.

[0067] With this design, the color paste detection module 8 continuously monitors the remaining color paste in the printing roller using a high-precision sensor, ensuring sufficient color paste to avoid interruptions or quality degradation in printing. Once the module detects that the color paste level is below a preset threshold, it immediately sends a signal to the control system. Upon receiving the signal, the slurry pump motor 9 automatically starts according to the remaining color paste level, accurately driving the corresponding slurry pump to replenish the appropriate amount of color paste to the printing roller. This intelligent replenishment process not only ensures the uniformity and continuity of the printed color, but also improves production efficiency and response speed by reducing human intervention. Furthermore, this automated color paste management mechanism helps reduce material waste, optimize production costs, and ensure high efficiency and high-quality output during the printing process.

[0068] Specifically, the color paste detection module 8 may include a liquid level relay and a detection needle. The slurry pump motor 9 detects the amount of color paste in the rotary screen (printing roller) through the liquid level relay. If it is not enough, it will automatically start the corresponding slurry pump to replenish the slurry and control the height of the color paste liquid level to remain unchanged. The remaining amount of color paste is achieved by controlling the liquid level in the rotary screen with a detection needle in conjunction with the liquid level relay. When the liquid level is lower than the detection needle, the slurry pump is started to supply slurry. The magnetic rod is placed on the inside of the rotary screen, and the magnetic table under the rotary screen is controlled to generate magnetic force, which attracts the magnetic rod to make the rotary screen ooze out the slurry in the rotary screen and print it on the cloth. The slurry pump is in the opposite position and pumps the color paste adjusted into each corresponding rotary screen. By adjusting the magnetic force value, the pressure of the magnetic rod on the rotary screen can be adjusted to adapt to the printing of fabrics with various patterns and various thick and thin color pastes.

[0069] Furthermore, the second user interaction terminal 7 is connected to the main control processing module 5 , and the main control processing module 5 is connected to the slurry pump motor 9 .

[0070] The second user interface 7, which serves as an operator interface for controlling colorant replenishment, is connected to the main control processing module 5 and provides an intuitive operating platform. Through the second interface 7, the operator can input instructions for colorant replenishment or adjustment based on actual needs and current colorant level information.

[0071] In some embodiments, the main control processing module 5 is specifically used to:

[0072] (1) Determine the printing quality and complexity of the printing pattern based on the fabric printing image.

[0073] Specifically, the main control processing module 5 uses image processing technology to perform real-time analysis of the fabric print images captured by the camera module. It comprehensively assesses print quality by identifying key quality indicators such as color uniformity, pattern boundary clarity, and color registration accuracy. It also evaluates the complexity of the printed pattern, including the number of colors, the number of detailed elements, and their layout, to determine the specific requirements of the pattern for the printing process.

[0074] (2) Determine the guide belt adjustment speed based on the printing quality and the complexity of the printing pattern.

[0075] Based on the evaluation results of print quality and pattern complexity, the main control processing module 5 uses an intelligent algorithm to dynamically calculate the required belt speed. If the print quality is below standard or the pattern complexity is high, the system may decide to reduce the belt speed to improve printing accuracy. Conversely, for simple patterns or high-quality prints, the speed may be increased to increase production efficiency.

[0076] In some embodiments, the main control processing module 5 determines the complexity of the printing pattern as follows:

[0077] Firstly, the print color complexity and pattern detail richness are extracted from the fabric print image; then, the print pattern complexity is determined according to the print color complexity and pattern detail richness.

[0078] Specifically, the main control processing module 5 first performs image preprocessing steps, such as noise removal and contrast enhancement, to improve the accuracy of subsequent analysis. Next, a color recognition algorithm is applied to quantify the types of colors in the image and the transitions between them. The greater the number of colors and the more complex the color transitions, the higher the color complexity. Simultaneously, edge detection and feature extraction techniques are used to identify and count small elements in the pattern, such as lines, shapes, and textures. The greater the number of these details in the pattern, the richer the pattern detail. Using these quantitative metrics, the system can assess the overall visual complexity of the print, providing data support for subsequent quality control and production adjustments.

[0079] Next, the main control processing module 5 comprehensively analyzes the extracted color and detail information and determines the overall complexity level of the printed pattern based on pre-set evaluation criteria and algorithms. This assessment takes into account the diversity of color types, the smoothness of color transitions, and the density of pattern details, combining these factors to form a quantitative index reflecting the overall complexity of the pattern. This index not only guides subsequent production adjustments but also provides the system with a basis for adjusting the belt speed and printing parameters, ensuring that high-quality printing standards are maintained even when processing highly complex patterns.

[0080] In some embodiments, the main control processing module 5 determines the printing quality in the following manner:

[0081] Firstly, the printing color uniformity and printing pattern clarity are extracted from the fabric printing image; and the printing quality is determined according to the printing color uniformity and printing pattern clarity.

[0082] Specifically, the main control processing module 5 analyzes these images using image processing software. The software evaluates the color distribution within the image and determines color uniformity by calculating color deviation. The more consistent the color distribution, the higher the uniformity. The software also evaluates the edge sharpness and internal details of the pattern, determining pattern clarity by measuring edge sharpness and detail discernibility. The sharper the edges and the clearer the details, the higher the pattern clarity. These analysis results are converted into quantifiable data, providing a basis for evaluating print quality.

[0083] The main control processing module 5 then compares the color uniformity and pattern clarity data extracted from the image with pre-set quality standards. Color uniformity reflects the color consistency across the entire printed area; if the measurement results meet or exceed the standard value, the print is considered color uniform. Pattern clarity reflects the discernibility of printed details; if the pattern edges are sharp and details are visible, the print has high clarity.

[0084] If both of these indicators meet or exceed a predetermined quality threshold, the system determines the print quality is acceptable. Conversely, if any one indicator falls short, the batch may be marked as defective and trigger adjustments, such as those made to ink distribution or printing pressure, to improve print quality. Through this intelligent evaluation process, the main control processing module 5 ensures high-precision and efficient quality control of printed products.

[0085] In some embodiments, the main control processing module 5 determines the guide belt adjustment speed based on the printing quality and the complexity of the printing pattern as follows:

[0086] The conduction belt speed adjustment formula is used to calculate the conduction belt speed adjustment formula. The mathematical form of the conduction belt speed adjustment formula is:

[0087] V(t)=V0·e -k·F·A(t) ;

[0088] Among them, V0 is the preset reference guide belt speed, A(t) is the dynamic adjustment factor, and F is the comprehensive index of printing difficulty. The comprehensive index of printing difficulty is determined based on the printing color uniformity, printing pattern clarity, printing color complexity and pattern detail richness.

[0089] The relationship between printing quality and guide belt speed is often nonlinear. This embodiment uses an exponential model to better simulate this relationship and make the calculation result more accurate.

[0090] Furthermore, the mathematical form of the comprehensive index formula of printing difficulty is:

[0091]

[0092] Among them, U, C, Co, and D are the standardized scoring values ​​of the four quality indicators: printing color uniformity, printing pattern clarity, printing color complexity, and pattern detail richness. U 、w C 、w Co 、w D are weight parameters respectively. Different quality indicators have different effects on the overall quality of the print. By assigning weights to each indicator, they can be associated with their relative importance in the production process.

[0093] The mathematical expression of the dynamic adjustment factor is: A(t) = a0 + a1·sin(ωt) + a2·cos(ωt);

[0094] Where a0, a1, and a2 are adjustment parameters, and ω is the time-varying frequency. This factor allows the model to adapt to production conditions, such as fabric type and ink characteristics, and adjust the belt speed in real time, taking into account that production conditions may change over time.

[0095] Speed ​​adjustment is designed to optimize production efficiency without sacrificing print quality. By precisely controlling the speed of the belt, production speed can be increased without sacrificing quality.

[0096] This embodiment takes into account the complexity of the colors and richness of the details of the printed pattern, which may increase the production difficulty. The speed adjustment formula needs to take these factors into account, and the speed may need to be reduced to process more complex patterns. The guide belt speed adjustment formula provides an effective and reliable reference.

[0097] (3) Generate frequency conversion control instructions according to the speed of the conduction belt adjustment.

[0098] Based on the calculated guide belt speed adjustment, the main control processing module 5 generates corresponding frequency conversion control instructions. These instructions specify the new frequency and speed that the guide belt motor should adjust to, ensuring that the speed change matches the printing quality and pattern complexity to achieve the best printing effect.

[0099] (4) Send the frequency conversion control instruction to the frequency conversion control module 1.

[0100] Finally, the main control processing module 5 sends the frequency conversion control command to the frequency conversion control module 1 through the system's internal communication network. Upon receiving the command, the frequency conversion control module 1 immediately adjusts the power supply frequency of the guide belt motor to achieve precise control of the guide belt speed, ensuring that the printing machine operates stably according to the established process parameters.

[0101] In some embodiments, the main control processing module 5 is provided with a main interface, which mainly includes operation control, parameter setting, status monitoring and other main screens, and can independently control each control unit (including the cylinder, fan, each guide belt, etc.). Specifically, the main operation screen can be referred to Figure 4 , the fan control screen can refer to Figure 5 , the unit selection setting interface can refer to Figure 6 , the parameter setting interface can refer to Figure 7 , the monitoring screen can refer to Figure 8 .

[0102] In some embodiments, during the operation of a rotary screen printing machine, the fabric is directly bonded to the printing blanket. This bonding ensures that there is no relative slippage between the fabric and the blanket during printing, thereby ensuring accurate transfer of the printed pattern. To enhance adhesion between the fabric and the blanket, the control system periodically applies an appropriate amount of glue to the blanket. This prevents shifting or sliding of the fabric during high-speed printing, ensuring accurate alignment and clarity of the printed pattern.

[0103] At the same time, when the printing belt needs to be stopped for cleaning or maintenance, the main control unit will start the virtual spindle function. The virtual spindle is a control concept at the software level. It uses control components such as encoders and PLC (programmable logic controller) to keep the rotation of the printing roller synchronized. Even when the belt stops moving, the printing roller can still rotate at the set synchronous speed. Specifically, Figure 9As shown in the figure, the speed of the virtual spindle is controlled by the encoder signal, and the rotary screen servo (axis 1 to axis 12) follows the rotation of the virtual spindle to control the rotation of the rotary screen. The virtual spindle is the active one, and the rotary screen servo is the passive one. This self-rotation synchronization mechanism helps maintain the state of the printing roller, preventing the color paste from drying and sticking on the rotary screen during downtime, thereby avoiding damage to the printing roller and deterioration of printing quality. In this way, the rotary screen printing machine can quickly resume production after cleaning or maintenance, reducing production interruption time, improving production efficiency and equipment stability.

[0104] The rotary screen printing machine control system provided in this embodiment achieves significant technical effects through a series of innovative modules and processes, which not only improves the efficiency and quality of printing production, but also enhances the flexibility and intelligence level of production.

[0105] First, the system achieves precise control of the belt motor's speed through the frequency conversion control module 1, ensuring the stability and controllability of the belt speed. This control mechanism is crucial for maintaining uniform movement of the fabric during the printing process, thus avoiding printing defects caused by uneven speed, such as pattern deformation caused by stretching or compression.

[0106] Secondly, the introduction of speed detection module 2 provides the system with real-time speed feedback, enabling motion control module 3 to dynamically adjust the speed of the printing roller servo motor based on the difference between the actual speed and the preset speed. This closed-loop control strategy significantly improves the synchronization accuracy of the printing process and ensures accurate alignment of the printed pattern during high-speed production.

[0107] The use of the Vision Capture Module 4 enables the system to automatically capture and analyze fabric print images, using image processing technology to assess print quality and pattern complexity. This automated quality control not only reduces the need for manual inspection and reduces costs, but also improves inspection accuracy and repeatability, ensuring consistent product quality.

[0108] The main control processing module 5 is the core of the system. It integrates advanced algorithms and data processing capabilities, and can intelligently generate frequency conversion control instructions based on the data provided by the visual acquisition module 4. This intelligent decision-making support system enables the printing machine to adapt to different production conditions and design requirements, optimizing the production process.

[0109] The belt speed adjustment formula in the technical solution achieves dynamic optimization of the belt speed by comprehensively considering the printing difficulty index and the dynamic adjustment factor. This optimization not only takes into account the requirements for printing quality, but also the needs of production efficiency and system stability, achieving the optimal operating speed under different production conditions.

[0110] The application of a comprehensive index formula for printing difficulty further refines the assessment of print complexity and quality. By assigning weights to different quality indicators, the system can more accurately reflect the difficulty of the printed pattern, providing a more reasonable basis for adjusting the belt speed.

[0111] The introduction of dynamic adjustment factors enables the system to adjust the operating parameters of the printing machine according to time changes, to cope with various changes that may occur in the production process, such as changes in fabric types, fluctuations in environmental conditions, etc., and enhances the adaptability and flexibility of the system.

[0112] The integration of the color paste detection module 8 and the slurry pump motor 9 enables automatic management of the color paste supply during the printing process. By automatically detecting and replenishing the color paste, the system ensures the continuity and uniformity of the color paste during the printing process, avoiding printing quality problems caused by insufficient or uneven color paste.

[0113] The user interface design provides an intuitive interface between the operator and the control system. It allows the operator to input control commands, monitor system status, and perform manual intervention when necessary. This design not only improves operational convenience but also enhances the system's user-friendliness.

[0114] In summary, the overall technical solution of this embodiment, by integrating multiple innovative modules and processes, achieves an efficient, precise, flexible, and intelligent control system for rotary screen printing machines. This system not only improves the quality of printed products and optimizes production efficiency, but also reduces production costs, enhances operational simplicity, and improves system stability, meeting the modern textile printing and dyeing industry's continuous pursuit of automated and intelligent production.

[0115] Example 2:

[0116] The embodiment of the present invention also provides a rotary screen printing machine, including a rotary screen printing machine body and the rotary screen printing machine control system provided in the first embodiment, wherein the rotary screen printing machine body and the rotary screen printing machine control system are connected.

[0117] The rotary screen printing machine body, i.e., the physical components of the machine, such as the guide belt, printing roller, drying device, etc., is also included. The rotary screen printing machine control system is the core of this embodiment. It realizes precise control of the operation of the rotary screen printing machine through a series of highly integrated and coordinated modules.

[0118] The control system's main modules include a frequency conversion control module 1, a speed detection module 2, a motion control module 3, a visual acquisition module 4, and a main control processing module 5. The frequency conversion control module 1 regulates the speed of the guide belt motor to ensure stable operation. The speed detection module 2 monitors the guide belt speed in real time and provides feedback to achieve closed-loop control. The motion control module 3 adjusts the speed of the printing roller based on the coordination requirements between the guide belt speed and the printing roller servo motor, ensuring synchronization and accuracy during the printing process.

[0119] The visual acquisition module 4 uses a high-resolution camera to capture print images, providing visual data for quality assessment. The main control processing module 5 is the brain of the system, integrating image processing, data analysis, and intelligent decision-making algorithms. This module analyzes the images provided by the visual acquisition module 4 to assess the print quality and pattern complexity. Based on these evaluation results, it calculates the guide belt adjustment speed using complex mathematical models and algorithms and generates variable frequency control instructions.

[0120] The system also includes a paste detection module 8 and a paste pump motor 9, which together ensure the continuity and stability of the paste supply during the printing process. The paste detection module 8 monitors the remaining amount of paste in the printing roller, while the paste pump motor 9 automatically replenishes the paste based on the detection results to maintain printing quality.

[0121] The user interface provides an interface between the operator and the control system, enabling the operator to input control commands, monitor system status, and perform manual intervention when necessary. The first user interface 6 is connected to the motion control module 3, while the second user interface 7 is connected to the main control processing module 5.

[0122] This embodiment achieves a production process with a high degree of automation, fast response, simple operation, and high-quality printing. This system design not only improves production efficiency and reduces maintenance costs, but also enhances the consistency and reliability of printed products through intelligent control, meeting the dual needs of high efficiency and high quality in the modern textile printing and dyeing industry.

[0123] It can be understood that the rotary screen printing machine of this embodiment includes the control system of the first embodiment, and thus can achieve all the technical effects of the first embodiment, which will not be described in detail here.

[0124] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A rotary screen printing machine control system, characterized in that: include: A frequency conversion control module is connected to the guide belt motor of the rotary screen printing machine and is used to control the speed of the guide belt motor; A speed detection module, used to detect the speed of the guide belt of the rotary screen printing machine; a motion control module, connected to the speed detection module and the printing roller servo motor of the rotary screen printing machine, respectively, for controlling the speed of the printing roller servo motor according to the guide belt speed; Visual acquisition module, used to collect fabric printing images; a main control processing module connected to the frequency conversion control module, configured to determine the printing quality according to the fabric printing image, and send a frequency conversion control instruction to the frequency conversion control module according to the printing quality; The main control processing module is specifically used for: determining the printing quality and the complexity of the printing pattern based on the fabric printing image; Determining the guide belt adjustment speed based on the print quality and the print pattern complexity, including dynamically calculating the required guide belt running speed, and if it is detected that the print quality is below standard or the pattern complexity is high, reducing the guide belt speed to improve the printing accuracy; for simple patterns or high-quality prints, increasing the speed to increase production efficiency; generating a variable frequency control instruction according to the guide belt adjustment speed; The frequency conversion control instruction is sent to the frequency conversion control module.

2. The rotary screen printing machine control system according to claim 1, characterized in that: The main control processing module is specifically used for: extracting print color complexity and pattern detail richness from the fabric print image; The complexity of the print pattern is determined according to the complexity of the print color and the richness of the pattern details.

3. The rotary screen printing machine control system according to claim 1, characterized in that: The main control processing module is specifically used for: Extracting print color uniformity and print pattern clarity from the fabric print image; The printing quality is determined based on the printing color uniformity and the printing pattern clarity.

4. The rotary screen printing machine control system according to any one of claims 1 to 3, characterized in that: The main control processing module is specifically used for: The conduction belt speed adjustment formula is used to calculate the conduction belt speed adjustment formula. The mathematical form of the conduction belt speed adjustment formula is: V(t)=V0·e -k·F·A(t) ; Among them, V0 is the preset reference guide belt speed, A(t) is the dynamic adjustment factor, and F is the comprehensive index of printing difficulty, which is determined based on the printing color uniformity, printing pattern clarity, printing color complexity and pattern detail richness.

5. The rotary screen printing machine control system according to claim 4, characterized in that: The main control processing module is specifically used to calculate the printing difficulty comprehensive index according to the printing difficulty comprehensive index formula. The mathematical form of the printing difficulty comprehensive index formula is: Among them, U, C, Co, and D are the standardized scoring values ​​of the print color uniformity, the print pattern clarity, the print color complexity, and the pattern detail richness, respectively. U 、w C 、w Co 、w D are weight parameters respectively.

6. The rotary screen printing machine control system according to claim 4, characterized in that: The mathematical expression of the dynamic adjustment factor is A(t)=a0+a1·sin(ωt)+a2·cos(ωt), where a0, a1, and a2 are adjustment parameters, and ω is the time-varying frequency.

7. The rotary screen printing machine control system according to claim 1, characterized in that: It also includes a connected color paste detection module and a pulp pump motor, wherein the color paste detection module is used to detect the remaining amount of color paste in the printing roller, and the pulp pump motor is used to drive the corresponding pulp pump to replenish the color paste to the printing roller according to the remaining amount of the color paste.

8. The rotary screen printing machine control system according to claim 7, characterized in that: It also includes a first user interaction end and a second user interaction end, the second user interaction end is connected to the main control processing module, the main control processing module is connected to the slurry pump motor, and the first user interaction end is connected to the motion control module for receiving control instructions input by the user.

9. A rotary screen printing machine, comprising a rotary screen printing machine body and the rotary screen printing machine control system according to any one of claims 1 to 8, wherein the rotary screen printing machine body and the rotary screen printing machine control system are connected.

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