Intelligent electric control method for chenille spinning machine

Abstract

The invention discloses an intelligent electric control method for a chenille spinning machine, which belongs to the technical field of chenille spinning, and comprises the following steps of: analyzing production requirements to obtain the production specification of a product for producing chenille yarns, and analyzing the production specification to obtain the initial state of each motor in the chenille spinning machine; the motion state of each motor is detected in real time, comprehensive analysis is conducted by combining current material feeding parameters and technological parameters of chenille yarn, the current optimal motion state of each motor for producing the yarn with the optimal quality is judged, and therefore a direct-current feedback instruction and a stepping feedback instruction are generated; the direct current motor and the stepping motor tend to the optimal motion state all the time, so that the probability that the product quality is reduced due to the environmental influence during yarn production is reduced, and the product quality of the produced chenille yarn is greatly improved.

Description

Technical Field

[0001] The invention relates to the technical field of chenille spinning, and in particular to an intelligent electric control method for a chenille spinning machine. Background Art

[0002] The chenille spinning machine cuts 2-3 strands of yarn such as wool, cotton, acrylic, nylon, etc. into short strands through a rotating head and clamps them into two core strands, and twists them into full chenille yarn through a spindle. In the production process of chenille yarn, it is necessary to control the rotary motor, roller motor, spindle motor and wire feeding motor separately. In order to control these motors, the existing technical solution is to use an MCU such as a single-chip microcomputer to independently control these motors. However, this control method requires a large amount of space to set up the controller, which affects the resource utilization space during production, and indirectly affects the production output and production cost. In addition, since each controller is arranged independently, there is a certain delay in the feedback connection between the controllers, and it is impossible to make timely adjustments according to the feedback during the production process, thereby affecting the production quality of the chenille yarn.

[0003] Chinese patent, publication number: CN 109056126 A, publication date: December 21, 2018, discloses a slub chenille yarn electrical control system and method, including a power supply circuit and a PLC control system connected to the power supply circuit, the PLC control system is connected to the spindle motor and the roller motor through a frequency converter and an AC contactor in turn, the spindle motor output end has a speed sensor for detecting the speed of the spindle motor output end, the speed sensor is connected to the PLC control system, the scheme controls the motor through the PLC control system, but only controls the roller motor and the spindle motor, i.e., the stepping drive motor, which have a small speed change in the chenille yarn production process, and does not control the spindle motor and the rotary motor, which are relatively complex to control, and the motors that control the yarn production type are still used. The traditional input target speed is used to move according to the target speed, and no feedback is given to it, and it is adjusted according to the actual production process, which will affect the production quality of the chenille yarn. Summary of the invention

[0004] Aiming at the problem that the driving feedback control of the stepper motor and the DC motor in the existing chenille spinning machine is not perfect, resulting in the low quality of the produced products, the present invention proposes an intelligent electric control method for the chenille spinning machine, analyzes the production demand, obtains the product production specifications of the chenille yarn, analyzes the production specifications to obtain the initial state of each motor in the chenille spinning machine, detects the motion state of each motor in real time, and conducts a comprehensive analysis in combination with the current material feeding parameters and process parameters of the chenille yarn, judges the current best motion state of each motor for producing the best quality yarn, generates a DC feedback instruction and a stepper feedback instruction, and allows the DC motor and the stepper motor to always tend to the best motion state, thereby reducing the probability of product quality degradation caused by environmental influences during yarn production, and greatly improving the product quality of the produced chenille yarn.

[0005] In the first aspect, a technical solution provided in an embodiment of the present invention is: an intelligent electric control method for a chenille spinning machine, applicable to an intelligent electric control device, wherein the intelligent electric control device comprises: A control module is used to generate control instructions and send the control instructions to the control instruction interface; The stepper drive module includes a stepper feedback interface and a control instruction interface, which is used to parse the control instruction to generate a stepper drive instruction to control the stepper motor; A brushless DC drive module, including a DC feedback interface and a control command interface, is used to parse control commands to generate DC drive commands to control a DC motor; The brushless DC drive module is composed of multiple parallel power drive circuits, and each DC motor is connected to one power drive circuit respectively; The following steps are involved: S1. Obtain the production demand of chenille yarn and generate control instructions based on the production demand; S2. Analyze the control instruction to obtain the production specifications of the chenille yarn, wherein the production specifications include material feeding parameters and product process parameters; S3, generating a stepper drive instruction based on the material feeding parameters of the chenille yarn to control the movement of the stepper motor; generating a DC drive instruction based on the process parameters of the chenille yarn product to control the movement of the DC motor; S4, detecting the current motion state of the stepper motor and the DC motor and the current material feeding parameters and process parameters of the chenille yarn in real time, generating a stepper feedback instruction based on the current material feeding parameters of the chenille yarn and the current motion state of the stepper motor; generating a DC feedback instruction based on the current process parameters of the chenille yarn and the current motion state of the DC motor; S5. Send the stepper feedback instruction and the DC feedback instruction to the stepper feedback interface and the DC feedback interface respectively, adjust the motion state of the stepper motor based on the stepper feedback instruction, and adjust the motion state of the DC motor based on the DC feedback instruction.

[0006] In this scheme, in order to improve the product quality of chenille yarn, various parameters of the product are determined according to the production requirements of the product before the formal production begins, and the material feeding parameters and product process parameters are obtained. The material feeding parameters are controlled by a stepper motor, which is mainly responsible for stably and continuously delivering the yarn raw materials to the processing area of ​​the spinning machine. It controls the feeding speed and tension of the yarn to ensure that the yarn maintains a proper tension state during the processing process, thereby avoiding quality problems caused by yarn breakage or excessive relaxation; and the product process parameters include twist degree, twist direction, yarn cone tightness and yarn relaxation, etc., which are controlled by a DC motor. To control, the initial states of the DC motor and the stepper motor are determined according to the material feeding parameters and the product process parameters, and the production of chenille yarn is carried out. During the production process, the state of the chenille yarn and the movement state of the DC motor and the stepper motor are monitored in real time, and the optimal state of the motor is inferred according to the real-time state of the chenille yarn, and the feedback is given to the drive module, so that the motor tends to the working state of producing higher-quality chenille yarn in real time. This can significantly reduce the probability of reduced quality of chenille yarn products due to external influences in the production process, and improve the overall quality of chenille yarn products.

[0007] Preferably, in S1, obtaining the production demand of chenille yarn and generating a control instruction based on the production demand include the following steps: Analyze production requirements, obtain the product types of chenille yarn, and obtain the initial motion states of the stepper motor and DC motor in the chenille spinning machine based on the product types; Control instructions are generated based on the product type of chenille yarn and the initial motion states of the stepper motor and DC motor.

[0008] In this scheme, in order to set the parameters of all motors in the chenille spinning machine, the production requirements are first obtained, wherein the production requirements include the purpose of the products produced and the production costs of the products, etc. After the production requirements are clarified, the product types of chenille yarns that meet the production requirements can be selected, and the production methods are obtained according to the product types, wherein the production methods include the operating parameters of all motors in the chenille spinning machine and the various product parameters for producing the chenille yarn. The chenille spinning machine will strictly produce according to the product parameters to prevent the actual production products from being too different from the demand products.

[0009] Preferably, in S3, generating a stepping drive instruction based on the material feeding parameter of the chenille yarn to control the movement of the stepping motor comprises the following steps: Analyze the material feeding parameters in the control instructions, and convert the control instructions into level signals and PWM wave signals output by the microcontroller; generate stepper drive instructions based on the high and low level information in the level signal and the duty cycle in the PWM wave signal, and control the rotation direction and speed of the stepper motor based on the stepper drive instructions.

[0010] In this scheme, in order to realize the control of the stepper motor in the chenille spinning machine, a single-chip microcomputer is adopted, and the start and stop and rotation direction of the stepper motor are controlled by the level signal output by the single-chip microcomputer. When the single-chip microcomputer outputs a high level, the stepper motor starts and rotates forward; when the single-chip microcomputer output level is 0, it is not enabled and the stepper motor stops; when the single-chip microcomputer output level is negative, the motor starts and rotates in the opposite direction; the rotation speed of the stepper motor is controlled by the PWM wave output by the single-chip microcomputer. The higher the PWM wave duty cycle, the faster the stepper motor rotates, and the lower the PWM wave duty cycle, the slower the stepper motor rotates. The instructions for controlling the high and low levels and PWM waves output by the single-chip microcomputer are integrated to obtain stepper drive instructions. The single-chip microcomputer is controlled according to the stepper drive instructions to control the motion state of the stepper motor. The motion state of the stepper motor can be finely adjusted, so as to meet the various parameters required by chenille yarns of different production needs, and improve the working adaptability of the stepper motor.

[0011] Preferably, in S3, generating a DC drive instruction based on the product process parameters of the chenille yarn to control the movement of the DC motor includes the following steps: Parse the product process parameters in the control instructions, convert the control instructions into multiple level signals output by the GPIO port of the microcontroller and multiple PWM wave signals output by the PWM channel of the microcontroller, and synchronously encode each DC motor based on the GPIO port number of the microcontroller connected to each DC motor; Based on the single chip microcomputer, the Hall position of the DC motor is obtained and multiple Hall signals are generated; A DC drive instruction is generated based on multiple level signals, multiple PWM wave signals, and multiple Hall signals, and the rotation direction and rotation speed of the DC motor are controlled based on the DC drive instruction.

[0012] In this scheme, in order to control the DC motor connected to each power drive circuit, the GPIO of the single-chip microcomputer is used to realize the Hall position feedback of the DC motor, and the Hall signal is generated by the feedback result of the Hall position. The use of the Hall signal to feedback the DC motor state can reduce the response time during feedback, improve the response speed of controlling the DC motor, thereby improving the self-regulation ability of the chenille spinning machine, and can adjust the DC motor in real time according to the changes in the working state, thereby improving the production quality of chenille yarn.

[0013] Preferably, a DC drive instruction is generated based on multiple level signals, multiple PWM wave signals, and multiple Hall signals, and the rotation direction of the DC motor is controlled based on the DC drive instruction, including the following steps: Combining multiple Hall signals based on the DC motor encoding sequence so that the DC motor rotor phases are divided into several phases and numbered based on the phase angle range; The read Hall signal is used as the target Hall signal, the power drive circuit where the target Hall signal is located is used as the target power drive circuit, and the DC motor driven by the target power drive circuit is used as the target DC motor; The target Hall signal is analyzed to obtain the target Hall state of the target DC motor, the phase of the target DC motor rotor is obtained based on the target Hall state, the phase angle number is obtained based on the phase of the target DC motor rotor, and the power tube switches of the target power drive circuit are switched in sequence based on the order of the phase angle numbers to control the rotation direction of the target motor.

[0014] In this scheme, in order to control the rotation of the motor through the Hall position, the various Hall signals are combined. Within the phase range of the DC motor rotor, the Hall signal is different according to different ranges. Therefore, the DC motor rotor phase is divided into several phases and the phases are numbered according to the angle range. A commutation switching logic table is constructed according to the DC motor rotor phase, the Hall state and the Hall value contained in the Hall signal, and the numbering information corresponding to the Hall state of the DC motor controlled by each power drive circuit is obtained. The phase of the motor rotor is queried according to the numbering information, so as to determine what kind of excitation the motor stator coil needs to provide to generate a positive torque on the rotor, so that each power drive circuit can independently control one DC motor, improve the control accuracy, and can more sensitively and accurately control each DC motor, thereby improving the control accuracy when producing chenille yarn and improving product production quality.

[0015] Preferably, in S4, generating a stepping feedback instruction based on the current material feeding parameter of the chenille yarn and the current motion state of the stepping motor comprises the following steps: Analyze the current material feeding parameters of the chenille yarn to obtain the optimal motion state of the stepper motor, and compare the optimal motion state of the stepper motor with the current motion state of the stepper motor to obtain the motion deviation of the stepper motor, wherein the motion deviation of the stepper motor includes at least a rotation speed and a rotation direction; Generate stepper feedback commands based on stepper motor motion deviations.

[0016] In this scheme, in the process of producing chenille yarn, since the parameters such as yarn diameter, yarn tube diameter and twist degree are changing in real time, the material feeding parameters of each production stage are different, which will affect the subsequent production of the yarn. Therefore, each stepper motor in the chenille spinning machine cannot always operate according to the initially set parameters, and must be adjusted in real time according to the production situation. Therefore, it is necessary to monitor the rotation speed and rotation direction of the stepper motor in real time, and also to monitor the current material feeding parameters of the yarn controlled by the stepper motor in real time. Since the material feeding parameters are determined according to the production specifications of the yarn, the optimal material feeding parameters of each production link in the production process can be determined. Therefore, in order to make the current material feeding parameters of each production link of the yarn in the optimal state, the optimal motion state of the stepper motor can be inferred according to the optimal material feeding parameters, and the optimal motion state of the stepper motor is compared with the current motion state to obtain the motion deviation of the two, and the motion state of the stepper motor is adjusted to be close to the optimal motion state, so that the chenille yarn is in a relatively optimal production state in each link of the production process, which can significantly improve the overall production quality of the product.

[0017] Preferably, in S4, generating a DC feedback instruction based on the current process parameters of the chenille yarn and the current motion state of the DC motor includes the following steps: Analyze the current process parameters of the chenille yarn to obtain the optimal motion state of the DC motor, compare the optimal motion state of the DC motor with the current motion state of the DC motor to obtain the motion deviation of the DC motor, wherein the motion deviation of the DC motor includes at least a rotation speed and a rotation direction; Generates DC feedback commands based on DC motor motion deviations.

[0018] In this scheme, in the process of producing chenille yarn, since the parameters such as the yarn diameter, the yarn tube diameter and the twist degree are changing in real time, which will affect the subsequent production of the yarn, the various DC motors in the chenille spinning machine cannot always operate according to the initially set parameters, and must be adjusted in real time according to the production situation. Therefore, it is necessary to monitor the rotation speed and rotation direction of the DC motor in real time, and also to monitor the current process parameters of the yarn controlled by the DC motor in real time. Since the process parameters are determined according to the production specifications of the yarn, the optimal process parameters of each production link in the production process can be determined. Therefore, in order to make the current process parameters of each production link of the yarn in the optimal state, the optimal motion state of the DC motor can be inferred according to the optimal process parameters, and the optimal motion state of the DC motor can be compared with the current motion state to obtain the motion deviation between the two, and the motion state of the DC motor can be adjusted to be close to the optimal motion state, so that the chenille yarn is in a relatively optimal production state in each link of the production process, which can significantly improve the overall production quality of the product.

[0019] Preferably, in S5, the stepper feedback instruction and the DC feedback instruction are sent to the stepper feedback interface and the DC feedback interface respectively, the stepper motor motion state is adjusted based on the stepper feedback instruction, and the DC motor motion state is adjusted based on the DC feedback instruction, including the following steps: Respectively obtain the stepper motor motion deviation and the DC motor motion deviation in the stepper feedback instruction and the DC feedback instruction, and adjust the stepper motor motion state to the optimal stepper motor motion state based on the stepper motor motion deviation; adjusting the motion state of the DC motor to an optimal motion state of the DC motor based on the motion deviation of the DC motor; If the current process parameters of the chenille yarn are equal to the product process parameters, the stepper motor and the DC motor are controlled to decelerate linearly until the speed is 0.

[0020] In this scheme, after the stepper motor and the DC motor are produced, the motor does not stop instantly during the shutdown process. The motor will have a deceleration process, and the production actions such as twisting are still being performed during the deceleration process. In order to prevent the problem of uneven twist on the cloth surface caused by continued twisting during the shutdown, the wire feeding motor is linearly decelerated during the shutdown deceleration stage. Deceleration at the same deceleration rate will not affect the uniformity of the cloth twist, thereby improving the production quality of the product.

[0021] Preferably, the product process parameters at least include twist degree, twist direction, yarn cone tightness and yarn relaxation.

[0022] In this scheme, since the parameters such as twist degree, twist direction, yarn cone tightness and yarn relaxation of different types of chenille yarns are different, these product process parameters need to be determined before producing chenille yarns. Only then can the working status of each motor in the chenille spinning machine be analyzed based on these product parameters, so as to ensure that the product obtained after the production process is completed is consistent with the required product.

[0023] Preferably, the stepper motor includes at least a wire feeding motor and a roller motor, and the DC motor includes at least a spindle motor and a rotary motor.

[0024] In this scheme, since a large number of motors are needed to produce chenille yarn, each motor plays a different role in the production process. The wire feeding motor in the chenille spinning machine is mainly responsible for feeding the fiber into the machine to provide raw materials for the subsequent spinning process. The speed and power of the wire feeding motor directly affect the speed and quantity of the feed, and have an important impact on the stability of the spinning process and the quality of the yarn; the roller motor is usually used to drive the rotation of the roller device in the chenille spinning machine. The roller device plays the role of combing, drafting and feeding the fiber during the spinning process; the rotary motor is responsible for driving the rotary head and other components to cut and clamp multiple strands of yarn into the core wire to form chenille yarn; the spindle motor is responsible for driving the rotation of the spindle in the spinning machine. By driving the rotation of the spindle, the input fiber or yarn is twisted to form a yarn with a certain strength and structure; therefore, the speed, rotation direction, start and stop time and other parameters of each motor need to be precisely controlled and adjusted in real time to ensure that every step in the production process meets the production requirements and provides high-quality chenille yarn.

[0025] Advantages of the present invention: (1) The present invention sets multiple parallel power drive circuits, uses a single chip microcomputer to generate multiple PWMs and uses multiple GPIO ports to control the power drive circuits. A single chip microcomputer controls the multiple power drive circuits, and one power drive circuit independently controls a DC motor, thereby realizing one controller to control multiple motors, improving the control precision of each DC motor, so that the corresponding DC motor in each production stage of chenille yarn production can be adjusted independently, thereby improving the overall quality of the product, saving control center resource space, and reducing production costs; (2) The present invention generates a Hall signal by acquiring the Hall position of the DC motor, combines the acquired Hall signals, controls the DC motor rotor based on the information in the Hall signal, and collects and feeds back the data inside a single-chip microcomputer, thereby reducing the delay of information transmission and improving the feedback and automatic adjustment capabilities of the system, thereby improving the adaptability to various situations encountered during product production and improving product production quality; (3) The present invention monitors the motion state of each motor and the state of the chenille yarn in real time during the production process, and can adjust each motor in real time according to the current state of the chenille yarn, thereby ensuring that the chenille yarn is always in the best production state during the production process, thereby improving the overall production quality of the chenille yarn.

[0026] The above invention content is only an overview of the technical solution of the present invention. In order to more clearly understand the technical means of the present invention, it can be implemented according to the contents of the specification. In order to make the above and other purposes, features and advantages of the present invention more obvious and easy to understand, the specific implementation methods of the present invention are listed below. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Other features, objects and advantages of the present invention will become more apparent by reading the detailed description of non-limiting embodiments made with reference to the following drawings. The drawings are only for the purpose of illustrating preferred embodiments and are not to be considered as limiting the present invention. Also, the same reference symbols are used throughout the drawings to represent the same parts.

[0028] Figure 1 This is a flow chart of an intelligent electric control method for a chenille spinning machine of the present invention; Figure 2 This is a flow chart of the present invention controlling the operation of a DC motor through a Hall signal; Figure 3 This is a diagram showing the internal structure of the brushless DC drive module of the present invention; Figure 4 It is a schematic structural diagram of the chenille spinning machine of the present invention. DETAILED DESCRIPTION

[0029] In order to make the objectives, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific implementation method described herein is only an optimal embodiment of the present invention, which is only used to explain the present invention and does not limit the scope of protection of the present invention. All other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0030] Before discussing the exemplary embodiments in more detail, it should be mentioned that some exemplary embodiments are described as processes or methods depicted as flow charts. Although the flow charts describe the operations (or steps) as sequential processes, many of the operations (or steps) therein can be implemented in parallel, concurrently, or simultaneously. In addition, the order of the operations can be rearranged. The process can be terminated when its operation is completed, but can also have additional steps not included in the drawings; the process can correspond to a method, function, procedure, subroutine, subprogram, etc.

[0031] Example 1: Figure 1 As shown, in order to solve the problem that the driving feedback control of the stepper motor and the DC motor in the existing chenille spinning machine is not perfect, resulting in the problem of low quality of the produced products, an intelligent electric control method for a chenille spinning machine is provided, which is applicable to an intelligent electric control device, and the intelligent electric control device includes: A control module is used to generate control instructions and send the control instructions to the control instruction interface; The stepper drive module includes a stepper feedback interface and a control instruction interface, which is used to parse the control instruction to generate a stepper drive instruction to control the stepper motor; A brushless DC drive module, including a DC feedback interface and a control command interface, is used to parse control commands to generate DC drive commands to control a DC motor; The brushless DC drive module is composed of multiple parallel power drive circuits, and each DC motor is connected to one power drive circuit respectively. Figure 3 As shown, in this embodiment, the brushless DC drive module uses the PWM channel of the TIM module of the single-chip microcomputer to generate n PWMs to control the upper bridge of the power drive circuit, and uses n GPIO ports to control the lower bridge of the power drive circuit, and uses the GPIO port of the single-chip microcomputer to feedback the Hall position of the spindle motor and the rotary motor to generate n Hall signals; The following steps are involved: S1: Obtain the production demand of chenille yarn and generate control instructions based on the production demand.

[0032] In this embodiment, obtaining the production demand of chenille yarn and generating control instructions based on the production demand include the following steps: Analyze production requirements, obtain the product types of chenille yarn, and obtain the initial motion states of the stepper motor and DC motor in the chenille spinning machine based on the product types; Control instructions are generated based on the product type of chenille yarn and the initial motion states of the stepper motor and DC motor.

[0033] In order to set parameters for all motors in the chenille spinning machine, this embodiment first obtains production requirements, wherein the production requirements include the purpose of the products produced and the production costs of the products. After the production requirements are clarified, the product type of chenille yarn that meets the production requirements can be selected, and the production method is obtained according to the product type, wherein the production method includes the operating parameters of all motors in the chenille spinning machine and various product parameters for producing the chenille yarn. The chenille spinning machine will strictly produce according to the product parameters to prevent a large difference between the actual production products and the demanded products.

[0034] S2: Analyze the control instruction to obtain the production specifications of the chenille yarn, wherein the production specifications include material feeding parameters and product process parameters.

[0035] S3: Generate a stepper drive command based on the material feeding parameters of the chenille yarn to control the movement of the stepper motor; generate a DC drive command based on the process parameters of the chenille yarn product to control the movement of the DC motor.

[0036] In this embodiment, generating a DC drive instruction based on the product process parameters of the chenille yarn to control the movement of the DC motor includes the following steps: Parse the product process parameters in the control instructions, convert the control instructions into multiple level signals output by the GPIO port of the microcontroller and multiple PWM wave signals output by the PWM channel of the microcontroller, and synchronously encode each DC motor based on the GPIO port number of the microcontroller connected to each DC motor; Based on the single chip microcomputer, the Hall position of the DC motor is obtained and multiple Hall signals are generated; Combining multiple Hall signals based on the DC motor encoding sequence so that the DC motor rotor phases are divided into several phases and numbered based on the phase angle range; The read Hall signal is used as the target Hall signal, the power drive circuit where the target Hall signal is located is used as the target power drive circuit, and the DC motor driven by the target power drive circuit is used as the target DC motor; The target Hall signal is analyzed to obtain the target Hall state of the target DC motor, the phase of the target DC motor rotor is obtained based on the target Hall state, the phase angle number is obtained based on the phase of the target DC motor rotor, and the power tube switches of the target power drive circuit are switched in sequence based on the order of the phase angle numbers to control the rotation direction of the target motor.

[0037] In order to control the DC motor connected to each power drive circuit, this embodiment uses the GPIO of the single-chip microcomputer to implement the Hall position feedback of the DC motor, and generates a Hall signal through the feedback result of the Hall position. Using the Hall signal to feedback the DC motor state can reduce the response time during feedback, improve the response speed of controlling the DC motor, thereby improving the self-regulation ability of the chenille spinning machine, and can adjust the DC motor in real time according to changes in the working state, thereby improving the production quality of chenille yarn.

[0038] like Figure 2 As shown, in this embodiment, controlling the start-stop sequence and starting speed of the DC motor includes the following steps: Initialize the coding information of each power drive circuit, and input the target speed and start-stop sequence of each motor in sequence based on the coding information; obtain the Hall signal of the drive circuit according to the coding information of the power drive circuit, and synchronously analyze the obtained Hall signal to calculate the movement speed of the motor; The target speed and the motion speed are input into the PI controller for speed PI calculation, and the speed PI calculation result is converted into the duty cycle of the PWM wave; Based on the duty cycle of the PWM wave, the Hall signal and encoding information are obtained to obtain the phase number of each motor rotor, and the power tube switch is switched according to the order of the phase number to drive the motor to rotate.

[0039] In order to control the rotation of the motor through the Hall position, this embodiment combines various Hall signals. Within the phase range of the DC motor rotor, the Hall signal is different according to different ranges. Therefore, the DC motor rotor phase is divided into several phases and the phases are numbered according to the angle range. A commutation switching logic table is constructed according to the DC motor rotor phase, the Hall state and the Hall value contained in the Hall signal, and the numbering information corresponding to the Hall state of the DC motor controlled by each power drive circuit is obtained. The phase of the motor rotor is queried according to the numbering information, so as to determine what kind of excitation the motor stator coil needs to provide to generate a positive torque on the rotor, so that each power drive circuit can independently control one DC motor, improve the control accuracy, and can more sensitively and accurately control each DC motor, thereby improving the control accuracy when producing chenille yarn and improving the product production quality.

[0040] In order to reduce the deviation between the actual movement speed of the motor and the theoretical target speed to be achieved when the chenille spinning machine is actually working, and to improve the overall stability during operation, this embodiment adopts a PI controller to adjust the speed of the DC motor. The PI controller is a linear controller, which constitutes a control deviation based on a given value and an actual output value, and forms a control quantity by linearly combining the proportion and integral of the deviation to control the controlled object. Proportional regulation is to proportionally react to the deviation of the system. Once a deviation occurs in the system, the proportional regulation immediately produces a regulating effect to reduce the deviation. A large proportional effect can speed up the regulation and reduce the error; integral regulation is to eliminate the steady-state error of the system and improve the error-free degree. Because there is an error, the integral regulation is carried out until there is no difference, the integral regulation stops and outputs a constant value. This method can reduce the deviation between the actual speed of the motor and the target speed, and improve the stability of the system operation, reduce the gap between the actual parameters and the target parameters of the product, and improve the precision of product production and product quality.

[0041] The speed PI calculation process in this embodiment is: Set the initial proportional adjustment coefficient Kp and integral adjustment coefficient Ki, and form the control deviation according to the deviation between the target speed and the motion speed; When a deviation occurs, the proportional adjustment coefficient Kp and the integral adjustment coefficient Ki are adjusted to reduce the control deviation; The proportional adjustment coefficient Kp and the integral adjustment coefficient Ki when the minimum control deviation is formed by linear combination are used as the control quantity output.

[0042] In order to reduce the deviation between the optimal speed and the actual speed of the DC motor, the PI controller of this embodiment adopts a regulation method that combines proportional regulation and integral regulation. A large proportional effect can speed up the regulation and reduce the error, but an excessively large proportion will reduce the stability of the system, form a steady-state error, and cause system instability; and the strength of the integral regulation depends on the integral time constant Ti. The smaller Ti is, the stronger the integral effect is, and vice versa, the larger Ti is, the weaker the integral effect is. Adding integral regulation can reduce the steady-state error caused by proportional regulation, but excessive regulation will cause system oscillation. Therefore, the two adjustments are coordinated with each other to keep the system stable while reducing the deviation. The optimal regulation parameters are found through linear combination, which can improve the dynamic regulation ability of the chenille spinning machine.

[0043] S4: Real-time detection of the current motion state of the stepper motor and the DC motor and the current material feeding parameters and process parameters of the chenille yarn, and generation of a stepper feedback instruction based on the current material feeding parameters of the chenille yarn and the current motion state of the stepper motor; and generation of a DC feedback instruction based on the current process parameters of the chenille yarn and the current motion state of the DC motor.

[0044] In this embodiment, the stepping feedback instruction is generated based on the current material feeding parameters of the chenille yarn and the current motion state of the stepping motor, including the following steps: Analyze the current material feeding parameters of the chenille yarn to obtain the optimal motion state of the stepper motor, and compare the optimal motion state of the stepper motor with the current motion state of the stepper motor to obtain the motion deviation of the stepper motor, wherein the motion deviation of the stepper motor includes at least a rotation speed and a rotation direction; Generate stepper feedback commands based on stepper motor motion deviations.

[0045] In the process of producing chenille yarn in this embodiment, since the parameters such as the yarn diameter, the yarn tube diameter and the twist degree are changing in real time, the material feeding parameters of each production stage are different, which will affect the subsequent production of the yarn. Therefore, each stepper motor in the chenille spinning machine cannot always operate according to the initially set parameters, and must be adjusted in real time according to the production situation. Therefore, it is necessary to monitor the rotation speed and rotation direction of the stepper motor in real time, and also to monitor the current material feeding parameters of the yarn controlled by the stepper motor in real time. Since the material feeding parameters are determined according to the production specifications of the yarn, the optimal material feeding parameters of each production link in the production process can be determined. Therefore, in order to make the current material feeding parameters of each production link of the yarn in the optimal state, the optimal motion state of the stepper motor can be inferred according to the optimal material feeding parameters, and the optimal motion state of the stepper motor is compared with the current motion state to obtain the motion deviation of the two, and the motion state of the stepper motor is adjusted to be close to the optimal motion state, so that the chenille yarn is in a relatively optimal production state in each link of the production process, which can significantly improve the overall production quality of the product.

[0046] In this embodiment, generating a DC feedback instruction based on the current process parameters of the chenille yarn and the current motion state of the DC motor includes the following steps: Analyze the current process parameters of the chenille yarn to obtain the optimal motion state of the DC motor, compare the optimal motion state of the DC motor with the current motion state of the DC motor to obtain the motion deviation of the DC motor, wherein the motion deviation of the DC motor includes at least a rotation speed and a rotation direction; Generates DC feedback commands based on DC motor motion deviations.

[0047] In the process of producing chenille yarn in this embodiment, since the parameters such as the yarn diameter, the yarn tube diameter and the twist degree are changing in real time, which will affect the subsequent production of the yarn, the various DC motors in the chenille spinning machine cannot always operate according to the initially set parameters, and must be adjusted in real time according to the production situation. Therefore, it is necessary to monitor the rotation speed and rotation direction of the DC motor in real time, and also to monitor the current process parameters of the yarn controlled by the DC motor in real time. Since the process parameters are determined according to the production specifications of the yarn, the optimal process parameters of each production link in the production process can be determined. Therefore, in order to make the current process parameters of each production link of the yarn in the optimal state, the optimal motion state of the DC motor can be inferred according to the optimal process parameters, and the optimal motion state of the DC motor is compared with the current motion state to obtain the motion deviation between the two, and the motion state of the DC motor is adjusted to be close to the optimal motion state, so that the chenille yarn is in a relatively optimal production state in each link of the production process, which can significantly improve the overall production quality of the product.

[0048] S5: sending the stepper feedback instruction and the DC feedback instruction to the stepper feedback interface and the DC feedback interface respectively, adjusting the motion state of the stepper motor based on the stepper feedback instruction, and adjusting the motion state of the DC motor based on the DC feedback instruction.

[0049] In this embodiment, the stepper feedback instruction and the DC feedback instruction are sent to the stepper feedback interface and the DC feedback interface respectively, and the motion state of the stepper motor is adjusted based on the stepper feedback instruction, and the motion state of the DC motor is adjusted based on the DC feedback instruction, including the following steps: Respectively obtain the stepper motor motion deviation and the DC motor motion deviation in the stepper feedback instruction and the DC feedback instruction, and adjust the stepper motor motion state to the optimal stepper motor motion state based on the stepper motor motion deviation; adjusting the motion state of the DC motor to an optimal motion state of the DC motor based on the motion deviation of the DC motor; If the current process parameters of the chenille yarn are equal to the product process parameters, the stepper motor and the DC motor are controlled to decelerate linearly until the speed is 0.

[0050] In this embodiment, after the chenille yarn production is completed, the stepper motor and the DC motor are stopped during the shutdown process. The motor will go through a deceleration process. During the deceleration process, the production actions such as twisting are still being performed. In order to prevent the problem of uneven twist on the cloth surface caused by continued twisting during the shutdown, the wire feeding motor is linearly decelerated during the shutdown deceleration stage. Deceleration at the same deceleration rate will not affect the uniformity of the cloth twist, thereby improving the production quality of the product.

[0051] In this embodiment, the product process parameters at least include twist degree, twist direction, yarn cone tightness and yarn relaxation.

[0052] In this embodiment, since parameters such as twist degree, twist direction, yarn cone tightness and yarn relaxation of different types of chenille yarns are different, these product process parameters need to be determined before producing chenille yarns. Only then can the working status of each motor in the chenille spinning machine be analyzed based on these product parameters, thereby ensuring that the product obtained after the production process is completed is consistent with the required product.

[0053] In this embodiment, the stepper motor includes at least a wire feeding motor and a roller motor, and the DC motor includes at least a spindle motor and a rotary motor.

[0054] In this embodiment, since a large number of motors are required to produce chenille yarn, each motor plays a different role in the production process. The wire feeding motor in the chenille spinning machine is mainly responsible for feeding the fiber into the machine to provide raw materials for the subsequent spinning process. The speed and power of the wire feeding motor directly affect the speed and quantity of the feed, and have an important impact on the stability of the spinning process and the quality of the yarn; the roller motor is usually used to drive the rotation of the roller device in the chenille spinning machine. The roller device plays the role of combing, drafting and feeding the fiber during the spinning process; the rotary motor is responsible for driving the rotary head and other components to cut and clamp multiple strands of yarn into the core wire to form chenille yarn; the spindle motor is responsible for driving the rotation of the spindle in the spinning machine. By driving the rotation of the spindle, the input fiber or yarn is twisted to form a yarn with a certain strength and structure; therefore, the speed, rotation direction, start and stop time and other parameters of each motor need to be accurately controlled and adjusted in real time to ensure that each step in the production process meets the production requirements and provides high-quality chenille yarn.

[0055] In order to improve the product quality of chenille yarn, this embodiment first determines various parameters of the product according to the production requirements of the product before officially starting production, obtains material feeding parameters and product process parameters, wherein the material feeding parameters are controlled by a stepper motor, which is mainly responsible for stably and continuously delivering the yarn raw materials to the processing area of ​​the spinning machine. It controls the feeding speed and tension of the yarn to ensure that the yarn maintains a proper tension state during the processing process, thereby avoiding quality problems caused by yarn breakage or excessive relaxation; and the product process parameters include twist degree, twist direction, yarn cone tightness and yarn relaxation, etc., which are controlled by a DC motor To control, the initial states of the DC motor and the stepper motor are determined according to the material feeding parameters and the product process parameters, and the production of chenille yarn is carried out. During the production process, the state of the chenille yarn and the movement state of the DC motor and the stepper motor are monitored in real time, and the optimal state of the motor is inferred according to the real-time state of the chenille yarn, and the feedback is given to the drive module, so that the motor tends to the working state of producing higher-quality chenille yarn in real time. This can significantly reduce the probability of reduced quality of chenille yarn products due to external influences in the production process, and improve the overall quality of chenille yarn products.

[0056] As a further supplement to this embodiment, the following scenario is taken as an example to further illustrate this solution: Figure 4As shown, this embodiment uses a 1-way stepper motor as a wire feeding motor to realize the wire feeding function of the chenille spinning process. Wire feeding is to wind up the raw yarn through the wire feeding motor, pull the raw yarn off the yarn rack, and send it back to the rotary head. The wire feeding motor is directly driven to rotate by the stepper drive circuit integrated in the system; 2-way stepper motors are used as the left roller motor and the right roller motor respectively. The function of the roller is to send the two strands of yarn wound by the wire feeding motor to the scissors under the rotary head. Through the rotation of the roller wheel, the two strands of yarn clamp the broken yarn cut by the scissors and send it to the spindle.

[0057] This embodiment adopts a DC brushless motor as a rotary motor to realize the rotation function. The rotary motor rotates at high speed to repeatedly cut a strand of original yarn on the scissors to form short yarns. The two core yarns pulled by the roller mechanism will sandwich these short yarns in the middle. After twisting by the spindle, a plump chenille yarn is obtained; 2 DC motors are directly driven as the left spindle motor and the right spindle motor to realize the spindle twisting function. A total of 6 motors are used to realize all the functions of the chenille spinning machine.

[0058] In this embodiment, a single single-chip microcomputer chip is used to realize multi-channel DC motor drive with Hall feedback, the PWM channel of the TIM module of the single-chip microcomputer is used to generate 3 PWMs to control the upper bridge of the power drive circuit, and 3 GPIOs are used to control the lower bridge of the power drive circuit to realize the output function of the motor drive.

[0059] This embodiment uses the GPIO of the single-chip microcomputer to implement the Hall position feedback of the brushless DC motor. The three Hall signals are square waves with a phase difference of 120°. By combining the three signals, the DC motor rotor phase is divided into 6 phases. The current rotor phase is determined based on the Hall signal, thereby determining what kind of excitation the DC motor stator coil needs to provide to generate a positive torque on the rotor.

[0060] This embodiment uses the EXTI port of the microcontroller to implement speed feedback of the brushless DC motor. The Hall signal is used as the input of the EXTI port of the microcontroller. By monitoring the change cycle of its rising edge or falling edge, the time required for the motor to rotate to a corresponding angle, such as 120 degrees, is calculated, thereby calculating the current speed of the motor.

[0061] The brushless DC motor of this embodiment adopts a six-step commutation control logic: the power drive circuit is generally composed of six power tubes, and the six power tubes are T1 as the upper tube of the first pair of H bridges, T2 as the lower tube of the first pair of H bridges, T3 as the upper tube of the second pair of H bridges, T4 as the lower tube of the second pair of H bridges, T5 as the upper tube of the second pair of H bridges, and T6 as the lower tube of the second pair of H bridges. The three Hall signals are set to ABC. The switching logic of the PWM output tube can be performed through the following table. By constructing a commutation switching logic table, the corresponding tube switches are switched in sequence to make the motor rotate smoothly. Table 1 is the commutation switching logic table constructed in this embodiment. Table 1. Reversing switching logic table angle 30-90 90-150 150-210 210-270 270-330 330-30 Hall state 101 100 110 010 011 001 Hall value 5 4 6 2 3 1 Forward switch T1, T4 T1, T6 T3, T6 T3, T2 T5, T2 T5, T4 Reverse switch T3, T2 T5, T2 T5, T4 T1, T4 T1, T6 T3, T6

[0062] The speed closed-loop control of the brushless DC motor in this embodiment is as follows: The program is first in a shutdown waiting state. When it receives the start command from the application layer, it starts to enter the running state and initializes the functional modules of the driver program at the same time. It obtains the given target speed from the upper-level program and the state of the Hall. The program calculates the current motor speed through the change of the Hall feedback signal, and inputs the given speed and feedback speed into the PI controller of the speed loop for speed PI operation. The speed PI controller operation result is converted into the duty cycle of the PWM wave. The six PWM outputs are switched according to the state of the Hall. The execution result of the current time is output to drive the motor.

[0063] It can be seen from the above embodiments that at least the following substantial effects are achieved: (1) The present invention sets multiple parallel power drive circuits, uses a single chip microcomputer to generate multiple PWMs and uses multiple GPIO ports to control the power drive circuits. A single chip microcomputer controls the multiple power drive circuits, and one power drive circuit controls a DC motor independently. Thus, one controller controls multiple motors, and the control precision of each DC motor is improved. When producing chenille yarn, the corresponding DC motors in each production stage can be adjusted independently, thereby improving the overall quality of the product, saving the control center resource space, and reducing the production cost. (2) The present invention generates a Hall signal by acquiring the Hall position of the DC motor, combines the acquired Hall signals, controls the DC motor rotor based on the information in the Hall signal, and collects and feeds back the data inside a single-chip microcomputer, thereby reducing the delay of information transmission and improving the feedback and automatic adjustment capabilities of the system, thereby improving the adaptability to various situations encountered during product production and improving product production quality; (3) The present invention monitors the motion state of each motor and the state of the chenille yarn in real time during the production process, and can adjust each motor in real time according to the current state of the chenille yarn, thereby ensuring that the chenille yarn is always in the best production state during the production process, thereby improving the overall production quality of the chenille yarn.

[0064] The specific implementation described above is a preferred implementation of an intelligent electronic control system for a chenille spinning machine of the present invention, and is not intended to limit the specific implementation scope of the present invention. The scope of the present invention includes but is not limited to this specific implementation. All equivalent changes made in accordance with the shape and structure of the present invention are within the protection scope of the present invention.

Claims

1. An intelligent electric control method for a chenille spinning machine, applicable to an intelligent electric control device, the intelligent electric control device comprising: A control module is used to generate control instructions and send the control instructions to the control instruction interface; The stepper drive module includes a stepper feedback interface and a control instruction interface, which is used to parse the control instruction to generate a stepper drive instruction to control the stepper motor; A brushless DC drive module, including a DC feedback interface and a control command interface, is used to parse control commands to generate DC drive commands to control a DC motor; The brushless DC drive module is composed of multiple parallel power drive circuits, and each DC motor is connected to one power drive circuit respectively; It is characterized by comprising the following steps: S1. Obtain the production demand of chenille yarn and generate control instructions based on the production demand; S2. Analyze the control instruction to obtain the production specifications of the chenille yarn, wherein the production specifications include material feeding parameters and product process parameters; S3, generating a stepper drive instruction based on the material feeding parameters of the chenille yarn to control the movement of the stepper motor; generating a DC drive instruction based on the process parameters of the chenille yarn product to control the movement of the DC motor; S4, detecting the current motion state of the stepper motor and the DC motor and the current material feeding parameters and process parameters of the chenille yarn in real time, generating a stepper feedback instruction based on the current material feeding parameters of the chenille yarn and the current motion state of the stepper motor; generating a DC feedback instruction based on the current process parameters of the chenille yarn and the current motion state of the DC motor; S5. Send the stepper feedback instruction and the DC feedback instruction to the stepper feedback interface and the DC feedback interface respectively, adjust the motion state of the stepper motor based on the stepper feedback instruction, and adjust the motion state of the DC motor based on the DC feedback instruction.

2. The intelligent electronic control method for a chenille spinning machine according to claim 1, characterized in that: In S1, the production demand of chenille yarn is obtained, and a control instruction is generated based on the production demand, including the following steps: Analyze production requirements, obtain the product types of chenille yarn, and obtain the initial motion states of the stepper motor and DC motor in the chenille spinning machine based on the product types; Control instructions are generated based on the product type of chenille yarn and the initial motion states of the stepper motor and DC motor.

3. The intelligent electronic control method of a chenille spinning machine according to claim 1, characterized in that: In S3, a stepping drive instruction is generated based on the material feeding parameters of the chenille yarn to control the movement of the stepping motor, including the following steps: Analyze the material feeding parameters in the control instructions, and convert the control instructions into level signals and PWM wave signals output by the microcontroller; generate stepper drive instructions based on the high and low level information in the level signal and the duty cycle in the PWM wave signal, and control the rotation direction and speed of the stepper motor based on the stepper drive instructions.

4. The intelligent electronic control method for a chenille spinning machine according to claim 1, characterized in that: In S3, a DC drive instruction is generated based on the product process parameters of the chenille yarn to control the movement of the DC motor, including the following steps: Parse the product process parameters in the control instructions, convert the control instructions into multiple level signals output by the GPIO port of the microcontroller and multiple PWM wave signals output by the PWM channel of the microcontroller, and synchronously encode each DC motor based on the GPIO port number of the microcontroller connected to each DC motor; Based on the single chip microcomputer, the Hall position of the DC motor is obtained and multiple Hall signals are generated; A DC drive instruction is generated based on multiple level signals, multiple PWM wave signals, and multiple Hall signals, and the rotation direction and rotation speed of the DC motor are controlled based on the DC drive instruction.

5. The intelligent electronic control method of a chenille spinning machine according to claim 4, characterized in that: Generating a DC drive instruction based on multiple level signals, multiple PWM wave signals, and multiple Hall signals, and controlling the rotation direction of the DC motor based on the DC drive instruction, including the following steps: Combining multiple Hall signals based on the DC motor encoding sequence so that the DC motor rotor phases are divided into several phases and numbered based on the phase angle range; The read Hall signal is used as the target Hall signal, the power drive circuit where the target Hall signal is located is used as the target power drive circuit, and the DC motor driven by the target power drive circuit is used as the target DC motor; The target Hall signal is analyzed to obtain the target Hall state of the target DC motor, the phase of the target DC motor rotor is obtained based on the target Hall state, the phase angle number is obtained based on the phase of the target DC motor rotor, and the power tube switches of the target power drive circuit are switched in sequence based on the order of the phase angle numbers to control the rotation direction of the target motor.

6. The intelligent electronic control method of a chenille spinning machine according to claim 1, characterized in that: In S4, a stepping feedback instruction is generated based on the current material feeding parameter of the chenille yarn and the current motion state of the stepping motor, including the following steps: Analyze the current material feeding parameters of the chenille yarn to obtain the optimal motion state of the stepper motor, and compare the optimal motion state of the stepper motor with the current motion state of the stepper motor to obtain the motion deviation of the stepper motor, wherein the motion deviation of the stepper motor includes at least a rotation speed and a rotation direction; Generate stepper feedback commands based on stepper motor motion deviations.

7. The intelligent electronic control method of a chenille spinning machine according to claim 1, characterized in that: In S4, a DC feedback instruction is generated based on the current process parameters of the chenille yarn and the current motion state of the DC motor, including the following steps: Analyze the current process parameters of the chenille yarn to obtain the optimal motion state of the DC motor, compare the optimal motion state of the DC motor with the current motion state of the DC motor to obtain the motion deviation of the DC motor, wherein the motion deviation of the DC motor includes at least a rotation speed and a rotation direction; Generates DC feedback commands based on DC motor motion deviations.

8. The intelligent electronic control method of a chenille spinning machine according to claim 1, characterized in that: In S5, the stepper feedback instruction and the DC feedback instruction are sent to the stepper feedback interface and the DC feedback interface respectively, the motion state of the stepper motor is adjusted based on the stepper feedback instruction, and the motion state of the DC motor is adjusted based on the DC feedback instruction, including the following steps: respectively obtaining the stepper motor motion deviation and the DC motor motion deviation in the stepper feedback instruction and the DC feedback instruction, and adjusting the stepper motor motion state to the optimal motion state of the stepper motor based on the stepper motor motion deviation; adjusting the motion state of the DC motor to an optimal motion state of the DC motor based on the motion deviation of the DC motor; If the current process parameters of the chenille yarn are equal to the product process parameters, the stepper motor and the DC motor are controlled to decelerate linearly until the speed is 0.

9. The intelligent electronic control method for a chenille spinning machine according to claim 1, 4 or 8, characterized in that: The product process parameters at least include twist degree, twist direction, yarn cone tightness and yarn relaxation.

10. An intelligent electronic control method for a chenille spinning machine according to claim 1, 2 or 8, characterized in that: The stepper motor at least includes a wire feeding motor and a roller motor, and the DC motor at least includes a spindle motor and a rotary motor.

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