A large capacity intensive warp tension control distribution device and method

Abstract

The application provides a large-capacity dense yarn tension control distribution device and method, which comprises a yarn drum frame, a tension frame, a bundling frame, a tension control device, a monitoring device, a yarn drum, a yarn conveying pipe, a three-roller type tension sensor and an electric control system; the yarn drum frame is located on one side of the tension frame, and yarn drum shafts are uniformly distributed on the tension frame in the vertical and horizontal directions; the yarn drum is arranged on the yarn drum shaft and can rotate freely; the yarn drum frame and the tension frame are connected through the yarn conveying pipe, the input end of the yarn conveying pipe is fixed to the lower right side of the yarn drum, and the other end is connected with the input end of the tension frame; each yarn conveying pipe corresponds to a row of yarn drums; the bundling frame is located on the other side of the tension frame, and the tension frame and the bundling frame are relatively independent. The application realizes the dense distribution of large-capacity yarns, the arrangement of the yarns is clear in hierarchy, and the yarn abrasion is reduced.

Description

Technical Field

[0001] This application relates to the field of textile machinery and tension technology, and in particular to a device and method for high-capacity, dense warp tension control and distribution. Background Technology

[0002] Three-dimensional loom prefabrication is a new type of weaving technology. It is an integral structure formed by yarns being distributed and interwoven in two mutually perpendicular directions (warp and weft) in three-dimensional space. As a high-performance composite material reinforcement, composite material components have many advantages such as light weight, high strength, and excellent mechanical properties. At present, it has been widely used in many fields such as aerospace, defense, transportation, and energy, and is constantly expanding into the civilian field.

[0003] In three-dimensional woven preforms, the control of radial tension and yarn loss are crucial factors affecting preform forming, directly impacting the manufacturing process, dimensions, and mechanical properties. Traditional warp tension detection systems typically test a group of yarns, making it difficult to detect specific yarns experiencing changes. Furthermore, installing detection systems for individual yarns requires significant space when weaving large volumes of yarn, making implementation impractical in textile machines handling large quantities of yarn.

[0004] The method and device for controlling the distribution of high-density warp tension are of great significance for the molding of three-dimensional woven preforms. Summary of the Invention

[0005] This application provides a high-capacity, dense warp tension control and distribution device and method, which can solve the problems of difficult tension control and large space occupation during the weaving of large-capacity yarns. It has the advantages of high tension control accuracy, fast communication speed, strong scalability, and easy maintenance.

[0006] This application provides a high-capacity, dense warp tension control and distribution device, which includes a yarn bobbin frame, a tension frame, a bundler frame, a tension control device, a monitoring device, a yarn bobbin, a delivery pipe, a three-roller tension sensor, and an electronic control system.

[0007] The yarn bobbin frame is located on one side of the tension frame, and yarn bobbin shafts are evenly distributed on the tension frame. The yarn bobbins are placed on the yarn bobbin shafts and can rotate freely. The yarn bobbin frame and the tension frame are connected by a feed tube. The input end of the feed tube is fixed to the lower right side of the yarn bobbin, and the other end is connected to the input end of the tension frame. Each feed tube corresponds to a row of yarn bobbins.

[0008] The bundle frame is a grid made of interwoven steel wires, with each grid corresponding to a single yarn; the bundle frame is located on the other side of the tension frame, and the tension frame and the bundle frame are relatively independent of each other.

[0009] Furthermore, the tension control devices are evenly distributed in an array on the tension frame; the monitoring device and the three-roller tension sensor are fixed at the end of the tension frame, and the tension of each yarn corresponds to a separate set of tension control devices, monitoring devices and three-roller tension sensors.

[0010] Furthermore, each yarn passes through a separate set of yarn bobbins, feed tubes, tension control devices, monitoring devices, three-roller tension sensors, and bundlers; the yarn bobbin frame, tension frame, and bundler are all axisymmetric structures made of aluminum profiles, spatially separated, with their axes of symmetry located on the same central axis.

[0011] Furthermore, each tension control device is independently controlled by a separate motor and a separate driver, and the tension is obtained by a brushless motor, generating a constant tension of 0 to 300g.

[0012] The tension control device controls the motor under the critical tension set by the motor. It uses a three-roller tension sensor for feedback and performs closed-loop tension control based on software algorithms, achieving a tension control accuracy of ±2g.

[0013] Furthermore, each tension frame is a unit, divided into m layers, with each layer containing n modules. Each module is equipped with a PCB board, which can connect and control 24 sets of tension control devices. One tension frame unit can control the tension of 24*m*n yarns.

[0014] Furthermore, each PCB board has an independent IP address, which corresponds to its own physical location. In the event of a single-path failure, the IP address can be located and the PCB board can be updated, facilitating maintenance.

[0015] Furthermore, each tension control device is individually controlled by an electronic control system, and the tension changes of each yarn can be monitored in real time by a three-roller tension sensor;

[0016] In the electrical control system, the single-channel motor controller communicates with the host computer at the workstation via a link, allowing for stepless tension setting from 0 to 300g to meet the needs of various weaving processes. Simultaneously, the outer loop communication uses an industrial Ethernet bus, with each motor controller assigned an IP address, acting as an IP sub-node in the communication system. This allows for batch tension settings by inputting the IP addresses and values ​​of tension sensors at specified locations into a designated document, or by setting tension for individual yarns via the host computer, facilitating various application scenarios. To achieve tension control for high-capacity yarns, VLAN technology is employed, enabling communication between two VLANs in different subnets via an industrial Ethernet switch. The IP addresses of the sub-nodes are set in different network segments, significantly increasing the number of scalable sub-nodes and communication speed, reaching a maximum communication rate of 100Mbps.

[0017] Furthermore, the yarn bobbins are evenly fixed in an array on both sides of the yarn bobbin frame. Each yarn bobbin has an information QR code on its surface. All records from yarn bobbin testing and production to product use are stored on a cloud server. For each yarn and its corresponding tension controller, various data during operation can be obtained by scanning the QR code with a mobile phone, and its working status can be traced, providing digital management for production and manufacturing.

[0018] Furthermore, the yarn bobbin frame, tension frame, bundle frame, tension control device, monitoring device, yarn bobbin, delivery tube, and three-roller tension sensor can all be configured with multiple multi-layer yarn bobbin frames and tension frames for combined use as needed; by arranging multiple sets of multi-layer yarn bobbin frames and tension frames, the number of yarns can be controlled to increase exponentially, thereby achieving controllable and dense tension of large-capacity yarns.

[0019] This application also provides a method for controlling and distributing high-capacity, densely packed warp yarn tension, implemented by the apparatus provided in this application, and the method includes:

[0020] Several yarn bobbins are installed on the yarn bobbin holder, so that the warp yarns are drawn out from the yarn bobbins and connected to the input end of the tension frame through the yarn bobbin holder via the feed tube;

[0021] Several tension control devices and several monitoring devices are fixed on the tension frame, so that each tension control device and monitoring device corresponds to a separate warp yarn;

[0022] Several three-roller tension sensors are installed at the output end of the tension frame, so that the warp yarn passes through the tension control device, the monitoring device and the three-roller tension sensors in sequence on the tension frame;

[0023] The three-roller tension sensor at the output end of the warp tension frame is directly connected to the bundler to achieve yarn densification.

[0024] This application separates the generation of yarn tension from the yarn bobbin itself, saving space occupied by the yarn tension generating device. As the cross-sectional area of ​​the yarn bobbin frame, tension frame, and bundling frame decreases in sequence, the high-capacity yarn density is achieved. Attached Figure Description

[0025] Figure 1 An overall diagram of a high-capacity, densely packed warp tension control and distribution device;

[0026] Figure 2 A top view of a high-capacity, densely packed warp tension control and distribution device;

[0027] Figure 3 A top view of a high-capacity, dense warp tension control and distribution device used in batches.

[0028] Figure 4This is a side view schematic diagram of a large-capacity, dense warp tension control distribution device used in batches. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0030] This application provides a high-capacity, dense warp tension control and distribution device, which includes a yarn bobbin frame 1, a tension frame 2, a bundled frame 3, a tension control device 4, a monitoring device 5, a yarn bobbin 6, a delivery pipe 7, a three-roller tension sensor 8, and an electrical control system 9.

[0031] The yarn bobbin frame 1 is located on one side of the tension frame 2, and yarn bobbin shafts are evenly distributed on the tension frame 2. The yarn bobbins 6 are placed on the yarn bobbin shafts and can rotate freely. The yarn bobbin frame 1 and the tension frame 2 are connected by a feed pipe 7. The input end of the feed pipe 7 is fixed to the lower right side of the yarn bobbin 6, and the other end is connected to the input end of the tension frame 2. Each feed pipe 7 corresponds to a row of yarn bobbins 6.

[0032] The bundle frame 3 is located on the other side of the tension frame, and the tension frame 2 and the bundle frame 3 are relatively independent of each other.

[0033] Furthermore, the tension control devices 4 are evenly distributed in an array on the tension frame;

[0034] The monitoring device 5 and the three-roller tension sensor 8 are fixed at the end of the tension frame 2. Each yarn tension corresponds to a separate tension control device 4, monitoring device 5 and three-roller tension sensor 8.

[0035] Furthermore, each yarn passes individually through a set of yarn bobbins 6, feed tubes 7, tension control devices 4, monitoring devices 5, three-roller tension sensors 8, and bundlers 3.

[0036] Furthermore, the yarn tube frame 1, tension frame 2, and bundle frame 3 are spatially separated but located on the same central axis.

[0037] Furthermore, each tension control device is individually controlled by the control system, and the tension changes of each yarn can be monitored in real time via a three-roller tension sensor.

[0038] Furthermore, the yarn bobbin frame 1, tension frame 2, and bundled frame 3 are all axisymmetric structures made of aluminum profiles.

[0039] Furthermore, the yarn spools 6 are evenly fixed in an array on both sides of the yarn spool frame 1, and each yarn spool 6 has an information QR code on its surface.

[0040] Furthermore, the yarn bobbin 1, tension frame 2, bundled frame 3, tension control device 4, monitoring device 5, yarn bobbin 6, delivery tube 7, and three-roller tension sensor 8 can all be combined and multiplied as needed to achieve controllable tension and high-capacity density of yarn 10.

[0041] Furthermore, the yarn bobbin frame evenly arrays several yarn bobbins, each yarn bobbin having a feed tube connected to a corresponding tension control device. By setting up multiple layers and groups of yarn bobbins and tension controllers, the tension of large-capacity yarn can be controlled and densely distributed.

[0042] This application also provides a method for controlling and distributing high-capacity, densely packed warp yarn tension, implemented by the apparatus provided in this application, and the method includes:

[0043] Several yarn bobbins 6 are installed on the yarn bobbin frame 1, so that the warp yarns are drawn out from the yarn bobbins 6 and connected to the input end of the tension frame 2 through the yarn bobbin frame 1 via the feed pipe 7;

[0044] Several tension control devices 4 and several monitoring devices 5 are fixed on the tension frame 2, so that each tension control device 4 and monitoring device 5 corresponds to a separate warp yarn 10.

[0045] Several three-roller tension sensors 8 are installed at the output end of the tension frame 2, so that the warp yarn 10 passes through the tension control device 4, the monitoring device 5 and the three-roller tension sensors 8 in sequence on the tension frame 2.

[0046] The warp yarn 10 is directly connected to the bundler 3 via the three-roller tension sensor 8 at the output end of the tension frame 2, thus completing the densification of the yarn 10.

[0047] Figure 2 This is a top view of a method and apparatus for controlling and distributing warp tension in a high-capacity manner, intended to demonstrate that the method and apparatus for controlling and distributing warp tension in this invention can achieve high-capacity yarn density.

[0048] Figure 3 This is a top view of a batch combination of a method and device for controlling and distributing warp tension of a large capacity yarn. It aims to demonstrate that by combining the warp tension control and distribution method and device of the present invention, the tension of more warp yarns can be controlled simultaneously, and the cross-sectional area of ​​large capacity yarns can be further reduced to achieve greater capacity yarn density.

[0049] Figure 4 This is a side view schematic diagram of a method and device for controlling and distributing warp tension in a large capacity and used in batches. It is intended to demonstrate that the method and device for controlling and distributing warp tension of the present invention can also be stacked and combined in a two-dimensional space, which can further expand the number of controlled warp yarns and achieve ultra-large capacity yarn density.

[0050] The embodiments described above do not constitute a limitation on the scope of protection of this application.

Claims

1. A high-capacity, densely distributed warp tension control device, characterized in that, The device includes a yarn bobbin holder (1), a tension holder (2), a bundle holder (3), a tension control device (4), a monitoring device (5), a yarn bobbin (6), a delivery tube (7), a three-roller tension sensor (8), and an electrical control system (9). The yarn bobbin frame (1) is located on one side of the tension frame (2), and yarn bobbin shafts are evenly distributed on the yarn bobbin frame (1). The yarn bobbins (6) are placed on the yarn bobbin shafts and can rotate freely. The yarn bobbin frame (1) and the tension frame (2) are connected by a feed pipe (7). The input end of the feed pipe (7) is fixed to the lower right side of the yarn bobbin (6), and the other end is connected to the input end of the tension frame (2). Each feed pipe (7) corresponds to a row of yarn bobbins (6). The bundle frame (3) is a grid made of interwoven steel wires, with each grid corresponding to a yarn passing through it; the bundle frame (3) is located on the other side of the tension frame, and the tension frame (2) and the bundle frame (3) are relatively independent of each other; The tension control devices (4) are evenly distributed in an array on the tension frame; the monitoring device (5) and the three-roller tension sensor (8) are fixed at the end of the tension frame (2), and each yarn tension corresponds to a separate set of tension control devices (4), monitoring devices (5) and three-roller tension sensors (8). Each tension frame is a unit, divided into m layers, and each layer is divided into n modules. Each module is equipped with a PCB board, which can connect and control 24 sets of tension control devices. One tension frame unit can control the tension of 24×m×n yarns. Each PCB board has a unique IP address, which corresponds to its own physical location. In the event of a single-path failure, the IP address can be located and the PCB board can be updated accordingly. Each tension control device is individually controlled by an electronic control system, and the tension changes of each yarn can be monitored in real time by a three-roller tension sensor. In the electrical control system, the single-channel motor controller communicates with the host computer at the workstation via a link, allowing for stepless tension setting from 0 to 300g to meet the needs of various weaving processes. Simultaneously, the outer loop communication uses an industrial Ethernet bus, with each motor controller assigned an IP address, acting as an IP sub-node in the communication system. This allows for batch tension settings by inputting the IP addresses and values ​​of tension sensors at specified locations into a designated document, or by setting the tension of individual yarns via the host computer. To achieve tension control for high-capacity yarns, VLAN technology is employed, enabling communication between two VLANs in different subnets via an industrial Ethernet switch, with the sub-nodes' IP addresses set in different network segments.

2. The high-capacity, dense warp tension control and distribution device according to claim 1, characterized in that, Each yarn passes through a set of yarn bobbins (6), a delivery tube (7), a tension control device (4), a monitoring device (5), a three-roller tension sensor (8), and a bundler (3) individually; the yarn bobbin frame (1), the tension frame (2), and the bundler (3) are all axisymmetric structures made of aluminum profiles, separated in space, with the axis of symmetry located on the same central axis.

3. The high-capacity, dense warp tension control and distribution device according to claim 1, characterized in that, Each tension control device (4) is independently controlled by a separate motor and a separate driver. The tension is obtained by a brushless motor, generating a constant tension of 0~300g. The tension control device controls the motor under the critical tension set by the motor, provides feedback through a three-roller tension sensor, and performs closed-loop tension control adjustment based on software algorithms.

4. The high-capacity, dense warp tension control and distribution device according to claim 1, characterized in that, Yarn spools (6) are evenly fixed on both sides of the yarn spool frame (1) in an array. Each yarn spool (6) has an information QR code on its surface. All records from yarn spool testing and production to product use are stored on the cloud server. For each yarn and its corresponding tension controller, various data during operation can be obtained by scanning the QR code with a mobile phone, and its working status can be traced.

5. The high-capacity, dense warp tension control and distribution device according to claim 1, characterized in that, The yarn bobbin frame (1), tension frame (2), bundle frame (3), tension control device (4), monitoring device (5), yarn bobbin (6), delivery pipe (7) and three-roller tension sensor (8) can all be configured to use multiple multi-layer yarn bobbin frames and tension frames as needed; by arranging multiple layers of yarn bobbin frames and tension frames, the number of yarns can be controlled to increase exponentially.

6. A method for controlling and distributing warp tension in high-capacity, densely packed yarns, wherein the method is implemented by any one of the devices described in claims 1 to 5, characterized in that... The method includes: Several yarn bobbins (6) are installed on the yarn bobbin frame (1) so that the warp yarn is drawn out from the yarn bobbin (6) and connected to the input end of the tension frame (2) through the yarn bobbin frame (1) via the feed pipe (7); Several tension control devices (4) and several monitoring devices (5) are fixed on the tension frame (2), so that each tension control device (4) and monitoring device (5) corresponds to a separate warp (10). Several three-roller tension sensors (8) are installed at the output end of the tension frame (2) so that the warp yarn (10) passes through the tension control device (4), the monitoring device (5) and the three-roller tension sensor (8) in sequence on the tension frame (2). The warp yarn (10) is directly connected to the bundler (3) via the three roller tension sensor (8) at the output end of the tension frame (2) to complete the densification of the warp yarn (10).

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