An intelligent control system for dye concentration in the process of textile fabric printing and dyeing

Abstract

The present invention provides an intelligent control system for dye concentration in the printing and dyeing process of textile fabrics, and relates to the technical field of printing and dyeing control. The present invention can ensure that the obtained dye concentration value is more accurate by acquiring dye concentration data of the textile fabric at the current time point in real time, and filtering and correcting the data. The concentration adjustment amount is obtained by combining a preset prediction model, and the dye amount that needs to be adjusted can be accurately calculated. A control instruction is generated according to the adjustment amount to adjust the opening or discharge rate of a valve. The precise control method can avoid waste and excessive use of dyes, thereby optimizing the use efficiency of dyes, helping to reduce production costs, and improving economic benefits.

Description

Technical Field

[0001] The invention relates to the technical field of printing and dyeing control, and in particular to an intelligent control system for dye concentration in the process of printing and dyeing of textile fabrics. Background Art

[0002] In the textile fabric printing and dyeing industry, dye concentration control is a crucial link. It not only directly affects the quality and color vividness of printed and dyed products, but is also closely related to production costs, environmental protection and the economic benefits of enterprises. However, in the actual production process, dye concentration control faces many technical difficulties, such as:

[0003] When obtaining the dye concentration data of the textile fabric at the current time point in real time, the response speed of the sensor and the delay time of data transmission often affect the accuracy of the data. If the sensor responds too slowly or there is a delay in data transmission, the acquired data will not be able to reflect the current dye concentration status in time, thus affecting subsequent control decisions. Many control systems still require manual regular inspection and adjustment of dye concentration, which not only increases labor costs, but is also easily affected by human factors. Secondly, due to the complexity of the printing and dyeing environment and the limitations of the sensor itself, the acquired dye concentration data often contains noise and outliers. These noises and outliers interfere with the accuracy of the data and make it difficult to formulate control instructions.

[0004] Therefore, it is necessary to provide an intelligent control system for dye concentration in the process of textile fabric printing and dyeing to solve the above technical problems. Summary of the invention

[0005] In order to solve the above technical problems, the present invention provides an intelligent control system for dye concentration in the printing and dyeing process of textile fabrics, which is used to solve the problem that the response speed of the sensor and the delay time of data transmission often affect the accuracy of the data, thereby affecting the precision of dye concentration control, and the acquired dye concentration data often contains noise and outliers that affect the precision of dye concentration control.

[0006] The present invention provides an intelligent control system for dye concentration in a textile fabric printing and dyeing process, the control system comprising:

[0007] The data acquisition module is used to obtain the historical data of current textile fabric printing and dyeing, obtain the sensor response speed and data transmission delay data in dye concentration control, generate control instructions to execute the adjustment of dye discharge time, and obtain the real-time detection response time and dye concentration control response time by statistics;

[0008] The data acquisition module is used to obtain the dye concentration data detected at the current time point of the textile fabric in real time, and to filter and correct the dye concentration data to obtain the dye concentration value after processing;

[0009] The estimation and analysis module is used to obtain the concentration estimation value of the real-time detection response time and the dye concentration control response time according to the dye concentration value after treatment and the current textile fabric printing and dyeing process parameters by using the preset prediction model;

[0010] A data processing module is used to add the estimated concentration to the deviation between the current concentration and the process target concentration, and calculate the required concentration adjustment;

[0011] The control and regulation module is used to generate control instructions according to the concentration adjustment amount, and adjust the corresponding valve opening through the control system to adjust the discharge amount of the dye.

[0012] Preferably, the method of obtaining the historical data of current textile fabric printing and dyeing, obtaining the sensor response speed and data transmission delay data in dye concentration control, generating control instructions to execute the time of adjusting dye discharge, and obtaining the real-time detection response time and dye concentration control response time by statistics, comprises the following specific steps:

[0013] Extracting historical data of current textile fabric printing and dyeing from the database, including but not limited to dye concentration records, fabric types and printing and dyeing process parameters;

[0014] Measure and record the response speed of the sensor in the current dye concentration control system and the delay time of data transmission.

[0015] Preferably, the real-time acquisition of dye concentration data detected at the current time point of the textile fabric, and filtering and concentration correction of the dye concentration data to obtain a processed dye concentration value, specifically comprises the following steps:

[0016] The sensor is used to obtain the dye concentration data of the textile fabric at the current time point in real time, and filter it to remove noise and outliers;

[0017] The dye concentration data at the current time point after filtering is corrected according to a known correction factor to obtain a processed dye concentration value.

[0018] Preferably, the concentration estimation value of the real-time detection response time and the dye concentration control response time is obtained by using a preset prediction model according to the dye concentration value after treatment and the current textile fabric printing and dyeing process parameters, and the specific steps are:

[0019] Through data statistical analysis methods, the corresponding relationship between the real-time detection response time and dye concentration control response time data in the historical data of current textile fabric printing and dyeing and the results of concentration numerical control in the process is obtained, and the corresponding relationship is used as a training set;

[0020] Select the neural network in the machine learning model as the architecture, and train it with the training set to obtain the estimation model;

[0021] Based on the dye concentration value after treatment and the current process parameters of textile fabric printing and dyeing, the time characteristics and concentration data characteristics are extracted and input into the estimation model, and the concentration estimation value of the real-time detection response time and the dye concentration control response time is output.

[0022] Preferably, the concentration estimate is added to the deviation between the current concentration and the process target concentration to calculate the required concentration adjustment, and the specific steps are:

[0023] Obtain the target concentration data in the current textile fabric printing and dyeing process, compare the dye concentration value after treatment with the process target concentration, and calculate the concentration deviation;

[0024] The obtained concentration estimate is introduced into the calculation of concentration deviation to obtain a final concentration deviation value;

[0025] The corresponding concentration adjustment amount is obtained based on the final concentration deviation value.

[0026] Preferably, the control instruction is generated according to the concentration adjustment amount, and the corresponding valve opening is adjusted by the control system to adjust the discharge amount of the dye, and the specific steps are:

[0027] Converting the concentration adjustment amount into corresponding valve opening change percentage control data, and generating corresponding valve control instructions, wherein if the concentration adjustment amount is positive, the valve opening change percentage control data is generated, and if the concentration adjustment amount is negative, the valve closing change percentage control data is generated;

[0028] The control element of the valve receives the generated valve control instruction and executes the corresponding control work to discharge the dye.

[0029] Compared with the related art, the intelligent control system for dye concentration in the textile fabric printing and dyeing process provided by the present invention has the following beneficial effects:

[0030] The present invention can ensure that the obtained dye concentration value is more accurate by acquiring the dye concentration data of the textile fabric at the current time point in real time, filtering and correcting the data, and obtaining the concentration adjustment amount by combining a preset prediction model, and can accurately calculate the amount of dye that needs to be adjusted, and generate a control instruction according to the adjustment amount to adjust the valve opening or discharge rate. Its precise control method can avoid waste and excessive use of dyes, thereby optimizing the use efficiency of dyes, helping to reduce production costs and improve economic benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1The present invention is a system block diagram of an intelligent control system for dye concentration in the textile fabric printing and dyeing process. DETAILED DESCRIPTION

[0032] The present invention will be further described below in conjunction with the accompanying drawings and implementation modes.

[0033] Embodiment 1

[0034] like Figure 1 As shown, an intelligent control system for dye concentration in the textile fabric printing and dyeing process specifically includes:

[0035] The data acquisition module is used to obtain the historical data of current textile fabric printing and dyeing, obtain the sensor response speed and data transmission delay data in dye concentration control, generate control instructions to execute the adjustment of dye discharge time, and obtain the real-time detection response time and dye concentration control response time by statistics;

[0036] In the specific implementation process, the data acquisition module is used to:

[0037] Extracting historical data of current textile fabric printing and dyeing from the database, including but not limited to dye concentration records, fabric types and printing and dyeing process parameters;

[0038] Specifically, use database query tools or write query scripts to extract historical data on current textile fabric printing and dyeing from the database, including obtaining: dye concentration records: recording the dye concentration data used in the past printing and dyeing process; fabric type: identifying the type of printed and dyed fabric, such as cotton, linen, and silk; printing and dyeing process parameters: recording various process parameters used in the printing and dyeing process, such as temperature, time, pressure, etc.

[0039] Measure and record the response speed of the sensor in the current dye concentration control system and the delay time of data transmission;

[0040] Specifically, the response speed of the sensor is measured by sending a test signal to the sensor and recording the time difference from sending the signal to the time when the sensor returns a response signal to obtain the response speed data of the sensor, and the delay time of the data transmission is obtained by recording the timestamps at the sensor end and the data processing system end respectively through identification;

[0041] In this embodiment, a test tool is used to send a test signal to the sensor, and the sending time T1 is recorded; after the sensor receives the test signal, it returns a response signal, and the return time T2 is recorded. The response speed of the sensor can be obtained by calculating T2-T1; after the control unit receives the response signal of the sensor, it will process the data and record the processing time T3; then the delay time of data transmission can be obtained by calculating T3-T2.

[0042] The data acquisition module is used to obtain the dye concentration data detected at the current time point of the textile fabric in real time, and to filter and correct the dye concentration data to obtain the dye concentration value after processing;

[0043] In the specific implementation process, the data acquisition module is used to:

[0044] The sensor is used to obtain the dye concentration data of the textile fabric at the current time point in real time, and filter it to remove noise and outliers;

[0045] Specifically, the dye concentration data of the textile fabric at the current time point is obtained in real time using a sensor installed on the printing and dyeing equipment. It should be noted that the sensor usually obtains the concentration data by direct contact with the dye solution or indirect measurement. Then, a mean filter is used to take the average value of every 5 data points as the filtered result, and the noise and outliers are removed according to the defined threshold value for filtering.

[0046] Correcting the dye concentration data at the current time point after filtering according to a known correction factor to obtain a processed dye concentration value;

[0047] Specifically, firstly, the correction factor under the current sensor and measurement conditions is obtained from the calibration record or database, and the dye concentration data after filtering is substituted into the correction factor formula for calculation to obtain the corrected dye concentration value, and finally the corrected dye concentration value is stored in the database;

[0048] In this embodiment, the correction factors k and b under the current sensor and measurement conditions are obtained from the calibration record, and the dye concentration data after filtering is substituted into the correction factor formula y=kx+b for calculation. For example, if the filtered data is 50g / L, the corrected data is y=k×50+b. Finally, the corrected dye concentration value is stored in the database and used in subsequent control and decision-making processes.

[0049] The estimation and analysis module is used to obtain the concentration estimation value of the real-time detection response time and the dye concentration control response time according to the dye concentration value after treatment and the current textile fabric printing and dyeing process parameters by using the preset prediction model;

[0050] In the specific implementation process, the estimation and analysis module is used to:

[0051] Through data statistical analysis methods, the corresponding relationship between the real-time detection response time and dye concentration control response time data in the historical data of current textile fabric printing and dyeing and the results of concentration numerical control in the process is obtained, and the corresponding relationship is used as a training set;

[0052] Specifically, historical data of current textile fabric printing and dyeing are extracted from the database, including the response time of real-time detection, the response time of dye concentration control, and the results of the concentration numerical control in the process. The collected data are cleaned to remove duplicate, erroneous or abnormal data. Then, features related to the response time and dye concentration control are extracted from the cleaned data, including timestamp, fabric type, and printing and dyeing process parameters. The corresponding relationship between the real-time detection response time and the dye concentration control response time data and the concentration numerical control results in the process is analyzed by using the correlation analysis function in the scikit-learn library in the data statistical analysis method. Finally, the corresponding relationship obtained by the analysis is used as a training set and saved as a file in a CSV or Excel format for subsequent use.

[0053] Select the neural network in the machine learning model as the architecture, and train it with the training set to obtain the estimation model;

[0054] Specifically, in this embodiment, a multilayer perceptron (MLP) is selected as the neural network architecture, the training set is input into the neural network model, the MLP model is constructed using the Keras API of TensorFlow, the input layer, two hidden layers (each hidden layer contains 100 neurons) and the output layer are defined, ReLU is used as the activation function of the hidden layer, and a linear function is used as the activation function of the output layer; then the training set is divided into input features and output targets, which are specifically the results of the numerical control of the concentration in the process, and they are converted into the TensorFlow tensor format, and finally the Model.fit method of TensorFlow is used to train the model to obtain the estimated model;

[0055] Extract the time characteristics and concentration data characteristics from the treated dye concentration value and the current textile fabric printing and dyeing process parameters and input them into the estimation model to output the concentration estimation value of the real-time detection response time and the dye concentration control response time;

[0056] Specifically, based on the dye concentration value after processing and the current process parameters of textile fabric printing and dyeing (fabric type, temperature, pressure), time-related features (timestamp, time interval) and concentration data features (dye concentration, concentration change trend) are extracted and used as input to the estimation model, and the output is the concentration estimation value of the real-time detection response time and the dye concentration control response time.

[0057] A data processing module is used to add the estimated concentration to the deviation between the current concentration and the process target concentration, and calculate the required concentration adjustment;

[0058] In the specific implementation process, the data processing module is used to:

[0059] Obtain the target concentration data in the current textile fabric printing and dyeing process, compare the dye concentration value after treatment with the process target concentration, and calculate the concentration deviation;

[0060] Specifically, the concentration value of the dye after treatment is compared with the target concentration data to calculate the concentration deviation. For example, if the target concentration data in the current textile fabric printing and dyeing process is 80%, and the concentration value of the dye after treatment is 78%, then the concentration deviation is 2% (absolute deviation) or 2.5% (relative deviation, i.e. (78-80) / 80×100%).

[0061] The obtained concentration estimate is introduced into the calculation of concentration deviation to obtain a final concentration deviation value;

[0062] Specifically, the obtained concentration estimate is fused or simply averaged with the current actually measured dye concentration value, and the fused or weighted averaged concentration estimate is compared with the target concentration data to calculate the final concentration deviation value;

[0063] For example, the concentration estimate obtained by the estimation model is 79%, while the actual measured dye concentration value is 78%. The simple average method is selected to fuse the two values, and the fused concentration estimate is 78.5%. Then, the fused concentration estimate is compared with the target concentration data 80%, and the final concentration deviation is calculated to be 1.5% (absolute deviation).

[0064] Obtaining a corresponding concentration adjustment amount based on the final concentration deviation value;

[0065] Specifically, the preset concentration adjustment strategy specifically includes setting different concentration deviation thresholds and corresponding adjustment ranges, and calculating the corresponding concentration adjustment amount according to the final concentration deviation value and the concentration adjustment strategy; in this embodiment, the formulated concentration adjustment strategy is: when the concentration deviation is greater than 2%, the dye concentration needs to be adjusted; the size of the adjustment amount is proportional to the size of the deviation;

[0066] For example, if the calculated final concentration deviation value is 1.5% (less than 2%), no adjustment is required. However, if the final concentration deviation value is greater than 2%, such as 3%, the corresponding concentration adjustment amount needs to be calculated according to the strategy.

[0067] A control and adjustment module is used to generate a control instruction according to the concentration adjustment amount, and adjust the corresponding valve opening through the control system to adjust the discharge amount of the dye;

[0068] In the specific implementation process, the control and regulation module is used to:

[0069] Converting the concentration adjustment amount into corresponding valve opening change percentage control data, and generating corresponding valve control instructions, wherein if the concentration adjustment amount is positive, the valve opening change percentage control data is generated, and if the concentration adjustment amount is negative, the valve closing change percentage control data is generated;

[0070] Specifically, the calculated concentration adjustment amount is obtained, and the operation direction of the valve is determined according to the positive or negative value of the concentration adjustment amount. If the concentration adjustment amount is judged to be positive, it means that the dye concentration needs to be increased, so the valve should be opened to increase the supply of the dye; if the concentration adjustment amount is judged to be negative, it means that the dye concentration needs to be reduced, so the valve should be closed to reduce the supply of the dye. Next, according to the data of the existing process flow, the conversion relationship between the percentage change of the valve opening and the concentration adjustment amount is determined, and then the control data of the percentage change of the valve opening is calculated according to the conversion logic and the concentration adjustment amount; the calculated control data is used to generate the corresponding valve control instruction, wherein the valve control instruction is specifically an electrical signal or a digital signal;

[0071] For example, if the concentration adjustment amount is +5% (indicating that the dye concentration needs to be increased by 5%), the system calculates the percentage change in the opening that the valve needs to open by 20%, and then generates a control instruction for opening the valve by 20%, and sends it to the control element of the valve;

[0072] The control element of the valve receives the generated valve control instruction and executes the corresponding control work to discharge the dye;

[0073] Specifically, the control element of the valve, specifically an electric actuator, a pneumatic actuator, etc., receives the valve control instruction, and the control element parses the received instruction to determine the operation direction (open or close) of the valve and the percentage of opening change. According to the instruction information obtained by the analysis, the control element of the valve performs the corresponding control work. It should be noted that the control element of the valve, etc. belongs to the prior art control and has the function of receiving and executing the control instruction, so it is not described here in detail; furthermore, the discharge of the dye is realized by controlling the valve to adjust the concentration of the dye;

[0074] For example, suppose the valve control command is to open 20%. When the control element receives this command, it will interpret the command and drive the mechanical parts of the valve to move, so that the valve gradually opens to 20%. As the valve opens, the supply of dye will gradually increase, thereby adjusting the dye concentration.

[0075] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems), and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of the processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor, or other programmable data processing device to generate a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0076] Those skilled in the art can understand that all or part of the steps in the various methods of the above embodiments can be completed by instructing related hardware through a program, and the program can be stored in a computer-readable storage medium, and the storage medium includes a read-only memory (ROM), a random access memory (RAM), a programmable read-only memory (PROM), an erasable programmable read-only memory (EPROM), a one-time programmable read-only memory (OTPROM), an electronically erasable rewritable read-only memory (EEPROM), a compact disc (CD-ROM) or other optical disc storage, magnetic disk storage, magnetic tape storage, or any other computer-readable medium that can be used to carry or store data.

[0077] It should also be noted that the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, commodity or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, commodity or device. In the absence of more restrictions, the elements defined by the sentence "comprises a ..." do not exclude the existence of other identical elements in the process, method, commodity or device including the elements.

Claims

1. An intelligent control system for dye concentration in the process of textile fabric printing and dyeing, characterized in that: The control system comprises: The data acquisition module is used to obtain the historical data of current textile fabric printing and dyeing, obtain the sensor response speed time in dye concentration control, the delay time of data transmission, and the time to generate control instructions to execute the adjustment of dye discharge, and obtain the real-time detection response time and dye concentration control response time by statistics; The data acquisition module is used to obtain the dye concentration data detected at the current time point of the textile fabric in real time, and to filter and correct the dye concentration data to obtain the dye concentration value after processing; The estimation and analysis module is used to obtain the concentration estimation value of the real-time detection response time and the dye concentration control response time according to the dye concentration value after treatment and the current textile fabric printing and dyeing process parameters by using the preset prediction model; A data processing module is used to add the estimated concentration to the deviation between the current concentration and the process target concentration, and calculate the required concentration adjustment; The control and regulation module is used to generate control instructions according to the concentration adjustment amount, and adjust the corresponding valve opening through the control system to adjust the discharge amount of the dye.

2. The intelligent control system for dye concentration in the textile fabric printing and dyeing process according to claim 1 is characterized in that: The specific steps of obtaining the historical data of current textile fabric printing and dyeing, obtaining the sensor response speed time, data transmission delay time and the time for generating control instructions to execute the adjustment of dye discharge in dye concentration control, and obtaining the real-time detection response time and dye concentration control response time by statistics are as follows: Extracting historical data of current textile fabric printing and dyeing from the database, including but not limited to dye concentration records, fabric types and printing and dyeing process parameters; Measure and record the response speed of the sensor in the current dye concentration control system and the delay time of data transmission.

3. The intelligent control system for dye concentration in the textile fabric printing and dyeing process according to claim 1 is characterized in that: The real-time acquisition of dye concentration data detected at the current time point of the textile fabric, and filtering and concentration correction of the dye concentration data to obtain a processed dye concentration value, the specific steps are: The sensor is used to obtain the dye concentration data of the textile fabric at the current time point in real time, and filter it to remove noise and outliers; The dye concentration data at the current time point after filtering is corrected according to a known correction factor to obtain a processed dye concentration value.

4. The intelligent control system for dye concentration in the textile fabric printing and dyeing process according to claim 1 is characterized in that: The method uses a preset prediction model to obtain a concentration estimate of a real-time detection response time and a dye concentration control response time based on the processed dye concentration value and the current textile fabric printing and dyeing process parameters, and the specific steps are as follows: Through data statistical analysis methods, the corresponding relationship between the real-time detection response time and dye concentration control response time data in the historical data of current textile fabric printing and dyeing and the results of concentration numerical control in the process is obtained, and the corresponding relationship is used as a training set; Select the neural network in the machine learning model as the architecture, and train it with the training set to obtain the estimation model; Based on the dye concentration value after treatment and the current process parameters of textile fabric printing and dyeing, the time characteristics and concentration data characteristics are extracted and input into the estimation model, and the concentration estimation value of the real-time detection response time and the dye concentration control response time is output.

5. The intelligent control system for dye concentration in the textile fabric printing and dyeing process according to claim 1 is characterized in that: The concentration estimate is added to the deviation between the current concentration and the process target concentration to calculate the required concentration adjustment amount, and the specific steps are as follows: Obtain the target concentration data in the current textile fabric printing and dyeing process, compare the dye concentration value after treatment with the process target concentration, and calculate the concentration deviation; The obtained concentration estimate is introduced into the calculation of concentration deviation to obtain a final concentration deviation value; The corresponding concentration adjustment amount is obtained based on the final concentration deviation value.

6. The intelligent control system for dye concentration in the textile fabric printing and dyeing process according to claim 1 is characterized in that: The control command is generated according to the concentration adjustment amount, and the corresponding valve opening is adjusted through the control system to adjust the discharge amount of the dye. The specific steps are: Converting the concentration adjustment amount into corresponding valve opening change percentage control data, and generating corresponding valve control instructions, wherein if the concentration adjustment amount is positive, the valve opening change percentage control data is generated, and if the concentration adjustment amount is negative, the valve closing change percentage control data is generated; The control element of the valve receives the generated valve control instruction and executes the corresponding control work to discharge the dye.

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