Multi-layer fabric opening control system and method

Abstract

The invention discloses a multi-layer fabric opening control system and method. The system comprises a multi-layer fabric opening control device, an opening carding and transfer control device and an integrated control unit, the motion law of a heald frame is determined by establishing a multi-layer opening formula database, and a high-precision grating ruler, a strip-shaped photoelectric sensor and the like are combined. According to the method, the integrated control unit is used for accurately controlling automatic opening, opening definition recognition, accurate layering and long-distance yarn low-damage opening transmission of the multi-layer fabric opening control device and the opening carding and transmission control device. The invention provides a flexible and quick-response formula control method which is more suitable for quick development of diversified three-dimensional fabrics, and through X-Y-axis bidirectional synchronous motion control, yarn thrust borne by a carding rod in the opening transfer process is detected in real time in combination with a shaft type pressure sensor, a low-damage yarn automatic opening transfer method is established, and the production efficiency is improved. And the technical barrier of continuous automatic preparation of the multi-layer three-dimensional woven fabric is broken.

Description

Technical Field

[0001] The present invention belongs to the field of textile technology, and in particular to a multi-layer fabric opening control system and method. Background Art

[0002] Multi-layer three-dimensional woven fabrics have the characteristics of flexible structural design and short production cycle, and have excellent properties such as wave transmission and heat resistance. They are now widely used in new energy, aerospace and other fields, and their demand is growing. The existing multi-layer three-dimensional woven fabric forming equipment has the problem of long multi-layer heald frame opening transmission distance and narrow opening channel space. Manual assisted opening transmission is required to meet the weft insertion requirements, resulting in the inability to meet the automatic continuous forming of multi-layer high-thickness three-dimensional woven fabrics, resulting in low fabric preparation efficiency; at present, multi-layer three-dimensional woven fabrics are developing in the direction of high thickness and complex structure, which makes the opening movement rules of multiple heald frame combinations gradually increase, and the original traditional fixed movement mode is difficult to adapt to market demand.

[0003] The invention patent with patent number 202311852371.8 discloses a loom control method, a loom control cabinet and a loom. By obtaining user setting information, according to the process control library, the process control information corresponding to the user setting information is obtained, and the movement of each heald frame is driven separately according to the opening control information, and the motion state information of the opening mechanism is detected in real time. The adaptive learning model is used to obtain the process adjustment information according to the motion state information, and the motion state of each heald frame is adjusted according to the opening adjustment information. The problem of inconvenience and production efficiency of single-eye heald close-range single-layer opening when changing fabric patterns or fabric types is solved. However, when multi-eye healds are opened in multi-layer high-thickness three-dimensional woven fabrics, multi-layer long-distance openings will be formed. The existing technology cannot realize multi-layer long-distance diversified openings, automatic combing and transmission, and it is difficult to meet the needs of automatic continuous forming of multi-layer high-thickness three-dimensional woven fabrics.

[0004] The existing technology cannot realize the layering, combing, transfer and diversified opening movement rules of multiple heald frames in the preparation process of multi-layer three-dimensional woven fabrics. Therefore, it is necessary to propose a multi-layer fabric opening control system and method, and use the opening formula design to realize the automatic opening, combing and transfer of the diversified opening movement rules of the multi-layer three-dimensional woven fabrics to ensure the quality and efficiency of product preparation. Summary of the invention

[0005] The purpose of the present invention is to solve the problems raised in the background technology, to provide a multi-layer fabric opening control system and method, to establish an opening formula database for diversified multi-layer fabrics, to automatically realize precise layering, combing, and long-distance yarn low-damage opening transmission of each layer, and to meet the requirements of continuous and automated forming of diversified multi-layer three-dimensional woven fabrics.

[0006] In order to achieve the purpose of the present invention, the present invention discloses a multi-layer fabric opening control system, including a multi-layer fabric opening control device, an opening combing and transfer control device, and an integrated control unit;

[0007] The multi-layer fabric opening control device comprises a number of heald frames greater than or equal to two, a servo motor, and a photoelectric position sensor; the number of the servo motors is equal to the number of the heald frames, that is, the lifting and lowering movement of each heald frame is controlled by a different servo motor to achieve multi-layer opening;

[0008] The opening combing and transfer control device comprises a left lifting mechanism, a right lifting mechanism, a combing rod advance and retreat mechanism, a locking mechanism, a left horizontal advance and retreat mechanism, and a right horizontal advance and retreat mechanism, and all are driven and controlled by a servo motor; wherein the left lifting mechanism is used to control the movement height of the combing rod advance and retreat mechanism, and the right lifting mechanism is used to control the movement height of the locking mechanism, the combing rod advance and retreat mechanism is used to enter the opening layer by layer, and the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism are used to transfer the combing rod advance and retreat mechanism that has entered the opening area and is in a locked state to the cloth fell position;

[0009] The integrated control unit includes an integrated motion controller, an analog input module, a digital input and output module, a servo drive controller, and a host computer; the integrated motion controller establishes communication connections with the multi-layer fabric opening control device, the opening combing control device, and the opening transfer control device through the EtherCAT industrial bus; and establishes a connection with the host computer through Ethernet communication to achieve automatic opening and transfer according to product input requirements, thereby meeting the preparation requirements of the subsequent processes.

[0010] Furthermore, each heald frame in the multi-layer fabric opening control device uses three photoelectric position sensors to detect the position status of the three key movement positions of the upper, middle and lower heald frames in real time, that is, the number of photoelectric position sensors is three times the number of heald frames.

[0011] Furthermore, the left lifting mechanism and the right lifting mechanism in the open combing and transfer control device have two movement modes: independent and synchronous. In the independent mode, the left lifting mechanism and the right lifting mechanism can move independently, respectively, to adjust or calibrate the vertical movement position of the combing rod advance and retreat mechanism and the locking mechanism. In the synchronous mode, the left lifting mechanism is the lifting main shaft, and the right lifting mechanism is the lifting slave shaft, and a synchronous interpolation relationship is established to ensure the stable lifting of the combing rod movement mechanism.

[0012] The left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism in the open combing and transmission control device have two motion modes: independent and synchronous. In the independent mode, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism can move independently, which is used to adjust or calibrate the horizontal movement position of the combing rod advance and retreat mechanism and the locking mechanism; in the synchronous mode, the left horizontal advance and retreat mechanism is the horizontal main axis, and the right horizontal advance and retreat mechanism is the horizontal slave axis, establishing a synchronous interpolation relationship to ensure the stable transmission of the combing rod motion mechanism.

[0013] Furthermore, the left lifting mechanism and the right lifting mechanism respectively adopt high-precision grating rulers to detect in real time and feed back the position information of the left lifting mechanism and the right lifting mechanism to the integrated control unit. The integrated control unit accurately controls the positioning of the left lifting mechanism and the right lifting mechanism in a closed loop.

[0014] Furthermore, a strip photoelectric sensor is provided at the top of the combing rod advance and retreat mechanism to detect in real time the clarity of the opening channel in the vertical 1 to 60 mm and horizontal 10 to 60 mm area in the forward direction of the combing rod; the locking mechanism adopts an electric cylinder for locking, and a magnetic position sensor is installed on the electric cylinder to detect in real time the docking status of the combing rod advance and retreat mechanism and the locking mechanism.

[0015] Furthermore, an axial pressure sensor is embedded inside the combing rod advance and retreat mechanism to detect the thrust of the combing rod during the opening transmission process in real time; the integrated control unit is connected to the axial pressure sensor through an analog input module, and by comparing the actual combing rod thrust during the opening transmission process with the theoretical value, the position of the left and right lifting mechanisms is synchronously closed-loop controlled.

[0016] Furthermore, the host computer in the integrated control unit establishes a multi-layer fabric opening formula database for storing different movement rules of the heald frame opening; the multi-layer fabric opening formula database establishes an association with the internal digital quantity of the integrated motion controller through the internal register, realizes the movement of multiple heald frames with different opening formulas, and meets the requirements of multi-layer fabric diversity opening control.

[0017] Furthermore, the integrated motion controller in the integrated control unit adopts a digital input module to connect with the photoelectric position sensor of the heald frame, the strip photoelectric sensor of the combing rod advance and retreat mechanism, and the magnetic position sensor of the locking mechanism, so as to detect in real time the movement of each heald frame into position, the clear opening status, and the locking status information of the combing rod.

[0018] Furthermore, the integrated motion controller in the integrated control unit is connected to the axial pressure sensor and two high-precision grating rulers through the analog input module to detect the thrust of the combing rod and the displacement of the lifting mechanism during the opening transfer process in real time.

[0019] In order to achieve the purpose of the present invention, the present invention also discloses a multi-layer fabric opening control method, comprising the following steps:

[0020] Step 1, setting parameters; according to the fabric structure parameters, set the opening transfer distance L, the total number of fabric layers N, the total distance S of the forward and backward movement of the carding rod, the step angle of the locking mechanism, the lifting and lowering micro-step distance Δh, the single-layer thickness of the fabric h, the number of carding rod lifting and lowering adjustments m, the heald eyelet offset spacing Δs, the single-layer yarn thrust F0 and the movement speed of each mechanism and other parameters;

[0021] Step 2, determine the initial position of the mechanism; in the independent mode, move the left lifting mechanism, the right lifting mechanism, the left horizontal advance and retreat mechanism, the right horizontal advance and retreat mechanism, the carding rod advance and retreat mechanism, and the locking mechanism to the initial position and set them to zero point;

[0022] Step 3, setting the opening motion formula; according to the structural requirements of the fabric, determine the opening motion formula of the heald frame, and retrieve the opening formula database of the multi-layer fabric established by the host computer. If such a formula already exists, it is directly called; otherwise, a new opening motion formula of the heald frame is created and stored in the opening formula database as a new record to facilitate the need for rapid calling of the opening motion formula of the subsequent fabric; each heald frame opening motion formula is digitally associated with the integrated motion controller to control the motion laws of different heald frames to meet the diversified opening requirements of multi-layer fabrics;

[0023] Step 4, establish the lifting synchronization relationship; in the synchronization mode, establish the left lifting mechanism and the right lifting mechanism synchronization interpolation relationship, the synchronization coupling coefficient k1 is as follows:

[0024]

[0025] Among them, a1 is the direction coefficient. When a1=-1, the left lifting mechanism and the right lifting mechanism are synchronized in the reverse direction; when a1=1, the left lifting mechanism and the right lifting mechanism are synchronized in the forward direction; D1 is the position parameter of the left lifting mechanism; D2 is the position parameter of the right lifting mechanism;

[0026] Step 5, establish a horizontal advance and retreat synchronization relationship; in the synchronization mode, establish a synchronous interpolation relationship between the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism, and the synchronization coupling coefficient k2 is as follows:

[0027]

[0028] Among them, a2 is the direction coefficient. When a2=-1, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism are synchronized in the reverse direction; when a2=1, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism are synchronized in the forward direction; D3 is the position parameter of the left horizontal advance and retreat mechanism; D4 is the position parameter of the right horizontal advance and retreat mechanism;

[0029] Step 6: Multiple heald frames move to form multi-layer openings; the integrated motion controller controls the servo motor movement of each heald frame according to the set opening motion formula until the photoelectric position sensor detects in real time that each heald frame has completed the movement, and then stops the servo motor movement of the heald frame;

[0030] Step 7: Open and comb the layers, as follows:

[0031] The lifting mechanism moves synchronously; the integrated motion controller controls the servo motors of the left and right lifting mechanisms to move synchronously to the theoretical height H of the center of the i-th layer opening. i , the initial value of i is During the movement, two high-precision grating rulers detect the position H' of the left and right lifting mechanisms in real time iL , H' iR , to control the position H' of the lifting mechanism on the right side of the slave axis in a closed loop iR The position of the lifting mechanism on the left side of the spindle is H' iL The deviation is less than ±0.5mm, ensuring that the positions of the left and right lifting mechanisms match; at the same time, the integrated motion controller real-time adjusts the position H' of the left lifting mechanism of the spindle iL Theoretical height H from the center of the opening of the i-th layer i Compare and adjust the left and right servo motors to move synchronously to ensure that the position of the lifting mechanism is within the range of ±0.5mm from the theoretical deviation value ΔH;

[0032]

[0033] The carding rods move forward in different areas; the left and right lifting mechanisms move to the theoretical height H of the center of the i-th layer opening. i After that, the integrated motion controller divides the fabric into n1 areas along the width direction, and detects the clear opening state in each area in turn through the strip photoelectric sensor. If there is no yarn obstruction and the opening is clear in this area, the combing rod is controlled to enter the opening channel and accurately positioned to j×S'(j∈[1,m1]); at the same time, the integrated motion controller judges the clear opening state of the next area in advance near j×S'. If the channel is clear, the combing rod continues to run to (j+1)×S' until the positioning is completed to S. The magnetic position sensor of the locking mechanism detects the in-place state of the combing rod, drives the locking mechanism to complete the locking of the combing rod, and realizes the docking of the combing rod advance and retreat mechanism and the locking mechanism; if the yarn is blocked and the opening is unclear during the forward process of the combing rod, the combing rod and the locking mechanism are controlled to be fine-tuned one by one according to the set lifting and lowering adjustment times m and the small step distance Δh to try to complete the layered combing; if the lifting and lowering adjustment times m are exceeded and there is still yarn obstruction, the abnormal opening warning at the current area j is output, and the combing rod advance and retreat mechanism stops moving, and moves again after confirmation by the host computer;

[0034]

[0035] Where S' is the distance of the carding rod partition step, and n1 is the number of times the carding rod segment runs;

[0036] Step 8, opening transfer; for the N openings formed after opening, the single-layer fabric thickness h, take the N / 2 heald eyes of the first heald frame as the origin, establish the xy axis with the first heald frame as the reference, the x axis represents the horizontal advance and retreat distance during the opening transfer process, the y axis represents the movement distance of the lifting mechanism during the opening transfer process, and the axial pressure sensor detects the yarn thrust F exerted on the combing rod in real time during the opening transfer process i , single-layer yarn thrust F0, correction coefficient α to prevent yarn wear during opening transfer, α∈[0.1~2], the horizontal forward and backward movement distance x of the left side of the main shaft during the carding rod's layer-by-layer transfer to the fabric fell, and the movement distance y of the lifting mechanism on the left side of the main shaft are as follows:

[0037]

[0038] When the combing rod is transferred to the cloth fell position, the opening transfer is completed, and the integrated motion controller controls the execution of the next weft insertion process. When the next process is completed, the i-th layer opening transfer completion signal is output, and the locking mechanism is controlled to return to its position, and the combing rod advance and retreat mechanism automatically returns to the initial position;

[0039] Step 9: Next layer of opening combing and transfer judgment; if Then i plus 1, the integrated motion controller controls the left and right lifting mechanisms to move synchronously to the theoretical height H of the center of the i-th layer opening i , at the same time, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism move synchronously to zero position, and execute steps 7 and 8 in a loop; if Then all the layers of this multi-layer opening movement are combed, and the integrated motion controller controls the locking mechanism to return, and the carding rod advance and retreat mechanism automatically returns to the initial position, and then controls the left and right lifting mechanisms and the left and right horizontal advance and retreat mechanisms to synchronously retreat to the initial position; if the fabric is not prepared, it enters the next heald frame opening movement, and executes steps 6 to 9 in a loop until the fabric is prepared.

[0040] Compared with the prior art, the significant progress of the present invention is that: 1) relative to the traditional opening method, it provides a flexible and fast-response formula control method, which is more suitable for the rapid development of diversified three-dimensional fabrics; 2) for the left and right lifting mechanisms, a servo synchronous positioning, strip photoelectric switch, and high-precision grating scale combined control method are adopted to automatically identify the opening clarity and accurately position the closed-loop control mechanism, thereby realizing high-precision stratification and combing functions of the opening; 3) through XY axis bidirectional synchronous motion control, combined with axial pressure sensors to detect the yarn thrust exerted on the combing rod during the opening transfer process in real time, an automatic opening transfer method for low-damage yarns is established, breaking the technical barriers to the continuous automatic preparation of multi-layer three-dimensional woven fabrics.

[0041] In order to more clearly illustrate the functional characteristics and structural parameters of the present invention, further description is given below in conjunction with the accompanying drawings and specific implementation methods. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0043] Figure 1 This is a structural diagram of a multi-layer fabric opening control system of the present invention;

[0044] Figure 2 This is a schematic diagram of the hardware structure of a multi-layer fabric opening control system of the present invention;

[0045] Figure 3 A schematic diagram of a multi-layer fabric opening transfer coordinate system established by the present invention;

[0046] Figure 4 The present invention is a multi-layer fabric opening control flow chart. DETAILED DESCRIPTION

[0047] The technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments; based on the embodiments 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.

[0048] Combination Figure 1 , a multi-layer fabric opening control system, comprising a multi-layer fabric opening control device, an opening combing and transfer control device, wherein the multi-layer fabric opening control device is the premise and basis of the opening combing and transfer control device;

[0049] A control system for multi-layer fabric opening, the opening combing and transfer control device is composed of a left lifting mechanism, a right lifting mechanism, a combing rod advance and retreat mechanism, and a locking mechanism. The spatial position analysis completes the accurate identification of the opening position of the multi-layer fabric; according to the shaft pressure sensor, the target cloth opening height, and the opening transfer distance, the linear interpolation relationship between the opening combing and the opening transfer control device is established to realize the opening transfer layer by layer;

[0050] The integrated motion control unit uses Delta's integrated motion controller DVP-50MC as the CPU, supports multi-servo multi-mode synchronous motion, supports Ethernet and EtherCAT fieldbus communications, and expands 2 analog input and output modules DVP06XA-S;

[0051] The multi-layer fabric opening control device uses Delta's servo driver ASD-A2-0721-E that supports EtherCAT communication and the servo motor ECMA-CA0807SS with an absolute encoder to control the mutual movement of multiple heald frames to achieve the multi-layer fabric opening process requirements;

[0052] The opening combing uses Delta's servo driver ASD-A2-0421-E that supports EtherCAT communication and the servo motor ECMA-CA0604SS with an absolute encoder to control the left and right lifting mechanisms to complete the opening position identification layer by layer;

[0053] The carding rod advance and retreat mechanism uses Delta's servo driver ASD-A2-0421-E that supports EtherCAT communication and the servo motor ECMA-CA0604SS with an absolute encoder to control the carding rod advance and retreat mechanism to complete the position identification of the opening channel layer by layer;

[0054] The locking mechanism uses Delta's servo driver ASD-A2-0221-E that supports EtherCAT communication and a servo motor ECMA-CA0602SS with an absolute encoder to control the movement of the locking mechanism, provide torque and displacement modes, and achieve locking with the carding rod advance and retreat mechanism;

[0055] The opening transfer uses Delta's servo driver ASD-A2-0721-E that supports EtherCAT communication and the servo motor ECMA-CA0807SS with an absolute encoder to control the linear interpolation movement of the left horizontal advance and retreat mechanism and the left lifting mechanism to achieve rapid opening transfer layer by layer;

[0056] The axial pressure sensor selected is Jinnuo JHBT-H series with a detection range of 0 to 5KN. The strip photoelectric sensor uses Kingence DK-D561 with an adjustable detection range that meets the requirements of vertical 1 to 100mm and horizontal 10 to 100mm. The photoelectric position sensor uses Omron E3FA-D21, the magnetic position sensor uses Taibang TBAL-39R, and the grating ruler uses Xinhe KA600-2000 with a detection range of 0-2000mm. The detection signal is transmitted to the integrated motion controller DVP-50MC through the digital input module DVP-16SM11N and the analog module DVP06XA-S, realizing the functions of clear real-time detection of combing thrust, opening height and opening channel, and position closed-loop control.

[0057] The integrated motion controller DVP-50MC establishes the longitudinal synchronous interpolation relationship between the left and right lifting mechanisms of the open combing and transfer control device. Taking the left lifting mechanism as the main axis and the right lifting mechanism as the slave axis, four-piece heald frame bent fabric is taken as an example. Figure 2 , 3 4. This example also provides a multi-layer fabric opening control method, the specific steps are as follows:

[0058] Step 1, parameter setting: according to the fabric structure parameters, set the opening transfer distance L, the total number of fabric layers N, the total distance S of the forward and backward movement of the carding rod, the step angle of the locking mechanism, the lifting micro-step distance Δh, the single-layer thickness of the fabric h, the number of carding rod lifting and lowering adjustments m, the heald eyelet offset spacing Δs, the single-layer yarn thrust F0 and the movement speed of each mechanism and other parameters;

[0059] Step 2, determining the initial position of the mechanism: in the independent mode, the left lifting mechanism, the right lifting mechanism, the left horizontal advance and retreat mechanism, the right horizontal advance and retreat mechanism, the carding rod advance and retreat mechanism, and the locking mechanism are moved to the initial position and set to zero point;

[0060] Step 3, setting the opening motion formula: according to the structural requirements of the fabric, determine the opening motion formula of the heald frame, and retrieve the opening formula database of the multi-layer fabric established by the host computer. If such a formula already exists, it is directly called; otherwise, a new opening motion formula of the heald frame is created and stored in the opening formula database as a new record, so as to meet the needs of the subsequent fabric to quickly call the opening motion formula; each of the heald frame opening motion formulas is digitally associated with the integrated motion controller to control the motion laws of different heald frames and meet the diversified opening requirements of the multi-layer fabric;

[0061] Step 4: Establishing the lifting synchronization relationship: In the synchronization mode, establish the synchronous interpolation relationship between the left lifting mechanism and the right lifting mechanism, and the synchronous coupling coefficient k1 is as follows:

[0062]

[0063] Among them, a1 is the directional coefficient. When a1=-1, the left lifting mechanism and the right lifting mechanism are synchronized in the reverse direction; when a1=1, the left lifting mechanism and the right lifting mechanism are synchronized in the forward direction; D1 is the position parameter of the left lifting mechanism; D2 is the position parameter of the right lifting mechanism.

[0064] Step 5, establishing the horizontal advance and retreat synchronization relationship: In the synchronization mode, establish the synchronous interpolation relationship between the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism, and the synchronous coupling coefficient k2 is as follows:

[0065]

[0066] Among them, a2 is the directional coefficient. When a2=-1, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism are synchronized in the reverse direction; when a2=1, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism are synchronized in the forward direction; D3 is the position parameter of the left horizontal advance and retreat mechanism; D4 is the position parameter of the right horizontal advance and retreat mechanism.

[0067] Step 6: Multiple heald frames move to form multi-layer openings: the integrated motion controller controls the servo motor movement of each heald frame according to the set opening motion formula until the photoelectric position sensor detects in real time that each heald frame has completed the movement, and then stops the servo motor movement of the heald frame;

[0068] Step 7: Open and comb the layers, as follows:

[0069] (1) Synchronous lifting movement of the lifting mechanism: The integrated motion controller controls the servo motors of the left and right lifting mechanisms to move synchronously to the theoretical height H of the center of the i-th layer opening. i , the initial value of i is During the movement, two high-precision grating rulers detect the position H' of the left and right lifting mechanisms in real time iL , H' iR , to control the position H' of the lifting mechanism on the right side of the slave axis in a closed loop iR The position of the lifting mechanism on the left side of the spindle is H' iL The deviation is less than ±0.5mm, ensuring that the positions of the left and right lifting mechanisms match; at the same time, the integrated motion controller real-time adjusts the position H' of the left lifting mechanism of the spindle iL Theoretical height H from the center of the opening of the i-th layer i Compare and adjust the left and right servo motors to move synchronously to ensure that the position of the lifting mechanism is within the range of ±0.5mm from the theoretical deviation value ΔH;

[0070]

[0071] (2) The combing rods move forward in different areas: the left and right lifting mechanisms move to the theoretical height H of the center of the i-th layer opening iAfter that, the integrated motion controller divides the fabric into n1 areas along the width direction, and detects the clear opening state in each area in turn through the strip photoelectric sensor. If there is no yarn obstruction and the opening is clear in this area, the combing rod is controlled to enter the opening channel and accurately positioned to j×S'(j∈[1,n1]); at the same time, the integrated motion controller judges the clear opening state in the next area in advance near j×S'. If the channel is clear, the combing rod continues to run to (j+1)×S' until the positioning is completed to S, and the magnetic position sensor of the locking mechanism detects the in-place state of the combing rod, drives the locking mechanism to complete the locking of the combing rod, and realizes the docking of the combing rod advance and retreat mechanism and the locking mechanism; if the yarn is blocked and the opening is unclear during the forward process of the combing rod, the combing rod and the locking mechanism are controlled to be fine-tuned one by one according to the set lifting and lowering adjustment times m and the small step distance Δh to try to complete the layered combing; if the lifting and lowering adjustment times m are exceeded and there is still yarn obstruction, an abnormal opening warning at the current area j is output, and the combing rod advance and retreat mechanism stops moving, and moves again after confirmation by the host computer;

[0072]

[0073] Where S' is the distance of the carding rod partition step, and n1 is the number of times the carding rod segment runs;

[0074] Step 8, opening transfer: for the N openings formed after opening, the single-layer fabric thickness h, take the N / 2 heald eyes of the first heald frame as the origin, establish the xy axis with the first heald frame as the reference, the x axis represents the horizontal advance and retreat distance during the opening transfer process, the y axis represents the movement distance of the lifting mechanism during the opening transfer process, and the axial pressure sensor detects the yarn thrust F on the combing rod in real time during the opening transfer process i , single-layer yarn thrust F0, correction coefficient α to prevent yarn wear during opening transfer, α∈[0.1~2], the horizontal forward and backward movement distance x of the left side of the main shaft during the carding rod's layer-by-layer transfer to the fabric fell, and the movement distance y of the lifting mechanism on the left side of the main shaft are as follows:

[0075]

[0076] When the combing rod is transferred to the cloth fell position, the opening transfer is completed, and the integrated motion controller controls the execution of the next weft insertion process. When the next process is completed, the i-th layer opening transfer completion signal is output, and the locking mechanism is controlled to return to its position, and the combing rod advance and retreat mechanism automatically returns to the initial position;

[0077] Step 9: Next layer of opening combing and transfer judgment: If Then i is increased by 1, and the integrated motion controller controls the left and right lifting mechanisms to move synchronously to the theoretical height H of the center of the i-th layer opening. i, at the same time, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism move synchronously to zero position, and steps 7 and 8 are executed cyclically; if Then, all layers of this multi-layer opening movement are combed, and the integrated motion controller controls the locking mechanism to return and the combing rod advance and retreat mechanism to automatically return to the initial position, and then controls the left and right lifting mechanisms and the left and right horizontal advance and retreat mechanisms to synchronously retreat to the initial position; if the fabric is not prepared, enter the next heald frame opening movement, and repeat steps 6 to 9 until the fabric is prepared.

[0078] The multi-layer fabric opening control system and method of the present invention provide a flexible and fast-response multi-layer fabric opening control method relative to the auxiliary opening in the three-dimensional fabric preparation process, which is more suitable for the rapid preparation of three-dimensional woven fabrics of multiple varieties and small batches; multi-mode synchronous detection methods such as displacement sensors and axial pressure sensors are used to achieve yarn thrust / displacement control during the multi-layer fabric opening transmission process, ensuring the stability of the fabric opening during the preparation process and meeting product quality requirements; the use of the multi-layer fabric opening control system and method can meet the preparation requirements of three-dimensional fabric molding and provide technical support for the development of diversity in three-dimensional weaving.

[0079] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article 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, article or device.

[0080] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A multi-layer fabric opening control system, characterized in that: It includes a multi-layer fabric opening control device, an opening combing and transfer control device, and an integrated control unit; The multi-layer fabric opening control device comprises a number of heald frames greater than or equal to two, a servo motor, and a photoelectric position sensor; the number of the servo motors is equal to the number of the heald frames, that is, the lifting and lowering movement of each heald frame is controlled by a different servo motor to achieve multi-layer opening; The opening combing and transfer control device comprises a left lifting mechanism, a right lifting mechanism, a combing rod advance and retreat mechanism, a locking mechanism, a left horizontal advance and retreat mechanism, and a right horizontal advance and retreat mechanism, and all are driven and controlled by a servo motor; wherein the left lifting mechanism is used to control the movement height of the combing rod advance and retreat mechanism, and the right lifting mechanism is used to control the movement height of the locking mechanism, the combing rod advance and retreat mechanism is used to enter the opening layer by layer, and the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism are used to transfer the combing rod advance and retreat mechanism that has entered the opening area and is in a locked state to the cloth fell position; The integrated control unit includes an integrated motion controller, an analog input module, a digital input and output module, a servo drive controller, and a host computer; the integrated motion controller establishes a communication connection with a multi-layer fabric opening control device, an opening combing control device, and an opening transfer control device via the EtherCAT industrial bus; and establishes a connection with the host computer via Ethernet communication to achieve automatic opening and transfer according to product input requirements, thereby meeting the preparation requirements of the subsequent process.

2. A multi-layer fabric opening control system according to claim 1, characterized in that: Each heald frame in the multi-layer fabric opening control device uses three photoelectric position sensors to detect the in-place status of the three key movement positions of the upper, middle and lower heald frames in real time, that is, the number of the photoelectric position sensors is three times the number of the heald frames.

3. A multi-layer fabric opening control system according to claim 1, characterized in that: The left lifting mechanism and the right lifting mechanism in the open combing and transfer control device have two movement modes: independent and synchronous. In the independent mode, the left lifting mechanism and the right lifting mechanism can move independently, respectively, to adjust or calibrate the vertical movement position of the combing rod advance and retreat mechanism and the locking mechanism. In the synchronous mode, the left lifting mechanism is the lifting main shaft, and the right lifting mechanism is the lifting slave shaft, and a synchronous interpolation relationship is established to ensure the stable lifting of the combing rod movement mechanism. The left-side horizontal advance and retreat mechanism and the right-side horizontal advance and retreat mechanism in the open combing and transfer control device have two movement modes: independent and synchronous. In the independent mode, the left-side horizontal advance and retreat mechanism and the right-side horizontal advance and retreat mechanism can move independently, respectively, to adjust or calibrate the horizontal movement position of the combing rod advance and retreat mechanism and the locking mechanism; in the synchronous mode, the left-side horizontal advance and retreat mechanism is the horizontal main axis, and the right-side horizontal advance and retreat mechanism is the horizontal slave axis, to establish a synchronous interpolation relationship, to ensure that the combing rod movement mechanism can stably transfer the movement.

4. A multi-layer fabric opening control system according to claim 3, characterized in that: The left lifting mechanism and the right lifting mechanism respectively adopt high-precision grating rulers to detect in real time and feed back the position information of the left lifting mechanism and the right lifting mechanism to the integrated control unit. The integrated control unit accurately controls the positioning of the left lifting mechanism and the right lifting mechanism in a closed loop.

5. A multi-layer fabric opening control system according to claim 3, characterized in that: A strip photoelectric sensor is provided at the top of the combing rod advance and retreat mechanism to detect in real time the clear state of the opening channel in the vertical 1 to 60 mm and horizontal 10 to 60 mm area in the forward direction of the combing rod; the locking mechanism adopts an electric cylinder for locking, and a magnetic position sensor is installed on the electric cylinder to detect in real time the docking state of the combing rod advance and retreat mechanism and the locking mechanism.

6. A multi-layer fabric opening control system according to claim 3, characterized in that: An axial pressure sensor is embedded inside the combing rod advance and retreat mechanism to detect the thrust of the combing rod in real time during the opening transfer process; the integrated control unit is connected to the axial pressure sensor through an analog input module, and by comparing the actual combing rod thrust during the opening transfer process with the theoretical value, the positions of the left and right lifting mechanisms are synchronously closed-loop controlled.

7. The multi-layer fabric opening control system according to claim 1, characterized in that: The host computer in the integrated control unit establishes a multi-layer fabric opening formula database for storing different movement rules of the heald frame opening; the multi-layer fabric opening formula database establishes an association with the internal digital quantity of the integrated motion controller through the internal register, realizes the movement of different opening formulas of multiple heald frames, and meets the diversified opening control requirements of multi-layer fabrics.

8. The multi-layer fabric opening control system according to claim 1, characterized in that: The integrated motion controller in the integrated control unit adopts a digital input module to be connected with the photoelectric position sensor of the heald frame, the strip photoelectric sensor of the carding rod advance and retreat mechanism, and the magnetic position sensor of the locking mechanism, so as to detect the movement of each heald frame into place, the clear opening state, and the locking state information of the carding rod in real time.

9. The multi-layer fabric opening control system according to claim 1, characterized in that: The integrated motion controller in the integrated control unit is connected to the shaft pressure sensor and two high-precision grating rulers through an analog input module to detect the thrust of the combing rod and the displacement of the lifting mechanism during the opening transmission process in real time.

10. A multi-layer fabric opening control method, the method is based on a multi-layer fabric opening control system according to any one of claims 1 to 9, characterized in that: The steps include: Step 1, setting parameters; according to the fabric structure parameters, set the opening transfer distance L, the total number of fabric layers N, the total distance S of the forward and backward movement of the carding rod, the step angle of the locking mechanism, the lifting and lowering micro-step distance Δh, the single-layer thickness of the fabric h, the number of carding rod lifting and lowering adjustments m, the heald eyelet offset spacing Δs, the single-layer yarn thrust F0 and the movement speed parameters of each mechanism; Step 2, determine the initial position of the mechanism; in the independent mode, move the left lifting mechanism, the right lifting mechanism, the left horizontal advance and retreat mechanism, the right horizontal advance and retreat mechanism, the carding rod advance and retreat mechanism, and the locking mechanism to the initial position and set them to zero point; Step 3, setting the opening movement formula: according to the structural requirements of the fabric, determine the opening movement formula of the heald frame, and retrieve the opening formula database of the multi-layer fabric established by the host computer. If such a formula already exists, it is directly called; Otherwise, a new heald frame shedding motion formula is created and stored as a new record in the shedding formula database to facilitate the need for quick call of the shedding motion formula for subsequent fabrics; The shedding motion formula of each heald frame is digitally associated with the integrated motion controller to control the motion laws of different heald frames to meet the diversified shedding requirements of multi-layer fabrics; Step 4, establish the lifting synchronization relationship; in the synchronization mode, establish the left lifting mechanism and the right lifting mechanism synchronization interpolation relationship, the synchronization coupling coefficient k1 is as follows: Among them, a1 is the direction coefficient. When a1=-1, the left lifting mechanism and the right lifting mechanism are synchronized in the reverse direction; when a1=1, the left lifting mechanism and the right lifting mechanism are synchronized in the forward direction; D1 is the position parameter of the left lifting mechanism; D2 is the position parameter of the right lifting mechanism; Step 5, establish a horizontal advance and retreat synchronization relationship; in the synchronization mode, establish a synchronous interpolation relationship between the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism, and the synchronization coupling coefficient k2 is as follows: Among them, a2 is the direction coefficient. When a2=-1, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism are synchronized in the reverse direction; when a2=1, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism are synchronized in the forward direction; D3 is the position parameter of the left horizontal advance and retreat mechanism; D4 is the position parameter of the right horizontal advance and retreat mechanism; Step 6: Multiple heald frames move to form multi-layer openings; the integrated motion controller controls the servo motor movement of each heald frame according to the set opening motion formula until the photoelectric position sensor detects in real time that each heald frame has completed the movement, and then stops the servo motor movement of the heald frame; Step 7: Open and comb the layers, as follows: The lifting mechanism moves synchronously; the integrated motion controller controls the servo motors of the left and right lifting mechanisms to move synchronously to the theoretical height H of the center of the i-th layer opening. i , the initial value of i is During the movement, two high-precision grating rulers detect the position H' of the left and right lifting mechanisms in real time iL , H' iR , to control the position H' of the lifting mechanism on the right side of the slave axis in a closed loop iR The position of the lifting mechanism on the left side of the spindle is H' iL The deviation is less than ±0.5mm, ensuring that the positions of the left and right lifting mechanisms match; at the same time, the integrated motion controller real-time adjusts the position H' of the left lifting mechanism of the spindle iL Theoretical height H from the center of the opening of the i-th layer i Compare and adjust the left and right servo motors to move synchronously to ensure that the position of the lifting mechanism is within the range of ±0.5mm from the theoretical deviation value ΔH; The carding rods move forward in different areas; the left and right lifting mechanisms move to the theoretical height H of the center of the i-th layer opening. i After that, the integrated motion controller divides the fabric into n1 areas along the width direction, and detects the clear opening state in each area in turn through the strip photoelectric sensor. If there is no yarn obstruction and the opening is clear in this area, the combing rod is controlled to enter the opening channel and accurately positioned to j×S'(j∈[1,n1]); at the same time, the integrated motion controller judges the clear opening state of the next area in advance near j×S'. If the channel is clear, the combing rod continues to run to (j+1)×S' until the positioning is completed to S, and the magnetic position sensor of the locking mechanism detects the in-place state of the combing rod, drives the locking mechanism to complete the locking of the combing rod, and realizes the docking of the combing rod advance and retreat mechanism and the locking mechanism; if the yarn is blocked and the opening is unclear during the forward process of the combing rod, the combing rod and the locking mechanism are controlled to be fine-tuned one by one according to the set lifting and lowering adjustment times m and the small step distance Δh to try to complete the layered combing; if the lifting and lowering adjustment times m are exceeded and there is still yarn obstruction, an abnormal opening warning at the current area j is output, and the combing rod advance and retreat mechanism stops moving, and moves again after confirmation by the host computer; Where S' is the distance of the carding rod partition step, and n1 is the number of times the carding rod segment runs; Step 8, opening transfer; for the N openings formed after opening, the single-layer fabric thickness h, take the N / 2 heald eyes of the first heald frame as the origin, establish the xy axis with the first heald frame as the reference, the x axis represents the horizontal advance and retreat distance during the opening transfer process, the y axis represents the movement distance of the lifting mechanism during the opening transfer process, and the axial pressure sensor detects the yarn thrust F exerted on the combing rod in real time during the opening transfer process i , single-layer yarn thrust F0, correction coefficient α to prevent yarn wear during opening transfer, α∈[0.1~2], the horizontal forward and backward movement distance x of the left side of the main shaft during the carding rod's layer-by-layer transfer to the fabric fell, and the movement distance y of the lifting mechanism on the left side of the main shaft are as follows: When the combing rod is transferred to the cloth fell position, the opening transfer is completed, and the integrated motion controller controls the execution of the next weft insertion process. When the next process is completed, the i-th layer opening transfer completion signal is output, and the locking mechanism is controlled to return to its position, and the combing rod advance and retreat mechanism automatically returns to the initial position; Step 9: Next layer of opening combing and transfer judgment; if Then i is increased by 1, and the integrated motion controller controls the left and right lifting mechanisms to move synchronously to the theoretical height H of the center of the i-th layer opening. i , at the same time, the left horizontal advance and retreat mechanism and the right horizontal advance and retreat mechanism move synchronously to zero position, and steps 7 and 8 are executed cyclically; if Then, all layers of this multi-layer opening movement are combed, and the integrated motion controller controls the locking mechanism to return and the combing rod advance and retreat mechanism to automatically return to the initial position, and then controls the left and right lifting mechanisms and the left and right horizontal advance and retreat mechanisms to synchronously retreat to the initial position; if the fabric is not prepared, enter the next heald frame opening movement, and repeat steps 6 to 9 until the fabric is prepared.

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