Monitoring system and method for spinning production

Abstract

The invention discloses a monitoring system and method for spinning production, and relates to the technical field of monitoring, the monitoring system comprises a cotton yarn detection module, a cotton carding process troubleshooting module, an analysis module and a control monitoring module, in the cotton carding process, a photoelectric sensor is used for detecting the uniformity degree of the cotton yarn thickness, and if the uniformity degree of the cotton yarn thickness is poor, the control monitoring module is started; if the carding machine breaks down, the carding machine and the fibers are detected, if the carding machine breaks down, the reason for the failure of the carding machine is analyzed and maintained, if the fiber quality is unqualified, the reason for the unqualified fiber quality is analyzed and processed, when the carding machine is maintained or the fibers are processed, the maintenance effect and the processing effect are monitored, and if the effect is not good, the carding machine is repaired. If not, the maintenance scheme or the processing scheme is adjusted, the reliability of the cotton yarn detection result is guaranteed, the reason causing the poor cotton yarn thickness uniformity degree can be accurately found out, and the implementation effectiveness of the solution and the quality of follow-up produced yarn are guaranteed.

Description

Technical Field

[0001] The invention relates to the technical field of monitoring, and in particular to a monitoring system and method for spinning production. Background Art

[0002] In the spinning production process, when the fiber becomes cotton yarn after the carding process, the cotton yarn is further processed into yarn. The quality of the cotton yarn affects the quality of the yarn, and the uniformity of the cotton yarn thickness affects the quality of the cotton yarn. If the uniformity of the cotton yarn thickness is poor, the quality of the cotton yarn will decrease, which will in turn affect the quality of the yarn. Therefore, when the fiber becomes cotton yarn after the carding process, it is necessary to detect the uniformity of the cotton yarn thickness.

[0003] The traditional monitoring system and method for spinning production is to intercept multiple cotton yarn samples from the cotton yarn output by the carding machine, use a high-precision balance to weigh the weight of each section of cotton sliver, and evaluate the uniformity of cotton yarn thickness by comparing the difference in weight of each section of cotton sliver. When the uniformity of cotton yarn thickness is poor, the carding machine is tested. If the carding machine fails, a solution is formulated and implemented based on the carding machine failure. Obviously, this monitoring system and method for spinning production has at least the following shortcomings: 1. The traditional monitoring system and method for spinning production is relatively cumbersome to detect the uniformity of cotton yarn thickness, and the discrimination is not accurate enough for the case of small weight difference, and the reliability of the test results cannot be guaranteed.

[0004] 2. The quality of the fiber also affects the uniformity of the cotton yarn thickness. When the uniformity of the cotton yarn thickness is poor, the traditional monitoring system and method of spinning production only detects the carding machine, but does not detect the quality of the fiber, and cannot accurately find out the cause of the poor uniformity of the cotton yarn thickness.

[0005] 3. When implementing solutions, the traditional monitoring systems and methods for spinning production do not test the implementation effects of the solutions, and thus cannot determine whether the solutions solve the problem of poor uniformity of cotton yarn thickness, cannot guarantee the effectiveness of the implementation of the solutions, and cannot guarantee the quality of subsequent yarn production. Summary of the invention

[0006] In view of the above-mentioned technical deficiencies, the object of the present invention is to provide a monitoring system and method for spinning production.

[0007] In order to solve the above technical problems, the present invention adopts the following technical solutions: The first aspect of the present invention provides a monitoring system for spinning production, including a cotton yarn detection module, a combing process troubleshooting module, an analysis module and a control monitoring module.

[0008] The cotton yarn detection module is used to install a photoelectric sensor at the exit of the cotton carding machine during the cotton carding process to detect the uniformity of the cotton yarn thickness. When the uniformity of the cotton yarn thickness is poor, it means that a fault has occurred in the cotton carding process, and the cotton carding process fault detection module is executed at this time.

[0009] The carding process fault detection module includes an equipment fault detection unit and a fiber quality detection unit.

[0010] The equipment fault detection unit is used to obtain the cylinder speed, doffer speed and impurity content of the card clothing, and analyze whether the carding machine fails. If the carding machine fails, the equipment fault analysis unit of the analysis module is executed.

[0011] The fiber quality detection unit is used to obtain the length and impurity content of the fiber and analyze whether the fiber quality is qualified. If the fiber quality is unqualified, the fiber quality analysis unit of the analysis module is executed.

[0012] The analysis module includes an equipment failure analysis module and a fiber quality analysis module.

[0013] The equipment fault analysis module is used to analyze the obtained cylinder speed, doffer speed and impurity content of the card clothing, determine the cause of the carding machine failure, and replace the card clothing or adjust the motor belt diameter according to the preset adjustment plan based on the cause of the failure.

[0014] The fiber quality analysis module is used to analyze the length and impurity content of the acquired fibers, determine the cause of the unqualified fiber quality, and remove the fibers or remove impurities from the fibers according to a preset impurity removal scheme based on the cause of the unqualified quality.

[0015] The control monitoring module includes a belt diameter adjustment monitoring unit and a dirt removal monitoring unit.

[0016] The belt diameter adjustment monitoring unit is used to monitor the diameter and tension of the belt when adjusting the motor belt diameter, and analyze the adjustment effect. If the effect is not good, the adjustment plan is modified.

[0017] The impurity removal monitoring unit is used to monitor the solubility of the cleaning solution in real time when removing impurities from the fibers, and to analyze the impurity removal effect. If the effect is not good, the impurity removal plan is adjusted.

[0018] The second aspect of the present invention provides a spinning production monitoring method based on a spinning production monitoring system, comprising the following steps: Step 1, detecting the uniformity of cotton yarn thickness: installing a photoelectric sensor at the exit of a carding machine to detect the uniformity of cotton yarn thickness. When the uniformity of cotton yarn thickness is poor, it indicates that a fault has occurred in the carding process.

[0019] Step 2: Check whether the carding machine has any faults: obtain the cylinder speed, doffer speed and impurity content of the card clothing, and analyze whether the carding machine has any faults. If the carding machine has any faults, it means that the carding process fault is caused by the carding machine fault.

[0020] Step 3: Check whether the fiber quality is qualified: obtain the fiber length and impurity content, and analyze whether the fiber quality is qualified. If the fiber quality is unqualified, it means that the carding process failure is caused by unqualified fiber quality.

[0021] Step 4. Analyze the cause of the carding machine failure: Analyze the obtained cylinder speed, doffer speed and impurity content of the card clothing to determine the cause of the carding machine failure. According to the cause of the failure, replace the card clothing or adjust the motor belt diameter according to the preset adjustment plan.

[0022] Step 5: Analyze the reasons for the unqualified fiber quality: Analyze the length and impurity content of the obtained fibers to determine the reasons for the unqualified fiber quality. According to the reasons for the unqualified quality, remove the fibers or remove impurities from the fibers according to a preset impurity removal scheme.

[0023] Step 6. Analyze the adjustment effect of the motor belt diameter: When adjusting the diameter of the motor belt, monitor the belt diameter and belt tension, and analyze the adjustment effect. If the effect is not good, modify the adjustment plan.

[0024] Step 7: Analyze the fiber impurity removal effect: When removing impurities from the fiber, monitor the solubility of the cleaning solution in real time and analyze the impurity removal effect. If the effect is not good, adjust the impurity removal plan.

[0025] The beneficial effects of the present invention are as follows: the purpose of the present invention is to provide a monitoring system and method for spinning production, using a photoelectric sensor to detect the uniformity of cotton yarn thickness. If the uniformity of cotton yarn thickness is poor, the carding machine and the fiber are detected. If the carding machine fails, the cause of the failure is analyzed and repaired. If the fiber quality is unqualified, the cause of the unqualified fiber quality is analyzed and processed. When the carding machine is repaired or the fiber is processed, the maintenance effect and the processing effect are monitored. If the effect is not good, the maintenance plan or the processing plan is adjusted, thereby ensuring the reliability of the cotton yarn detection results, accurately finding the cause of the poor uniformity of cotton yarn thickness, and ensuring the effectiveness of the implementation of the solution and the quality of subsequent yarn production. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0027] Figure 1 It is a schematic diagram of the system structure connection of the present invention.

[0028] Figure 2 The present invention is a schematic flow chart of the steps for implementing the method. DETAILED DESCRIPTION

[0029] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0030] See also Figure 1 As shown, the first aspect of the present invention provides a monitoring system for spinning production, which includes a cotton yarn detection module, a combing process troubleshooting module, an analysis module and a control monitoring module.

[0031] The cotton yarn detection module is connected to the combing process fault detection module, the combing process fault detection module is connected to the analysis module, and the analysis module is connected to the control and monitoring module.

[0032] The cotton yarn detection module is used to install a photoelectric sensor at the exit of the cotton carding machine during the cotton carding process to detect the uniformity of the cotton yarn thickness. When the uniformity of the cotton yarn thickness is poor, it means that the cotton carding process has a fault. At this time, the cotton carding process fault detection module is executed.

[0033] In a specific embodiment, the uniformity of the cotton yarn thickness is detected, and the specific process is as follows: a photoelectric sensor is installed at the exit of the carding machine, and each collection moment is arranged according to a preset time interval. The photoelectric sensor emits a light beam to the cotton yarn at each collection moment, receives the radiated light of the cotton yarn at each collection moment, outputs the reflected light intensity, and compares the reflected light intensity of the cotton yarn at each collection moment with a preset reflected light intensity range. If the reflected light intensity of the cotton yarn at each collection moment is within the preset reflected light intensity range, it means that the uniformity of the cotton yarn thickness is good. If the reflected light intensity of the cotton yarn at one or more collection moments is not within the preset reflected light intensity range, it means that the uniformity of the cotton yarn thickness is poor. When the uniformity of the cotton yarn thickness is poor, it means that a fault has occurred in the carding process.

[0034] It should be noted that the intensity of the reflected light received by the photoelectric sensor is related to the thickness of the cotton yarn. The thicker the cotton yarn, the weaker the intensity of the reflected light received by the photoelectric sensor. The thinner the cotton yarn, the stronger the intensity of the reflected light received by the photoelectric sensor. When using the photoelectric sensor to obtain the uniformity of the thickness of the cotton yarn, the distance between the photoelectric sensor and the cotton yarn needs to be kept constant, and ensure that the light beam is irradiated vertically onto the cotton yarn.

[0035] The carding process troubleshooting module includes an equipment fault detection unit and a fiber quality detection unit.

[0036] The equipment fault detection unit is used to obtain the cylinder speed, doffer speed and impurity content of the card clothing, and analyze whether the carding machine fails. If the carding machine fails, the equipment fault analysis unit of the analysis module is executed.

[0037] In a specific embodiment, the carding machine is analyzed to determine whether it is faulty. The specific process is as follows: S11, a speed sensor is installed at the shaft end of the cylinder and the doffer to obtain the cylinder speed and the doffer speed, a high-definition camera is installed in the carding machine to collect the card clothing image, and transmit it to the system, and the number of impurities in the card clothing is output according to the analysis formula: , get the impurity content of the card clothing , where Represents the amount of impurities in the card clothing, Represents the card clothing area.

[0038] It should be noted that the area of ​​the card clothing is known, and the information of the carding machine is retrieved from the database, and the information of the carding machine includes the area of ​​the card clothing.

[0039] It should also be noted that the amount of impurities in the card clothing is obtained using image processing technology.

[0040] S12. Calculate the operation coefficient of the carding machine based on the obtained cylinder speed, doffer speed and impurity content of the card clothing: , In the formula , , Respectively represent cylinder speed, doffer speed, and impurity content of card clothing. , They represent the minimum value and the maximum value of the preset cylinder speed range respectively. , Respectively represent the minimum value of the preset doffer speed range and the maximum value of the preset doffer speed range. Represents the preset threshold value of impurity content in card clothing, , , They represent the weight coefficient of cylinder speed, doffer speed, and impurity content of card clothing respectively. Represents the operating coefficient of the carding machine.

[0041] It should be noted that the weight coefficient of the cylinder speed, the weight coefficient of the doffer speed and the weight coefficient of the impurity content of the card clothing are set by the staff according to the influence of the cylinder speed, the doffer speed and the impurity content of the card clothing on the carding machine, and the sum of the weight coefficient of the cylinder speed, the weight coefficient of the doffer speed and the weight coefficient of the impurity content of the card clothing is 1.

[0042] It should also be noted that when the carding machine is operating normally, the staff obtains the range of the cylinder speed, and uses the minimum value of the range as the minimum value of the preset cylinder speed range, and uses the maximum value of the range as the maximum value of the preset cylinder speed range.

[0043] It should also be noted that when the carding machine is operating normally, the staff obtains the doffer speed range, and uses the minimum value of the range as the minimum value of the preset doffer speed range, and uses the maximum value of the range as the maximum value of the preset doffer speed range.

[0044] It should also be noted that when the thickness uniformity of the cotton yarn output by the carding machine is good, the staff obtains the impurity content of the card clothing and uses it as the preset threshold value of the impurity content of the card clothing.

[0045] S13, comparing the carding machine's operating coefficient with a preset operating coefficient range. If the carding machine's operating coefficient is within the preset operating coefficient range, it indicates that the carding machine has no fault. If the carding machine's operating coefficient is not within the preset operating coefficient range, it indicates that the carding machine has a fault.

[0046] It should be noted that the staff sets the operating coefficient range of the carding machine based on the cylinder speed, doffer speed and impurity content of the card clothing during normal operation of the carding machine.

[0047] It should be noted that when the carding machine is operating normally, the staff obtains the cylinder speed range, doffer speed range and impurity content of the card clothing of the carding machine, and sets a preset operating coefficient range based on the cylinder speed range, doffer speed range and impurity content of the card clothing.

[0048] The fiber quality detection unit is used to obtain the length and impurity content of the fiber and analyze whether the fiber quality is qualified. If the fiber quality is unqualified, the fiber quality analysis unit of the analysis module is executed.

[0049] In a specific embodiment, the fiber quality is analyzed to determine whether it is qualified. The specific process is as follows: S21, using a high-definition camera to take an image of the fiber, transmitting it to the system, and outputting the fiber length, the number of impurity particles in the fiber, and the number of fiber particles in the fiber image according to the analysis formula: , get the impurity content of the fiber , where Represents the number of impurity particles in the fiber, Represents the number of fiber particles.

[0050] It should be noted that the number of impurity particles and the number of fiber particles in the fiber image are obtained using image processing technology.

[0051] S22. Analyze the fiber quality indexes according to the output fiber length and the calculated fiber impurity content: , In the formula , They represent the length of the fiber and the impurity content of the fiber respectively. , They represent the preset fiber length range and the preset fiber impurity content threshold respectively. Represents the quality index of fiber. When it is 0, it means the fiber quality is qualified. When it is 1, it means the fiber quality is unqualified.

[0052] It should be noted that the staff sets the required length range and impurity content threshold of qualified quality fibers according to the working performance of the carding machine.

[0053] It should also be noted that the staff sets the preset fiber impurity content threshold according to the cylinder speed and doffer speed during normal operation of the carding machine.

[0054] The analysis module includes an equipment failure analysis module and a fiber quality analysis module.

[0055] The equipment fault analysis module is used to analyze the obtained cylinder speed, doffer speed and impurity content of the card clothing, determine the cause of the carding machine failure, and replace the card clothing or adjust the motor belt diameter according to the preset adjustment plan based on the cause of the failure.

[0056] It should be noted that before the system is put into operation, the staff will formulate a preset adjustment plan based on the possible failures of the carding machine.

[0057] In a specific embodiment, the determination of the cause of the carding machine failure is carried out as follows: the obtained cylinder speed, doffer speed and impurity content of the card cloth are compared with the preset cylinder speed range, the preset doffer speed range and the preset impurity content threshold: if the cylinder speed is greater than the maximum value of the preset cylinder speed range, it means that the cylinder speed is too high; if the cylinder speed is less than the minimum value of the preset cylinder speed range, it means that the cylinder speed is too low; when the cylinder speed is too high or too low, it means that the failure of the carding machine is caused by unreasonable cylinder speed. At this time, the controller adjusts the motor belt diameter according to the preset adjustment plan.

[0058] It should be noted that if the cylinder speed is too high, the force exerted by the needle teeth in the carding machine on the fibers will be too great, which may easily cause fiber damage and produce more short fibers. It may cause more short fibers to gather in some areas and relatively less in other areas, thus affecting the uniformity of the cotton yarn thickness. If the cylinder speed is too low, the combing frequency of the needle teeth in the carding machine on the fibers will be reduced, and the fibers cannot be fully combed. The fiber clusters that have not been combed will be randomly distributed in the cotton yarn, thus affecting the uniformity of the cotton yarn thickness.

[0059] If the doffer speed is greater than the maximum value of the preset doffer speed range, it means that the doffer speed is too high. If the doffer speed is less than the minimum value of the preset doffer speed range, it means that the doffer speed is too low. When the doffer speed is too high or too low, it means that the fault of the carding machine is caused by unreasonable doffer speed. At this time, the controller adjusts the motor belt diameter according to the preset adjustment plan.

[0060] It should be noted that if the doffer speed is too high, the fibers will be transferred from the cylinder to the doffer too quickly, causing the structure of the fiber web to become disordered and the local density of the fiber web to be uneven, thus affecting the uniformity of the cotton yarn thickness. If the doffer speed is too low, the fibers may be repeatedly combed and rubbed on the cylinder, producing more short fibers and the distribution of the fibers may become uneven, thus affecting the uniformity of the cotton yarn thickness.

[0061] If the impurity content of the card clothing is lower than the preset impurity content threshold, it means that there are few impurities on the card clothing. If the impurity content of the card clothing is higher than the preset impurity content threshold, it means that there are too many impurities on the card clothing. When there are too many impurities on the card clothing, it means that the failure of the carding machine is caused by the impurities on the card clothing. At this time, notify the maintenance personnel to replace the card clothing.

[0062] It should be noted that if the impurity content of the card clothing is too high, reducing the effective combing space of the needle teeth will reduce the ability to comb the fibers, and the fibers cannot be fully combed, thereby affecting the uniformity of the cotton yarn thickness.

[0063] The fiber quality analysis module is used to analyze the length and impurity content of the acquired fibers, determine the cause of the unqualified fiber quality, and remove the fibers or remove impurities from the fibers according to a preset impurity removal scheme based on the cause of the unqualified quality.

[0064] It should be noted that before the system is put into operation, the staff will formulate a preset impurity removal plan based on the impurities that may exist in the fibers.

[0065] In a specific embodiment, the reason for determining the unqualified fiber quality is as follows: if the fiber length is greater than the maximum value of a preset fiber length range, it means that the fiber is too long; if the fiber length is less than the minimum value of a preset fiber length range, it means that the fiber is too short. When the fiber is too long or too short, it means that the unqualified fiber quality is caused by unqualified fiber length. At this time, the fiber that does not meet the fiber length standard is removed.

[0066] It should be noted that if the fiber length is too long, it may be entangled on the needle teeth of the needle clothing to form cotton knots. The cotton knots will form local fiber clumps and affect the uniformity of the cotton yarn thickness. If the fiber length is too short, it will lead to insufficient holding. Short fibers are prone to local accumulation or vacancies when condensed, affecting the uniformity of the cotton yarn thickness.

[0067] It should also be noted that the staff obtains cotton yarns with good uniformity of thickness, and reads the fiber lengths of the fibers used to make each cotton yarn from the database, sets a fiber length range according to each fiber length, and uses the minimum value of the fiber length range as the minimum value of the preset fiber length range, and uses the maximum value of the fiber length range as the maximum value of the preset fiber length range.

[0068] If the impurity content of the fiber is lower than the preset fiber impurity content threshold, it means that the fiber has few impurities. If the impurity content of the fiber is higher than the preset fiber impurity content threshold, it means that the fiber has too many impurities. When there are too many fiber impurities, it means that the unqualified fiber quality is caused by too many fiber impurities. At this time, the fiber is de-impurified according to the preset impurity removal scheme.

[0069] It should be noted that when the fiber impurity content is too high, the impurities are easily attached to the needle teeth of the card clothing, resulting in a reduction in the effective combing space of the needle teeth. This makes it impossible for the card clothing to fully comb the fibers, and the entanglement between the fibers cannot be effectively untangled, affecting the uniformity of the cotton yarn thickness.

[0070] It should also be noted that the staff sets the preset fiber impurity content threshold according to the cylinder speed and doffer speed during normal operation of the carding machine.

[0071] The control monitoring module includes a belt diameter adjustment monitoring unit and a dirt removal monitoring unit.

[0072] The belt diameter adjustment monitoring unit is used to monitor the diameter and tension of the belt when adjusting the motor belt diameter, and analyze the adjustment effect. If the effect is not good, the adjustment plan is modified.

[0073] In a specific embodiment, the adjustment effect is analyzed, and if the effect is not good, the adjustment plan is modified. The specific process is as follows: S31. According to the preset time interval, each collection moment is arranged. At each collection moment, a laser sensor and a tension sensor are used to obtain the diameter and tension of the motor belt at each collection moment.

[0074] S32. Calculate the diameter change rate of the motor belt at each collection time according to the diameter of the motor belt at adjacent collection times: , In the formula Representative The diameter of the motor belt at the time of collection, Representative The diameter of the motor belt at the time of collection, Representative The change rate of the motor belt diameter at each acquisition moment, represents the number of each collection moment, =1,2,3,..., , Represents the total number of acquisition moments, and All are positive integers.

[0075] S33. Compare the diameter change rate and tension of the motor belt at each collection moment with the preset diameter change rate range and the preset tension range. If the diameter change rate and tension of the motor belt at each collection moment are within the preset diameter change rate range and the preset tension range, it means that the adjustment effect is good. If there is a certain collection moment when the diameter change rate of the motor belt is not within the preset diameter change rate range or the tension is not within the preset tension range, it means that the adjustment effect is not good.

[0076] It should be noted that when the change rate of the motor belt diameter is not within the preset diameter change rate range, it means that an abnormality has occurred during the adjustment process. The tension is used to reflect the change in belt path length caused by adjusting the diameter. When the tension is not within the preset tension range, it means that the adjustment has an adverse effect on the machine operation.

[0077] It should also be noted that the staff sets the preset diameter change rate range and the preset tension range according to the operating status of the carding machine.

[0078] S34. When the adjustment effect is not good, the diameter change rate and tension of the motor belt at each acquisition time in each historical adjustment scheme are obtained from the database, according to the analysis formula: , get the The average value of the diameter change rate of the adjustment scheme , according to the analysis formula: , get the The average tension of the adjustment scheme , where Represents the historical adjustment plan The diameter change rate at each acquisition moment, Represents the historical adjustment plan The tension of each collection moment, represents the number of each collection moment, =1,2,3,..., , Represents the total number of acquisition moments, and are all positive integers, and this method is used to obtain the average diameter change rate and the average tension in each historical adjustment scheme, calculate the difference between the average diameter change rate in each historical adjustment scheme and the preset diameter change rate range, and the difference between the average tension in each historical adjustment scheme and the preset tension range, and compare them, and select the historical adjustment scheme with the smallest difference between the average diameter change rate and the preset diameter change rate range and the smallest difference between the average tension and the preset tension range, and use this scheme as the secondary adjustment scheme for the motor belt diameter and implement it.

[0079] The impurity removal monitoring unit is used to monitor the solubility of the cleaning solution in real time when removing impurities from the fibers, and to analyze the impurity removal effect. If the effect is not good, the impurity removal plan is adjusted.

[0080] In a specific embodiment, the impurity removal effect is described and analyzed, and if the effect is not good, the impurity removal scheme is adjusted. The specific process is as follows: S41, using a high-definition camera to capture fiber images, using image processing technology to obtain the impurity type of each impurity in the fiber image, and recording the number of impurities in each impurity type, obtaining the cleaning solution corresponding to each impurity type from a database, and mixing the cleaning solutions according to the number of impurities in each impurity type to obtain a mixed cleaning solution, using the mixed cleaning solution as a standard cleaning solution, and using a conductivity meter to obtain the solubility of the standard cleaning solution.

[0081] S42. Use a conductivity meter to monitor the solubility of the cleaning solution in real time, and compare the solubility of the cleaning solution with that of the standard cleaning solution. If the solubility of the cleaning solution is equal to that of the standard cleaning solution, it means that the impurity removal effect is good. If the solubility of the cleaning solution is not equal to that of the standard cleaning solution, it means that the impurity removal effect is poor.

[0082] S43. When the impurity removal effect is not good, the solubility of the cleaning solution in each historical impurity removal scheme is obtained from the database, the difference between the solubility of the cleaning solution in each historical impurity removal scheme and the solubility of the standard cleaning solution is calculated, and a comparison is made. The historical impurity removal scheme with the smallest difference between the solubility of the cleaning solution and the solubility of the standard cleaning solution is selected, and the scheme is used as the secondary impurity removal scheme and implemented.

[0083] In the above, the cleaning solutions are mixed according to the amount of impurities in each impurity type. The specific process is as follows: According to the analysis formula: , get the The ratio of the number of impurity types in all impurity types , according to the analysis formula: , get the The volume of cleaning fluid required for each impurity , where Represents the volume of cleaning fluid required for impurity removal, Representative The number of impurities, The number representing each impurity type, =1,2,3,..., , Represents the total number of impurity types, and All of them are positive integers. This method is used to obtain the volume of cleaning solution required for each impurity type, and the cleaning solutions are mixed according to the required volume of each cleaning solution.

[0084] See also Figure 2 As shown, the second aspect of the present invention provides a spinning production monitoring method based on a spinning production monitoring system, comprising the following steps: Step 1, detecting the uniformity of cotton yarn thickness: installing a photoelectric sensor at the exit of a carding machine to detect the uniformity of cotton yarn thickness. When the uniformity of cotton yarn thickness is poor, it indicates that a fault occurs in the carding process.

[0085] Step 2: Check whether the carding machine has any faults: obtain the cylinder speed, doffer speed and impurity content of the card clothing, and analyze whether the carding machine has any faults. If the carding machine has any faults, it means that the carding process fault is caused by the carding machine fault.

[0086] Step 3: Check whether the fiber quality is qualified: obtain the fiber length and impurity content, and analyze whether the fiber quality is qualified. If the fiber quality is unqualified, it means that the carding process failure is caused by unqualified fiber quality.

[0087] Step 4. Analyze the cause of the carding machine failure: Analyze the obtained cylinder speed, doffer speed and impurity content of the card clothing to determine the cause of the carding machine failure. According to the cause of the failure, replace the card clothing or adjust the motor belt diameter according to the preset adjustment plan.

[0088] Step 5: Analyze the reasons for the unqualified fiber quality: Analyze the length and impurity content of the obtained fibers to determine the reasons for the unqualified fiber quality. According to the reasons for the unqualified quality, remove the fibers or remove impurities from the fibers according to a preset impurity removal scheme.

[0089] Step 6. Analyze the adjustment effect of the motor belt diameter: When adjusting the diameter of the motor belt, monitor the belt diameter and belt tension, and analyze the adjustment effect. If the effect is not good, modify the adjustment plan.

[0090] Step 7: Analyze the fiber impurity removal effect: When removing impurities from the fiber, monitor the solubility of the cleaning solution in real time and analyze the impurity removal effect. If the effect is not good, adjust the impurity removal plan.

[0091] In the embodiment of the present invention, a photoelectric sensor is used to detect the uniformity of the thickness of the cotton yarn. If the uniformity of the thickness of the cotton yarn is poor, the carding machine and the fiber are inspected. If the carding machine fails, the cause of the failure is analyzed and repaired. If the fiber quality is unqualified, the cause of the unqualified fiber quality is analyzed and processed. When the carding machine is repaired or the fiber is processed, the maintenance effect and the processing effect are monitored. If the effect is not good, the maintenance plan or the processing plan is adjusted, thereby ensuring the reliability of the cotton yarn detection result, being able to accurately find the cause of the poor uniformity of the cotton yarn thickness, and ensuring the effectiveness of the implementation of the solution and the quality of the subsequent yarn production.

[0092] The above contents are merely examples and explanations of the concept of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in a similar manner. As long as they do not deviate from the concept of the invention or exceed the scope defined in this specification, they shall all fall within the protection scope of the present invention.

Claims

1. A monitoring system for spinning production, characterized in that: Includes the following modules: The cotton yarn detection module is used to install a photoelectric sensor at the exit of the cotton carding machine during the cotton carding process to detect the uniformity of the cotton yarn thickness. When the uniformity of the cotton yarn thickness is poor, it means that the cotton carding process has a fault. At this time, the cotton carding process fault detection module is executed; The carding process troubleshooting module includes equipment fault detection unit and fiber quality detection unit: The equipment fault detection unit is used to obtain the cylinder speed, the doffer speed and the impurity content of the card clothing, and analyze whether the carding machine fails. If the carding machine fails, the equipment fault analysis unit of the analysis module is executed; The fiber quality detection unit is used to obtain the length and impurity content of the fiber and analyze whether the fiber quality is qualified. If the fiber quality is unqualified, the fiber quality analysis unit of the analysis module is executed; The analysis module includes equipment failure analysis unit and fiber quality analysis unit: The equipment fault analysis unit is used to analyze the obtained cylinder speed, doffer speed and impurity content of the card clothing, determine the cause of the carding machine failure, and replace the card clothing or adjust the motor belt diameter according to the preset adjustment plan according to the cause of the failure; The fiber quality analysis unit is used to analyze the length and impurity content of the acquired fibers, determine the cause of the unqualified fiber quality, and remove the fibers or remove impurities from the fibers according to a preset impurity removal scheme according to the cause of the unqualified quality; The control and monitoring module includes a belt diameter adjustment monitoring unit and a dust removal monitoring unit: The belt diameter adjustment monitoring unit is used to monitor the diameter and tension of the belt when adjusting the motor belt diameter, and analyze the adjustment effect. If the effect is not good, the adjustment plan is modified; The impurity removal monitoring unit is used to monitor the solubility of the cleaning solution in real time when removing impurities from the fibers, and to analyze the impurity removal effect. If the effect is not good, the impurity removal plan is adjusted.

2. A monitoring system for spinning production according to claim 1, characterized in that: The specific process of detecting the uniformity of the cotton yarn thickness is as follows: A photoelectric sensor is installed at the exit of the carding machine, and each collection moment is arranged according to a preset time interval. The photoelectric sensor emits a light beam to the cotton yarn at each collection moment, receives the radiated light of the cotton yarn at each collection moment, outputs the reflected light intensity, and compares the reflected light intensity of the cotton yarn at each collection moment with the preset reflected light intensity range. If the reflected light intensity of the cotton yarn at each collection moment is within the preset reflected light intensity range, it means that the uniformity of the cotton yarn thickness is good. If the reflected light intensity of the cotton yarn at one or more collection moments is not within the preset reflected light intensity range, it means that the uniformity of the cotton yarn thickness is poor. When the uniformity of the cotton yarn thickness is poor, it means that there is a fault in the carding process.

3. A monitoring system for spinning production according to claim 1, characterized in that: Describe and analyze whether the carding machine has a fault, the specific process is as follows: S11. Install speed sensors at the shaft ends of the cylinder and doffer to obtain the cylinder speed and doffer speed. Install a high-definition camera in the carding machine to collect the card clothing image and transmit it to the system to output the number of impurities in the card clothing according to the analysis formula: , get the impurity content of the card clothing , where Represents the amount of impurities in the card clothing, Represents the card clothing area; S12. Calculate the operation coefficient of the carding machine based on the obtained cylinder speed, doffer speed and impurity content of the card clothing: ， In the formula , , Respectively represent cylinder speed, doffer speed, and impurity content of card clothing. , They represent the minimum value and the maximum value of the preset cylinder speed range respectively. , Respectively represent the minimum value of the preset doffer speed range and the maximum value of the preset doffer speed range. Represents the preset threshold value of impurity content in card clothing, , , They represent the weight coefficient of cylinder speed, doffer speed, and impurity content of card clothing respectively. Represents the operating coefficient of the carding machine; S13, comparing the carding machine's operating coefficient with a preset operating coefficient range. If the carding machine's operating coefficient is within the preset operating coefficient range, it indicates that the carding machine has no fault. If the carding machine's operating coefficient is not within the preset operating coefficient range, it indicates that the carding machine has a fault.

4. A monitoring system for spinning production according to claim 1, characterized in that: Describe and analyze whether the fiber quality is qualified, the specific process is as follows: S21. Use a high-definition camera to capture an image of the fiber, transmit it to the system, and output the fiber length, the number of impurity particles in the fiber, and the number of fiber particles in the fiber image according to the analysis formula: , get the impurity content of the fiber , where Represents the number of impurity particles in the fiber, Represents the number of fiber particles; S22. Analyze the fiber quality indexes according to the output fiber length and the calculated fiber impurity content: ， In the formula , They represent the length of the fiber and the impurity content of the fiber respectively. , They represent the preset fiber length range and the preset fiber impurity content threshold respectively. Represents the quality index of fiber. When it is 0, it means the fiber quality is qualified. When it is 1, it means the fiber quality is unqualified.

5. A monitoring system for spinning production according to claim 1, characterized in that: The specific process of determining the cause of the carding machine failure is as follows: The obtained cylinder speed, doffer speed and impurity content of the card clothing are compared with the preset cylinder speed range, the preset doffer speed range and the preset impurity content threshold value: If the cylinder speed is greater than the maximum value of the preset cylinder speed range, it means that the cylinder speed is too high. If the cylinder speed is less than the minimum value of the preset cylinder speed range, it means that the cylinder speed is too low. When the cylinder speed is too high or too low, it means that the failure of the carding machine is caused by unreasonable cylinder speed. At this time, the controller adjusts the motor belt diameter according to the preset adjustment plan; If the doffer speed is greater than the maximum value of the preset doffer speed range, it means that the doffer speed is too high. If the doffer speed is less than the minimum value of the preset doffer speed range, it means that the doffer speed is too low. When the doffer speed is too high or too low, it means that the fault of the carding machine is caused by unreasonable doffer speed. At this time, the controller adjusts the motor belt diameter according to the preset adjustment plan; If the impurity content of the card clothing is lower than the preset impurity content threshold, it means that there are few impurities on the card clothing. If the impurity content of the card clothing is higher than the preset impurity content threshold, it means that there are too many impurities on the card clothing. When there are too many impurities on the card clothing, it means that the failure of the carding machine is caused by the impurities on the card clothing. At this time, notify the maintenance personnel to replace the card clothing.

6. A monitoring system for spinning production according to claim 1, characterized in that: The specific process of determining the cause of unqualified fiber quality is as follows: If the fiber length is greater than the maximum value of the preset fiber length range, it means that the fiber is too long. If the fiber length is less than the minimum value of the preset fiber length range, it means that the fiber is too short. When the fiber is too long or too short, it means that the fiber quality is unqualified due to the unqualified fiber length. At this time, the fiber that does not meet the fiber length standard is removed. If the impurity content of the fiber is lower than the preset fiber impurity content threshold, it means that the fiber has few impurities. If the impurity content of the fiber is higher than the preset fiber impurity content threshold, it means that the fiber has too many impurities. When there are too many fiber impurities, it means that the unqualified fiber quality is caused by too many fiber impurities. At this time, the fiber is de-impurified according to the preset impurity removal scheme.

7. A monitoring system for spinning production according to claim 1, characterized in that: Describe and analyze the adjustment effect. If the effect is not good, modify the adjustment plan. The specific process is as follows: S31, arranging each collection moment according to a preset time interval, and using a laser sensor and a tension sensor at each collection moment to obtain the diameter and tension of the motor belt at each collection moment; S32. Calculate the diameter change rate of the motor belt at each collection time according to the diameter of the motor belt at adjacent collection times: ， In the formula Representative The diameter of the motor belt at the time of collection, Representative The diameter of the motor belt at the time of collection, Representative The change rate of the motor belt diameter at each acquisition moment, Represents the number of each collection moment, =1,2,3,..., , Represents the total number of acquisition moments, and All are positive integers; S33, comparing the diameter change rate and tension of the motor belt at each acquisition moment with a preset diameter change rate range and a preset tension range. If the diameter change rate and tension of the motor belt at each acquisition moment are within the preset diameter change rate range and the preset tension range, it means that the adjustment effect is good. If there is a case where the diameter change rate of the motor belt at a certain acquisition moment is not within the preset diameter change rate range or the tension is not within the preset tension range, it means that the adjustment effect is not good. S34. When the adjustment effect is not good, the diameter change rate and tension of the motor belt at each acquisition time in each historical adjustment scheme are obtained from the database, according to the analysis formula: , get the The average diameter change rate of the adjustment scheme , according to the analysis formula: , get the The average tension of the adjustment scheme , where Represents the historical adjustment plan The diameter change rate at each acquisition moment, Represents the historical adjustment plan The tension of each collection moment, represents the number of each collection moment, =1,2,3,..., , Represents the total number of acquisition moments, and are all positive integers, and the average diameter change rate and the average tension in each historical adjustment scheme are obtained by this method. The difference between the average diameter change rate in each historical adjustment scheme and the preset diameter change rate range and the difference between the average tension in each historical adjustment scheme and the preset tension range are calculated and compared, and the historical adjustment scheme with the smallest difference between the average diameter change rate and the preset diameter change rate range and the smallest difference between the average tension and the preset tension range is selected, and this scheme is used as the secondary adjustment scheme for the motor belt diameter and implemented.

8. A monitoring system for spinning production according to claim 1, characterized in that: The impurity removal effect is described and analyzed. If the effect is not good, the impurity removal plan is adjusted. The specific process is as follows: S41, using a high-definition camera to collect fiber images, using image processing technology to obtain the impurity type of each impurity in the fiber image, and recording the number of impurities in each impurity type, obtaining the cleaning solution corresponding to each impurity type from a database, mixing each cleaning solution according to the number of impurities in each impurity type to obtain a mixed cleaning solution, using the mixed cleaning solution as a standard cleaning solution, and using a conductivity meter to obtain the solubility of the standard cleaning solution; S42. Use a conductivity meter to monitor the solubility of the cleaning solution in real time, and compare the solubility of the cleaning solution with that of the standard cleaning solution. If the solubility of the cleaning solution is equal to that of the standard cleaning solution, it means that the impurity removal effect is good. If the solubility of the cleaning solution is not equal to that of the standard cleaning solution, it means that the impurity removal effect is poor. S43. When the impurity removal effect is not good, the solubility of the cleaning solution in each historical impurity removal scheme is obtained from the database, the difference between the solubility of the cleaning solution in each historical impurity removal scheme and the solubility of the standard cleaning solution is calculated, and a comparison is made. The historical impurity removal scheme with the smallest difference between the solubility of the cleaning solution and the solubility of the standard cleaning solution is selected, and the scheme is used as the secondary impurity removal scheme and implemented.

9. A monitoring system for spinning production according to claim 8, characterized in that: The cleaning solutions are mixed according to the amount of impurities in each impurity type. The specific process is as follows: According to the analysis formula: , get the The ratio of the number of impurity types in all impurity types , according to the analysis formula: , get the The volume of cleaning fluid required for each impurity , where Represents the volume of cleaning fluid required for impurity removal, Representative The number of impurities, The number representing each impurity type, =1,2,3,..., , Represents the total number of impurity types, and All of them are positive integers. This method is used to obtain the volume of cleaning solution required for each impurity type, and the cleaning solutions are mixed according to the required volume of each cleaning solution.

10. A method for monitoring spinning production based on the monitoring system for spinning production according to any one of claims 1 to 9, characterized in that: The steps include: Step 1: Detect the uniformity of cotton yarn thickness: Install a photoelectric sensor at the exit of the carding machine to detect the uniformity of cotton yarn thickness. When the uniformity of cotton yarn thickness is poor, it means that there is a fault in the carding process; Step 2: Check whether the carding machine has any faults: obtain the cylinder speed, doffer speed and impurity content of the card clothing, and analyze whether the carding machine has any faults. If the carding machine has any faults, it means that the carding process fault is caused by the carding machine fault. Step 3: Check whether the fiber quality is qualified: obtain the fiber length and impurity content, and analyze whether the fiber quality is qualified. If the fiber quality is unqualified, it means that the carding process failure is caused by unqualified fiber quality; Step 4: Analyze the cause of the carding machine failure: Analyze the cylinder speed, doffer speed and impurity content of the card clothing to determine the cause of the carding machine failure. According to the cause of the failure, replace the card clothing or adjust the motor belt diameter according to the preset adjustment plan; Step 5: Analyze the reasons for the unqualified fiber quality: Analyze the length and impurity content of the obtained fibers to determine the reasons for the unqualified fiber quality. According to the reasons for the unqualified quality, remove the fibers or remove impurities from the fibers according to a preset impurity removal scheme; Step 6: Analyze the adjustment effect of the motor belt diameter: When adjusting the motor belt diameter, monitor the belt diameter and belt tension, and analyze the adjustment effect. If the effect is not good, modify the adjustment plan; Step 7: Analyze the fiber impurity removal effect: When removing impurities from the fiber, monitor the solubility of the cleaning solution in real time and analyze the impurity removal effect. If the effect is not good, adjust the impurity removal plan.

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