Digital control system for uniform padder

Abstract

The invention discloses a digital control system for a uniform padder, which comprises a non-contact elastic detection module, an intelligent analysis control module and a pressure execution module, and is characterized in that the non-contact elastic detection module, the intelligent analysis control module and the pressure execution module are in mutual signal connection; wherein the non-contact elastic detection module is used for acquiring the elastic characteristic of a fabric in real time and providing data support for dynamically adjusting the pressure of a roller; the intelligent analysis control module is used for carrying out analysis operation on the detection data, converting the detection data into a control instruction, realizing real-time dynamic adjustment of the roller pressure and ensuring the permeation uniformity of the mangle liquid; the pressure execution module is used for executing the control instruction and converting the theoretical pressure value obtained through calculation into the actual mechanical pressure of the roller, and the device has the advantages of being uniform in rolling liquid permeation and high in machining efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of textile printing and dyeing machinery control, in particular to a digital control system for a uniform padder. Background Art

[0002] In the textile printing and dyeing industry, the padder is one of the key processing equipment. Its main function is to apply a certain pressure to the fabric through the rollers so that the padding liquid can penetrate the fabric evenly. However, the elastic properties of the fabric place high demands on the working pressure setting of the padder. Traditional padders usually use a fixed pressure setting value and cannot be dynamically adjusted according to the actual elastic properties of the fabric, which leads to uneven penetration of the padding liquid, affecting the dyeing effect and fabric quality.

[0003] Traditional padding control systems often rely on manual experience or simple mechanical pressure adjustment, which has many shortcomings. On the one hand, it is difficult for manually set pressure values ​​to accurately reflect the real-time elastic changes of fabrics, especially when dealing with special fabrics such as high elasticity and ultra-thin fabrics, which are prone to problems such as uneven penetration of the padding liquid and fabric damage. On the other hand, mechanical pressure regulation has a slow response speed and cannot quickly adapt to the rapid changes in fabric elasticity, which can easily lead to overshoot or undershoot of pressure, affecting processing efficiency and product quality. Therefore, it is necessary to design a digital control system for uniform padding with uniform padding penetration and high processing efficiency. Summary of the invention

[0004] The object of the present invention is to provide a digital control system for uniform rolling to solve the problems raised in the above-mentioned background technology.

[0005] In order to solve the above technical problems, the present invention provides the following technical solutions: a digital control system for uniform rolling, comprising a non-contact elastic detection module, an intelligent analysis and control module and a pressure execution module, wherein the non-contact elastic detection module, the intelligent analysis and control module and the pressure execution module are mutually connected by signals; wherein,

[0006] Non-contact elasticity detection module, used to obtain the elasticity characteristics of the fabric in real time, providing data support for dynamic adjustment of roller pressure;

[0007] Intelligent analysis and control module, used to analyze and calculate the detection data, convert the detection data into control instructions, realize real-time dynamic adjustment of the roller pressure, and ensure the uniformity of the rolling liquid penetration;

[0008] The pressure execution module is used to execute control instructions and convert the calculated theoretical pressure value into the actual mechanical pressure of the roller.

[0009] According to the above technical solution, the non-contact elastic detection module further includes a laser displacement sensor array, a high-speed imaging module and a tension transient excitation unit; wherein,

[0010] The laser displacement sensor array, which consists of several groups of line laser transmitters and CMOS optical receivers, is used to scan the deformation of the fabric surface in real time, generate three-dimensional deformation data, and calculate the macroscopic elongation ΔL of the fabric under transient tension;

[0011] High-speed imaging module, composed of an industrial camera and an FPGA image processing chip, is used to capture the microstructural changes of the fabric and identify the slippage S;

[0012] The tension transient excitation unit is used to apply instantaneous tension to the cloth guide rollers driven by dual servo motors, ensuring that the tension application is synchronized with the detection timing of the laser and the camera.

[0013] According to the above technical solution, the intelligent analysis control module further includes an elastic characteristic calculation unit and a dynamic pressure compensation control unit; wherein,

[0014] The elastic feature calculation unit consists of an embedded processor and a slip fusion algorithm database, which is used to fuse laser deformation data and image analysis results to calculate the equivalent elastic modulus;

[0015] The dynamic pressure compensation control unit is used to calculate the target pressure in real time according to the elastic modulus and output a control signal to the pressure execution module.

[0016] According to the above technical solution, the pressure execution module further includes a precision pressure adjustment unit and a safety protection unit; wherein,

[0017] Precision pressure regulating unit, including linear servo motor and proportional relief valve, used to convert control signal into actual pressure of roller, realizing fast dynamic adjustment;

[0018] The safety protection unit is used to determine if the pressure deviation exceeds the preset safety threshold, trigger an emergency shutdown and record the fault code and upload it to the MES system.

[0019] According to the above technical solution, the logic for obtaining the macroscopic elongation ΔL is as follows:

[0020] In the tension-free state, the laser displacement sensor array scans the fabric surface and records the initial position coordinate set Then a three-dimensional benchmark model of the fabric surface is established;

[0021] When the tension transient excitation unit controls the dual servo motors to drive the cloth guide rollers to apply instantaneous tension, the laser displacement sensor array scans synchronously to obtain the coordinates after deformation.

[0022] The longitudinal displacement of each monitoring point Perform statistical analysis and remove outliers that deviate from the mean by more than 3σ;

[0023] Calculate the average displacement, which is expressed as follows: Where N is the valid data point;

[0024] According to the laser sensor temperature t, the drift error is corrected, and its expression is as follows: ΔL=ΔL raw ×[1-β(tt 0 )], where β is the temperature compensation coefficient, t 0 is the preset reference temperature, ΔL raw is the original average elongation;

[0025] The final output ΔL is the macroscopic elongation of the fabric under transient tension.

[0026] According to the above technical solution, the acquisition logic of the slip amount S is as follows:

[0027] The captured image of the high-speed imaging module is divided into m×m sub-areas, and the main direction angle θ of each area is obtained based on the histogram. When the main direction angle θ=0°, it is divided into the longitude direction, and when the main direction angle θ=90°, it is divided into the latitude direction;

[0028] Perform feature matching on the tension-free image and the deformation image after applying tension, and calculate the displacement field Δy(x,y) in the latitude direction, i.e., the Y-axis.

[0029] Count the Y-axis displacement Δy of all feature points i , remove outliers beyond the range of μ+3σ, where μ is the mean and σ is the standard deviation;

[0030] Calculate the slip amount S, the expression is as follows: Where M is the number of valid feature points, and k is the conversion coefficient between pixels and physical size.

[0031] According to the above technical solution, the calculation expression of the equivalent elastic modulus is:

[0032]

[0033] Where ΔL is the macroscopic elongation, T is the fabric thickness, W is the fabric width, F is the applied tension value, L is the length of the detection area, S is the yarn slippage, S max is the maximum slip allowed by the material, and E is the equivalent elastic modulus; It is a macro elastic term, which is used to reflect the overall tensile properties of the fabric. is the micro slip correction term.

[0034] According to the above technical solution, the calculation expression for calculating the target pressure in real time according to the elastic modulus is:

[0035]

[0036] Where K is the reference pressure coefficient, α is the differential compensation coefficient, Indicates the rate of change of elastic modulus, P 0 The base pressure is preset according to the fabric type.

[0037] According to the above technical solution, the safety protection unit includes a multi-level pressure monitoring mechanism, and the specific logic is:

[0038] When the pressure deviation exceeds 5% and lasts for ≥1 second, the first-level warning mode is activated, triggering the yellow warning light and reducing the rolling speed to 50% of the original speed;

[0039] When the pressure deviation exceeds 10% or the slip S ≥ 0.9S max When the secondary protection mode is activated, a red alarm is triggered and the servo motor power is cut off;

[0040] After an emergency shutdown, the machine will automatically perform a three-level self-check, which includes the following operations:

[0041] a. Release the roller pressure to a safe value;

[0042] b. Generate fault diagnosis report;

[0043] c. Send maintenance work order request to MES system through OPC UA protocol.

[0044] According to the above technical solution, the fault diagnosis report generated in the three-level self-check includes a machine learning recommended solution, and the specific method is:

[0045] Compare current fault characteristics with historical database;

[0046] The k-NN algorithm is used to calculate the Euclidean distance of fault features, match similar fault cases, and display the top three high-probability maintenance suggestions.

[0047] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: the present invention can accurately obtain the macroscopic elongation and microscopic slip of the fabric in real time through the collaborative detection of non-contact laser scanning and high-speed imaging, and combines temperature compensation and slip correction algorithms to break through the technical bottleneck of traditional elastic modulus detection being greatly affected by environmental interference and evaluation distortion. At the same time, based on the elastic pressure dynamic mapping model and the feedforward feedback composite control strategy, the millisecond-level adaptive adjustment of the roller pressure is achieved, significantly improving the uniformity of the rolling liquid. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] The accompanying drawings are used to provide further understanding of the present invention and constitute a part of the specification. They are used to explain the present invention together with the embodiments of the present invention and do not constitute a limitation of the present invention.

[0049] In the attached picture:

[0050] Figure 1 It is a schematic diagram of the system module composition of the present invention. DETAILED DESCRIPTION

[0051] 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.

[0052] See also Figure 1 The present invention provides a technical solution: a digital control system for uniform rolling, comprising a non-contact elastic detection module, an intelligent analysis and control module and a pressure execution module, wherein the non-contact elastic detection module, the intelligent analysis and control module and the pressure execution module are mutually connected by signals; wherein,

[0053] Non-contact elasticity detection module, used to obtain the elasticity characteristics of the fabric in real time, providing data support for dynamic adjustment of roller pressure;

[0054] Intelligent analysis and control module, used to analyze and calculate the detection data, convert the detection data into control instructions, realize real-time dynamic adjustment of the roller pressure, and ensure the uniformity of the rolling liquid penetration;

[0055] The pressure execution module is used to execute the control instructions and convert the calculated theoretical pressure value into the actual mechanical pressure of the roller;

[0056] The system integrates non-contact elasticity detection module, intelligent analysis control module and pressure execution module to achieve real-time detection, intelligent analysis and dynamic pressure adjustment of fabric elasticity. It not only improves the uniformity of liquid penetration, but also enhances the processing ability of special fabrics. It also has intelligent functions such as fault classification response and machine learning recommendation solutions, providing strong support for the intelligent upgrade of the textile printing and dyeing industry.

[0057] The non-contact elastic detection module further includes a laser displacement sensor array, a high-speed imaging module and a tension transient excitation unit; wherein,

[0058] The laser displacement sensor array, which consists of several groups of line laser transmitters and CMOS optical receivers, is used to scan the deformation of the fabric surface in real time, generate three-dimensional deformation data, and calculate the macroscopic elongation ΔL of the fabric under transient tension, thus avoiding damage to the fabric caused by contact measurement.

[0059] High-speed imaging module, composed of an industrial camera and an FPGA image processing chip, is used to capture the microstructural changes of the fabric and identify the slippage S;

[0060] The tension transient excitation unit is used to apply instantaneous tension to the cloth guide rollers through dual servo motors, ensuring that the tension application is synchronized with the detection timing of the laser and camera; it not only realizes online detection of elastic properties, but also can accurately detect special fabrics such as highly elastic and ultra-thin fabrics;

[0061] The logic for obtaining the macroscopic elongation ΔL is as follows:

[0062] In the tension-free state, the laser displacement sensor array scans the fabric surface and records the initial position coordinate set Then a three-dimensional benchmark model of the fabric surface is established;

[0063] When the tension transient excitation unit controls the dual servo motors to drive the cloth guide rollers to apply instantaneous tension, the laser displacement sensor array scans synchronously to obtain the coordinates after deformation.

[0064] The longitudinal displacement of each monitoring point Perform statistical analysis and remove outliers that deviate from the mean by more than 3σ; thus effectively avoiding interference caused by fabric wrinkles or foreign objects;

[0065] Calculate the average displacement, which is expressed as follows: Where N is the valid data point;

[0066] According to the laser sensor temperature t, the drift error is corrected, and its expression is as follows: ΔL=ΔL raw ×[1-β(tt 0 )], where β is the temperature compensation coefficient, t 0 is the preset reference temperature, ΔL raw is the original average elongation;

[0067] The final output ΔL is the macroscopic elongation of the fabric under transient tension. By introducing the temperature compensation term, the interference of thermal drift on the elongation measurement is eliminated, and the measurement error caused by the laser sensor being affected by the ambient temperature is effectively avoided, which leads to inaccurate ΔL calculation, thereby effectively improving the measurement accuracy and adapting to the temperature fluctuations in the workshop.

[0068] The logic for obtaining the slip amount S is as follows:

[0069] The captured image of the high-speed imaging module is divided into m×m sub-areas, and the main direction angle θ of each area is obtained based on the histogram. When the main direction angle θ=0°, it is divided into the longitude direction, and when the main direction angle θ=90°, it is divided into the latitude direction, so as to realize the extraction of the direction field;

[0070] Perform feature matching on the tension-free image and the deformation image after applying tension, and calculate the displacement field Δy(x,y) in the latitude direction, i.e., the Y-axis.

[0071] Count the Y-axis displacement Δy of all feature points i , remove outliers beyond the range of μ+3σ, where μ is the mean and σ is the standard deviation;

[0072] Calculate the slip amount S, the expression is as follows: Where M is the number of effective feature points, and k is the conversion coefficient between pixels and physical dimensions. In the formula, the online measurement of slippage is achieved through high-speed imaging and non-contact image analysis, which avoids the problem that the traditional manual detection of yarn slippage is time-consuming and cannot be quantitatively analyzed, greatly improving the detection efficiency.

[0073] The intelligent analysis control module further includes an elastic characteristic calculation unit and a dynamic pressure compensation control unit; wherein,

[0074] The elastic feature calculation unit consists of an embedded processor and a slip fusion algorithm database, which is used to fuse laser deformation data and image analysis results to calculate the equivalent elastic modulus;

[0075] A dynamic pressure compensation control unit, used to calculate the target pressure in real time according to the elastic modulus, and output a control signal to the pressure execution module;

[0076] The calculation expression of equivalent elastic modulus is:

[0077]

[0078] Where ΔL is the macroscopic elongation, T is the fabric thickness, W is the fabric width, F is the applied tension value, L is the length of the detection area, S is the yarn slippage, S max is the maximum slip allowed by the material, and E is the equivalent elastic modulus; It is a macro elastic term, which is used to reflect the overall tensile properties of the fabric. It is a micro-slip correction item. The traditional elastic modulus test ignores the influence of yarn slippage, which leads to pressure setting deviation. The elastic modulus is corrected by the slippage S, thereby avoiding the distortion of elastic evaluation caused by yarn slippage, achieving the effect of improving pressure matching, and effectively reducing the error of elastic modulus.

[0079] When a decrease in elastic modulus is detected, such as spandex aging, the roller pressure is automatically reduced, and the time for the squeeze liquid to penetrate is increased to compensate; the elastic value of each meter of fabric is monitored in real time during the production process, and the pressure is automatically adjusted for abnormal elastic sections, such as fabric joints, to avoid uneven squeeze liquid penetration caused by sudden changes in material elasticity;

[0080] The calculation expression for real-time calculation of target pressure based on elastic modulus is:

[0081]

[0082] Where K is the reference pressure coefficient, α is the differential compensation coefficient, Indicates the rate of change of elastic modulus, P 0 The reference pressure is preset according to the fabric type. Through the feedforward-to-feedback compliance control, the pressure demand is predicted in combination with the elastic change trend, so as to shorten the pressure adjustment response time, thereby achieving the effect of improving the uniformity of the squeeze liquid, solving the problem that the traditional method is difficult to adapt to the rapid change of elastic modulus and is prone to overshoot.

[0083] The pressure execution module further includes a precision pressure adjustment unit and a safety protection unit; wherein,

[0084] Precision pressure regulating unit, including linear servo motor and proportional relief valve, used to convert control signal into actual pressure of roller, realizing fast dynamic adjustment;

[0085] Safety protection unit, used to determine if the pressure deviation exceeds the preset safety threshold, trigger emergency shutdown and record the fault code and upload it to the MES system;

[0086] The safety protection unit includes a multi-level pressure monitoring mechanism, the specific logic is:

[0087] When the pressure deviation exceeds 5% and lasts for ≥1 second, the first-level warning mode is activated, triggering the yellow warning light and reducing the rolling speed to 50% of the original speed to prevent minor abnormalities from expanding;

[0088] When the pressure deviation exceeds 10% or the slip S ≥ 0.9S max When the secondary protection mode is activated, a red alarm is triggered and the servo motor power is cut off to avoid equipment damage;

[0089] After an emergency shutdown, the machine will automatically perform a three-level self-check, which includes the following operations:

[0090] a. Release the roller pressure to a safe value;

[0091] b. Generate fault diagnosis report;

[0092] c. Send maintenance work order requests to the MES system through the OPC UA protocol; balance production efficiency and safety through a graded response strategy. Compared with the traditional single safety mechanism that cannot distinguish the fault level, the above steps shorten the equipment failure downtime and improve the maintenance response efficiency;

[0093] The fault diagnosis report generated in the third level self-check contains machine learning recommended solutions, which are as follows:

[0094] Compare current fault characteristics with historical database;

[0095] The k-NN algorithm is used to calculate the Euclidean distance of fault features, match similar fault cases, and display the top three high-probability maintenance suggestions.

[0096] 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.

[0097] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A digital control system for uniform rolling, characterized in that: It includes a non-contact elastic detection module, an intelligent analysis and control module and a pressure execution module, wherein the non-contact elastic detection module, the intelligent analysis and control module and the pressure execution module are mutually connected by signals; wherein, Non-contact elasticity detection module, used to obtain the elasticity characteristics of the fabric in real time, providing data support for dynamic adjustment of roller pressure; Intelligent analysis and control module, used to analyze and calculate the detection data, convert the detection data into control instructions, realize real-time dynamic adjustment of the roller pressure, and ensure the uniformity of the rolling liquid penetration; The pressure execution module is used to execute control instructions and convert the calculated theoretical pressure value into the actual mechanical pressure of the roller.

2. A digital control system for uniform rolling according to claim 1, characterized in that: The non-contact elastic detection module further includes a laser displacement sensor array, a high-speed imaging module and a tension transient excitation unit; wherein, The laser displacement sensor array, which consists of several groups of line laser transmitters and CMOS optical receivers, is used to scan the deformation of the fabric surface in real time, generate three-dimensional deformation data, and calculate the macroscopic elongation ΔL of the fabric under transient tension; High-speed imaging module, composed of an industrial camera and an FPGA image processing chip, is used to capture the microstructural changes of the fabric and identify the slippage S; The tension transient excitation unit is used to apply instantaneous tension to the cloth guide rollers driven by dual servo motors, ensuring that the tension application is synchronized with the detection timing of the laser and the camera.

3. A digital control system for uniform rolling according to claim 1, characterized in that: The intelligent analysis and control module further includes an elastic characteristic calculation unit and a dynamic pressure compensation control unit; in, The elastic feature calculation unit consists of an embedded processor and a slip fusion algorithm database, which is used to fuse laser deformation data and image analysis results to calculate the equivalent elastic modulus; The dynamic pressure compensation control unit is used to calculate the target pressure in real time according to the elastic modulus and output a control signal to the pressure execution module.

4. A digital control system for uniform rolling according to claim 1, characterized in that: The pressure execution module further includes a precision pressure adjustment unit and a safety protection unit; wherein, Precision pressure regulating unit, including linear servo motor and proportional relief valve, used to convert control signal into actual pressure of roller, realizing fast dynamic adjustment; The safety protection unit is used to determine if the pressure deviation exceeds the preset safety threshold, trigger an emergency shutdown and record the fault code and upload it to the MES system.

5. A digital control system for uniform rolling according to claim 2, characterized in that: The logic for obtaining the macroscopic elongation ΔL is as follows: In the tension-free state, the laser displacement sensor array scans the fabric surface and records the initial position coordinate set Then a three-dimensional benchmark model of the fabric surface is established; When the tension transient excitation unit controls the dual servo motors to drive the cloth guide rollers to apply instantaneous tension, the laser displacement sensor array scans synchronously to obtain the coordinates after deformation. The longitudinal displacement of each monitoring point Perform statistical analysis and remove outliers that deviate from the mean by more than 3σ; Calculate the average displacement, which is expressed as follows: Where N is the valid data point; According to the laser sensor temperature t, the drift error is corrected, and its expression is as follows: ΔL=ΔL raw ×[1-β(t-t0)], where β is the temperature compensation coefficient, t0 is the preset reference temperature, ΔL raw is the original average elongation; The final output ΔL is the macroscopic elongation of the fabric under transient tension.

6. A digital control system for uniform rolling according to claim 2, characterized in that: The acquisition logic of the slip amount S is as follows: The captured image of the high-speed imaging module is divided into m×m sub-areas, and the main direction angle θ of each area is obtained based on the histogram. When the main direction angle θ=0°, it is divided into the longitude direction, and when the main direction angle θ=90°, it is divided into the latitude direction; Perform feature matching on the tension-free image and the deformation image after applying tension, and calculate the displacement field Δy(x,y) in the latitude direction, i.e., the Y-axis. Count the Y-axis displacement Δy of all feature points i , remove outliers beyond the range of μ+3σ, where μ is the mean and σ is the standard deviation; Calculate the slip amount S, the expression is as follows: Where M is the number of valid feature points, and k is the conversion coefficient between pixels and physical size.

7. A digital control system for uniform rolling according to claim 3, characterized in that: The calculation expression of equivalent elastic modulus is: Where ΔL is the macroscopic elongation, T is the fabric thickness, W is the fabric width, F is the applied tension value, L is the length of the detection area, S is the yarn slippage, S max is the maximum slip allowed by the material, and E is the equivalent elastic modulus; It is a macro elastic term, which is used to reflect the overall tensile properties of the fabric. is the micro slip correction term.

8. A digital control system for uniform rolling according to claim 7, characterized in that: The calculation expression for real-time calculation of target pressure based on elastic modulus is: Where K is the reference pressure coefficient, α is the differential compensation coefficient, It represents the rate of change of elastic modulus, and P0 is the reference pressure preset according to the fabric type.

9. A digital control system for uniform rolling according to claim 4, characterized in that: The safety protection unit includes a multi-level pressure monitoring mechanism, the specific logic is: When the pressure deviation exceeds 5% and lasts for ≥1 second, the first-level warning mode is activated, triggering the yellow warning light and reducing the rolling speed to 50% of the original speed; When the pressure deviation exceeds 10% or the slip S ≥ 0.9S max When the secondary protection mode is activated, a red alarm is triggered and the servo motor power is cut off; After an emergency shutdown, the machine will automatically perform a three-level self-check, which includes the following operations: a. Release the roller pressure to a safe value; b. Generate fault diagnosis report; c. Send maintenance work order request to MES system through OPC UA protocol.

10. A digital control system for uniform rolling according to claim 9, characterized in that: The fault diagnosis report generated in the third level self-check contains machine learning recommended solutions, which are as follows: Compare current fault characteristics with historical database; The k-NN algorithm is used to calculate the Euclidean distance of fault features, match similar fault cases, and display the top three high-probability maintenance suggestions.

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