A digital control system for uniform rolling mills

Abstract

This invention discloses a digital control system for uniform rolling mills, comprising a non-contact elasticity detection module, an intelligent analysis and control module, and a pressure execution module, which are interconnected. The non-contact elasticity detection module acquires the elastic properties of the fabric in real time, providing data support for dynamically adjusting the roll pressure. The intelligent analysis and control module analyzes and processes the detection data, converting it into control commands to achieve real-time dynamic adjustment of the roll pressure and ensure uniform penetration of the rolling fluid. The pressure execution module executes the control commands, converting the calculated theoretical pressure value into the actual mechanical pressure of the roll. This invention features uniform rolling fluid penetration and high processing efficiency.

Description

TECHNICAL FIELD

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

[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 roller, so that the liquid penetrates uniformly into the fabric. However, the elastic properties of the fabric put higher requirements on the working pressure setting of the padder. The traditional padder usually adopts fixed pressure setting value, which cannot be dynamically adjusted according to the actual elastic properties of the fabric, which leads to uneven liquid penetration, affecting the dyeing effect and fabric quality.

[0003] The traditional padder control system often relies on manual experience or simple mechanical pressure adjustment, which has many shortcomings. On the one hand, it is difficult for manual pressure setting to accurately reflect the real-time elastic change of the fabric, especially when processing special fabrics such as high elasticity and ultra-thin fabrics, which is prone to uneven liquid penetration and fabric damage. On the other hand, the mechanical pressure adjustment has slow response speed and cannot quickly adapt to the rapid change of fabric elasticity, which is prone to pressure overshoot or deficiency, affecting the processing efficiency and product quality. Therefore, it is necessary to design a digital control system for uniform padder with uniform liquid penetration and high processing efficiency. SUMMARY

[0004] The purpose of the present application is to provide a digital control system for uniform padder to solve the problems raised in the background.

[0005] In order to solve the above technical problems, the present application provides the following technical scheme: a digital control system for uniform padder, comprising a non-contact elastic detection module, an intelligent analysis control module and a pressure execution module, the non-contact elastic detection module, the intelligent analysis control module and the pressure execution module are signal connected with each other; wherein,

[0006] The non-contact elastic detection module is used to obtain the elastic properties of the fabric in real time, and provides data support for dynamic adjustment of the roller pressure;

[0007] The intelligent analysis control module is 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 liquid penetration;

[0008] 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.

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

[0010] Laser displacement sensor array, composed of several groups of linear laser transmitters and CMOS optical receivers, for real-time scanning of fabric surface deformation, generating three-dimensional deformation data, calculating the macroscopic elongation of the fabric under transient tension ;

[0011] High-speed imaging module, composed of an industrial camera and a FPGA image processing chip, for capturing the microstructure changes of the fabric, identifying the slip S;

[0012] Tension transient excitation unit, for applying transient tension by driving the guide roller with double servo motors, ensuring that the tension application is synchronized with the detection timing of the laser and camera.

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

[0014] The elastic characteristic calculation unit, composed of an embedded processor and a slip fusion algorithm database, is used to fuse the laser deformation data and image analysis results, and 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 the control signal to the pressure execution module.

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

[0017] The precision pressure regulation unit, containing a linear servo motor and a proportional overflow valve, is used to convert the control signal into the actual pressure of the roller, realizing rapid dynamic adjustment;

[0018] The safety protection unit is used to determine whether the pressure deviation exceeds the preset safety threshold, and when it does, trigger an emergency stop and record the fault code for uploading to the MES system.

[0019] According to the above technical solution, the macroscopic elongation is obtained as follows:

[0020] In the tension-free state, the laser displacement sensor array scans the fabric surface, recording the initial position coordinate set , and then establishes a three-dimensional reference model of the fabric surface;

[0021] When the tension transient excitation unit controls the double servo motors to drive the guide roller to apply transient tension, the laser displacement sensor array scans synchronously to obtain the coordinates after deformation;

[0022] The longitudinal displacement of each monitoring point is statistically analyzed and removed if it deviates from the mean value by more than outliers;

[0023] The average displacement is calculated using the following expression: Where N is the number of valid data points;

[0024] The drift error is corrected based on the laser sensor temperature t, and its expression is as follows: ,in Temperature compensation coefficient, For preset reference temperature, This represents the original average elongation.

[0025] Final output It represents the macroscopic elongation of the fabric under transient tension.

[0026] According to the above technical solution, the logic for obtaining the slippage S is as follows:

[0027] The captured images from the high-speed imaging module are divided into Sub-regions, obtaining the principal orientation angle of each region based on the histogram. , when the main direction angle Time zones are divided into meridian directions, when the principal direction angle = Time zones are divided into parallels of latitude;

[0028] Feature matching is performed between the tension-free image and the deformation image after tension is applied to calculate the displacement field along the latitudinal direction, i.e., the Y-axis. ;

[0029] Calculate the Y-axis displacement of all feature points Remove excess outliers in the range, where The mean, Standard deviation;

[0030] The slip S is calculated using the following expression: , where M is the number of effective feature points and k is the conversion coefficient between pixels and physical size.

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

[0032]

[0033] in, For macroscopic elongation, For fabric thickness, For fabric width, To apply tension value, For the length of the detection area, For yarn slippage, The maximum allowable slip of the material, The equivalent elastic modulus; where This is the macroscopic elasticity term, used to reflect the overall tensile properties of the fabric. This is a micro-slip correction term.

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

[0035]

[0036] Where K is the reference pressure coefficient, For differential compensation coefficient, This represents the rate of change of the elastic modulus. This is a preset reference pressure based on the fabric type.

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

[0038] When the pressure deviation exceeds 5% and lasts for ≥1 second, the Level 1 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 slippage... When this occurs, the secondary protection mode is activated, triggering a red alarm and cutting off the power to the servo motor;

[0040] After an emergency shutdown, a three-level self-test is automatically performed, which includes the following operations:

[0041] a. Release the roll pressure to a safe level;

[0042] b. Generate a fault diagnosis report;

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

[0044] According to the above technical solution, the fault diagnosis report generated in the three-level self-test includes a machine learning recommendation solution, specifically as follows:

[0045] Compare the current fault characteristics with the 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 most probable maintenance suggestions.

[0047] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: The present invention obtains the macroscopic elongation and microscopic slip of the fabric in real time and accurately through the collaborative detection of non-contact laser scanning and high-speed imaging. Combined with temperature compensation and slip correction algorithms, it breaks through the technical bottleneck of traditional elastic modulus detection being greatly affected by environmental interference and resulting in evaluation distortion. At the same time, based on the elastic pressure dynamic mapping model and feedforward feedback composite control strategy, it realizes millisecond-level adaptive adjustment of roll pressure, which significantly improves the uniformity of the slurry. Attached Figure Description

[0048] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0049] Figure 1 This is a schematic diagram of the system module composition of the present invention. Detailed Implementation

[0050] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0051] Please see Figure 1 This invention provides a technical solution: a digital control system for uniform rolling mills, 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 interconnected by signals; wherein,

[0052] A non-contact elasticity detection module is used to acquire the elasticity properties of fabrics in real time, providing data support for dynamically adjusting the roller pressure;

[0053] The intelligent analysis and control module is used to analyze and process the detection data, convert the detection data into control commands, realize real-time dynamic adjustment of the roll pressure, and ensure uniform penetration of the rolling slurry.

[0054] The pressure execution module is used to execute control commands and convert the calculated theoretical pressure value into the actual mechanical pressure of the roll;

[0055] This system integrates a non-contact elasticity detection module, an intelligent analysis and control module, and a pressure execution module, enabling real-time detection, intelligent analysis, and dynamic pressure adjustment of fabric elastic properties. It not only improves the uniformity of liquid penetration but also enhances the processing capabilities for special fabrics. Furthermore, it possesses intelligent functions such as fault classification response and machine learning-based solution recommendations, providing strong support for the intelligent upgrading of the textile printing and dyeing industry.

[0056] The non-contact elasticity detection module further includes a laser displacement sensing array, a high-speed imaging module, and a tension transient excitation unit; among which,

[0057] The laser displacement sensing array, composed of several sets of line laser emitters and CMOS optical receivers, is used to scan the surface deformation of fabrics in real time, generate three-dimensional deformation data, and calculate the macroscopic elongation of the fabric under transient tension. To avoid damage to the fabric caused by contact measurement;

[0058] The high-speed imaging module, consisting of an industrial camera and an FPGA image processing chip, is used to capture microstructural changes in fabrics and identify slippage S.

[0059] The tension transient excitation unit is used to apply instantaneous tension by driving the guide roller with dual servo motors, ensuring that the tension application is synchronized with the detection timing of the laser and camera; it can not only realize online detection of elastic properties, but also accurately detect special fabrics such as high elasticity and ultra-thin fabrics;

[0060] Macro elongation The logic for obtaining it is as follows:

[0061] Under tension-free conditions, a laser displacement sensor array scans the fabric surface and records the initial position coordinate set. Then, a three-dimensional reference model of the fabric surface is established;

[0062] When the tension transient excitation unit controls the dual servo motors to drive the guide rollers and apply instantaneous tension, the laser displacement sensor array scans synchronously to acquire the coordinates after deformation. ;

[0063] Longitudinal displacement at each monitoring point Perform statistical analysis and remove those that deviate from the mean by more than [a certain amount]. Abnormal values; thus effectively avoiding interference from fabric wrinkles or foreign objects;

[0064] The average displacement is calculated using the following expression: Where N is the number of valid data points;

[0065] The drift error is corrected based on the laser sensor temperature t, and its expression is as follows: ,in Temperature compensation coefficient, For preset reference temperature, This represents the original average elongation.

[0066] Final output This refers to the macroscopic elongation of the fabric under transient tension. By introducing a temperature compensation term, the interference of thermal drift on the elongation measurement is eliminated, effectively avoiding the measurement error easily caused by the influence of ambient temperature on the laser sensor. The calculation was inaccurate, which effectively improved the measurement accuracy and adapted to the temperature fluctuations in the workshop.

[0067] The logic for obtaining the slip S is as follows:

[0068] The captured images from the high-speed imaging module are divided into Sub-regions, obtaining the principal orientation angle of each region based on the histogram. , when the main direction angle Time zones are divided into meridian directions, when the principal direction angle = The time zone is divided into latitude directions to extract the direction field;

[0069] Feature matching is performed between the tension-free image and the deformation image after tension is applied to calculate the displacement field along the latitudinal direction, i.e., the Y-axis. ;

[0070] Calculate the Y-axis displacement of all feature points Remove excess outliers in the range, where The mean, Standard deviation;

[0071] The slip S is calculated using the following expression: Where M is the number of effective feature points and k is the conversion coefficient between pixels and physical size; the formula realizes online measurement of slippage through high-speed imaging and non-contact image analysis, avoiding the problems of time-consuming and unquantifiable analysis of traditional manual yarn slippage detection, and greatly improving detection efficiency;

[0072] The intelligent analysis and control module further includes an elastic characteristic calculation unit and a dynamic pressure compensation control unit; among which,

[0073] The elastic feature calculation unit, consisting of an embedded processor and a slip fusion algorithm database, is used to fuse laser deformation data and image analysis results to calculate the equivalent elastic modulus.

[0074] The dynamic pressure compensation control unit is used to calculate the target pressure in real time based on the elastic modulus and output control signals to the pressure execution module.

[0075] The expression for calculating the equivalent elastic modulus is:

[0076]

[0077] in, For macroscopic elongation, For fabric thickness, For fabric width, To apply tension value, For the length of the detection area, For yarn slippage, The maximum allowable slip of the material, The equivalent elastic modulus; where This is the macroscopic elasticity term, used to reflect the overall tensile properties of the fabric. This is a micro-slip correction term. Traditional elastic modulus testing ignores the influence of yarn slippage, leading to pressure setting deviations. By correcting the elastic modulus through the slippage amount S, the distortion of elasticity assessment caused by yarn slippage is avoided, thereby improving the pressure matching degree and effectively reducing the error of elastic modulus.

[0078] When a decrease in elastic modulus is detected, such as due to spandex aging, the roller pressure is automatically reduced while the compensation for the penetration time of the molten metal is increased. This enables real-time monitoring of the elasticity value of each meter of fabric during the production process. For sections with abnormal elasticity, such as fabric joints, the pressure is automatically adjusted to avoid uneven penetration of molten metal caused by sudden changes in material elasticity.

[0079] The formula for calculating the target pressure in real time based on the elastic modulus is as follows:

[0080]

[0081] Where K is the reference pressure coefficient, For differential compensation coefficient, This represents the rate of change of the elastic modulus. The reference pressure is preset according to the fabric type; by using feedforward to feedback conformal control, combined with the elastic change trend to predict the pressure demand, the pressure adjustment response time is shortened, thereby improving the uniformity of the slurry and solving the problem that traditional methods are difficult to adapt to rapid changes in elastic modulus and are prone to overshoot.

[0082] The pressure actuation module further includes a precision pressure regulating unit and a safety protection unit; wherein,

[0083] The precision pressure regulating unit, which includes a linear servo motor and a proportional relief valve, is used to convert the control signal into the actual pressure of the rolls, enabling rapid dynamic adjustment.

[0084] The safety protection unit is used to trigger an emergency shutdown and record the fault code when the pressure deviation exceeds the preset safety threshold;

[0085] The safety protection unit includes a multi-level pressure monitoring mechanism, the specific logic of which is as follows:

[0086] 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 escalating.

[0087] When the pressure deviation exceeds 10% or the slippage... When this occurs, the secondary protection mode is activated, triggering a red alarm and cutting off the power to the servo motor to prevent equipment damage.

[0088] After an emergency shutdown, a three-level self-test is automatically performed, which includes the following operations:

[0089] a. Release the roll pressure to a safe level;

[0090] b. Generate a fault diagnosis report;

[0091] c. Send maintenance work order requests to the MES system via the OPC UA protocol; through a tiered response strategy, balance production efficiency and safety. Compared with the traditional single safety mechanism that cannot distinguish the level of fault, the above steps shorten equipment downtime and improve maintenance response efficiency.

[0092] The fault diagnosis report generated during the Level 3 self-check includes machine learning-recommended solutions, specifically using the following method:

[0093] Compare the current fault characteristics with the historical database;

[0094] The k-NN algorithm is used to calculate the Euclidean distance of fault features, match similar fault cases, and display the top three most probable maintenance suggestions.

[0095] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0096] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A digital control system for a uniform rolling mill, characterized by: It comprises a non-contact elastic detection module, an intelligent analysis control module and a pressure execution module, which are signal connected with each other. The non-contact elastic detection module is used for real-time acquisition of the elastic properties of the fabric, and provides data support for dynamic adjustment of the roll pressure. The intelligent analysis control module is used for analysis and operation of the detection data, conversion of the detection data into control instructions, real-time dynamic adjustment of the roll pressure, and ensuring of the uniformity of the liquid penetration. The pressure execution module is used for execution of the control instructions, and conversion of the calculated theoretical pressure value into the actual mechanical pressure of the roll. The non-contact elastic detection module further comprises a laser displacement sensing array, a high-speed imaging module and a tension transient excitation unit. The laser displacement sensor array, composed of several groups of linear laser transmitters and CMOS optical receivers, is used for real-time scanning of fabric surface deformation, generating three-dimensional deformation data, and calculating the macroscopic elongation of the fabric under transient tension ; The high-speed imaging module is composed of an industrial camera and a FPGA image processing chip, and is used for capturing the microstructure changes of the fabric and identifying the slip S. The tension transient excitation unit is used for applying transient tension through double servo motor driving of the guide roller, and ensuring that the tension application is synchronized with the detection timing of the laser and the camera. The intelligent analysis control module further comprises an elastic characteristic calculation unit and a dynamic pressure compensation control unit. The elastic characteristic calculation unit is composed of an embedded processor and a slip fusion algorithm database, and is used for fusing the laser deformation data and the image analysis results, and calculating the equivalent elastic modulus. The dynamic pressure compensation control unit is used for real-time calculation of the target pressure according to the elastic modulus, and output of the control signal to the pressure execution module. macroscopic elongation The acquisition logic is as follows: In the tensionless state, the laser displacement sensor array scans the fabric surface, and records the initial position coordinate set Then a three-dimensional reference model of the fabric surface is established; When the tension transient excitation unit controls the double servo motor to drive the guide roller to apply transient tension, the laser displacement sensor array synchronously scans and obtains the coordinates after deformation ; longitudinal displacement of each monitoring point Statistical analysis was performed and outliers deviating more than 3 standard deviations from the mean were removed. The average displacement is calculated, the expression of which is as follows: where N is the effective data points; According to the laser sensor temperature t, the drift error is corrected, and its expression is as follows: Wherein is a temperature compensation coefficient, is a preset reference temperature, is the original average elongation; Final output is the macroscopic elongation of the fabric under transient tension; The logic for obtaining the slip S is as follows: dividing the captured image of the high-speed imaging module into sub-regions, obtaining a main direction angle of each region based on a histogram , when the main direction angle is in a meridian direction, when the main direction angle = is in a latitude direction; The tension-free image and the deformed image after tension are matched in features, and a displacement field of the weft direction, i.e. Y axis, is calculated ; Statistical all feature points Y axis displacement , remove outliers beyond range, wherein is the mean, is the standard deviation; The slip amount S is calculated, which is expressed as follows: where M is the number of effective feature points, and k is a conversion coefficient of pixels and physical size. The calculation expression of the equivalent elastic modulus is as follows: wherein, is the macroscopic elongation, is the fabric thickness, is the fabric width, is the applied tension value, is the detection zone length, is the yarn slippage, is the maximum slippage allowed by the material, is the equivalent elastic modulus; in which is the macroscopic elastic term, which reflects the overall tensile properties of the fabric, is the microscopic slippage correction term. The calculation expression for real-time calculation of the target pressure according to the elastic modulus is as follows: wherein K is a reference pressure coefficient, is a differential compensation coefficient, represents a rate of change of the elastic modulus, is a reference pressure preset according to the fabric type.

2. A digital control system for a homogenous rolling mill according to claim 1, characterized in that: The pressure execution module further comprises a precise pressure adjustment unit and a safety protection unit. The precise pressure adjustment unit contains a linear servo motor and a proportional overflow valve, and is used for conversion of the control signal into the actual pressure of the roll, and realization of fast dynamic adjustment. The safety protection unit is used for judging whether the pressure deviation exceeds the preset safety threshold, triggering emergency stop when the pressure deviation exceeds the preset safety threshold, and recording fault codes and uploading the fault codes to the MES system.

3. A digital control system for a homogenous rolling mill according to claim 2, characterized in that: The safety protection unit contains a multi-stage pressure monitoring mechanism, and the specific logic is as follows: When the pressure deviation exceeds 5% and the duration is greater than or equal to 1 second, a first-level warning mode is started, a yellow warning light is triggered, and the speed of the rolling mill is reduced to 50% of the original speed. When the pressure deviation exceeds 10% or the slip amount When the pressure deviation exceeds 10% or the slip amount When the pressure deviation exceeds 10% or the slip amount When the pressure deviation exceeds 10% or the slip amount When the pressure deviation exceeds 10% or the slip amount <000009 After emergency stop, a three-level self-check is automatically performed, which specifically includes the following operations: a. releasing the roll pressure to a safety value; b. generating a fault diagnosis report; c. sending a maintenance work order request to the MES system through the OPC UA protocol.

4. A digital control system for a homogenous rolling mill according to claim 3, characterized in that: The fault diagnosis report generated in the three-level self-check contains a machine learning recommended solution, and the specific method is as follows: The current fault characteristics are compared with the historical database; Through the k-NN algorithm, the Euclidean distance of the fault characteristics is calculated, similar fault cases are matched, and the top three high-probability maintenance suggestions are displayed.

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