High-efficiency, high-tension continuous automatic winding and defect monitoring device and operation method for fabric tape

Abstract

This invention discloses a high-efficiency, high-tension continuous automatic winding and defect monitoring device and its operating method for fabric tape. The device includes an unwinding mechanism, a quality inspection mechanism, a secondary tension mechanism, a tension detection mechanism, a rear pressing mechanism, a sewing mechanism, a front pressing mechanism, a deviation correction mechanism, a film take-up mechanism, a preheated guide roller, a pressure roller mechanism, and a hot air device. The quality inspection mechanism is fixedly connected to one end face of the unwinding mechanism. A secondary tension mechanism is provided between the quality inspection mechanism and the tension detection mechanism. The rear pressing mechanism, sewing mechanism, front pressing mechanism, deviation correction mechanism, and film take-up mechanism are sequentially arranged on one end face of the tension detection mechanism. This invention employs graded tension increases to meet the tension winding requirements of different processes. By adding intelligent detection, it can predict material defects in advance, thus avoiding product quality defects caused by raw material defects.

Description

Technical Field

[0001] This invention belongs to the field of carbon fiber processing technology, specifically relating to a high-efficiency, high-tension continuous automatic winding and defect monitoring device and operating method for fabric tape. Background Technology

[0002] With the continuous advancement of materials science, carbon fiber, a high-performance material, has gradually gained recognition and importance. Carbon fiber possesses excellent properties such as high strength, high modulus, low density, and corrosion resistance, making it widely applicable in aerospace, automotive, and sporting goods industries. However, the processing and molding technology of carbon fiber materials is relatively complex, requiring specialized equipment. The carbon fiber tape winding machine was developed to meet this need. It can wind carbon fiber tape onto mandrels of various shapes according to specific process requirements, producing carbon fiber products with specific shapes and properties.

[0003] Currently, CNC tape wrapping machines are still immature and have many problems, such as low production efficiency, requiring a lot of manual intervention, which can easily lead to product defects. Although tape wrapping machines have improved production efficiency to some extent, their wrapping speed is still limited compared to some more automated production equipment. Especially in large-scale production, the production efficiency of tape wrapping machines may not be able to meet the demand. Regular maintenance and upkeep are required to ensure their normal operation and extend their service life.

[0004] Maintenance costs include the expenses for replacing vulnerable parts, calibrating equipment, and repairing it. Operating a tape wrapping machine requires certain professional knowledge and skills; operators need specialized training to master the operation methods and maintenance techniques. This not only requires time and effort for training but may also increase the company's training costs. Because the operation of a tape wrapping machine is relatively complex, improper operation by the operator may lead to equipment malfunctions, product quality problems, or even safety accidents. This necessitates that operators be highly focused and meticulous, strictly adhering to the operating procedures.

[0005] Quality defects in raw materials (carbon fiber prepreg) are also a major cause of defective products. This invention improves production efficiency, enhances intelligent detection, and proactively predicts material defects through automation.

[0006] Therefore, in order to address the above-mentioned technical problems, it is necessary to provide a high-efficiency, high-tension continuous automatic winding and defect monitoring device and operating method for the fabric tape.

[0007] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0008] The purpose of this invention is to provide a high-efficiency, high-tension continuous automatic winding and defect monitoring device and operating method for fabric tape, which can solve the problems raised in the background art.

[0009] To achieve the above objectives, a specific embodiment of the present invention provides the following technical solution:

[0010] A high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape includes an unwinding mechanism, a quality inspection mechanism, a secondary tension mechanism, a tension detection mechanism, a rear pressing mechanism, a sewing mechanism, a front pressing mechanism, a deviation correction mechanism, a film take-up mechanism, a preheating guide roller, a pressure roller mechanism, and a hot air device. The quality inspection mechanism is fixedly connected to one end face of the unwinding mechanism. A secondary tension mechanism is provided between the quality inspection mechanism and the tension detection mechanism. The rear pressing mechanism, sewing mechanism, front pressing mechanism, deviation correction mechanism, and film take-up mechanism are sequentially arranged on one end face of the tension detection mechanism. The preheating guide roller and pressure roller mechanism are sequentially arranged on the lower end face of the film take-up mechanism. The hot air device is fixedly connected to the bottom end face of the pressure roller mechanism. The hot air device includes a hot air nozzle, which is positioned to meet the tangent of the pressure roller mechanism and the mold.

[0011] In one or more embodiments of the present invention, the unwinding mechanism includes a first guide roller, a second guide roller, and an unwinding air shaft. The first guide roller, the second guide roller, and the unwinding air shaft are all fixedly connected to the back plate of the winding unit. The unwinding air shaft is located on the upper end face of the first guide roller and the second guide roller. The quality detection mechanism is located between the first guide roller and the second guide roller.

[0012] In one or more embodiments of the present invention, the secondary tension mechanism includes a tension-enhancing roller and a synchronous belt conveyor, wherein the tension-enhancing roller is connected to the synchronous belt conveyor, and the synchronous belt conveyor is fixedly connected to one end face of the back plate of the winding unit.

[0013] In one or more embodiments of the present invention, the tension detection mechanism includes a tension sensor and a side plate. A tension enhancement roller and an encoder guide roller are fixedly connected to a pair of opposite end faces of the side plate, respectively. A tension sensor protective cover is fixedly connected to the middle end face of the side plate. A guide roller support is fixedly connected to each pair of tension sensor protective covers, and a third guide roller is fixedly connected to the guide roller support.

[0014] In one or more embodiments of the present invention, the rear pressing mechanism includes a fixed seat, a first automatic sliding mechanism and a pressure plate. The fixed seat is fixedly connected to the top end face of the winding base. A pair of first automatic sliding mechanisms are movably connected to one side end face of the fixed seat. The pressure plate is fixedly connected to the bottom end face of the pair of first automatic sliding mechanisms.

[0015] In one or more embodiments of the present invention, the sewing mechanism includes a sewing machine mounting plate, a sewing machine head mounting plate is slidably connected to the sewing machine mounting plate, and a sewing machine head is fixedly connected to the sewing machine head mounting plate.

[0016] In one or more embodiments of the present invention, an automatic slide assembly is slidably connected to the top end face of the winding base, and a correction mechanism is connected to the top end face of the automatic slide assembly. The front pressing mechanism includes a traction mechanism, which is fixedly connected to one end face near the correction mechanism. One end face of the correction mechanism is mounted on the pressure roller mechanism. The correction mechanism includes a photoelectric position sensor and multiple correction rollers, and multiple pairs of correction rollers are arranged parallel to each other.

[0017] In one or more embodiments of the present invention, the film receiving mechanism includes a permanent magnet torque motor, which is fixedly connected to one end face of the automatic slide assembly. The permanent magnet torque motor is connected to multiple tiles, and each of the multiple tiles is connected to a hinge on one end face. Each of the multiple hinges is connected to a handle. The hot air device includes a hot air system and a hot air rod assembly, which is fixedly connected to one end face of the hot air system. The hot air rod assembly is fixedly connected to one end face of the automatic slide assembly.

[0018] In one or more embodiments of the present invention, the secondary tension mechanism employs a two-stage tension amplification method to progressively increase the tension applied to the fabric belt. The secondary tension amplification uses a 4Ω incremental tension amplification principle, and the total tension amplification factor is:

[0019] K = K1 * K2 * K3 * K4

[0020] In the formula, Ki is the amplification factor for each stage.

[0021] An operating method for a high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape includes the following steps;

[0022] S1. Unwinding: Initial tension is generated through the unwinding mechanism;

[0023] S2. Fabric tape defect detection: After tension is generated, the fabric tape is straightened by the unwinding mechanism and then enters the quality inspection agency for inspection.

[0024] S3, Secondary Tension Upgrade: After the quality inspection agency confirms that the quality inspection agency has no errors, the fabric belt enters the secondary tension mechanism for secondary tension upgrade. The secondary tension mechanism and the tension inspection mechanism form a closed-loop control.

[0025] S4. Sewing: The rear pressing mechanism and the front pressing mechanism press the fabric tape together. The fabric tape is pulled by the traction mechanism for double-sewing. The sewing mechanism automatically sewn the front and rear fabric tapes together when the fabric tape is changed.

[0026] S5. Correction: Correction is carried out simultaneously through a correction mechanism;

[0027] S6. Preheating and softening the fabric belt: The fabric belt is preheated by the preheating guide roller, and the separation film between the fabric belts is collected by the film collection mechanism;

[0028] S7. Press the fabric tape onto the mold: The fabric tape is fed into the pressing roller mechanism through the preheated guide roller and finally wound onto the mold. At the same time, the fabric tape is preheated and softened before pressing by the hot air device.

[0029] Compared with the prior art, the high-efficiency high-tension continuous automatic winding and defect monitoring device and operation method of the present invention have the following advantages;

[0030] By adopting graded tension increases to meet the tension winding requirements of different processes, and by adding intelligent detection to predict material defects in advance, product quality defects caused by raw material defects can be avoided.

[0031] By adding functional modules such as correction, stitching, hot pressing, and hot blowing, the automation level of winding is improved, manual intervention is reduced, and work efficiency is increased.

[0032] 3. It can greatly improve production efficiency, reduce product defects, reduce labor intensity, and ensure the physical and health safety of personnel. Attached Figure Description

[0033] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0034] Figure 1 This is a front view of a high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to an embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of the structure of a high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape in one embodiment of the present invention;

[0036] Figure 3 for Figure 2 A schematic diagram of the structure at point A;

[0037] Figure 4 for Figure 2 A schematic diagram of the structure at point B;

[0038] Figure 5 This is a schematic diagram of the structure of a high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to an embodiment of the present invention. Figure 2 ;

[0039] Figure 6 This is a schematic diagram of the structure of a high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to an embodiment of the present invention. Figure 3 ;

[0040] Figure 7 for Figure 6 A schematic diagram of the structure at point C;

[0041] Figure 8 This is a schematic diagram of the tension device of the present invention.

[0042] Figure 9 This is a schematic diagram of the working principle of the high tension amplifier of the present invention;

[0043] Figure 10 This is a schematic diagram of the quality inspection mechanism of the present invention;

[0044] Figure 11 This is a flowchart of the operation method of the high-efficiency high-tension continuous automatic winding and defect monitoring device for the present invention.

[0045] Explanation of key figure labels:

[0046] 1-Unwinding mechanism, 101-First guide roller, 102-Second guide roller, 103-Unwinding air shaft, 2-Quality inspection mechanism, 3-Secondary tension mechanism, 301-Tension reinforcing roller, 302-Synchronous belt conveyor, 4-Tension detection mechanism, 401-Third guide roller, 402-Guide roller support, 403-Knurled high-head screw, 404-Tension sensor protective cover, 405-Encoder guide roller, 406-Side plate, 5-Rear pressing mechanism, 501-Fixed seat, 502-First automatic sliding mechanism, 503-Pressure plate, 6-Sewing mechanism, 601-Sewing machine head, 602-Sewing machine head mounting plate, 603-Slider, 60 4-Slide rail, 605-Sewing machine mounting plate, 7-Front pressing mechanism, 701-Traction mechanism, 8-Correction mechanism, 801-Correction roller, 9-Wrap-up mechanism, 901-Permanent magnet torque motor, 902-Tile, 903-Handle, 904-Hinge, 10-Preheating guide roller, 1001-Electric heating roller protective cover, 11-Pressure roller mechanism, 12-Hot air device, 1201-Hot air system, 1202-Hot air nozzle, 1203-Hot air rod assembly, 13-Wrapping unit back plate, 14-Wrapping base, 15-Automatic slide assembly, 1501-Slide, 1502-Second automatic sliding mechanism, 1503-Correction bracket. Detailed Implementation

[0047] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this invention.

[0048] like Figure 1 As shown in the figure, an embodiment of the present invention discloses a high-efficiency, high-tension continuous automatic winding and defect monitoring device and operating method for fabric tape. The high-efficiency, high-tension continuous automatic winding and defect monitoring device includes an unwinding mechanism 1, a quality inspection mechanism 2, a secondary tension mechanism 3, a tension inspection mechanism 4, a rear pressing mechanism 5, a sewing mechanism 6, a front pressing mechanism 7, a deviation correction mechanism 8, a film take-up mechanism 9, a preheated guide roller 10, a pressure roller mechanism 11, and a hot air device 12. It meets the tension winding requirements of different processes. By adding intelligent detection, it can predict material defects in advance, avoiding product quality defects caused by raw material defects. By adding functional modules such as deviation correction, sewing, hot pressing, and hot air blowing, the automation level of winding is improved, manual intervention is reduced, and work efficiency is increased.

[0049] The unwinding mechanism 1, quality inspection mechanism 2, secondary tension mechanism 3, tension inspection mechanism 4, rear pressing mechanism 5, sewing mechanism 6, front pressing mechanism 7, correction mechanism 8, film winding mechanism 9, preheating guide roller 10, pressure roller mechanism 11 and hot air device 12 are all fixedly connected to the winding base 14 at the bottom, and the high-speed winding of the fabric tape is achieved through linkage with the CNC system.

[0050] A quality inspection mechanism 2 is fixedly connected to one end face of the unwinding mechanism 1. A secondary tension mechanism 3 is set between the quality inspection mechanism 2 and the tension inspection mechanism 4. A rear pressing mechanism 5, a sewing mechanism 6, a front pressing mechanism 7, a correction mechanism 8 and a film taking-up mechanism 9 are sequentially set on one end face of the tension inspection mechanism 4. A preheating guide roller 10 and a pressure roller mechanism 11 are sequentially set on the lower end face of the film taking-up mechanism 9. A hot air device 12 is fixedly connected to the bottom end face of the pressure roller mechanism 11. The hot air device 12 includes a hot air nozzle 1202, which is in contact with the tangent position of the pressure roller mechanism 11 and the mold.

[0051] Furthermore, the unwinding mechanism 1 includes a first guide roller 101, a second guide roller 102, and an unwinding air shaft 103. The first guide roller 101, the second guide roller 102, and the unwinding air shaft 103 are all fixedly connected to the back plate 13 of the winding unit. The unwinding air shaft 103 is located on the upper end face of the first guide roller 101 and the second guide roller 102. The quality inspection mechanism 2 is located between the first guide roller 101 and the second guide roller 102. The unwinding mechanism 1 is located at the rear end of the device and is used to generate initial tension. After the tension is generated, the fabric belt is aligned by the first guide roller 101 and the second guide roller 102 before entering the quality inspection mechanism 2.

[0052] Quality inspection unit 2 is used to detect quality defects in the fabric tape, including the presence of metal impurities and the uniformity of tape thickness. When a defect is detected, the machine will automatically stop and issue an alarm signal.

[0053] like Figure 10 As shown, the quality inspection unit 2 can detect and alarm for foreign objects such as metal inclusions in the raw materials of the fabric tape. Its principle is to use a magnetic field to detect metallic foreign objects. By energizing the metal wire of the coil, a magnetic field is generated. The sample being inspected passes through the magnetic field, and the change in the magnetic field's influence is measured to detect the mixed-in foreign objects, thus reducing the generation of waste products.

[0054] like Figure 2-7 As shown, the secondary tension mechanism 3 includes a tension-enhancing roller 301 and a synchronous belt conveyor 302. The tension-enhancing roller 301 is connected to the synchronous belt conveyor 302, which is fixedly connected to one end face of the winding unit back plate 13. The tension detection mechanism 4 includes a tension sensor and a side plate 406. A pair of opposite end faces of the side plate 406 are respectively fixedly connected to the tension-enhancing roller 301 and the encoder guide roller 405. A tension sensor protective cover 404 is fixedly connected to the middle end face of the side plate 406. A tension sensor is installed inside the tension sensor protective cover 404. A guide roller support 402 is fixedly connected to each pair of tension sensor protective covers 404. A third guide roller 401 is fixedly connected to the guide roller support 402, and a knurled high-head screw 403 is connected to the third guide roller 401. Tension is detected by the tension detection mechanism 4.

[0055] The secondary tension mechanism 3 further enhances the tension to achieve a larger process tension; the secondary tension mechanism 3 and the tension detection mechanism 4 form a closed-loop control, thereby achieving precise tension control, with an accuracy of ±1N during constant speed winding.

[0056] like Figure 8 As shown, the tension control principle is as follows: A two-stage tensioning system is used, with tension increasing progressively to effectively ensure tension control. Closed-loop control between unwinding and the tension controller allows tension to reach 1500N. The two-stage tensioning system gradually increases the tension applied to the fabric belt, effectively protecting the fibers from damage caused by sudden increases in tension and facilitating precise tension control.

[0057] The secondary tension amplification principle using 4Ω incremental tension amplification has a total tension amplification factor of:

[0058] K = K1 * K2 * K3 * K4

[0059] In the formula, Ki is the amplification factor for each stage.

[0060] like Figure 9 As shown, the single-stage amplifier uses a magnetic powder brake to apply tension. To ensure uniform tension application and prevent overshoot / undershoot in a single stage from damaging the yarn, the operating parameters of each stage's magnetic powder brake are measured online. The programmable controller (PLC) calculates and adjusts the input current of each stage to achieve tension distribution. The PLC can be manually adjusted online or communicated with the winding machine control system via a bus.

[0061] The rear pressing mechanism 5 includes a fixed base 501, a first automatic sliding mechanism 502, and a pressure plate 503. The fixed base 501 is fixedly connected to the top end face of the winding base 14. A pair of first automatic sliding mechanisms 502 are movably connected to one side end face of the fixed base 501. The pressure plate 503 is fixedly connected to the bottom end face of the pair of first automatic sliding mechanisms 502. The pressure plate 503 is pressed to the fabric belt by the up and down movement of the first automatic sliding mechanism 502.

[0062] The front pressing mechanism 7 includes a traction mechanism 701, which is fixedly connected to one end face near the correction mechanism 8. The front pressing mechanism 7 differs in structure from the rear pressing mechanism 5, the only difference being that the traction mechanism 701 is fixedly connected to the rear end face of the fixing seat 501 of the front pressing mechanism 7, enabling a certain number of sewing operations. The fabric tape is pressed and fixed by the rear pressing mechanism 5 and the front pressing mechanism 7.

[0063] The sewing mechanism 6 includes a sewing machine mounting plate 605, a sewing machine head mounting plate 602 slidably connected to the sewing machine mounting plate 605, and a sewing machine head 601 fixedly connected to the sewing machine head mounting plate 602.

[0064] Furthermore, a cylinder is provided on the inner end face of the sewing machine mounting plate 605, and a slide rail 604 and a slider 603 are provided on the outer end face of the sewing machine mounting plate 605. The cylinder drives the slider 603 to slide on the slide rail 604, thereby driving the sewing machine head 601 to move up and down.

[0065] A sliding mechanism is installed on the bottom end face of the sewing machine mounting plate 605. The sliding mechanism drives the sewing machine mounting plate 605 to move back and forth. The bottom end face of the sliding mechanism is fixedly connected to the bottom end face of the winding base 14.

[0066] Preferably, the sliding mechanism includes a cylinder, with a mounting plate connected to the top of the cylinder, and the mounting plate is connected to a sewing machine mounting plate 605.

[0067] Specifically, during the tape change, the sewing mechanism 6 automatically sewn the front and rear tapes together. Controlled by a servo motor, the sewing mechanism 6 achieves accurate positioning and movement, and automatically cuts off thread ends, thus ensuring product quality and improving production efficiency. Compared to traditional hand sewing, it can complete a large number of sewing tasks in a short time, saving companies time and labor costs. The stitches are even and strong.

[0068] An automatic slide assembly 15 is slidably connected to the top end face of the winding base 14. The automatic slide assembly 15 includes a slide 1501, a second automatic sliding mechanism 1502, and a correction bracket 1503. The second automatic sliding mechanism 1502 is fixed on the winding base 14. The top end face of the second automatic sliding mechanism 1502 is fixedly connected to the slide 1501. The top end face of the slide 1501 is fixedly connected to the correction bracket 1503. The second automatic sliding mechanism 1502 drives the slide 1501 and the correction bracket 1503 to move, thereby driving the correction mechanism 8 to move.

[0069] The top end face of the automatic slide assembly 15 is connected to the correction mechanism 8. The correction mechanism 8 is mounted on the pressure roller mechanism 11 via one side end face of the slide 1501. The correction mechanism 8 includes a photoelectric position sensor and multiple correction rollers 801, with multiple pairs of correction rollers 801 arranged parallel to each other. That is, the correction mechanism 8 is mounted on the pressure roller mechanism 11 and is relatively stationary to the pressure roller mechanism 11 to ensure the correction accuracy of the fabric belt. The correction mechanism 8 adopts a closed-loop control with dual parallel proportional rollers. The correction mechanism 8 mainly includes: a photoelectric position sensor, a drive motor, a driver, and a controller. The web guiding mechanism 8 uses a photoelectric position sensor to detect the edge position of the fabric tape. The measured position error signal is sent to the controller, which processes and judges the signal before controlling the drive motor to correct the deviated fabric tape to the correct position, achieving automatic web guiding. After testing with specialized equipment, the web guiding system's control accuracy can reach up to 0.08-0.1mm at a material linear speed of 3000m / min and a steady-state initial deviation. Therefore, the web guiding accuracy can be guaranteed within 0.5mm, with a guiding swing angle range of ±5°, and it can guide fabric tape with a width range of 10~200mm. It supports web guiding on either the left or right side of the fabric tape roll and allows for easy switching. The web guiding device is independently controlled, driven by a servo electric cylinder for left and right swing adjustment, and features overtravel protection and an LCD Chinese menu display.

[0070] The film collection mechanism 9 includes a permanent magnet torque motor 901, which is fixedly connected to one side of the automatic slide assembly 15. The permanent magnet torque motor 901 is connected to multiple tiles 902, and each tile 902 has a hinge 904 connected to one side of its side. Each hinge 904 has a handle 903 connected to it. The film collection mechanism 9 is located on the upper side of the preheating guide roller 10. The permanent magnet torque motor 901 drives the multiple tiles 902 to rotate and thus wind the isolation film, collecting the isolation film between the fabric strips.

[0071] The hot air device 12 includes a hot air system 1201 and a hot air rod assembly 1203. The hot air system 1201 is fixedly connected to one end face of the hot air rod assembly 1203, and the hot air rod assembly 1203 is fixedly connected to one end face of the automatic slide assembly 15. The hot air device 12 is located below the pressure roller mechanism 11, and its angle and position can be adjusted arbitrarily. The air outlet of the hot air nozzle 1202 is aligned with the tangent position of the pressure roller mechanism 11 and the mold to complete the preheating and softening of the fabric before pressing.

[0072] The preheating guide roller 10 is equipped with an electric heating roller protective cover 1001 on its upper end face, which protects the preheating guide roller 10. The preheating guide roller 10 can preheat and soften the fabric strip, increasing its adhesion, thereby making the fabric strips adhere more tightly and firmly during winding. The pressure roller mechanism 11, under the action of the cylinder, applies pressure to the fabric strip and the die components, squeezing out air bubbles and improving the winding effect.

[0073] like Figure 11 As shown, an operation method for a high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape includes the following steps;

[0074] S1. Unwinding: Initial tension is generated through unwinding mechanism 1;

[0075] S2. Fabric Belt Defect Detection: After tension is generated, the fabric belt is aligned by the first guide roller 101, the second guide roller 102, and the unwinding air shaft 103 before entering the quality inspection mechanism 2 for inspection. The inspection checks for quality defects in the fabric belt, including the presence of metal impurities and the uniformity of the fabric belt thickness. When a defect is detected, the machine will automatically stop and issue an alarm signal.

[0076] S3, Secondary Tension Upgrade: After the quality inspection mechanism 2 confirms that the quality is correct, the fabric belt enters the secondary tension mechanism 3 for secondary tension upgrade to obtain a large process tension. The secondary tension mechanism 3 and the tension detection mechanism 4 form a closed-loop control, thereby achieving precise tension control and tension detection.

[0077] S4. Sewing: The rear pressing mechanism 5 and the front pressing mechanism 7 press the fabric tape together, and the fabric tape is pulled and double-sewn by the traction mechanism 701. The sewing mechanism 6 automatically sews the front and rear fabric tapes together when the fabric tape is changed roll.

[0078] S5. Correction: Simultaneously, correction mechanism 8 is used to correct the position of the fabric belt;

[0079] S6. Preheating and softening the fabric belt: The fabric belt is preheated by the preheating guide roller 10, and the separation film between the fabric belts is collected by the film collection mechanism 9.

[0080] S7. Pressing the fabric strip onto the mold: After the fabric strip is preheated by the preheating guide roller 10, it enters the pressing roller mechanism 11 and is finally wound onto the mold. At the same time, the fabric strip is preheated and softened by the hot air device 12 before pressing.

[0081] The present invention has the following advantages;

[0082] The modular design of each functional component makes it easier to combine and maintain.

[0083] By adopting graded tension closed-loop control, high-tension, high-precision winding can be achieved with tension fluctuation <±1N;

[0084] The module incorporates functions such as automatic stitching, deviation correction, and automatic film collection, enabling automated winding.

[0085] The pressure rollers adopt a quick-change method and are locked by a cylinder, which can realize automatic roller changing.

[0086] Quality testing agencies can detect quality defects in raw materials, ensuring product quality and increasing economic benefits;

[0087] Preheating the guide roller with a heated roller before pressing the roller softens it in advance, which can improve the winding quality.

[0088] The position-adjustable hot air mechanism can heat the tangent of the pressure roller and the mold, improving the adhesion strength.

[0089] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0090] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high-efficiency, high-tension continuous automatic winding and defect monitoring device for textile tape, characterized in that, The system includes an unwinding mechanism, a quality inspection mechanism, a secondary tension mechanism, a tension detection mechanism, a rear pressing mechanism, a sewing mechanism, a front pressing mechanism, a web guiding mechanism, a film take-up mechanism, a preheating guide roller, a pressure roller mechanism, and a hot air device. The quality inspection mechanism is fixedly connected to one end face of the unwinding mechanism. A secondary tension mechanism is provided between the quality inspection mechanism and the tension detection mechanism. The rear pressing mechanism, sewing mechanism, front pressing mechanism, web guiding mechanism, and film take-up mechanism are sequentially arranged on one end face of the tension detection mechanism. A preheating guide roller and a pressure roller mechanism are sequentially arranged on the lower end face of the film take-up mechanism. A hot air device is fixedly connected to the bottom end face of the pressure roller mechanism. The hot air device includes a hot air nozzle, which is positioned tangentially to the pressure roller mechanism and the mold. The tension applied to the fabric by the secondary tension mechanism increases progressively, employing a 4Ω incremental tension amplification principle. The total tension amplification factor is: K = K1 * K2 * K3 * K4 In the formula, K1, K2, K3, and K4 are the amplification coefficients for each level.

2. The high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to claim 1, characterized in that, The unwinding mechanism includes a first guide roller, a second guide roller, and an unwinding air shaft. The first guide roller, the second guide roller, and the unwinding air shaft are all fixedly connected to the back plate of the winding unit. The unwinding air shaft is located on the upper end face of the first guide roller and the second guide roller. The quality inspection mechanism is located between the first guide roller and the second guide roller.

3. The high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to claim 1, characterized in that, The secondary tension mechanism includes a tension reinforcing roller and a synchronous belt conveyor. The tension reinforcing roller is connected to the synchronous belt conveyor, which is fixedly connected to one end face of the back plate of the winding unit.

4. The high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to claim 1, characterized in that, The tension detection mechanism includes a tension sensor and a side plate. A tension enhancement roller and an encoder guide roller are fixedly connected to a pair of opposite end faces of the side plate, respectively. A tension sensor protective cover is fixedly connected to the middle end face of the side plate. A guide roller support is fixedly connected to each pair of tension sensor protective covers. A third guide roller is fixedly connected to the guide roller support.

5. The high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to claim 1, characterized in that, The rear pressing mechanism includes a fixed seat, a first automatic sliding mechanism and a pressure plate. The fixed seat is fixedly connected to the top end face of the winding base. A pair of first automatic sliding mechanisms are movably connected to one side end face of the fixed seat. The pressure plate is fixedly connected to the bottom end face of the pair of first automatic sliding mechanisms.

6. The high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to claim 1, characterized in that, The sewing mechanism includes a sewing machine mounting plate, on which a sewing machine head mounting plate is slidably connected, and on which a sewing machine head is fixedly connected.

7. The high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to claim 1, characterized in that, An automatic slide table assembly is slidably connected to the top end face of the winding base. The top end face of the automatic slide table assembly is connected to a correction mechanism. The front pressing mechanism includes a traction mechanism. The traction mechanism is fixedly connected to one end face near the correction mechanism. One end face of the correction mechanism is mounted on the pressure roller mechanism. The correction mechanism includes a photoelectric position sensor and multiple correction rollers, which are arranged parallel to each other.

8. The high-efficiency, high-tension continuous automatic winding and defect monitoring device for fabric tape according to claim 1, characterized in that, The film-collecting mechanism includes a permanent magnet torque motor, which is fixedly connected to one end face of the automatic slide assembly. The permanent magnet torque motor is connected to multiple tiles, and each tile has a hinge connected to one end face. Each hinge has a handle connected to it. The hot air device includes a hot air system and a hot air rod assembly. The hot air system has a hot air rod assembly fixedly connected to one end face of the hot air system, and the hot air rod assembly is fixedly connected to one end face of the automatic slide assembly.

9. An operation method for a high-efficiency, high-tension continuous automatic winding and defect monitoring device for textile tape, comprising the high-efficiency, high-tension continuous automatic winding and defect monitoring device as described in claim 1, characterized in that... Includes the following steps; S1. Unwinding: Initial tension is generated through the unwinding mechanism; S2. Fabric tape defect detection: After tension is generated, the fabric tape is straightened by the unwinding mechanism and then enters the quality inspection agency for inspection. S3, Secondary Tension Upgrade: After the quality inspection agency confirms that the quality inspection agency has no errors, the fabric belt enters the secondary tension mechanism for secondary tension upgrade. The secondary tension mechanism and the tension inspection mechanism form a closed-loop control. S4. Sewing: The rear pressing mechanism and the front pressing mechanism press the fabric tape together. The fabric tape is pulled by the traction mechanism for double-sewing. The sewing mechanism automatically sewn the front and rear fabric tapes together when the fabric tape is changed. S5. Correction: Correction is carried out simultaneously through a correction mechanism; S6. Preheating and softening the fabric belt: The fabric belt is preheated by the preheating guide roller, and the separation film between the fabric belts is collected by the film collection mechanism; S7. Press the fabric strip onto the mold: The fabric strip is fed into the pressure roller mechanism through the preheated guide roller and finally wound onto the mold. At the same time, the fabric strip is preheated and softened by the hot air device.

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