Integrated online yarn tension detection system

Abstract

The invention relates to the field of tension detection, and particularly discloses an integrated online yarn tension detection system which comprises a sensor end and an upper computer and is mainly used for dynamically monitoring yarn tension in the production process of a spinning machine. The sensor end adopts a modular design, and a strain detection unit, a signal conditioning module, an MCU and an Ethernet communication module are integrated in the sensor end. The strain detection unit is responsible for converting a tension signal into a voltage signal, the voltage signal is amplified and filtered by the signal conditioning module and then transmitted to the MCU, the MCU performs AD conversion and digital filtering processing on the signal, a tension value is calibrated and calculated, and data is packaged through the Ethernet communication module and transmitted to the upper computer through the router. The upper computer system integrates the functions of real-time monitoring, data storage and intelligent analysis, tension data of each spindle position can be displayed in real time, historical tension data are stored, trend prediction and anomaly detection are conducted on the tension data, and accurate monitoring and fault pre-judgment in the spinning production process are achieved.

Description

Technical Field

[0001] The present invention belongs to the technical field of textile machinery detection, and particularly relates to an integrated on-line yarn tension detection system, which is mainly used for real-time monitoring of the dynamic changes of the tension during the yarn processing and production process of a spinning machine, and realizing data acquisition, transmission, storage and intelligent analysis. Background Art

[0002] During the textile processing and production process, yarn tension is one of the key process parameters, which directly affects the quality and production efficiency of textiles. In each process from spinning to weaving, the magnitude and stability of the tension play a crucial role in product quality and production efficiency. During the silk thread production process, keeping the tension within an ideal fluctuation range can significantly improve the production efficiency of the textile process. Therefore, the precise control and monitoring of tension are of great significance for all aspects of textile production.

[0003] During the high-speed spinning production process, the yarn tension change presents the characteristics of high frequency and small amplitude, which poses extremely high requirements on the measurement accuracy, reliability and stability of the tension sensor. Most traditional tension detection systems adopt independent sensors and display instruments, and have the following problems: complex wiring, the sensors need independent power supply lines and signal lines, and there is line redundancy in the multi-spindle position scenario, which is vulnerable to interference and difficult to maintain; weak data processing ability, lacking real-time data storage and in-depth analysis functions; poor scalability, not supporting multi-sensor networking and remote monitoring, and it is difficult to meet the requirements of modern intelligent factories. In view of the above problems, the present invention proposes an integrated on-line yarn tension detection system, which realizes high-precision and real-time tension monitoring and intelligent decision-making through modular design, POE power supply and intelligent analysis algorithms, and significantly improves the detection efficiency and system reliability. Summary of the Invention

[0004] The present invention provides an integrated on-line yarn tension detection system, including a collaborative working architecture of a sensor end and a host computer. In view of the high-frequency and small-amplitude characteristics of the tension change in the high-speed spinning scenario, through hardware integration and algorithm intelligent design, high-precision and high-reliability real-time tension monitoring and fault prediction are realized, and the production efficiency is improved.

[0005] To achieve the above object, the present invention provides the following technical solutions, including two parts: a sensor end and a host computer:

[0006] The yarn tension sensor has a split shell structure, which is composed of an upper cover and a base, and includes a strain detection unit, a signal conditioning module, an MCU and an Ethernet communication module; wherein the strain detection unit is installed in the upper cover by mechanical fixation, and the signal conditioning module, the MCU and the Ethernet communication module are integrated on a circuit board and installed on the base in a detachable manner.

[0007] The strain detection unit includes a cantilever beam, an elastomer, and a full-bridge resistance strain gauge group. The resistance strain gauge group consists of four metal foil strain gauges, which are symmetrically pasted on both sides of the elastomer to form a Wheatstone full-bridge circuit. The yarn tension acts on the cantilever beam to cause deformation of the elastomer, resulting in a change in the resistance value of the strain gauge. A differential voltage signal proportional to the tension is output through the Wheatstone bridge.

[0008] Further, the signal conditioning module, MCU, and Ethernet communication module are integrally installed on the sensor base. The signal conditioning module includes two-stage differential amplifier circuits and an RC low-pass filter circuit, and establishes an electrical connection with the strain gauge group through a flexible cable to amplify the weak differential signal and suppress noise, and output a standardized analog signal; The MCU uses the STM32F103RCT6 chip, and the built-in 12-bit ADC digitizes the analog signal, and combines the moving average filtering and the moving window mean method to eliminate noise and baseline drift, and complete the tension calibration calculation; The Ethernet communication module uses the ENC28J60 chip, communicates with the MCU through the SPI interface, encapsulates the calibrated tension value into a UDP protocol packet including a frame header, a sensor ID, a tension value, a timestamp, and a checksum, and uploads it to the host computer through a router.

[0009] Further, the yarn tension sensor adopts a POE power supply method, receives a 12V DC power supply through an Ethernet cable, steps down to 5V and 3.3V through a DC-DC converter, and supplies power to each module to realize single-line integration of power supply and communication.

[0010] As a further solution of the present invention: The host computer includes a communication interface module, a real-time monitoring module, a data storage module, and an intelligent analysis module. The communication interface module is used to receive and parse the UDP protocol packet sent by the sensor end and extract the tension data; The real-time monitoring module provides a multi-window split-screen display interface, including a real-time tension waveform diagram, a statistical panel (displaying the mean value, standard deviation, and over-limit alarm times), and a color mapping heat map (marking abnormal areas according to the spindle position distribution); The data storage module stores the sensor ID, timestamp, original voltage value, calibrated tension value, and alarm status code in association with the spindle position in the database; The intelligent analysis module can predict the tension change trend through time series analysis, realize the early warning of broken yarn risk and equipment degradation, analyze the waveform characteristics in real time, identify abnormal sudden increases, sudden decreases, and periodic fluctuations, and output the fault type and code.

[0011] Compared with the prior art, the beneficial effects of the present invention are:

[0012] Through modular encapsulation at the sensor end (integrating strain detection, signal conditioning, MCU, and Ethernet communication) and POE power supply technology, single-line integration of power supply and communication is achieved, solving the problems of complex wiring and poor anti-interference in traditional solutions, and being applicable to multi-spindle expansion scenarios; a full-bridge strain gauge is combined with two-stage differential amplification and an adaptive filtering algorithm to improve measurement accuracy; millisecond-level multi-spindle data synchronization and upload are realized based on the UDP protocol, and together with the real-time data display function and trend prediction of the upper computer, it helps in the early detection of faults; at the same time, the original data and alarm information are stored in association with timestamps, supporting quality traceability and equipment health management, significantly improving the stability and intelligent level of spinning production. Brief Description of the Drawings

[0013] Figure 1 This is the overall design block diagram of the integrated online yarn tension detection system of the present invention;

[0014] Figure 2 This is the overall architecture schematic diagram of the integrated online yarn tension detection system of the present invention;

[0015] Figure 3 This is the structural schematic diagram of the tension sensor of the integrated online yarn tension detection system of the present invention;

[0016] Figure 4 This is the schematic diagram of the sensor hardware circuit of the integrated online yarn tension detection system of the present invention;

[0017] Figure 5 This is the function flow chart of the integrated online yarn tension detection system of the present invention. Detailed Embodiments

[0018] To make the objectives, features, and advantages of the present invention more clearly understood, the following provides a detailed description of the specific embodiments of the present invention in conjunction with the accompanying drawings of the specification. It should be noted that the following embodiments are only for exemplary description, and those skilled in the art can make appropriate adjustments or expansions to the embodiments without departing from the core idea of the present invention. Therefore, the present invention is not limited to the following specific embodiments.

[0019] Embodiment 1

[0020] Please refer to Figure 1-2In this embodiment: the integrated online yarn tension detection system adopts a distributed sensor terminal and a centralized host computer collaborative architecture; an independent sensor terminal is installed on each spindle position, which integrates a strain detection unit, a signal conditioning module, an MCU and an Ethernet communication module. The sensor terminal is connected to a POE router via a network cable to achieve integrated transmission of power supply and data communication; multiple sensors in each area are connected to a POE router, and the router is connected to the PC in the area via an RS485 bus for local processing. Finally, the PCs in all areas aggregate the data to a central data terminal; the host computer system includes four major modules: communication interface, real-time monitoring, data storage and intelligent analysis. Each module realizes loosely coupled interaction through a message queue. The system supports horizontal expansion and can improve data processing capabilities by adding server nodes.

[0021] Example 2

[0022] See also Figure 3 In this embodiment: the yarn tension sensor adopts a split structure, consisting of an upper cover 1 and a base 2. Low-friction ceramic yarn guides 6 are symmetrically installed on the left and right sides of the upper cover 1 to guide the yarn; the elastic body 4 is fixed inside the upper cover 1 by bolts. The elastic body is made of 17-4PH steel, and four metal foil resistance strain gauges are symmetrically attached to its upper and lower surfaces to form a Wheatstone bridge; the support beam in the center of the elastic body 4 is fixedly connected to one end of the cantilever beam 3 to sense the tension of the yarn; a card slot with a shockproof gasket is provided inside the base 2 to fix the circuit board 5 integrating the signal conditioning module, MCU and Ethernet communication module. The circuit board 5 is connected to the strain gauge group by a flexible cable, and finally the upper cover 1 and the base 2 are locked by two M3 countersunk screws.

[0023] Example 3

[0024] See also Figure 4, in this embodiment: The hardware circuit of the tension sensor includes a signal conditioning circuit, an MCU, a POE power supply circuit, an Ethernet communication circuit, and other peripheral circuits. The signal conditioning circuit includes a first-stage differential amplifier circuit, a second-stage amplifier circuit, and an RC low-pass filter circuit, which are responsible for amplifying and filtering the weak voltage signal output by the strain detection unit; The MCU uses STM32F103RCT6, with a built-in 12-bit ADC, and also has excellent computing performance and interrupt response functions; The POE power supply circuit adopts a two-stage conversion architecture, POE power supply +12V, which is stepped down to +5V through the LM2596S-5.0 buck regulator chip, responsible for driving the amplifier circuit and the Wheatstone bridge circuit, and then stepped down to 3.3V by the AMS1117-3.3V chip to drive the MCU to work; The Ethernet communication circuit is mainly composed of the ENC28J60 chip, communicates with the MCU through the SPI interface, and uploads the encapsulated UDP protocol packet to the upper computer through the router; Other peripheral circuits include a clock signal circuit, a button reset circuit, and a debugging interface circuit, all of which are functional circuits of the MCU.

[0025] Embodiment 4

[0026] Please refer to Figure 5 , in this embodiment: The system operation process of the integrated online yarn tension detection system is as follows. The yarn tension acts on the cantilever beam, and the force on the cantilever beam causes the elastic body to deform, resulting in a differential change in the resistance values of the four strain gauges. The Wheatstone full-bridge circuit outputs a millivolt-level voltage signal; This voltage signal is amplified to 0-3.3V by a two-stage amplifier circuit. The first stage uses a high-precision, low-noise amplifier OPA277 (gain 100 times), and the second stage uses an operational amplifier LM358 (gain 10 times), with a total gain of 1000 times; The amplified signal is input to the MCU (STM32F103) after low-pass filtering, undergoes analog-to-digital conversion through the built-in 12-bit ADC, and combines with a filtering algorithm to eliminate noise interference, and then calibrates and calculates the tension value; The obtained tension value is encapsulated into a UDP protocol packet containing a frame header, sensor ID, tension value, timestamp, and checksum, and sent to the upper computer through Ethernet. The upper computer receives the UDP packet, parses out the sensor ID, tension value, and timestamp through CRC check, writes them into the shared memory pool, the real-time monitoring module reads the data from the memory pool, and displays the tension waveform diagram and the statistical panel on the interface; The data storage module stores the sensor ID, timestamp, original voltage value, calibrated tension value, and alarm status code in the database associated with the spindle position; The intelligent analysis module calls historical data to perform time series analysis to predict the future tension change trend of the sensor for a period of time to achieve the purpose of early warning.

[0027] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered within the scope of the claims of the present invention.

Claims

1. An integrated online yarn tension detection system, characterized in that: Including sensor end and host computer; The sensor end adopts a modular packaging structure, including: a strain detection unit, which converts the yarn tension signal into a differential voltage signal; a signal conditioning module, which is connected to the strain detection unit and amplifies and suppresses noise on the voltage signal; an MCU, which is connected to the signal conditioning module and performs ADC conversion, digital filtering and tension calibration calculation on the conditioned signal, and outputs a calibrated tension value; an Ethernet communication module, which is connected to the MCU through an SPI interface, and uses an ENC28J60 chip to encapsulate the calibrated tension value into a custom UDP protocol packet, which is uploaded to a host computer through a router; the host computer includes: a communication interface module, which is used to receive the UDP protocol packet sent by the sensor end and parse the tension data; a real-time monitoring module, which provides a graphical interface to dynamically display the real-time tension value and fluctuation curve of each spindle position; and a data storage module, which stores historical tension data in a database in association with spindle position information according to timestamps.

2. The integrated online yarn tension detection system according to claim 1, characterized in that: The strain detection unit includes a cantilever beam, an elastic body and a full-bridge resistance strain gauge group. The yarn tension acts on the cantilever beam to cause the elastic body to generate strain, the resistance value of the resistance strain gauge changes differentially, and a differential voltage signal proportional to the tension is output through a Wheatstone bridge.

3. The integrated online yarn tension detection system according to claim 1, characterized in that: The signal conditioning module includes a two-stage differential amplifier circuit and an RC low-pass filter circuit, which converts the weak differential voltage signal output by the strain detection unit into a high-precision, low-noise standardized signal for subsequent digital processing by the MCU.

4. The integrated online yarn tension detection system according to claim 1, characterized in that: The MCU adopts STM32F103RCT6 with a built-in 12-bit ADC module to collect the analog signal output by the signal conditioning module and convert it into a digital signal; a sliding average filter is used to reduce random noise, and a sliding window mean method is used to correct the baseline drift to ensure zero point stability.

5. The integrated online yarn tension detection system according to claim 1, characterized in that: The Ethernet communication module adopts the ENC28J60 chip and is driven by the MCU through the SPI interface; the structure of the data packet includes a frame header, a sensor ID, a tension value, a timestamp and a checksum.

6. The integrated online yarn tension detection system according to claim 1, characterized in that: The real-time monitoring module of the host computer supports multi-window split-screen display, including: real-time tension waveform; statistical panel, displaying the current tension mean, standard deviation and number of over-limit alarms; color mapping heat map, marking the tension abnormality area according to the spindle position distribution.

7. The integrated online yarn tension detection system according to claim 1, characterized in that: The storage fields of the data storage module include: sensor ID, timestamp, original voltage value, calibrated tension value, and alarm status code.

8. The integrated online yarn tension detection system according to claim 1, characterized in that: The host computer further includes trend prediction and anomaly detection functions; the trend prediction function can perform time series analysis on historical tension data, predict future tension change trends, and achieve early warning of potential problems such as yarn break risks and equipment performance degradation; the anomaly detection function can analyze the current tension waveform in real time, identify sudden increases, sudden decreases, and periodic fluctuations, and output fault types and codes.

9. The integrated online yarn tension detection system according to claim 1, characterized in that: The sensor end adopts POE power supply mode, receives 12V DC power from the POE router through the Ethernet cable, and steps down the voltage to 5V and 3.3V through the DC-DC converter to power the MCU, signal conditioning module and strain detection unit, realizing single-line integration of power supply and communication, avoiding the complexity and safety hazards of independent power line layout in traditional solutions, and significantly improving the applicability of industrial scenarios.

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