A control method and system for high-speed rapier loom based on switched reluctance motor drive

Abstract

This invention provides a control method and system for a high-speed rapier loom driven by a switched reluctance motor. The method collects weft tension data and rapier stroke data along with their corresponding acquisition time data, correlates the two to generate tension-stroke correlation data, and then identifies high-tension and low-tension stroke segments. Based on this, the rotational speed of the rapier drive motor is dynamically adjusted. This control method combines real-time monitoring with dynamic adjustment, achieving intelligent control during the weft insertion process. By precisely adjusting the rapier motion characteristics, it effectively reduces weft breakage and avoids weft slack, significantly improving weaving quality and enhancing the production efficiency and weaving stability of the high-speed rapier loom.

Description

Technical Field

[0001] This application relates to the textile field, and in particular to a control method and system for a high-speed rapier loom based on a switched reluctance motor drive. Background Technology

[0002] High-speed rapier looms are important weaving equipment in the textile industry. They use rapiers as weft insertion elements to introduce weft yarns from one side of the loom into the weaving hole, thus completing the weaving process.

[0003] The advantages of existing high-speed rapier looms are multifaceted. They significantly increase weaving speed, greatly improving production efficiency; the looms are highly adaptable, capable of processing various yarns from fine to roving, suitable for a wide range of materials including cotton, wool, silk, and synthetic fibers; they also possess a high degree of automation, equipped with automatic stopping and automatic weft finding functions, reducing manual intervention; furthermore, they produce stable fabric quality and flexible pattern variations, providing a solid foundation for modern textile production.

[0004] However, high-speed rapier looms also have significant drawbacks in practical applications. First, at high speeds, the reciprocating motion of the rapier generates substantial inertial and impact forces, leading to increased wear on mechanical components and high maintenance costs. Second, the complex rapier motion mechanism requires precise synchronous control; any deviation can easily cause warp and weft breaks, impacting production efficiency. Furthermore, high-speed rapier looms face challenges in tension control during weft insertion, and their adaptability to certain special yarn materials is insufficient, easily resulting in quality problems such as uneven weft yarns and edge curling. Summary of the Invention

[0005] This application provides a control method for a high-speed rapier loom based on a switched reluctance motor drive, comprising the following steps:

[0006] A1, when performing weft insertion operation on a preset rapier loom, acquire preset weft yarn tension data and corresponding weft yarn tension acquisition time data;

[0007] A2, when the rapier loom is performing weft insertion operation, acquire the preset rapier stroke data of the rapier mechanism and the corresponding rapier stroke acquisition time data;

[0008] A3, generate tension-stroke correlation data by combining the weft tension acquisition time data and the rapier stroke acquisition time data with the corresponding weft tension data and rapier stroke data;

[0009] A4, calculate and determine the corresponding high-tension stroke segment data and low-tension stroke segment data based on the tension stroke correlation data;

[0010] A5. Adjust the motor speed of the scissor drive motor corresponding to the scissor mechanism based on the high-tension stroke segment data and the low-tension stroke segment data.

[0011] By adopting the above technical solution, the high-speed rapier loom control method based on switched reluctance motor drive can establish the correlation between weft yarn tension data and rapier stroke data in real time, and then identify high-tension stroke segments and low-tension stroke segments, thereby dynamically adjusting the speed of the rapier drive motor to achieve intelligent dynamic control of the weft insertion process of the loom. This can effectively reduce weft yarn breakage and avoid weft yarn slack, thereby improving weaving quality and production efficiency.

[0012] Optionally, step A4 includes the following steps:

[0013] A401 divides the rapier stroke data in the tension stroke association data into preset stroke intervals to generate each stroke segment and combines them to generate the corresponding stroke segment sequence;

[0014] A402, obtain the corresponding weft yarn tension data based on the weft yarn tension data in the tension travel association data of each travel segment in the travel segment sequence;

[0015] A403, calculate the average tension of the corresponding weft yarn segment based on the average tension data of each weft yarn segment;

[0016] A404, calculate the corresponding average weft tension based on the average weft tension data;

[0017] A405, calculate the corresponding weft yarn tension difference based on the difference between the average tension of each weft yarn segment and the average tension of the weft yarn;

[0018] A406, If the tension difference of the weft yarn segment is greater than the preset high tension threshold, then the stroke segment corresponding to the tension difference of the weft yarn segment is defined as the high tension stroke segment.

[0019] A407, If the tension difference of the weft yarn segment is less than the preset low tension threshold, then the stroke segment corresponding to the tension difference of the weft yarn segment is defined as the low tension stroke segment.

[0020] A408 generates high-tension stroke segment data based on the combination of each high-tension stroke segment;

[0021] A409 generates low-tension stroke segment data based on the combination of each low-tension stroke segment.

[0022] By adopting the above technical solution, the high-speed rapier loom control method based on switched reluctance motor drive can divide the stroke data, calculate the average weft tension of each segment, and compare it with the overall average tension to obtain the tension difference, thereby determining the high and low tension segments. This achieves the identification of tension anomalies, avoids subjective judgment errors, and can more accurately guide the adjustment of motor speed, thereby improving the accuracy of loom control and effectively improving the weaving problems caused by tension fluctuations in traditional control methods.

[0023] Optionally, step A5 includes the following steps:

[0024] A501, when the rapier loom is performing weft insertion operation, acquire the motor speed data of the rapier drive motor corresponding to the rapier mechanism and the corresponding motor speed acquisition time;

[0025] A502 generates motor speed-stroke correlation data by combining the motor speed acquisition time and rapier stroke acquisition time data with the corresponding motor speed data and rapier stroke data.

[0026] A503: Obtain the corresponding motor segment speed data based on the motor speed data in the motor speed stroke correlation data of each stroke segment in the stroke segment sequence;

[0027] A504, determine the corresponding motor speed data based on each high-tension stroke segment in the high-tension stroke segment data and define it as the high-tension segment motor speed data;

[0028] A505, calculate the average speed of the motor in each high-tension section by averaging the motor speed data of each high-tension section.

[0029] A506, calculate the target speed of the motor in each high-tension section by multiplying the average speed of the motor in each high-tension section with the preset speed reduction coefficient;

[0030] A507, when the rapier mechanism inserts the weft into the high-tension stroke section, the motor speed of the corresponding rapier drive motor is adjusted according to the target speed of the high-tension section motor.

[0031] By adopting the above technical solution, the high-speed rapier loom control method based on switched reluctance motor drive can identify the actual motor speed corresponding to the high tension section by associating motor speed data with rapier stroke data, and calculate the corresponding target speed value with reference to the preset reduction coefficient. Thus, when the rapier runs to the high tension area during the next weft insertion, the speed is precisely reduced. The closed-loop feedback control method not only avoids the problem of excessive weft tension in the traditional fixed speed mode, but also can achieve smooth deceleration in key sections, greatly reducing the risk of weft breakage and improving weaving quality and production efficiency.

[0032] Optionally, step A5 may further include the following steps:

[0033] A508 determines the corresponding motor speed data based on each low-tension stroke segment in the low-tension stroke segment data and defines it as the low-tension segment motor speed data.

[0034] A509, calculate the average speed of the motor in each low-tension section by averaging the motor speed data of each low-tension section.

[0035] A510 calculates the target speed of the motor in each low-tension section by multiplying the average speed of the motor in each low-tension section with the preset speed increase coefficient.

[0036] A511, when the rapier mechanism inserts the weft into the low-tension stroke section, the motor speed of the corresponding rapier drive motor is increased according to the target speed of the motor in the low-tension section.

[0037] By adopting the above technical solution, the high-speed rapier loom control method based on switched reluctance motor drive can calculate the average motor speed in the low-tension segment using low-tension stroke data and refer to a preset speed increase coefficient. This allows for timely increase of the motor speed when the rapier reaches the low-tension region. This dynamic speed regulation mechanism based on real-time data solves the weft yarn breakage problem caused by the high-tension segment and overcomes the weft yarn slack phenomenon that may occur in the low-tension segment, making the weft insertion operation of the loom more balanced and efficient, and the weaving quality more stable.

[0038] Optionally, the high-speed rapier loom control method based on switched reluctance motor drive further includes the following steps for acquiring rapier stroke data:

[0039] B1, LED beads of corresponding colors are respectively provided on the weft feeding head and the weft receiving head of the rapier mechanism, wherein each of the LED beads emits light vertically upward;

[0040] B2, When the rapier loom is performing weft insertion, the rapier mechanism is photographed from above at a preset installation height using a preset camera module to obtain corresponding rapier movement video data;

[0041] B3, based on each image frame in the rapier movement video data, identify the corresponding weft feeding rapier LED bead pixel position data and weft receiving rapier LED bead pixel position data;

[0042] B4, determine the current pixel travel of the corresponding weft yarn based on the pixel position data of the weft-feeding lamp bead and the pixel position data of the weft-receiving lamp bead;

[0043] B5, calculate the corresponding weft feed stroke ratio by quotient of the current pixel travel of the weft yarn and the preset maximum pixel travel of the LED;

[0044] B6 generates corresponding rapier stroke data by multiplying the proportion of each weft feed stroke and the preset maximum stroke of the loom rapier.

[0045] By adopting the above technical solution, the high-speed rapier loom control method based on switched reluctance motor drive can install LED beads of different colors on the weft feeding rapier and the weft receiving rapier. Combined with top-down shooting by the camera module, the system can calculate the pixel position and stroke ratio of the LED beads based on image recognition technology, thereby converting them into actual rapier stroke data. This avoids the interference and wear problems of traditional mechanical sensors, improves the accuracy and reliability of data acquisition, and does not affect the normal operation of the loom. It provides high-quality basic data for subsequent tension stroke correlation analysis and motor speed control, further improving the intelligence level and control precision of the entire control system.

[0046] Optionally, the high-speed rapier loom control method based on switched reluctance motor drive further includes the following steps:

[0047] C1, determine whether the weft feeding sword head is located at the weft feeding start position based on the pixel position data of the weft feeding sword LED beads;

[0048] C2, determine whether the weft insertion sword head is located at the weft insertion start position based on the pixel position data of the weft insertion sword lamp beads;

[0049] C3, if the weft feeding sword head is located at the weft feeding start position and the weft receiving sword head is located at the weft receiving start position, then the acquisition time of the image frame corresponding to the weft feeding sword lamp bead pixel position data and the weft receiving sword lamp bead pixel position data is obtained and defined as the weft insertion end time.

[0050] C4, based on the end time of weft insertion, obtain the corresponding image frame from the rapier movement video data and define it as the weft insertion end image data;

[0051] C5, based on the corresponding latitude end time, sequentially combines all latitude end image data to generate latitude time-lapse video data.

[0052] By adopting the above technical solution, the high-speed rapier loom control method based on switched reluctance motor drive can determine the end time of weft insertion by monitoring the pixel position of the weft feed rapier and weft insertion rapier LED beads, and can automatically acquire and combine the corresponding image frames to generate weft insertion delay video data. This achieves high-precision monitoring and recording of the weft insertion process of the loom, enabling operators to intuitively analyze possible problems during the weft insertion process, improving the stability and reliability of the loom operation, and providing strong image data support for fault diagnosis and performance optimization.

[0053] Optionally, the high-speed rapier loom control method based on switched reluctance motor drive further includes the following steps:

[0054] D1, Calculate the cumulative stroke of the weft feeding scissors corresponding to the weft feeding scissors based on the scissor stroke data;

[0055] D2, calculate the wear degree value of the weft feeding scissors corresponding to the weft feeding scissors based on the cumulative stroke of the weft feeding scissors using a preset wear degree algorithm;

[0056] D3. Determine whether the weft feeding head needs to be replaced based on the wear level value of the weft feeding sword and the preset wear threshold of the weft feeding sword.

[0057] D4, Calculate the cumulative stroke of the weft insertion scissor head corresponding to the weft insertion scissor head based on the scissor stroke data;

[0058] D5, calculate the wear degree value of the weft insertion sword corresponding to the weft insertion sword head based on the cumulative stroke of the weft insertion sword head using the wear degree algorithm;

[0059] D6. Determine whether the weft insertion sword head needs to be replaced based on the wear level value of the weft insertion sword and the preset wear threshold value.

[0060] By adopting the above technical solution, the high-speed rapier loom control method based on switched reluctance motor drive can automatically determine the timing of rapier replacement based on a preset wear degree algorithm and threshold by calculating the cumulative stroke of the weft feeding rapier and the weft receiving rapier. This avoids the problem of reduced weaving quality and production interruption caused by excessive rapier wear. This proactive early warning mechanism not only extends the service life of the rapier loom, but also improves equipment utilization and production efficiency, reduces maintenance costs, and transforms maintenance work from passive response to proactive prevention.

[0061] This application also provides a high-speed rapier loom control system based on a switched reluctance motor drive, including:

[0062] Weft tension detection module;

[0063] Rapier stroke detection module;

[0064] Motor control module;

[0065] Processing control module;

[0066] The weft tension detection module, the rapier stroke detection module, and the motor control module are connected to the processing and control module.

[0067] The rapier stroke detection module includes LED beads and a camera module. The LED beads are set in the rapier mechanism of a preset rapier loom, and the camera module is connected to the processing and control module.

[0068] The motor control module includes a motor speed detection module and a motor speed control module, which are data-connected to the rapier drive motor of the rapier loom.

[0069] The high-speed rapier loom control system based on switched reluctance motor drive further includes a weft feed control strategy, comprising the following steps:

[0070] E1, when performing weft insertion operation on a preset rapier loom, the preset weft tension data and corresponding weft tension acquisition time data are obtained through the weft tension detection module;

[0071] E2, when the rapier loom is performing weft insertion, the preset rapier stroke data of the rapier mechanism and the corresponding rapier stroke acquisition time data are obtained through the rapier stroke detection module;

[0072] E3, through the processing and control module, generates tension-stroke correlation data by combining the weft tension acquisition time data and the rapier stroke acquisition time data with the corresponding weft tension data and rapier stroke data;

[0073] E4, the processing control module calculates and determines the corresponding high-tension stroke segment data and low-tension stroke segment data based on the tension stroke correlation data;

[0074] E5, based on the high-tension stroke segment data and the low-tension stroke segment data, adjusts the motor speed of the scissor drive motor corresponding to the scissor mechanism through the motor control module.

[0075] By adopting the above technical solution, the high-speed rapier loom control system based on switched reluctance motor drive can establish the correlation between weft yarn tension data and rapier stroke data in real time, and then identify high-tension stroke segments and low-tension stroke segments, thereby dynamically adjusting the speed of the rapier drive motor to achieve intelligent dynamic control of the weft insertion process of the loom. This can effectively reduce weft yarn breakage and avoid weft yarn slack, thereby improving weaving quality and production efficiency.

[0076] In summary, this application includes at least one of the following beneficial technical effects:

[0077] 1. By collecting weft tension data and rapier stroke data in real time, a correlation can be established between the two. Then, high-tension stroke segments and low-tension stroke segments can be identified, and the speed of the rapier drive motor can be dynamically adjusted to achieve intelligent dynamic control of the weft insertion process of the loom. This can effectively reduce weft breakage and avoid weft slack, thereby improving weaving quality and production efficiency.

[0078] 2. By segmenting the travel data, the average weft tension of each segment can be calculated and compared with the overall average tension to obtain the tension difference, thereby determining the high and low tension segments. This enables the identification of tension anomalies, avoids subjective judgment errors, and can more accurately guide the adjustment of motor speed, thus improving the precision of loom control and effectively improving weaving problems caused by tension fluctuations in traditional control methods.

[0079] 3. By associating motor speed data with rapier stroke data, the actual motor speed corresponding to the high-tension section can be identified, and the corresponding target speed value can be calculated with reference to the preset reduction coefficient. Thus, when the rapier moves to the high-tension area during the next weft insertion, the speed can be precisely reduced. The closed-loop feedback control method not only avoids the problem of excessive weft tension in the traditional fixed speed mode, but also can achieve smooth deceleration in key sections, which greatly reduces the risk of weft breakage and improves weaving quality and production efficiency. Attached Figure Description

[0080] Figure 1 This is a schematic diagram of the process of a high-speed rapier loom control method based on a switched reluctance motor drive according to the present invention.

[0081] Figure 2 This is a schematic diagram of the principle of a high-speed rapier loom control system based on a switched reluctance motor drive according to the present invention. Detailed Implementation

[0082] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0083] The embodiments of this application will now be described in further detail with reference to the accompanying drawings.

[0084] refer to Figure 1 This invention provides a control method for a high-speed rapier loom based on a switched reluctance motor drive, which is used to dynamically control the rotational speed of the rapier drive motor to adjust the weft tension during weft insertion, avoid excessive or insufficient weft tension, and thus ensure the weft insertion quality of the rapier loom.

[0085] The control method for a high-speed rapier loom based on a switched reluctance motor includes the following steps:

[0086] A1, when performing weft insertion operation on a preset rapier loom, acquire preset weft yarn tension data and corresponding weft yarn tension acquisition time data;

[0087] Weft tension data refers to the tension continuously experienced by the weft yarn during the weft insertion operation on a rapier loom.

[0088] The weft tension acquisition time data refers to the data at the acquisition time corresponding to each data sample when acquiring weft tension data.

[0089] A2, when the rapier loom is performing weft insertion operation, acquire the preset rapier stroke data of the rapier mechanism and the corresponding rapier stroke acquisition time data;

[0090] The rapier stroke data refers to the stroke data of the rapier in the rapier mechanism during weft insertion.

[0091] The data collected at the rapier stroke time point are the data collected at the corresponding time point for each data sample when collecting rapier stroke data.

[0092] A3, generate tension-stroke correlation data by combining the weft tension acquisition time data and the rapier stroke acquisition time data with the corresponding weft tension data and rapier stroke data;

[0093] Tension stroke correlation data is generated by matching sample data from the same acquisition time in weft tension data and rapier stroke data one-to-one. It can reflect the tension value of the weft yarn at different stroke positions during the weft insertion process.

[0094] A4, calculate and determine the corresponding high-tension stroke segment data and low-tension stroke segment data based on the tension stroke correlation data;

[0095] The high-tension stroke segment data is a dataset of stroke segments with high weft tension in the tension stroke correlation data;

[0096] The low-tension travel segment data is a dataset of travel segments with lower weft tension in the tension travel correlation data.

[0097] A5. Adjust the motor speed of the scissor drive motor corresponding to the scissor mechanism according to the high-tension stroke segment data and the low-tension stroke segment data;

[0098] By appropriately reducing the rotational speed of the rapier drive motor during the high-tension stroke section, the tension on the weft yarn can be reduced, thereby reducing the probability of weft yarn breakage.

[0099] By appropriately increasing the rotational speed of the rapier drive motor within the low-tension stroke section, the tension on the weft yarn can be increased to prevent the weft yarn from becoming too loose and affecting the weft insertion quality.

[0100] Through the above steps, the high-speed rapier loom control method based on switched reluctance motor drive can establish the correlation between weft tension data and rapier stroke data in real time, and then identify high-tension stroke segments and low-tension stroke segments, thereby dynamically adjusting the speed of the rapier drive motor to achieve intelligent dynamic control of the weft insertion process of the loom. This can effectively reduce weft breakage and avoid weft slack, thereby improving weaving quality and production efficiency.

[0101] Further, step A4 includes the following steps:

[0102] A401 divides the rapier stroke data in the tension stroke association data into preset stroke intervals to generate each stroke segment and combines them to generate the corresponding stroke segment sequence;

[0103] The travel interval is a preset sampling interval that can be set according to requirements to meet different subsequent data precision.

[0104] The stroke segments are the segments generated by dividing the rapier stroke data into stroke intervals;

[0105] The sequence of travel segments is the sequential data of each travel segment generated in sequence.

[0106] A402, obtain the corresponding weft yarn tension data based on the weft yarn tension data in the tension travel association data of each travel segment in the travel segment sequence;

[0107] The weft tension data is the tension data of the weft yarn corresponding to the weft tension data in the stroke segment, that is, the tension data of the weft yarn when it is pulled into the stroke segment.

[0108] A403, calculate the average tension of the corresponding weft yarn segment based on the average tension data of each weft yarn segment;

[0109] The average tension of the weft yarn section is the average value corresponding to the tension data of the weft yarn section.

[0110] A404, calculate the corresponding average weft tension based on the average weft tension data;

[0111] The average weft tension is the average value of the weft tension data, that is, the average tension experienced by the weft yarn during a single weft insertion process.

[0112] A405, calculate the corresponding weft yarn tension difference based on the difference between the average tension of each weft yarn segment and the average tension of the weft yarn;

[0113] The tension difference of the weft yarn segment is the difference between the average tension of the weft yarn segment and the average tension of the weft yarn, reflecting the relationship between the average tension of the weft yarn segment and the average tension of the weft yarn, as well as the degree of deviation.

[0114] A406, If the tension difference of the weft yarn segment is greater than the preset high tension threshold, then the stroke segment corresponding to the tension difference of the weft yarn segment is defined as the high tension stroke segment.

[0115] The high tension threshold is a preset reference value that can be set based on experience or reference data. It is used to determine whether the tension difference of the weft yarn section is too large.

[0116] A high-tension travel segment is a travel segment where the tension difference of the weft yarn segment is greater than the high-tension threshold. This indicates that the tension experienced by the weft yarn when it is drawn into this travel segment is too high.

[0117] A407, If the tension difference of the weft yarn segment is less than the preset low tension threshold, then the stroke segment corresponding to the tension difference of the weft yarn segment is defined as the low tension stroke segment.

[0118] The low tension threshold is a preset reference value that can be set based on experience or reference data. It is used to determine whether the tension difference of the weft yarn section is too small.

[0119] A low-tension travel segment is a travel segment where the tension difference of the weft yarn segment is less than the low-tension threshold. This means that when the weft yarn is drawn into this travel segment, the tension it experiences is relatively low.

[0120] A408 generates high-tension stroke segment data based on the combination of each high-tension stroke segment;

[0121] The high-tension stroke segment data is a collection of data for all high-tension stroke segments.

[0122] A409 generates low-tension stroke segment data based on the combination of each low-tension stroke segment;

[0123] The low-tension stroke segment data is a collection of data for all low-tension stroke segments.

[0124] Through the above steps, the high-speed rapier loom control method based on switched reluctance motor drive can segment the stroke data, calculate the average weft tension of each segment, and compare it with the overall average tension to obtain the tension difference, thereby determining the high and low tension segments. This achieves the identification of tension anomalies, avoids subjective judgment errors, and can more accurately guide the adjustment of motor speed, thus improving the accuracy of loom control and effectively improving the weaving problems caused by tension fluctuations in traditional control methods.

[0125] Further, step A5 includes the following steps:

[0126] A501, when the rapier loom is performing weft insertion operation, acquire the motor speed data of the rapier drive motor corresponding to the rapier mechanism and the corresponding motor speed acquisition time;

[0127] The motor speed data refers to the speed data of the rapier drive motor;

[0128] The motor speed acquisition time refers to the data at the acquisition time corresponding to each data sample when the motor speed data is collected.

[0129] A502 generates motor speed-stroke correlation data by combining the motor speed acquisition time and rapier stroke acquisition time data with the corresponding motor speed data and rapier stroke data.

[0130] The motor speed-stroke correlation data is a matching data generated by matching the sample data of the same acquisition time in the motor speed data and the rapier stroke data. It can reflect the motor speed corresponding to the weft yarn at different stroke positions during the weft insertion process.

[0131] A503: Obtain the corresponding motor segment speed data based on the motor speed data in the motor speed stroke correlation data of each stroke segment in the stroke segment sequence;

[0132] The motor speed data for each stroke segment is the motor speed data corresponding to that stroke segment in the motor speed data.

[0133] A504, determine the corresponding motor speed data based on each high-tension stroke segment in the high-tension stroke segment data and define it as the high-tension segment motor speed data;

[0134] The motor speed data for the high-tension segment refers to the motor speed data corresponding to the high-tension stroke segment.

[0135] A505, calculate the average speed of the motor in each high-tension section by averaging the motor speed data of each high-tension section.

[0136] The average speed of the motor in the high-tension segment is the average of the motor speed data in the high-tension segment, which is reflected in the average speed of the motor in the high-tension stroke segment.

[0137] A506, calculate the target speed of the motor in each high-tension section by multiplying the average speed of the motor in each high-tension section with the preset speed reduction coefficient;

[0138] The speed reduction coefficient is a preset coefficient used to adjust the motor speed in the high-tension section. It can be set to a number less than 1, such as 0.95.

[0139] The target speed of the motor in the high-tension section is the motor speed that needs to be reached during the next weft insertion process within the high-tension stroke section.

[0140] A507, when the rapier mechanism inserts the weft into the high-tension stroke section, the motor speed of the corresponding rapier drive motor is adjusted according to the target speed of the high-tension section motor;

[0141] During the next weft insertion process, when the rapier mechanism inserts the weft into the high-tension stroke section, the motor speed of the rapier drive motor is adjusted to the target speed of the high-tension section motor.

[0142] Through the above steps, the high-speed rapier loom control method based on switched reluctance motor drive can identify the actual motor speed corresponding to the high tension section by associating motor speed data with rapier stroke data, and calculate the corresponding target speed value with reference to the preset reduction coefficient. Thus, when the rapier runs to the high tension area during the next weft insertion, the speed is precisely reduced. The closed-loop feedback control method not only avoids the problem of excessive weft tension in the traditional fixed speed mode, but also can achieve smooth deceleration in key sections, greatly reducing the risk of weft breakage and improving weaving quality and production efficiency.

[0143] Furthermore, step A5 further includes the following steps:

[0144] A508 determines the corresponding motor speed data based on each low-tension stroke segment in the low-tension stroke segment data and defines it as the low-tension segment motor speed data.

[0145] The motor speed data for the low-tension segment refers to the motor speed data corresponding to the low-tension stroke segment.

[0146] A509, calculate the average speed of the motor in each low-tension section by averaging the motor speed data of each low-tension section.

[0147] The average motor speed in the low-tension segment is the average of the motor speed data in the low-tension segment, which is reflected in the average motor speed in the low-tension stroke segment.

[0148] A510 calculates the target speed of the motor in each low-tension section by multiplying the average speed of the motor in each low-tension section with the preset speed increase coefficient.

[0149] The speed increase coefficient is a preset coefficient used to adjust the motor speed in the low tension range. It can be set to a number greater than 1, such as 1.05.

[0150] The target motor speed for the low-tension section is the motor speed that needs to be achieved during the next weft insertion process within the low-tension stroke section.

[0151] A511, when the rapier mechanism inserts the weft into the low-tension stroke section, the motor speed of the corresponding rapier drive motor is increased according to the target speed of the motor in the low-tension section;

[0152] During the next weft insertion process, when the rapier mechanism inserts the weft into the low-tension stroke section, the motor speed of the rapier drive motor is adjusted to the target motor speed for the low-tension section.

[0153] Through the above steps, the high-speed rapier loom control method based on switched reluctance motor drive can calculate the average motor speed in the low-tension segment using low-tension stroke data and refer to a preset speed increase coefficient. This allows for timely increase of the motor speed when the rapier reaches the low-tension region. This dynamic speed regulation mechanism based on real-time data not only solves the weft yarn breakage problem caused by the high-tension segment but also overcomes the weft yarn slack phenomenon that may occur in the low-tension segment, making the weft insertion operation of the loom more balanced and efficient, and the weaving quality more stable.

[0154] Furthermore, the high-speed rapier loom control method based on switched reluctance motor drive also includes the following steps for acquiring rapier stroke data:

[0155] B1, LED beads of corresponding colors are respectively provided on the weft feeding head and the weft receiving head of the rapier mechanism, wherein each of the LED beads emits light vertically upward;

[0156] Different colored LED beads, such as green and yellow, are set on the weft feeding rapier and the weft insertion rapier respectively. When inserting the weft, the light emitted by the LED beads can pass through the warp yarn well, which is used to confirm the position of the weft feeding rapier and the weft insertion rapier, and thus determine the travel position of the weft yarn during the weft insertion operation.

[0157] For example, when the weft feeding scalpel feeds the weft, the LED beads of the weft feeding scalpel emit light, while the LED beads of the weft receiving scalpel emit weak light; after the weft receiving scalpel receives the weft yarn, the LED beads of the weft receiving scalpel emit light, while the LED beads of the weft feeding scalpel emit weak light, and thus the current weft insertion stroke can be determined based on the light spots of the LED beads.

[0158] B2, When the rapier loom is performing weft insertion, the rapier mechanism is photographed from above at a preset installation height using a preset camera module to obtain corresponding rapier movement video data;

[0159] The installation height of the camera module is preset, and combined with the lens parameters of the camera module, the frame of the camera module should be able to capture the entire weft insertion process.

[0160] The rapier movement video data refers to the video image data of the rapier mechanism moving during the weft insertion operation.

[0161] B3, based on each image frame in the rapier movement video data, identify the corresponding weft feeding rapier LED bead pixel position data and weft receiving rapier LED bead pixel position data;

[0162] The pixel position data of the LED bead in the weft feeding head is the pixel position of the light spot of the LED bead in the image frame;

[0163] The pixel position data of the weft insertion sword LED bead is the pixel position of the light spot of the LED bead of the weft insertion sword head in the image frame.

[0164] B4, determine the current pixel travel of the corresponding weft yarn based on the pixel position data of the weft-feeding lamp bead and the pixel position data of the weft-receiving lamp bead;

[0165] The current pixel travel of the weft yarn is the pixel travel position of the weft yarn in the image frame;

[0166] By combining the pixel position data of the weft-feeding lamp bead and the pixel position data of the receiving lamp bead, the existence or intensity of the corresponding lamp bead pixel light point can be determined, and the pixel travel of the current weft yarn can be determined.

[0167] B5, calculate the corresponding weft feed stroke ratio by quotient of the current pixel travel of the weft yarn and the preset maximum pixel travel of the LED;

[0168] The maximum pixel travel of the LED bead is the maximum pixel travel of the LED bead in the rapier movement video data, that is, the maximum pixel travel of the rapier mechanism in the rapier movement video data. It can usually be determined after the camera module is fixed, and can be determined by measurement or by calculation in combination with the lens parameters of the camera module.

[0169] The weft feed travel ratio is the quotient of the current weft feed travel of the weft yarn and the maximum pixel travel of the LED, reflecting the ratio of the current weft yarn travel to the total weft insertion travel.

[0170] B6 generates corresponding rapier stroke data by multiplying the proportion of each weft feed stroke and the preset maximum stroke of the loom rapier.

[0171] The maximum stroke of the rapier is the actual travel distance of the rapier weft insertion, which is preset and determined according to the production specifications of the fabric.

[0172] The corresponding rapier stroke is determined by multiplying the weft feed stroke ratio and the maximum stroke of the loom rapier, and all rapier strokes are combined to generate rapier stroke data.

[0173] Through the above steps, the high-speed rapier loom control method based on switched reluctance motor drive can install LED beads of different colors on the weft feeding rapier and the weft receiving rapier. Combined with top-down shooting by the camera module, the system can calculate the pixel position and stroke ratio of the LED beads based on image recognition technology, thereby converting them into actual rapier stroke data. This avoids the interference and wear problems of traditional mechanical sensors, improves the accuracy and reliability of data acquisition, and does not affect the normal operation of the loom. It provides high-quality basic data for subsequent tension stroke correlation analysis and motor speed control, further improving the intelligence level and control precision of the entire control system.

[0174] Furthermore, the high-speed rapier loom control method based on switched reluctance motor drive also includes the following steps:

[0175] C1, determine whether the weft feeding sword head is located at the weft feeding start position based on the pixel position data of the weft feeding sword LED beads;

[0176] The starting position of the weft feeding is the initial position of the weft feeding sword head. After one weft feeding is completed, the weft feeding sword head and the weft receiving sword head will return to the initial position to facilitate the weft insertion operation and start the next weft insertion operation.

[0177] C2, determine whether the weft insertion sword head is located at the weft insertion start position based on the pixel position data of the weft insertion sword lamp beads;

[0178] The starting position of weft insertion is the initial position of the weft insertion sword head.

[0179] C3, if the weft feeding sword head is located at the weft feeding start position and the weft receiving sword head is located at the weft receiving start position, then the acquisition time of the image frame corresponding to the weft feeding sword lamp bead pixel position data and the weft receiving sword lamp bead pixel position data is obtained and defined as the weft insertion end time.

[0180] The end time of weft insertion is the time when a weft insertion operation ends. When both the weft feeding head and the weft receiving head are in their corresponding starting positions, it indicates that a weft insertion operation has ended.

[0181] C4, based on the end time of weft insertion, obtain the corresponding image frame from the rapier movement video data and define it as the weft insertion end image data;

[0182] The image data at the end of weft insertion is the image frame corresponding to the moment of weft insertion in the rapier movement video data.

[0183] C5, based on the corresponding latitude end time, sequentially combine all latitude end image data to generate latitude time-lapse video data;

[0184] The weft insertion delay video data is video image data generated by sequentially combining all weft insertion end image data. Each frame in the video represents one weft insertion, which can be used to play back and detect the quality of each weft insertion. It can also be used to trace the workflow when weaving quality problems occur in order to analyze the cause of the quality problems.

[0185] Through the above steps, the high-speed rapier loom control method based on switched reluctance motor drive can determine the end time of weft insertion by monitoring the pixel positions of the weft feed rapier and weft insertion rapier LED beads, and can automatically acquire and combine the corresponding image frames to generate weft insertion delay video data. This achieves high-precision monitoring and recording of the weft insertion process of the loom, enabling operators to intuitively analyze potential problems during the weft insertion process, improving the stability and reliability of the loom operation, and providing strong image data support for fault diagnosis and performance optimization.

[0186] Furthermore, the high-speed rapier loom control method based on switched reluctance motor drive also includes the following steps:

[0187] D1, Calculate the cumulative stroke of the weft feeding scissors corresponding to the weft feeding scissors based on the scissor stroke data;

[0188] The cumulative travel of the weft feed tip is the total cumulative travel of the weft feed tip.

[0189] D2, calculate the wear degree value of the weft feeding scissors corresponding to the weft feeding scissors based on the cumulative stroke of the weft feeding scissors using a preset wear degree algorithm;

[0190] The wear rate calculation algorithm is a pre-set algorithm that can estimate the wear rate of the weft feeding scissor head based on the cumulative stroke of the weft feeding scissor head and related working conditions.

[0191] The wear degree value of the weft feeding scissor is an estimated value of the wear degree of the weft feeding scissor head under the cumulative stroke of the weft feeding scissor head.

[0192] D3. Determine whether the weft feeding head needs to be replaced based on the wear level value of the weft feeding sword and the preset wear threshold of the weft feeding sword.

[0193] The wear threshold of the weft feed scissors is a preset reference value used to determine whether the weft feed scissors head is worn to the point that it needs to be replaced.

[0194] D4, Calculate the cumulative stroke of the weft insertion scissor head corresponding to the weft insertion scissor head based on the scissor stroke data;

[0195] The cumulative travel of the weft insertion tip refers to the total cumulative travel of the weft insertion tip.

[0196] D5, calculate the wear degree value of the weft insertion sword corresponding to the weft insertion sword head based on the cumulative stroke of the weft insertion sword head using the wear degree algorithm;

[0197] The wear degree value of the weft insertion sword is an estimated value of the wear degree of the weft insertion sword head under the cumulative stroke of the weft insertion sword head.

[0198] D6. Determine whether the weft insertion sword head needs to be replaced based on the wear level value of the weft insertion sword and the preset wear threshold of the weft insertion sword.

[0199] The wear threshold of the weft insertion sword is a preset reference value used to determine whether the weft insertion sword head is worn to the point that it needs to be replaced.

[0200] Through the above steps, the high-speed rapier loom control method based on switched reluctance motor drive can automatically determine the timing of rapier replacement based on a preset wear degree algorithm and threshold by calculating the cumulative stroke of the weft feeding rapier and the weft receiving rapier. This avoids the problem of reduced weaving quality and production interruption caused by excessive rapier wear. This proactive early warning mechanism not only extends the service life of the rapier loom, but also improves equipment utilization and production efficiency, reduces maintenance costs, and transforms maintenance work from passive response to proactive prevention.

[0201] refer to Figure 2 This application also provides a high-speed rapier loom control system based on a switched reluctance motor drive, comprising:

[0202] Weft tension detection module 10;

[0203] Rapier stroke detection module 20;

[0204] Motor control module 30;

[0205] Processing control module 40;

[0206] The weft tension detection module 10, the rapier stroke detection module 20, and the motor control module 30 are data-connected to the processing control module 40.

[0207] The rapier stroke detection module 10 includes an LED light bead 11 and a camera module 12. The LED light bead 11 is set in the rapier mechanism of a preset rapier loom, and the camera module 12 is connected to the processing and control module 40.

[0208] The motor control module 30 includes a motor speed detection module 31 and a motor speed control module 32, which are connected to the rapier drive motor of the rapier loom.

[0209] The weft tension detection module 10 is mainly used to detect the tension data of the weft yarn during the weft insertion operation.

[0210] The rapier stroke detection module 20 is mainly used to detect the stroke data of the rapier mechanism during weft insertion operations.

[0211] The light-emitting LED beads 11 are mainly used to trace the stroke of the rapier mechanism in order to reduce the visual obstruction of the warp yarn on the rapier mechanism.

[0212] The camera module 12 is mainly used to acquire the operating video data of the rapier mechanism, so as to determine the current stroke of the rapier mechanism based on the video data.

[0213] The motor control module 30 is mainly used to detect and control the speed of the drive motor of the rapier mechanism.

[0214] The motor speed detection module 31 is mainly used to detect the motor speed of the rapier drive motor;

[0215] The motor speed control module 32 is mainly used to control the motor speed of the rapier drive motor.

[0216] The processing and control module 40 is mainly used to receive data collected by other modules and perform calculations, thereby enabling communication control of other modules.

[0217] The high-speed rapier loom control system based on switched reluctance motor drive further includes a weft feed control strategy, comprising the following steps:

[0218] E1, when performing weft insertion operation on a preset rapier loom, the preset weft tension data and corresponding weft tension acquisition time data are obtained through the weft tension detection module 10;

[0219] E2, when the rapier loom is performing weft insertion operation, the rapier stroke detection module 20 acquires the preset rapier stroke data of the rapier mechanism and the corresponding rapier stroke acquisition time data;

[0220] E3, through the processing control module 40, tension stroke association data is generated by combining the weft tension acquisition time data and the rapier stroke acquisition time data with the corresponding weft tension data and rapier stroke data;

[0221] E4, the processing control module 40 calculates and determines the corresponding high-tension stroke segment data and low-tension stroke segment data based on the tension stroke correlation data;

[0222] E5, based on the high-tension stroke segment data and the low-tension stroke segment data, adjusts the motor speed of the scissor drive motor corresponding to the scissor mechanism through the motor control module 30.

[0223] Through the above technical solutions, the high-speed rapier loom control system based on switched reluctance motor drive can establish the correlation between weft yarn tension data and rapier stroke data in real time, and then identify high-tension stroke segments and low-tension stroke segments, thereby dynamically adjusting the speed of the rapier drive motor to achieve intelligent dynamic control of the weft insertion process of the loom. This can effectively reduce weft yarn breakage and avoid weft yarn slack, thereby improving weaving quality and production efficiency.

[0224] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. A control method for a high-speed rapier loom based on a switched reluctance motor drive, characterized in that, Includes the following steps: A1, when performing weft insertion operation on a preset rapier loom, acquire preset weft yarn tension data and corresponding weft yarn tension acquisition time data; A2, when the rapier loom is performing weft insertion operation, acquire the preset rapier stroke data of the rapier mechanism and the corresponding rapier stroke acquisition time data; A3, generate tension-stroke correlation data by combining the weft tension acquisition time data and the rapier stroke acquisition time data with the corresponding weft tension data and rapier stroke data; A4, calculate and determine the corresponding high-tension stroke segment data and low-tension stroke segment data based on the tension stroke correlation data; A5. Adjust the motor speed of the scissor drive motor corresponding to the scissor mechanism based on the high-tension stroke segment data and the low-tension stroke segment data.

2. The control method for a high-speed rapier loom based on a switched reluctance motor drive according to claim 1, characterized in that, Step A4 includes the following steps: A401 divides the rapier stroke data in the tension stroke association data into preset stroke intervals to generate each stroke segment and combines them to generate the corresponding stroke segment sequence; A402, obtain the corresponding weft yarn tension data based on the weft yarn tension data in the tension travel association data of each travel segment in the travel segment sequence; A403, calculate the average tension of the corresponding weft yarn segment based on the average tension data of each weft yarn segment; A404, calculate the corresponding average weft tension based on the average weft tension data; A405, calculate the corresponding weft yarn tension difference based on the difference between the average tension of each weft yarn segment and the average tension of the weft yarn; A406, If the tension difference of the weft yarn segment is greater than the preset high tension threshold, then the stroke segment corresponding to the tension difference of the weft yarn segment is defined as the high tension stroke segment. A407, If the tension difference of the weft yarn segment is less than the preset low tension threshold, then the stroke segment corresponding to the tension difference of the weft yarn segment is defined as the low tension stroke segment. A408 generates high-tension stroke segment data based on the combination of each high-tension stroke segment; A409 generates low-tension stroke segment data based on the combination of each low-tension stroke segment.

3. The control method for a high-speed rapier loom based on a switched reluctance motor drive according to claim 2, characterized in that, Step A5 includes the following steps: A501, when the rapier loom is performing weft insertion operation, acquire the motor speed data of the rapier drive motor corresponding to the rapier mechanism and the corresponding motor speed acquisition time; A502 generates motor speed-stroke correlation data by combining the motor speed acquisition time and rapier stroke acquisition time data with the corresponding motor speed data and rapier stroke data. A503: Obtain the corresponding motor segment speed data based on the motor speed data in the motor speed stroke correlation data of each stroke segment in the stroke segment sequence; A504, determine the corresponding motor speed data based on each high-tension stroke segment in the high-tension stroke segment data and define it as the high-tension segment motor speed data; A505, calculate the average speed of the motor in each high-tension section by averaging the motor speed data of each high-tension section. A506, calculate the target speed of the motor in each high-tension section by multiplying the average speed of the motor in each high-tension section with the preset speed reduction coefficient; A507, when the rapier mechanism inserts the weft into the high-tension stroke section, the motor speed of the corresponding rapier drive motor is adjusted according to the target speed of the high-tension section motor.

4. The control method for a high-speed rapier loom based on a switched reluctance motor drive according to claim 3, characterized in that, Step A5 further includes the following steps: A508 determines the corresponding motor speed data based on each low-tension stroke segment in the low-tension stroke segment data and defines it as the low-tension segment motor speed data. A509, calculate the average speed of the motor in each low-tension section by averaging the motor speed data of each low-tension section. A510 calculates the target speed of the motor in each low-tension section by multiplying the average speed of the motor in each low-tension section with the preset speed increase coefficient. A511, when the rapier mechanism inserts the weft into the low-tension stroke section, the motor speed of the corresponding rapier drive motor is increased according to the target speed of the motor in the low-tension section.

5. The control method for a high-speed rapier loom based on a switched reluctance motor drive according to claim 4, characterized in that, Further steps are included for obtaining rapier stroke data: B1, LED beads of corresponding colors are respectively provided on the weft feeding head and the weft receiving head of the rapier mechanism, wherein each of the LED beads emits light vertically upward; B2, When the rapier loom is performing weft insertion, the rapier mechanism is photographed from above at a preset installation height using a preset camera module to obtain corresponding rapier movement video data; B3, based on each image frame in the rapier movement video data, identify the corresponding weft feeding rapier LED bead pixel position data and weft receiving rapier LED bead pixel position data; B4, determine the current pixel travel of the corresponding weft yarn based on the pixel position data of the weft-feeding lamp bead and the pixel position data of the weft-receiving lamp bead; B5, calculate the corresponding weft feed stroke ratio by quotient of the current pixel travel of the weft yarn and the preset maximum pixel travel of the LED; B6 generates corresponding rapier stroke data by multiplying the weft feed stroke ratio and the preset maximum rapier stroke of the loom.

6. The control method for a high-speed rapier loom based on a switched reluctance motor drive according to claim 5, characterized in that, Further steps include: C1, determine whether the weft feeding sword head is located at the weft feeding start position based on the pixel position data of the weft feeding sword LED beads; C2, determine whether the weft insertion sword head is located at the weft insertion start position based on the pixel position data of the weft insertion sword lamp beads; C3, if the weft feeding sword head is located at the weft feeding start position and the weft receiving sword head is located at the weft receiving start position, then the acquisition time of the image frame corresponding to the weft feeding sword lamp bead pixel position data and the weft receiving sword lamp bead pixel position data is obtained and defined as the weft insertion end time. C4, based on the end time of weft insertion, obtain the corresponding image frame from the rapier movement video data and define it as the weft insertion end image data; C5, based on the corresponding latitude end time, sequentially combines all latitude end image data to generate latitude time-lapse video data.

7. The control method for a high-speed rapier loom based on a switched reluctance motor drive according to claim 6, characterized in that, Further steps include: D1, Calculate the cumulative stroke of the weft feeding scissors corresponding to the weft feeding scissors based on the scissor stroke data; D2, calculate the wear degree value of the weft feeding scissors corresponding to the weft feeding scissors based on the cumulative stroke of the weft feeding scissors using a preset wear degree algorithm; D3. Determine whether the weft feeding head needs to be replaced based on the wear level value of the weft feeding sword and the preset wear threshold of the weft feeding sword. D4, Calculate the cumulative stroke of the weft insertion scissor head corresponding to the weft insertion scissor head based on the scissor stroke data; D5, calculate the wear degree value of the weft insertion sword corresponding to the weft insertion sword head based on the cumulative stroke of the weft insertion sword head using the wear degree algorithm; D6. Determine whether the weft insertion sword head needs to be replaced based on the wear level value of the weft insertion sword and the preset wear threshold value.

8. A control system for a high-speed rapier loom based on a switched reluctance motor drive, characterized in that, include: Weft tension detection module; Rapier stroke detection module; Motor control module; Processing control module; The weft tension detection module, the rapier stroke detection module, and the motor control module are connected to the processing and control module. The rapier stroke detection module includes LED beads and a camera module. The LED beads are set in the rapier mechanism of a preset rapier loom, and the camera module is connected to the processing and control module. The motor control module includes a motor speed detection module and a motor speed control module, which are data-connected to the rapier drive motor of the rapier loom. The high-speed rapier loom control system based on switched reluctance motor drive further includes a weft feed control strategy, comprising the following steps: E1, when performing weft insertion operation on a preset rapier loom, the preset weft tension data and corresponding weft tension acquisition time data are obtained through the weft tension detection module; E2, when the rapier loom is performing weft insertion, the preset rapier stroke data of the rapier mechanism and the corresponding rapier stroke acquisition time data are obtained through the rapier stroke detection module; E3, through the processing and control module, generates tension-stroke correlation data by combining the weft tension acquisition time data and the rapier stroke acquisition time data with the corresponding weft tension data and rapier stroke data; E4, the processing control module calculates and determines the corresponding high-tension stroke segment data and low-tension stroke segment data based on the tension stroke correlation data; E5, based on the high-tension stroke segment data and the low-tension stroke segment data, adjusts the motor speed of the scissor drive motor corresponding to the scissor mechanism through the motor control module.

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