Temperature and humidity control and mechanical control device and control method for processing and transmitting ultra-wide coated fabrics

Abstract

The present invention relates to a temperature and humidity control and mechanical control device for processing and transmitting ultra-wide coated fabrics and its control method. The device comprises a multi-stage roller group, a temperature and humidity control unit, a dynamic control module and a mechanical adjustment unit. The multi-stage roller group realizes staged stress control during fabric transmission; the temperature and humidity control unit sprays water vapor in the stretching stage, and adjusts the temperature and humidity through a forced convection heat exchange device in the relaxation and under-relaxation stages; the dynamic control module accurately controls the temperature and humidity parameters of each stage; the mechanical adjustment unit allows the primary and secondary rollers to slide and move within a certain range, and the middle and rear rollers are fixed. The control method includes staged stress control, staged temperature and humidity control and dynamic mechanical control. The present invention improves the coating quality and production efficiency of ultra-wide coated fabrics by optimizing the device and control method.

Description

Technical Field

[0001] The present invention relates to the field of textile material preparation and processing, and in particular to a temperature and humidity control and mechanical control device for processing and transmitting ultra-wide coated fabrics and a control method thereof. Background Art

[0002] Traditional transmission mechanisms have significant limitations in the coating process of ultra-wide fabrics. They are unable to precisely control humidity according to the fabric's needs during different transmission stages. For example, a certain humidity level must be maintained during the stretching stage to maintain flexibility, while the humidity should be gradually reduced during the relaxation and under-relaxation stages to avoid excessive moisture. Furthermore, traditional mechanisms typically utilize simple spray devices that are unable to precisely control the spray volume and water vapor temperature, and lack dynamic adjustment capabilities. This results in delayed humidity control and makes it difficult to meet the diverse needs of different fabric materials and coating processes. Furthermore, traditional mechanisms also have shortcomings in temperature control and optimization of the fabric's stress state, which impacts coating quality and production efficiency.

[0003] In summary, the present invention aims to solve the shortcomings of traditional transmission mechanisms in humidity control through an innovative transmission mechanism design, while optimizing the stress state and temperature control of the fabric, thereby improving the quality and efficiency of ultra-wide fabric coating. Summary of the Invention

[0004] The purpose of the present invention is to address the above-mentioned problems existing in the prior art and provide a temperature and humidity control and mechanical control device and control method for the processing and transmission of ultra-wide coated fabrics. By utilizing the spatial arrangement of the multi-stage roller group and the temperature and humidity and mechanical control strategy, the processing quality and efficiency of ultra-wide coated fabrics are improved by accurately controlling the temperature and humidity at different stages, optimizing the stress state and enhancing mechanical flexibility, so as to solve the problem that the traditional fabric coating processing and transmission mechanism cannot accurately and dynamically control the temperature, humidity and stress state, resulting in unstable coating quality.

[0005] In order to achieve the above application objectives, the present invention adopts the following technical solutions: A temperature and humidity control and mechanical control device for processing and transmitting ultra-wide coated fabrics includes:

[0006] The multi-stage roller group includes a feed roller, a first-stage roller, an intermediate-stage roller group, a middle-rear-stage roller group, and a final-stage roller, which are arranged in sequence along the transmission direction; the feed roller is located at the starting position, flush with the horizontal position of the upstream material direction, so that the fabric is in the feeding stage; the height of the first-stage roller is raised by several meters relative to the feed roller to apply initial tensile stress to the fabric, so that the fabric is in the stretching stage; the intermediate-stage roller group is arranged with a horizontal span to achieve fabric relaxation, so that the fabric is in the relaxation stage; the middle-rear-stage roller group is symmetrically distributed on both sides of the transmission center line to achieve under-relaxation of the fabric, so that the fabric is in the under-relaxation stage; the final-stage roller is used to complete the stress release of the fabric, so that the fabric is in the stress release stage;

[0007] The temperature and humidity control unit includes a forced convection heat exchange device and a first-stage roller with a built-in blowing device or an independent spraying device for spraying water vapor during the stretching stage. The forced convection heat exchange device is installed in the middle and rear roller groups to adjust the temperature and humidity of the fabric during the relaxation and under-relaxation stages.

[0008] The dynamic control module is configured to: control the built-in blowing device or the independent spraying device to spray water vapor during the stretching stage; and reduce the temperature and humidity of the fabric at two preset heat exchange rates through the forced convection heat exchange device during the relaxation stage and the under-relaxation stage;

[0009] The mechanical adjustment unit, including the primary roller and the secondary roller, allows the speed to slip within a first preset range and the unilateral axial movement within a second preset range; the middle and rear roller groups adopt a fixed offset structure to ensure transmission stability.

[0010] Furthermore, the first-stage roller adopts an inner and outer double-layer structure, equipped with a spiral nozzle and a diffuser, the water vapor atomization rate is ≥60%, and the spiral nozzle outlet diffusion angle is 30-40 degrees.

[0011] Furthermore, during the relaxation stage and the under-relaxation stage, the forced convection heat exchange device is used to heat the room at 0.5-1.0kW / m 2 and 1.5-2.5kW / m 2 The heat exchange rate reduces the temperature and humidity of the fabric.

[0012] Furthermore, the first preset range is 5% of the rotation speed, and the second preset range is 5-10 cm in the axial direction.

[0013] Furthermore, the temperature control range of the water vapor sprayed by the self-contained blowing device or independent spraying device of the first-stage roller is 10-15°C higher than the room temperature, and the diffusion angle of the atomized water vapor of its spiral nozzle is 35±5 degrees.

[0014] In order to achieve the above application objectives, the present invention also adopts the following technical solutions:

[0015] A method for controlling a temperature and humidity control and mechanical control device for processing and transmitting ultra-wide coated fabrics, comprising the following steps:

[0016] S00, staged stress control:

[0017] Through the spatial layout of the multi-stage roller group, the fabric goes through the stages of stretching, relaxation, under-relaxation and stress release in sequence;

[0018] S10, staged temperature and humidity control:

[0019] Stretching stage: Spray 35-40℃ water vapor through the first roller's built-in blowing device or independent spraying device, with a spraying volume of 0.2-0.3L / m2 per unit area.2 ;

[0020] Relaxation and under-relaxation stage: The temperature and humidity are gradually reduced through the forced convection heat exchange device, and the heat exchange rate is 0.5-1.0kW / m 2 and 1.5-2.5kW / m 2 ;

[0021] S20, Dynamic Mechanical Control:

[0022] The primary and secondary rollers adapt to changes in fabric transmission tension through speed slippage and axial movement;

[0023] The middle and rear rollers remain relatively fixed, and the final roller corrects the fabric transmission direction in real time.

[0024] Furthermore, in step S00, the piecewise function of the spatial layout of the multi-stage roller group is:

[0025]

[0026] Among them, x1, x2, x3, and x4 are the horizontal coordinates of the dividing points of different stages, indicating the position of the fabric in the transmission direction; k is the slope of the lifting section, indicating the rate of change of the material height per unit distance in the roller group; z represents the height of the material in the vertical direction, which is a function of the position x in the transmission direction and is used to describe the spatial configuration change of the material in the roller group; m is the slope of the stress release section, indicating the rate of height decrease of the material per unit distance.

[0027] Furthermore, in step S00, the stress curve of staged stress control is:

[0028]

[0029] Among them, x, x1-x4 are the positions of the fabric in the transmission direction; σ0 is the initial stress; k1 is the stress increase rate in the stretching stage; σ1 is the stress value at the end of the stretching stage; k2 is the stress decrease rate in the relaxation stage; σ2 is the stress value at the beginning of the under-relaxation stage; k3 is the stress decrease rate in the final stress release stage; σ3 is the stress value in the final stress release stage.

[0030] Furthermore, in step S10, the temperature curve for staged temperature and humidity control is:

[0031]

[0032] Wherein, T0 is the initial temperature; k1 is the temperature increase rate in the stretching stage; T1 is the temperature value at the end of the stretching stage; k2 is the temperature drop rate in the relaxation stage; T2 is the temperature value at the beginning of the under-relaxation stage; k3 is the temperature drop rate in the under-relaxation stage; T3 is the temperature value at the end of the under-relaxation stage; K4 is the temperature drop rate in the final stress release stage.

[0033] Furthermore, in step S10, the humidity curve for staged temperature and humidity control is:

[0034]

[0035] Among them, RH0 is the initial humidity; k1 is the humidity increase rate in the stretching stage; RH1 is the humidity value at the end of the stretching stage; k2 is the humidity decrease rate in the relaxation stage; RH2 is the humidity value at the beginning of the under-relaxation stage; k3 is the humidity decrease rate in the under-relaxation stage; RH3 is the humidity value at the end of the under-relaxation stage; K4 is the humidity decrease rate in the final stress release stage.

[0036] Beneficial effects compared with existing technologies:

[0037] 1. Accurately control temperature and humidity in stages:

[0038] Traditional technology uses a single spray device and is unable to control temperature and humidity in stages. The present invention maintains the flexibility of the fabric by spraying high-temperature water vapor (35-40°C) during the stretching stage, and gradually reduces the temperature and humidity through forced convection heat exchange during the relaxation and under-relaxation stages to ensure uniform coating penetration.

[0039] The first-stage roller has its own air blowing device or spiral nozzle (atomization rate ≥ 60%, diffusion angle 30-40°) to achieve precise spraying of water vapor, avoiding local over-wetting or under-wetting of traditional spray devices.

[0040] 2. Dynamic mechanical adaptability:

[0041] Traditional rollers are fixed and cannot adapt to changes in fabric stress; the present invention allows the primary and secondary rollers to slip by 5% in speed and move 5-10cm in the axial direction, dynamically adjusting tension and reducing wrinkles and stretching deformation.

[0042] 3. Improve coating quality and efficiency:

[0043] Through multi-stage rollers, stress is released in stages (stretching → relaxation → under-relaxation → stress release), which avoids stress concentration inside the fabric and improves coating adhesion by 15%-25%.

[0044] The coordinated optimization of temperature, humidity and mechanical parameters reduces coating defects, improves production efficiency and meets the diverse needs of different fabric materials (cotton, chemical fiber, blended).

[0045] 4. Energy saving and environmental protection:

[0046] The forced convection heat exchange device precisely adjusts energy consumption by controlling the heat exchange area, temperature difference and fluid parameters, thus reducing energy waste compared to traditional processes.

[0047] Water vapor recycling and efficient atomization design reduce water consumption and comply with the trend of green manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 It is a structural diagram of an embodiment of the present invention;

[0049] Figure 2 2 is a schematic structural diagram of a first-stage roller according to an embodiment of the present invention;

[0050] Figure 3 2. It is a schematic structural diagram of a spiral nozzle according to an embodiment of the present invention;

[0051] Figure 4 1 is a stress curve diagram of each stage of an embodiment of the present invention;

[0052] Figure 5 1 is a temperature curve diagram of each stage of an embodiment of the present invention;

[0053] Figure 6 1 is a humidity curve diagram of each stage of an embodiment of the present invention.

[0054] In the figure, 1, first-stage roller; 2-3, intermediate-stage roller group; 4-7, middle- and rear-stage roller group; 8, final-stage roller; 9, forced convection heat exchange device; 10, temperature and humidity control unit; 11, roller; 12, shaft; 13, spiral nozzle. DETAILED DESCRIPTION

[0055] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary technicians in this field based on the embodiments of the present invention are within the scope of protection of the present invention.

[0056] Those skilled in the art should understand that, in the disclosure of the present invention, the terms "longitudinal", "transverse", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, which are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, the above terms cannot be understood as limiting the present invention.

[0057] Example 1: Cotton fiber fabric processing system

[0058] 1. Device structure

[0059] Multi-stage roller group:

[0060] Feed roller: 40cm diameter, 3.5m width, feeds fabric within 3.3m of width, made of high-strength aluminum alloy or stainless steel. Located at the starting position of the conveyor mechanism, aligned with the upstream material direction.

[0061] First roller 1: A double-layer structure, with an inner spiral nozzle 13 (65% atomization rate, 35° diffusion angle) and an outer layer of heat-conducting stainless steel (with holes for the nozzle to spray water vapor). It has a diameter of 40 cm. Located behind the feed roller, it is 2.5 meters higher than the feed roller and is used to apply initial tensile stress to the fabric.

[0062] Intermediate roller set (No. 2-3): Located after the primary rollers, No. 2 is the secondary roller. No. 2 and No. 3 are separated by a certain horizontal span to allow the fabric to fully relax. For example, if the diameter is 30cm, the horizontal span is 1.5m, and the spacing is 0.8m, there are 4 sets in total.

[0063] Middle and rear rollers (No. 4-7): symmetrically distributed on both sides of the center line of the entire conveyor mechanism, with a spacing of 1.2m and a diameter of 20cm. They are used to moderately relax the fabric.

[0064] Final roller (No. 8): 40 cm in diameter, can be equipped with a laser guide mechanism. Located at the end of the conveyor, it is used to fully relieve the fabric's stress.

[0065] The rollers are connected by a transmission device (such as motor drive, belt or chain drive) to ensure that the fabric can be transmitted smoothly. The transmission device belongs to the existing technology and will not be described here. Compared with the horizontal transmission method of the existing technology, the present invention only arranges the roller groups at different heights and spacings and different diameters, and does not change the basic mechanical principle.

[0066] In summary, the typical curve equation of the roller group spatial configuration can be described as a piecewise function:

[0067]

[0068] Here, x1, x2, x3, and x4 are the horizontal coordinates of the dividing points in different stages, indicating the position of the fabric in the conveying direction. k is the slope of the lifting section, which represents the rate of change of the material's height per unit distance in the roller group. z represents the material's vertical height, a function of the conveying position x, and is used to describe the spatial configuration change of the material in the roller group. m is the slope of the stress release section, which represents the rate of decrease of the material's height per unit distance.

[0069] Based on the above, the stress curve of the fabric can be expressed as a piecewise function. Assume that the stress is represented by σ(x), where x, x1-x4 are the positions of the fabric in the transmission direction, such as Figure 4 As shown, the stress curve can be expressed as:

[0070]

[0071] Where σ0 is the initial stress, which is usually a very small value. k1 is the rate of stress increase during the tension phase. σ1 is the stress value at the end of the tension phase. k2 is the rate of stress decrease during the relaxation phase. σ2 is the stress value at the beginning of the under-relaxation phase. k3 is the rate of stress decrease during the final stress-relaxation phase. σ3 is the stress value during the final stress-relaxation phase.

[0072] Temperature and humidity control unit 10:

[0073] like Figure 2 As shown, the first roller is equipped with a spiral nozzle independent spraying device or a self-contained jet device, with roller 11 on the top and shaft 12 on the bottom. Roller 11 can rotate around shaft 12. The spray temperature is 35℃ (room temperature is 25℃), and the spraying volume per unit area is 0.2L / m 2 For example, the first-stage roller has a double-layer structure with an inner and outer layer, and the nozzle and diffuser are combined to achieve a water vapor atomization rate of over 60%, with a water vapor diffusion angle of 30-40° (adjustable angle) at the nozzle outlet. The self-contained jet device is a hollow tube in the middle of the roller, connected to a hot steam pipe. The hollow tube has many small hollow holes on it to facilitate the discharge of steam from the middle.

[0074] The temperature curve of the fabric can be expressed as a piecewise function. Assume that the temperature is represented by T(x), where x is the position of the fabric in the transmission direction, such as Figure 5 As shown, the temperature curve can be expressed as:

[0075]

[0076] Where T0 is the initial temperature, which is usually a very small value. k1 is the rate of temperature increase during the stretching phase. T1 is the temperature at the end of the stretching phase. k2 is the rate of temperature decrease during the relaxation phase. T2 is the temperature at the beginning of the under-relaxation phase. k3 is the rate of temperature decrease during the under-relaxation phase. T3 is the temperature at the end of the under-relaxation phase. K4 is the rate of temperature decrease during the final stress release phase.

[0077] Similarly, the humidity curve of the fabric can be expressed as a piecewise function. Assume that the humidity is represented by RH(x), where x is the position of the fabric in the transmission direction, such as Figure 6 As shown, the humidity curve can be expressed as:

[0078]

[0079] Where RH0 is the initial humidity, which is usually a very low value. k1 is the rate of increase in humidity during the stretching phase. RH1 is the humidity value at the end of the stretching phase. k2 is the rate of decrease in humidity during the relaxation phase. RH2 is the humidity value at the beginning of the under-relaxation phase. k3 is the rate of decrease in humidity during the under-relaxation phase. RH3 is the humidity value at the end of the under-relaxation phase. K4 is the rate of decrease in humidity during the final stress release phase.

[0080] Forced convection heat exchange device 9, the intermediate roller group is equipped with a circulating cold water system (the heat exchange rate design is 0.5kW / m 2 , the adjustment range is 0.5-1.0 kW / m 2 ), the middle and rear roller groups adopt semiconductor temperature control devices (the heat exchange rate design is 1.5kW / m 2 , the adjustment range is 1.5-2.5 kW / m 2 ). The temperature and humidity of the fabric are gradually reduced through forced convection heat exchange. A fan can also be used.

[0081] In this embodiment, the cotton fiber fabric needs to gradually increase the heat exchange in the relaxation and under-relaxation stages. The heat exchange distribution of the two stages is 3:7, where the heat exchange rate q can be expressed by the following formula:

[0082] q=h*A*ΔT

[0083] h is the heat transfer coefficient, which is related to the properties of the fluid, flow rate, temperature difference, etc.

[0084] A is the heat exchange area, that is, the contact area between the fabric and the roller.

[0085] ΔT is the temperature difference, that is, the difference between the fabric temperature and the roller temperature

[0086] Therefore, during the relaxation phase, the heat transfer rate is 0.5-1.0kW / m 2 Under-relaxation stage: heat transfer rate is 1.5-2.5kW / m 2 .

[0087] Mechanical adjustment unit:

[0088] The motors of the primary roller 1 and the secondary roller 2 are variable frequency regulated, allowing a speed fluctuation of ±5%, and an axial movement range of 5-10cm on one side.

[0089] The middle and rear rollers are kept offset (relatively fixed) by fixed brackets, and the final roller can achieve a response accuracy of ±2mm through a laser correction mechanism.

[0090] 2. Work process

[0091] Feeding stage: The fabric is smoothly introduced by the feed roller at a speed of 1.2m / s. At this time, the roller height is flush with the upstream material direction, and the fabric is in its initial state.

[0092] Stretching phase:

[0093] The fabric passes through the first roller 1, and the roller height rises sharply by 2-3 meters, exerting initial tensile stress on the fabric (e.g., stress value of about 100N), and the spraying volume per unit area is 0.2L / m 2 .

[0094] The spiral nozzle or the first-stage roller 1 has a built-in blowing device that simultaneously sprays 35°C water vapor with a droplet size of 10-20μm, evenly covering the surface of the fabric.

[0095] Relaxation phase:

[0096] The intermediate roller group is unfolded horizontally, and the fabric tension is reduced to 30N.

[0097] The temperature and humidity of the fabric are gradually reduced by the forced convection heat exchange device, and the heat exchange rate is 0.5kW / m 2 .

[0098] Under-relaxation stage:

[0099] The middle and rear roller groups apply a slight reverse tension (e.g., stress 60N).

[0100] The heat transfer rate of the forced convection heat exchange device is 1.5kW / m 2 .

[0101] Stress release stage: After the final roller corrects the deviation, the fabric is output without tension.

[0102] 3. Implementation Effect

[0103] Coating thickness uniformity is improved by approximately 15%, and wear and chemical resistance are also improved.

[0104] The coating adhesion reaches 2.8N / cm (2.4N / cm for traditional process), and the number of wear resistance test cycles increases by 20%.

[0105] In this embodiment, the stress curves at each stage are as follows: Figure 4 The temperature curves of each stage are shown in Figure 5 As shown in the figure, the humidity curves of each stage are as follows Figure 6 shown.

[0106] Example 2: Chemical fiber fabric processing system

[0107] 1. Parameter adjustment

[0108] Stretching stage: spraying temperature 40℃, spraying volume per unit area 0.3L / m2 .

[0109] Relaxation stage: heat transfer rate 1.0kW / m 2 (Cold water temperature 15℃).

[0110] Under-relaxation stage: heat transfer rate 2.5kW / m 2 (hot air circulation, temperature 30℃).

[0111] 2. Innovation verification

[0112] The axial movement of the first-stage roller effectively compensates for the thermal expansion and contraction of chemical fiber fabrics, reducing the occurrence of edge wrinkles.

[0113] The final-stage correction mechanism controls the transmission deviation within ±3mm, which is 50% higher than the traditional process.

[0114] 3. Implementation Effect

[0115] Coating thickness uniformity is improved by approximately 25%, and wear and chemical resistance are also improved.

[0116] Example 3: Blended fabric processing system

[0117] 1. Parameter adjustment

[0118] Stretching stage: spraying temperature 38°C, spraying volume per unit area 0.25L / m 2 .

[0119] Relaxation stage: heat transfer rate 0.8kW / m 2 (Cold water temperature 17℃).

[0120] Under-relaxation stage: heat transfer rate 2.0kW / m 2 (hot air circulation, temperature 28℃).

[0121] 2. Dynamic Control

[0122] The tension sensor can be used to monitor the fabric tension in real time. When the tension fluctuation exceeds 8% during the stretching stage, the speed of the first-stage roller is dynamically adjusted (within the range of ±5%).

[0123] The humidity monitoring module feeds back data to the control system, automatically adjusting the spraying volume (0.2-0.3L / m 2 Dynamic adjustment).

[0124] 3. Implementation Effect

[0125] The forced convection heat exchange device adopts waste heat recovery technology, which saves 18% energy compared with Example 1.

[0126] Coating thickness uniformity is improved by approximately 20%, and wear and chemical resistance are also improved.

[0127] Other variant implementations

[0128] Nozzle structure replacement: An independent high-pressure spray device can be used to replace the built-in nozzle of the first-stage roller, which is suitable for modifying existing equipment.

[0129] Heat exchange medium selection: Forced convection heat exchange device can use air or thermal oil, which can be adjusted according to the temperature resistance of the fabric.

[0130] Mechanical adjustment expansion: The secondary roller can be equipped with a pneumatic compensation device to achieve bidirectional movement.

[0131] Example 4

[0132] Based on the same concept, this embodiment is based on parameter optimization of digital twins and genetic algorithms, specifically including:

[0133] 1. Digital Twin Model Construction

[0134] 1.1 Model composition

[0135] Geometric model: Use CATIA 3D modeling software (such as CATIA V5R21, accuracy ±0.1mm) to establish an accurate geometric model of the multi-stage roller group (feed roller, first-stage roller, intermediate-stage roller group, mid-to-back-stage roller group, and final-stage roller), including parameters such as roller diameter, height difference, and horizontal span.

[0136] The fabric is simulated using shell elements with a thickness of 0.3-2mm (adjusted according to the actual fabric), and the material properties (elastic modulus, Poisson's ratio) are input through experimental testing. For example, the fabric property database:

[0137] Cotton fiber: elastic modulus 8-12GPa, Poisson's ratio 0.3, permeability 5×10 -12 m 2 .

[0138] Polyester fiber: elastic modulus 15-20GPa, Poisson's ratio 0.35, permeability 3×10 -13 m 2 .

[0139] Blended (50% cotton + 50% polyester): elastic modulus 11-16GPa, permeability 4×10 -13 m 2 .

[0140] Physics Model:

[0141] Stress field: Based on ANSYS Workbench (such as ANSYS Workbench 2023 R1), a nonlinear finite element model is established to simulate the stress distribution of the fabric during stretching, relaxation, and under-relaxation stages. For example:

[0142]

[0143] Where σ is the stress tensor, ρ is the density, b is the body force, and u is the displacement vector.

[0144] Temperature and humidity field: Combined with COMSOL Multiphysics (such as COMSOL Multiphysics 6.1), a coupled model of water vapor diffusion and forced convection heat transfer is established, taking into account parameters such as fabric permeability and evaporation rate. For example:

[0145]

[0146] Where θ is the humidity, D is the diffusion coefficient, and v is the air velocity.

[0147] Coating effect prediction: Use custom functions to associate stress, temperature and humidity data with coating adhesion (formula: adhesion = f(stress history, humidity gradient, temperature curve)). For example, the coating adhesion prediction model:

[0148]

[0149] Among them, Δσ is the stress change gradient, Δθ is the humidity change gradient, T is the temperature, and α, β, γ, and δ are experimental fitting parameters (determined by single-factor experiments).

[0150] 1.2 Model Validation

[0151] Comparison of experimental data:

[0152] In the cotton fabric processing of Example 1, the digital twin model predicted a peak stress of 15.2 MPa. This qualified strain gauge was attached to the cotton fabric of Example 1 to monitor stress changes during the stretching phase. The measured value was 15 MPa, with an error of 1.3%. The specific data is shown in Table 1:

[0153] Table 1

[0154]

[0155] Thermocouples and humidity sensors were placed on the surface of the fabric to record the temperature and humidity changes at each stage. The results are shown in Table 2:

[0156] Table 2

[0157]

[0158] The predicted value of coating adhesion is 2.8N / cm, the measured value is 2.75N / cm, and the error is 1.8%.

[0159] 2. Genetic algorithm optimization process

[0160] 2.1 Optimization parameters and objectives

[0161] Variable parameters:

[0162] Height difference of first-stage roller (H, 2-3 meters)

[0163] Intermediate roller horizontal span (L1, 1.2-1.8 meters)

[0164] Intermediate and rear roller spacing (L2, 1.0-1.5 meters)

[0165] Objective function:

[0166] Main goal: coating uniformity index (σ≤5%)

[0167] Secondary target: Energy consumption (kW・h / m2)

[0168] 2.2 Algorithm Implementation

[0169] Population size: 50 individuals

[0170] Number of iterations: 100 generations

[0171] Crossover probability: 0.8

[0172] Mutation probability: 0.1

[0173] 2.3 Optimization steps

[0174] Initialization population: Randomly generate 50 sets of parameter combinations, each set of parameters includes H, L1, L2, and the step size is 0.1m, 0.1m, and 0.1m respectively. Initial population example:

[0175] Table 3

[0176]

[0177] Fitness calculation:

[0178] Each set of parameters is input into the digital twin model to simulate and calculate the coating uniformity σ and energy consumption E.

[0179] Fitness function: ,

[0180] Where Emax is the energy consumption of the traditional process, σ is the standard deviation of coating uniformity (target ≤5%), E is the energy consumption (kW・h / m), ω1=0.7 (main target weight), and ω2=0.3.

[0181] Constraints:

[0182] Coating uniformity σ ≤ 5%;

[0183] Energy consumption E ≤ 1.8kW・h / m (traditional process benchmark value).

[0184] 2.4 Algorithm Iteration Process

[0185] Typical iteration results are shown in the following table:

[0186] Table 4

[0187]

[0188] Convergence analysis:

[0189] After the 50th generation, the fitness growth rate is <0.005 / generation, which meets the termination condition.

[0190] 3. Optimization results and implementation

[0191] 3.1 The comparison of parameters before and after optimization is shown in Table 5-7:

[0192] Table 5 Cotton fabrics

[0193]

[0194] Table 6 Chemical fiber fabrics

[0195]

[0196] Table 7 Blended fabrics

[0197]

[0198] 4. Virtual commissioning process

[0199] Parameter input: Input the optimized H=2.8m, L1=1.7m, L2=1.4m into the digital twin model.

[0200] Extreme working condition test:

[0201] Simulating nozzle clogging (30% reduction in spray volume): The model predicts that the coating adhesion will drop to 2.5 N / cm, triggering an alarm and recommending nozzle cleaning.

[0202] Simulating synthetic fabrics (elastic modulus increased by 20%): The model automatically adjusts the first-stage roller speed slip range to ±6% to prevent fabric breakage.

[0203] Control strategy update: Feedback virtual debugging results to the dynamic control module to optimize control parameters.

[0204] Therefore, the parameters of the multi-level roller space layout can be optimized through the genetic algorithm of the digital twin module, such as:

[0205] a. A 3D parametric model based on CATIA and ANSYS to simulate the stress, temperature and humidity distribution during fabric transport;

[0206] b. Genetic algorithm optimization unit, which solves the optimal roller layout parameters (H, L1, L2) by maximizing the coating uniformity index and minimizing energy consumption.

[0207] The parts not described in detail in the present invention are prior art, so the present invention does not describe them in detail.

[0208] It is to be understood that the term "one" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element may be one, while in another embodiment, the number of the elements may be multiple, and the term "one" should not be understood as a limitation on the quantity.

[0209] Although this document uses a lot of professional terms, it does not exclude the possibility of using other terms. These terms are used only to more conveniently describe and explain the essence of the present invention; interpreting them as any additional limitations is contrary to the spirit of the present invention.

[0210] The present invention is not limited to the above-mentioned optimal implementation mode. Anyone can derive other forms of products under the inspiration of the present invention. However, no matter what changes are made in the shape or structure, any technical solution that is the same or similar to the present invention falls within the scope of protection of the present invention.

Claims

1. Temperature and humidity control and mechanical control device for processing and transmitting ultra-wide coated fabrics, characterized by: include: The multi-stage roller group includes a feed roller, a first-stage roller, an intermediate-stage roller group, a middle- and rear-stage roller group, and a final-stage roller, which are arranged in sequence along the transmission direction; the feed roller is located at the starting position and is flush with the horizontal position of the upstream incoming material direction, so that the fabric is in the feeding stage; the height of the first-stage roller is raised by several meters relative to the feed roller to apply initial tensile stress to the fabric, so that the fabric is in the stretching stage; the intermediate-stage roller group is arranged with a horizontal span to achieve fabric relaxation, so that the fabric is in the relaxation stage; the middle- and rear-stage roller groups are symmetrically distributed on both sides of the transmission centerline to achieve under-relaxation of the fabric, so that the fabric is in the under-relaxation stage; the final-stage roller is used to complete the stress release of the fabric, so that the fabric is in the stress release stage; The temperature and humidity control unit includes a forced convection heat exchange device and a first-stage roller with a built-in blowing device or an independent spraying device for spraying water vapor during the stretching stage. The forced convection heat exchange device is installed in the middle and rear roller groups to adjust the temperature and humidity of the fabric during the relaxation and under-relaxation stages. The dynamic control module is configured to: control the built-in blowing device or the independent spraying device to spray water vapor during the stretching stage; and reduce the temperature and humidity of the fabric at two preset heat exchange rates through the forced convection heat exchange device during the relaxation stage and the under-relaxation stage; The mechanical adjustment unit, including the primary roller and the secondary roller of the intermediate roller group, allows the speed to slip within a first preset range and unilateral axial movement within a second preset range; the intermediate and rear roller groups adopt a fixed offset structure to ensure transmission stability; Among them, the piecewise function of the spatial layout of the multi-stage roller group is: Among them, x1, x2, x3, and x4 are the horizontal coordinates of the dividing points of different stages, indicating the position of the fabric in the transmission direction; k is the slope of the lifting section, indicating the rate of change of the material height per unit distance in the roller group; z represents the height of the material in the vertical direction, which is a function of the position x in the transmission direction and is used to describe the spatial configuration change of the material in the roller group; m is the slope of the stress release section, indicating the rate of height decrease of the material per unit distance.

2. The temperature and humidity control and mechanical control device for processing and transporting ultra-wide coated fabrics according to claim 1 is characterized in that: The first-stage roller adopts an inner and outer double-layer structure and is equipped with a spiral nozzle. The water vapor atomization rate is ≥60%, and the spiral nozzle outlet diffusion angle is 30-40 degrees.

3. The temperature and humidity control and mechanical control device for processing and transporting ultra-wide coated fabrics according to claim 1 is characterized in that: In the relaxation stage and the under-relaxation stage, the forced convection heat exchange device is used to heat the air at 0.5-1.0kW / m 2 and 1.5-2.5kW / m 2 The heat exchange rate reduces the temperature and humidity of the fabric.

4. The temperature and humidity control and mechanical control device for processing and transporting ultra-wide coated fabrics according to claim 1 is characterized in that: The first preset range is 5% of the rotation speed, and the second preset range is 5-10 cm of axial offset.

5. The temperature and humidity control and mechanical control device for processing and transporting ultra-wide coated fabrics according to claim 1 is characterized in that: The temperature control range of the water vapor sprayed by the self-contained blowing device or independent spraying device of the first-stage roller is 10-15° C. higher than the room temperature, and the diffusion angle of the atomized water vapor of its spiral nozzle is 35±5 degrees.

6. The control method of the temperature and humidity control and mechanical control device for processing and transporting ultra-wide coated fabrics according to any one of claims 1 to 5, characterized in that: The following steps are involved: S00, staged stress control: Through the spatial layout of the multi-stage roller group, the fabric goes through the stages of stretching, relaxation, under-relaxation and stress release in sequence; S10, staged temperature and humidity control: Stretching stage: Spray 35-40℃ water vapor through the first roller's built-in blowing device or independent spraying device, with a spraying volume of 0.2-0.3L / m2 per unit area. 2 ; Relaxation and under-relaxation stage: The temperature and humidity are gradually reduced through the forced convection heat exchange device, and the heat exchange rate is 0.5-1.0kW / m 2 and 1.5-2.5kW / m 2 ; S20, Dynamic Mechanical Control: The primary and secondary rollers adapt to changes in fabric transmission tension through speed slippage and axial movement; The middle and rear rollers remain relatively fixed, and the final roller corrects the fabric transmission direction in real time.

7. The control method according to claim 6, characterized in that: In step S00, the stress curve of staged stress control is: Among them, x, x1-x4 are the positions of the fabric in the transmission direction; σ0 is the initial stress; k1 is the stress increase rate in the stretching stage; σ1 is the stress value at the end of the stretching stage; k2 is the stress decrease rate in the relaxation stage; σ2 is the stress value at the beginning of the under-relaxation stage; k3 is the stress decrease rate in the final stress release stage; σ3 is the stress value in the final stress release stage.

8. The control method according to claim 6, characterized in that: In step S10, the temperature curve for staged temperature and humidity control is: Wherein, T0 is the initial temperature; k1 is the temperature increase rate in the stretching stage; T1 is the temperature value at the end of the stretching stage; k2 is the temperature drop rate in the relaxation stage; T2 is the temperature value at the beginning of the under-relaxation stage; k3 is the temperature drop rate in the under-relaxation stage; T3 is the temperature value at the end of the under-relaxation stage; K4 is the temperature drop rate in the final stress release stage.

9. The control method according to claim 6, characterized in that: In step S10, the humidity curve for staged temperature and humidity control is: Among them, RH0 is the initial humidity; k1 is the humidity increase rate in the stretching stage; RH1 is the humidity value at the end of the stretching stage; k2 is the humidity decrease rate in the relaxation stage; RH2 is the humidity value at the beginning of the under-relaxation stage; k3 is the humidity decrease rate in the under-relaxation stage; RH3 is the humidity value at the end of the under-relaxation stage; K4 is the humidity decrease rate in the final stress release stage.

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