Design method of modularized direct-current power supply system applied to automatic winder

Abstract

The invention provides a design method of a modular direct-current power supply system applied to an automatic winder. The design method comprises the following steps: determining the matching quantity of modular power supplies according to the power supply demand of the automatic winder; designing and manufacturing the required modular power supply according to the input and output indexes of the single modular power supply and the matching number of the modular power supplies; designing and manufacturing the modularized direct-current power supply system according to functional requirements of the modularized direct-current power supply system; a communication mechanism of the modularized direct-current power supply system is designed, the communication mechanism is coded and then written into the modularized direct-current power supply system, and mutual communication of the automatic winder upper computer, the automatic winder controller and the modularized power supply is achieved; and an upper computer display interface is designed on an upper computer of the automatic winder according to the communication information of each modular power supply, so that man-machine interaction display of the communication state, effective current, effective voltage, effective temperature and alarm record of each modular power supply is realized.

Description

Technical Field

[0001] The present invention relates to the field of textile equipment manufacturing, and particularly to a design method for a modular DC power supply system applied to an automatic winder. Background Art

[0002] The DC power supply system of an automatic winder refers to a dedicated power supply system that converts 380V alternating current into 280V direct current required for each spindle in the automatic winder, and it has characteristics such as special power conversion, high temperature resistance, high humidity resistance, and impurity prevention.

[0003] Currently, the mainstream is to use an integrated DC power supply system to supply power to each spindle. The integrated DC power supply system consists of a transformer that converts 380V alternating current to 110V alternating current, a power supply box that converts 110V alternating current to 280V direct current, and a filter reactor. It is suitable for automatic winders with any number of spindles. However, for the fine winding and connecting automatic winder with a low number of spindles, there is a phenomenon of over-function, which is contrary to the enterprise's cost control goal. Moreover, the automatic winder plays a key role in improving the quality and output of textile products in the textile production line. When the integrated DC power supply system fails, it will cause the entire textile production line to stop production, affecting production efficiency and economic benefits. However, from the analysis of market demand, the fine winding and connecting type automatic winder with a low number of spindles still has a large market demand in the future.

[0004] Therefore, the modular design of the original integrated DC power supply system of the automatic winder has become an important development direction for controlling the cost and improving the maintainability of the DC power supply system of the automatic winder. Summary of the Invention

[0005] Aiming at the problems existing in the prior art, the present invention provides a design method for a modular DC power supply system applied to an automatic winder, which modularly decomposes the original integrated DC power supply system to obtain a modular DC power supply system for the automatic winder, designs a communication mechanism for the modular DC power supply system of the automatic winder to obtain information such as the communication status, effective current, effective voltage, effective temperature, and alarm of all modular power supplies, and designs a host computer display interface for the modular DC power supply system of the automatic winder based on the communication information to realize the human-computer interaction display of information such as the communication status, effective current, effective voltage, effective temperature, and alarm of all modular power supplies.

[0006] The present invention provides a design method for a modular DC power supply system applied to an automatic winder, including:

[0007] (1) Determine the selected number of modular power supplies according to the power supply requirements of the automatic winder, where the power supply requirements of the automatic winder are determined according to the number of spindles of the automatic winder;

[0008] (2) Design and draw the functional block diagram of a single modular power supply according to the input and output indicators of the single modular power supply, and design and manufacture the required modular power supplies according to the functional block diagram of the single modular power supply and the selected quantity of modular power supplies;

[0009] (3) Design the circuit schematic diagram of the modular DC power supply system according to the functional requirements of the modular DC power supply system, and design and manufacture the modular DC power supply system according to the circuit schematic diagram of the modular DC power supply system; the modular DC power supply system includes three-phase five-wire power supply, main switch, contactor, circuit breaker, electrical control cabinet transformer, switching power supply, automatic winder host computer, automatic winder controller, fan, emergency stop button, input electrical transfer component, modular power supply, output electrical transfer component;

[0010] (4) Design the communication mechanism of the modular DC power supply system, and write the encoded communication mechanism into the modular DC power supply system to realize the mutual communication between the automatic winder host computer, the automatic winder controller and the modular power supply;

[0011] (5) Design the host computer display interface on the automatic winder host computer according to the communication information of each modular power supply, and realize the human-computer interaction display of the communication status, effective current, effective voltage, effective temperature, and alarm record of each modular power supply.

[0012] Optionally, in the step (1), determining the selected quantity of modular power supplies according to the power supply requirements of the automatic winder includes:

[0013] P sum = P1 * n

[0014]

[0015] where P sum is the total power of all single spindles, P1 is the power of a single spindle, n is the number of spindles, M is the selected quantity of modular power supplies, and P2 is the normal working power of the modular power supply.

[0016] Optionally, in the step (2), the single modular power supply includes an input EMI circuit, a power frequency rectification circuit, a PFC circuit, an LLC conversion circuit, and an output rectification circuit.

[0017] Optionally, the automatic winder host computer, the automatic winder controller, and the modular power supply communicate with each other through a 485 interface.

[0018] Optionally, in the step (4), designing the communication mechanism of the modular DC power supply system includes:

[0019] Design the communication mechanism of a single modular power supply, specifically as follows:

[0020] Step 1: Define communication failure as alarm 0, temperature protection as alarm 1, current mutual inductance as alarm 2, undervoltage as alarm 3, braking resistor as alarm 4, and other alarms as alarm 5;

[0021] Step 2: Send a communication signal from the automatic winder controller to the modular power supply, and determine whether the communication is successful. If the communication fails for more than 1 second, the counter increments by 1, and a communication signal is sent from the automatic winder controller to the modular power supply. If the communication fails for less than 1 second, a communication signal is directly sent from the automatic winder controller to the modular power supply. If the communication is successful for more than 1 second, alarm 0 is reset and the counter is cleared to indicate successful communication. If the communication is successful for less than 1 second, a communication signal is sent back from the automatic winder controller to the modular power supply;

[0022] Step 3: If the counter reaches 3, alarm 0 is set to indicate communication failure;

[0023] Step 4: After successful communication, the automatic winder controller converts the read effective current information into a real number type, multiplies it by the current proportionality coefficient of 1.415, and then transmits it to the automatic winder host computer. If any alarm occurs, the information transmission stops. The automatic winder controller converts the read effective voltage information into a real number type, multiplies it by the voltage proportionality coefficient of 0.485, and then transmits it to the automatic winder host computer. If any alarm occurs, the information transmission stops. The automatic winder controller converts the read effective temperature information into a real number type and transmits it to the host computer. If any alarm occurs, the information transmission stops;

[0024] Step 5: The automatic winder controller reads the valid value of the fault information address to judge alarms 1 to 5. If they match, they are set; if they don't match, they are reset;

[0025] Design the communication mechanism between the automatic winder controller and all modular power supplies as follows:

[0026] The automatic winder controller uses the above single modular power supply communication mechanism to perform polling communication with all modular power supplies in sequence. After communication, it judges whether the current modular power supply has a fault. If so, it feeds back the fault information to the automatic winder host computer. Otherwise, it continues to perform polling communication with other modular power supplies.

[0027] After adopting the above technical solution, the present invention has at least the following beneficial effects:

[0028] 1. The modular DC power supply system designed for the automatic winder in the present invention does not require an external transformer and filter reactor on the basis of meeting the usage functions of the automatic winder, and different numbers of modular power supplies can be selected according to different single spindle numbers, effectively reducing the production cost of the automatic winder power supply.

[0029] 2. The modular DC power supply system designed for the automatic winder of the present invention allows short-time overload operation. When any one of the modular power supplies needs to be maintained, the remaining power supplies can maintain power supply for a short time, which not only ensures production but also provides time for equipment maintenance, effectively improving the maintainability of the DC power supply system of the automatic winder. The modular power supply is encapsulated, effectively reducing the difficulty of installation and maintenance. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for use in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0031] Figure 1 It is the functional block diagram of a single modular power supply provided by the embodiment of the present invention;

[0032] Figure 2 It is the circuit schematic diagram of the modular DC power supply system provided by the embodiment of the present invention;

[0033] Figure 3 It is the schematic diagram of the communication mechanism of a single modular power supply provided by the embodiment of the present invention;

[0034] Figure 4 It is the schematic diagram of the polling communication mechanism of all modular power supplies provided by the embodiment of the present invention;

[0035] Figure 5 It is the functional design diagram of the upper computer interface of the new modular DC power supply for the automatic winder provided by the embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0036] The following will clearly and completely describe the technical solutions in the embodiments of the present invention with reference to the drawings in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, rather than all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts belong to the scope of protection of the present invention.

[0037] Currently, the following problems exist in the mainstream integrated DC power supply system:

[0038] 1. For some models, there is a problem of over-function, which leads to waste of manufacturing costs;

[0039] 2. During maintenance, production will stop, and at the same time, the circuit is not integrated with protection, and the maintainability needs to be improved;

[0040] 3. The human-machine interaction is weak, and the feedback on power supply failures is not timely.

[0041] After research, the inventors introduced the modular concept. Reasonable and safe power supply design and control system design of the modular DC power supply are problems that must be overcome when introducing the modular concept. At the same time, the logic of the original integrated DC power supply system requires continuous communication for fault judgment, while the modular design needs to use a polling method for individual access. If the original continuous communication cycle is still maintained, the communication timeliness and security of the modular power supply cannot be guaranteed. The original DC power supply human-machine interface cannot perform human-machine interaction on the status of multiple modular power supplies, which also adds difficulties and challenges to the introduction of the modular concept.

[0042] To solve the above problems, an embodiment of the present invention provides a design method for a modular DC power supply system applied to an automatic winding machine, including:

[0043] (1) Determine the selected number of modular power supplies according to the power supply requirements of the automatic winding machine, where the power supply requirements of the automatic winding machine are determined according to the number of single spindles of the automatic winding machine;

[0044] In this embodiment, the number of single spindles n of the automatic winding machine is 72, the power P1 of a single spindle is 250W, and the normal operating power P2 of the modular power supply is 3kW. It can be calculated from the following formula that the total power P of all single spindles sum is 18kW, and the selected number of modular power supplies is 6, that is, the original integrated DC power supply is modularized into 6;

[0045] P sum = P1 * n

[0046]

[0047] (2) Design and draw the functional block diagram of a single modular power supply according to the input and output indicators of a single modular power supply. As Figure 1 shown, a single modular power supply includes an input EMI circuit, a power frequency rectification circuit, a PFC circuit, an LLC conversion circuit, and an output rectification circuit. Single-phase 220V alternating current effectively reduces the interference of the power supply line to the module through the input EMI circuit, is rectified through the power frequency rectification, and the rectified direct current is boosted to 400V direct current through the PFC circuit. Then, the 400V direct current is converted into 280V direct current by the LLC conversion circuit and the output rectification circuit;

[0048] Design and manufacture the required modular power supplies according to the functional block diagram of a single modular power supply and the selected number of modular power supplies. The modular power supplies adopt an integrated encapsulation process;

[0049] (3) Design the circuit schematic diagram of the modular DC power supply system according to the functional requirements of the modular DC power supply system. As Figure 2As shown in the figure, the modular DC power supply system includes a three-phase five-wire power supply, a main switch, a contactor, a circuit breaker, a transformer in the electric control cabinet, a switching power supply, the upper computer of the automatic winder, the controller of the automatic winder, a fan, an emergency stop button, electrical transfer component 1 (the main component consists of 5 RPD terminals), 6 modular power supplies, and electrical transfer component 2 (the main component consists of 2 RPD terminals). The controller of the automatic winder controls the modular power supply through the contactor. The upper computer of the automatic winder, the controller of the automatic winder, and the modular power supplies communicate with each other through the 485 interface. Safe power supply is achieved through electrical transfer components 1 and 2. The modular power supply is cooled and dehumidified by the fan;

[0050] When any power-off condition is met (the emergency stop button is pressed, any modular power supply alarms, the upper computer of the automatic winder sends a stop signal), the contactor coil disconnects, and the modular DC power supply system stops supplying power to the automatic winder; when power is on and no power-off condition is met and after a 3-second delay, the contactor coil closes, and the modular DC power supply system starts supplying power to the automatic winder;

[0051] (4) Design the communication mechanism of the modular DC power supply system, and write the encoded communication mechanism into the modular DC power supply system to achieve the mutual communication between the upper computer of the automatic winder, the controller of the automatic winder, and the modular power supplies;

[0052] Design the communication mechanism of a single modular power supply, as Figure 3 shown in the figure, specifically as follows:

[0053] Step 1: Define communication failure as alarm 0, temperature protection as alarm 1, current mutual inductance as alarm 2, undervoltage as alarm 3, braking resistor as alarm 4, and other alarms as alarm 5;

[0054] Step 2: Initiate a communication signal between the controller of the automatic winder and the modular power supply, and determine whether the communication is successful. If the communication fails for more than 1 second, the counter increments by 1, and a communication signal is initiated between the controller of the automatic winder and the modular power supply. If the communication fails for less than 1 second, a communication signal is directly initiated between the controller of the automatic winder and the modular power supply. If the communication is successful for more than 1 second, alarm 0 is reset and the counter is cleared to indicate successful communication. If the communication is successful for less than 1 second, a communication signal is initiated between the controller of the automatic winder and the modular power supply;

[0055] Step 3: If the counter reaches 3, alarm 0 is set to indicate communication failure;

[0056] Step 4: After successful communication, the automatic winder controller converts the read valid current information into real number type, multiplies it by the current proportionality coefficient 1.415, and then transmits it to the upper computer of the automatic winder. If any alarm occurs, the information transmission stops. The automatic winder controller converts the read valid voltage information into real number type, multiplies it by the voltage proportionality coefficient 0.485, and then transmits it to the upper computer of the automatic winder. If any alarm occurs, the information transmission stops. The automatic winder controller converts the read valid temperature information into real number type and transmits it to the upper computer. If any alarm occurs, the information transmission stops;

[0057] Step 5: The automatic winder controller reads the valid value of the fault information address to judge alarms 1 to 5. If they match, it sets the bit; if not, it resets the bit;

[0058] Design the polling communication mechanism between the automatic winder controller and all modular power supplies, as Figure 4 shown below:

[0059] Step 1: Initialize all the tags used for polling communication with the modular power supplies;

[0060] Step 2: Communicate with modular power supply 1. After communication, judge whether a fault occurs. If so, go to Step 8; otherwise, judge whether the number of power supplies is greater than or equal to 2. If so, enter Step 3; otherwise, return to Step 2;

[0061] Step 3: Communicate with modular power supply 2. After communication, judge whether a fault occurs. If so, go to Step 8; otherwise, judge whether the number of power supplies is greater than or equal to 3. If so, enter Step 4; otherwise, return to Step 2.

[0062] Step 4: Communicate with modular power supply 3. After communication, judge whether a fault occurs. If so, go to Step 8; otherwise, judge whether the number of power supplies is greater than or equal to 4. If so, enter Step 5; otherwise, return to Step 2;

[0063] Step 5: Communicate with modular power supply 4. After communication, judge whether a fault occurs. If so, go to Step 8; otherwise, judge whether the number of power supplies is greater than or equal to 5. If so, enter Step 5; otherwise, return to Step 2;

[0064] Step 6: Communicate with modular power supply 5. After communication, judge whether a fault occurs. If so, go to Step 8; otherwise, judge whether the number of power supplies is greater than or equal to 6. If so, enter Step 6; otherwise, return to Step 2;

[0065] Step 7: Communicate with modular power supply 6. After communication, judge whether a fault occurs. If so, go to Step 8; otherwise, return to Step 2;

[0066] Step 8: Feed back the fault information to the host computer of the automatic winder, and the technical personnel perform fault maintenance;

[0067] (5) Design a host computer display interface on the host computer of the automatic winder according to the communication information of each modular power supply, and realize the man-machine interaction display of the communication status, effective current, effective voltage, effective temperature, and alarm record of each modular power supply, as Figure 5 shown.

[0068] Although the present invention has been disclosed above by way of examples, it is not intended to limit the present invention. Any person skilled in the art within the scope of the present invention may make some changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be determined by the scope defined by the claims.

Claims

1. A design method for a modular DC power supply system applied to an automatic winding machine, characterized in that, Including: (1) Determine the selected quantity of modular power supplies according to the power supply requirements of the automatic winder, where the power supply requirements of the automatic winder are determined according to the number of spindles of the automatic winder; (2) Design and draw the functional block diagram of a single modular power supply according to the input and output indicators of a single modular power supply, and design and manufacture the required modular power supplies according to the functional block diagram of a single modular power supply and the selected quantity of modular power supplies; (3) Design the circuit schematic diagram of the modular DC power supply system according to the functional requirements of the modular DC power supply system, and design and manufacture the modular DC power supply system according to the circuit schematic diagram of the modular DC power supply system; the modular DC power supply system includes three-phase five-wire power supply, main switch, contactor, circuit breaker, electrical control cabinet transformer, switching power supply, automatic winder host computer, automatic winder controller, fan, emergency stop button, input electrical transfer component, modular power supply, output electrical transfer component; (4) Design the communication mechanism of the modular DC power supply system, and write the encoded communication mechanism into the modular DC power supply system to realize the mutual communication between the automatic winder host computer, the automatic winder controller, and the modular power supply; (5) Design the host computer display interface on the automatic winder host computer according to the communication information of each modular power supply to realize the human-computer interaction display of the communication status, effective current, effective voltage, effective temperature, and alarm record of each modular power supply.

2. The design method of the modular DC power supply system applied to an automatic winder according to claim 1, wherein In the step (1), determining the selected quantity of modular power supplies according to the power supply requirements of the automatic winder includes: P sum = P1 * n Wherein, P sum is the total power of all single spindles, P1 is the power of a single spindle, n is the number of single spindles, M is the selected number of modular power supplies, and P2 is the normal operating power of the modular power supply.

3. The design method of the modular DC power supply system applied to an automatic winder according to claim 1, characterized in that, In the step (2), a single modular power supply includes an input EMI circuit, a power frequency rectification circuit, a PFC circuit, an LLC conversion circuit, and an output rectification circuit.

4. The design method of the modular DC power supply system applied to an automatic winder according to claim 1, characterized in that The automatic winder host computer, the automatic winder controller, and the modular power supply communicate with each other through a 485 interface.

5. The design method of the modular DC power supply system applied to an automatic winder according to claim 1, characterized in that, In the step (4), designing the communication mechanism of the modular DC power supply system includes: Design the communication mechanism of a single modular power supply, specifically as follows: Step 1: Define communication failure as alarm 0, temperature protection as alarm 1, current mutual induction as alarm 2, undervoltage as alarm 3, braking resistor as alarm 4, and other alarms as alarm 5; Step 2: Initiate a communication signal between the automatic winder controller and the modular power supply, and determine whether the communication is successful. If the communication fails for more than 1 second, the counter counts +1, and a communication signal is initiated between the automatic winder controller and the modular power supply. If the communication fails for less than 1 second, a communication signal is directly initiated between the automatic winder controller and the modular power supply. If the communication is successful for more than 1 second, alarm 0 is reset and the counter is cleared to indicate successful communication. If the communication is successful for less than 1 second, a communication signal is initiated between the automatic winder controller and the modular power supply; Step 3: If the counter count reaches 3, alarm 0 is set to indicate communication failure; Step 4: After successful communication, the automatic winder controller converts the read effective current information into a real number type, multiplies it by the current proportionality coefficient 1.415, and then transmits it to the upper computer of the automatic winder. If any alarm occurs, the information transmission stops. The automatic winder controller converts the read effective voltage information into a real number type, multiplies it by the voltage proportionality coefficient 0.485, and then transmits it to the upper computer of the automatic winder. If any alarm occurs, the information transmission stops. The automatic winder controller converts the read effective temperature information into a real number type and transmits it to the upper computer. If any alarm occurs, the information transmission stops; Step 5: The automatic winder controller reads the effective value of the fault information address to judge alarms 1 to 5. If they match, they are set; if they do not match, they are reset; Design the communication mechanism between the automatic winder controller and all modular power supplies as follows: The automatic winder controller uses the above single modular power supply communication mechanism to perform polling communication with all modular power supplies in turn. After communication, it judges whether the current modular power supply has a fault. If so, it feeds back the fault information to the upper computer of the automatic winder. Otherwise, it continues to perform polling communication with other modular power supplies.

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