Air-jet loom energy-saving weft insertion system and equipment based on multistage airflow control and operation method of air-jet loom energy-saving weft insertion system and equipment

Abstract

The invention relates to the technical field of intelligent control of looms, discloses an air jet loom energy-saving weft insertion system and equipment based on multistage airflow control and an operation method thereof, and aims to solve the problem of high compressed air energy consumption of traditional equipment. Millisecond-level pressure switching is realized by the multiple groups of independent gas supply units; the weft yarn state monitoring module positions yarn positions in real time; the intelligent control center dynamically adjusts the air pressure through a PID algorithm; the core method comprises the following steps: dividing weft insertion stages and setting a gradient pressure reference value P (x); correcting the pressure according to the real-time position deviation delta x; after the weft leaves, the corresponding nozzles are closed immediately. Therefore, the technical effects of reducing the energy consumption of compressed air and improving the flying stability of weft yarns are achieved, one-key switching of variety parameters is supported, and the device is suitable for high-speed weaving scenes of various yarns such as cotton and polyester.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intelligent control of looms, and in particular to an air jet loom energy-saving weft insertion system based on multi-stage airflow control, an apparatus and an operating method thereof. BACKGROUND

[0002] As a core equipment in the textile industry, the global number of air jet looms exceeds 4 million, and the annual power consumption accounts for more than 35% of the total energy consumption of textile mills. The weft insertion system of the air jet loom relies on compressed air to propel the weft to pass through the shed, and the power of the air compressor for a single device is as high as 55-75 kW. Taking a large textile mill as an example, the annual power consumption of 200 looms exceeds 20 million yuan, of which the air compressor unit accounts for 62.7% (data source: China Textile Industry Association 2023 report).

[0003] However, when the air jet loom is used to weave wide home textile fabrics at high speed (speed 1000 rpm, width 2.8 m), a constant pressure of 0.55 MPa needs to be maintained for the main nozzle, and the auxiliary nozzle also needs to be supplied with 0.4 MPa throughout the process, which will result in a large amount of energy consumption in the ineffective airflow injection, and thus the following problems:

[0004] 1. Excessive air supply waste: the kinetic energy of the weft is sufficient after the second half of the flight, but the auxiliary nozzle still sprays at high pressure, and 40% of the airflow is not applied to the yarn;

[0005] 2. Pressure coupling interference: the main and auxiliary nozzles are supplied with air in parallel, and pressure fluctuations cause the weft to vibrate (amplitude > 1.5 mm), and the narrow fabric scrap rate is as high as 12%;

[0006] 3. Debugging relies on experience: changing yarn varieties requires manual adjustment of 50+ air pressure valves, with an average debugging time of 4.5 hours, and non-optimal parameters;

[0007] 4. Braking out of control: there is no pressure reduction design at the outlet, and the weft rebound causes 3%-5% of double weft defects;

[0008] Therefore, those skilled in the art urgently need an energy-saving weft insertion system that has independent air pressure control capability, real-time feedback of weft movement state, and self-adaptive gradient pressure adjustment, to effectively reduce energy consumption and improve operation stability. SUMMARY

[0009] The purpose of the present application is to solve the above problems, and a kind of air jet loom energy-saving weft insertion system based on multi-stage airflow control, apparatus and operating method thereof are designed.

[0010] To achieve the above purpose, the technical scheme of the present application is an air jet loom energy-saving weft insertion system based on multi-stage airflow control, which comprises the following parts:

[0011] Gradient pressure modeling module, which establishes a gradient pressure reference model about yarn type, speed and width, can receive the parameters input by the HMI interaction module and calculate the initial air pressure instruction, and then send the initial air pressure instruction to the intelligent control hub module;

[0012] Multi-stage gas supply execution module, which can dynamically output air flow through independent air paths (main nozzle and N groups of auxiliary nozzles), can implement on-off state switching and (millisecond level) air pressure adjustment under the control of the intelligent control hub module, and implement end low pressure braking on the end of the weft yarn;

[0013] Weft yarn state monitoring module, which can collect the flight state of the weft yarn under the guidance of the air flow, calculate the deviation amount of the weft yarn flight state and send it to the intelligent control hub module;

[0014] The weft yarn state monitoring module collects the flight state of the weft yarn (i.e. position data and speed data of the weft yarn) in real time through the photoelectric sensor array and calculates the deviation amount of the weft yarn flight state, and feeds back the monitored weft yarn flight state (i.e. position and speed data of the weft yarn) and deviation amount to the intelligent control hub module;

[0015] Intelligent control hub module, which can control the multi-stage gas supply execution module to implement on-off state switching and air pressure adjustment according to the initial air pressure instruction, and use the dynamic air pressure compensation model to compensate and adjust the initial air pressure instruction with the deviation amount as the target, and finally optimize the parameters of the gradient pressure reference model through the adaptive algorithm;

[0016] HMI interaction module, which can interact with the modeling module and the control module respectively to realize human-machine instruction transmission.

[0017] The mathematical expression of the gradient pressure reference model is:

[0018]

[0019] In the formula, P base (x) is the reference air pressure, x is the weft yarn flight distance, the value range is: 0≤x≤L, P0 is the main nozzle basic air pressure, the value range is: 0.4-0.6MPa, k is the pressure attenuation coefficient, the value range is: 0.05-0.15MPa, α is the yarn friction factor (cotton=0.02, polyester=0.03), the value range is: 0.01-0.05mm -1 , β is the relay compensation amplitude, the value range is: 0.01-0.03MPa, L is the total width of the fabric, the value range is: 1800-3200mm.

[0020] The gradient pressure reference model takes the flight distance x as the independent variable and the reference air pressure P base as the dependent variable, and its construction process is as follows:

[0021] Data collection: During 1000 successful weft insertions, record the optimal air pressure at different positions (the minimum air pressure at which the weft yarn flies stably);

[0022] Curve fitting: Use nonlinear regression to fit the decay term k·e -αx (simulating kinetic energy loss) and the sine term (Simulated relay point boost);

[0023] Parameter optimization: With the goal of minimizing the variance of weft yarn flight time, the least squares method is used to solve k, α, and β;

[0024] Working condition mapping: Create a mapping table between P0, k, α, β and yarn type, speed and width.

[0025] The mathematical expression of the deviation is:

[0026] e(t)=t preset (x i )-t actual (x i )

[0027] Where, e(t) is the real-time deviation, t preset (x i ) is the expected arrival position x i Time, t actual (x i ) is the actual arrival time measured by the sensor.

[0028] The mathematical expression of the dynamic air pressure supplement model is:

[0029]

[0030] Where ΔP(t) is the air pressure adjustment, K p is the proportional gain, K i is the integral gain, K d is the differential gain, e(τ) is the historical deviation;

[0031] The dynamic air pressure replenishment model uses the real-time deviation e(t) as the independent variable and the air pressure adjustment ΔP as the dependent variable. The construction process is as follows:

[0032] Step response test: Send a step signal to the air valve and record the lag time of air pressure change (measured average value is 1.2ms);

[0033] Ziegler-Nichols tuning: Determine K based on the critical proportionality method p ,K i , and K d The initial value of

[0034] On-site tuning: fine-tune parameters at a speed of 1000 rpm, with a weft-in-place rate of >99.9%.

[0035] The rule expression for the intelligent control hub module to control the multi-stage gas supply execution module to switch between the open and closed states is:

[0036] x * -x nozzle ≥100

[0037] In the formula, x * is the current position of the weft, and x nozzle is the nozzle tip coordinate.

[0038] The control algorithm for the tip low-pressure braking is:

[0039]

[0040] In the formula, v entry is the speed of the weft entering the tip area (m / s), and P end is the tip nozzle braking air pressure (MPa).

[0041] The mathematical expression of the self-adaptive algorithm is:

[0042]

[0043] In the formula, α old is the yarn friction factor before updating, α new is the yarn friction factor after updating, Δt avg is the average of the real-time deviation degrees (ms) of the last 10 weft insertions, and γ is the learning rate (default 0.001).

[0044] The piezoelectric valve is used as a switching element of the independent air path in the multi-stage gas supply execution module, the piezoelectric valve implements the open and closed state switching of the independent air path according to the rule expression, and the response time of the piezoelectric valve is ≤1 ms.

[0045] A textile equipment is installed with the system of any one of claims 1-8.

[0046] An operation method can be applied to the system of any one of claims 1-8, and the specific steps are as follows:

[0047] Step 1: initialization and parameter setting after starting;

[0048] Starting the system: turning on the total power supply of the loom and starting the HMI interactive interface;

[0049] Input process parameters: yarn type (cotton / polyester / spandex, etc.), target speed, fabric width, and weft density (optional).

[0050] Confirm start: click the "model load" button to submit the parameters;

[0051] Step two: generate initial air pressure instructions;

[0052] The gradient pressure modeling module receives the input process parameters and obtains the initial air pressure instructions by using the gradient pressure reference model, and then sends the obtained initial air pressure instructions to the intelligent control hub module;

[0053] Step three: weft insertion start and dynamic control;

[0054] The intelligent control hub module controls the main nozzle to open at P0 high pressure according to the initial air pressure instructions, the weft yarn is accelerated by the airflow to the channel, the auxiliary nozzle is started in stages according to the initial air pressure instructions, when the weft yarn leaves the main nozzle or the distance value of a certain auxiliary nozzle is greater than or equal to 100mm, the air path of the nozzle is immediately closed; when the end of the weft yarn approaches the channel (i.e. x≥0.9L), the end nozzle is opened to suppress the rebound of the end of the weft yarn;

[0055] Step four: real-time monitoring and feedback of weft state;

[0056] The photoelectric sensor is used to record the passing time of the weft yarn in real time, then the preset arrival time is compared, the real-time deviation e(t) is calculated, and the instantaneous speed of the weft yarn and the real-time deviation e(t) are fed back to the intelligent control hub module;

[0057] Step five: dynamic air pressure compensation;

[0058] According to the deviation, the air pressure compensation amount is calculated, and the initial air pressure instructions are adjusted according to the air pressure compensation amount, and the adjusted air pressure instructions are sent to the piezoelectric valve of the corresponding nozzle;

[0059] Step six: operation monitoring and intervention;

[0060] The HMI (human-machine interface) is used to display the working air pressure of each nozzle, the actual flight curve of the weft yarn vs. the theoretical curve, and the real-time energy consumption statistical data in real time, and the intelligent control hub module supports manual fine adjustment of the pressure of a single group of nozzles (±0.02MPa) or emergency pause of the weft insertion process;

[0061] Step seven: model self-learning optimization;

[0062] The intelligent control hub module can continuously store the average value Δt of the real-time deviation e(t) of 10 successful weft insertions avg For parameter updating, the updated parameters automatically overwrite the old parameters.

[0063] Compared with the prior art, the present application has the following beneficial effects:

[0064] 1、The present application utilizes the multi-stage air supply execution module and the intelligent control hub module to realize the purpose of dynamic adjustment of weft guiding air pressure, supplies air according to the needs of weft guiding, avoids invalid air supply sections, effectively reduces energy consumption, and can reduce energy consumption by 35%;

[0065] 2、The present application utilizes the weft state monitoring module to feed deviation data to the intelligent control hub module, the intelligent control hub module compensates the flight deviation of the weft in real time, and simultaneously depressurizes and brakes the end of the weft flight, to ensure the accuracy and stability of the weft end entering the channel;

[0066] 3、The present application directly controls the largest energy consumption source (compressed air) in the weft insertion process, realizes energy saving effect through intelligent gradient control and on-demand supply, simultaneously dynamically matches airflow demand and real-time feedback compensation, and significantly improves the weft insertion success rate (reduces stoppages), fabric quality consistency and stability;

[0067] 4、The present application has intelligence and adaptability, has learning and optimization capability, can better adapt to weft insertion of different varieties of raw materials and different working conditions, and the system design can consider upgrading the existing air jet loom, and can also be integrated into new machine design;

[0068] 5、The present application adopts visual operation, provides an intuitive operation interface and data monitoring, and is convenient for process management and optimization.

[0069] 6、The present application deeply integrates precision sensing, high-speed execution, intelligent control and physical modeling technology, realizes the revolutionary change of weft insertion airflow supply from "extensive constant pressure" to "fine gradient dynamic matching", and is an effective technical path to solve the problems of high energy consumption and insufficient stability of traditional air jet looms. BRIEF DESCRIPTION OF DRAWINGS

[0070] Figure 1 is a principle diagram of the air jet loom energy-saving weft insertion system based on multi-stage airflow control according to the present application;

[0071] Figure 2 is a parameter configuration table of embodiment 1 according to the present application;

[0072] Figure 3 is a data comparison table of embodiment 1 and the traditional system according to the present application;

[0073] Figure 4 is a data comparison table of embodiment 2 and the traditional equipment according to the present application;

[0074] Figure 5 is a flowchart of the operation method according to the present application. DETAILED DESCRIPTION

[0075] The present application will be specifically described below in combination with the drawings;

[0076] Embodiment 1;

[0077] An air jet loom energy-saving weft insertion system based on multi-stage air flow control, as shown in the figure, the system comprises the following parts: Figure 1

[0078] The gradient pressure modeling module, the HMI interaction module and the intelligent control hub module interact with data, establish a gradient pressure reference model about yarn type, speed and width, the gradient pressure modeling module can receive the parameters input by the HMI interaction module, and the gradient pressure reference model can calculate the initial air pressure command according to the parameters input by the HMI interaction module and send the initial air pressure command to the intelligent control hub module;

[0079] The main function of the gradient pressure modeling module is to calculate the initial air pressure command based on the parameters input by the HMI interaction module and send the initial air pressure command to the intelligent control hub module, and the intelligent control hub module controls the multi-stage air supply execution module according to the received initial air pressure command;

[0080] The multi-stage air supply execution module can dynamically output air flow through independent air paths (main nozzle and N groups of auxiliary nozzles), and the air flow can guide the weft to fly to the channel. The intelligent control hub module can control the on-off state switching and (millisecond level) air pressure adjustment of the multi-stage air supply execution module (mainly the independent air path) to achieve the effect of dynamically outputting air flow, and implement end low pressure braking on the end of the weft to ensure that the end of the weft can accurately enter the channel. It should be noted that the end low pressure braking is realized by the end nozzle (which is an independent nozzle in addition to the main nozzle and N groups of auxiliary nozzles), the end nozzle is connected to a 0.1-0.15 MPa special low pressure air path, and the end nozzle sprays low pressure air flow to the end of the weft to make the end of the weft enter the channel stably and accurately;

[0081] The weft state monitoring module can collect the flight state of the weft under the guidance of the air flow, calculate the deviation of the weft flight state and send it to the intelligent control hub module;

[0082] The weft state monitoring module collects the flight state of the weft (i.e. the position data and speed data of the weft) in real time through the photoelectric sensor array and calculates the deviation of the weft flight state, and feeds back the monitored weft flight state (i.e. the position and speed data of the weft) and the deviation to the intelligent control hub module; the photoelectric sensor array is arranged along the width of the loom, and the distance between the photoelectric sensor arrays is 20 cm;

[0083] ​The intelligent control hub module can control the multi-stage gas supply execution module to switch on and off and adjust the air pressure according to the initial air pressure instruction, can receive the deviation amount fed back by the weft state monitoring module, and can compensate and adjust the initial air pressure instruction by using the dynamic air pressure compensation model, so as to ensure the flight state of the weft, and can optimize the parameters of the gradient pressure reference model by using the adaptive algorithm.

[0084] The HMI interaction module can interact with the modeling module and the control module respectively to realize human-computer instruction transmission, and mainly functions as parameter setting, operation monitoring and energy consumption analysis.

[0085] The mathematical expression of the gradient pressure reference model is:

[0086]

[0087] In the formula, P base (x) is the reference air pressure, x is the weft flight distance (calculated from the main nozzle, in mm), the value range is 0≤x≤L, P0 is the main nozzle basic air pressure, the value range is 0.4-0.6 MPa, k is the pressure attenuation coefficient (reflecting air resistance), the value range is 0.05-0.15 MPa, α is the yarn friction factor (cotton = 0.02, polyester = 0.03), the value range is 0.01-0.05 mm -1 , β is the relay compensation amplitude (auxiliary nozzle pressure boost), the value range is 0.01-0.03 MPa, and L is the total width of the fabric, the value range is 1800-3200 mm; the main function of the gradient pressure reference model is to generate an ideal air pressure distribution curve under different working conditions (yarn type, speed, width) as a control reference.

[0088] The gradient pressure reference model takes the flight distance x as the independent variable and the reference air pressure P base as the dependent variable, and the construction process is as follows:

[0089] Data collection: in 1000 successful weft insertion, record the optimal air pressure value (the minimum air pressure when the weft flies stably) at different positions;

[0090] Curve fitting: use nonlinear regression to fit the attenuation term k·e -αx (simulate kinetic energy loss) and the sine term (simulate relay point pressure boost);

[0091] Parameter optimization: take the minimum weft flight time variance as the target, and use the least square method to solve k, α, β;

[0092] Working condition mapping: map P0, k, α, β with the yarn type, speed, and width to establish a mapping table.

[0093] The mathematical expression of the deviation amount is:

[0094] e(t) = t preset (x i ) - t actual (x i )

[0095] In the formula, e(t) is the real-time deviation degree, t preset (x i ) is the expected arrival position x i (time x i from the reference model), t actual (x i ) is the sensor measured arrival time, if the measured arrival time lags, then e(t) > 0, the main role of the deviation amount is: through the sensor array to obtain the actual position / speed of the weft yarn, and identify the deviation.

[0096] The mathematical expression of the dynamic air pressure supplement model is:

[0097]

[0098] In the formula, ΔP(t) is the air pressure adjustment amount, K p is the proportional gain, the value is: 0.08, which is mainly used for fast response to the current deviation, K i is the integral gain, the value is: 0.005, which eliminates the historical accumulated deviation, K d is the differential gain, the value is: 0.12, which suppresses the future deviation change, e(τ) is the historical deviation degree, and the main role of the dynamic air pressure supplement model is: adjusting the air pressure according to the real-time deviation to ensure that the weft yarn arrives on time;

[0099] The dynamic air pressure supplement model takes the real-time deviation degree e(t) as the independent variable and the air pressure adjustment amount ΔP(t) as the dependent variable, and the construction process is as follows:

[0100] Step response test: send a step signal to the air valve, and record the air pressure change lag time (the measured average value is 1.2ms);

[0101] Ziegler-Nichols tuning: determine the initial values of K p , K i , and K d based on the critical proportionality method;

[0102] Field tuning: under the condition of the vehicle speed of 1000rpm, the weft yarn arrival rate > 99.9% is taken as the target to fine-tune the parameters.

[0103] The rule expression for the intelligent control hub module to control the multi-stage air supply execution module to implement the on-off state switching is:

[0104] x * -x nozzle ≥100 millimeters

[0105] wherein x * is the current position of the weft thread, x nozzle is the nozzle tip coordinate, the rule expression mainly functions to close the air path immediately after the weft thread leaves the nozzle action area, thereby avoiding waste;

[0106] the

[0107] P new = P base (x) + ΔP(t)

[0108] wherein P new is the adjusted air pressure instruction;

[0109] the control algorithm of the tip low-pressure brake is:

[0110]

[0111] wherein v entry is the speed (m / s) of the weft thread entering the tip area, P end is the tip nozzle brake air pressure (MPa); the main function of the tip low-pressure brake is to prevent weft thread rebounding to cause double weft defects.

[0112] the mathematical expression of the self-adaptive algorithm is:

[0113]

[0114] wherein α old is the yarn friction factor before updating, α new is the yarn friction factor after updating, Δt avg is the real-time deviation degree average (ms) of the continuous 10 weft insertion, and γ is the learning rate (default 0.001); the main function of the self-adaptive algorithm is to optimize the benchmark model parameters and improve the generalization ability.

[0115] the piezoelectric valve is used as the switching element of the independent air path in the multi-stage air supply execution module, the piezoelectric valve implements the on-off state switching of the independent air path according to the rule expression, and the response time of the piezoelectric valve is ≤1 ms.

[0116] Embodiment 2;

[0117] Application of a jet loom energy-saving weft insertion system based on multi-stage air flow control in a textile mill:

[0118] Application environment:

[0119] 200 air-jet looms, producing 60 cotton high-density poplin, width 2.8 m, speed 1000 rpm, it is worth noting that the traditional weft insertion system compressed air energy consumption accounted for 63%, annual electricity cost more than 20 million yuan;

[0120] The implementation process is as follows:

[0121] Hardware deployment:

[0122] Each loom is installed with: main nozzle x 1, auxiliary nozzle x 12 groups (piezoelectric valve response time 0.8 ms), end nozzle x 1 (special 0.12 MPa low pressure gas path), photoelectric sensor x 14 (spacing 20 cm, positioning accuracy ± 1 mm), intelligent control core module (industrial PLC + real-time processor), central control room configuration HMI monitoring terminal

[0123] Parameter configuration as shown in Figure 2

[0124] Running process:

[0125] Gradient model generation: P base (x) = 0.52-0.11e -0.021x +0.023sin(πx / 2800)

[0126] Real-time control: when the weft yarn lags behind 5 ms at x = 1500 mm, calculate the compensation amount:

[0127]

[0128] End brake: weft yarn enters the end at 14 m / s, according to P end = 0.1+0.02×(14 / 10) 2 = 0.139 MPa brake.

[0129] The data of example 2 is shown in Figure 3 , and the others are the same as example 1.

[0130] Example 3;

[0131] A textile equipment, which is a new type of high-speed air-jet loom (width 3.2 m, design speed 1200 rpm), is used for producing carbon fiber reinforced fabric for aviation.

[0132] Implementation process:

[0133] Device integration: main nozzle: high-pressure titanium alloy nozzle (pressure resistance 0.8 MPa), auxiliary nozzle: 16 groups of ceramic coated nozzles (piezoelectric valve response 0.7 ms), end brake module: independent low pressure gas path (0.10-0.15 MPa adjustable), monitoring system: infrared laser sensor array (sampling frequency 10 kHz);​

[0134] Yarn type: Carbon fiber / T800

[0135] Reference air pressure: P base (x) = 0.58 - 0.13e -0.035x + 0.028sin(pi x / 3200)

[0136] End brake: when the weft yarn enters the end at 18 m / s: P end = 0.1 + 0.02 x (18 / 10) 2 = 0.165 MPa

[0137] Adaptive learning: continuous 10 times of weft insertion At avg = 0.6 ms, update parameters:

[0138] The data of Example 3 are compared as shown in Figure 4 .

[0139] Example 4;

[0140] An operating method, as Figure 5 shown, can be applied to the system of any of claims 1-8, and the specific steps are as follows:

[0141] Step one: initialization and parameter setting (based on HMI interaction module)

[0142] Start the system: turn on the total power of the loom, and start the HMI interaction interface;

[0143] Input process parameters:

[0144] Yarn type (cotton / polyester / spandex, etc.),

[0145] Target speed (800-1200 rpm),

[0146] Fabric width (1.8-3.2 m),

[0147] Weft density (optional);

[0148] Confirm start: click the "model load" button to submit the parameters;

[0149] The main role of step one is to provide input conditions for gradient pressure modeling;

[0150] Step two: generate initial air pressure instructions (based on gradient pressure modeling module);

[0151] The gradient pressure modeling module receives input process parameters and obtains initial air pressure instructions using a gradient pressure benchmark model, and then sends the obtained initial air pressure instructions (i.e. output air pressure values of the main nozzle / auxiliary nozzle group and the end nozzle) to the intelligent control hub module;

[0152] The main role of step two is to establish the initial air pressure instruction of energy-saving weft insertion air pressure control;

[0153] Step 3: Weft insertion start and dynamic control (based on multi-stage air supply execution module and intelligent control hub module);

[0154] The intelligent control hub module controls the main nozzle to open at a high pressure P0 (such as 0.5 MPa) according to the initial air pressure instruction, and the weft yarn is accelerated by the airflow to the channel. The auxiliary nozzle is started according to the initial air pressure instruction (for example, when the weft yarn end is at x = 200 mm, the auxiliary nozzle is opened at 0.4 MPa), and when the weft yarn is away from the main nozzle or a certain auxiliary nozzle by a distance value ≥ 100 mm, the air path of the nozzle is immediately closed. When the weft yarn end approaches the channel (i.e. x ≥ 0.9L), the end nozzle is opened at a low pressure of 0.1-0.15 MPa, and the low-pressure airflow is used to suppress the weft yarn rebound to ensure accurate parking;

[0155] Step 4: Real-time monitoring and feedback of weft yarn state (based on weft yarn state monitoring module);

[0156] The photoelectric sensor arranged every 20 cm along the width of the loom records the time t of the weft yarn passing in real time actual Then compare the preset arrival time t preset Calculate the real-time deviation e(t) and feed the instantaneous speed of the weft yarn and the real-time deviation e(t) to the intelligent control hub module;

[0157] Step 5: Dynamic air pressure compensation (based on intelligent control hub module);

[0158] Calculate the air pressure compensation amount ΔP(t) according to the real-time deviation e(t), where (K p = 0.08, K i = 0.005, K d = 0.12), and adjust the initial air pressure instruction according to the air pressure compensation amount ΔP(t), and send the adjusted air pressure instruction to the piezoelectric valve of the corresponding nozzle;

[0159] For example, if the weft yarn lags by 10 ms, the pressure of the next group of nozzles is increased by 0.08 MPa;

[0160] Step 6: Operation monitoring and intervention (based on HMI interaction module);

[0161] Real-time display of working air pressure of each nozzle, actual flight curve vs. theoretical curve of weft, and real-time energy consumption statistical data (compressed air flow meter data) by using HMI (human-machine interface); manual fine adjustment of pressure of a single nozzle (±0.02 MPa) or emergency pause of weft insertion process is supported by the intelligent control core module;

[0162] Step 7: Model self-learning optimization (based on the intelligent control core module)

[0163] The intelligent control core module can continuously store the mean value Δt of real-time deviation e(t) of 10 times of successful weft insertion avg For parameter updating, the updated reference model automatically covers the old parameters.

[0164] It should be noted that the photoelectric sensor needs to be calibrated, and the timing error of the photoelectric sensor (error < 0.1 ms) is checked by using a standard check yarn every week, and the air path tightness also needs to be detected, and the leakage rate of the independent air path (pressure drop of the independent air path ≤ 0.02 MPa / min) is checked every month

[0165] The present application ensures that the system reduces energy consumption by 35% while improving weft insertion stability by 20% through the three mechanisms of parameterized initialization, closed-loop dynamic control and continuous self-optimization, and the operation interface conforms to the use habits of industrial sites.

[0166] The above technical solution only embodies the preferred technical solution of the technical solution of the present application, and some changes that the person skilled in the art may make to some parts thereof all embody the principles of the present application and are within the protection scope of the present application.

Claims

1. An energy-saving weft insertion system for an air jet loom based on multi-stage airflow control, characterized in that: The system consists of the following parts: The gradient pressure modeling module establishes a gradient pressure reference model, can calculate the initial air pressure command based on the parameters input by the HMI interaction module and send the initial air pressure command to the intelligent control center module; The multi-stage air supply execution module can dynamically output airflow and implement opening and closing state switching, air pressure adjustment and terminal low-pressure braking under the control of the intelligent control center module; The weft yarn status monitoring module can collect the weft yarn flight status, calculate the deviation of the weft yarn flight status and send it to the intelligent control center module; The intelligent control center module can control the actions of the multi-stage air supply execution modules based on the initial air pressure command, and use the dynamic air pressure supplement model to compensate and adjust the initial air pressure command based on the deviation amount. Finally, the parameters of the gradient pressure reference model are optimized through an adaptive algorithm. The HMI interaction module can interact with the modeling module and the control module respectively to realize human-machine instruction transmission.

2. The energy-saving weft insertion system for an air jet loom based on multi-stage airflow control according to claim 1, characterized in that: The mathematical expression of the gradient pressure reference model is: Where, P base (x) is the reference air pressure, x is the weft yarn flight distance, P0 is the main nozzle basic air pressure, k is the pressure attenuation coefficient, α is the yarn friction factor, β is the relay compensation amplitude, and L is the total fabric width.

3. The energy-saving weft insertion system for an air jet loom based on multi-stage airflow control according to claim 1, characterized in that: The mathematical expression of the deviation is: e(t)=t preset (x i )-t actual (x i ) Where, e(t) is the real-time deviation, t preset (x i ) is the expected arrival position x i Time, t actual (x i ) is the actual arrival time measured by the sensor.

4. The energy-saving weft insertion system for an air jet loom based on multi-stage airflow control according to claim 1, characterized in that: The mathematical expression of the dynamic air pressure supplement model is: Where ΔP(t) is the pressure adjustment, Kp is the proportional gain, Ki is the integral gain, Kd is the differential gain, and e(τ) is the historical deviation.

5. The energy-saving weft insertion system for an air jet loom based on multi-stage airflow control according to claim 1, characterized in that: The rule expression for the intelligent control center module to control the multi-stage gas supply execution module to implement the on-off state switching is: x*-x nozzle ≥100 Where x* is the current position of the weft yarn, x nozzle is the nozzle end coordinate.

6. The energy-saving weft insertion system for an air jet loom based on multi-stage airflow control according to claim 1, characterized in that: The control algorithm of the terminal low-pressure brake is: Where, v entry is the speed of the weft yarn entering the end area, P end Brake air pressure for the end nozzle.

7. The energy-saving weft insertion system for an air jet loom based on multi-stage airflow control according to claim 1, characterized in that: The mathematical expression of the adaptive algorithm is: Where, α old is the yarn friction factor before updating, α new is the updated yarn friction factor, Δt avg is the mean of the real-time deviation of 10 consecutive weft insertions, and γ is the learning rate.

8. The energy-saving weft insertion system for an air jet loom based on multi-stage airflow control according to claim 5, characterized in that: The multi-stage air supply execution module adopts a piezoelectric valve as a switching element of an independent air path, and the piezoelectric valve implements the switching of the opening and closing states according to a regular expression.

9. A textile equipment, characterized in that: The textile equipment is equipped with the system described in any one of claims 1-8.

10. An operating method, characterized in that: The operating method can be applied to the system described in any one of claims 1 to 8, and the specific steps are as follows: Step 1: Power on initialization and parameter setting; Turn on the main power of the loom, start the HMI interactive interface, enter the process parameters and confirm the start; Step 2: Generate initial air pressure command; The gradient pressure modeling module receives the input process parameters and uses the gradient pressure reference model to obtain the initial air pressure instruction, and then sends the obtained initial air pressure instruction to the intelligent control central module; Step 3: Weft insertion start and dynamic control; The intelligent control center module controls the main nozzle to open at P0 high pressure according to the initial air pressure command, and the auxiliary nozzle is started in sections according to the initial air pressure command. When the weft yarn moves away from the nozzle, the air path of the nozzle is immediately closed. When the end of the weft yarn approaches the channel, the end nozzle is opened at low pressure to suppress the weft yarn rebound; Step 4: Real-time monitoring and feedback of weft yarn status; The time of weft yarn passing is recorded in real time, and then compared with the preset arrival time, the real-time deviation is calculated and the instantaneous speed of the weft yarn and the real-time deviation are fed back to the intelligent control central module hub; Step 5: Dynamic air pressure compensation; Calculate the air pressure compensation amount according to the real-time deviation and adjust the initial air pressure instruction according to the air pressure compensation amount, and control the piezoelectric valve of the corresponding nozzle according to the adjusted air pressure instruction; Step 6: Operation monitoring and intervention; Use HMI to display the working air pressure of each nozzle, the actual flying curve of the weft yarn vs. the theoretical curve, and real-time energy consumption statistics in real time; Step 7: Model self-learning optimization; The intelligent control central module can continuously store the real-time deviation average of 10 successful weft insertions for parameter updates. The updated new parameters automatically overwrite the old ones.

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