Magnetic suspension weft insertion driving system and method

Abstract

The invention belongs to the technical field of textile machinery, and discloses a magnetic suspension weft insertion driving system and method.The system comprises a weft insertion base, a weft insertion device, a control system, a posture active stabilization module, a weft yarn dynamic tension servo module and a predictive heat management module. According to the invention, the attitude active stabilization module performs high-frequency closed-loop control on the multi-degree-of-freedom attitude of the weft insertion device through a non-contact sensor and an attitude adjustment coil; the weft yarn dynamic tension servo module is arranged in the weft insertion device and achieves whole-course dynamic closed-loop servo control over weft yarn tension through a micro sensor and an actuator. And the predictive heat management module predicts the heating power of the track by using a digital twin heat model, and performs feed-forward active control on the cooling system. The weft insertion speed, stability and reliability can be remarkably improved, meanwhile, constant weft yarn tension is guaranteed, and the weaving efficiency and the fabric quality are improved.

Description

Technical Field

[0001] This invention belongs to the field of textile machinery technology, specifically relating to a magnetic levitation weft insertion drive system and method. Background Technology

[0002] In the weaving process, weft insertion is a crucial step that introduces the weft yarn from one side of the weft hole to the other. Its efficiency and quality directly determine the production efficiency of the loom and the quality of the fabric. Traditional weft insertion methods, such as rapier, shuttle, air-jet, and water-jet weft insertion, generally suffer from problems such as mechanical friction, wear, high noise, limited speed, high energy consumption, and lubricant contamination of the fabric.

[0003] To overcome the aforementioned shortcomings, some engineers have proposed using magnetic levitation or electromagnetic drive technology for weft insertion. The principle behind these solutions is to use electromagnetic force to drive a contactless weft inserter (shuttle), theoretically enabling higher speeds and lower noise and wear. However, existing magnetic levitation weft insertion solutions are mostly still in the conceptual or preliminary verification stage, failing to address the key technological bottlenecks in industrial applications:

[0004] Poor high-speed stability: The weft guide is lightweight and fast, making it highly susceptible to airflow disturbances and other factors during high-speed flight, which can lead to attitude instability and operational failure.

[0005] Severe heat buildup: The drive coil requires high-frequency, high-current switching, and the large amount of heat generated is difficult to dissipate effectively, which limits the system's continuous working capability and maximum speed.

[0006] Uncontrolled weft tension: During rapid acceleration and deceleration, the weft yarn will experience severe tension fluctuations due to inertia, which seriously affects the quality of the fabric and may even lead to yarn breakage. Summary of the Invention

[0007] The present invention aims to at least partially solve the aforementioned technical problems. Therefore, the objective of the present invention is to provide a magnetic levitation weft insertion drive system and method.

[0008] The technical solution adopted in this invention is as follows:

[0009] This invention provides a magnetically levitated right-hand weft insertion drive system, including a weft insertion base, a weft inserter, and a control system. The weft insertion base is equipped with driving electromagnetic coils arranged along a preset weft insertion track; the weft inserter is adapted to levitate and move above the weft insertion base, and has a permanent magnet inside; the control system is used to control the driving electromagnetic coils to generate a traveling wave magnetic field to drive the weft inserter.

[0010] To solve the problem of high-speed stability, the present application further includes a posture active stabilization module. The module contains multiple position sensors (such as Hall sensors, laser range finders or eddy current sensors) arranged on the weft insertion base and multiple sets of posture adjustment coils. The control system monitors the spatial pose information (such as lateral, vertical displacement and pitch, yaw, roll angle) of the weft inserter in real time through the position sensors. Once any attitude deviation is detected, the control system immediately calculates the required correction force or torque through a closed-loop control algorithm (such as PID or LQR), and drives the corresponding posture adjustment coil to generate the corresponding electromagnetic force, thereby actively and quickly suppressing the attitude deviation and ensuring the stable operation of the weft inserter throughout the high-speed stroke.

[0011] To solve the problem of uncontrolled weft tension, the weft inserter of the present application is internally provided with a weft dynamic tension servo module. The module is composed of a tension sensor, a tension adjustment actuator (such as a piezoelectric actuator or a micro brushless motor) and an on-board controller. It can monitor the weft tension in real time, and according to the tension feedback and the motion instructions (acceleration and deceleration information) issued by the main control system, it can actively wind and unwind a small amount of weft through the actuator. This closed-loop control method combining feedforward and feedback ensures that the weft tension remains constant during the dynamic process, fundamentally improving the fabric quality.

[0012] To solve the problem of heat accumulation, the present application further includes a predictive thermal management module. The module contains an efficient cooling system (such as a micro-channel liquid cooling system) and a temperature sensor. The core is the digital twin thermal model built in the control system. The model can accurately predict the heat generated by each part of the coil on the trajectory according to the target motion trajectory of the weft inserter. Based on this prediction, the control system can perform feedforward control to adjust the cooling system in advance, and accurately and actively cool down before or at the early stage of heat generation, so as to strictly control the trajectory temperature within the set range and ensure the long-term stable operation of the system.

[0013] As a preferred solution, the posture stabilization algorithm can use mature and efficient PID or LQR algorithm; the tension adjustment actuator can use piezoelectric actuator with fast response speed and small size; the cooling system can use micro-channel liquid cooling system with extremely high heat dissipation efficiency. In addition, the present application also retains and optimizes the braking energy recovery function, which converts the kinetic energy of the weft inserter during deceleration into electrical energy and stores it in the energy storage unit (such as super capacitor), improving the energy efficiency of the system.

[0014] The present application also provides a corresponding magnetic levitation weft insertion driving method, which includes the steps of stabilizing the levitated weft inserter, driving the weft inserter to move, and introducing the key steps of actively correcting the motion posture, dynamically closed-loop controlling the weft tension, and feedforward actively cooling the weft insertion trajectory throughout the motion.

[0015] The beneficial effects of the present application are:

[0016] The present application can keep the precise posture of the weft feeder at ultra-high speed (for example, > 40 m / s) through the multi-degree-of-freedom posture active stabilization module, and the operation reliability is greatly improved. The built-in weft dynamic tension servo system effectively eliminates the tension fluctuation caused by acceleration and deceleration, significantly reduces fabric defects, and reduces the yarn breakage rate.

[0017] The predictive thermal management module of the present application solves the heat dissipation bottleneck during high-speed operation, ensures that the system can work stably for a long time under high load, and combines high speed, high stability and brake energy recovery to comprehensively improve the production efficiency and energy utilization rate of the loom. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 is a schematic diagram of the magnetic suspension weft feeding driving system of the embodiment of the present application.

[0019] Figure 2 is a cross-sectional view of the weft feeder in the embodiment of the present application.

[0020] Figure 3 is a functional module block diagram of the control system in the embodiment of the present application.

[0021] Figure 4 is a flowchart of the magnetic suspension weft feeding driving method of the embodiment of the present application. DETAILED DESCRIPTION

[0022] The embodiments of the present application are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference signs represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the accompanying drawings are exemplary and are intended to explain the present application, and cannot be understood as a limitation of the present application. The components of the embodiments of the present application described and shown herein can be arranged and designed in various different configurations.

[0023] Referring to Figure 1 and Figure 2 , the magnetic suspension weft feeding driving system provided by the embodiment of the present application comprises a weft feeding base 1, a weft feeder 3 and a control system.

[0024] The weft feeding base 1 is of a ring structure, and the upper surface thereof forms a weft feeding track. A plurality of groups of driving electromagnetic coils 2 are arranged in the circumferential direction on the track, for generating a traveling wave magnetic field.

[0025] The weft feeder 3 is an execution body of the weft feeding action, and the bottom thereof is packaged with a high-magnetic-energy-product permanent magnet 4 (such as an NdFeB magnet array) for interacting with the driving electromagnetic coils 2 to generate suspension force and driving force. The weft feeder 3 is internally provided with a weft dynamic tension servo module, such as Figure 2As shown, it includes a yarn passage, in which a tension sensor and a tension adjustment actuator are arranged, the tension sensor adopts a micro piezoelectric ceramic tension sensor, and the tension adjustment actuator is a tension adjustment actuator (for example, a precision yarn guide wheel) driven by a micro brushless DC motor. The weft yarn 5 passes through the module. A board-mounted controller (a micro PCB integrated in the weft feeder) is responsible for the operation of the module.

[0026] The magnetic suspension weft feeding drive system of the embodiment further comprises a posture active stabilization module. In addition to the drive electromagnetic coil 2, a plurality of posture adjustment coils are independently arranged on the weft feeding base 1. At the same time, a plurality of position sensors (laser triangulation sensors in this example) are installed on the track side wall, which are used to accurately measure the lateral gap and suspension height between the weft feeder 3 and the track, and to calculate the pitch angle and yaw angle of the weft feeder through multi-point measurement.

[0027] The magnetic suspension weft feeding drive system of the embodiment further comprises a predictive thermal management module. The shell of the weft feeding base 1 is internally processed with a micro-channel flow path to form a cooling system. The cooling liquid (such as deionized water) is driven to circulate by an external pump-heat exchange unit. Near each group of drive electromagnetic coils 2, a micro temperature sensor (such as a PT100 platinum resistance) is embedded.

[0028] Referring to Figure 3 , the control system is composed of a high-performance DSP or FPGA. It includes the following modules:

[0029] Trajectory planning module: according to the main shaft signal of the loom, the ideal motion trajectory (position, velocity, acceleration as a function of time) of the weft feeder 3 is generated.

[0030] Drive control module: the trajectory is decomposed into real-time current instructions for each drive electromagnetic coil 2, and space vector pulse width modulation (SVPWM) and other technologies are used to generate drive signals.

[0031] Posture stabilization controller: receives real-time posture data from the position sensor, compares it with the set value (ideal central suspension position), calculates the compensation current required by the posture adjustment coil through the LQR algorithm, and the frequency can reach 20 kHz, realizing the instantaneous correction of the weft feeder posture.

[0032] Thermal management controller: receives the target trajectory of the trajectory planning module and the real-time temperature from the temperature sensor. The digital twin thermal model (a mathematical model based on finite element analysis and pre-established and online corrected) in the controller predicts the heat power distribution of each coil section in the future 0-50 ms according to the trajectory. The controller generates a feedforward control signal for the pump speed and valve opening of the cooling system according to the heat power distribution, realizing pre-cooling. The feedback of the temperature sensor is used for online calibration of the model and closed-loop temperature regulation.

[0033] Wireless communication module: for high-speed bidirectional communication with the on-board controller inside the weft inserter 3, sending motion commands, and receiving state information such as tension data.

[0034] The on-board controller inside the weft inserter 3 is used for weft tension control. It receives the acceleration command a(t) from the main control system as a feedforward signal, and reads the real-time tension T(t) of the tension sensor as a feedback signal. Its internal PID controller calculates the target speed / displacement of the tension adjustment actuator, so that T(t) is stable at the set value (e.g. 5±0.2 cN) in any dynamic process.

[0035] Referring to Figure 4 The magnetic suspension weft insertion driving method of the present application has the following process flow:

[0036] Step S101: system initialization, the weft inserter 3 is controlled by the attitude stabilization module at the starting position to achieve stable suspension.

[0037] Step S102: the trajectory planning module of the control system generates the motion curve for this weft insertion.

[0038] Step S103: the thermal management controller receives the motion curve and starts predictive thermal management. According to the predicted heat power, the working state of the cooling system is adjusted in advance.

[0039] Step S104: the drive control module starts to execute the motion curve to drive the weft inserter 3 to accelerate. At the same time, the control system sends the acceleration information to the on-board controller inside the weft inserter 3.

[0040] Step S105: during the entire motion process (acceleration, constant speed, deceleration), the following three sub-processes run continuously at high frequency:

[0041] S105a: the attitude stabilization controller continuously works to monitor and correct the attitude of the weft inserter 3 in real time.

[0042] S105b: the on-board controller continuously adjusts the tension adjustment actuator according to the acceleration feedforward and tension feedback to maintain constant weft tension.

[0043] S105c: the thermal management controller continuously adjusts the cooling intensity according to the weft inserter position and the prediction model.

[0044] Step S106: the weft inserter 3 reaches the deceleration zone, the drive control module implements electromagnetic braking, and the generated electric energy is recovered to the energy storage unit (super capacitor) through the inverter-rectifier link.

[0045] Step S107: the weft inserter 3 stops accurately at the end position, completing a weft insertion.

[0046] In order to verify the technical effect of the present application, simulation and experimental comparison are carried out. Test conditions: weft insertion width 1.9 m, weft inserter mass 50 g.

[0047] Performance indicators Conventional high-speed rapier Existing magnetic levitation solution (without improvements) The present solution Maximum weft insertion speed ~20 m / s ~25 m / s (limited by stability) >45 m / s Weft insertion rate ~1000 wefts / min ~1300 wefts / min >2200 wefts / min Flight attitude deviation (pitch / yaw) Not applicable ±0.8° <±0.05° Weft tension fluctuation ±50% ±30% (only during acceleration / deceleration phases) <3% (overall) Yarn breakage rate (for specific yarns) 0.5 times / hour 0.2 times / hour <0.01 times / hour Maximum track temperature rise (1 h of continuous operation) Not applicable 45°C <15°C

[0048] As can be seen from the above table, through the improvement of posture active stabilization, dynamic tension servo and predictive thermal management, compared with the prior art, the weft insertion speed, production efficiency, running stability, weaving quality and system reliability are all improved.

[0049] The present application is not limited to the above optional embodiments, and anyone can derive other various forms of products under the inspiration of the present application, but regardless of any changes in shape or structure, any technical solutions falling within the scope defined by the claims of the present application fall within the protection scope of the present application.

Claims

1. A magnetic levitation weft insertion drive system, characterized by, Comprising: A weft guiding base (1) provided with driving electromagnetic coils (2) along a preset weft guiding track; A weft guide (3) adapted to be suspended above the weft guiding base (1) and move along the weft guiding track, and provided with a permanent magnet (4) inside; A control system for controlling the driving electromagnetic coils (2) to generate a traveling wave magnetic field to drive the weft guide (3); An attitude active stabilization module, comprising: a plurality of position sensors and a plurality of attitude adjusting coils arranged on the weft guiding base (1); The control system monitors the attitude information of at least three degrees of freedom of the weft guide (3) in real time according to the position sensors, generates electromagnetic force or torque through the attitude adjusting coils, and performs closed-loop control on the motion attitude of the weft guide (3) to suppress attitude deviation.

2. The magnetic levitation weft insertion drive system according to claim 1, characterized in that The weft guide (3) is provided with a weft dynamic tension servo module, which comprises: A tension sensor for measuring the real-time tension of the weft (5); A tension adjusting actuator for actively winding and unwinding the weft (5); An on-board controller for controlling the tension adjusting actuator to work according to the feedback of the tension sensor and / or the motion instructions issued by the control system, so as to maintain the tension of the weft (5) within a preset range.

3. The magnetic levitation weft insertion drive system according to claim 2, characterized in that The tension adjusting actuator is a piezoelectric actuator or a micro brushless DC motor.

4. The magnetic weft insertion drive system according to any one of claims 1 to 3, characterized in that: It also includes a predictive thermal management module; the predictive thermal management module comprises: A cooling system and a plurality of temperature sensors provided in the weft guiding base (1); The control system includes a digital twin thermal model, which predicts the future heating power of the driving electromagnetic coils (2) based on the target motion trajectory of the weft guide (3), and performs feedforward control on the cooling system based on the predicted future heating power.

5. The magnetic levitation weft insertion drive system according to claim 4, characterized in that The cooling system is a micro-channel liquid cooling system.

6. The magnetic levitation weft insertion drive system according to claim 1, wherein, The attitude active stabilization module realizes the attitude closed-loop control of the weft guide (3) through proportional-integral-derivative control algorithm or linear quadratic regulator algorithm.

7. The magnetic levitation weft insertion drive system of claim 1, wherein: It also includes an energy storage unit; the control system controls the driving electromagnetic coils (2) to convert the kinetic energy of the weft guide (3) into electrical energy and store it in the energy storage unit when the weft guide (3) is decelerated and braked.

8. A magnetic levitation weft insertion drive method characterized by, Applied to the magnetic levitation weft guiding and driving system of any one of claims 1-7, characterized by the following steps: a) The control system controls the driving electromagnetic coils (2) and the attitude adjusting coils to make the weft guide (3) stably suspended above the weft guiding base (1); b) The control system generates a traveling wave magnetic field to drive the weft guide (3) to accelerate, move at a constant speed and decelerate along the weft guiding track; c) During the whole movement process of step b), the attitude active stabilization module is used to monitor and actively correct the motion attitude deviation of the weft guide (3).

9. The magnetic levitation weft insertion drive method according to claim 8, characterized by, It also includes the following steps: d) During the movement process of step b), the weft dynamic tension servo module built in the weft guide (3) is used to perform real-time dynamic closed-loop control on the tension of the weft (5).

10. The magnetic weft insertion drive method according to claim 8 or 9, characterized in that It also includes the following steps: e) before or during the execution of step b), by means of said predictive thermal management module, predicting the heating trend of the drive electromagnetic coil (2) and performing a feedforward active cooling of said weft insertion base (1).

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