Tension sensor calibration system and method

Abstract

The invention relates to a tension sensor calibration system and method, and the system comprises a calibration yarn which passes through a to-be-calibrated tension sensor; the standard measuring device is connected to one end of the calibration yarn, and the servo motor is connected to the other end of the calibration yarn; the motor controller is used for driving the servo motor and the main controller, the main controller is used for comparing the tension, measured by the standard measuring device, of the calibrated yarn with a set tension value and outputting PID parameters to the motor controller according to a calibration algorithm, and the tension of the calibrated yarn is adjusted through the servo motor. And completing calibration of the to-be-calibrated tension sensor. One-key automatic calibration of the to-be-calibrated tension sensor is achieved, manual intervention is not needed, calibration efficiency is high, meanwhile, dynamic tension can be simulated through the servo motor, fine adjustment of the tension can be accurately controlled, and accurate calibration of the tension sensor is achieved.

Description

Technical Field

[0001] This application relates to the field of sensor calibration, specifically to a tension sensor calibration system and method. Background Technology

[0002] The calibration process of a yarn tension sensor is the process of establishing a precise correspondence between the output signal of the tension sensor and a known standard tension value. Its necessity lies in:

[0003] 1. Ensure measurement accuracy: Tension sensors inevitably experience individual differences, zero-point drift, sensitivity variations (such as strain gauge aging and minor creep of the elastomer), and temperature drift during production, transportation, installation, and use. Calibration can correct these errors, ensuring that the voltage / current values ​​output by the sensor accurately reflect the actual yarn tension.

[0004] 2. Achieving process control objectives: Textile processes have strict requirements on yarn tension. For example:

[0005] Weaving: The warp tension must be uniform and stable, otherwise it will cause warp breakage, skipped patterns, and uneven fabric surface.

[0006] Warping: Uneven tension will cause the warp beam to be wound unevenly, affecting subsequent weaving.

[0007] Winding: Excessive tension damages the yarn, while insufficient tension results in poor yarn formation.

[0008] Only with data provided by accurately calibrated tension sensors can the control system perform precise tension adjustment (such as by adjusting the brake, yarn feed roller speed, etc.) to achieve the optimal tension value set by the process.

[0009] 3. Ensure consistent product quality: For the same process, different machines and time periods require sensors to provide consistent measurement benchmarks to produce products of stable quality. Calibration is a crucial step in ensuring this consistency.

[0010] 4. Equipment maintenance and fault diagnosis: Regular calibration can monitor the changing trend of sensor performance, detect potential faults in time (such as decreased sensitivity, severe zero drift), and carry out preventive maintenance.

[0011] 5. Meet quality system requirements: Many industry standards and quality systems (such as ISO) require that critical measuring equipment be calibrated / calibrated regularly to demonstrate the reliability of its measurement data.

[0012] There are two main types of tension sensors: strain gauge type and piezoelectric type. While their measurement principles differ, their operation is almost identical: both involve pressing the yarn onto the sensor's pressure roller to generate strain or a change in electrical charge. Currently, the most common calibration method for tension sensors is the static calibration method using weights. This method utilizes the gravity of the weights to create different tensions, thereby completing the calibration. Lateral calibration using a screw pull is also available; the principle is the same: to create various different tension values.

[0013] The traditional weight calibration method cannot measure continuous tension or simulate dynamic tension. Frequent manual handling of weights is also inefficient. While the screw method can simulate dynamic tension and eliminates the need for weight handling, fine-tuning of tension is often uncontrollable, requiring manual experience and leading to significant errors. There is an urgent need to establish a third-generation calibration system with environmental awareness, dynamic adaptation, and intelligent decision-making capabilities.

[0014] At the same time, due to the special characteristics of textile yarn materials and application scenarios, the following may occur:

[0015] (1) Insufficient accuracy in the low tension zone leads to distortion of the calibration curve and yarn breakage in the high tension zone;

[0016] (2) Different yarns have different friction behaviors, which leads to inaccurate calibration.

[0017] In addition to the two points mentioned above, environmental disturbances such as workshop vibrations can also cause many uncertainties in automatic calibration. Without human intervention and supervision, automatic calibration may fail to achieve the desired level of results, or even be worse than manual calibration, due to inaccuracies, safety concerns, susceptibility to interference, and failure to consider material differences. Summary of the Invention

[0018] In view of the above problems, this application provides a tension sensor calibration system and method, which solves the problems of existing tension sensor calibration methods using weights, such as the inability to simulate dynamic tension, the labor-intensive and inefficient nature of frequently removing and placing weights, and the uncontrollable tension fine-tuning in the screw method, which relies on manual experience and has large errors.

[0019] To achieve the above objectives, the inventors provide a tension sensor calibration system, comprising:

[0020] A calibration yarn is passed through a tension sensor to be calibrated.

[0021] A standard measuring device is connected to one end of the calibration yarn and is used to measure the tension of the calibration yarn.

[0022] A servo motor is connected to the other end of the calibration yarn, and the servo motor is used to drive the calibration yarn to extend and shorten.

[0023] A motor controller, which is used to drive a servo motor;

[0024] The main controller is connected to a standard measuring device, a tension sensor to be calibrated, and a motor controller. The main controller is used to compare the tension of the calibration yarn measured by the standard measuring device with the set tension value, and output PID parameters to the motor controller according to the calibration algorithm. The tension of the calibration yarn is adjusted by the servo motor to complete the calibration of the tension sensor to be calibrated.

[0025] In some embodiments, when the main controller outputs PID parameters to the motor controller according to the calibration algorithm, it determines the tension range in which the current tension of the calibration yarn is located. When the current tension of the calibration yarn is in the low tension range, it increases the micro-vibration parameter value and extends the stabilization time in the PID parameters. When the current tension of the calibration yarn is in the standard tension range, it outputs the standard PID parameters. When the current tension of the calibration yarn is in the high tension range, it automatically switches the PID parameters to the strong damping mode.

[0026] In some embodiments, the main controller is further configured to immediately control the servo motor to reverse when a standard measuring device detects that the tension of the calibrated yarn drops instantaneously by more than a preset ratio.

[0027] In some embodiments, the main controller is further configured to map the characteristic parameters of the calibrated yarn to PID parameters to generate an adaptive adjustment strategy, wherein the characteristic parameters include friction coefficient, breaking strength, creep rate and surface roughness.

[0028] In some embodiments, the main controller is also used to update and alarm the parameters between the characteristic parameters and PID parameters of the calibration yarn when an abnormality occurs during the calibration test of the tension sensor to be calibrated.

[0029] Another technical solution is also provided: a tension sensor calibration method, which is applied to the tension sensor calibration system described above, and includes the following steps:

[0030] The tension of the calibration yarn passing through the tension sensor to be calibrated is detected in real time using a standard measuring device.

[0031] The measured tension of the calibrated yarn is compared with the set pressure value, and the PID parameters are output according to the calibration algorithm.

[0032] The servo motor is driven according to the PID parameters to adjust the tension of the calibration yarn until the tension of the calibration yarn reaches the set tension value.

[0033] The tension sensor to be calibrated is calibrated according to the set tension value.

[0034] In some embodiments, the step of outputting PID parameters according to the calibration algorithm specifically includes the following steps;

[0035] When the PID parameters are output to the motor controller according to the calibration algorithm, the tension range in which the current tension of the calibration yarn is located is determined.

[0036] When the current tension of the calibrated yarn is in the low tension range, increase the micro-vibration parameter value and extend the settling time in the PID parameters;

[0037] When the current tension of the calibrated yarn is within the standard tension range, output standard PID parameters;

[0038] When the current tension of the calibrated yarn is in the high tension range, the PID parameters will be automatically switched to the strong damping mode.

[0039] In some embodiments, the following steps are also included:

[0040] When the standard measuring device detects that the tension of the calibrated yarn drops instantaneously by more than a preset ratio, the servo motor is immediately controlled to reverse.

[0041] In some embodiments, the following steps are also included:

[0042] The characteristic parameters of the calibrated yarn are mapped to the PID parameters to generate an adaptive adjustment strategy. The characteristic parameters include the coefficient of friction, breaking strength, creep rate and surface roughness.

[0043] In some embodiments, the following steps are also included:

[0044] During the calibration test of the tension sensor to be calibrated, if an abnormality occurs, the parameters between the characteristic parameters of the calibration yarn and the PID parameters will be updated and an alarm will be triggered.

[0045] Unlike existing technologies, the above-mentioned technical solution, when calibrating a tension sensor, involves threading a calibration yarn through the sensor, connecting one end of the yarn to a scalar measuring device, and the other end to a servo motor. The main controller detects the tension on the calibration yarn using the standard measuring device, compares the tension on the yarn with a set tension value, outputs a PID value, and then controls the servo motor via a motor controller to adjust the tension on the calibration yarn until it reaches the set tension value. This establishes a correspondence between the tension value output by the tension sensor and the set tension value, thus completing the calibration of the tension sensor. This achieves one-click automatic calibration of the tension sensor without manual intervention, resulting in high calibration efficiency. Furthermore, the servo motor can simulate dynamic tension and precisely control tension fine-tuning, enabling accurate calibration of the tension sensor.

[0046] The above description of the invention is merely an overview of the technical solution of this application. In order to enable those skilled in the art to better understand the technical solution of this application and to implement it based on the description and drawings, and to make the above-mentioned objectives and other objectives, features and advantages of this application easier to understand, the following description is provided in conjunction with the specific embodiments and drawings of this application. Attached Figure Description

[0047] The accompanying drawings are only used to illustrate the principles, implementation methods, applications, features, and effects of specific embodiments of this application and other related content, and should not be considered as limitations on this application.

[0048] In the accompanying drawings of the instruction manual:

[0049] Figure 1 This is a schematic diagram of a tension sensor calibration system according to a specific implementation method;

[0050] Figure 2 A flowchart illustrating the dynamic sequence process of the segmented tension loading algorithm described in a specific implementation;

[0051] Figure 3 This is a flowchart illustrating the real-time update process of the mapping relationship between the characteristic parameters of the calibration yarn and the PID parameters in a specific implementation method.

[0052] Figure 4 This is a schematic flowchart of a specific implementation of the tension sensor calibration method;

[0053] Figure 5 This is a flowchart illustrating the process of outputting PID parameters based on a calibration algorithm, as described in a specific implementation.

[0054] The reference numerals used in the above figures are explained as follows:

[0055] 110. Standardize the yarn.

[0056] 120. Standard measuring device

[0057] 130. Servo motor

[0058] 140. Motor controller

[0059] 150. Main controller

[0060] 200. Tension sensor to be calibrated. Detailed Implementation

[0061] To illustrate the possible application scenarios, technical principles, implementable specific solutions, and achievable objectives and effects of this application in detail, the following description, in conjunction with the listed specific embodiments and accompanying drawings, provides a detailed explanation. The embodiments described herein are merely illustrative of the technical solutions of this application and are therefore intended to limit the scope of protection of this application.

[0062] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0063] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit this application.

[0064] In the description of this application, the term "and / or" is used to describe the logical relationship between objects, indicating that three relationships can exist. For example, A and / or B means: A exists, B exists, and A and B exist simultaneously. Additionally, the character " / " in this document generally indicates that the preceding and following objects have an "or" logical relationship.

[0065] In this application, terms such as “first” and “second” are used only to distinguish one entity or operation from another, and do not necessarily require or imply any actual quantity, hierarchy or order relationship between these entities or operations.

[0066] Unless otherwise specified, the use of terms such as “comprising,” “including,” “having,” or other similar expressions in this application is intended to cover non-exclusive inclusion, which does not exclude the presence of additional elements in a process, method, or product that includes the stated elements, such that a process, method, or product that includes a list of elements may include not only those defined elements but also other elements not expressly listed, or elements inherent to such a process, method, or product.

[0067] Similar to the understanding in the Examination Guidelines, in this application, expressions such as "greater than," "less than," and "exceeding" are understood to exclude the stated number; expressions such as "above," "below," and "within" are understood to include the stated number. Furthermore, in the description of the embodiments in this application, "multiple" means two or more (including two), and similar expressions related to "multiple" are also understood in this way, such as "multiple groups" and "multiple times," unless otherwise explicitly specified.

[0068] In the description of the embodiments of this application, the space-related expressions used, such as "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "vertical," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," indicate the orientation or positional relationship based on the orientation or positional relationship shown in the specific embodiments or drawings. They are only for the purpose of describing the specific embodiments of this application or for the reader's understanding, and do not indicate or imply that the device or component referred to must have a specific position, a specific orientation, or be constructed or operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of this application.

[0069] Unless otherwise expressly specified or limited, the terms "installation," "connection," "linking," "fixing," and "setting," as used in the description of the embodiments of this application, should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral setting; it can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be the internal connection of two components or the interaction between two components. For those skilled in the art to which this application pertains, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.

[0070] Please see Figure 1 This embodiment provides a tension sensor calibration system, including:

[0071] Calibration yarn 110, the calibration yarn 110 passing through tension sensor 200 to be calibrated;

[0072] A standard measuring device 120 is connected to one end of the calibration yarn 110 and is used to measure the tension on the calibration yarn 110.

[0073] Servo motor 130, the servo motor 130 is connected to the other end of the calibration yarn 110, and the servo motor 130 is used to drive the calibration yarn 110 to extend and shorten.

[0074] Motor controller 140, which is used to drive servo motor 130;

[0075] The main controller 150 is connected to the standard measuring device 120, the tension sensor 200 to be calibrated, and the motor controller 140. The main controller 150 is used to compare the tension of the calibration yarn 110 measured by the standard measuring device 120 with the set tension value, and output PID parameters to the motor controller 140 according to the calibration algorithm. The tension of the calibration yarn 110 is adjusted by the servo motor 130 to complete the calibration of the tension sensor 200 to be calibrated.

[0076] When calibrating the tension sensor 200, the calibration yarn 110 is passed through it. One end of the yarn is connected to a scalar measuring device, and the other end to a servo motor 130. The main controller 150 detects the tension on the yarn 110 through the standard measuring device 120, compares the tension with a set tension value, outputs a PID value, and controls the servo motor 130 via the motor controller 140 to adjust the tension on the yarn 110 until it reaches the set tension value. A correspondence is established between the tension value output by the tension sensor 200 and the set tension value, thus completing the calibration of the tension sensor 200. This achieves one-click automatic calibration of the tension sensor 200 without manual intervention, resulting in high calibration efficiency. Furthermore, the servo motor 130 can simulate dynamic tension and precisely control tension fine-tuning, enabling accurate calibration of the tension sensor.

[0077] In some embodiments, when the main controller 150 outputs PID parameters to the motor controller 140 according to the calibration algorithm, it determines the tension range in which the current tension of the calibration yarn 110 is located. When the current tension of the calibration yarn 110 is in the low tension range, it increases the micro-vibration parameter value and extends the stabilization time in the PID parameters. When the current tension of the calibration yarn 110 is in the standard tension range, it outputs standard PID parameters. When the current tension of the calibration yarn 110 is in the high tension range, it automatically switches the PID parameters to the strong damping mode.

[0078] The PID parameters output are adjusted for different tension ranges using a segmented tension loading algorithm. The specific dynamic sequence flow of the segmented tension loading algorithm is as follows: Figure 2 As shown.

[0079] When the yarn is in the low tension range, there is a transition from static friction to dynamic friction between the yarn and the guide wheel of the tension sensor, and there is a transition point. The transition point is discontinuous, not uniform. Therefore, to capture this transition point, the load must be applied in small increments. The guide wheel of the tension sensor has a groove in the middle to regulate the yarn movement and prevent the yarn from slipping to the sides.

[0080] Under constant force, yarn will exhibit creep, which also needs to be taken into account. The effect of yarn creep can be offset by extending the stabilization time.

[0081] Specifically, static friction hysteresis is eliminated or reduced by using 20Hz micro-vibration (amplitude <0.05mm), thereby expanding the calibration range as much as possible.

[0082] The high tension zone poses a risk of yarn breakage, so the step size is automatically reduced; the PID parameters are automatically switched to strong damping mode (e.g., proportional gain decreases by 50%, integral time increases by 200%, forced smoothing) to prevent overshoot; at the same time, yarn breakage prediction is performed, and when the tension drops by more than 30% instantaneously, the motor is immediately reversed to reduce force to protect the device.

[0083] Specifically, when calibration begins, the tension of the calibration yarn 110 is measured using the standard measuring device 120 to determine the current tension range. If the current tension T is less than 10%FS, it is determined to be in the low tension range, and the system enters the low-tension precision mode. The tension on the calibration yarn 110 is adjusted in steps of 0.5%FS, and the PID parameters are output, along with micro-vibration and extended stabilization time. If the current tension T is greater than 10%FS but less than 80%FS, it is determined to be in the standard tension range, and the system enters the standard mode. The tension on the calibration yarn 110 is adjusted in steps of 2%FS, and the standard P is output. ID parameter; when the current tension T is greater than 80% FS, it is determined to be in the high tension range, and then enters the high-zone safety mode, adjusting the tension on the calibration yarn 110 in steps of 8% FS, outputting PID parameters, and performing strong damping control and overshoot detection; according to the corresponding PID parameters, the servo motor 130 is controlled, thereby adjusting the tension on the calibration yarn 110. When the tension on the calibration yarn 110 reaches stability, the data point is recorded; by repeatedly recording multiple data points until the range is completed, the calibration of the tension sensor is completed, where FS is the full scale.

[0084] In some embodiments, the main controller 150 is further configured to immediately control the servo motor 130 to reverse when the tension of the calibrated yarn 110 drops instantaneously beyond a preset ratio as detected by the standard measuring device 120.

[0085] During the tension adjustment of the calibration yarn 110, a yarn breakage prediction is made for the calibration yarn 110. Especially when the calibration yarn 110 is in the high tension range, if the tension of the calibration yarn 110 drops instantaneously by more than a preset ratio, such as an instantaneous drop of more than 30%, the motor is immediately reversed to reduce the force to protect the device.

[0086] In some embodiments, the main controller 150 is further configured to map the characteristic parameters of the calibration yarn 110 to PID parameters to generate an adaptive adjustment strategy, wherein the characteristic parameters include friction coefficient, breaking strength, creep rate and surface roughness.

[0087] Different yarns have different properties. For example, spandex has a high creep rate, requiring strict steady-state determination; cotton yarn has a high coefficient of friction and a significant delay in tension transmission; polyester has a smooth surface and is prone to intermittent slippage; glass fiber has low breaking strength and a high risk of overshoot. Because of these different yarn characteristics, the automatic calibration methods used are also different.

[0088] Therefore, the first step is to build a basic parameter library that contains the physical properties of the material, including parameters such as friction coefficient, fracture strength, creep rate, and surface roughness. These parameters are then mapped to PID parameters using a yarn characteristic adaptive algorithm to generate an adaptive adjustment strategy.

[0089] The specific expression is shown in the following system of equations:

[0090] K p =K p0 *[1+K f *(friction coefficient - 0.2)];

[0091] MaxSlope = K slope * Fracture strength;

[0092] Settling time = 0.5 + K t * Creep coefficient;

[0093] Micro-vibration frequency = 40+K v / Surface roughness.

[0094] Among them, K p It is the proportionality coefficient, MaxSlope is the maximum slope of ascent, and K is the maximum slope of ascent. p0 This is the initial proportionality coefficient. And factors such as the friction adjustment coefficient K... f Slope adjustment coefficient K slope Creep adjustment factor K t Vibration adjustment coefficient K v These results were all obtained through experiments.

[0095] In some embodiments, the main controller 150 is also used to update and alarm the parameters between the characteristic parameters and PID parameters of the calibration yarn 110 when an abnormality occurs during the calibration test of the tension sensor 200 to be calibrated.

[0096] During the calibration process, a threshold range must also be set. If an anomaly occurs, an alarm will be triggered, and the mapping relationship between the characteristic parameters and PID parameters of the calibration yarn 110 will be updated. The real-time update process of the mapping relationship between the characteristic parameters and PID parameters of the calibration yarn is as follows: Figure 3 As shown, the calibration system determines whether to adjust the mapping relationship based on the response curve returned by the tension sensor when performing a 3cN step test on the tension sensor. For example, if the overshoot reaches 8%, parameter optimization is required, and new parameters are calculated, adjusting the proportional coefficient K. p Adjust the current value to 80%, and the maximum slope (MaxSlope) to 70%. Then, recalibrate the tension sensor according to the new parameters until the overshoot is reduced to 2%. Confirm the optimization results and update the mapping rules. The 3cN step test involves applying a small, incrementally increasing force (3CN, or 3 centinenewtons) and observing the fiber's deformation response to analyze its elastic modulus, yield point, or creep characteristics. In this case, the step amplitude can be set to 1cN, increasing by 1cN each step until the target value of 3cN is reached. Each step is maintained for 5-10 seconds, and the deformation data is recorded to check for overshoot and the extent of overshoot.

[0097] This mapping system achieves precise adaptation of different yarns through a closed loop of material property perception → control parameter generation → dynamic performance verification → rule self-learning.

[0098] In some embodiments, a tension sensor calibration system is provided, in which a calibration yarn 110 is passed through the tension sensor 200 to be calibrated. One end of the calibration yarn 110 is connected to a standard measuring device 120, and the other end is connected to a servo motor 130. The calibration yarn 110 can be connected to the guide rail of the servo motor 130; when the servo motor 130 moves, the guide rail will lengthen or shorten, causing the yarn to lengthen or shorten, thus resulting in tension changes. Alternatively, the calibration yarn 110 can be connected to a spool on the servo motor 130; when the servo motor 130 moves, the spool rotates, causing the calibration yarn 110 to lengthen or shorten, thus resulting in tension changes. The standard measuring device 120 compares the measured tension with a pre-set tension value in the main controller 150, designs a calibration algorithm, outputs PID parameters, and performs constant torque control of the servo motor 130 to adjust the yarn tension, achieving a closed-loop effect. Simultaneously, a segmented tension loading algorithm and a yarn characteristic adaptive algorithm are combined to adjust the PID parameters. It enables one-click automatic calibration of tension sensors without manual intervention, and solves the problems of tension loading step size setting and anti-disturbance during the calibration process, so that the calibration effect reaches or even exceeds that of manual calibration.

[0099] This invention employs a motor-driven, dynamic yarn tension detection, and torque control system to achieve automated, continuous, and non-intrusive yarn tension sensor calibration. Compensation is provided through algorithms such as progressive tension loading, multimodal vibration recognition, and yarn friction adaptive adjustment. By utilizing scenario-based intelligent strategies (dynamic sequence + adaptive control + multimodal compensation), the automatic calibration becomes more accurate, safer, and more universally applicable. This facilitates the promotion and application of the method, significantly reducing human workload and enhancing the level of enterprise intelligence.

[0100] Furthermore, this system is not only applicable to the calibration of yarn tension sensors, but also to the calibration of other similar sensors.

[0101] Please see Figure 4 A method for calibrating a tension sensor, applied to the tension sensor calibration system described above, includes the following steps:

[0102] Step S410: Detect the tension of the calibration yarn 110 passing through the tension sensor to be calibrated in real time using a standard measuring device;

[0103] Step S420: Compare the measured tension of the calibration yarn 110 with the set pressure value, and output PID parameters according to the calibration algorithm;

[0104] Step S430: Drive the servo motor according to the PID parameters to adjust the tension of the calibration yarn 110 until the tension of the calibration yarn 110 reaches the set tension value.

[0105] Step S440: Calibrate the tension sensor to be calibrated according to the set tension value.

[0106] When calibrating a tension sensor, the calibration yarn 110 is passed through the sensor. One end of the yarn is connected to a scalar measuring device, and the other end to a servo motor. The main controller detects the tension on the yarn 110 using the standard measuring device. It compares the tension on the yarn 110 with a set tension value, outputs a PID value, and controls the servo motor via the motor controller to adjust the tension on the yarn 110 until it reaches the set tension value. This establishes a correspondence between the tension value output by the sensor and the set tension value, completing the calibration of the tension sensor. This method enables one-click automatic calibration of the tension sensor without manual intervention, resulting in high calibration efficiency. Furthermore, the servo motor can simulate dynamic tension and precisely control tension fine-tuning, achieving accurate calibration of the tension sensor.

[0107] Please see Figure 5 In some embodiments, the step of outputting PID parameters according to the calibration algorithm specifically includes the following steps;

[0108] Step S510: When outputting PID parameters to the motor controller according to the calibration algorithm, determine the tension range in which the current tension of the calibration yarn 110 is located;

[0109] When the current tension of the calibrated yarn 110 is in the low tension range, step S520 is executed: increase the micro-vibration parameter value and extend the stabilization time in the PID parameters;

[0110] When the current tension of the calibrated yarn 110 is within the standard tension range, step S530 is executed: output standard PID parameters;

[0111] When the current tension of the calibrated yarn 110 is in the high tension range, step S540 is executed: the PID parameters are automatically switched to the strong damping mode.

[0112] The PID parameters output are adjusted for different tension ranges using a segmented tension loading algorithm. The specific dynamic sequence flow of the segmented tension loading algorithm is as follows: Figure 2 As shown.

[0113] When the yarn is in the low tension range, there is a transition from static friction to dynamic friction between the yarn and the guide wheel of the tension sensor, and there is a transition point. The transition point is discontinuous, not uniform. Therefore, to capture this transition point, the load must be applied in small increments. The guide wheel of the tension sensor has a groove in the middle to regulate the yarn movement and prevent the yarn from slipping to the sides.

[0114] Under constant force, yarn will exhibit creep, which also needs to be taken into account. The effect of yarn creep can be offset by extending the stabilization time.

[0115] Specifically, static friction hysteresis is eliminated or reduced by using 20Hz micro-vibration (amplitude <0.05mm), thereby expanding the calibration range as much as possible.

[0116] The high tension zone poses a risk of yarn breakage, so the step size is automatically reduced; the PID parameters are automatically switched to strong damping mode (e.g., proportional gain decreases by 50%, integral time increases by 200%, forced smoothing) to prevent overshoot; at the same time, yarn breakage prediction is performed, and when the tension drops by more than 30% instantaneously, the motor is immediately reversed to reduce force to protect the device.

[0117] Specifically, when calibration begins, the tension of the calibration yarn 110 is measured using a standard measuring device to determine the current tension range. If the current tension T is less than 10%FS, it is determined to be in the low tension range, and the system enters the low-tension precision mode. The tension output PID parameters on the calibration yarn 110 are adjusted in steps of 0.5%FS, and micro-vibration is applied while extending the stabilization time. If the current tension T is greater than 10%FS but less than 80%FS, it is determined to be in the standard tension range, and the system enters the standard mode. The tension on the calibration yarn 110 is adjusted in steps of 2%FS, and the standard P output is... ID parameter; when the current tension T is greater than 80% FS, it is determined to be in the high tension range, and then enters the high-zone safety mode, adjusting the tension on the calibration yarn 110 in steps of 8% FS, outputting PID parameters, and performing strong damping control and overshoot detection; according to the corresponding PID parameters, the servo motor is controlled, thereby adjusting the tension on the calibration yarn 110. When the tension on the calibration yarn 110 reaches stability, the data point is recorded; by repeatedly recording multiple data points until the range is completed, the calibration of the tension sensor is completed, where FS is the full scale.

[0118] In some embodiments, the following steps are also included:

[0119] When the standard measuring device detects that the tension of the calibrated yarn 110 drops instantaneously beyond a preset ratio, the servo motor is immediately controlled to reverse.

[0120] During the tension adjustment of the calibration yarn 110, a yarn breakage prediction is made for the calibration yarn 110. Especially when the calibration yarn 110 is in the high tension range, if the tension of the calibration yarn 110 drops instantaneously by more than a preset ratio, such as an instantaneous drop of more than 30%, the motor is immediately reversed to reduce the force to protect the device.

[0121] In some embodiments, the following steps are also included:

[0122] The characteristic parameters of the calibrated yarn 110 are mapped to the PID parameters to generate an adaptive adjustment strategy. The characteristic parameters include the friction coefficient, breaking strength, creep rate and surface roughness.

[0123] Different yarns have different properties. For example, spandex has a high creep rate, requiring strict steady-state determination; cotton yarn has a high coefficient of friction and a significant delay in tension transmission; polyester has a smooth surface and is prone to intermittent slippage; glass fiber has low breaking strength and a high risk of overshoot. Because of these different yarn characteristics, the automatic calibration methods used are also different.

[0124] Therefore, the first step is to build a basic parameter library that contains the physical properties of the material, including parameters such as friction coefficient, fracture strength, creep rate, and surface roughness. These parameters are then mapped to PID parameters using a yarn characteristic adaptive algorithm to generate an adaptive adjustment strategy.

[0125] The specific expression is shown in the following system of equations:

[0126] K p =K p0 *[1+K f *(friction coefficient - 0.2)];

[0127] MaxSlope = K slope * Fracture strength;

[0128] Settling time = 0.5 + K t * Creep coefficient;

[0129] Micro-vibration frequency = 40+K v / Surface roughness.

[0130] Among them, K p It is the proportionality coefficient, MaxSlope is the maximum slope of ascent, and K is the maximum slope of ascent. p0 This is the initial proportionality coefficient. And factors such as the friction adjustment coefficient K... f Slope adjustment coefficient K slope Creep adjustment factor K t Vibration adjustment coefficient K v These results were all obtained through experiments.

[0131] In some embodiments, the following steps are also included:

[0132] During the calibration test of the tension sensor to be calibrated, if an abnormality occurs, the parameters between the characteristic parameters and PID parameters of the calibration yarn 110 are updated and an alarm is triggered.

[0133] During the calibration process, a threshold range must also be set. If an anomaly occurs, an alarm will be triggered, and the mapping relationship between the characteristic parameters of the calibration yarn 110 and the PID parameters will be updated. The real-time update process of the mapping relationship between the characteristic parameters of the calibration yarn 110 and the PID parameters is as follows: Figure 3 As shown, the calibration system determines whether to adjust the mapping relationship based on the response curve returned by the tension sensor when performing a 3cN step test on the tension sensor. For example, if the overshoot reaches 8%, parameter optimization is required, and new parameters are calculated, adjusting the proportional coefficient K. p Adjust the current value to 80%, adjust the maximum slope MaxSlope to 70% of the current value, and then recalibrate the tension sensor according to the new parameters until the overshoot is reduced to 2%. Confirm the optimization results and update the mapping rules.

[0134] This mapping system achieves precise adaptation of different yarns through a closed loop of material property perception → control parameter generation → dynamic performance verification → rule self-learning.

[0135] Finally, it should be noted that although the above embodiments have been described in the text and drawings of this application, this should not limit the scope of patent protection of this application. Any technical solutions that are based on the essential concept of this application and utilize the content described in the text and drawings of this application, resulting in equivalent structural or procedural substitutions or modifications, as well as the direct or indirect application of the technical solutions of the above embodiments to other related technical fields, are all included within the scope of patent protection of this application.

Claims

1. A tension sensor calibration system, characterized in that, include: A calibration yarn is passed through a tension sensor to be calibrated. A standard measuring device is connected to one end of the calibration yarn and is used to measure the tension of the calibration yarn. A servo motor is connected to the other end of the calibration yarn, and the servo motor is used to drive the calibration yarn to extend and shorten. A motor controller, which is used to drive a servo motor; The main controller is connected to a standard measuring device, a tension sensor to be calibrated, and a motor controller. The main controller is used to compare the tension of the calibration yarn measured by the standard measuring device with the set tension value, and output PID parameters to the motor controller according to the calibration algorithm. The tension of the calibration yarn is adjusted by the servo motor to complete the calibration of the tension sensor to be calibrated.

2. The tension sensor calibration system according to claim 1, characterized in that, The main controller is used to determine the tension range of the current tension of the calibrated yarn when outputting PID parameters to the motor controller according to the calibration algorithm. When the current tension of the calibrated yarn is in the low tension range, the micro-vibration parameter value is increased and the stabilization time is extended in the PID parameters. When the current tension of the calibrated yarn is in the standard tension range, the standard PID parameters are output. When the current tension of the calibrated yarn is in the high tension range, the PID parameters are automatically switched to the strong damping mode.

3. The tension sensor calibration system according to claim 1, characterized in that, The main controller is also used to immediately control the servo motor to reverse when the tension of the calibrated yarn drops instantaneously by more than a preset ratio as detected by a standard measuring device.

4. The tension sensor calibration system according to claim 1, characterized in that, The main controller is also used to map the characteristic parameters of the calibrated yarn to PID parameters to generate an adaptive adjustment strategy. The characteristic parameters include friction coefficient, breaking strength, creep rate and surface roughness.

5. The tension sensor calibration system according to claim 4, characterized in that, The main controller is also used to update and alarm the parameters between the characteristic parameters and PID parameters of the calibration yarn when an abnormality occurs during the calibration test of the tension sensor to be calibrated.

6. A method for calibrating a tension sensor, characterized in that, The method, when applied to the tension sensor calibration system as described in claim 1, includes the following steps: The tension of the calibration yarn passing through the tension sensor to be calibrated is detected in real time using a standard measuring device. The measured tension of the calibrated yarn is compared with the set pressure value, and the PID parameters are output according to the calibration algorithm. The servo motor is driven according to the PID parameters to adjust the tension of the calibration yarn until the tension of the calibration yarn reaches the set tension value. The tension sensor to be calibrated is calibrated according to the set tension value.

7. The tension sensor calibration method according to claim 6, characterized in that, The specific steps for outputting PID parameters according to the calibration algorithm include the following: When the PID parameters are output to the motor controller according to the calibration algorithm, the tension range in which the current tension of the calibration yarn is located is determined. When the current tension of the calibrated yarn is in the low tension range, increase the micro-vibration parameter value and extend the settling time in the PID parameters; When the current tension of the calibrated yarn is within the standard tension range, output standard PID parameters; When the current tension of the calibrated yarn is in the high tension range, the PID parameters will be automatically switched to the strong damping mode.

8. The tension sensor calibration method according to claim 6, characterized in that, It also includes the following steps: When the standard measuring device detects that the tension of the calibrated yarn drops instantaneously by more than a preset ratio, the servo motor is immediately controlled to reverse.

9. The tension sensor calibration method according to claim 6, characterized in that, It also includes the following steps: The characteristic parameters of the calibrated yarn are mapped to the PID parameters to generate an adaptive adjustment strategy. The characteristic parameters include the coefficient of friction, breaking strength, creep rate and surface roughness.

10. The tension sensor calibration method according to claim 9, characterized in that, It also includes the following steps: During the calibration test of the tension sensor to be calibrated, if an abnormality occurs, the parameters between the characteristic parameters of the calibration yarn and the PID parameters will be updated and an alarm will be triggered.

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