Non-woven fabric gram weight automatic control method, system, program, storage medium and device

Abstract

The invention relates to the technical field of non-woven fabric production, in particular to a non-woven fabric gram weight automatic control method, which comprises the following steps: S1, acquiring non-woven fabric gram weight data in real time through an online gram weight detector; s2, calculating the draw ratio of the lapping machine at the corresponding position according to the obtained gram weight data; s3, correcting the draw ratio obtained by calculation according to preset upper and lower limit values of the draw ratio to obtain a target draw ratio; s4, controlling the lapping machine to adjust the drafting of each section according to the target drafting ratio; s5, calculating the verification time of the adjusted non-woven fabric reaching the online gram weight detector; and S6, after the verification time is over, repeating the steps S1 to S5 based on the new real-time gram weight data to realize closed-loop adjustment. The drafting speed of the lapping machine is automatically adjusted according to real-time feedback data of the on-line gram weight detector, the use time of traditional adjustment is shortened, and errors caused by manual operation can be completely eradicated. After feedback data is received, the system responds immediately, the number of defective products is reduced, waste is reduced, and the yield is increased.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of non-woven fabric production, and in particular to a non-woven fabric gram weight automatic control method, system, program, storage medium and device. BACKGROUND

[0002] As a non-woven material directly bonded by fibers through physical or chemical methods, non-woven fabric is widely used in medical and health care, agriculture, industrial filtration and other fields due to its short production process, low cost and wide application. In the production process of non-woven fabric, the gram weight (weight per unit area) of the finished product is one of the core indicators for measuring product quality, directly affecting the strength, air permeability, water absorption and other key properties of the product, and therefore needs to be strictly controlled within a predetermined range.

[0003] Currently, the adjustment of gram weight in non-woven fabric production mainly relies on traditional offline manual adjustment methods. Combined with the actual production process, the present application provides a non-woven fabric gram weight automatic control method, system, program, storage medium and device. Figure 1 The specific process is as follows: after the non-woven fabric is laid by the laying machine and reinforced by the needle punching machine, it is wound by the winding machine to form a finished product roll; the staff samples and inspects the finished product after winding to obtain the deviation value of the actual gram weight and the target gram weight; and then manually adjusts the draft speed of the laying machine according to the deviation value to correct the gram weight deviation.

[0004] The existing technology has the disadvantages of slow adjustment speed, long process and many product defects. Each adjustment needs to wait for the end of the winding machine to inspect the specific deviation value, and then adjust the draft of the laying machine according to the actual deviation value, and then wait for the completion of the winding to perform the next adjustment. If a defective product appears during the process, it must be inspected after the next winding to determine whether the adjustment is effective, during which a large number of unqualified products will be produced, causing waste of raw materials and energy. SUMMARY

[0005] The technical problem to be solved by the present application is to design a non-woven fabric gram weight automatic control method and system that can realize real-time detection and automatic adjustment of gram weight, solve the problems of long adjustment cycle, many product defects and low automation degree in the existing non-woven fabric gram weight adjustment method, improve production efficiency and product quality, and reduce production cost, thereby solving the existing technical problems.

[0006] To solve the above technical problems, the present application provides a non-woven fabric gram weight automatic control method, comprising the following steps:

[0007] Step S1: Real-time acquisition of non-woven fabric gram weight data G through an online gram weight detector.

[0008] Step S2: According to the acquired gram weight data G, calculate the draft ratio of the laying machine at the corresponding position , and the calculation formula of the draft ratio is: wherein, is the current grammage, is the average grammage.

[0009] Step S3: According to the preset upper and lower limit values of the draft ratio, the calculated draft ratio is corrected to obtain the target draft ratio .

[0010] Step S4: The laying machine adjusts the draft of each section according to the target draft ratio .

[0011] Step S5: Calculate the verification time T of the adjusted non-woven fabric reaching the online grammage detector.

[0012] Step S6: After the verification time T ends, repeat steps S1-S5 based on the new real-time grammage data G to realize closed-loop adjustment.

[0013] Further, in step S1, the PLC controls the online grammage detector to communicate with the online grammage detector in real time through Modbus TCP to obtain the real-time product grammage data G of the scanner.

[0014] Further, in step S3, the method for correcting the draft ratio is as follows: judge the size of the calculated draft ratio and the preset upper and lower limit values:

[0015] If , then ;

[0016] If , then no correction is made;

[0017] If , then ;

[0018] wherein, is the preset lower limit value of the draft ratio, is the preset upper limit value of the draft ratio.

[0019] Further, in step S5, the verification time T is calculated in the following way:

[0020] ;

[0021] wherein:

[0022] is the laying running distance, is the laying machine running speed;

[0023] is the pre-punching machine input running distance, input speed for the pre-piercing machine;

[0024] output running distance for the pre-piercing machine, output running speed for the pre-piercing machine;

[0025] input running distance for the main piercing machine, running speed for the main piercing machine;

[0026] output running distance for the main piercing machine, output speed for the main piercing machine;

[0027] running distance for the scanner, speed for the scanner.

[0028] The present application also provides a non-woven fabric grammage automatic control system, which adopts the non-woven fabric grammage automatic control method and specifically comprises the following modules:

[0029] an online grammage detection module for detecting the grammage data of the non-woven fabric in real time and outputting.

[0030] a data processing module comprising an average grammage calculation unit, a draft ratio calculation unit, a draft ratio correction unit, a verification time calculation unit and an instruction generation unit, the average grammage calculation unit being configured to calculate the average grammage according to the detected grammage data, the draft ratio calculation unit being configured to calculate the draft ratio based on the formula (current grammage-average grammage) / average grammage, the draft ratio correction unit being configured to correct the calculated draft ratio to a target draft ratio in combination with preset upper and lower limit values, the verification time calculation unit being configured to calculate the verification time of the adjusted non-woven fabric reaching the online grammage detection module, the verification time being the sum of the ratios of the running distances of the device sections to the corresponding section speeds, and the instruction generation unit being configured to generate an adjustment instruction according to the target draft value.

[0031] an execution module configured to control the laying machine to adjust the draft of each section according to the adjustment instruction.

[0032] Further, the system further comprises a parameter setting module configured to allow a user to input preset upper and lower limit values of the draft ratio, the running distance and speed parameters of each device section.

[0033] Further, the system further comprises a display module configured to display the collected grammage data in the form of a curve.

[0034] The present application also provides a non-woven fabric grammage automatic control device, which comprises:

[0035] at least one processor; and

[0036] at least one memory in communication with the processor;

[0037] The memory stores instructions executable by the processor, and the instructions are executed by the processor to enable the device to perform the non-woven fabric basis weight automatic control method.

[0038] The application also provides a computer readable storage medium, which stores computer execution instructions, and when the processor executes the computer execution instructions, the non-woven fabric basis weight automatic control method is realized.

[0039] The application also provides a computer program product, which comprises computer instructions, and when the computer instructions are run by the processor, the computer device performs the non-woven fabric basis weight automatic control method.

[0040] The application has the following beneficial effects:

[0041] The non-woven fabric basis weight automatic control method of the application automatically adjusts the drafting speed of the web laying machine according to the real-time feedback data of the online basis weight detector, shortens the time for traditional adjustment, and can eliminate the errors caused by manual operation. After receiving the feedback data, the system immediately reacts, reduces the number of defective products, reduces waste, and improves the yield. The product uniformity can be automatically adjusted in real time, the product CV (Coefficient of Variation) is automatically adjusted in a very low range, the product quality is improved, and the generation of defective products is reduced. BRIEF DESCRIPTION OF DRAWINGS

[0042] The specific embodiments of the application are further illustrated below in combination with the drawings.

[0043] Figure 1 It is a logic block diagram of the existing non-woven fabric basis weight adjustment.

[0044] Figure 2 It is a flow chart of the non-woven fabric basis weight automatic control method in the application.

[0045] Figure 3 It is a logic block diagram of the non-woven fabric basis weight automatic control adjustment in the method of the application.

[0046] Figure 4 It is a system block diagram of the non-woven fabric basis weight automatic control system in the application.

[0047] Figure 5 It is a basis weight curve generated by collection in the non-woven fabric basis weight automatic control system in the application. DETAILED DESCRIPTION

[0048] Example 1

[0049] In combination Figure 2 andFigure 3 The non-woven fabric grammage automatic control method of the embodiment comprises the following steps:

[0050] Step S1: Real-time acquisition of non-woven fabric grammage data G through an online grammage detector.

[0051] In the embodiment, preferably, in step S1, the real-time product grammage data G of the scanner is acquired through real-time communication between the control PLC and the online grammage detector through Modbus TCP.

[0052] In the embodiment, specifically, the real-time acquired product grammage data is displayed in a curve form on a terminal device, as shown in FIG. 1. Figure 5 As shown in the figure, the horizontal coordinate is 10 acquisition points of the scanner average division, and the vertical coordinate is the non-woven fabric grammage data, in units of g / m².

[0053] Step S2: Calculation of the draft ratio of the laying machine at the corresponding position according to the acquired grammage data G , the calculation formula of the draft ratio is as follows: , wherein is the current grammage, is the average grammage, is the absolute value symbol.

[0054] In the embodiment, specifically, the acquired grammage data G is 10 data from front to back, as follows:

[0055] Collecting weight data Grammage (g / m2) 1280 1250 1230 1180 1150 1150 1200 1210 1245 1270

[0056] The average grammage is g / m²; and the values of the draft ratio of the laying machine at the corresponding positions are as follows:

[0057] Corresponding position Draft ratio 5.2% 2.8% 1.1% 3.0% 5.5% 5.5% 1.4% 0.5% 2.3% 4.4%

[0058] In the embodiment, specifically, the laying machine usually has a pair of cooperating rollers, which are respectively referred to as a slow roller and a fast roller. The slow roller is close to the input side of the fiber web, and the line speed of the slow roller is . The fast roller is close to the output side of the fiber web, and the line speed of the fast roller is . When the line speed of the fast roller is greater than the line speed of the slow roller , the fiber web is stretched when passing through the two rollers, which is referred to as draft. The ratio of the two line speeds is the draft ratio, that is, the calculation formula of the draft ratio is as follows: .

[0059] Step S3: According to the preset upper and lower limit values of the draft ratio, the calculated draft ratio​ The target draft ratio is obtained by correction .

[0060] In step S3, the method for correcting the draft ratio is preferably as follows: judging the size of the calculated draft ratio and the preset upper and lower limit values:

[0061] If , then ;

[0062] If , then no correction is performed;

[0063] If , then ;

[0064] wherein, is the preset lower limit value of the draft ratio, is the preset upper limit value of the draft ratio.

[0065] In this embodiment, the preset lower limit value of the draft ratio is preferably in the range of , and the preset upper limit value of the draft ratio is preferably in the range of .

[0066] In this embodiment, the preset lower limit value of the draft ratio is preferably 0.5, and the preset upper limit value of the draft ratio is preferably 1.5. If the draft ratio is:

[0067] Corresponding position Target draft ratio 5.2% 2.8% 1.1% 3.0% 5.5% 5.5% 1.4% 1.0% 2.3% 4.4%

[0068] Step S4: controlling the laying machine to adjust the draft ratio of each section according to the target draft ratio .

[0069] Step S5: calculating the verification time T of the adjusted nonwoven fabric reaching the online weight detector.

[0070] In step S5, the verification time T is calculated in the following manner:

[0071] ;

[0072] wherein:

[0073] is the running distance of the laying machine, is the running speed of the laying machine.

[0074] inputting the running distance for the pre-stripping machine, inputting the speed for the pre-stripping machine;

[0075] outputting the running distance for the pre-stripping machine, outputting the running speed for the pre-stripping machine;

[0076] inputting the running distance for the main stripping machine, inputting the running speed for the main stripping machine;

[0077] outputting the running distance for the main stripping machine, outputting the running speed for the main stripping machine;

[0078] inputting the running distance for the scanner, inputting the speed for the scanner.

[0079] In this embodiment, the running distance for the laying machine is 4 m, the running speed for the laying machine is 5.62 m / min, the inputting running distance for the pre-stripping machine is 2 m, the inputting speed for the pre-stripping machine is 5.79 m / min, the outputting distance for the pre-stripping machine is 1 m, the outputting running speed for the pre-stripping machine is 6.95 m / min, the inputting running distance for the main stripping machine is 1 m, the inputting running speed for the main stripping machine is 7.3 m / min, the outputting running distance for the main stripping machine is 1 m, the outputting running speed for the main stripping machine is 8 m / min, the inputting running distance for the scanner is 1 m, the inputting speed for the scanner is 8 m / min, then the verification time T is:

[0080] .

[0081] Step S6: after the verification time T ends, repeating steps S1-S5 based on the new real-time basis weight data G to realize closed-loop adjustment. That is, after 1.59 minutes ends, the next adjustment is performed on the basis of the last adjustment.

[0082] The nonwoven fabric basis weight automatic control method of this embodiment constructs a full-closed loop system of “detection—calculation—adjustment—verification”. After the adjusted web reaches the scanner, the system will again correct the draft value based on the new real-time data, forming a dynamic feedback cycle.

[0083] Embodiment 2

[0084] In combination Figure 2 And Figure 3 , the non-woven fabric grammage automatic control system of the embodiment adopts the non-woven fabric grammage automatic control method in embodiment 1, and specifically includes the following modules:

[0085] An online grammage detection module: used for detecting the grammage data of the non-woven fabric in real time and outputting.

[0086] A data processing module: including an average grammage calculation unit, a draft ratio calculation unit, a draft ratio correction unit, a verification time calculation unit and an instruction generation unit, the average grammage calculation unit is used for calculating the average grammage according to the detected grammage data, the draft ratio calculation unit calculates the draft ratio based on the formula (current grammage-average grammage) / average grammage, the draft ratio correction unit corrects the calculated draft ratio to the target draft ratio in combination with the preset upper and lower limit values, the verification time calculation unit is used for calculating the verification time of the adjusted non-woven fabric reaching the online grammage detection module, the verification time is the sum of the ratio of the running distance of each device section to the corresponding section speed; the instruction generation unit is used for generating an adjustment instruction according to the target draft value.

[0087] An execution module: used for controlling the laying machine to adjust the draft of each section according to the adjustment instruction.

[0088] The embodiment preferably further includes a parameter setting module for user to input the preset draft ratio upper and lower limit values, the running distance and speed parameters of each device section.

[0089] The embodiment preferably further includes a display module, the display module is used for displaying the collected grammage data in the form of a curve, as shown in Figure 5 .

[0090] Embodiment 3

[0091] The non-woven fabric grammage automatic control device of the embodiment includes:

[0092] At least one processor; and

[0093] At least one memory in communication connection with the processor;

[0094] Wherein, the memory stores instructions executable by the processor, and the instructions are executed by the processor to make the device execute the non-woven fabric grammage automatic control method in embodiment 1.

[0095] Embodiment 4

[0096] The computer readable storage medium of the embodiment stores computer execution instructions, when the processor executes the computer execution instructions, the non-woven fabric grammage automatic control method in embodiment 1 is realized.

[0097] Example 5

[0098] The computer program product of this embodiment includes computer instructions which, when executed by a processor, cause a computer device to perform the nonwoven fabric weight automatic control method in embodiment 1.

[0099] In the above description, many specific details are set forth in order to provide a thorough understanding of the present application. However, the above description is merely a preferred embodiment of the present application, and the present application can be carried out in many different ways other than those described above, and the present application is not limited to the specific embodiments disclosed above. Meanwhile, any person skilled in the art can make many possible changes and modifications to the technical solutions disclosed above, or modify them into equivalent embodiments with equivalent changes, without departing from the scope of the technical solutions of the present application. Any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present application, without departing from the technical solutions of the present application, shall still fall within the scope of protection of the technical solutions of the present application.

Claims

1. A method for automatically controlling the basis weight of nonwoven fabric, characterized in that: The method comprises the following steps: Step S1: Real-time acquisition of non-woven fabric grammage data G through an online grammage detector; Step S2: According to the obtained gram weight data G, the draft ratio of the laying net machine at the corresponding position is calculated The calculation formula of the draft ratio is as follows: Wherein, is the current gram weight, is the average gram weight; Step S3: According to the preset upper and lower limit values of draft ratio, the calculated draft ratio is corrected to obtain the target draft ratio . Step S4: The target draft ratio is used to control the draft ratio of the spinning frame . Step S4: controlling the lapper to follow the target draft ratio adjusting the draft of each section; Step S5: Calculation of the verification time T of the adjusted non-woven fabric reaching the online grammage detector; Step S6: After the verification time T ends, repeating steps S1-S5 based on the new real-time grammage data G to realize closed-loop adjustment.

2. The nonwoven basis weight automatic control method according to claim 1, characterized by: In step S1, the real-time product grammage data G of the scanner is acquired through real-time communication between the control PLC and the online grammage detector through Modbus TCP.

3. The nonwoven basis weight automatic control method according to claim 1, characterized by: In step S3, the method for correcting the draft ratio is to judge the calculated draft ratio the size of the preset upper and lower limit values: If then ; If then no correction is made; If then ; wherein is a preset lower limit value of the draft ratio, is a preset upper limit value of the draft ratio.

4. The nonwoven basis weight automatic control method according to claim 1, characterized by: In step S5, the verification time T is calculated in the following manner: ； Wherein: for the web laying run, for the web laying machine running speed; inputting a running distance for the pre-piercing machine, inputting a speed for the pre-piercing machine; a distance to run for the pre-piercing machine, a speed to run for the pre-piercing machine; operating distance for the main needle machine, operating speed for the main needle machine; output distance for the main needle machine, output speed for the main needle machine; for the scanner to run, for the scanner speed.

5. An automatic control system for the weight of nonwoven fabric, characterized in that: The non-woven fabric grammage automatic control method according to any one of claims 1-4 comprises the following modules: An online grammage detection module for real-time detection of non-woven fabric grammage data and output; A data processing module comprising an average grammage calculation unit, a draft ratio calculation unit, a draft ratio correction unit, a verification time calculation unit, and an instruction generation unit, the average grammage calculation unit is used to calculate the average grammage based on the detected grammage data, the draft ratio calculation unit calculates the draft ratio based on the formula (current grammage-average grammage) / average grammage, the draft ratio correction unit corrects the calculated draft ratio to the target draft ratio in combination with the preset upper and lower limit values, the verification time calculation unit is used to calculate the verification time of the adjusted non-woven fabric reaching the online grammage detection module, and the verification time is the sum of the running distance of each device section and the corresponding speed; the instruction generation unit is used to generate adjustment instructions according to the target draft value; An execution module for controlling the laying machine to adjust the draft of each section according to the adjustment instructions.

6. The nonwoven basis weight automatic control system of claim 5, wherein: It also includes a parameter setting module for user input of preset draft ratio upper and lower limit values, running distance and speed parameters of each device section.

7. The nonwoven basis weight automatic control system of claim 1, wherein: It also includes a display module for displaying the collected grammage data in the form of a curve.

8. An automatic control device for the basis weight of nonwoven fabric, characterized in that: It comprises: At least one processor; And At least one memory connected to the processor in communication; Wherein the memory stores instructions executable by the processor, and the instructions are executed by the processor to enable the device to perform the non-woven fabric grammage automatic control method according to any one of claims 1-4.

9. A computer-readable storage medium, characterized in that: It has computer execution instructions stored thereon, which, when executed by the processor, implement the non-woven fabric grammage automatic control method according to any one of claims 1-4.

10. A computer program product, characterised in that: It comprises computer instructions that, when executed by a processor, cause a computer device to perform the non-woven fabric grammage automatic control method according to any one of claims 1-4.

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