Tension-pressure coupling regulation and control method for double-layer composite fabric

Abstract

The invention discloses a tension-pressure coupling regulation and control method for double-layer composite fabric, which belongs to the technical field of automatic control and comprises the following steps: acquiring thickness distribution parameters of fabric at an unwinding end and a winding end and pressure distribution parameters of the surface of a composite roller; based on the thickness distribution parameter and the pressure distribution parameter, analyzing, calculating and generating a compensation amount; according to preset fabric characteristic parameters, a tension regulation and control instruction and a pressure regulation and control instruction are generated in combination with the compensation amount; and executing the tension regulation and control instruction to adjust the rotating speed of an unwinding roller or a winding roller, and executing the pressure regulation and control instruction to dynamically adjust the partition pressure of the composite roller at the same time. According to the invention, the dual-ring embedded sensing and dynamic decoupling algorithm is adopted to realize the cooperative control of tension and pressure, so that the interlayer lamination defect can be eliminated and the energy consumption can be reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automatic control, in particular to a double-layer composite fabric tension-pressure coupling regulation method. BACKGROUND

[0002] At present, double-layer composite fabric production needs to realize double-layer fabric bonding through unwinding, interlayer compounding and winding processes, wherein tension control affects the deformation of the base cloth, and pressure control determines the interlayer bonding strength. The existing technology uses independent control systems to adjust the unwinding / winding roller speed and the compounding roller pressure respectively.

[0003] The current industry generally detects the tension change of the base cloth through tension rollers, and adjusts the roller speed through a frequency converter to maintain constant tension; the compounding pressure relies on air cylinders or hydraulic cylinders to implement overall pressure, and some advanced equipment uses partition pressure rollers to realize local pressure regulation.

[0004] The existing control method has two main defects: tension adjustment and pressure application belong to independent systems, which causes the interlayer bubbles due to the lagging response of pressure when the tension fluctuates; in order to compensate for the control mismatch, the parameters need to be over-adjusted, resulting in energy waste; in the face of high elasticity or temperature and humidity sensitive fabrics, fixed threshold control is easy to cause excessive stretching or weak bonding of materials. SUMMARY

[0005] To solve the above problems, the present application provides a double-layer composite fabric tension-pressure coupling regulation method, which uses double-ring embedded sensing and dynamic decoupling algorithm to realize tension and pressure collaborative control, and can eliminate interlayer fitting defects and reduce energy consumption.

[0006] The above object can be achieved by the following scheme: A double-layer composite fabric tension-pressure coupling regulation method, comprising: obtaining thickness distribution parameters of the fabric at the unwinding end and the winding end and pressure distribution parameters of the compounding roller surface; generating a compensation amount based on the thickness distribution parameters and the pressure distribution parameters; generating a tension regulation instruction and a pressure regulation instruction in combination with the compensation amount according to preset fabric characteristic parameters; executing the tension regulation instruction to adjust the unwinding or winding roller speed, and simultaneously executing the pressure regulation instruction to dynamically adjust the partition pressure of the compounding roller.

[0007] Optionally, the obtaining of the thickness distribution parameters of the fabric at the unwinding end and the winding end comprises: scanning the fabric layer through a non-contact ultrasonic thickness sensor to generate a real-time thickness distribution map; acquiring a pressure distribution thermogram through a flexible piezoresistive film array embedded on the surface of the compounding roller; and extracting features based on the real-time thickness distribution map to obtain the thickness distribution parameters.

[0008] Optionally, the generating the compensation amount comprises: spatially mapping the real-time thickness distribution map and the pressure distribution thermal map to generate an interlayer adhesion state feature vector with a thickness change amount; and performing correlation analysis based on the interlayer adhesion state feature vector and a preset elastic deformation threshold to generate the compensation amount.

[0009] Optionally, the method further comprises: when it is detected that the thickness change amount exceeds a preset elastic deformation threshold, extracting a wrinkle risk area coordinate; and generating a first instruction for reducing a corresponding area tension and a second instruction for increasing an adjacent area pressure in a synchronous manner according to a coordinate position of the wrinkle risk area; wherein the tension control instruction comprises the first instruction, and the pressure control instruction comprises the second instruction.

[0010] Optionally, the executing the pressure control instruction to dynamically adjust the composite roller partition pressure comprises: acquiring a partition gas pressure control unit of the composite roller; inputting the second instruction into the partition gas pressure control unit and performing gas pressure distribution to calculate an influence weight value; and dynamically adjusting the composite roller partition pressure in combination with the influence weight value and the wrinkle risk area to realize self-elimination of wrinkles.

[0011] Optionally, the method further comprises: acquiring an environmental temperature and humidity parameter through a temperature and humidity sensor; performing analysis and calculation based on the environmental temperature and humidity parameter and the compensation amount to generate a temperature and humidity compensation coefficient; and correcting a tension threshold in the tension control instruction based on the temperature and humidity compensation coefficient.

[0012] Optionally, the correcting the tension threshold in the tension control instruction comprises: acquiring humidity distribution data collected by the temperature and humidity sensor and a high humidity area with an average humidity calculated in real time; when the average humidity exceeds a preset humidity threshold, proportionally reducing the tension threshold of the tension control instruction; and simultaneously triggering an infrared preheating roller to perform softening processing on the high humidity area.

[0013] Optionally, the softening processing comprises: analyzing and calculating the humidity distribution data to locate a coordinate of the high humidity area; and controlling the infrared preheating roller to emit a softening wave band only to the coordinate of the high humidity area to generate a softened area coordinate and a softened area.

[0014] Optionally, the method further comprises: feeding back the softened area coordinate; and triggering the pressure control instruction to perform a pressurization operation only on the softened area.

[0015] Based on the same inventive concept, the application also provides a double-layer composite fabric tension-pressure coupling regulation system, which comprises: a parameter acquisition module, configured to acquire thickness distribution parameters of the unwinding end and winding end fabrics and pressure distribution parameters of the composite roller surface; a coupling modeling module, configured to generate compensation based on the thickness distribution parameters and the pressure distribution parameters; an instruction generation module, configured to generate tension regulation instructions and pressure regulation instructions according to preset fabric characteristic parameters and in combination with the compensation; and a dynamic regulation module, configured to execute the tension regulation instructions to adjust the unwinding or winding roller speed, and simultaneously execute the pressure regulation instructions to dynamically adjust the composite roller partition pressure.

[0016] Compared with the prior art, the application has the following beneficial effects: 1. The application realizes dynamic perception and coordinated regulation of the fabric interlayer fitting state by constructing a tension-pressure double-loop coupling control mechanism, effectively eliminates the stress concentration phenomenon caused by traditional step-by-step control, and significantly reduces the bubble and wrinkle defect rate.

[0017] 2. The dynamic decoupling algorithm based on the physical model breaks through the linear compensation limitation, accurately adapts to fabric elastic mutation and environmental interference, maintains the integrity of the material structure, and improves the composite uniformity, especially for high-elasticity special fabrics.

[0018] 3. The application realizes the synergy of directional energy application and local defect repair based on the linkage operation of partition pressure regulation and infrared softening technology, avoids energy waste caused by overall parameter adjustment, and greatly reduces the production energy consumption.

[0019] 4. The application enhances the stability of the system under fluctuating temperature and humidity conditions through the intelligent coupling mechanism of environmental parameters and material characteristics, solves the frequent false triggering problem caused by traditional fixed threshold control, and improves the continuous operation reliability of the production line.

[0020] Other features and advantages of the application will be set forth in the following description, and in part will become apparent to those skilled in the art from the description, or can be learned by practice of the application. The objects and other advantages of the application will be realized and attained by the structure particularly pointed out in the description, claims and drawings. BRIEF DESCRIPTION OF DRAWINGS

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or prior art description. Obviously, the drawings in the following description are some embodiments of the application, and for those skilled in the art, other drawings can also be obtained from these drawings without creative labor.

[0022] Figure 1is a flowchart of a double-layer composite fabric tension-pressure coupling regulation method according to an embodiment of the present application.

[0023] Figure 2 is an effect comparison diagram of a dynamic decoupling algorithm according to an embodiment of the present application.

[0024] Figure 3 is a temperature and humidity compensation diagram according to an embodiment of the present application.

[0025] Figure 4 is an infrared softening control diagram according to an embodiment of the present application.

[0026] Figure 5 is a structural diagram of a double-layer composite fabric tension-pressure coupling regulation system according to an embodiment of the present application. DETAILED DESCRIPTION

[0027] In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0028] With reference to Figure 1 , one embodiment of the present application proposes a double-layer composite fabric tension-pressure coupling regulation method, which realizes tension-pressure collaborative control through double-ring embedded sensing and dynamic decoupling algorithm, and can eliminate interlayer adhesion defects and reduce energy consumption.

[0029] The method of the embodiment specifically includes: Obtaining thickness distribution parameters of the fabric at the unwinding end and the winding end and pressure distribution parameters of the surface of the composite roller; Generating a compensation amount based on the thickness distribution parameters and the pressure distribution parameters; Generating a tension regulation instruction and a pressure regulation instruction based on the compensation amount according to preset fabric characteristic parameters; Adjusting the rotation speed of the unwinding or winding roller by executing the tension regulation instruction, and dynamically adjusting the partition pressure of the composite roller by executing the pressure regulation instruction.

[0030] Specifically, by acquiring the thickness distribution parameters of the fabric at the unwinding end and the winding end and the pressure distribution parameters of the composite roller surface in real time, a tension-pressure coupling model is constructed; the preset fabric characteristic parameters are obtained through laboratory standard tests, including the elastic modulus, Poisson's ratio, moisture absorption expansion coefficient, etc. of the fabric. For example, uniaxial tensile test, shear test and moisture absorption test are performed on the sample, and the mechanical property data under different temperature and humidity conditions are recorded to establish a fabric characteristic database. The model dynamically generates tension control instructions and pressure control instructions based on the fabric characteristic parameters and real-time working condition data; finally, through synchronous adjustment of the unwinding or winding roller speed and the composite roller partition pressure, the coordinated control of tension and pressure is realized. Eliminate the mutual interference of tension and pressure in the traditional independent control mode, effectively suppress the bubble and wrinkle defects in the compounding process; through the double-parameter closed-loop control mechanism, the uniformity of interlayer adhesion is improved while maintaining the integrity of the fabric structure; significantly reduce the energy loss caused by control mismatch, suitable for the production of composite fabrics with different elasticity and viscosity.

[0031] Optionally, the acquisition of the thickness distribution parameters of the fabric at the unwinding end and the winding end comprises: Scanning the fabric layer by a non-contact ultrasonic thickness sensor to generate a real-time thickness distribution map; Collecting a pressure distribution thermodynamic map by embedding a flexible piezoresistive film array on the surface of the composite roller; Extracting features based on the real-time thickness distribution map to obtain the thickness distribution parameters.

[0032] Specifically, first, a non-contact ultrasonic thickness sensor is used to scan along the width direction of the fabric, the sensor emits ultrasonic waves and receives reflected signals, and the thickness value of each point is obtained by calculating the product of the round-trip time difference and the speed of sound, thereby constructing a real-time thickness distribution map. The thickness distribution map is stored in the form of a two-dimensional matrix, the matrix row number corresponds to the scan position number, the column number corresponds to the time sequence number, and each matrix element value is the fabric thickness measurement value at that position at that time. At the same time, a flexible piezoresistive film array is embedded on the surface of the composite roller, the array is composed of multiple micro pressure sensing units, each unit changes the resistance value according to the pressure it receives, and the pressure value is converted by measuring the resistance change, and finally a pressure distribution thermodynamic map is formed. After obtaining the real-time thickness distribution map, the system extracts its features, calculates the average thickness, maximum thickness difference, thickness change rate, etc. These parameters are collectively referred to as thickness distribution parameters. The average thickness is obtained by dividing the sum of the thickness values of all measurement points by the number of measurement points, the maximum thickness difference is the difference between the maximum and minimum thickness values, and the thickness change rate is obtained by calculating the average value of the thickness difference and the distance between adjacent measurement points. The thickness distribution parameters obtained in this way can fully characterize the spatial distribution characteristics and dynamic change trend of the fabric thickness.

[0033] For example, suppose that during the composite production process, an ultrasonic thickness sensor scans the fabric and finds a thickness of 0.5 mm on the left side, 0.3 mm on the right side, and a periodic fluctuation of 0.1 mm in the middle. A flexible piezoresistive thin-film array detects a corresponding pressure of 20 kPa on the left and 15 kPa on the right. The system calculates an average thickness of 0.4 mm, a maximum thickness difference of 0.2 mm, and a thickness variation rate of 0.02 mm per centimeter. By combining non-contact measurement with embedded sensing, real-time monitoring of the fabric thickness and pressure across the entire fabric area is achieved. This avoids potential fabric damage caused by traditional contact measurements and accurately captures subtle changes in thickness distribution, providing a reliable data foundation for subsequent tension and pressure control.

[0034] Optionally, the generated compensation amount includes: The real-time thickness distribution map and the pressure distribution heat map are spatially mapped and associated to generate an interlayer bonding state feature vector with thickness variation. Based on the interlayer bonding state feature vector and the preset elastic deformation threshold, a correlation analysis is performed to generate a compensation amount.

[0035] Specifically, firstly, a spatial coordinate correspondence is established between the real-time thickness distribution map and the pressure distribution heatmap, and a grid matching algorithm is used to ensure that the detection areas of the two maps completely overlap. The thickness variation matrix is ​​obtained by subtracting the standard thickness value from the measured value at each point in the thickness distribution map, while the pressure matrix is ​​constructed by extracting the measured pressure values ​​at each point in the pressure distribution heatmap. The thickness variation matrix and the pressure matrix are then combined through matrix multiplication to generate an interlayer bonding state feature vector with thickness variation. For each component of this vector, a specific calculation is performed. ,have: , in, Indicates the first The thickness change at each point Indicates the first The pressure value at each point characterizes the coupling effect between thickness anomalies and pressure distribution at a specific location. Uniaxial tensile tests are performed on sample fabric, and stress-strain curves are plotted. A specific proportion (e.g., 80%) of the strain value corresponding to the end of the linear segment of the curve or the strain value corresponding to the yield point is used as a preset elastic deformation threshold to ensure that the control occurs within the elastic deformation zone of the material. When the eigenvector component exceeds the corresponding threshold, the system triggers a decoupling process. The decoupling algorithm first marks the thickness abrupt change region as an anomaly region, then uses Gaussian filtering to smooth the thickness and pressure data of the surrounding normal region, separating noise signals caused by interference factors such as mechanical vibration. The algorithm calculates the actual independent compensation amount required for the anomaly region. The calculation of the compensation amount... ,have: , wherein, is the fabric elastic compensation coefficient, which is obtained by measuring the thickness recovery rate and pressure relationship by applying a step pressure to the sample; is the characteristic vector component. This calculation process ensures that the compensation amount is proportional to the actual degree of defect in the lamination, while considering the resistance of material properties to deformation. The specific implementation effect is shown in Figure 2 , the gray vertical line represents the time when the algorithm detects the thickness mutation and starts decoupling, and the area enclosed by the solid line and the dashed line in the figure is the effective area of the decoupling algorithm.

[0036] Exemplarily, in the production process of medical polytetrafluoroethylene composite film, when the real-time thickness distribution map shows that the thickness change rate of the coordinate area increases by one hundred and twenty percent to the preset threshold value, and the pressure distribution thermograph detects that the pressure gradient of the area reaches two and a half times of the adjacent area, the system generates an interlayer lamination state characteristic vector containing abnormal data. After the dynamic decoupling algorithm determines that it exceeds the elastic deformation threshold, the required pressure of the area is calculated to be reduced by fifteen percent and the pressure of the adjacent area is calculated to be increased by eight percent according to the formula. The actuator adjusts the partition air pressure of the composite roller accordingly, and eliminates the wrinkle to be formed within zero point five seconds. The decoupling algorithm driven by the physical model accurately implements pressure redistribution before the material is plastically deformed, effectively avoids irreversible damage to high-elasticity special fabrics caused by local stress concentration, and at the same time maintains the normal composite pressure of non-abnormal areas, significantly improving the yield of finished functional composite fabrics.

[0037] Optionally, the method further comprises: extracting the wrinkle risk area coordinates when detecting that the thickness change amount exceeds the preset elastic deformation threshold; synchronously generating a first instruction for reducing the tension of the corresponding area and a second instruction for increasing the pressure of the adjacent area according to the coordinate position of the wrinkle risk area; wherein, the tension control instruction contains the first instruction, and the pressure control instruction contains the second instruction.

[0038] Specifically, the determination condition of the wrinkle risk area is that when the dynamic decoupling algorithm detects that the thickness change amount in the interlayer lamination state characteristic vector exceeds the preset elastic deformation threshold, the center coordinates of the area are automatically marked as the wrinkle risk area. Then, two control instructions are generated through the coordinate position of the marked wrinkle risk area. Among them, the first instruction reduces the tension by reducing the speed of the corresponding unwinding roller, and the adjustment amount is proportional to the thickness mutation amplitude. For the first instruction generation, the adjusted tension value , , wherein, is the current tension reference value, is the tension compensation coefficient, which is obtained by fabric tensile test, such as uniaxial tensile test on the sample, record the thickness change under different tension, fitting to get The second instruction balances the stress by increasing the adjacent area composite roller pressure, and the pressure adjustment amount is determined by the product of the thickness change gradient and the material elastic modulus. For the calculation of the adjusted pressure value in the second instruction generation , , wherein, is the current pressure reference value, is the pressure compensation coefficient, which is obtained by testing the minimum effective bonding pressure under different thickness gradients, and the value is fitted . The tension control instruction contains the first instruction, and the pressure control instruction contains the second instruction. In the conventional case, the system automatically matches the optimal tension-pressure control combination based on the preset fabric characteristic database and process parameter library. The tension control instruction is generated according to the ratio of the thickness deviation value to the standard value, and the pressure control instruction is calculated according to the product of the thickness change rate and the pressure sensitivity coefficient. This process ensures that the material deformation is within a controllable range through real-time feedback mechanism, avoiding wrinkles caused by local stress concentration. The principle of the overall method is to balance the local tension and the pressure of the adjacent area through dynamic balance, to offset the unevenness of material deformation, so as to maintain the overall flatness of the material. The technical effect lies in the ability to actively prevent the formation of wrinkles and improve the stability of the material during processing or use.

[0039] Exemplarily, in the process of waterproof and breathable fabric compounding, the dynamic decoupling algorithm detects that the thickness change of the coordinate area exceeds twenty-five percent of the threshold value and the pressure gradient reaches three times of the adjacent area, and determines that it is a wrinkle risk area. The system calls the tension compensation coefficient of and the pressure compensation coefficient of to generate the first instruction to reduce the tension of the area by twenty percent and the second instruction to increase the pressure of the adjacent area by fourteen percent. The double instructions are transmitted to the unwinding roller frequency converter and the composite roller air pressure partition controller simultaneously to execute the double instruction cooperative mechanism driven by physical parameters, which can accurately eliminate local stress concentration while maintaining the overall compounding strength, avoiding the problem of material overstretching or insufficient bonding caused by traditional single adjustment, especially suitable for functional fabrics with microporous structure on the surface, significantly improving the air tightness and durability of the compounded product.

[0040] Optionally, the execution of the pressure control instruction to dynamically adjust the partition pressure of the composite roller includes: obtaining a partition air pressure control unit of the composite roller; inputting the second instruction into the partition air pressure control unit and performing air pressure distribution to calculate an influence weight value; By combining the influence weight value with the wrinkle risk area, the pressure of the composite roller zone is dynamically adjusted to achieve wrinkle self-elimination.

[0041] Specifically, the first step is to acquire the zoned air pressure control unit of the composite roll. This unit consists of multiple independently controllable air pressure zones, each corresponding to a different area of ​​the composite roll. Next, a second command is input to the zoned air pressure control unit. Based on the location and deformation degree of the wrinkle risk area, an influence weight value is calculated. This weight value reflects the contribution of each zone to wrinkle elimination. The calculation of the influence weight value is based on the relative distance between the zone and the wrinkle risk area and the deformation gradient; the closer the distance or the greater the deformation gradient, the higher the weight of the zone. The calculation of the influence weight value... ,have: ， in, Indicates which partition, Indicates the first The geometric distance between each zone and the fold risk area is obtained by measuring the position sensor; To determine the distance attenuation coefficient, multiple pressure zones are set on the surface of the composite roller. A fixed pressure is applied at a specific location (e.g., coordinate x=0), and the deformation at different distances is measured. The pressure transmission attenuation curve is recorded, and the relationship between the deformation and distance is fitted. After taking the logarithm, linear regression is performed to obtain the coefficient. value; For the first The thickness changes detected in each zone are collected in real time by the thickness sensor. The maximum thickness variation across all zones is used. The system then dynamically allocates air pressure based on the influence weight values, prioritizing increased pressure in high-weight zones while coordinating pressure changes in adjacent zones, thus achieving precise adjustment of the composite roll zone pressure. This process uses closed-loop control to ensure the pressure distribution matches the wrinkle-prone areas, ultimately achieving wrinkle self-elimination. The overall method's principle lies in utilizing the coordinated regulation of zoned air pressure to balance the material's stress distribution and eliminate localized stress concentrations. The technical effectiveness is reflected in its ability to quickly respond to material deformation, automatically adjust pressure distribution, and effectively prevent wrinkles from forming or expanding.

[0042] For example, suppose that during film production, the detection system detects a slight wrinkle in the film. Upon receiving a second instruction, the zoned air pressure control unit of the composite roller calculates that the three zones closest to the wrinkle area have higher influence weights. The system then increases the air pressure in these three zones while slightly decreasing the air pressure in adjacent zones to create a smooth transition. The beneficial effects of this verification example are: by dynamically adjusting the zoned pressure, wrinkles on the film surface are quickly smoothed out, production continuity is ensured, product surface quality is significantly improved, and manual intervention and scrap rates are reduced.

[0043] Optionally, the method further comprises: obtaining an environmental temperature and humidity parameter through a temperature and humidity sensor; analyzing and calculating based on the environmental temperature and humidity parameter and the compensation amount to generate a temperature and humidity compensation coefficient; correcting a tension threshold value in the tension control instruction based on the temperature and humidity compensation coefficient.

[0044] Specifically, obtaining an environmental temperature and humidity parameter is achieved through a temperature and humidity sensor installed within one meter of the composite station. The sensor collects air absolute humidity values and temperature values in real time to form an environmental temperature and humidity parameter. The humidity deviation of the current absolute humidity in the environmental temperature and humidity parameter from a preset standard working condition humidity reference value is calculated. The standard working condition humidity reference value is calibrated in a laboratory. For example, the mechanical properties of polyester fabric significantly decrease when the humidity is 70% RH, so the standard working condition humidity reference value is set as 65% RH as a safety threshold value. The humidity deviation obtained from the environmental temperature and humidity parameter and the compensation amount are combined to determine whether to trigger temperature and humidity compensation. When the humidity deviation is greater than 0 and the compensation amount exceeds the elastic deformation threshold value, compensation is started. A temperature and humidity compensation coefficient is generated in combination with a moderate deviation value and an expansion sensitivity factor corresponding to the fabric type, otherwise compensation is skipped or only relies on basic tension control. For calculating the temperature and humidity compensation coefficient , there are: , wherein, is an expansion sensitivity factor corresponding to the fabric type, which reflects the deformation proportion caused by unit humidity change (such as polyester , i.e. 0.15% of the tension threshold value needs to be compensated for every 1% of humidity exceeding the reference value); is the current absolute humidity value; is the standard working condition humidity reference value. Based on the temperature and humidity compensation coefficient, the tension threshold value in the tension control instruction is corrected. For calculating the corrected tension threshold value , there are: , wherein, is the original tension threshold value. The sample is cyclically stretched at different tensions (10-100 N, step 5 N) under standard environment (23℃, 50% RH) to determine the maximum tension value that does not cause permanent deformation. As shown in Figure 3 , the solid line in the figure is the environmental humidity change curve, simulating the humidity sudden increase working condition in the plum rain season. The dashed line is the tension threshold value automatically corrected by the system. When the humidity is greater than the preset threshold value (such as 60% RH), the tension output is reduced according to the moisture absorption characteristics of the fabric. The gray vertical line is the humidity overrun triggering time, at which time the dynamic correction of the tension threshold value and the infrared preheating roller are activated simultaneously.

[0045] Exemplarily, when producing automobile roof composite fabric in the rainy season, the absolute humidity value detected by the temperature and humidity sensor exceeds the benchmark value by forty percent, and the system corrects the tension threshold value from the original value to ninety-four point three percent according to the characteristics of the polyester base fabric . When the ultrasonic thickness sensor detects the thinning trend of the fabric, the dynamic decoupling algorithm uses the corrected threshold value to make a judgment, triggers the tension adjusting mechanism in advance, and activates the infrared preheating function. Through the coupling operation of environmental parameters and material characteristics, the accuracy of tension control is maintained in the climate mutation working condition, effectively preventing the fabric from being stretched too much in a high humidity environment, while avoiding the energy waste caused by frequent false triggering of the traditional fixed threshold system, and significantly improving the running stability of the composite production line in harsh environments.

[0046] Optionally, the method further includes: acquiring humidity distribution data collected by the temperature and humidity sensor and a high-humidity area with an average humidity calculated in real time; when the average humidity exceeds a preset humidity threshold value, proportionally reducing the tension threshold value of the tension control instruction; simultaneously triggering the infrared preheating roller to soften the high-humidity area.

[0047] Specifically, the operation of correcting the tension threshold value includes two steps of humidity exceeding judgment and linkage softening triggering. The humidity exceeding judgment is realized by comparing the real-time environmental humidity value with the preset humidity threshold value. The preset humidity threshold value is based on the moisture absorption characteristic experiment of the fabric. The humidity is gradually increased under constant temperature conditions, the size change or mechanical property inflection point of the fabric is monitored, and the humidity value when the performance significantly decreases is set as the preset humidity threshold value. For example, if the tensile strength of polyester fabric decreases by 10% when the humidity is 70% RH, the preset humidity threshold value is 65% RH, and the tension correction is triggered when the limit is exceeded. First, the humidity distribution data of the production environment is collected in real time by the array type temperature and humidity sensor. The sensor is arranged in a grid form above the fabric transmission path, and each node measurement value constitutes a humidity matrix. The average value and standard deviation of the humidity of each area are monitored and calculated in real time, and when the humidity value of a certain area exceeds the sum of the average humidity and twice the standard deviation, it is marked as a high-humidity area. The preset humidity threshold value is determined according to the moisture absorption characteristics of the fabric. If the average humidity of the high-humidity area exceeds the preset humidity threshold value, the tension threshold value correction is triggered. For calculating the correction coefficient , there are: ， wherein, is the material humidity sensitivity coefficient, which is obtained through laboratory moisture absorption tensile test, such as measuring the elastic modulus change rate of the material at each humidity in a humidity controllable environment box (such as 40% RH→90% RH, step 10%), a ratio of the rate of change of the elastic modulus to the amount of change in relative humidity (90%-40%); is the current average humidity value, is the preset humidity threshold value. Finally, the corrected tension threshold value is obtained. At the same time, the correction coefficient linearly reduces the output voltage value of the tension control instruction, sends a start signal to the infrared preheating roller controller, and triggers the humidity distribution data collected based on the distributed temperature and humidity sensor array. The array is composed of multiple miniature temperature-sensitive resistors, each of which changes with the ambient humidity. The humidity value is converted through a measurement circuit. The system scans the sensor data to generate a humidity distribution map and identifies the continuous area exceeding the local humidity threshold value in the map as the high humidity area coordinates.

[0048] For example, when producing curtain composite fabrics in the Meiyu season at a textile factory, the distributed temperature and humidity sensor detects that the average humidity exceeds thirty percent and lasts for five minutes. The system generates a proportional adjustment coefficient of 0.85, reduces the tension control instruction output voltage from 5 volts to 4.25 volts, and at the same time, the humidity distribution map shows that the humidity value of area No. 3 reaches 150 percent of the average value, which is marked as a high humidity area. The infrared preheating roller immediately emits softening rays of a specific wavelength to the area through intelligent linkage of humidity data and material properties, accurately softening the high humidity area while reducing the overall tension. This avoids interlayer misalignment caused by moisture absorption and expansion of the fabric, and prevents material performance degradation caused by excessive softening, significantly improving the dimensional stability of home textiles in a humid environment.

[0049] Optionally, the softening process comprises: analyzing and calculating the humidity distribution data to locate the coordinates of the high humidity area; controlling the infrared preheating roller to emit softening waves only to the coordinates of the high humidity area, generating the coordinates of the softened area and the softened area.

[0050] Specifically, the operation of positioning the high-humidity area coordinates is based on the humidity distribution data collected by a distributed temperature and humidity sensor array composed of multiple temperature-sensitive resistance units, the resistance value of each unit linearly changes with the ambient humidity, the resistance change is converted into a voltage signal through a constant voltage circuit, the system scans all sensor voltage values at a frequency of ten times per second, a two-dimensional humidity distribution map is generated using a spatial interpolation algorithm, and the infrared preheating roller emits a softening wave band. The selection principle of the softening wave band is to select the characteristic absorption peak wave band of the target fabric in the infrared spectrum according to the material of the target fabric, so as to achieve the most efficient energy absorption and softening effect; for example, the preferred wave band of polyester fabric is 2.8-3.2 μm, the temperature rise efficiency is more than 75% under this wave band, and the softening time is shortened by 30%; the preferred wave band of cotton / cellulose fiber fabric is 2.9-3.5 μm, the hydroxyl group in cellulose has significant absorption (absorption rate > 80%) in the 3.2-3.5 μm wave band; the preferred wave band of polyurethane elastic fabric is 3.3-3.7 μm, and the urethane group in polyurethane has a characteristic absorption near 3.5 μm. The opening position and radiation parameters of the infrared emitter are calculated according to the high-humidity area coordinates, the radiation intensity of each radiation unit is calculated, and the radiation intensity is calculated as follows: , wherein, represents the deviation of the humidity value of the coordinate point from the local threshold value, is the radiation conversion coefficient, which is determined by a fabric heat softening experiment, the absorption rate of the material in the 2.5-3.5 μm wave band is detected by a Fourier infrared spectrometer, and the temperature rise caused by unit radiation intensity (W / cm²) is measured by a thermal imaging instrument. The radiation conversion coefficient is obtained by fitting the absorption rate and the temperature rise. Only the radiation units within the coordinate range emit wave band infrared rays, which match the hydroxyl absorption peak of cellulose fiber. The range of the softening area is adjusted in real time by a thermal imaging instrument to ensure that the temperature is maintained in the optimized softening interval of . After softening, the system records the actual heated area coordinates and the duration, and generates a softening area report containing parameters such as position, temperature, and action time. As shown in Figure 4 , the red dashed line in the figure is the softening threshold value 35℃, and the solid line represents the temperature of the softening area, which reaches a maximum of 39.9℃ at the 4th second. Only when the temperature exceeds this value, the composite roller is triggered to pressurize the softening area. The orange filled area represents the effective softening range.

[0051] For example, in a medical protective clothing composite production line, the distributed sensor detects that the humidity value of the coordinate area exceeds forty percent of the local threshold value, the system marks the area as a high-humidity area, and according to the characteristics of the polyurethane material, the , the required radiation intensity is thirty-two milliwatts per square centimeter, the infrared preheating roller only emits softening rays of three-point-five-micron wavelength in the coordinate area, and the other areas remain standby. Through precise radiation control driven by humidity distribution characteristics, the influence of local humidity is eliminated while the heat energy loss is minimized, the denaturation of temperature-sensitive materials caused by traditional overall heating is avoided, and the functional integrity of the antibacterial layer of the medical composite material is effectively maintained.

[0052] Optionally, the method further comprises: feedback of the softened area coordinates; triggering the pressure regulation instruction to only implement pressure increasing operation on the softened area.

[0053] Specifically, the feedback of the softened area coordinates to the operation of the dynamic decoupling algorithm is realized through a coordinate conversion module. The module receives the position signal of the infrared preheating roller controller, calculates the mapping coordinates of the softened area in the composite roller coordinate system according to the mechanical position relationship between the composite roller and the preheating roller through geometric transformation formula, and calculates the composite roller surface coordinates , there are: ， wherein, is the irradiation angle of the preheating roller, is the fabric running line speed, is the signal transmission delay time, is the composite roller radius; when triggering the pressure regulation instruction to only implement pressure increasing operation on the softened area, the dynamic decoupling algorithm calculates the pressure increasing amount according to the mapping coordinates, and calculates the pressure value to be increased , there are: , wherein, is the softened area temperature actually measured by the infrared thermometer, is the target softened temperature, is the pressure-temperature coupling coefficient, which is calibrated through material hot pressing experiment. On the controllable temperature and pressure platform (temperature: 50-100℃, pressure: 10-100kPa), the interlayer peeling strength under different temperature and pressure combinations is measured, and the relationship curve between temperature-pressure combination and interlayer peeling strength is obtained through fitting.

[0054] Exemplarily, in the production of aviation seat composite fabric, after the infrared preheating system irradiates the coordinate area, the temperature detector detects that the actual temperature is fifteen degrees Celsius lower than the target value. The coordinate conversion module calculates the corresponding mapping coordinates of the composite roller according to the running speed of one point five meters per second and the roller diameter parameters, and the dynamic decoupling algorithm calculates the pressure increasing amount according to the mapping coordinates The pressure of 7.5 kPa needs to be increased, and only the composite roller corresponding to the coordinate is outputted with the pressure increasing instruction. Through the real-time linkage of the hot softening state and the pressure control, the pressure range is accurately controlled under the premise of ensuring the full melting and bonding of the material, which not only avoids the fracture of the reinforcing fibers caused by excessive pressure in the high-temperature zone, but also prevents the weak bonding problem caused by insufficient pressure in the non-softening zone, and significantly improves the interface bonding quality and fatigue life of the high-strength composite material.

[0055] Based on the same inventive concept, as shown in Figure 5 The application also provides a double-layer composite fabric tension-pressure coupling regulation system, which comprises: A parameter acquisition module is configured to acquire thickness distribution parameters of the unwinding end and the winding end fabric and pressure distribution parameters of the composite roller surface; A coupling modeling module is configured to analyze and calculate a compensation amount based on the thickness distribution parameters and the pressure distribution parameters; An instruction generation module is configured to generate a tension regulation instruction and a pressure regulation instruction according to preset fabric characteristic parameters and in combination with the compensation amount; A dynamic regulation module is configured to execute the tension regulation instruction to adjust the unwinding or winding roller speed, and simultaneously execute the pressure regulation instruction to dynamically adjust the composite roller partition pressure.

[0056] To make the purpose, technical solutions and advantages of the embodiments of the application clearer, the technical solutions in the embodiments of the application will be clearly and completely described below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are some embodiments of the application, rather than all the embodiments. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the application.

[0057] It should be noted that the electrical connection between the above-mentioned units does not necessarily represent the direct connection of the line, and the indirect connection mode can also be applied to the embodiments of the application as long as the purpose of the application is achieved. The above-described is only an exemplary embodiment of the application, and cannot limit the scope of the application.

[0058] That is, any equivalent changes and modifications made according to the teachings of the application still fall within the scope of the application. Other embodiments of the application will be easily obtained by those skilled in the art after considering the description and the disclosure of the truth. This application aims to cover any variations, uses or adaptive changes of the application, which follow the general principles of the application and include common knowledge or conventional technical means in the art not disclosed in the application.

Claims

1. A method for tension-pressure coupling regulation of a double-layer composite fabric, characterized in that, The method comprises: Obtaining the thickness distribution parameters of the fabric at the unwinding end and the winding end and the pressure distribution parameters of the composite roller surface; Based on the thickness distribution parameters and the pressure distribution parameters, a compensation amount is generated by analysis and calculation; According to the preset fabric characteristic parameters, the tension control instruction and the pressure control instruction are generated in combination with the compensation amount; The tension control instruction is executed to adjust the unwinding or winding roller speed, and the pressure control instruction is executed to dynamically adjust the partition pressure of the composite roller.

2. The method of claim 1, wherein, The method comprises: Scanning the fabric layer by a non-contact ultrasonic thickness sensor to generate a real-time thickness distribution map; Collecting a pressure distribution thermal map by a flexible piezoresistive film array embedded in the surface of the composite roller; Based on the real-time thickness distribution map, feature extraction is performed to obtain the thickness distribution parameters.

3. The method of claim 2, wherein, The method comprises: The real-time thickness distribution map and the pressure distribution thermal map are spatially mapped and associated to generate a layer adhesion state feature vector with a thickness change amount; Based on the layer adhesion state feature vector and the preset elastic deformation threshold, a compensation amount is generated by correlation analysis.

4. The method of claim 3, wherein, The method further comprises: When it is detected that the thickness change amount exceeds the preset elastic deformation threshold, the wrinkle risk area coordinates are extracted; According to the coordinate position of the wrinkle risk area, a first instruction for reducing the tension of the corresponding area and a second instruction for increasing the pressure of the adjacent area are generated synchronously; The tension control instruction includes the first instruction, and the pressure control instruction includes the second instruction.

5. The method of claim 4, wherein, The method further comprises: A partition gas pressure control unit of the composite roller is obtained; The second instruction is input into the partition gas pressure control unit and gas pressure distribution is performed to calculate the influence weight value; In combination with the influence weight value and the wrinkle risk area, the partition pressure of the composite roller is dynamically adjusted to realize self-elimination of wrinkles.

6. The method of claim 1, wherein, The method further comprises: The environmental temperature and humidity parameters are obtained by a temperature and humidity sensor; Based on the environmental temperature and humidity parameters and the compensation amount, a temperature and humidity compensation coefficient is generated by analysis and calculation; The tension threshold in the tension control instruction is corrected based on the temperature and humidity compensation coefficient.

7. The method of claim 6, wherein, The method further comprises: The humidity distribution data collected by the temperature and humidity sensor and the high-humidity area with an average humidity calculated in real time are obtained; When the average humidity exceeds the preset humidity threshold, the tension threshold of the tension control instruction is proportionally reduced; The infrared preheating roller is triggered to perform softening treatment on the high-humidity area.

8. The method of claim 7, wherein, The method further comprises: The coordinates of the high-humidity area are located by analyzing and calculating the humidity distribution data; The infrared preheating roller is controlled to emit softening wave bands only to the coordinates of the high-humidity area to generate softened area coordinates and a softened area.

9. The method of claim 8, wherein, The method further comprises: The softened area coordinates are fed back; The pressure control instruction is triggered to perform pressure increasing operation only on the softened area.

10. A double-layer composite fabric tension-pressure coupling regulation system applied to the double-layer composite fabric tension-pressure coupling regulation method according to any one of claims 1-9, characterized in that, The system comprises: A parameter acquisition module is configured to obtain the thickness distribution parameters of the fabric at the unwinding end and the winding end and the pressure distribution parameters of the composite roller surface; a coupling modeling module configured to generate a compensation amount based on analysis of the thickness distribution parameter and the pressure distribution parameter; an instruction generating module configured to generate a tension control instruction and a pressure control instruction according to a preset fabric characteristic parameter in combination with the compensation amount; a dynamic control module configured to execute the tension control instruction to adjust the unwinding or winding roller rotation speed, and execute the pressure control instruction to dynamically adjust the composite roller partition pressure.

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