Micro-tension automatic cloth releasing machine

Abstract

The invention discloses a micro-tension automatic cloth releasing machine which comprises a pedal platform, a movable rack, a deviation rectifying mechanism, a micro-tension control mechanism and a controller, the movable rack is arranged on the pedal platform, and the deviation rectifying mechanism is connected between the movable rack and the pedal platform so as to drive the rack to transversely move and center; a servo driving assembly and a clamping assembly are arranged on the movable rack, and a servo motor drives the clamping assembly to release cloth through a magnetic powder clutch; the micro-tension control mechanism comprises a tension control frame, and a tension balance module, a tension cylinder and a tension angle sensor which are arranged on the tension control frame; the tension balancing module suspends a balancing weight and a tension guide roller through a closed-loop chain, a tension air cylinder applies adjustable balancing force to the balancing module through a chain, and a tension angle sensor monitors the rotating angle of the balancing module through a transmission mechanism. The controller receives signals of the sensor and controls the servo motor and the deviation rectifying electric cylinder to cooperatively act to form closed-loop control. According to the invention, the problems of overlarge cloth releasing tension, instability, much manual intervention, low qualification rate and high cost in the compounding of the existing automotive interior fabric are solved.

Description

Technical Field

[0001] This invention relates to the field of automotive interior production equipment technology, and in particular to a micro-tension automatic fabric feeding machine for automotive interior composite processes. Background Technology

[0002] In current automotive interior fabric lamination processes, flame bonding technology is commonly used to bond leather with various substrates such as sponge and fabric. Currently, the industry generally employs a passive fabric feeding method controlled by magnetic powder brakes combined with manual assistance to complete this lamination process.

[0003] However, with the increasing variety of automotive interior fabrics, the requirements for tension control during the lamination process are becoming more and more refined. The traditional magnetic powder braking combined with manual fabric feeding mode is difficult to achieve precise and stable tension control, which in turn leads to a large number of unqualified products in the production process.

[0004] Different fabrics exhibit significantly different sensitivities to tension, especially for special materials such as directional stretch knitted fabrics. Their composite processes require tension control of ≤1N / m, but the tension control precision of traditional methods falls far short of this requirement. This results in frequent defects such as width loss, deformation, and surface roughness during the production of these fabrics. Existing technologies suffer from numerous drawbacks, including excessive and fluctuating fabric release tension, difficulty in manual fabric release operations, low production efficiency, and low product qualification rates. Ultimately, this leads to a large number of defective products and persistently high production costs, severely hindering the improvement of the quality and efficiency of automotive interior fabric composite processes. Summary of the Invention

[0005] The purpose of this invention is to provide a micro-tension automatic fabric feeding machine, which can solve the problems of excessive and unstable fabric feeding tension, difficulty in manual fabric feeding, low product qualification rate, and continuously high production costs in the existing automotive interior fabric composite process.

[0006] To solve the above problems, the technical solution adopted by the present invention is as follows: This micro-tension automatic fabric feeding machine includes a pedal platform, a movable frame, a correction mechanism, a micro-tension control mechanism, and a controller. The movable frame is placed on the pedal platform, the correction mechanism is connected between the movable frame and the pedal platform, and the micro-tension control mechanism is located next to the pedal platform. The movable frame is equipped with a servo drive assembly for driving fabric feeding and a clamping assembly for mounting the fabric roll. The servo drive assembly includes a servo motor and a magnetic powder clutch. The servo motor is drively connected to the magnetic powder clutch, and the output end of the magnetic powder clutch is connected to the rotating shaft of the clamping assembly. The correction mechanism includes a servo correction electric cylinder. The cylinder body of the servo correction electric cylinder is fixed on the pedal platform, and its lead screw end is connected to the movable frame, driving the movable frame on the pedal platform. The platform reciprocates horizontally perpendicular to the fabric's running direction. The micro-tension control mechanism includes a tension control frame and a tension balancing module, a tension cylinder, and a tension angle sensor mounted on the tension control frame. The tension balancing module includes a counterweight and a tension guide roller. The ends of the counterweight and the tension guide roller are connected by a chain to form a closed-loop structure. The chain meshes with at least two sprockets fixed on the tension control frame. The piston rod of the tension cylinder is connected to the tension balancing module via a chain to apply a balancing force to the tension balancing module. The rotating shaft of the tension angle sensor is connected to the rotating shaft of the tension balancing module via a transmission mechanism. The signal input terminal of the controller is electrically connected to the signal output terminal of the tension angle sensor, and the output terminal of the controller is electrically connected to the control terminals of the servo motor and the servo correction cylinder, respectively.

[0007] In the above-mentioned technical solution of the micro-tension automatic fabric feeding machine, a more specific technical solution could be: the piston rod of the tension cylinder is connected to the tension guide roller via a chain.

[0008] In some possible implementations, the servo motor and the magnetic powder clutch are connected by a chain drive mechanism.

[0009] In some possible implementations, a linear slide rail is fixed to the pedal platform, and a slider is provided at the bottom of the movable frame, the slider slidingly engaging with the linear slide rail.

[0010] In some possible implementations, the clamping assembly includes two safety chucks arranged opposite each other and an air shaft mounted between the two safety chucks, with the output end of the magnetic powder clutch connected to the shaft of one of the safety chucks via a coupling.

[0011] In some possible implementations, the controller is a PLC controller.

[0012] By adopting the above technical solution, the present invention has the following advantages compared with the prior art: 1. A servo drive assembly consisting of a servo motor and a magnetic powder clutch works in conjunction with the clamping assembly. The servo motor provides stable driving force, while the magnetic powder clutch separates and engages the driving force, replacing the traditional manual passive fabric feeding mode. Automatic fabric feeding can be completed without manual intervention, significantly reducing the difficulty of manual operation, improving production efficiency, and reducing labor costs. It can also switch to passive unwinding mode in case of drive system failure to ensure production continuity. Combined with the closed-loop design of the micro-tension control mechanism, through the balance module composed of counterweights and tension guide rollers, the balancing force applied by the tension cylinder, and the signal detection of the tension angle sensor, a precise closed-loop feedback control is formed with the controller. This can meet the micro-tension requirements of special fabrics ≤1N / m, effectively eliminating defects such as fabric width loss and deformation caused by excessive tension and significant fluctuations. At the same time, the correction mechanism works with the controller to drive the movable frame to move automatically to achieve fabric centering, avoiding deviation problems, improving fabric feeding stability and product consistency. Ultimately, through the synergistic effect of automated operation, precise tension control, and automatic correction, the generation of defective products is reduced, thereby reducing raw material waste costs and improving the quality and efficiency of automotive interior composite products.

[0013] 2. The tension guide roller is in direct contact with the fabric, and its stress state directly reflects the actual fabric tension. By applying the balancing force of the tension cylinder directly to the tension guide roller through the chain, the stress balance of the tension guide roller can be adjusted more directly and quickly. This makes the signal detected by the tension angle sensor more closely match the actual tension, thereby improving the accuracy of the controller in adjusting the servo motor speed, further ensuring the stability of micro-tension control, reducing defects caused by fabric tension fluctuations, and improving the product qualification rate.

[0014] 3. Chain drives are characterized by high transmission efficiency, stable transmission ratio, and strong load-bearing capacity. The servo motor and the magnetic powder clutch are connected by a chain drive mechanism, which can ensure that the driving force of the servo motor is stably transmitted to the magnetic powder clutch, avoiding power loss or speed fluctuation during transmission, ensuring the stability of the unwinding speed of the clamping components, and thus improving the stability of the unwinding tension. At the same time, the chain drive has a simple structure and is easy to maintain, which can reduce the subsequent maintenance cost of the equipment.

[0015] 4. The sliding block and linear guide rail between the movable frame and the pedal platform can reduce the friction during the movement of the movable frame, making the movement of the movable frame driven by the servo correction electric cylinder smoother and more precise, improving the response speed and centering accuracy of automatic correction; at the same time, it can avoid wear caused by direct friction, extend the service life of the equipment, reduce the equipment maintenance cost, and ensure the stability of correction in long-term production.

[0016] 5. The clamping assembly adopts a safety chuck and an air shaft, which provides overload protection, improves the safety and reliability of the equipment, and can also be adapted to different specifications of fabric rolls, improving the versatility of the equipment; the air shaft firmly clamps the fabric roll, avoiding the fluctuation of the unwinding speed caused by the loosening of the fabric roll during the unwinding process, and further ensuring tension stability. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of this micro-tension automatic fabric feeding machine.

[0018] Figure 2 yes Figure 1 Top view.

[0019] Figure 3 yes Figure 1 A three-dimensional image.

[0020] Figure 4 This is a schematic diagram showing the operating status of this micro-tension automatic fabric feeding machine.

[0021] The following are the labeling instructions in the diagram: 1. Pedal platform; 2. First guide roller; 3. Servo correction cylinder; 4. Second guide roller; 5. Tension control frame; 6. Lower balance sprocket; 6-1. Balance chain; 7. Tension cylinder; 8. Counterweight; 9. Tension guide roller; 10. Piston rod; 11. Cylinder balance chain; 12. Upper balance sprocket; 13. Signal transmission chain; 14. Angle position sensor sprocket; 15. Servo motor; 16. Magnetic powder clutch; 17. Driven sprocket; 18. Main drive chain; 19. Active drive sprocket; 20. Movable frame; 21. Slider; 22. Linear slide rail; 23. Coupling; 24. Safety chuck; 25. Tension angle position sensor; 26. Angle position signal sprocket; 27. Balance module shaft; 28. Air shaft; 29. ​​Composite machine; A1. First fabric; A2. Second fabric; A3. Third fabric. Detailed Implementation

[0022] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments: Figures 1 to 3 The micro-tension automatic fabric feeding machine shown mainly includes a pedal platform 1, a movable frame 20, a correction mechanism, a micro-tension control mechanism, and a controller. The movable frame 20 is placed on the pedal platform 1, and the correction mechanism is connected between the movable frame 20 and the pedal platform 1 to adjust the position of the movable frame 20 to achieve fabric centering. The micro-tension control mechanism is located next to the pedal platform 1 and is used to precisely control the tension during the fabric feeding process. The controller is electrically connected to each actuator and detection component.

[0023] The movable frame 20 is equipped with a servo drive assembly for driving the fabric unloading and a clamping assembly for mounting the fabric roll. The servo drive assembly and the clamping assembly are connected to drive the fabric roll to rotate and unload the fabric. The actuator of the web-correcting mechanism is connected to the movable frame 20 and can drive the movable frame 20 to move in a specific direction. The micro-tension control mechanism senses tension changes in real time through a detection component and feeds the signal back to the controller, which adjusts the action of the servo drive assembly to form a tension closed-loop control. The servo drive assembly includes a servo motor 15 and a magnetic powder clutch 16, which are connected by a chain drive mechanism. The output shaft of the servo motor 15 is equipped with a drive sprocket 19, and the input shaft of the magnetic powder clutch 16 is equipped with a driven sprocket 17. The drive sprocket 19 and the driven sprocket 17 are connected by a main drive chain 18, thereby transmitting the precise rotational power of the servo motor 15 to the magnetic powder clutch 16. To enhance the smoothness and reliability of the transmission, the sprocket mechanism is symmetrically arranged on both sides of the movable frame 20, employing dual active drive sprockets, dual driven drive sprockets, and two main drive chains to form a symmetrical double-chain transmission mechanism. The output end of the magnetic powder clutch 16 is connected to the rotating shaft of the clamping assembly via a coupling 23. The clamping assembly includes two opposing safety chucks 24 and an air expansion shaft 28 installed between the two safety chucks 24. The coupling 23 connects the output end of the magnetic powder clutch 16 to the rotating shaft of one of the safety chucks 24. The fabric roll is fitted onto the air expansion shaft 28, and the secure clamping and positioning of the fabric roll is achieved through the cooperation of the safety chucks 24 and the air expansion shaft 28. The output power of the magnetic powder clutch 16 is transmitted to one of the safety chucks 24 via the coupling 23, driving the air expansion shaft 28 to rotate. The safety chucks 24 have overload protection, while the air expansion shaft 28 can achieve rapid locking and unlocking of the fabric roll by inflation and deflation, adapting to different core specifications.

[0024] The correction mechanism includes a servo correction cylinder 3, a linear slide rail 22 fixed on the pedal platform 1, the direction of the linear slide rail 22 being perpendicular to the fabric running direction, and a slider 21 at the bottom of the movable frame 20. The slider 21 slides and engages with the linear slide rail 22 to form a guide structure for the movement of the movable frame 20. The cylinder body of the servo correction cylinder 3 is fixed on the pedal platform 1, and its lead screw end is connected to the movable frame 20. Through the extension and retraction of the lead screw of the servo correction cylinder 3, the movable frame 20 can be driven to reciprocate along the linear slide rail 22, thereby driving the clamping components and the fabric roll to move synchronously, realizing automatic centering during the fabric unwinding process and preventing the fabric from deviating.

[0025] The micro-tension control mechanism includes a tension control frame 5 and a tension balancing module, a tension cylinder 7, and a tension angle sensor 25 mounted on the tension control frame 5. The tension control frame 5 has symmetrically arranged bearing seats on both sides, and balancing module shafts 27 are mounted on them. Each balancing module shaft 27 has a lower balancing sprocket 6 and an upper balancing sprocket 12 mounted at both ends, forming multiple pairs of symmetrical sprocket groups. Taking the tension balancing module on one side as an example, its specific structure is illustrated. The tension balancing module includes a counterweight 8 and a tension guide roller 9. The ends of the counterweight 8 and the tension guide roller 9 are connected by a balancing chain 6-1 to form a closed-loop structure. The tension control frame 5 has a lower balancing sprocket 6 and an upper balancing sprocket 12. The balancing chain 6-1 meshes with the lower balancing sprocket 6 and the upper balancing sprocket 12, allowing the counterweight 8 and the tension guide roller 9 to move in opposite directions with the chain's transmission. The piston rod 10 of the tension cylinder 7 is connected to the tension guide roller 9 of the tension balancing module via the cylinder balance chain 11 to apply a balancing force to the tension balancing module and adjust the force state of the tension balancing module. The rotating shaft of the tension angle sensor 25 is connected to the balancing module rotating shaft 27 of the tension balancing module via a transmission mechanism. In this embodiment, the transmission mechanism is a chain drive structure, that is, an angle sensor sprocket 14 is installed on the rotating shaft of the tension angle sensor 25. The angle sensor sprocket 14 is connected to the angle signal sprocket 26 installed at one end of the balancing module rotating shaft 27 via a signal transmission chain 13, thereby transmitting the change in the rotation angle of the tension balancing module to the tension angle sensor 25 to realize the detection of tension changes. It is worth mentioning that the chain drive mechanism on each frame in this embodiment adopts a double-sided symmetrical arrangement, which not only makes the power transmission and motion transmission more stable and reliable, but also provides symmetrical support for rotating components such as tension guide roller 9 and air expansion shaft 28, effectively preventing eccentric loading and vibration caused by unilateral force, thereby ensuring the long-term operating accuracy and stability of the entire fabric feeding machine under micro-tension control.

[0026] The controller adopts a PLC controller, whose signal input terminal is electrically connected to the signal output terminal of the tension angle sensor 25 to receive the tension signal detected by the tension angle sensor 25; the output terminal of the controller is electrically connected to the control terminals of the servo motor 15 and the servo correction cylinder 3 respectively, and can output speed adjustment commands to the servo motor 15 according to the received tension signal, and simultaneously output action commands to the servo correction cylinder 3 to realize coordinated automated control of tension control and correction action.

[0027] like Figure 4As shown, when this micro-tension automatic unwinding machine is working, the second fabric roll A2, which requires a micro-tension of ≤1N / m, is first mounted on the air shaft 28. The fabric roll is securely fixed by the air-locking engagement of the safety chuck 24 and the air shaft 28. The second fabric A2, drawn from the fabric roll, must pass around the tension guide roller 9 in the micro-tension control mechanism. At the same time, the first fabric roll A1 is unwound through an independent unwinding device. This fabric is guided from the bottom around the first guide roller 2 and the second guide roller 4 at different heights on the pedal platform 1 and enters the subsequent laminating machine 29. The third fabric A3 enters the laminating machine 29 from the top through another independent unwinding device. Once all fabric paths are ready, the servo motor 15 is started. The servo motor 15 drives the magnetic powder clutch 16 via the main drive sprocket mechanism. The output of the magnetic powder clutch 16 drives the safety chuck 24 and the air shaft 28 to rotate via the coupling 23, thereby rotating the second fabric roll A2 to achieve smooth automatic unwinding. After unwinding, the second fabric A2 passes through the tension guide roller 9 of the micro-tension control mechanism and enters the subsequent laminating process. Inside the laminating machine 29, the first fabric A1 is turned by the steering rollers inside the laminating machine 29, and then, together with the second fabric A2, passes around multiple guide rollers, with its upper surface initially adhering to the lower surface of the second fabric A2. The third fabric A3 is introduced from above, with its lower surface initially adhering to the upper surface of the second fabric A2. These three fabrics together form a laminate, which is then laminated into a single unit by multiple sets of heating and pressure rollers inside the laminating machine under set temperature, pressure, and speed. Throughout the unwinding and lamination process, the micro-tension control mechanism continuously performs closed-loop adjustment: any minute tension change on the second fabric A2 is transmitted in real time to the tension detection guide roller 9 in contact with it, causing the guide roller to shift. This shift is converted into the rotation of the balance module shaft 27 via the balance chain 6-1. When the actual tension deviates from the preset target value, it breaks the mechanical balance established by the counterweight module 8 and the tension cylinder 7, causing the tension detection guide roller 9 to produce a small angular displacement proportional to the measured tension. This angular displacement is precisely captured and transmitted by the angle detection sprocket mechanism. The rotation of the balance module shaft 27 drives the angle signal sprocket 26 installed at one end of it to rotate, which in turn drives the angle sensor sprocket 14 installed on the shaft of the tension angle sensor 25 to rotate synchronously via the signal transmission chain 13. The tension angle sensor 25 transmits the detected rotation angle signal to the PLC controller in real time. This angle signal directly corresponds to the tension change of the fabric.

[0028] The PLC controller compares and calculates the real-time tension signal with the internally set target tension value ≤1N / m. If the detected tension is greater than the preset value, the controller outputs a command to the servo motor 15 to increase its speed, thereby increasing the unwinding speed of the second fabric roll A2 and reducing the fabric tension. If the detected tension is less than the preset value, the controller outputs a command to the servo motor 15 to decrease its speed, thereby decreasing the unwinding speed and increasing the fabric tension. Simultaneously, the pressure of the tension cylinder 7 can be adjusted according to process requirements to optimize the baseline state of the tension balance module. Through this continuous, high-response closed-loop feedback adjustment process, the force on the tension guide roller 9 is dynamically maintained within the set range, thus stably maintaining the tension during the unwinding process at an extremely low level of ≤1N / m. This meets the unwinding requirements of special fabrics such as directional stretch knitted fabrics and avoids fabric stretching deformation or surface texture damage caused by improper tension.

[0029] In addition, if the fabric deviates during the unwinding process, the PLC controller can output an action command to the servo correction cylinder 3 according to the preset centering standard. The extension and retraction of the screw of the servo correction cylinder 3 drives the movable frame 20 to reciprocate along the linear slide rail 22. Since the clamping component is fixedly connected to the movable frame 20, the fabric roll moves synchronously with the movable frame 20, realizing automatic centering of the fabric and avoiding the occurrence of deviance problems.

[0030] The magnetic powder clutch 16 provides important operational redundancy for the system. During normal operation, it is engaged, transmitting power to the servo motor 15. When the servo motor 15 or other drive systems malfunction, the power to the magnetic powder clutch 16 can be quickly cut off, disengaging it. At this point, the clamping assembly can switch to a passive unwinding mode, driven by subsequent equipment, thus ensuring the continuity of the production line and preventing a complete shutdown due to a localized failure.

[0031] This micro-tension automatic fabric feeding machine is specifically designed for automotive interior fabric lamination processes. Targeting highly tension-sensitive fabrics such as directional stretch knitted fabrics, it integrates active servo drive, high-sensitivity tension detection and closed-loop feedback control, and automatic correction and centering technology to achieve fully automated micro-tension fabric feeding, meeting stringent process requirements of tension ≤1N / m. It replaces the traditional manual-assisted passive feeding mode, eliminating unstable feeding speed and tension, effectively avoiding quality problems such as width loss and deformation during the unwinding of special fabrics, improving product qualification rates, and reducing labor and production costs, significantly enhancing the quality and production efficiency of automotive interior fabric lamination processes.

Claims

1. A micro-tension automatic fabric feeding machine, characterized in that: The system includes a pedal platform, a movable frame, a web guiding mechanism, a micro-tension control mechanism, and a controller. The movable frame is placed on the pedal platform, the web guiding mechanism is connected between the movable frame and the pedal platform, and the micro-tension control mechanism is located beside the pedal platform. The movable frame is equipped with a servo drive assembly for driving fabric feeding and a clamping assembly for mounting the fabric roll. The servo drive assembly includes a servo motor and a magnetic powder clutch. The servo motor is drively connected to the magnetic powder clutch, and the output end of the magnetic powder clutch is connected to the rotating shaft of the clamping assembly. The web guiding mechanism includes a servo web guiding electric cylinder. The cylinder body of the servo web guiding electric cylinder is fixed on the pedal platform, and its lead screw end is connected to the movable frame, driving the movable frame on the pedal platform along a horizontal path perpendicular to the fabric's running direction. The device moves in a reciprocating direction. The micro-tension control mechanism includes a tension control frame and a tension balancing module, a tension cylinder, and a tension angle sensor mounted on the tension control frame. The tension balancing module includes a counterweight and a tension guide roller. The ends of the counterweight and the tension guide roller are connected by a chain to form a closed-loop structure. The chain meshes with at least two sprockets fixed on the tension control frame. The piston rod of the tension cylinder is connected to the tension balancing module via a chain to apply a balancing force to the tension balancing module. The rotating shaft of the tension angle sensor is connected to the rotating shaft of the tension balancing module via a transmission mechanism. The signal input terminal of the controller is electrically connected to the signal output terminal of the tension angle sensor, and the output terminal of the controller is electrically connected to the control terminals of the servo motor and the servo correction cylinder, respectively.

2. The micro-tension automatic fabric feeding machine according to claim 1, characterized in that: The piston rod of the tension cylinder is connected to the tension guide roller via a cylinder balance chain.

3. The micro-tension automatic fabric feeding machine according to claim 1, characterized in that: The servo motor and the magnetic powder clutch are connected by a chain drive mechanism.

4. The micro-tension automatic fabric feeding machine according to claim 1, characterized in that: A linear slide rail is fixed on the pedal platform, and a slider is provided at the bottom of the movable frame. The slider slides in cooperation with the linear slide rail.

5. The micro-tension automatic fabric feeding machine according to claim 1, characterized in that: The clamping assembly includes two safety chucks arranged opposite each other and an air shaft installed between the two safety chucks. The output end of the magnetic powder clutch is connected to the rotating shaft of one of the safety chucks via a coupling.

6. The micro-tension automatic fabric feeding machine according to claim 1, characterized in that: The controller is a PLC controller.

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