Roller cloth winding rapid detection and automatic release control system and dyeing machine thereof

Abstract

A rapid detection and automatic release control system for cloth twining on a roller and a dyeing machine thereof relate to the technical field of dyeing machines, overcome the defects that a traditional dyeing machine lifting system is controlled by a frequency converter, and comprise a lifting roller, a servo motor and a servo driver, the servo motor is a non-band-type brake servo motor and is in transmission connection with the lifting roller through a synchronous belt; the servo driver is connected with and controls the speed of the servo motor, and the servo driver further comprises a brake resistor which enables a rotor of the servo motor to generate reverse electromagnetic brake torque and controls the free rotation speed of the rotor of the servo motor. The system can effectively reduce accidents that the fabric is tangled in the roller, reduce fabric wiping marks and improve the fabric quality, and after the system is introduced, a mechanical tangling detection device can be omitted, the machine design can be simplified, the machine cost can be effectively reduced, and the competitiveness is improved.

Description

Technical Field

[0001] This invention relates to the field of dyeing machine technology, specifically to improvements in the drive control of the lifting roller in a dyeing machine. Background Technology

[0002] Traditional dyeing machines use a three-phase asynchronous motor to drive the lifting roller, with the speed adjusted by a frequency converter. This control method has several drawbacks: when the pressure of the circulating pump nozzles and the speed of the lifting roller are mismatched, the fabric may become entangled. This requires a mechanical entanglement detection device on the lifting roller, but due to insufficient sensitivity, too much fabric becomes entangled, causing smears on the fabric surface. Furthermore, the inability to automatically untangle the fabric makes it difficult for operators to do so. While the torque protection function of the frequency converter can assist in detecting entanglement, different protection torques need to be set in advance according to different fabrics, which is difficult for operators to master. In addition, the slow response of the frequency converter's torque control still cannot fundamentally solve the smear problem. When locating seams after fabric exit, rope-like fabrics may experience excessive over-rushing due to the difficulty of stopping the lifting roller immediately with the frequency converter. After locating the seam, manual pulling is required, increasing the operator's workload. This manual pulling can also cause smears on the fabric surface, resulting in quality problems. Analysis revealed that some of the smudges on the fabric caused by the dyeing machine were mainly due to the frequency converter's inability to adapt to different operating conditions of the dyeing machine in a timely manner. Summary of the Invention

[0003] In summary, the purpose of this invention is to address the many shortcomings of traditional dyeing machine lifting systems that use frequency converter control, and to propose a rapid detection and automatic release control system for roll-wound fabric and its dyeing machine.

[0004] To solve the technical problem proposed in this invention, the technical solution adopted is as follows: A rapid detection and automatic unwinding control system for cloth wrapped around a roller, comprising a lifting roller, characterized in that it further comprises a servo motor and a servo driver; The servo motor is a non-brake servo motor, which is connected to the lifting roller via a synchronous belt; the encoder of the servo motor is connected to the servo driver, which feeds back the real-time detected servo motor speed to the servo driver. The servo driver is connected to control the speed of the servo motor. The servo driver also includes a braking resistor for consuming the regenerative electrical energy output by the inertial drive servo motor of the lifting drum, so that the rotor of the servo motor generates a reverse electromagnetic braking torque and controls the free rotation speed of the servo motor rotor.

[0005] The technical features that further define the present invention include: The servo driver is connected to the PLC for communication, and the PLC program executes rapid detection of the fabric winding on the lifting roller. The aforementioned rapid detection method for roller-wound fabric is as follows: After receiving the start signal for the lifting drum's forward rotation, the PLC outputs 100% torque to start the drum's forward rotation. The servo motor speed is detected via its encoder. If the speed is 0, it indicates the lifting drum is entangled, and the drum's forward rotation stops, the servo motor stops, and a drum entanglement alarm signal is issued. If the servo motor speed is non-zero, it indicates the lifting drum is operating normally. When the speed reaches the target speed, the servo driver activates the speed limiting function. Then, the PLC calculates the average load torque of the lifting drum based on the actual torque within a preset time during which the servo motor has been operating normally, and updates the servo motor's output torque accordingly to ensure consistency with the actual torque. If the servo motor speed abruptly drops to 0 from normal operation within a preset time, or if the actual torque reaches more than 1.9 times the average load torque for a preset duration, it is determined that the lifting drum is entangled, and the servo motor is stopped.

[0006] The PLC program executes an automatic release control method: After the PLC determines that the lifting roller is tangled, it waits for the nozzle to drag the lifting roller to rotate freely within a preset time. If the encoder feedback speed of the servo motor remains at 0, it is determined that the untangling is invalid, and the PLC program will issue a roller tangling alarm. If the encoder feedback speed of the servo motor is not 0, and the number of free rotations of the lifting roller reaches the preset value, it is determined that the untangling is successful, and the forward rotation control of the lifting roller is restored. This cycle of control repeats.

[0007] The PLC considers two successful untangling attempts within one minute as abnormal, stops the lifting drum from rotating forward again, and issues a drum tangling alarm.

[0008] A dyeing machine includes a cylinder and a circulating pump. The cylinder is equipped with a rapid detection and automatic release control system for cloth wrapping on the roller. The inlet of the circulating pump is connected below the liquid level of the cylinder, and the outlet of the circulating pump is connected to a nozzle. The spray direction of the nozzle corresponds to the cloth feeding path of the lifting roller.

[0009] The beneficial effects of this invention are as follows: The closed-loop control system of the lifting roller driven by a non-brake servo motor achieves high-precision position, speed, and torque control, eliminating the need for mechanical entanglement detection devices and solving the rubbing problem caused by frequency converter control of the lifting roller. Fabric entanglement on the lifting roller can be quickly detected and automatically released. Through servo motor speed control combined with constant torque control and rapid positioning control, the dyeing quality of the dyeing machine can be greatly improved, overcoming many shortcomings of traditional frequency converter control in dyeing machine lifting systems and promoting the technological upgrade of dyeing and finishing equipment. Simultaneously, different start-stop strategies can be adopted according to different start-stop requirements, effectively reducing the occurrence of fabric entanglement roller accidents, reducing fabric rubbing, and improving fabric quality. Introducing this system also eliminates the need for mechanical entanglement detection devices, simplifying machine design, effectively reducing machine costs, and enhancing competitiveness. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of the electrical control of the entire dyeing machine lifting system described in this invention; Figure 2 This is a schematic diagram of a single lifting control system according to the present invention; Figure 3 This is a cross-sectional view of a single lifting system of the dyeing machine described in this invention; Figure 4 This is a diagram of the reciprocating system of the dyeing machine for rope-shaped fabrics according to the present invention; Among them, 1 is the controller, 2 is the PLC, 3 is the first lifting system, 4 is the second lifting system, 5 is the servo driver, 6 is the brake resistor, 7 is the servo motor, 8 is the encoder, 9 is the synchronous belt, 10 is the lifting roller, 11 is the cylinder, 12 is the rope-like fabric, 13 is the circulating pump, 14 is the nozzle, and 15 is the dye liquor. Detailed Implementation

[0011] The technical solution of the present invention will be described below with reference to the accompanying drawings and preferred embodiments, in a non-limiting manner.

[0012] like Figures 1 to 3 As shown, the present invention discloses a rapid detection and automatic release control system for roll-wound fabric, which includes a lifting roller 10, a servo motor 7, a servo driver 5, and a PLC 2.

[0013] The servo motor 7 is a non-brake servo motor, and it is connected to the lifting roller 10 via a synchronous belt 9. The synchronous belt 9 ensures that the lifting roller 10 and the servo motor 7 operate synchronously and will not slip when stopped. The servo motor 7 is a non-brake servo motor to ensure that its rotor has low resistance, allowing for smooth dragging during nozzle unwinding. A brake servo motor cannot meet the requirement of free rotation of the lifting roller 10 under external force in this invention. The encoder 8 of the servo motor 7 is connected to the servo driver 5, feeding back the real-time detected speed of the servo motor 7 to the servo driver 5. This allows the PLC 2 to detect the speed of the servo motor 7 in real time, enabling speed tracking and accurate speed control of the servo motor 7.

[0014] In order to achieve speed control of the servo motor 7 under inertia or external force dragging, the servo driver 5 also includes a braking resistor 6. When the servo motor 7 is freely rotating under inertia or external force dragging, the servo motor 7 is equivalent to a generator and will output regenerative electrical energy. The braking resistor 6 is mainly used to consume the regenerative electrical energy output by the rotation of the servo motor 7, so that the rotor of the servo motor 7 generates a reverse electromagnetic braking torque, controls the free rotation speed of the rotor of the servo motor 7, and can realize the quick stopping of the lifting roller 10 to prevent the fabric from overshooting.

[0015] like Figure 1 As shown in the diagram, in practical applications, the servo drive 5 is connected to the PLC for communication. The PLC program executes the rapid detection and automatic release control of the fabric winding on the lifting roller. Typically, multiple lifting systems share one PLC. The diagram illustrates an example of one PLC controlling the first lifting system 3 and the second lifting system 4. The number of lifting systems is determined by the number of tubes in the dyeing machine. Each lifting system is independently controlled by the PLC and does not interfere with each other. The PLC is connected to the controller 1, which sets the speed of the lifting roller and the circulating pump, acting as a host computer. The PLC controls the operating status of each servo drive 5, monitors and automatically releases the fabric winding during operation, and controls rapid stopping when searching for the fabric seam. The servo drive 5 drives the servo motor to start and stop, and the braking resistor 6 is used for rapid braking when searching for the fabric seam to prevent overshoot. The servo motor is equipped with an encoder 8 for speed feedback to ensure precise speed control.

[0016] The aforementioned rapid detection method for roller-wound fabric is as follows: After receiving the forward rotation start signal of the lifting drum 10 from the controller 1, the PLC outputs 100% torque to start the drum's forward rotation. The encoder 8 of the servo motor 7 detects the speed of the servo motor. If the speed is 0, it means that the lifting drum 10 is tangled, so the forward rotation of the lifting drum is stopped, the servo motor 7 is switched to a stopped state, and a drum tangling alarm signal is given. If the servo motor speed is not 0, it means that the lifting drum is running normally. When the speed reaches the target speed, the servo driver will start the speed limiting function. For example, after one minute, the encoder 8 detects that the speed of the servo motor 7 has reached the preset value, and the servo driver 5 controls the servo motor 7 to maintain the speed of the preset value.

[0017] Typically, when the lifting roller 10 becomes entangled, the actual torque of the servo motor 7 will increase sharply, instantly becoming much greater than the output torque. The PLC of this invention calculates the average load torque of the lifting roller based on the actual torque within a preset time during which the servo motor 7 has been running normally. For example, after the servo driver 5 controls the servo motor 7 to run at a preset speed for 3 minutes, the average load torque of the lifting roller is calculated based on the actual torque within these 3 minutes, and the output torque of the servo motor is updated according to the average load torque to keep the output torque consistent with the actual torque, so that the servo motor 7 runs at a speed close to the set speed and maintains a constant torque. When the speed of the servo motor 7 suddenly drops to 0 from the normal operating state within a preset time, or when the actual torque reaches more than 1.9 times the average load torque for a duration of a preset value, it is determined that the lifting roller is entangled, and the servo motor is controlled to stop running or to decelerate rapidly to prevent the lifting roller from rubbing against the cloth.

[0018] The PLC program executes an automatic release control method: Because this invention uses a non-brake servo motor to drive the lifting roller 10, and the rotor of the non-brake servo motor has low resistance, when the non-brake servo motor is stopped, the nozzle can drag the lifting roller 10 to rotate freely in the reverse direction when spraying the fabric entering the lifting roller 10. When the PLC of this invention determines that the lifting roller 10 is tangled, it waits for the nozzle to drag the lifting roller to rotate freely within a preset time. If the encoder feedback speed of the servo motor remains at 0, it is determined that untangling is ineffective, and the PLC program will issue a roller tangling alarm. For example, if the encoder feedback speed remains at 0 within 30 seconds of the servo motor being stopped, it indicates that the nozzle is not dragging the lifting roller 10 to rotate in the reverse direction, the lifting roller 10 is tightly tangled, and cannot be automatically untangled. An alarm is issued to remind manual intervention. If the encoder feedback speed of the servo motor is not 0, and the number of free rotations of the lifting roller reaches a preset value, it is determined that untangling is successful, and the forward rotation control of the lifting roller 10 is restored, and this cycle repeats.

[0019] To prevent repeated successful untangling within a short period of time, thus avoiding a vicious cycle of "successful untangling," especially when the circulation pump speed is set too low and the lifting drum speed is set too high, this vicious cycle is most likely to occur when the two are mismatched. The PLC program of this invention will consider two successful untanglings within one minute as abnormal, and will also stop the forward rotation of the lifting drum and issue a drum tangling alarm.

[0020] In addition, if a need for rapid stopping occurs during the forward rotation of the lifting roller 10, such as when the fabric seam is found and the forward rotation of the lifting roller needs to be stopped immediately to prevent the fabric seam from being over-rushed and to reduce the rubbing marks on the fabric surface when the fabric is pulled back, the PLC program will issue a rapid stop command to the servo drive 5. Since the servo drive 5 is equipped with a brake resistor 6, the servo drive 5 can achieve rapid stopping. After a rapid stop of 3 seconds, it will return to the stopped state, which is convenient for the operator to enter and exit the fabric.

[0021] Reference Figure 3 and Figure 4 As shown, the present invention discloses a dyeing machine, which includes a cylinder 11 and a circulating pump 13. The cylinder 11 is equipped with the aforementioned roller wrapping rapid detection and automatic release control system. The cylinder 11 contains dye liquor 15. The inlet of the circulating pump 13 is connected to a position below the level of the dye liquor 15 in the cylinder 11. The outlet of the circulating pump 13 is connected to a nozzle 14. The spray direction of the nozzle 14 corresponds to the feeding path of the fabric 12 of the lifting roller 10.

Claims

1. A rapid detection and automatic unwinding control system for roll-wound fabric, comprising a lifting roll, characterized in that: It also includes servo motors and servo drives; The servo motor is a non-brake servo motor, which is connected to the lifting roller via a synchronous belt; the encoder of the servo motor is connected to the servo driver, which feeds back the real-time detected servo motor speed to the servo driver. The servo driver is connected to control the speed of the servo motor. The servo driver also includes a braking resistor for consuming the regenerative electrical energy output by the inertial drive servo motor of the lifting drum, so that the rotor of the servo motor generates a reverse electromagnetic braking torque and controls the free rotation speed of the servo motor rotor.

2. The rapid detection and automatic release control system for roll-wound fabric according to claim 1, characterized in that: The servo driver is connected to the PLC for communication, and the PLC program executes rapid detection of the fabric winding on the lifting roller. The aforementioned rapid detection method for roller-wound fabric is as follows: After receiving the start signal for the lifting drum's forward rotation, the PLC outputs 100% torque to start the drum's forward rotation. The servo motor speed is detected via its encoder. If the speed is 0, it indicates the lifting drum is entangled, and the drum's forward rotation stops, the servo motor stops, and a drum entanglement alarm signal is issued. If the servo motor speed is non-zero, it indicates the lifting drum is operating normally. When the speed reaches the target speed, the servo driver activates the speed limiting function. Then, the PLC calculates the average load torque of the lifting drum based on the actual torque within a preset time during which the servo motor has been operating normally, and updates the servo motor's output torque accordingly to ensure consistency with the actual torque. If the servo motor speed abruptly drops to 0 from normal operation within a preset time, or if the actual torque reaches more than 1.9 times the average load torque for a preset duration, it is determined that the lifting drum is entangled, and the servo motor is stopped.

3. The rapid detection and automatic release control system for roll-wound fabric according to claim 2, characterized in that: The PLC program executes an automatic release control method: After the PLC determines that the lifting roller is tangled, it waits for the nozzle to drag the lifting roller to rotate freely within a preset time. If the encoder feedback speed of the servo motor remains at 0, it is determined that the untangling is invalid, and the PLC program will issue a roller tangling alarm. If the encoder feedback speed of the servo motor is not 0, and the number of free rotations of the lifting roller reaches the preset value, it is determined that the untangling is successful, and the forward rotation control of the lifting roller is restored. This cycle of control repeats.

4. The rapid detection and automatic release control system for roll-wound fabric according to claim 3, characterized in that: The PLC considers two successful untangling attempts within one minute as abnormal, stops the lifting drum from rotating forward again, and issues a drum tangling alarm.

5. A dyeing machine, comprising a cylinder and a circulation pump, characterized in that: The cylinder is equipped with a rapid detection and automatic release control system for roll wrapping as described in any one of claims 1-4. The inlet of the circulation pump is connected below the liquid level of the cylinder, and the outlet of the circulation pump is connected to a nozzle. The spray direction of the nozzle corresponds to the fabric feeding path of the lifting roller.

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