Method and device for controlling circular knitting machine

Abstract

The invention discloses a control method and device for a circular knitting machine, and relates to the technical field of equipment control, and the method comprises the steps: reading a current working mode of the circular knitting machine; when the current working mode is read as a pure timing working mode, triggering a relay to output air pressure based on a timing period; when the manual working mode is read, air pressure output is carried out based on the instruction information; when the self-adaptive working mode is read, comparing the air pressure monitoring data with a first air pressure preset threshold T1 and a second air pressure preset threshold T2; if the air pressure monitoring data is smaller than T1, a closing instruction is sent out, if the air pressure monitoring data is larger than or equal to T1 and smaller than T2, a plurality of electromagnetic valves are opened based on a stable timing mode, and if the air pressure monitoring data is larger than or equal to T2, all the electromagnetic valves are opened; and when the accumulated operation time is larger than or equal to T1, determining an oil injection and air blowing strategy based on the accumulated operation time. According to the invention, the influence of high-load operation of equipment on overall air supply balance can be avoided, and energy-saving and stable operation of the equipment are realized.

Description

Technical Field

[0001] This invention relates to the field of equipment control technology, and in particular to a control method and device for a circular knitting machine. Background Technology

[0002] As a crucial component of the textile industry, the knitting industry widely utilizes circular knitting machines for fabric production. During the daily operation and maintenance of these machines, the compressed air system provides a stable air supply for cleaning and lubrication. However, in current circular knitting machine cleaning processes, to meet the simultaneous air demands of multiple machines, air compressors often operate continuously at full or overload. Even during low-load or shutdown periods, effective output adjustment is difficult, leading to significant energy waste. With the increasing number of circular knitting machines operating in parallel, the total air consumption of the pipeline network surges, causing a rapid drop in system pressure. When the air pressure falls below the required process threshold, cleaning and lubrication operations cannot be effectively performed, easily causing yarn entanglement, mechanical interference, and other problems, affecting product quality and equipment lifespan. Furthermore, the compressed air system of circular knitting machines has complex piping and numerous joints, making it prone to minor leaks during long-term operation. These leaks are often difficult to detect in real time using traditional manual inspections, resulting in the system continuously operating in a low-pressure, high-power state. This not only exacerbates energy waste but may also cause sluggish or malfunctioning pneumatic components due to insufficient air supply, accelerating equipment wear and even leading to shutdowns.

[0003] To address these issues, most knitting companies employ a management model that combines a normally open air compressor with manually controlled air valves. However, this model lacks real-time sensing and intelligent control capabilities for air pressure. While some solutions introduce timers or simple relay controls, they cannot dynamically adjust the air consumption strategy based on actual air pressure, nor do they offer flexible multi-mode switching, making it difficult to balance energy efficiency, reliability, and ease of operation. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art. This invention provides a control method and device for a circular knitting machine, which can avoid the equipment from operating under high load and affecting the overall air supply balance, thereby achieving energy saving and stable operation of the equipment.

[0005] To solve the above-mentioned technical problems, the present invention provides a control method for a circular knitting machine, the method comprising: After the circular knitting machine is started, the main control chip of the circular knitting machine reads the current working mode from the storage unit. The current working mode includes adaptive working mode, pure timed working mode and manual working mode. When the current working mode is read as pure timed working mode, the timing period is determined, and the relay is triggered to output air pressure based on the timing period; When the current working mode is read as manual working mode, the relay is controlled to output air pressure based on the user input command information; When the current working mode is read as adaptive working mode, air pressure monitoring data is continuously collected and compared with the first preset air pressure threshold and the second preset air pressure threshold. If the air pressure monitoring data is less than the first air pressure preset threshold, a shutdown command is issued to the circular knitting machine. If the air pressure monitoring data is greater than or equal to the first air pressure preset threshold but less than the second air pressure preset threshold, several corresponding solenoid valves are opened based on a stable timing method. If the air pressure monitoring data is greater than or equal to the second air pressure preset threshold, all solenoid valves are opened. When the air pressure monitoring data is greater than or equal to the first preset air pressure threshold, the cumulative running time of the circular knitting machine is monitored, and the oil spraying and air blowing strategy is determined based on the cumulative running time.

[0006] Optionally, the step of triggering the relay to output air pressure based on the timed period includes: Based on the timed periodic trigger relay, the relay controls the AC power to drive the solenoid valve to close, and based on the closed state of the solenoid valve, controls the air pipe to output air pressure.

[0007] Optionally, the step of opening the corresponding plurality of solenoid valves based on a stable timing method includes: Acquire prior experience data, and use deep learning algorithms to analyze the on / off time based on the prior experience data to obtain the first target on / off time; The relay's activation information is determined based on the first target on / off time, and the relay is controlled to open several corresponding solenoid valves based on the activation information and the first target on / off time.

[0008] Optionally, determining the fuel injection and blowing strategy based on the cumulative runtime includes: The cumulative runtime is compared with a first preset runtime threshold and a second preset runtime threshold; If the cumulative running time is less than the first time preset threshold, then the intermittent time information is determined, and the fuel injection and air blowing operation is performed based on the intermittent time information; If the cumulative runtime is greater than or equal to the first preset runtime threshold and less than the second preset runtime threshold, then the increase data of the blowing frequency is analyzed, and the fuel injection and blowing operation is performed based on the increase data. If the cumulative runtime is greater than or equal to the second time preset threshold, then lubrication error compensation is determined, and oil injection and air blowing operations are performed based on the lubrication error compensation.

[0009] Optionally, the analysis of the increase in blowing frequency data includes: Determine the target constraints, and based on the target constraints, use a preset clean and stable value combined with a proportional-integral model to analyze the relay switching time to obtain the second target switching time; The increased data for determining the blowing frequency is based on the second target on / off time.

[0010] Optionally, determining the lubrication error compensation includes: Acquire monitoring signal data from the circular knitting machine, and extract statistical features based on the monitoring signal data to obtain statistical feature information; Based on the statistical feature information, a cleaning contribution analysis is performed to obtain cleaning contribution information; Based on the statistical feature information, a pure lubrication contribution analysis is performed to obtain pure lubrication contribution information; A mapping model is constructed, and lubrication error compensation is determined based on the cleaning contribution information and pure lubrication contribution information using the mapping model.

[0011] Optionally, after performing the oil injection and air blowing operation based on the lubrication error compensation, the following steps are included: Acquire equipment operating data during the fuel injection and air blowing operation, and perform abnormal shutdown analysis based on the equipment operating data to obtain abnormal shutdown data; Based on the equipment operation data, air pressure fluctuation analysis is performed to obtain air pressure fluctuation data; The first and second preset time thresholds are adjusted based on the air pressure fluctuation data and abnormal shutdown data.

[0012] Optionally, the step of performing abnormal shutdown analysis based on the equipment operating data to obtain abnormal shutdown data includes: Mechanical wear analysis is performed based on the equipment operation data to obtain mechanical wear data; Based on the equipment operation data, fiber debris adhesion analysis is performed to obtain fiber debris adhesion data; Anomaly shutdown analysis is performed based on the mechanical wear data and fiber debris adhesion data to obtain abnormal shutdown data.

[0013] Optionally, the step of performing air pressure fluctuation analysis based on the equipment operating data to obtain air pressure fluctuation data includes: The equipment operation data is subjected to low-pass filtering to obtain low-pass filtered equipment operation data. The air pressure fluctuation amplitude is obtained by analyzing the equipment operation data after low-pass filtering. Based on the pressure fluctuation amplitude, a time point analysis of the pressure fluctuation is performed to obtain the time point information of the pressure fluctuation. The air pressure fluctuation data is determined based on the air pressure fluctuation amplitude and the time point information of the air pressure fluctuation.

[0014] In addition, the present invention also provides a control device for a circular knitting machine, the device comprising: a power supply module, a voltage regulator module, a step-down module, an inverting control module, a crystal oscillator module, a serial port module, a switch module, a reset module, a main control chip, an air pressure detection module, a high / low level switching module, an optocoupler module, a relay module, a digital tube module, an LED module, and a power indicator module. The main control chip is connected to the LED module, digital tube module, air pressure detection module, high / low level switching module, serial port module, switch module, reset module, inverting control module, and crystal oscillator module respectively. The power supply module is connected to the voltage regulator module and the inverting control module respectively. The power indicator module is connected to the voltage regulator module, step-down module, high / low level switching module, optocoupler module, and LED module respectively. The optocoupler module is connected to the relay module. The device is configured to execute the above-described control method for a circular knitting machine.

[0015] In this embodiment of the invention, after the circular knitting machine is started, the main control chip of the circular knitting machine reads the current working mode from the storage unit. When the current working mode is read as a pure timed working mode, the timing period is determined, and the relay is triggered to output air pressure based on the timing period. When the current working mode is read as a manual working mode, the relay is controlled to output air pressure based on the user-input command information. When the current working mode is read as an adaptive working mode, air pressure monitoring data is continuously collected, and the air pressure monitoring data is compared with a first preset air pressure threshold and a second preset air pressure threshold. If the air pressure monitoring data is less than the first preset air pressure threshold, a shutdown command is issued to the circular knitting machine. If the air pressure monitoring data is greater than or equal to the first preset air pressure threshold and less than the second preset air pressure threshold, several corresponding solenoid valves are opened based on a stable timing method. If the air pressure monitoring data is greater than or equal to the second preset air pressure threshold, all solenoid valves are opened. This allows for dynamic adjustment of the air consumption strategy according to the actual air pressure, effectively solving the problem of insufficient air pressure causing cleaning failure during the operation of the circular knitting machine. At the same time, through multiple mode settings, the adaptability to complex industrial scenarios can be improved. When the air pressure monitoring data is greater than or equal to the first preset air pressure threshold and less than the second preset air pressure threshold, the cumulative running time of the circular knitting machine is monitored, and the oil injection and air blowing strategy is determined based on the cumulative running time. By monitoring the air pressure and running time distribution of the circular knitting machine in real time, air pressure resources are dynamically allocated to avoid the equipment from operating under high load and affecting the overall air supply balance, thereby achieving energy saving and stable operation of the system. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a flowchart illustrating the control method of a circular knitting machine according to an embodiment of the present invention; Figure 2 This is a flowchart illustrating the control method of a circular knitting machine according to another embodiment of the present invention; Figure 3 This is a schematic diagram of the structural composition of the control device of the circular knitting machine in an embodiment of the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] Example 1 Please see Figure 1 , Figure 1 This is a flowchart illustrating the control method of a circular knitting machine according to an embodiment of the present invention. The method includes: S11: After the circular knitting machine is started, the main control chip of the circular knitting machine reads the current working mode from the storage unit. The current working mode includes adaptive working mode, pure timed working mode and manual working mode. In the specific implementation of this invention, after the circular knitting machine is started, the main control chip of the circular knitting machine reads the current working mode from the storage unit. The current working mode includes adaptive working mode, pure timed working mode and manual working mode. By setting different working modes, the circular knitting machine can be more adaptable to complex industrial scenarios.

[0020] S12: When the current working mode is read as pure timed working mode, determine the timing period and trigger the relay to output air pressure based on the timing period; In the specific implementation of this invention, when the current working mode is read as a pure timed working mode, the timed period is determined, and a relay is triggered based on the timed period. The relay controls the AC power to drive the solenoid valve to close, and the air pipe is controlled to output air pressure based on the closed state of the solenoid valve, thus realizing timed air pressure output.

[0021] S13: When the current working mode is read as manual working mode, control the relay to output air pressure based on the user input command information; In the specific implementation of this invention, when the current working mode is read as manual working mode, the relay is controlled to output air pressure based on the instruction information input by the user. Emergency intervention can be achieved through manual working mode.

[0022] S14: When the current working mode is read as adaptive working mode, continuously collect air pressure monitoring data and compare the air pressure monitoring data with the first preset air pressure threshold and the second preset air pressure threshold. In the specific implementation of this invention, when the current working mode is read as adaptive working mode, air pressure monitoring data is continuously collected, and the air pressure monitoring data is compared with the first preset air pressure threshold and the second preset air pressure threshold. Based on the comparison result between the air pressure value and the preset threshold, the device start-up and shutdown strategy can be dynamically decided.

[0023] S15: If the air pressure monitoring data is less than the first air pressure preset threshold, a shutdown command is issued to the circular knitting machine. If the air pressure monitoring data is greater than or equal to the first air pressure preset threshold and less than the second air pressure preset threshold, several corresponding solenoid valves are opened based on a stable timing method. If the air pressure monitoring data is greater than or equal to the second air pressure preset threshold, all solenoid valves are opened. In the specific implementation of this invention, if the air pressure monitoring data is less than the first air pressure preset threshold, a shutdown command is issued to the circular knitting machine. If the air pressure monitoring data is greater than or equal to the first air pressure preset threshold but less than the second air pressure preset threshold, several corresponding solenoid valves are opened based on a stable timing method. If the air pressure monitoring data is greater than or equal to the second air pressure preset threshold, all solenoid valves are opened, realizing a three-level air pressure response mechanism. This mechanism effectively solves the problem of insufficient air pressure causing cleaning failure when the circular knitting machine is running in parallel.

[0024] S16: When the air pressure monitoring data is greater than or equal to the first air pressure preset threshold, monitor the cumulative running time of the circular knitting machine, and determine the oil spraying and air blowing strategy based on the cumulative running time.

[0025] In the specific implementation of this invention, when the air pressure monitoring data is greater than or equal to a first preset air pressure threshold and less than a second preset air pressure threshold, the cumulative running time of the circular knitting machine is monitored, and the cumulative running time is compared with the first and second preset time thresholds. If the cumulative running time is less than the first preset time threshold, the intermittent time information is determined, and oil spraying and air blowing operations are performed based on the intermittent time information. If the cumulative running time is greater than or equal to the first preset time threshold and less than the second preset time threshold, the increase data of the air blowing frequency is analyzed, and oil spraying and air blowing operations are performed based on the increase data. If the cumulative running time is greater than or equal to the second preset time threshold, lubrication error compensation is determined, and oil spraying and air blowing operations are performed based on the lubrication error compensation. This achieves dual-factor control of air pressure parameters and circular knitting machine running time, significantly improving energy efficiency and equipment reliability, and is particularly suitable for circular knitting machines that operate continuously for long periods of time.

[0026] In this embodiment of the invention, after the circular knitting machine is started, the main control chip of the circular knitting machine reads the current working mode from the storage unit. When the current working mode is read as a pure timed working mode, the timing period is determined, and the relay is triggered to output air pressure based on the timing period. When the current working mode is read as a manual working mode, the relay is controlled to output air pressure based on the user-input command information. When the current working mode is read as an adaptive working mode, air pressure monitoring data is continuously collected, and the air pressure monitoring data is compared with a first preset air pressure threshold and a second preset air pressure threshold. If the air pressure monitoring data is less than the first preset air pressure threshold, a shutdown command is issued to the circular knitting machine. If the air pressure monitoring data is greater than or equal to the first preset air pressure threshold and less than the second preset air pressure threshold, several corresponding solenoid valves are opened based on a stable timing method. If the air pressure monitoring data is greater than or equal to the second preset air pressure threshold, all solenoid valves are opened. This allows for dynamic adjustment of the air consumption strategy according to the actual air pressure, effectively solving the problem of insufficient air pressure causing cleaning failure during the operation of the circular knitting machine. At the same time, through multiple mode settings, the adaptability to complex industrial scenarios can be improved. When the air pressure monitoring data is greater than or equal to the first preset air pressure threshold and less than the second preset air pressure threshold, the cumulative running time of the circular knitting machine is monitored, and the oil injection and air blowing strategy is determined based on the cumulative running time. By monitoring the air pressure and running time distribution of the circular knitting machine in real time, air pressure resources are dynamically allocated to avoid the equipment from operating under high load and affecting the overall air supply balance, thereby achieving energy saving and stable operation of the system.

[0027] Example 2 Please see Figure 2 , Figure 2 This is a flowchart illustrating a control method for a circular knitting machine according to another embodiment of the present invention, the method comprising: S201: After the circular knitting machine is started, the main control chip of the circular knitting machine reads the current working mode from the storage unit. The current working mode includes adaptive working mode, pure timed working mode and manual working mode. In the specific implementation of this invention, after the circular knitting machine is started, its energy-saving control device is started simultaneously, and the circular knitting machine enters the initialization state. The main control chip of the circular knitting machine reads the current working mode from the storage unit. The current working mode includes adaptive working mode, pure timed working mode and manual working mode. The user determines the corresponding working mode according to the on-site working conditions. The adaptive working mode is automatic operation and can autonomously seek the optimal energy-saving control. The pure timed working mode can be autonomously selected for control based on human experience. The manual working mode can be used during debugging.

[0028] S202: When the current working mode is read as pure timed working mode, determine the timing period and trigger the relay to output air pressure based on the timing period; In a specific implementation of the present invention, the step of outputting air pressure based on the timed periodic triggering relay includes: based on the timed periodic triggering relay, the relay controls the AC power to drive the solenoid valve to close, and based on the closed state of the solenoid valve, controlling the air pipe to output air pressure.

[0029] Specifically, when the current working mode is read as a pure timed working mode, the user manually determines the timing period on the human-machine interface, such as selecting 10 seconds as the timing period. The main control chip triggers the relay based on the timing period. The relay controls the AC power to drive the solenoid valve to close. This AC power can be 24V AC power. Based on the closed state of the solenoid valve, the air pipe is controlled to output air pressure, and the solenoid valve is driven to close, opening the air pipe to output air pressure and completing the cleaning or lubrication operation. This mode is suitable for scenarios with a fixed production rhythm and no need to respond to air pressure changes in real time.

[0030] S203: When the current working mode is read as manual working mode, control the relay to output air pressure based on the user input command information; In the specific implementation of this invention, when the current working mode is read as manual working mode, the relay is controlled to output air pressure based on the user's input command information. The user inputs command information through the panel button or external switch to control the on / off state of the relay. The switch provides a low potential to the chip. When the chip receives the low potential, it controls the pin connected to the relay to be in a low potential state, and the relay is coupled. Otherwise, it is disconnected. The state of the relay is maintained according to the user's input command, thereby controlling the opening and closing of the solenoid valve to achieve direct control of the air pressure output from the air pipe. This mode is suitable for equipment debugging, emergency maintenance, or special process requirements.

[0031] S204: When the current working mode is read as adaptive working mode, continuously collect air pressure monitoring data and compare the air pressure monitoring data with the first preset air pressure threshold and the second preset air pressure threshold. In the specific implementation of this invention, when the current working mode is read as adaptive working mode, air pressure monitoring data is continuously collected through the air pressure detection module, and the air pressure monitoring data is compared with the first air pressure preset threshold and the second air pressure preset threshold. The first air pressure preset threshold and the second air pressure preset threshold are determined by manual testing. The first air pressure preset threshold indicates whether the air pressure of a single jet can clean the fibers on the equipment, and the second air pressure preset threshold indicates whether the fibers on the corresponding part of the equipment can be cleaned when two or three air pipes are started at the same time. If the air pressure monitoring data is less than the first air pressure preset threshold, then proceed to step S205. If the air pressure monitoring data is greater than or equal to the first air pressure preset threshold and less than the second air pressure preset threshold, then proceed to step S206. If the air pressure monitoring data is greater than or equal to the second air pressure preset threshold, then proceed to step S207.

[0032] S205: If the air pressure monitoring data is less than the first air pressure preset threshold, then issue a shutdown command to the circular knitting machine; In the specific implementation of this invention, if the air pressure monitoring data is less than the first air pressure preset threshold, it indicates that the current circular knitting machine has insufficient air supply capacity or leakage risk. At this time, the main control chip issues a shutdown command to the circular knitting machine to shut it down in reverse, so as to reduce the air consumption, prioritize the protection of key processes or prevent equipment damage.

[0033] S206: If the air pressure monitoring data is greater than or equal to the first preset air pressure threshold and less than the second preset air pressure threshold, then several corresponding solenoid valves will be opened based on a stable timing method. In a specific implementation of the present invention, the step of opening several corresponding solenoid valves based on a stable timing method includes: acquiring prior experience data, and using a deep learning algorithm to analyze the on / off time based on the prior experience data to obtain a first target on / off time; determining the relay's activation information based on the first target on / off time, and controlling the relay to open several corresponding solenoid valves based on the activation information and the first target on / off time.

[0034] Specifically, if the air pressure monitoring data is greater than or equal to the first preset air pressure threshold but less than the second preset air pressure threshold, it indicates that the air pressure is at a moderate level and can still meet basic needs. In this case, intermittent cleaning or lubrication is required to avoid excessive air consumption. First, prior experience data is acquired. Prior experience data refers to datasets accumulated from historical experiments or operations that reflect the relationship between air pressure and on / off time. Based on this prior experience data, a deep learning algorithm is used to analyze the on / off time. The deep learning model is trained using the prior experience data. The deep learning model can employ a recurrent neural network or a convolutional neural network. The input data is air pressure data, and the output is the target on / off time. The training objective is to minimize the control effect error. The air pressure monitoring data is input into the deep learning model to analyze the on / off time and obtain the first target on / off time, such as 10 seconds.

[0035] The relay's engagement information is determined based on the first target on / off time. The engagement information is the intermittent engagement time of the relay. Based on the engagement information and the first target on / off time, the relay is controlled to open several corresponding solenoid valves. That is, the relay is controlled to intermittently open some solenoid valves according to the engagement information and the target on / off time, thereby performing intermittent cleaning or lubrication.

[0036] S207: If the air pressure monitoring data is greater than or equal to the second preset air pressure threshold, then open all solenoid valves; In the specific implementation of this invention, if the air pressure monitoring data is greater than or equal to the second preset air pressure threshold, it indicates that the circular knitting machine has sufficient air supply capacity. At this time, all solenoid valves are allowed to open simultaneously to achieve the coordinated operation of the three air pipes, meet the high-intensity cleaning and lubrication requirements, and ensure the efficient operation of the circular knitting machine.

[0037] S208: When the air pressure monitoring data is greater than or equal to the first air pressure preset threshold, monitor the cumulative running time of the circular knitting machine and compare the cumulative running time with the first time preset threshold and the second time preset threshold; In the specific implementation of this invention, the running time of the circular knitting machine is also an important control indicator. When the machine starts running, it undergoes initial setup and operates at a slow speed, requiring relatively little oil and producing little fiber. As the running time increases, the machine gradually reaches its normal speed. Due to the increased mechanical speed, more oil is needed. After normal operation, the amount of fiber produced also continues to increase. After a certain period, a small amount of fiber cannot be cleaned off. Furthermore, without closed-loop control, the required oil level is unknown during prolonged operation. Therefore, a dual-factor control based on air pressure and time is necessary. When the air pressure monitoring data is greater than or equal to the first preset air pressure threshold, that is, when the current air pressure of the circular knitting machine is greater than or equal to the first preset air pressure threshold and less than the second preset air pressure threshold, or when the current air pressure is greater than or equal to the second preset air pressure threshold, the cumulative running time of the circular knitting machine is monitored, and the cumulative running time is compared with the first preset time threshold and the second preset time threshold. The first preset time threshold can be set to 2 hours, and the second preset time threshold can be set to 12 hours. If the cumulative running time is less than the first preset time threshold, proceed to step S209. If the cumulative running time is greater than or equal to the first preset time threshold and less than the second preset time threshold, proceed to step S210. If the cumulative running time is greater than or equal to the second preset time threshold, proceed to step S211.

[0038] S209: If the cumulative running time is less than the first time preset threshold, then determine the intermittent time information and perform fuel injection and air blowing operation based on the intermittent time information; In the specific implementation of this invention, if the cumulative running time is less than a first preset threshold, the equipment is in a debugging period, with a slower operating speed and less mechanical wear and fiber generation. Intermittent time information is determined; this intermittent time information can be preset by the user, and oil injection and air blowing operations are performed based on this intermittent time information to avoid resource waste.

[0039] S210: If the cumulative runtime is greater than or equal to the first preset runtime threshold and less than the second preset runtime threshold, then analyze the increase data of the blowing frequency and perform oil injection and blowing operation based on the increase data. In the specific implementation of this invention, the analysis of the increase in air blowing frequency includes: determining the target constraint conditions, and based on the target constraint conditions, using a preset clean stability value combined with a proportional-integral model to analyze the on / off time of the relay to obtain a second target on / off time; and determining the increase in air blowing frequency based on the second target on / off time.

[0040] Specifically, if the cumulative runtime is greater than or equal to a first preset threshold but less than a second preset threshold, it indicates that the equipment has entered normal operation, with increased friction and fiber accumulation, requiring an increase in the blowing frequency. First, target constraints are determined, such as minimizing energy consumption and avoiding excessive blowing while ensuring cleaning effectiveness. Based on these target constraints, a proportional-integral (PI) model is used to analyze the relay switching time using a preset cleaning stability value, obtaining the second target switching time. The PI model maps the magnitude and duration of load deviation to an increase in the blowing frequency; simple systems may use compensation linearly related to time or load.

[0041] The increased data of the blowing frequency is determined based on the second target on / off time. The database stores the increased data of the blowing frequency corresponding to different on / off times. The corresponding increased data can be quickly matched through the database. Based on the increased data, the oil injection and blowing operation is performed to enhance the cleaning effect and prevent the deposition of tiny fibers from causing blockage.

[0042] S211: If the cumulative runtime is greater than or equal to the second runtime preset threshold, then lubrication error compensation is determined, and oil injection and air blowing operations are performed based on the lubrication error compensation.

[0043] In a specific implementation of this invention, determining lubrication error compensation includes: acquiring monitoring signal data of a circular knitting machine, and extracting statistical features based on the monitoring signal data to obtain statistical feature information; performing cleaning contribution analysis based on the statistical feature information to obtain cleaning contribution information; performing pure lubrication contribution analysis based on the statistical feature information to obtain pure lubrication contribution information; constructing a mapping model, and determining lubrication error compensation based on the mapping model using the cleaning contribution information and the pure lubrication contribution information.

[0044] Specifically, if the cumulative runtime is greater than or equal to the second preset threshold, it indicates that the fiber accumulation in the equipment has reached a critical value, and conventional cleaning is insufficient to completely remove it. The system forcibly triggers a full-power cleaning program, that is, all solenoid valves open simultaneously for high-intensity blowing to remove stubborn dirt and complete lubrication error compensation. Monitoring signal data from the circular knitting machine is acquired. Before full-power cleaning, the system continuously records the spindle drive current / power, vibration or air pressure signals of key parts. Based on the monitoring signal data, statistical feature extraction is performed to obtain statistical feature information, such as mean and standard deviation. Statistical feature information is obtained by calculating the mean or standard deviation of the monitoring signal data.

[0045] Cleaning contribution analysis is performed based on the statistical feature information to obtain cleaning contribution information. Pure lubrication contribution analysis is performed based on the statistical feature information to obtain pure lubrication contribution information. The cleaning contribution and pure lubrication contribution can be analyzed by the corresponding deep neural network.

[0046] A mapping model is constructed, and an empirical model or function for lubrication compensation, cleaning contribution, and pure lubrication contribution is established through machine learning. Based on the mapping model, lubrication error compensation is determined using the cleaning contribution information and pure lubrication contribution information. Based on the lubrication error compensation, oil injection and air blowing operations are performed. Under this lubrication error compensation, oil injection error compensation is performed to clean fibers that cannot be cleaned under normal circumstances.

[0047] Furthermore, after performing the oil injection and air blowing operation based on the lubrication error compensation, the process includes: acquiring equipment operating data during the oil injection and air blowing operation, and performing abnormal shutdown analysis based on the equipment operating data to obtain abnormal shutdown data; performing air pressure fluctuation analysis based on the equipment operating data to obtain air pressure fluctuation data; and adjusting a first preset time threshold and a second preset time threshold based on the air pressure fluctuation data and the abnormal shutdown data.

[0048] Specifically, after performing the oil injection and air blowing operation based on the lubrication error compensation, the equipment operation data during the oil injection and air blowing operation is acquired. The equipment operation data includes equipment running time, air pressure data, debris adhesion and equipment wear data, etc. Based on the equipment operation data, abnormal shutdown analysis is performed to obtain abnormal shutdown data. The abnormal shutdown phenomenon of the equipment can be determined by analyzing mechanical wear and fiber debris adhesion through the equipment operation data.

[0049] Based on the equipment's operating data, air pressure fluctuation analysis is performed to obtain air pressure fluctuation data. The final air pressure fluctuation data can be determined by analyzing the amplitude and timing of the air pressure fluctuations. Based on the air pressure fluctuation data and abnormal shutdown data, a first preset threshold and a second preset threshold are adjusted. If no abnormal shutdowns occur consecutively, the equipment is considered to be in good condition, and the interval between the next full-power cleaning is appropriately extended. If air pressure fluctuations occur frequently or early intervention is required, the cleaning cycle is shortened, and the response sensitivity is improved.

[0050] Furthermore, the step of performing abnormal shutdown analysis based on the equipment operation data to obtain abnormal shutdown data includes: performing mechanical wear analysis based on the equipment operation data to obtain mechanical wear data; performing fiber and debris adhesion analysis based on the equipment operation data to obtain fiber and debris adhesion data; and performing abnormal shutdown analysis based on the mechanical wear data and fiber and debris adhesion data to obtain abnormal shutdown data.

[0051] Specifically, mechanical wear analysis is performed based on the equipment operation data to obtain mechanical wear data. Wear data of components is extracted from the equipment operation data. The degree of mechanical wear of the equipment is determined according to the wear data using preset rules. The preset rules include different wear values ​​corresponding to different wear degrees or wear levels, thus obtaining mechanical wear data, such as the wear degree of a pointer.

[0052] Based on the equipment operation data, fiber debris adhesion analysis is performed. Current, power, and debris adhesion area are extracted from the equipment operation data. The rate of change of current and power is calculated. This rate of change is a key measure of adhesion speed. The degree of fiber debris adhesion is analyzed based on the rate of change and debris adhesion area. In the analysis of the degree of fiber debris adhesion, machine learning algorithms can be used to analyze only the degree of adhesion, that is, to obtain fiber debris adhesion data.

[0053] An abnormal shutdown analysis is performed based on the mechanical wear data and fiber debris adhesion data to obtain abnormal shutdown data. This involves comparing the degree of mechanical wear and the degree of fiber debris adhesion with corresponding preset thresholds. If either the degree of mechanical wear or the degree of fiber debris adhesion is greater than or equal to the preset threshold, it indicates that the equipment has experienced an abnormal shutdown.

[0054] Furthermore, the step of performing air pressure fluctuation analysis based on the equipment operating data to obtain air pressure fluctuation data includes: performing low-pass filtering on the equipment operating data to obtain low-pass filtered equipment operating data; performing air pressure fluctuation amplitude analysis based on the low-pass filtered equipment operating data to obtain air pressure fluctuation amplitude; performing time point analysis on the air pressure fluctuation amplitude to obtain time point information of the air pressure fluctuation; and determining air pressure fluctuation data based on the air pressure fluctuation amplitude and the time point information of the air pressure fluctuation.

[0055] Specifically, the device operation data is subjected to low-pass filtering. The filter coefficient of the low-pass filter is set, and the device operation data is processed by the low-pass filter to obtain low-pass filtered device operation data. Low-pass filtering can smooth the data and reduce data noise.

[0056] Pressure fluctuation amplitude analysis is performed on equipment operating data after low-pass filtering to obtain the pressure fluctuation amplitude, which can be obtained by calculating the variance of the low-pass filtered equipment operating data. Based on the pressure fluctuation amplitude, time-point analysis is performed to obtain the time-point information of the pressure fluctuation, i.e., the time point of the pressure fluctuation amplitude and the time interval between adjacent fluctuation amplitudes. Pressure fluctuation data is determined based on the pressure fluctuation amplitude and the time-point information, i.e., the pressure fluctuation data consists of the pressure fluctuation amplitude and the time-point information. Through the analysis of pressure fluctuations, if frequent pressure fluctuations are detected, the cleaning cycle can be shortened and the response sensitivity improved.

[0057] In this embodiment of the invention, after the circular knitting machine is started, the main control chip of the circular knitting machine reads the current working mode from the storage unit. When the current working mode is read as a pure timed working mode, the timing period is determined, and the relay is triggered to output air pressure based on the timing period. When the current working mode is read as a manual working mode, the relay is controlled to output air pressure based on the user-input command information. When the current working mode is read as an adaptive working mode, air pressure monitoring data is continuously collected, and the air pressure monitoring data is compared with a first preset air pressure threshold and a second preset air pressure threshold. If the air pressure monitoring data is less than the first preset air pressure threshold, a shutdown command is issued to the circular knitting machine. If the air pressure monitoring data is greater than or equal to the first preset air pressure threshold and less than the second preset air pressure threshold, several corresponding solenoid valves are opened based on a stable timing method. If the air pressure monitoring data is greater than or equal to the second preset air pressure threshold, all solenoid valves are opened. This allows for dynamic adjustment of the air consumption strategy according to the actual air pressure, effectively solving the problem of insufficient air pressure causing cleaning failure during the operation of the circular knitting machine. At the same time, through multiple mode settings, the adaptability to complex industrial scenarios can be improved. When the air pressure monitoring data is greater than or equal to the first preset air pressure threshold and less than the second preset air pressure threshold, the cumulative running time of the circular knitting machine is monitored, and the oil injection and air blowing strategy is determined based on the cumulative running time. By monitoring the air pressure and running time distribution of the circular knitting machine in real time, air pressure resources are dynamically allocated to avoid the equipment from operating under high load and affecting the overall air supply balance, thereby achieving energy saving and stable operation of the system.

[0058] Example 3 Please see Figure 3 , Figure 3 This is a schematic diagram of the structural composition of the control device of the circular knitting machine in an embodiment of the present invention, as shown below. Figure 3As shown, the control device includes: a power supply module, a voltage regulator module, a step-down module, an inverting control module, a crystal oscillator module, a serial port module, a switch module, a reset module, a main control chip, an air pressure detection module, a high / low level switching module, an optocoupler module, a relay module, a digital tube module, a light-emitting diode (LED) module, and a power indicator module. The main control chip is connected to the LED module, digital tube module, air pressure detection module, high / low level switching module, serial port module, switch module, reset module, inverting control module, and crystal oscillator module. The power supply module is connected to the voltage regulator module and the inverting control module. The power indicator module is connected to the voltage regulator module, step-down module, high / low level switching module, optocoupler module, and LED module. The optocoupler module is connected to the relay module. The device is configured to execute the control method for a circular knitting machine according to the above embodiment.

[0059] In the specific implementation of this invention, the power supply module provides a stable operating power for the entire device. The power supply module receives a 24V AC input, which is rectified and filtered before being fed into the voltage regulator and buck circuit, outputting 5V DC to power the microcontroller and other digital circuits. The voltage regulator module stabilizes the input voltage at a set value of 5V to prevent voltage fluctuations from affecting system operation. The voltage regulator module uses a voltage regulator chip to ensure a constant power supply to the main control chip and peripheral circuits. The buck module converts the higher 5V to a lower 3.3V for low-power devices such as LED indicators. It is typically implemented using a DC-DC buck chip to improve power utilization. The reverse control module monitors the air pressure through the air pressure module. If the air pressure falls below a threshold, it reverse-controls the circular knitting machine to stop, preventing the machine from failing to perform cleaning and equipment oil spray protection functions when the output air pressure is below the threshold. The crystal oscillator module provides a stable clock signal to the main control chip, ensuring normal program operation. The crystal oscillator module uses a 12MHz quartz crystal resonator, which, together with the load capacitor, forms an oscillation circuit. The serial port module enables data communication between the main control chip and external devices such as a host computer. It supports the Universal Asynchronous Receiver and Transmitter (UART) protocol and can be used for parameter setting, status monitoring, or remote debugging. The switch module receives user key input for mode switching (automatic / timed / manual) or parameter setting. It reads the key status through General Purpose Input / Output (GPIO) ports and transmits the data to the main control chip for processing. The reset module provides a reset signal in case of system malfunction or startup, allowing the main control chip to reinitialize. It includes power-on reset and manual reset functions to ensure reliable system startup. The main control chip, acting as the brain of the device, is responsible for data acquisition, logic judgment, and output control. It uses an STC89C52RC microcontroller, runs a preset control program, and coordinates the work of each module. The air pressure detection module collects the air pressure value in the compressed air system in real time and converts the analog signal into a digital signal. It consists of a pressure sensor and an A / D conversion circuit, and the data is transmitted to the main control chip for comparison and judgment. The high / low level switching module converts the TTL level signal output by the main control chip into the high voltage / high current signal required for relay driving. It uses a transistor for level conversion, enhancing driving capability. The optocoupler module provides electrical isolation between the main control chip and the relays, preventing high-voltage interference from affecting the control system. It employs an optocoupler to ensure signal transmission while maintaining safety. The relay module acts as the actuator, controlling the on / off state of four air valves to enable and disable functions such as cleaning and lubrication. Each relay corresponds to a solenoid valve, driven by the main control chip through an optocoupler to achieve high voltage and high current switching.The digital tube module displays information such as current system status, air pressure value, and operating mode. It uses a common cathode digital tube and is dynamically scanned and driven by the main control chip, facilitating human-machine interaction. The LED module provides visual feedback, indicating system operating status such as power, alarm, and mode; different LEDs indicate different states. The power indicator module visually displays whether the power is on, assisting in judging the system's power supply status. A constantly lit LED is connected to the regulated output terminal and features low power consumption.

[0060] In this embodiment of the invention, the control device of the circular knitting machine integrates multiple modules, which can realize intelligent control of oil spraying lubrication and air blowing cleaning operations, effectively reducing energy consumption and improving cleaning efficiency and system stability while ensuring normal operation of the equipment.

[0061] Those skilled in the art will understand that all or part of the steps in the various methods of the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, which may include: read-only memory (ROM), random access memory (RAM), magnetic disk or optical disk, etc.

[0062] Furthermore, the control method and device for a circular knitting machine provided by the embodiments of the present invention have been described in detail above. Specific examples have been used to illustrate the principle and implementation of the present invention. The description of the above embodiments is only for the purpose of helping to understand the method and core idea of ​​the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation and application scope based on the idea of ​​the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A control method for a circular knitting machine, characterized in that, The method includes: After the circular knitting machine is started, the main control chip of the circular knitting machine reads the current working mode from the storage unit. The current working mode includes adaptive working mode, pure timed working mode and manual working mode. When the current working mode is read as pure timed working mode, the timing period is determined, and the relay is triggered to output air pressure based on the timing period; When the current working mode is read as manual working mode, the relay is controlled to output air pressure based on the user input command information; When the current working mode is read as adaptive working mode, air pressure monitoring data is continuously collected and compared with the first preset air pressure threshold and the second preset air pressure threshold. If the air pressure monitoring data is less than the first air pressure preset threshold, a shutdown command is issued to the circular knitting machine. If the air pressure monitoring data is greater than or equal to the first air pressure preset threshold but less than the second air pressure preset threshold, several corresponding solenoid valves are opened based on a stable timing method. If the air pressure monitoring data is greater than or equal to the second air pressure preset threshold, all solenoid valves are opened. When the air pressure monitoring data is greater than or equal to the first preset air pressure threshold, the cumulative running time of the circular knitting machine is monitored, and the oil spraying and air blowing strategy is determined based on the cumulative running time.

2. The control method for a circular knitting machine according to claim 1, characterized in that, The method of triggering the relay based on the timed period to output air pressure includes: Based on the timed periodic trigger relay, the relay controls the AC power to drive the solenoid valve to close, and based on the closed state of the solenoid valve, controls the air pipe to output air pressure.

3. The control method for a circular knitting machine according to claim 1, characterized in that, The method of opening several corresponding solenoid valves based on a stable timing method includes: Acquire prior experience data, and use deep learning algorithms to analyze the on / off time based on the prior experience data to obtain the first target on / off time; The relay's activation information is determined based on the first target on / off time, and the relay is controlled to open several corresponding solenoid valves based on the activation information and the first target on / off time.

4. The control method for a circular knitting machine according to claim 1, characterized in that, The determination of the fuel injection and blowing strategy based on the cumulative runtime includes: The cumulative runtime is compared with a first preset runtime threshold and a second preset runtime threshold; If the cumulative running time is less than the first time preset threshold, then the intermittent time information is determined, and the fuel injection and air blowing operation is performed based on the intermittent time information; If the cumulative runtime is greater than or equal to the first preset runtime threshold and less than the second preset runtime threshold, then the increase data of the blowing frequency is analyzed, and the fuel injection and blowing operation is performed based on the increase data. If the cumulative runtime is greater than or equal to the second time preset threshold, then lubrication error compensation is determined, and oil injection and air blowing operations are performed based on the lubrication error compensation.

5. The control method for a circular knitting machine according to claim 4, characterized in that, The analysis of the increase in blowing frequency data includes: Determine the target constraints, and based on the target constraints, use a preset clean and stable value combined with a proportional-integral model to analyze the relay switching time to obtain the second target switching time; The increased data for determining the blowing frequency is based on the second target on / off time.

6. The control method for a circular knitting machine according to claim 4, characterized in that, The determination of lubrication error compensation includes: Acquire monitoring signal data from the circular knitting machine, and extract statistical features based on the monitoring signal data to obtain statistical feature information; Based on the statistical feature information, a cleaning contribution analysis is performed to obtain cleaning contribution information; Based on the statistical feature information, a pure lubrication contribution analysis is performed to obtain pure lubrication contribution information; A mapping model is constructed, and lubrication error compensation is determined based on the cleaning contribution information and pure lubrication contribution information using the mapping model.

7. The control method for a circular knitting machine according to claim 4, characterized in that, After performing the oil injection and air blowing operation based on the lubrication error compensation, the following steps are included: Acquire equipment operating data during the fuel injection and air blowing operation, and perform abnormal shutdown analysis based on the equipment operating data to obtain abnormal shutdown data; Based on the equipment operation data, air pressure fluctuation analysis is performed to obtain air pressure fluctuation data; The first and second preset time thresholds are adjusted based on the air pressure fluctuation data and abnormal shutdown data.

8. The control method for a circular knitting machine according to claim 7, characterized in that, The abnormal shutdown analysis based on the equipment operation data to obtain abnormal shutdown data includes: Mechanical wear analysis is performed based on the equipment operation data to obtain mechanical wear data; Based on the equipment operation data, fiber debris adhesion analysis is performed to obtain fiber debris adhesion data; Anomaly shutdown analysis is performed based on the mechanical wear data and fiber debris adhesion data to obtain abnormal shutdown data.

9. The control method for a circular knitting machine according to claim 7, characterized in that, The step of performing air pressure fluctuation analysis based on the equipment operating data to obtain air pressure fluctuation data includes: The equipment operation data is subjected to low-pass filtering to obtain low-pass filtered equipment operation data. The air pressure fluctuation amplitude is obtained by analyzing the equipment operation data after low-pass filtering. Based on the pressure fluctuation amplitude, a time point analysis of the pressure fluctuation is performed to obtain the time point information of the pressure fluctuation. The air pressure fluctuation data is determined based on the air pressure fluctuation amplitude and the time point information of the air pressure fluctuation.

10. A control device for a circular knitting machine, characterized in that, The device includes: a power supply module, a voltage regulator module, a step-down module, an inverting control module, a crystal oscillator module, a serial port module, a switch module, a reset module, a main control chip, an air pressure detection module, a high / low level switching module, an optocoupler module, a relay module, a digital tube module, an LED module, and a power indicator module. The main control chip is connected to the LED module, digital tube module, air pressure detection module, high / low level switching module, serial port module, switch module, reset module, inverting control module, and crystal oscillator module. The power supply module is connected to the voltage regulator module and the inverting control module. The power indicator module is connected to the voltage regulator module, step-down module, high / low level switching module, optocoupler module, and LED module. The optocoupler module is connected to the relay module. The device is configured to execute the control method for a circular knitting machine according to any one of claims 1-9.

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