A double-drive tension control winding method and system for a warp knitting machine

Abstract

The present application relates to the technical field of fabric production, and particularly relates to a warp knitting machine double-drive tension control winding method and system, which comprises the following steps: making the knitted fabric pass through a pulling roller, a transition roller, a tension roller, a first friction roller and a second friction roller in sequence, and winding the fabric by a winding mechanism; driving the first friction roller and the second friction roller respectively, and synchronizing the first friction roller and the second friction roller with a virtual main shaft through an electronic gear; detecting the tension on the fabric by the tension roller; calculating the tension deviation according to the tension signal of the tension roller and a preset target tension, and generating a control output by using a PID control algorithm; calculating a real-time adjustment amount according to the control output, and superimposing the real-time adjustment amount on the synchronous rotating speed of the first friction roller, the second friction roller and the virtual main shaft. The present application can effectively suppress the tension fluctuation, ensure the stress stability of the fabric during the whole winding process, and improve the tightness consistency and flatness of the fabric roll. The winding rotating speed and the tension parameters can be set and adjusted online through a program, and there is no need to replace mechanical gears.

Description

A dual-drive tension control winding method and system for warp knitting machines Technical Field

[0001] This invention relates to the field of fabric production technology, and in particular to a dual-drive tension control winding method and system for warp knitting machines. Background Technology

[0002] After the warp knitting machine weaves the finished fabric, it needs to be wound up. Usually, a winding machine is used to wind the fabric into shape to achieve the required thickness. However, traditional friction winding has the following drawbacks: friction winding uses two friction rollers to create a speed difference to maintain the tension on the fabric, but the speed difference is achieved through mechanical gears. Modifying the speed difference requires replacing the gears, wasting manpower and resources; moreover, the tension during winding is uncontrollable, and the adjustment of winding parameters depends entirely on experience, with the winding tension entirely relying on feel.

[0003] The information disclosed in this background section is intended only to enhance the understanding of the general background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0004] This invention provides a dual-drive tension control winding method and system for warp knitting machines, thereby effectively solving the problems in the background art.

[0005] To achieve the above objectives, the technical solution adopted by this invention is: a dual-drive tension control winding method for a warp knitting machine, comprising the following steps:

[0006] The woven fabric passes sequentially through the tension roller, transition roller, tension roller, first friction roller, and second friction roller, and is then wound up by the winding mechanism.

[0007] The first and second friction rollers are driven respectively and synchronized with the virtual spindle via electronic gears;

[0008] The tension roller detects the tension on the fabric;

[0009] The tension deviation is calculated based on the tension signal of the tension roller and the preset target tension, and a PID control algorithm is used to generate the control output.

[0010] The real-time adjustment amount is calculated based on the control output, and the real-time adjustment amount is superimposed on the synchronous rotational speed of the first friction roller, the second friction roller, and the virtual spindle.

[0011] Further, the step of driving the first friction roller and the second friction roller respectively, and synchronizing them with the virtual spindle via electronic gears, includes:

[0012] ;

[0013] ;

[0014] In the formula, and Let be the linear velocity of the first friction roller and the second friction roller. The linear velocity of the main axis, and It is the synchronization ratio between the first and second friction rollers and the main shaft.

[0015] Further, the step of calculating the tension deviation based on the tension signal of the tension roller and the preset target tension, and generating a control output using a PID control algorithm, includes:

[0016] ;

[0017] In the formula, This is the control output at the k-th sampling time. The deviation at the k-th sampling time is denoted as , which is the preset target tension value minus the tension signal value, and T is the sampling period. This is the proportionality coefficient. The integral coefficient is... , The integral time constant is... These are the differential coefficients. , is the differential time constant.

[0018] Further, the step of calculating the real-time adjustment amount based on the control output and superimposing the real-time adjustment amount onto the synchronous rotational speeds of the first friction roller, the second friction roller, and the virtual spindle includes:

[0019] The synchronization ratio adjustment value is calculated based on the real-time adjustment amount. ;

[0020] The synchronization ratio adjustment value is superimposed on the synchronization speed between the first friction roller and the virtual spindle:

[0021] ;

[0022] .

[0023] Furthermore, the first friction roller and the second friction roller are driven by independent servo motors or frequency converters, respectively.

[0024] Furthermore, the tension roller is a tension measurement unit with a force sensor, and its output tension signal is sent to the controller after analog-to-digital sampling.

[0025] The present invention also includes a dual-drive tension control winding system for a warp knitting machine, using the method described above, wherein the system comprises:

[0026] The components include a tension roller, a transition roller, a tension roller, a first friction roller, a second friction roller, and a winding mechanism.

[0027] Two independent drive units and a virtual transmission unit drive the first friction roller and the second friction roller respectively, and synchronize them with the virtual spindle through electronic gears;

[0028] The tension roller detects the tension on the fabric;

[0029] The PID unit is used to calculate the tension deviation based on the tension signal of the tension roller and the preset target tension, and to generate control output using a PID control algorithm.

[0030] The controller is used to calculate the real-time adjustment amount based on the control output, and to superimpose the real-time adjustment amount onto the synchronous rotational speeds of the first friction roller, the second friction roller, and the virtual spindle.

[0031] The present invention also includes a computer device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor, when executing the computer program, implements the method as described above.

[0032] The present invention also includes a storage medium having a computer program stored thereon, which, when executed by a processor, implements the method as described above.

[0033] The beneficial effects of this invention are as follows: By setting tension rollers in the fabric running path, real-time detection of fabric tension is achieved. The detected tension signal is compared with a preset target tension to form a tension deviation, which is then adjusted in a closed loop using a PID control algorithm. This transforms tension control during the winding process from experience-based control to data-driven control. This method effectively suppresses tension fluctuations, ensures stable stress on the fabric throughout the winding process, and significantly improves the tightness, consistency, and flatness of the finished fabric roll. The dual-drive structure of the first and second friction rollers is synchronously controlled with the virtual spindle via electronic gears, replacing the traditional method of relying on mechanical gears to achieve speed difference. The winding speed and tension parameters can be set and adjusted online via a program, eliminating the need to replace mechanical gears, reducing manual intervention, lowering maintenance and debugging costs, and improving the automation and flexibility of equipment operation. It is particularly suitable for rapid changeover production of multiple varieties and specifications of fabrics. By superimposing the real-time adjustment output of the PID control onto the synchronous speed of the friction roller and the virtual spindle, fine and continuous dynamic compensation of the winding tension can be achieved without disrupting the overall synchronization relationship. This avoids fabric slippage or excessive stretching caused by sudden speed regulation, thereby further improving the stability and reliability of the winding process. Attached Figure Description

[0034] 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 recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0035] Figure 1 is a flowchart of the method of the present invention;

[0036] Figure 2 is a schematic diagram of the system of the present invention;

[0037] Figure 3 is a schematic diagram of the structure of the computer device of the present invention. Detailed Implementation

[0038] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0039] As shown in Figure 1: A dual-drive tension control winding method for a warp knitting machine includes the following steps:

[0040] The woven fabric passes sequentially through the tension roller, transition roller, tension roller, first friction roller, and second friction roller, and is then wound up by the winding mechanism.

[0041] The first and second friction rollers are driven separately and synchronized with the virtual spindle via electronic gears;

[0042] Tension rollers detect the tension on the fabric;

[0043] The tension deviation is calculated based on the tension signal from the tension roller and the preset target tension, and a PID control algorithm is used to generate the control output.

[0044] The real-time adjustment amount is calculated based on the control output and then superimposed on the synchronous speeds of the first friction roller, the second friction roller, and the virtual spindle.

[0045] By installing tension rollers along the fabric's running path, real-time detection of fabric tension is achieved. The detected tension signal is compared with a preset target tension to identify the tension deviation. A closed-loop adjustment is then implemented using a PID control algorithm, transforming tension control during the winding process from experience-based to data-driven. This method effectively suppresses tension fluctuations, ensuring stable stress on the fabric throughout the winding process and significantly improving the tightness, consistency, and smoothness of the finished fabric roll. The dual-drive structure of the first and second friction rollers, synchronized with the virtual spindle via electronic gears, replaces the traditional method relying on mechanical gears for speed difference. Winding speed and tension parameters can be set and adjusted online via a program, eliminating the need to replace mechanical gears, reducing manual intervention, lowering maintenance and debugging costs, and improving the automation and flexibility of equipment operation. This is particularly suitable for rapid production switching of multiple fabric varieties and specifications. By superimposing the real-time adjustment output from the PID control onto the synchronous speed of the friction rollers and the virtual spindle, fine and continuous dynamic compensation of the winding tension can be achieved without disrupting the overall synchronization relationship. This avoids fabric slippage or overstretching caused by sudden speed adjustments, further improving the stability and reliability of the winding process.

[0046] In this embodiment, the first friction roller and the second friction roller are driven respectively and synchronized with the virtual spindle via electronic gears, including:

[0047] ;

[0048] ;

[0049] In the formula, and Let be the linear velocity of the first friction roller and the second friction roller. The linear velocity of the main axis, and It is the synchronization ratio between the first and second friction rollers and the main shaft.

[0050] By introducing a virtual spindle and employing electronic gear synchronization control, the linear velocities of both the first and second friction rollers are proportionally correlated with the spindle speed. This avoids problems such as transmission backlash, wear accumulation, and fixed speed ratios inherent in traditional mechanical gear drives, achieving digital and high-precision control of the winding speed relationship. The synchronization ratio parameter can be directly set via a program or adjusted online without replacing mechanical parts, significantly improving the convenience of equipment adjustment and production flexibility. By setting the synchronization ratios for the first and second friction rollers respectively, differentiated configurations of the linear velocities of the two friction rollers can be achieved. This results in a smoother and more controllable stress transition for the fabric during winding, effectively reducing sudden changes in local tension between the friction rollers and lowering the risk of slippage, wrinkles, or stretching deformation. Consequently, the stability of the winding process and the consistency of the finished fabric roll are improved.

[0051] The process involves calculating the tension deviation based on the tension signal from the tension roller and the preset target tension, and then generating a control output using a PID control algorithm, including:

[0052] ;

[0053] In the formula, This is the control output at the k-th sampling time. The deviation at the k-th sampling time is denoted as , which is the preset target tension value minus the tension signal value, and T is the sampling period. This is the proportionality coefficient. The integral coefficient is... , The integral time constant is... These are the differential coefficients. , is the differential time constant.

[0054] By comparing the real-time collected tension signal with the preset target tension, a clear tension deviation is formed. This deviation is then used as the input to the PID control algorithm, giving the winding tension control a clear adjustment target and mathematical basis. This avoids the uncertainty caused by the traditional reliance on manual experience for tension adjustment, and is conducive to achieving quantitative and standardized control of winding tension.

[0055] As a preferred embodiment of the above, the real-time adjustment amount is calculated based on the control output, and the real-time adjustment amount is superimposed on the synchronous speeds of the first friction roller, the second friction roller, and the virtual spindle, including:

[0056] The synchronization ratio adjustment value is calculated based on the real-time adjustment amount. ;

[0057] The synchronization ratio adjustment value is superimposed on the synchronization speed between the first friction roller and the virtual spindle:

[0058] ;

[0059] .

[0060] By converting the control output obtained from the PID control algorithm into a synchronization ratio adjustment value, and superimposing it on the synchronization relationship between the first and second friction rollers and the virtual spindle in the form of a synchronization ratio, tension adjustment is applied to the friction roller speed in a proportional manner, achieving continuous and smooth adjustment of the winding tension. Compared with direct abrupt correction of the speed, this method can effectively avoid fabric impact and sudden tension changes caused by speed jumps, improving the stability of the winding process. Using a uniform synchronization ratio adjustment value applied simultaneously to the first and second friction rollers allows for coordinated correction of the overall winding speed while maintaining the original relative speed difference between the two friction rollers. This ensures that the force distribution of the fabric is consistent across multiple friction rollers, preventing localized tension anomalies or slippage caused by single-roller adjustment, and improving the coordination and reliability of system operation.

[0061] The first friction roller and the second friction roller are driven by independent servo motors or frequency converters, respectively.

[0062] Using a servo motor or variable frequency motor as the drive source, high-resolution speed adjustment and fast dynamic response can be achieved. Combined with electronic gears and PID tension control algorithms, the speed of the friction roller can be adjusted in a timely manner according to the tension changes, which significantly improves the response speed and adjustment accuracy of tension control and reduces the risk of tension fluctuations in the fabric when accelerating, decelerating or changing working conditions.

[0063] As a preferred embodiment of the above, the tension roller is a tension measurement unit with a force sensor, and the tension signal output by the roller is sent to the controller after analog-to-digital sampling.

[0064] By integrating a force sensor onto the tension roller, the actual tension generated by the fabric during operation can be directly converted into an electrical signal, enabling real-time and continuous measurement of fabric tension. Compared to methods that rely on indirect calculations or manual experience to judge tension, the measurement results are more objective and accurate, providing a reliable data foundation for tension closed-loop control. The analog tension signal is then sent to the controller via analog-to-digital sampling, allowing the tension data to be digitally processed in conjunction with electronic gear synchronization control and PID control algorithms. This facilitates high-precision calculations and rapid response, reduces interference and errors during signal transmission, and improves the overall system's anti-interference capability and control stability.

[0065] As shown in Figure 2, this embodiment also includes a warp knitting machine dual-drive tension control winding system, using the method described above. The system includes:

[0066] The components include a tension roller, a transition roller, a tension roller, a first friction roller, a second friction roller, and a winding mechanism.

[0067] Two independent drive units and a virtual transmission unit drive the first friction roller and the second friction roller respectively, and synchronize them with the virtual spindle through electronic gears;

[0068] Tension rollers detect the tension on the fabric;

[0069] The PID unit is used to calculate the tension deviation based on the tension signal of the tension roller and the preset target tension, and generates the control output using the PID control algorithm;

[0070] The controller is used to calculate the real-time adjustment amount based on the control output and superimpose the real-time adjustment amount onto the synchronous speed of the first friction roller, the second friction roller and the virtual spindle.

[0071] Two independent drive units drive the first and second friction rollers respectively, and combined with a virtual transmission unit and electronic gear synchronization mechanism, the friction rollers coordinate their operation with the virtual spindle as a unified speed reference. This avoids the transmission errors and inconvenience of adjustment caused by traditional mechanical linkage structures, achieving digital and flexible control of the winding speed relationship, and significantly improving the system's adjustment accuracy and responsiveness. By detecting the fabric tension in real time at the tension roller, and having the PID unit calculate the tension deviation based on the detected tension and the target tension to generate a control output, the system forms a complete tension closed-loop control structure. The controller further converts this control output into a real-time adjustment quantity and adds it to the synchronous speed of the friction rollers and the virtual spindle. This allows for continuous and smooth dynamic adjustment of the winding tension without disrupting the overall synchronization relationship, reducing tension fluctuations and winding defects.

[0072] Please refer to Figure 3, which shows a schematic diagram of the structure of a computer device provided in an embodiment of this application. An embodiment of this application provides a computer device 400, including a processor 410 and a memory 420. The memory 420 stores a computer program executable by the processor 410. When the computer program is executed by the processor 410, it performs the method described above.

[0073] This application embodiment also provides a storage medium 430, on which a computer program is stored, and the computer program is executed by a processor 410 to perform the above method.

[0074] The storage medium 430 can be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as Static Random Access Memory (SRAM), Electrically Erasable Programmable Read-Only Memory (EEPROM), Erasable Programmable Read Only Memory (EPROM), Programmable Red-Only Memory (PROM), Read-Only Memory (ROM), magnetic storage, flash memory, magnetic disk, or optical disk.

[0075] In the description of this invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. "A plurality of" means two or more, unless otherwise explicitly specified.

[0076] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0077] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Furthermore, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0078] Any process or method description in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or more executable instructions for implementing a particular logical function or process, and the scope of the preferred embodiments of the invention includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as will be understood by those skilled in the art to which embodiments of the invention pertain.

[0079] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a ordered list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device. More specific examples (a non-exhaustive list) of computer-readable media include: an electrical connection having one or more wires (electronic device), a portable computer disk drive (magnetic device), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Alternatively, the computer-readable medium may be paper or other suitable media on which the program can be printed, since the program can be obtained electronically, for example, by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in a computer memory.

[0080] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0081] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0082] The storage medium mentioned above can be a read-only memory, a disk, or an optical disk, etc. Although embodiments of the present invention have been shown and described above, it is to be understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of the present invention.

Claims

1. A dual-drive tension control winding method for a warp knitting machine, characterized in that, The process includes the following steps: passing the woven fabric sequentially through a tension roller, a transition roller, a tension roller, a first friction roller, and a second friction roller, and then winding it up by a winding mechanism; driving the first and second friction rollers respectively, and synchronizing them with the virtual spindle via electronic gears; The tension roller detects the tension on the fabric; the tension deviation is calculated based on the tension signal from the tension roller and the preset target tension, and a PID control algorithm is used to generate the control output; The real-time adjustment amount is calculated based on the control output, and the real-time adjustment amount is superimposed on the synchronous rotational speeds of the first friction roller, the second friction roller, and the virtual spindle; the step of driving the first friction roller and the second friction roller respectively, and synchronizing them with the virtual spindle via electronic gears, includes: ； In the formula, and Let be the linear velocity of the first friction roller and the second friction roller. The linear velocity of the main axis, and The synchronization ratio between the first and second friction rollers and the main shaft; the step of calculating the tension deviation based on the tension signal of the tension roller and the preset target tension, and generating the control output using a PID control algorithm, includes: In the formula, This is the control output at the k-th sampling time. The deviation at the k-th sampling time is denoted as , which is the preset target tension value minus the tension signal value, and T is the sampling period. This is the proportionality coefficient. The integral coefficient is... ， The integral time constant is... These are the differential coefficients. ， The step of calculating the real-time adjustment amount based on the control output and superimposing the real-time adjustment amount onto the synchronous speeds of the first friction roller, the second friction roller, and the virtual spindle includes: calculating the synchronization ratio adjustment value based on the real-time adjustment amount. The synchronization ratio adjustment value is superimposed on the synchronization speed of the first friction roller and the virtual spindle. ； 。 2. The warp knitting machine dual-drive tension control winding method according to claim 1, characterized in that, The first friction roller and the second friction roller are driven by independent servo motors or frequency converters, respectively.

3. The warp knitting machine dual-drive tension control winding method according to claim 1, characterized in that, The tension roller is a tension measurement unit with a force sensor, and its output tension signal is sent to the controller after analog-to-digital sampling.

4. A dual-drive tension control winding system for a warp knitting machine, characterized in that, Using the method of any one of claims 1 to 3, the system comprises: a tension roller, a transition roller, a tension roller, a first friction roller, a second friction roller, and a winding mechanism; two independent drive units and a virtual transmission unit, which drive the first friction roller and the second friction roller respectively, and synchronize them with the virtual spindle via electronic gears; the tension roller detects the tension on the fabric; a PID unit is used to calculate the tension deviation based on the tension signal of the tension roller and a preset target tension, and generate a control output using a PID control algorithm; a controller is used to calculate the real-time adjustment amount based on the control output, and superimpose the real-time adjustment amount onto the synchronous rotational speed of the first friction roller, the second friction roller, and the virtual spindle.

5. A computer device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method as described in any one of claims 1-3.

6. A storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by the processor, it implements the method as described in any one of claims 1-3.

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