Spinning control method and related device
By obtaining the target fiber torque and fineness during the spinning process, and adjusting the cooling air temperature and sizing solution composition, the problems of lag and inaccuracy in fiber quality control during the spinning process are solved, enabling timely and accurate process adjustments and improving the stability and quality consistency of the spinning process.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-31
- Publication Date
- 2026-04-03
AI Technical Summary
During the spinning process, the viscosity of the spinning solution changes rapidly under the synergistic effect of cooling, solidification and stretching in multiple stages, which leads to fiber breakage, uneven thickness or increased defects. Existing technologies rely on the results of finished product inspection for quality control, which results in strong lag and inaccuracy in process adjustment, affecting the quality compliance rate.
By obtaining the target fineness of the target fiber and the current torque, the target torque is determined, and torque-influencing factors such as cooling air temperature, adhesive composition, or adhesive temperature are adjusted according to the torque difference to achieve timely process adjustments.
It improves the timeliness and accuracy of process adjustments in the spinning process, reduces fiber quality problems, and enhances production stability and consistency.
Smart Images
Figure CN121781295A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of spinning technology, and in particular to a spinning control method and related apparatus. Background Technology
[0002] During the spinning process, the spinning solution is rapidly cooled in the air gap after being extruded through the spinneret and then solidified in the coagulation bath. Due to the rapid viscosity change and molecular orientation formation of the spinning solution under the synergistic effect of multiple stages of cooling, solidification and stretching, this process is extremely sensitive to process fluctuations. Once the forming tension is abnormal, it can easily lead to fiber breakage, uneven thickness or an increase in defects, thereby affecting the quality compliance rate.
[0003] In related technologies, quality control in the spinning process largely depends on the results of finished product inspection. That is, it is usually necessary to detect defects in the fibers after production is completed, and then adjust the relevant parameters of the production process based on the feedback of the finished product quality performance.
[0004] However, the aforementioned post-production corrective measures are not only highly delayed, but also cause a decline in the quality of already produced batches of fibers, or even batch scrapping, resulting in low timeliness and accuracy of process adjustments. Summary of the Invention
[0005] To address the aforementioned problems, this application provides a spinning control method and related apparatus to improve the timeliness and accuracy of process adjustments.
[0006] Based on this, the following technical solution is disclosed in this application:
[0007] In a first aspect, embodiments of this application provide a spinning control method, the method comprising:
[0008] Obtain the target fineness and current torque of the target fiber, wherein the current torque is the torque of the drafting roller currently producing the target fiber;
[0009] Based on the target fineness, the target torque of the target fiber is determined, wherein when the torque of the drawing roller that produces the target fiber is the target torque, the target fiber meets the quality condition, and the quality condition is used to indicate that the difference between the quality index of the target fiber and the quality target is less than the quality difference threshold.
[0010] If the difference between the current torque and the target torque is greater than a first difference threshold, then the adjustment target is to reduce the difference between the current torque and the target torque, and the factors affecting the target torque are adjusted. The factors affecting the target torque include at least one of cooling air temperature, adhesive composition, or adhesive temperature.
[0011] Optionally, prior to the step of adjusting the influencing factors of the target torque, the method further includes:
[0012] If the difference between the current torque and the target torque is greater than the first difference threshold and less than or equal to the second difference threshold, then the target torque influencing factors are determined based on the difference, wherein the target torque influencing factors include one of the cooling air temperature, the adhesive composition, or the adhesive temperature, and the second difference threshold is greater than the first difference threshold.
[0013] Optionally, prior to the step of adjusting the influencing factors of the target torque, the method further includes:
[0014] If the difference between the current torque and the target torque is greater than the second difference threshold, the target torque influencing factor is determined based on the difference and the priority of each torque influencing factor. The target torque influencing factor includes at least one of the cooling air temperature, the adhesive composition, or the adhesive temperature. The priority is used to identify the contribution of adjusting the torque influencing factor to reducing the difference.
[0015] Optionally, the method further includes:
[0016] Obtain the composition of a first adhesive solution at a first moment in the production of the target fiber, and the composition of a second adhesive solution at a second moment in the production of the target fiber, wherein the second moment is later than the first moment;
[0017] The step of adjusting the factors influencing the target torque, with the goal of reducing the difference between the current torque and the target torque, if the difference between the current torque and the target torque is greater than a first difference threshold, includes:
[0018] If the difference between the current torque and the target torque is greater than the first difference threshold, and the difference between the first adhesive composition and the second adhesive composition is greater than the third difference threshold, then the adjustment target is to reduce the difference between the current torque and the target torque, and at least one of the cooling air temperature or the adhesive temperature is adjusted.
[0019] Optionally, the current torque is obtained in the following manner:
[0020] The torque corresponding to each of the multiple drawing rollers used to produce the target fiber is obtained, and the multiple drawing rollers include a winding drawing roller, a washing drawing roller, and the cutting drawing roller.
[0021] The current torque is determined based on the torques corresponding to the plurality of drawing rollers and the torque weights corresponding to the plurality of drawing rollers, wherein the torque weight of the winding drawing roller is greater than the torque weight of the washing drawing roller, and the torque weight of the winding drawing roller is greater than the torque weight of the cutting drawing roller.
[0022] Optionally, the step of determining the target torque of the target fiber based on the target fineness includes:
[0023] The torque for the target fineness is determined based on a preset correspondence between the target torque and the target fineness;
[0024] The preset correspondence is determined in the following way:
[0025] Obtain fibers from multiple samples with different target fineness;
[0026] Determine the quality indicators of the fibers used to produce each target fineness sample under different torques;
[0027] The torques whose difference between the quality index and the quality target is less than the quality difference threshold are determined as the target torque samples corresponding to each target fineness sample;
[0028] The preset correspondence is obtained by fitting the target torque samples corresponding to each of the target fineness samples.
[0029] Secondly, embodiments of this application provide a spinning control device, the device comprising:
[0030] The acquisition unit is used to acquire the target fineness and current torque of the target fiber, wherein the current torque is the torque of the drafting roller currently producing the target fiber;
[0031] A determining unit is configured to determine the target torque of the target fiber based on the target fineness, wherein when the torque of the drawing roller that produces the target fiber is the target torque, the target fiber meets a quality condition, and the quality condition is used to indicate that the difference between the quality index of the target fiber and the quality target is less than a quality difference threshold.
[0032] An adjustment unit is configured to, if the difference between the current torque and the target torque is greater than a first difference threshold, adjust the factors influencing the target torque with the goal of reducing the difference between the current torque and the target torque, wherein the factors influencing the target torque include at least one of cooling air temperature, adhesive composition, or adhesive temperature.
[0033] Thirdly, embodiments of this application provide a spinning control system, which includes a torque acquisition module, a target torque determination module, and a process control module, wherein:
[0034] The torque acquisition module is used to acquire the current torque, which is the torque of the drafting roller currently producing the target fiber;
[0035] The target torque determination module is used to obtain the target fineness of the target fiber and determine the target torque of the target fiber based on the target fineness. When the torque of the drawing roller that produces the target fiber is the target torque, the target fiber meets the quality condition. The quality condition is used to indicate that the difference between the quality index of the target fiber and the quality target is less than the quality difference threshold.
[0036] The process adjustment module is used to adjust the influencing factors of the target torque if the difference between the current torque and the target torque is greater than a first difference threshold. The adjustment target is to reduce the difference between the current torque and the target torque. The influencing factors of the target torque include at least one of cooling air temperature, adhesive composition, or adhesive temperature.
[0037] Fourthly, this application provides a fiber production line, including the aforementioned spinning control system, drawing roller, spinneret, coagulation bath, and a cooling air temperature control device, a glue temperature control device, and a feeding device that are communicatively connected to the spinning control system. The feeding device is used to control the composition of the glue.
[0038] As can be seen from the above technical solutions, this application has at least the following beneficial effects:
[0039] The target fineness and current torque of the target fiber are obtained, with the current torque being the torque of the drafting roller currently producing the target fiber. Based on the target fineness, the target torque of the target fiber is determined. When the torque of the drafting roller producing the target fiber is the target torque, the target fiber meets a quality condition, which indicates that the difference between the target fiber's quality indicators and the quality target is less than a quality difference threshold. If the difference between the current torque and the target torque exceeds a first difference threshold, the adjustment target is to reduce this difference. Factors influencing the target torque are adjusted, including at least one of cooling air temperature, adhesive composition, or adhesive temperature. Thus, the current torque reflects the tension of the target fiber. If the difference between the current torque and the target torque is large, it indicates abnormal tension in the target fiber, allowing direct adjustment of the factors influencing the target torque to maintain fiber tension within the normal range more promptly. Furthermore, compared to the uncertainty of adjusting the process based on finished product inspection results after production, the adjustment method based on torque differences is quantifiable and has stronger certainty, improving the accuracy of process adjustments. Attached Figure Description
[0040] To more clearly illustrate the technical solutions in the embodiments of this application 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 this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0041] Figure 1 A schematic flowchart of a spinning control method provided in an embodiment of this application;
[0042] Figure 2 A schematic diagram of a spinning process provided in an embodiment of this application;
[0043] Figure 3 This is a schematic diagram of a spinning control device provided in an embodiment of this application. Detailed Implementation
[0044] Embodiments of this application will now be described in more detail with reference to the accompanying drawings. While some embodiments of this application are shown in the drawings, it should be understood that this application can be implemented in various forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to provide a more thorough and complete understanding of this application. It should be understood that the drawings and embodiments of this application are for illustrative purposes only and are not intended to limit the scope of protection of this application.
[0045] As mentioned above, quality control in the spinning process largely relies on finished product inspection results. This typically requires post-production quality checks, such as defect detection, on the fibers, followed by adjustments to relevant process parameters based on the finished product's quality performance. For example, if an increase in defects is detected, operators will retrospectively check the spinning process conditions and correct the parameters. However, since fiber quality defects often originate from real-time tension anomalies during the air gap formation stage, this type of detection method has a significant lag. By the time quality problems are discovered, they often extend throughout the entire production batch, making it difficult to prevent quality losses in a timely manner. Furthermore, the aforementioned control process relies on manual analysis and experience-based judgment, resulting in slow response times and difficulty in guaranteeing adjustment accuracy, failing to meet the requirements for stability and high consistency in spinning process control.
[0046] Based on this, embodiments of this application provide a spinning control method and related apparatus. The current torque reflects the tension of the target fiber. If the difference between the current torque and the target torque is significant, it indicates an abnormal tension in the target fiber. Therefore, the factors influencing the target torque can be directly adjusted to maintain the fiber tension within the normal range more promptly. Furthermore, compared to the uncertainty of adjusting the process based on finished product inspection results after production, the adjustment method based on torque differences is quantifiable and has stronger certainty, improving the accuracy of process adjustments.
[0047] The spinning control method provided in this application can be applied to computer devices with control capabilities, such as terminal devices and servers. Specifically, terminal devices can be desktop computers, laptops, mobile phones, and tablets; servers can be independent physical servers, server clusters composed of multiple physical servers, or distributed systems. Terminal devices and servers can be directly or indirectly connected via wired or wireless communication, and this application does not impose any restrictions on this connection.
[0048] See Figure 1 This figure is a schematic flowchart of the spinning control method provided in an embodiment of this application. For ease of description, the following embodiments use the controller in the spinning control system as an example to illustrate the execution of this spinning control method. Figure 1 As shown, the spinning control method includes S101-S103.
[0049] S101: Obtain the target fineness and current torque of the target fiber.
[0050] The target fiber is the fiber currently in production. During production, the target fiber can take various forms, such as nascent fiber, finished fiber, or spun yarn. The target fiber needs to meet preset quality indicators, such as the number of defects being less than a certain threshold. As one possible approach, the target fiber is produced using a dry-jet wet-spinning process, such as lyocell fiber.
[0051] Denier (D) is a physical indicator of the fineness of a fiber, and its unit can be grams per 10,000 meters (dtex). Target denier refers to the denier of the target fiber.
[0052] A drafting roll is an active roll used to apply traction or stretch to a filament bundle and transmit tension downstream. Depending on its position and function in the production line, drafting rolls include various types, such as winding drafting rolls, washing drafting rolls, and cutting drafting rolls.
[0053] In this embodiment, torque is the rotational torque generated when the drafting roller overcomes the load. Current torque is the torque of the drafting roller currently producing the target fiber. By obtaining the current torque of the target fiber, the tension change of the target fiber can be reflected.
[0054] The current torque can be acquired in real time or within a sampling period. The current torque can be directly measured by a torque sensor or indirectly estimated from motor parameters such as motor current and electrical angle; neither of these limitations is specified in the embodiments of this application.
[0055] like Figure 2As shown in the figure, this illustrates a spinning process. Taking the production of the target fiber as an example, the spinning solution is extruded from the spinneret 1 by a metering pump and drawn by a winding machine (including winding and drawing rollers) 5. It first passes through an air bath 2, where strong cooling air rapidly cools the filaments and initially shapes them. Then, the filament bundle enters a coagulation bath 3 to solidify and form nascent fibers. During the cooling process after passing through the guide rollers 4 and the winding and drawing rollers, the viscosity of the spun filaments continuously increases. Under the action of tensile force, cellulose molecules crystallize, orient, and undergo intermolecular displacement, causing the filament diameter to rapidly decrease, initially forming the fiber shape. In the above process, the force on the target fiber originates from the work done by the winding machine 5. Therefore, the change in fiber tension can be assessed by monitoring the torque change of the winding machine 5. Furthermore, the current torque source is not limited to the winding and drawing rollers; it can also include the torque of all drawing rollers before the target fiber passes through the cutting cutter head, such as the washing drawing machine (including washing and drawing rollers) 6 and the cutting drawing machine (including cutting and drawing rollers) 7. A method for determining the current torque will be explained later and will not be repeated here.
[0056] S102: Determine the target torque of the target fiber based on the target fineness.
[0057] The target torque is the torque of the drafting roller required to achieve the target fiber's quality indicators. Specifically, when the drafting roller used to produce the target fiber is at the target torque, the target fiber meets the quality conditions. These quality conditions indicate that the difference between the target fiber's quality indicators and the quality target is less than a quality difference threshold.
[0058] The quality index is the actual measurement obtained from the target fiber, and the quality target is the index that the fiber with the target fineness should meet. The quality difference threshold is used to determine whether the target fiber meets the quality conditions. That is, if the difference between the quality index of the target fiber and the quality target is less than the quality difference threshold, it means that the target fiber meets the quality conditions; if the difference between the quality index of the target fiber and the quality target is greater than or equal to the quality difference threshold, it means that the target fiber does not meet the quality conditions.
[0059] The embodiments in this application do not specifically limit the quality conditions; the following description uses three methods as examples:
[0060] Quality condition one, quality condition based on the number of defects.
[0061] Defects are localized structural defects that occur during the spinning and forming process of fibers. They manifest as point-like or segment-like areas where the fiber diameter, appearance, or surface quality changes abnormally. Their quantity directly affects the fiber quality and performance.
[0062] In this quality condition, the quality index is the number of defects actually measured on the target fiber, the quality target is the range of defect numbers used to judge whether the fiber quality meets the standard, and the quality difference threshold is 0. When the number of defects on the target fiber is within the defect number range, it means that the quality condition is met.
[0063] Quality condition two, quality condition based on fineness difference.
[0064] In this quality condition, the quality index is the fineness of the target fiber as actually measured, the quality target is the target fineness, and the quality difference threshold is used to indicate the upper limit of the difference between the measured fineness and the target fineness. When the difference between the fineness of the target fiber and the target fineness is less than the quality difference threshold, it is said that the quality condition is met.
[0065] Quality condition three: quality condition based on fracture strength.
[0066] In this quality condition, the quality index is the actual measured breaking strength of the target fiber, the quality target is the minimum breaking strength that the target fiber must meet, and the quality difference threshold is used to indicate the upper limit of the difference between the measured breaking strength and the minimum breaking strength when the measured breaking strength is less than the minimum breaking strength. When the difference between the breaking strength of the target fiber and the minimum breaking strength is less than the quality difference threshold, it is said that the quality condition is met.
[0067] It should be noted that the above three quality conditions are for illustrative purposes only, and the quality conditions can also be other conditions that affect the quality of the target fiber.
[0068] By determining the target torque of the target fiber, the specific adjustment target of the production process can be determined. This allows for the adjustment of the current torque to approximate the target torque, achieving stable control in the early stages of abnormal fiber tension and significantly reducing the risk of quality problems.
[0069] S103: If the difference between the current torque and the target torque is greater than the first difference threshold, then the adjustment target is to reduce the difference between the current torque and the target torque, and the factors affecting the target torque are adjusted.
[0070] The first difference threshold is the maximum allowable deviation between the current torque and the target torque, provided the target fiber meets the quality specifications. If the difference between the current torque and the target torque exceeds the first difference threshold, it indicates that the current production process cannot meet the quality specifications and may result in a large number of defects, requiring adjustments to the production process. If the difference between the current torque and the target torque is less than or equal to the first difference threshold, it indicates that the current production process can meet the quality specifications, and the number of defects generated is sufficient to meet the quality specifications, thus no adjustments to the production process are necessary.
[0071] Torque influencing factors refer to process parameters that can cause changes in the torque of the drafting roller during the spinning process. Target torque influencing factors are those used to adjust the current torque, and these factors include at least one of the following: cooling air temperature, sizing solution composition, or sizing solution temperature.
[0072] The target torque influencing factor can be one of multiple torque influencing factors, or a combination of multiple torque influencing factors; this application does not limit this. In other words, the current torque can be adjusted by one or more torque influencing factors.
[0073] The following section introduces the factors that affect torque mentioned above:
[0074] Cooling air temperature: The temperature of the cooling airflow blown into the air gap. Under single-factor control conditions, the lower the cooling air temperature, the higher the current torque; conversely, the higher the cooling air temperature, the lower the current torque.
[0075] Solution composition: The percentage of cellulose in the solution. The solution is a cellulose solution used to prepare the fiber. During the production process, the solution is extruded through a spinneret, cooled in an air gap, and coagulated in a coagulation bath to form the target fiber. The solution includes dissolved cellulose; for example, it may include at least cellulose, a solvent (such as an aqueous solution of N-methylmorpholine-N-oxide (NMMO),) and water. Changes in the solution composition affect the zero-shear viscosity, which in turn affects the stretching behavior of the spun yarn in the air gap, its cooling and solidification behavior, and the final fiber tension.
[0076] Under single-factor control conditions, the higher the cellulose ratio, the higher the current torque, and the lower the cellulose ratio, the lower the current torque.
[0077] Adhesive temperature: The temperature of the adhesive before it is extruded. Under single-factor control conditions, the higher the adhesive temperature, the lower the current torque, and vice versa.
[0078] For example, the cooling air temperature can be adjusted by regulating the settings of the air cooler or heat exchange module to change the cellulose coagulation rate in the air gap. For example, the glue composition can be adjusted by regulating the cellulose output rate. For example, the glue temperature can be adjusted by regulating the radiator temperature, the glue temperature control device of the spinneret, etc.
[0079] By adjusting the factors influencing the target torque with the goal of reducing the difference between the current torque and the target torque, the difference between the current torque and the target torque can be made smaller and smaller, so that the difference between the current torque and the target torque can gradually approach the level of less than the first difference threshold, thereby achieving the quality standard.
[0080] As can be seen from the above technical solution, the target fineness and current torque of the target fiber are obtained, where the current torque is the torque of the drafting roller used to produce the target fiber. Based on the target fineness, the target torque of the target fiber is determined. When the torque of the drafting roller used to produce the target fiber is the target torque, the target fiber meets the quality condition, which indicates that the difference between the quality index of the target fiber and the quality target is less than a quality difference threshold. If the difference between the current torque and the target torque is greater than a first difference threshold, the adjustment target is to reduce the difference between the current torque and the target torque. The factors affecting the target torque are adjusted, including at least one of cooling air temperature, adhesive composition, or adhesive temperature. Thus, the current torque reflects the tension of the target fiber. If the difference between the current torque and the target torque is large, it indicates that the tension of the target fiber is abnormal, allowing direct adjustment of the factors affecting the target torque to maintain the fiber tension within the normal range more promptly. Furthermore, compared to the uncertainty of adjusting the process based on finished product inspection results after production, the adjustment method based on torque differences is quantifiable and has stronger certainty, improving the accuracy of process adjustment.
[0081] In one possible implementation, if the difference between the current torque and the target torque is greater than a first difference threshold and less than or equal to a second difference threshold, then the target torque influencing factors are determined based on the difference, and the adjustment is made with the goal of reducing the difference between the current torque and the target torque.
[0082] Among them, the factors affecting the target torque include one of the following: cooling air temperature, adhesive composition, or adhesive temperature, and the second difference threshold is greater than the first difference threshold.
[0083] The second difference threshold is used to determine whether the difference between the current torque and the target torque is significant. If the difference between the current torque and the target torque is greater than the first difference threshold but less than or equal to the second difference threshold, it indicates that the current difference is within a slightly controllable range. In this case, the current torque can be adjusted by adjusting individual torque-influencing factors.
[0084] Therefore, by setting a first difference threshold and a second difference threshold and distinguishing the levels of torque difference, when the difference between the current torque and the target torque is within a slightly controllable range (i.e., greater than the first difference threshold and less than or equal to the second difference threshold), a single-factor rapid adjustment can be made using any one of the following: cooling air temperature, adhesive composition, or adhesive temperature, so that the current torque returns to near the target torque in a timely manner. Thus, without the need for complex control, the increase in torque difference can be effectively suppressed, reducing process fluctuations caused by over-control, improving system response speed and spinning process stability, thereby reducing defects caused by abnormal tension, and improving fiber quality consistency and production yield.
[0085] Furthermore, if the difference between the current torque and the target torque exceeds a second difference threshold, the target torque influencing factors are determined based on the difference and the priority of each torque influencing factor. The target torque influencing factors are adjusted with the goal of reducing the difference between the current torque and the target torque.
[0086] Among them, the target torque influencing factors include at least one of the following: cooling air temperature, adhesive composition, or adhesive temperature. Priority is used to identify the contribution of adjusting the torque influencing factors to reducing the difference.
[0087] If the difference between the current torque and the target torque is greater than the second difference threshold, it indicates that the current torque has deviated significantly from the target torque range, and there is a risk of serious defects caused by large fluctuations in fiber tension. Therefore, the target torque influencing factors that need to be adjusted can be determined based on the difference and the priority of each torque influencing factor, so as to achieve rapid adjustment.
[0088] As one possible implementation, the priority of the adhesive composition is higher than that of the cooling air temperature, and the priority of the cooling air temperature is higher than that of the adhesive temperature.
[0089] Therefore, when the torque difference exceeds the second difference threshold, appropriate torque influencing factors are selected based on priority. This allows for the preferential use of process factors with more significant and stable torque effects for torque compensation when significant torque differences occur. This helps to quickly suppress large fluctuations in fiber tension, avoid the concentration of defects, and improve adjustment efficiency in scenarios with large tension fluctuations. Furthermore, by introducing priority, process adjustments have more accurate judgment criteria and execution sequences, preventing ineffective or delayed control due to accidental triggering of low-contribution torque influencing factors, thereby further improving the robustness of tension control in the spinning process.
[0090] During the production of the same batch of fibers, the composition of the adhesive may undergo uncontrollable changes, such as changes in zero-shear viscosity. Based on this, other torque-influencing factors can be adjusted to maintain the stability of the current torque.
[0091] For example, when the following adjustment method is applied to zero-shear viscosity at 85°C >9000Pas and less than 30000Pas, when the zero-shear viscosity is between 13000-18000Pas, the torque increases by approximately 0.02-0.04 Nm for every 1000Pas increase.
[0092] In one possible implementation, the composition of the first adhesive solution at a first moment in the production of the target fiber and the composition of the second adhesive solution at a second moment in the production of the target fiber can be obtained. If the difference between the current torque and the target torque is greater than a first difference threshold, and the difference between the first adhesive solution composition and the second adhesive solution composition is greater than a third difference threshold, then at least one of the cooling air temperature or the adhesive solution temperature is adjusted with the goal of reducing the difference between the current torque and the target torque.
[0093] The second time step is later than the first time step. The third difference threshold is used to determine whether the composition of the adhesive has changed significantly. When the difference between the composition of the first and second adhesive solutions is greater than the third difference threshold, it indicates that the composition of the adhesive solution has changed significantly.
[0094] In other words, by comparing the composition of the adhesive in the same production batch at different times, when the composition of the adhesive changes involuntarily, since the composition itself may not be able to be corrected in time, adjustments can be made to rapidly controllable temperature factors (such as cooling air temperature and adhesive temperature) to maintain torque stability.
[0095] Therefore, when a significant change in the composition of the adhesive is detected and the current torque has deviated from the target torque, the torque-influencing factors such as cooling air temperature and adhesive temperature are adjusted first, so that the current torque can return to normal in a timely manner even when the composition of the adhesive is uncontrollable in the short term.
[0096] The embodiments of this application do not specifically limit how the current torque is obtained; the following description uses one method as an example.
[0097] Obtain the torque corresponding to each of the multiple drafting rollers used to produce the target fiber. Determine the current torque based on the torques of each drafting roller and their respective torque weights.
[0098] The multiple drafting rolls include winding drafting rolls, washing drafting rolls, and cutting drafting rolls. The torque weight of the winding drafting roll is greater than that of the washing drafting roll, and the torque weight of the winding drafting roll is greater than that of the cutting drafting roll. The torque weight is used to indicate the degree of influence of the drafting roll torque on the overall torque.
[0099] As a method of implementation, the change in spinning tension needs to reflect, and only reflects, the tension change of the yarn bundle during the deformation process. Therefore, the unloaded torque of all drafting rollers needs to be removed from all the drafting processes to reflect the tension change per unit mass of yarn bundle. In other words, the torque corresponding to each of the multiple drafting rollers needs to be reduced by the unloaded torque corresponding to each of the multiple drafting rollers.
[0100] Located upstream of the fiber forming section, the winding drafting roller's torque changes most directly reflect real-time tension fluctuations during fiber forming. When abnormal tension occurs and may affect fiber surface quality, the winding drafting roller can detect this change with the highest sensitivity. In contrast, the tension changes sensed by the downstream washing and cutting drafting rollers are partially absorbed and buffered, resulting in a delayed response. Therefore, the winding drafting roller contributes more to the torque and has a higher torque weighting.
[0101] As one possible implementation, if the drafting roller device includes multiple drafting rollers, the torque weight of the upper drafting roller is greater than that of the lower drafting roller (affected by gravity), and the torque weight of the drafting roller with a higher fiber winding degree is greater than that of the drafting roller with a lower fiber winding degree (affected by friction).
[0102] Therefore, by acquiring the torque of multiple drawing rolls and weighting and fusing them to determine the current torque, a more comprehensive and accurate tension assessment result can be obtained from multi-point monitoring.
[0103] In one possible implementation, the torque for the target fineness can be determined based on a preset correspondence between the target torque and the target fineness.
[0104] The preset correspondence is determined in the following way:
[0105] Obtain fiber samples with multiple different target finenesses. Each target fineness sample corresponds to a different fineness. Determine the quality indicators of the fiber produced for each target fineness sample under different torques.
[0106] The torque at which the difference between the quality index and the quality target is less than a quality difference threshold is defined as the target torque sample corresponding to each target fineness sample. The target torque sample is the torque that meets the quality conditions; that is, the torque that makes the corresponding fiber meet the quality conditions during the production process is defined as the target torque sample corresponding to the target fineness sample.
[0107] Based on the target torque samples corresponding to each target fineness sample, a preset correspondence is obtained by fitting.
[0108] Fitting is a method of processing data samples by constructing function curves or mathematical models to establish a continuous relationship between fineness and target torque. For example, linear fitting, quadratic fitting, or polynomial fitting can be used.
[0109] As an example, taking the adjustment from the standard fineness of 1.33 dtex to the target fineness as an example, the preset correspondence can be expressed by the formula: n = 0.2188 * D + 1.2429. Where n is the target torque and D is the target fineness.
[0110] As an example, this application also proposes a correspondence applicable to fibers with fineness from 0.9 dtex to 2.5 dtex. For fibers with the above fineness, the winding torque N and the fineness D (dtex) conform to the following correspondence: N = 0.5721 * D² - 2.4482D + 3.2245. Wherein, N is the winding torque and D is the fineness.
[0111] Therefore, by acquiring the quality indicators of fibers with different target fineness samples under various torque conditions and extracting target torque samples that meet the quality conditions, a preset correspondence between fineness and torque can be constructed. This allows for the acquisition of target torque based on real production data, eliminating reliance on manual experience and repeated trial production, and significantly improving the accuracy and consistency of target torque. Simultaneously, the preset correspondence can quickly adapt to the production needs of different finenesses during specification switching, helping to ensure that quality indicators remain within a controllable range from the initial stages of process adjustment, thereby improving the quality stability and production efficiency of spinning.
[0112] See Figure 3 , Figure 3 A spinning control device 300 provided in this application embodiment includes:
[0113] The acquisition unit 301 is used to acquire the target fineness and current torque of the target fiber, wherein the current torque is the torque of the drafting roller currently producing the target fiber;
[0114] The determining unit 302 is used to determine the target torque of the target fiber based on the target fineness, wherein when the torque of the drawing roller that produces the target fiber is the target torque, the target fiber meets the quality condition, and the quality condition is used to indicate that the difference between the quality index of the target fiber and the quality target is less than the quality difference threshold.
[0115] The adjustment unit 303 is used to adjust the influencing factors of the target torque if the difference between the current torque and the target torque is greater than a first difference threshold, with the goal of reducing the difference between the current torque and the target torque. The influencing factors of the target torque include at least one of cooling air temperature, adhesive composition, or adhesive temperature.
[0116] As one possible implementation, the device 300 further includes a first factor determining unit, used for:
[0117] If the difference between the current torque and the target torque is greater than the first difference threshold and less than or equal to the second difference threshold, then the target torque influencing factors are determined based on the difference, wherein the target torque influencing factors include one of the cooling air temperature, the adhesive composition, or the adhesive temperature, and the second difference threshold is greater than the first difference threshold.
[0118] As one possible implementation, the device 300 further includes a second factor determining unit, used for:
[0119] If the difference between the current torque and the target torque is greater than the second difference threshold, the target torque influencing factor is determined based on the difference and the priority of each torque influencing factor. The target torque influencing factor includes at least one of the cooling air temperature, the adhesive composition, or the adhesive temperature. The priority is used to identify the contribution of adjusting the torque influencing factor to reducing the difference.
[0120] The adjustment aims to reduce the difference between the current torque and the target torque, and adjusts the factors affecting the target torque.
[0121] As one possible implementation, the device 300 further includes an adhesive composition acquisition unit, used for:
[0122] Obtain the composition of a first adhesive solution at a first moment in the production of the target fiber, and the composition of a second adhesive solution at a second moment in the production of the target fiber, wherein the second moment is later than the first moment;
[0123] The adjustment unit 303 is specifically used for:
[0124] If the difference between the current torque and the target torque is greater than the first difference threshold, and the difference between the first adhesive composition and the second adhesive composition is greater than the third difference threshold, then the adjustment target is to reduce the difference between the current torque and the target torque, and at least one of the cooling air temperature or the adhesive temperature is adjusted.
[0125] As one possible implementation, the current torque is obtained in the following way:
[0126] The torque corresponding to each of the multiple drawing rollers used to produce the target fiber is obtained, and the multiple drawing rollers include a winding drawing roller, a washing drawing roller, and the cutting drawing roller.
[0127] The current torque is determined based on the torques corresponding to the plurality of drawing rollers and the torque weights corresponding to the plurality of drawing rollers, wherein the torque weight of the winding drawing roller is greater than the torque weight of the washing drawing roller, and the torque weight of the winding drawing roller is greater than the torque weight of the cutting drawing roller.
[0128] As one possible implementation, the determining unit 302 is specifically used for:
[0129] The torque for the target fineness is determined based on a preset correspondence between the target torque and the target fineness;
[0130] The preset correspondence is determined in the following way:
[0131] Obtain fibers from multiple samples with different target fineness;
[0132] Determine the quality indicators of the fibers used to produce each target fineness sample under different torques;
[0133] The torques whose difference between the quality index and the quality target is less than the quality difference threshold are determined as the target torque samples corresponding to each target fineness sample;
[0134] The preset correspondence is obtained by fitting the target torque samples corresponding to each of the target fineness samples.
[0135] This application embodiment also provides a spinning control system, which includes a torque acquisition module, a target torque determination module, and a process control module, wherein:
[0136] The torque acquisition module is used to acquire the current torque, which is the torque of the drafting roller currently producing the target fiber;
[0137] The target torque determination module is used to obtain the target fineness of the target fiber and determine the target torque of the target fiber based on the target fineness. When the torque of the drawing roller that produces the target fiber is the target torque, the target fiber meets the quality condition. The quality condition is used to indicate that the difference between the quality index of the target fiber and the quality target is less than the quality difference threshold.
[0138] The process adjustment module is used to adjust the influencing factors of the target torque if the difference between the current torque and the target torque is greater than a first difference threshold. The adjustment target is to reduce the difference between the current torque and the target torque. The influencing factors of the target torque include at least one of cooling air temperature, adhesive composition, or adhesive temperature.
[0139] This application embodiment also provides a fiber production line, including the above-mentioned spinning control system, drawing roller, spinneret, coagulation bath, and a cooling air temperature control device, a glue solution temperature control device, and a feeding device that are communicatively connected to the spinning control system. The feeding device is used to control the composition of the glue solution.
[0140] It should be noted that the various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the systems or apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple, and relevant parts can be referred to the method section.
[0141] The term "comprising" and its variations as used herein are open-ended inclusions, meaning "including but not limited to". The term "based on" means "at least partially based on". The term "one embodiment" means "at least one embodiment"; the term "another embodiment" means "at least one additional embodiment"; the term "some embodiments" means "at least some embodiments". Definitions of other terms will be given in the description below.
[0142] It should be understood that in this application, "at least one (item)" means one or more, and "more than" means two or more. "And / or" is used to describe the relationship between related objects, indicating that three relationships can exist. For example, "A and / or B" can represent three cases: only A exists, only B exists, and both A and B exist simultaneously, where A and B can be singular or plural. The character " / " generally indicates that the preceding and following related objects are in an "or" relationship. "At least one (item) of the following" or similar expressions refer to any combination of these items, including any combination of single or plural items. For example, at least one (item) of a, b, or c can represent: a, b, c, "a and b", "a and c", "b and c", or "a and b and c", where a, b, and c can be single or multiple.
[0143] It should also be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0144] The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein can be implemented directly by hardware, a software module executed by a processor, or a combination of both. The software module can be located in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, removable disk, CD-ROM, or any other form of storage medium known in the art.
[0145] The above description of the disclosed embodiments enables those skilled in the art to make or use this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A spinning control method, characterized in that, The method includes: Obtain the target fineness and current torque of the target fiber, wherein the current torque is the torque of the drafting roller currently producing the target fiber; Based on the target fineness, the target torque of the target fiber is determined, wherein when the torque of the drawing roller that produces the target fiber is the target torque, the target fiber meets the quality condition, and the quality condition is used to indicate that the difference between the quality index of the target fiber and the quality target is less than the quality difference threshold. If the difference between the current torque and the target torque is greater than a first difference threshold, then the adjustment target is to reduce the difference between the current torque and the target torque, and the factors affecting the target torque are adjusted. The factors affecting the target torque include at least one of cooling air temperature, adhesive composition, or adhesive temperature.
2. The method according to claim 1, characterized in that, Prior to the step of adjusting the factors influencing the target torque, the method further includes: If the difference between the current torque and the target torque is greater than the first difference threshold and less than or equal to the second difference threshold, then the target torque influencing factors are determined based on the difference, wherein the target torque influencing factors include one of the cooling air temperature, the adhesive composition, or the adhesive temperature, and the second difference threshold is greater than the first difference threshold.
3. The method according to claim 2, characterized in that, Prior to the step of adjusting the factors influencing the target torque, the method further includes: If the difference between the current torque and the target torque is greater than the second difference threshold, the target torque influencing factor is determined based on the difference and the priority of each torque influencing factor. The target torque influencing factor includes at least one of the cooling air temperature, the adhesive composition, or the adhesive temperature. The priority is used to identify the contribution of adjusting the torque influencing factor to reducing the difference.
4. The method according to claim 1, characterized in that, The method further includes: Obtain the composition of a first adhesive solution at a first moment in the production of the target fiber, and the composition of a second adhesive solution at a second moment in the production of the target fiber, wherein the second moment is later than the first moment; The step of adjusting the factors influencing the target torque, with the goal of reducing the difference between the current torque and the target torque, if the difference between the current torque and the target torque is greater than a first difference threshold, includes: If the difference between the current torque and the target torque is greater than the first difference threshold, and the difference between the first adhesive composition and the second adhesive composition is greater than the third difference threshold, then the adjustment target is to reduce the difference between the current torque and the target torque, and at least one of the cooling air temperature or the adhesive temperature is adjusted.
5. The method according to claim 1, characterized in that, The current torque is obtained in the following way: The torque corresponding to each of the multiple drawing rollers used to produce the target fiber is obtained, and the multiple drawing rollers include a winding drawing roller, a washing drawing roller, and the cutting drawing roller. The current torque is determined based on the torques corresponding to the plurality of drawing rollers and the torque weights corresponding to the plurality of drawing rollers, wherein the torque weight of the winding drawing roller is greater than the torque weight of the washing drawing roller, and the torque weight of the winding drawing roller is greater than the torque weight of the cutting drawing roller.
6. The method according to claim 1, characterized in that, The step of determining the target torque of the target fiber based on the target fineness includes: The torque for the target fineness is determined based on a preset correspondence between the target torque and the target fineness; The preset correspondence is determined in the following way: Obtain fibers from multiple samples with different target fineness; Determine the quality indicators of the fibers used to produce each target fineness sample under different torques; The torques whose difference between the quality index and the quality target is less than the quality difference threshold are determined as the target torque samples corresponding to each target fineness sample; The preset correspondence is obtained by fitting the target torque samples corresponding to each of the target fineness samples.
7. A spinning control device, characterized in that, The device includes: The acquisition unit is used to acquire the target fineness and current torque of the target fiber, wherein the current torque is the torque of the drafting roller currently producing the target fiber; A determining unit is configured to determine the target torque of the target fiber based on the target fineness, wherein when the torque of the drawing roller that produces the target fiber is the target torque, the target fiber meets a quality condition, and the quality condition is used to indicate that the difference between the quality index of the target fiber and the quality target is less than a quality difference threshold. An adjustment unit is configured to, if the difference between the current torque and the target torque is greater than a first difference threshold, adjust the factors influencing the target torque with the goal of reducing the difference between the current torque and the target torque, wherein the factors influencing the target torque include at least one of cooling air temperature, adhesive composition, or adhesive temperature.
8. The apparatus according to claim 1, characterized in that, The device further includes an adhesive composition acquisition unit, used for: Obtain the composition of a first adhesive solution at a first moment in the production of the target fiber, and the composition of a second adhesive solution at a second moment in the production of the target fiber, wherein the second moment is later than the first moment; The adjustment unit is specifically used for: If the difference between the current torque and the target torque is greater than the first difference threshold, and the difference between the first adhesive composition and the second adhesive composition is greater than the third difference threshold, then the adjustment target is to reduce the difference between the current torque and the target torque, and at least one of the cooling air temperature or the adhesive temperature is adjusted.
9. A spinning control system, characterized in that, The spinning control system includes a torque acquisition module, a target torque determination module, and a process control module, wherein: The torque acquisition module is used to acquire the current torque, which is the torque of the drafting roller currently producing the target fiber; The target torque determination module is used to obtain the target fineness of the target fiber and determine the target torque of the target fiber based on the target fineness. When the torque of the drawing roller that produces the target fiber is the target torque, the target fiber meets the quality condition. The quality condition is used to indicate that the difference between the quality index of the target fiber and the quality target is less than a quality difference threshold. The process adjustment module is used to adjust the influencing factors of the target torque if the difference between the current torque and the target torque is greater than a first difference threshold. The adjustment target is to reduce the difference between the current torque and the target torque. The influencing factors of the target torque include at least one of cooling air temperature, adhesive composition, or adhesive temperature.
10. A fiber production line, characterized in that, It includes the spinning control system as described in claim 9, the drawing roller, the spinneret, the coagulation bath, and a cooling air temperature control device, a glue temperature control device, and a feeding device that are communicatively connected to the spinning control system, wherein the feeding device is used to control the composition of the glue.