Intelligent control system of warp knitting machine

Abstract

The invention discloses an intelligent control system for a warp knitting machine. The intelligent control system comprises a control assembly, an execution assembly, a communication assembly and a management software system, the control assembly is provided with a motion controller and a servo driver, the motion controller is provided with a let-off control module, a guide bar transverse movement control module and a traction winding control module, and the control assembly further comprises an online monitoring and fault diagnosis module, a data collecting and tracing module and a remote operation and maintenance and cooperation module. According to the intelligent system, the rotating speed of equipment can be increased by 20-30%, the comprehensive productivity can be increased by 30% or above, the defective rate of grey cloth can be reduced by 50% or above through precise control and online monitoring of technological parameters, the downtime of the equipment can be shortened through remote operation and maintenance and preventive maintenance, the operation and maintenance cost can be reduced by 20-40%, the energy consumption of the equipment can be optimized through energy consumption monitoring and intelligent speed regulation, and the production efficiency of the grey cloth can be improved. And the power consumption of a unit product is reduced.

Description

Technical Field

[0001] This invention belongs to the field of control system technology, specifically, it relates to an intelligent control system for a warp knitting machine. Background Technology

[0002] With the rapid development of automation control technology and network communication technology, the production efficiency of traditional warp knitting machines can no longer keep up with the times. Feeding warp, combing bar lateral movement, and pulling and winding require multiple workers to spend time debugging various mechanical parts. Workers also need to patrol and supervise during the production process. The lack of automatic control and online monitoring results in low production efficiency and quality, and also consumes a lot of manpower. In order to improve production efficiency and quality, an intelligent control system for warp knitting machines is provided. Summary of the Invention

[0003] In view of this, the technical problem to be solved by the present invention is to provide an intelligent control system for warp knitting machines, which solves the problem of low production efficiency and quality of traditional warp knitting machines in the prior art.

[0004] To address the aforementioned technical problems, this invention discloses an intelligent control system for a warp knitting machine, comprising: a control component, an execution component, a communication component, and a management software system; the control component includes a motion controller and a servo driver, the motion controller includes a warp feed control module, a guide bar traverse control module, and a traction take-up control module, and the servo driver includes a warp feed servo motor, a guide bar traverse servo motor, and a traction take-up servo motor; the communication component includes an industrial Ethernet module, a wireless communication module, and a serial communication module; the management software system includes MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), a cloud platform, and big data analysis software; it also includes an online monitoring and fault diagnosis module, a data acquisition and traceability module, and a remote operation and maintenance and collaboration module.

[0005] Furthermore, the aforementioned warp feed control module monitors the yarn tension in real time through a tension sensor, and the warp feed servo motor dynamically adjusts the warp feed speed.

[0006] Furthermore, the aforementioned comb lateral movement control module adopts multi-axis servo synchronization technology to achieve independent or coordinated precise lateral movement of multiple combs.

[0007] Furthermore, the aforementioned pull-and-wind control module automatically matches the pull speed according to the fabric's structure and density to maintain stable fabric tension. At the same time, the winding mechanism can achieve constant tension winding of the fabric, ensuring the flatness of the fabric roll.

[0008] Furthermore, its online monitoring and fault diagnosis module monitors faults such as yarn breakage, abnormal tension, motor overload, and excessive temperature in real time.

[0009] Furthermore, the aforementioned data acquisition and traceability module automatically collects equipment operating parameters (speed, output, energy consumption), process parameters (pattern number, warp feed, drawing speed), and quality data (fabric weight, width deviation), and stores them in a local database or in the cloud.

[0010] Furthermore, its aforementioned remote operation and maintenance and collaboration modules enable remote parameter debugging, program upgrades, and fault diagnosis through a cloud platform.

[0011] Compared with the prior art, this application can achieve the following technical effects: The intelligent system of this invention can increase equipment speed by 20-30% and overall production capacity by more than 30%. Precise control and online monitoring of process parameters can reduce fabric defect rate by more than 50%. Remote operation and maintenance and preventive maintenance can reduce equipment downtime and reduce operation and maintenance costs by 20-40%. Through energy consumption monitoring and intelligent speed regulation, equipment energy consumption can be optimized and the power consumption per unit product can be reduced.

[0012] Of course, any product implementing this application does not necessarily need to achieve all of the technical effects described above at the same time. Attached Figure Description

[0013] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a logical schematic diagram of an intelligent control system according to an embodiment of the present invention. Attached Figure Labels

[0014] Control component 1, execution component 2, communication component 3, warp feed control module 4, comb transverse movement control module 5, traction and winding control module 6, online monitoring and fault diagnosis module 7, data acquisition and traceability module 8, remote operation and maintenance and collaboration module 9, host 10, switch 11. Detailed Implementation

[0015] The following will describe in detail the implementation of this application with reference to the accompanying drawings and embodiments, so that the implementation process of how this application uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0016] Please refer to Figure 1 , Figure 1 This is a logical schematic diagram of an intelligent control system according to an embodiment of the present invention.

[0017] An intelligent control system for a warp knitting machine includes: a control component 1, an execution component 2, a communication component 3, and a management software system. The control component 1 has a motion controller and a servo driver. The motion controller has a warp feed control module 4, a guide bar traverse control module 5, and a traction and take-up control module 6. The servo driver has a warp feed servo motor, a guide bar traverse servo motor, and a traction and take-up servo motor. The communication component 3 has an industrial Ethernet module, a wireless communication module, and a serial communication module. The management software system includes MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), a cloud platform, and big data analysis software. The control component 1 also includes an online monitoring and fault diagnosis module 7, a data acquisition and traceability module 8, and a remote operation and maintenance and collaboration module 9. The host 10 is connected to the control component 1, the execution component 2, and the communication component 3 through a switch 11. During operation, it can save and collect instructions and feedback data, which is convenient for the host 10 to integrate and analyze data through the management software system.

[0018] The execution component 2 includes various sensors (yarn tension sensor, yarn breakage detection sensor, needle bed displacement sensor, temperature and humidity sensor), servo motors (warp feed servo, tension servo, comb bar lateral movement servo), solenoid valves, stepper motors, etc., which collect equipment operating status and process parameters in real time, receive upper-level instructions and execute precise actions, such as controlling the lateral movement trajectory of the comb bar, stabilizing the tension of the warp feed, and matching the tension speed of the fabric.

[0019] Control component 1 includes a PLC (Programmable Logic Controller) or a dedicated motion controller, a servo driver, and a human-machine interface (HMI). It is the "computing center" of the system, responsible for parsing process pattern data, processing signals fed back from the sensing layer, outputting precise motion control commands, and realizing local operation, parameter setting, and fault alarm of the equipment.

[0020] The warp feed control module 4 monitors the yarn tension in real time through a tension sensor, and the warp feed servo motor dynamically adjusts the warp feed speed to ensure uniform tension in different areas and different yarns, avoiding defects such as sparse or dense patches and holes in the fabric. The control accuracy can reach ±0.1%.

[0021] The comb lateral movement control module 5 adopts multi-axis servo synchronization technology to achieve independent or coordinated precise lateral movement of multiple combs, with a lateral movement step accuracy of up to 0.01mm.

[0022] The pull-and-wind control module 6 automatically matches the pull speed according to the fabric's structure and density to maintain stable fabric tension. At the same time, the winding mechanism can achieve constant tension winding of the fabric to ensure the flatness of the roll.

[0023] The online monitoring and fault diagnosis module 7 monitors faults such as yarn breakage, abnormal tension, motor overload, and excessive temperature in real time. It issues audible and visual alarms or pushes early warning information through the HMI and cloud platform, and automatically records the fault time, cause, and location.

[0024] The data acquisition and traceability module 8 automatically collects equipment operating parameters (speed, output, energy consumption), process parameters (pattern number, warp feed, drafting speed), and quality data (fabric weight, width deviation), and stores them in a local database or in the cloud. It supports full product lifecycle traceability; by scanning a code, users can query the weaving equipment, process parameters, and operators corresponding to a specific batch of fabric, meeting quality control and customer traceability needs.

[0025] The remote operation and maintenance and collaboration module 9 enables remote parameter debugging, program upgrades, and fault diagnosis through a cloud platform. It supports cluster management of multiple warp knitting machines, allowing monitoring of the operating status of all equipment from the central control room and unified scheduling of production tasks.

[0026] The intelligent system of this invention can increase equipment speed by 20-30% and overall production capacity by more than 30%. Precise control and online monitoring of process parameters can reduce fabric defect rate by more than 50%. Remote operation and maintenance and preventive maintenance can reduce equipment downtime and reduce operation and maintenance costs by 20-40%. Through energy consumption monitoring and intelligent speed regulation, equipment energy consumption can be optimized and the power consumption per unit product can be reduced.

[0027] The foregoing description illustrates and describes several preferred embodiments of the present invention. However, as previously stated, it should be understood that the present invention is not limited to the forms disclosed herein and should not be construed as excluding other embodiments. It can be used in various other combinations, modifications, and environments, and can be altered within the scope of the inventive concept described herein through the foregoing teachings or techniques or knowledge in related fields. Any modifications and variations made by those skilled in the art that do not depart from the spirit and scope of the present invention should be within the protection scope of the appended claims.

Claims

1. An intelligent control system for a warp knitting machine, comprising: Control components, execution components, communication components, and management software systems; The system is characterized in that the control components include a motion controller and a servo driver; the motion controller includes a warp feed control module, a guide bar traverse control module, and a traction and take-up control module; the servo driver includes a warp feed servo motor, a guide bar traverse servo motor, and a traction and take-up servo motor; the communication components include an industrial Ethernet module, a wireless communication module, and a serial communication module; the management software system includes MES (Manufacturing Execution System), ERP (Enterprise Resource Planning), a cloud platform, and big data analysis software; and also includes an online monitoring and fault diagnosis module, a data acquisition and traceability module, and a remote operation and maintenance and collaboration module.

2. The intelligent control system for a warp knitting machine as described in claim 1, characterized in that, The warp feed control module monitors the yarn tension in real time through a tension sensor, and the warp feed servo motor dynamically adjusts the warp feed speed.

3. The intelligent control system for a warp knitting machine as described in claim 2, characterized in that, The comb lateral movement control module adopts multi-axis servo synchronization technology to achieve independent or coordinated precise lateral movement of multiple combs.

4. The intelligent control system for a warp knitting machine as described in claim 3, characterized in that, The pull-and-wind control module automatically matches the pull speed according to the fabric's structure and density to maintain stable fabric tension. At the same time, the winding mechanism can achieve constant tension winding of the fabric, ensuring the flatness of the fabric roll.

5. The intelligent control system for a warp knitting machine as described in claim 4, characterized in that, The online monitoring and fault diagnosis module monitors faults such as yarn breakage, abnormal tension, motor overload, and excessive temperature in real time.

6. The intelligent control system for a warp knitting machine as described in claim 5, characterized in that, The data acquisition and traceability module automatically collects equipment operating parameters (speed, output, energy consumption), process parameters (pattern number, warp feed, drawing speed), and quality data (fabric weight, width deviation), and stores them in a local database or in the cloud.

7. The intelligent control system for a warp knitting machine as described in claim 6, characterized in that, The remote operation and maintenance and collaboration module enables remote parameter debugging, program upgrades and fault diagnosis through a cloud platform.

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