A control system and method for preventing yarn overlap on a winding machine
By monitoring the relative phase of the yarn bobbin and the grooved bobbin in real time on the winding machine and dynamically adjusting the anti-overlapping parameters using a closed-loop control system, the problems of fixed anti-overlapping parameters and insufficient identification of overlapping trends in existing technologies are solved, achieving efficient and stable anti-overlapping effect and high-quality yarn bobbin forming.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- QINGDAO HONGDA TEXTILE MACHINERY
- Filing Date
- 2026-03-09
- Publication Date
- 2026-06-02
AI Technical Summary
Existing anti-overlap technology for winding machines cannot be adjusted according to dynamic working conditions such as yarn type and winding speed. It lacks accurate identification of overlapping trends, resulting in non-targeted anti-overlapping actions, large fluctuations in yarn tension, poor forming quality, and a lack of phase closed-loop control, leading to unstable anti-overlapping effects.
The relative phase is monitored in real time by encoders for yarn bobbin and grooved drum. The phase monitoring module, closed-loop control module and execution drive module of the central processing unit work together to achieve accurate identification and dynamic adjustment of phase locking trend, and build a phase displacement closed-loop adjustment mechanism to ensure the accuracy and adaptability of anti-overlap action.
It achieves adaptability and stability for multiple working conditions, improves anti-overlapping effect, reduces yarn tension fluctuation, ensures yarn forming quality and winding capacity, and reduces equipment modification and maintenance costs.
Smart Images
Figure CN122126703A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of textile machinery technology and relates to the improvement of automatic winding machines, specifically a winding machine yarn anti-overlapping control system and anti-overlapping method. Background Technology
[0002] The winding machine is a key piece of equipment in the textile production process. Its core function is to process raw yarns such as bobbins into yarn packages with large capacity, good shape, and uniform density, providing qualified yarn packages for subsequent warping, sizing, and weaving processes. During the operation of the winding machine, the yarn bobbin is driven to rotate by the grooved drum through friction transmission. At the same time, the grooved structure on the surface of the grooved drum guides the yarn to reciprocate and lay it up, ultimately forming a regular yarn package.
[0003] Under certain operating conditions, the speed ratio between the rotation of the slotted drum and the rotation of the yarn bobbin is close to a rational number, causing the yarn to fall onto the surface of the yarn bobbin periodically, resulting in a strip-like overlapping phenomenon. Overlapping yarn can lead to a decrease in forming quality, difficulty in subsequent unwinding, and even localized abrasions and an increased breakage rate.
[0004] Currently, the mainstream anti-overlap technologies for winding machines in the industry mainly include two types: mechanical and electrical. Mechanical anti-overlap technologies typically use special groove curves (such as spirals or zigzags) on the surface of the winding drum or add anti-overlap devices (such as anti-overlap pins or oscillating yarn guides) to change the yarn laying trajectory and avoid overlapping. Electrical anti-overlap technologies mostly use a fixed frequency and amplitude speed disturbance method, that is, by periodically changing the speed of the winding drum motor, the stable speed ratio between the winding drum and the yarn bobbin is broken, thereby suppressing overlapping.
[0005] However, existing technologies have the following problems and drawbacks:
[0006] (1) The anti-overlapping effect of mechanical anti-overlapping technology depends entirely on the groove structure design of the groove cylinder. After the equipment is manufactured, the anti-overlapping parameters are fixed and cannot be adjusted according to dynamic working conditions such as yarn type, winding speed, and yarn cylinder diameter. When the working conditions change, anti-overlapping failure and repeated yarn overlapping are likely to occur. Moreover, the special groove is difficult to process and costly. After long-term use, the groove wear will further reduce the anti-overlapping effect, resulting in high maintenance costs. For example, Chinese utility model patent (publication number: CN2174459Y) discloses an "anti-overlap groove cylinder", which changes the pointed return groove head of the original groove cylinder to a flat return groove head and increases the average pitch of the groove cylinder by 63.6 mm, so that the doffed yarn can slide freely in the return groove head and automatically change the movement position of the yarn, thus playing the role of anti-overlapping. This type of technology has the following inherent defects: the anti-overlapping parameters depend entirely on the mechanical structure and cannot be dynamically adjusted according to working conditions such as yarn type and winding speed. Moreover, the special groove processing requires high precision and is expensive. After long-term use and wear, the anti-overlapping effect is significantly reduced, resulting in high maintenance costs.
[0007] (2) Electrical anti-overlap technology uses open-loop speed disturbances with fixed frequency and amplitude, lacking accurate identification and feedback of overlapping trends. When there is no risk of overlapping, redundant disturbances will exacerbate yarn tension fluctuations and affect the quality of yarn bobbin forming; after the overlapping trend is formed, the fixed parameters may not be able to effectively break the phase lock, and the anti-overlapping effect is unstable; at the same time, it does not consider the individual differences in yarn bobbin inertia and friction characteristics, and is prone to excessive or insufficient disturbance, failing to balance winding capacity and yarn quality. For example, Chinese invention patent (publication number: CN113651173B) proposes "a method for preventing overlapping in electronic yarn forming", which uses the rotation speed of the winding or spindle motor to change the traverse speed of the traverse motor and make it irregular, avoiding periodic overlapping during yarn forming, thereby improving the quality of the yarn bobbin. The above technologies generally have the following problems: ① lack of real-time monitoring of overlapping trends, and redundant disturbances exacerbate tension fluctuations when there is no overlapping; ② fixed parameters are difficult to adapt to changes in working conditions, and the disturbance is excessive or insufficient; ③ no closed-loop control is formed, and it is impossible to dynamically adjust according to the actual phase state.
[0008] (3) Both of the above technologies have a common core defect: they fail to grasp the essential cause of yarn stacking - the phase lock formed when the speed ratio of the groove drum and the yarn drum approaches a rational number, which leads to the periodic repetition of the yarn landing point. Therefore, it is impossible to achieve real-time monitoring and closed-loop control of the relative phase relationship between the two.
[0009] Existing technologies rely solely on passive structural optimization or indiscriminate perturbations, failing to accurately determine the timing of yarn overlap trends. The anti-overlap actions lack specificity and cannot address the root cause of the problem. A search of Chinese patents (such as publication numbers CN2174459Y, CN113651173B, CN106829627B, and CN101104489B) reveals a focus on structural improvements or open-loop perturbations, with no solutions found that synchronously monitor the phase of both bobbins using encoders and construct a closed-loop control system. This core deficiency results in existing anti-overlap actions lacking specificity and failing to balance yarn quality with winding capacity.
[0010] Therefore, there is an urgent need in this field to design a control system and method for preventing yarn overlap on winding machines, in order to solve the following technical problems:
[0011] (1) Solve the problems of fixed anti-overlapping parameters and inability to adapt to dynamic working conditions such as yarn type and winding speed in existing mechanical anti-overlapping technology, as well as the defects of existing electrical anti-overlapping technology in lacking accurate identification of overlapping trend and insufficient anti-overlapping disturbance, to achieve accurate monitoring of the phase locking trend of the groove drum and the yarn drum, and achieve the goal of triggering anti-overlapping action on demand.
[0012] (2) To solve the problems of large yarn tension fluctuations and poor yarn forming quality caused by fixed parameter disturbance in the existing anti-overlap technology, and the unstable anti-overlap effect due to working conditions, controllable phase migration based on the overlap state is realized, which can effectively break phase lock and suppress overlap while reducing the adverse effects on yarn tension stability and winding capacity.
[0013] (3) To solve the problem that the existing technology lacks a closed-loop control mechanism for the relative phase of the grooved tube and the yarn tube, and cannot dynamically adjust the anti-overlapping action according to the actual phase relationship between the two, resulting in excessive or insufficient disturbance, by constructing a phase closed-loop control system, the accuracy and adaptability of the anti-overlapping action are ensured, and the reliability and consistency of the anti-overlapping effect under different working conditions are improved. Summary of the Invention
[0014] To address the aforementioned problems in the prior art, this invention provides a winding machine yarn anti-overlapping control system and method, which can monitor and intelligently determine the relative phase of the yarn bobbin and the grooved bobbin in real time, ensuring the accuracy and adaptability of the anti-overlapping action, while taking into account both yarn quality and winding capacity.
[0015] The objective of this invention is achieved through the following technical solution: a yarn anti-overlap control system for a winding machine, comprising a yarn bobbin, a yarn bobbin winding shaft, a grooved bobbin, a grooved bobbin rotating shaft, a grooved bobbin drive motor, and a central processing unit. The central processing unit is connected to the control terminal of the grooved bobbin drive motor and is used to control the grooved bobbin drive motor to operate at a commanded speed. The grooved bobbin drive motor drives the grooved bobbin on the grooved bobbin rotating shaft to rotate. The grooved bobbin rotates by rubbing its surface against the yarn bobbin on the yarn bobbin winding shaft, causing the yarn to be repeatedly laid between the grooved bobbins to form a package. The invention is characterized in that a yarn bobbin encoder is installed at the end of the yarn bobbin winding shaft, and a grooved bobbin encoder is installed at the end of the grooved bobbin rotating shaft. The central processing unit includes a phase monitoring module, a closed-loop control module, and an execution drive module. The phase monitoring module is respectively connected to... The yarn bobbin encoder, slotted drum encoder, closed-loop control module, and execution drive module are connected. The phase monitoring module collects the rotation angle and speed of the yarn bobbin and slotted drum through the yarn bobbin encoder and slotted drum encoder, respectively. After data processing, it calculates the relative phase relationship and speed ratio between the two, accurately identifies the timing of the formation of the phase locking trend, and provides phase data for triggering the anti-overlapping action. The closed-loop control module presets the phase threshold and dynamic disturbance strategy. Based on the phase data fed back by the phase monitoring module, it adjusts the anti-overlapping disturbance parameters in real time and constructs a phase displacement closed-loop adjustment mechanism. The execution drive module responds to the instructions of the closed-loop control module and controls the slotted drum drive motor to perform precise speed adjustment, realize controllable phase migration, break the formed phase locking state, and minimize the impact of speed fluctuations on yarn tension.
[0016] Improvements to the above technical solution: Both the slotted drum encoder and the yarn drum encoder adopt incremental magnetoelectric encoders.
[0017] Further improvements to the above technical solution: The closed-loop control module dynamically corrects the disturbance command according to the actual phase deviation to avoid excessive or insufficient disturbance; the controller in the closed-loop control module adopts a programmable logic controller or a digital signal processor, and the central processing unit has a built-in high-speed counting module to receive pulse signals from the slotted drum encoder and the yarn drum encoder, and performs phase calculation, yarn overlap determination and closed-loop control algorithm.
[0018] Further improvement to the above technical solution: The central processing unit communicates with the driver of the slotted cylinder drive motor through an analog output interface or an industrial bus to send a speed command signal for the slotted cylinder drive motor.
[0019] Further improvements to the above technical solution: The slotted cylinder drive motor adopts a servo motor or a variable frequency speed control motor; the slotted cylinder encoder outputs A / B phase quadrature pulse signals and Z phase zero-position pulse signals to the controller through a shielded cable as a reference phase reference for the slotted cylinder; the yarn drum encoder outputs A / B phase quadrature pulse signals and Z phase zero-position pulse signals to the controller through a shielded cable.
[0020] The present invention discloses a control method for the above-mentioned anti-overlapping control system for winding machine bobbins, characterized in that anti-overlapping of yarn is achieved through the coordinated operation of a phase monitoring module, a closed-loop control module, and an execution drive module. The control method includes the following steps:
[0021] Step 1: The phase monitoring module collects the rotation angle and speed of the yarn bobbin and the slotted drum through the yarn bobbin encoder and the slotted drum encoder. After data processing, it calculates the relative phase relationship and speed ratio between the two, accurately identifies the timing of the formation of the phase locking trend, and provides phase data for triggering the anti-overlapping action.
[0022] Step 2: The closed-loop control module presets the phase threshold and dynamic disturbance strategy. Based on the phase data fed back by the phase monitoring module, it adjusts the anti-overlap disturbance parameters in real time. At the same time, it constructs a phase displacement closed-loop adjustment mechanism to dynamically correct the disturbance command according to the actual phase deviation, so as to avoid excessive or insufficient disturbance.
[0023] Step 3: The drive module responds to the instructions of the closed-loop control module and controls the grooved drum drive motor to perform precise speed adjustment, realize controllable phase shift, break the phase lock state, and minimize the impact of speed fluctuation on yarn tension.
[0024] Improvements to the above technical solution: The phase sampling reference synchronization method of the phase monitoring module is implemented through a slotted cylinder reference phase-triggered sampling mechanism, as follows:
[0025] The cumulative pulse count of the slotted encoder is The cumulative pulse count of the yarn drum encoder is The real-time angle of the groove cylinder The calculation is as follows:
[0026]
[0027] real-time angle of yarn bobbin The calculation is as follows:
[0028]
[0029] Sampling triggering mechanism:
[0030] Sampling is triggered when the slotted bobbin is at a fixed reference phase. The slotted bobbin encoder's Z-phase is triggered, and the central processing unit captures the Z-phase pulse of the slotted bobbin encoder, triggering an interrupt once per revolution. The current cumulative value of the bobbin encoder is read in the interrupt service routine. This serves as the phase sample at that sampling moment;
[0031] The Z-phase pulse of the slotted cylinder encoder corresponds precisely to the mechanical position of slotted cylinder 3, with a repeatability of ±1 pulse.
[0032] The phase-locked monitoring and yarn overlap trend determination algorithm is as follows:
[0033] (1) Phase difference calculation
[0034] At the k-th sampling time, read the cumulative value of the yarn bobbin encoder. And calculate the phase change with respect to the (k-1)th sample. The calculation formula is as follows:
[0035]
[0036] In the formula: This reflects the relative displacement of the yarn bobbin within one cycle of the grooved drum; when the speed ratio between the grooved drum and the yarn bobbin approaches a rational number, It tends to a constant value; when the phase is locked, Small values that approach 0 or repeat stably;
[0037] (2) Calculation of Lock-in Degree Index
[0038] Given a window length of W, calculate the standard deviation or absolute mean of the phase changes from the most recent W samples using one of the following formulas:
[0039] Standard deviation index
[0040]
[0041] In the formula: For the window The arithmetic mean when At that time, the phase is determined to be highly locked. To determine the threshold parameter;
[0042] ② Absolute change index
[0043]
[0044] In the formula: At that time, the phase was determined to be highly locked. To determine the threshold parameter;
[0045] (3) Calculation of overlapping yarn trend
[0046] Set the decision threshold With the number of consecutive judgments K, a yarn overlap warning is triggered when the following conditions are met:
[0047]
[0048]
[0049] If the above conditions are met consecutively for K times, the yarn overlapping trend is determined to be established, and the anti-overlapping action is executed.
[0050] (4) Target phase displacement calculation
[0051] The anti-overlap action breaks the phase lock state through controllable sliding, requiring the setting of a reasonable phase displacement amount; target displacement. The following two principles should be met: ① The displacement amount needs to be large enough to significantly deviate the yarn landing point from its original trajectory, avoiding rapid relocking; ② The displacement amount should not be too large to avoid unnecessary tension fluctuations and production capacity loss.
[0052] Choose one of the following two implementation methods:
[0053] According to the diameter of the yarn bobbin and yarn diameter The calculation is performed, and the formula for calculating the target displacement is as follows:
[0054]
[0055] In the formula: The number of yarn loops per layer on the surface of the yarn tube. , The diameter of the yarn. It is the displacement coefficient;
[0056] ② The target displacement is calculated using an empirical method, and the formula is as follows:
[0057] In the formula: M is the multiplier factor.
[0058] Further improvements to the above technical solution: The working method of the closed-loop control module includes:
[0059] 1. Velocity disturbance curve of the groove cylinder
[0060] To reduce the impact on yarn tension, a trapezoidal acceleration / deceleration curve is preferred for speed regulation:
[0061] Deceleration section: from the current trough speed With acceleration Reduce speed to low speed ;
[0062] Low-speed maintenance phase: at low speed Maintain this position for a period of time, utilizing the inertia of the yarn bobbin to generate relative slippage;
[0063] Acceleration phase: with acceleration Accelerate to original speed .
[0064] To ensure that the anti-overlapping action does not disrupt yarn tension stability, prevent yarn breakage and quality defects, and avoid destructive slippage between the yarn bobbin and the grooved bobbin, acceleration is limited. The acceleration limit formula is calculated as follows:
[0065]
[0066] In the formula: F is the maximum static friction force between the grooved drum and the yarn bobbin. The moment of inertia of the yarn bobbin and yarn;
[0067] 2. Phase closed-loop monitoring
[0068] During the anti-overlapping action, the controller still samples the yarn bobbin phase at a period of T, calculates the cumulative phase lock degree, and when the condition is met... Under certain conditions, the anti-overlapping action is terminated, or the protection is exited after a timeout. When exiting, the controller sends a recovery command to drive the trough cylinder to accelerate to normal speed in a trapezoidal curve.
[0069] Further improvements to the above technical solution: The parameter adaptive optimization method in this invention is as follows:
[0070] To adapt to different yarn types and working conditions, an online parameter self-tuning method is provided:
[0071] Threshold self-learning
[0072] Recording during the normal winding phase Historical data, calculate the mean and standard deviation , The formula for dynamic adaptive adjustment is as follows:
[0073]
[0074] ② Adaptive velocity disturbance amplitude
[0075] Adjust as needed according to the diameter of the yarn package. The calculation formula is as follows:
[0076]
[0077] In the formula: and These are the minimum and maximum diameters of the yarn package.
[0078] Compared with the prior art, the present invention has the following advantages and positive effects:
[0079] 1. This invention has wider adaptability and is suitable for various working conditions. Existing technologies rely on fixed grooves for mechanical applications and fixed parameters for electrical applications, which cannot cope with changes in various working conditions. This invention, through real-time phase monitoring and closed-loop control, eliminates the need for special groove structures and can automatically adapt to dynamic working conditions such as yarn type and winding speed, improving equipment versatility and reducing working condition switching costs.
[0080] 1. The anti-scrapping effect of this invention is precise and stable. Existing technologies passively respond to or indiscriminately handle disturbances, making it difficult to capture phase-locking trends and resulting in fluctuating effectiveness. This invention monitors the relative phase and triggers controllable phase migration on demand, avoiding redundant disturbances and significantly improving the success rate and stability of anti-scrapping.
[0081] 3. This invention balances quality and capacity, improving production efficiency. By dynamically optimizing disturbance parameters and implementing closed-loop adjustment, this invention minimizes the impact on yarn tension, ensuring the quality of yarn package formation, reducing abrasion and breakage rates, while simultaneously avoiding ineffective disturbance losses, achieving a synergistic improvement in anti-overlap, quality, and efficiency.
[0082] 4. This invention offers superior economic efficiency and reduces overall costs. Existing mechanical grooved cylinders have high processing and maintenance costs. This invention eliminates the need for special grooved cylinders, allowing for upgrades to existing equipment by adding encoders and control modules. The modification is simple, cost-effective, and avoids groove wear and attenuation issues, extending maintenance cycles, reducing long-term operating costs, and facilitating widespread application. Attached Figure Description
[0083] Figure 1 This is a schematic diagram of the overall architecture and hardware connection structure of a winding machine yarn anti-overlap control system according to the present invention;
[0084] Figure 2 This is a schematic diagram of the functional module structure of a winding machine yarn anti-overlap control system according to the present invention.
[0085] The numbers in the diagram are: 1. Yarn bobbin; 2. Yarn bobbin encoder; 3. Grooved drum; 4. Grooved drum drive motor; 5. Control system; 6. Grooved drum encoder. Detailed Implementation
[0086] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments:
[0087] See Figure 1 , Figure 2 This invention discloses an embodiment of a yarn anti-overlap control system for a winding machine, comprising a yarn bobbin 1, a yarn bobbin winding shaft, a grooved drum 3, a grooved drum rotating shaft, a grooved drum drive motor 4, and a control system 5. The control system 5 is connected to the control terminal of the grooved drum drive motor 4 and is used to control the grooved drum drive motor 4 to operate at a commanded speed. The grooved drum drive motor 4 drives the grooved drum 3 on the grooved drum rotating shaft to rotate. The grooved drum 3 drives the yarn bobbin 1 on the yarn bobbin winding shaft to rotate through surface friction. The yarn is guided by the grooved structure on the surface of the grooved drum 3 and is repeatedly laid between the grooved drum 3 and the yarn bobbin 1 to form a package. Specifically, the grooved drum 3 can be directly driven to rotate by the grooved drum drive motor 4 through a coupling.
[0088] A yarn bobbin encoder 2 is installed at the end of the yarn bobbin winding shaft to collect the rotation angle and speed of the yarn bobbin 1 in real time. Specifically, a sensor is added inside the yarn bobbin winding shaft, and the yarn bobbin encoder 2 is installed close to the sensor. A slotted drum encoder 6 is installed at the end of the slotted drum rotating shaft. Specifically, a sensor is added inside the slotted drum rotating shaft, and the slotted drum encoder 6 is installed close to the sensor, to collect the rotation angle and speed of the slotted drum 3 in real time. The central processing unit includes a phase monitoring module, a closed-loop control module, and an execution drive module. The phase monitoring module is connected to the yarn bobbin encoder 2, the slotted drum encoder 5, the closed-loop control module, and the execution drive module, respectively. The phase monitoring module collects the rotation angle and speed of the yarn bobbin 1 and the slotted drum 3 through the yarn bobbin encoder 2 and the slotted drum encoder 6, respectively. After data processing, it calculates the relative phase relationship and speed ratio between the two, accurately identifies the timing of the formation of the phase locking trend, and provides phase data for triggering the anti-overlapping action. The closed-loop control module presets the phase threshold and dynamic disturbance strategy. Based on the phase data fed back by the phase monitoring module, it adjusts the anti-overlapping disturbance parameters in real time and constructs a phase displacement closed-loop adjustment mechanism. The aforementioned execution drive module responds to the instructions of the closed-loop control module, controls the grooved cylinder drive motor to perform precise speed adjustment, realizes controllable phase shift, breaks the established phase lock state, and minimizes the impact of speed fluctuations on yarn tension.
[0089] Furthermore, both the slotted drum encoder 6 and the yarn drum encoder 2 described above are incremental magnetoelectric encoders.
[0090] Furthermore, the aforementioned closed-loop control module can dynamically correct disturbance commands based on actual phase deviations to avoid excessive or insufficient disturbances. The controller in the aforementioned closed-loop control module adopts a programmable logic controller or a digital signal processor. The high-speed counting module built into the aforementioned central processing unit receives pulse signals from the slotted drum encoder 6 and the yarn drum encoder 2, and performs phase calculation, yarn overlap determination, and closed-loop control algorithm.
[0091] Furthermore, the aforementioned central processing unit communicates with the driver of the slotted drum drive motor via an analog output interface or an industrial bus, sending speed command signals to the slotted drum drive motor 4.
[0092] Furthermore, the aforementioned slotted cylinder drive motor 4 is a servo motor or a variable frequency speed control motor, and the aforementioned slotted cylinder encoder 6 outputs A / B phase quadrature pulse signals and Z phase zero-position pulse signals to the aforementioned controller via a shielded cable, serving as a reference phase standard for the slotted cylinder. The aforementioned yarn bobbin encoder 2 outputs A / B phase quadrature pulse signals and Z phase zero-position pulse signals to the controller via a shielded cable.
[0093] See Figure 1 , Figure 2 An embodiment of the control method for the above-mentioned anti-overlapping control system of a winding machine bobbin according to the present invention achieves yarn anti-overlapping through the coordinated work of a phase monitoring module, a closed-loop control module, and an execution drive module. The control method includes the following steps:
[0094] Step 1: The phase monitoring module collects the rotation angle and speed of yarn bobbin 1 and grooved drum 3 through yarn bobbin encoder 2 and grooved drum encoder 6. After data processing, it calculates the relative phase relationship and speed ratio between the two, accurately identifies the timing of the formation of the phase locking trend, and provides phase data for triggering the anti-overlapping action.
[0095] Step 2: The closed-loop control module presets the phase threshold and dynamic disturbance strategy. Based on the phase data fed back by the phase monitoring module, it adjusts the anti-overlap disturbance parameters in real time. At the same time, it constructs a phase displacement closed-loop adjustment mechanism to dynamically correct the disturbance command according to the actual phase deviation, so as to avoid excessive or insufficient disturbance.
[0096] Step 3: The drive module responds to the instructions of the closed-loop control module and controls the grooved cylinder drive motor 4 to perform precise speed adjustment, realize controllable phase shift, break the phase lock state that has been formed, and minimize the impact of speed fluctuation on yarn tension.
[0097] Furthermore, the phase sampling reference synchronization method of the phase monitoring module, through the slotted cylinder reference phase triggered sampling mechanism, is implemented as follows:
[0098] The cumulative pulse count of the slotted encoder is The cumulative pulse count of the yarn drum encoder is The real-time angle of the groove cylinder The calculation is as follows:
[0099]
[0100] real-time angle of yarn bobbin The calculation is as follows:
[0101]
[0102] Sampling triggering mechanism:
[0103] Sampling needs to be triggered when slotted cylinder 3 is in a fixed reference phase, triggered by the encoder's Z phase. The controller is configured to capture the Z phase pulse of slotted cylinder encoder 6, triggering an interrupt once per revolution. The current cumulative value of the yarn bobbin encoder is read in the interrupt service routine. This serves as the phase sample at that sampling moment;
[0104] The 6Z phase pulses of the slot encoder correspond precisely to the mechanical position of the slot 3, with a repeatability of ±1 pulse.
[0105] The phase-locked monitoring and yarn overlap trend determination algorithm is as follows:
[0106] (1) Phase difference calculation
[0107] At the k-th sampling time, read the cumulative value of yarn cylinder encoder 2. And calculate the phase change with respect to the (k-1)th sample. The calculation formula is as follows:
[0108]
[0109] In the formula: This reflects the relative displacement of bobbin 1 within one cycle of the grooved drum 3. When the rotational speed ratio between the grooved drum 3 and bobbin 1 approaches a rational number, It tends to a constant value; when the phase is locked, Small values that are close to 0 or repeat steadily.
[0110] (2) Calculation of Lock-in Degree Index
[0111] Calculate the standard deviation or absolute mean of the phase changes from the most recent W samples using one of the following formulas:
[0112] Standard deviation index
[0113]
[0114] In the formula: For the window The arithmetic mean when At that time, the phase is determined to be highly locked. To determine the threshold parameter;
[0115] ② Absolute change index
[0116]
[0117] In the formula: At that time, the phase was determined to be highly locked. To determine the threshold parameter.
[0118] (3) Calculation of overlapping yarn trend
[0119] Set the decision threshold With the number of consecutive judgments K, a yarn overlap warning is triggered when the following conditions are met:
[0120]
[0121]
[0122] If the above conditions are met consecutively for K times, the yarn overlapping trend is determined to be established, and the anti-overlapping action is executed.
[0123] (4) Target phase displacement calculation
[0124] The anti-overlap action breaks the phase lock state through controllable sliding, requiring a reasonable phase displacement amount to be set. Target displacement. The following two principles should be met: ① The displacement amount needs to be large enough to significantly deviate the yarn landing point from its original trajectory, avoiding rapid relocking; ② The displacement amount should not be too large to avoid unnecessary tension fluctuations and production capacity loss.
[0125] Choose one of the following two implementation methods:
[0126] According to the diameter of the yarn bobbin and yarn diameter The calculation is performed, and the formula for calculating the target displacement is as follows:
[0127]
[0128] In the formula: The number of yarn loops per layer on the surface of the yarn tube. , The diameter of the yarn. This is the displacement coefficient.
[0129] ② The target displacement is calculated using an empirical method, and the formula is as follows:
[0130] In the formula: M is the multiplier factor.
[0131] Furthermore, the working method of the closed-loop control module includes:
[0132] (1) Velocity disturbance curve of the groove cylinder
[0133] To reduce the impact on yarn tension, a trapezoidal acceleration / deceleration curve is preferred for speed regulation:
[0134] Deceleration section: from the current trough speed With acceleration Reduce speed to low speed ;
[0135] Low-speed maintenance phase: at low speed Maintain this position for a period of time, and utilize the inertia of yarn tube 1 to generate relative slippage;
[0136] Acceleration phase: with acceleration Accelerate to original speed .
[0137] To ensure that the anti-overlapping action does not disrupt yarn tension stability, prevent yarn breakage and quality defects, and avoid destructive slippage between yarn bobbin 1 and grooved bobbin 3, acceleration is limited. The acceleration limit formula is calculated as follows:
[0138]
[0139] In the formula: F is the maximum static friction force between the grooved cylinder 3 and the yarn cylinder 1. Let be the moment of inertia of the yarn bobbin 1 and the yarn.
[0140] (2) Phase closed-loop monitoring
[0141] During the anti-overlapping action, the central processing unit still samples the yarn bobbin phase at a fixed period to calculate the cumulative phase lock degree. When the condition is met... Under certain conditions, the anti-overlapping action is terminated, or the protection is exited after a timeout. When exiting, the central processing unit sends a recovery command to drive the trough cylinder 3 to accelerate to normal speed according to a trapezoidal curve.
[0142] Furthermore, the parameter adaptive optimization method in this invention is as follows:
[0143] To adapt to different yarn types and working conditions, an online parameter self-tuning method is provided:
[0144] Threshold self-learning
[0145] Recording during the normal winding phase Historical data, calculate the mean and standard deviation , The formula for dynamic adaptive adjustment is as follows:
[0146]
[0147] ② Adaptive velocity disturbance amplitude
[0148] Adjust as needed according to the diameter of the yarn package. The calculation formula is as follows:
[0149]
[0150] In the formula: and These are the minimum and maximum diameters of the yarn package.
[0151] In summary, this invention, through the logic of "monitoring first, then regulating, and dynamically adapting," does not rely on special groove structures. It can adaptively adjust the anti-overlapping parameters according to changes in working conditions such as yarn type and winding speed, thereby achieving precise suppression of yarn overlap and ensuring stable yarn forming quality and winding capacity.
[0152] The above description is not intended to limit the present invention, nor is the present invention limited to the examples given above. Any changes, modifications, additions, or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.
Claims
1. A yarn anti-overlap control system for a winding machine, comprising a yarn bobbin, a yarn bobbin winding shaft, a grooved drum, a grooved drum rotating shaft, a grooved drum drive motor, and a central processing unit. The central processing unit is connected to the control terminal of the grooved drum drive motor and is used to control the grooved drum drive motor to operate at a commanded speed. The grooved drum drive motor drives the grooved drum on the grooved drum rotating shaft to rotate. The grooved drum rotates by rubbing its surface against the yarn bobbin on the yarn bobbin winding shaft, causing the yarn to be repeatedly laid out between the grooved drums to form a package. The system is characterized in that... A yarn bobbin encoder is installed at the end of the yarn bobbin winding shaft, and a slotted drum encoder is installed at the end of the slotted drum rotating shaft. The central processing unit includes a phase monitoring module, a closed-loop control module, and an execution drive module. The phase monitoring module is connected to the yarn bobbin encoder, the slotted drum encoder, the closed-loop control module, and the execution drive module, respectively. The phase monitoring module collects the rotation angle and rotation speed of the yarn bobbin and the slotted drum through the yarn bobbin encoder and the slotted drum encoder, respectively. After data processing, it calculates the relative phase relationship and rotation speed ratio between the two, accurately identifies the timing of the formation of the phase locking trend, and provides phase data for triggering the anti-overlapping action. The closed-loop control module presets a phase threshold and a dynamic disturbance strategy, and adjusts the anti-overlap disturbance parameters in real time based on the phase data fed back by the phase monitoring module. The execution drive module responds to the instructions of the closed-loop control module and controls the slotted drum drive motor to perform precise speed adjustment, realize controllable phase migration, break the established phase lock state, and minimize the impact of speed fluctuations on yarn tension.
2. The anti-overlapping control system for winding machine bobbins according to claim 1, characterized in that, Both the slotted drum encoder and the yarn drum encoder are incremental magnetoelectric encoders.
3. The anti-overlapping control system for winding machine bobbins according to claim 1 or 2, characterized in that, The closed-loop control module dynamically corrects the disturbance command based on the actual phase deviation to avoid excessive or insufficient disturbance. The controller in the closed-loop control module adopts a programmable logic controller or a digital signal processor. The central processing unit has a built-in high-speed counting module that receives pulse signals from the slotted drum encoder and the yarn drum encoder, and performs phase calculation, yarn overlap determination and closed-loop control algorithm.
4. The anti-overlapping control system for winding machine bobbins according to claim 3, characterized in that, The central processing unit communicates with the driver of the slotted cylinder drive motor through an analog output interface or an industrial bus, and sends speed command signals to the slotted cylinder drive motor.
5. The anti-overlapping control system for winding machine bobbins according to claim 1 or 2, characterized in that, The slotted cylinder drive motor is a servo motor or a variable frequency speed control motor. The slotted cylinder encoder outputs A / B phase quadrature pulse signals and Z phase zero position pulse signals to the controller through a shielded cable as a reference phase reference for the slotted cylinder. The yarn drum encoder outputs A / B phase quadrature pulse signals and Z phase zero position pulse signals to the controller through a shielded cable.
6. The anti-overlapping control system for winding machine bobbins according to claim 3, characterized in that, The slotted cylinder drive motor is a servo motor or a variable frequency speed control motor. The slotted cylinder encoder outputs A / B phase quadrature pulse signals and Z phase zero position pulse signals to the controller through a shielded cable as a reference phase reference for the slotted cylinder. The yarn drum encoder outputs A / B phase quadrature pulse signals and Z phase zero position pulse signals to the controller through a shielded cable.
7. A control method for a winding machine yarn anti-overlap control system as described in any one of claims 1-6, characterized in that, Yarn anti-overlap is achieved through the coordinated operation of the phase monitoring module, closed-loop control module, and execution drive module. The control method includes the following steps: Step 1: The phase monitoring module collects the rotation angle and speed of the yarn bobbin and the slotted drum through the yarn bobbin encoder and the slotted drum encoder. After data processing, it calculates the relative phase relationship and speed ratio between the two, accurately identifies the timing of the formation of the phase locking trend, and provides phase data for triggering the anti-overlapping action. Step 2: The closed-loop control module presets the phase threshold and dynamic disturbance strategy. Based on the phase data fed back by the phase monitoring module, it adjusts the anti-overlap disturbance parameters in real time. At the same time, it constructs a phase displacement closed-loop adjustment mechanism to dynamically correct the disturbance command according to the actual phase deviation, so as to avoid excessive or insufficient disturbance. Step 3: The drive module responds to the instructions of the closed-loop control module and controls the grooved drum drive motor to perform precise speed adjustment, realize controllable phase shift, break the phase lock state, and minimize the impact of speed fluctuation on yarn tension.
8. The control method for the anti-overlapping control system of the winding machine bobbin according to claim 7, characterized in that, The phase sampling reference synchronization method of the phase monitoring module uses a slotted cylinder reference phase-triggered sampling mechanism, and the specific implementation is as follows: The cumulative pulse count of the slotted encoder is The cumulative pulse count of the yarn drum encoder is The real-time angle of the groove cylinder The calculation is as follows: ； real-time angle of yarn bobbin The calculation is as follows: ； Sampling triggering mechanism: Sampling is triggered when the slotted bobbin is at a fixed reference phase. The slotted bobbin encoder's Z-phase is triggered, and the central processing unit captures the Z-phase pulse of the slotted bobbin encoder, triggering an interrupt once per revolution. The current cumulative value of the bobbin encoder is read in the interrupt service routine. This serves as the phase sample at that sampling moment; The Z-phase pulse of the slotted cylinder encoder corresponds precisely to the mechanical position of the slotted cylinder, with a repeatability of ±1 pulse. The phase-locked monitoring and yarn overlap trend determination algorithm is as follows: (1) Calculation of phase difference At the k-th sampling time, read the cumulative value of the yarn bobbin encoder. And calculate the phase change with respect to the (k-1)th sample. The calculation formula is as follows: ； In the formula: This reflects the relative displacement of the yarn bobbin within one cycle of the grooved drum; when the speed ratio between the grooved drum and the yarn bobbin approaches a rational number, It tends to a constant value; when the phase is locked, Small values that approach 0 or repeat stably; (2) Calculation of Lock-in Degree Index Given a window length of W, calculate the standard deviation or absolute mean of the phase changes from the most recent W samples using one of the following formulas: Standard deviation index ； In the formula: For the window The arithmetic mean when At that time, the phase is determined to be highly locked. To determine the threshold parameter; ② Absolute change index ； In the formula: At that time, the phase was determined to be highly locked. To determine the threshold parameter; (3) Calculation of overlapping yarn trend Set the decision threshold With the number of consecutive judgments K, a yarn overlap warning is triggered when the following conditions are met: ； ； If the above conditions are met consecutively for K times, the yarn overlapping trend is determined to be established, and the anti-overlapping action is executed. (4) Target phase displacement calculation The anti-overlap action breaks the phase lock state through controllable sliding, requiring the setting of a reasonable phase displacement amount; target displacement. The following two principles should be met: ① The displacement amount needs to be large enough to significantly deviate the yarn landing point from its original trajectory, avoiding rapid relocking; ② The displacement amount should not be too large to avoid unnecessary tension fluctuations and production capacity loss. Choose one of the following two implementation methods: According to the diameter of the yarn bobbin and yarn diameter The calculation is performed, and the formula for calculating the target displacement is as follows: ； In the formula: The number of yarn loops per layer on the surface of the yarn tube. , The diameter of the yarn. It is the displacement coefficient; ② The target displacement is calculated using an empirical method, and the formula is as follows: In the formula: M is the multiplier factor.
9. The control method of the anti-overlapping control system for winding machine bobbins according to claim 7 or 8, characterized in that, The working method of the closed-loop control module includes: (1) Velocity disturbance curve of the groove cylinder To reduce the impact on yarn tension, a trapezoidal acceleration / deceleration curve is preferred for speed regulation: Deceleration section: from the current trough speed With acceleration Reduce speed to low speed ; Low-speed maintenance phase: at low speed Maintain this position for a period of time, utilizing the inertia of the yarn bobbin to generate relative slippage; Acceleration phase: with acceleration Accelerate to original speed ; To ensure that the anti-overlapping action does not disrupt yarn tension stability, prevent yarn breakage and quality defects, and avoid destructive slippage between the yarn bobbin and the grooved bobbin, acceleration is limited. The acceleration limit formula is calculated as follows: ； In the formula: F is the maximum static friction force between the grooved drum and the yarn bobbin. The moment of inertia of the yarn bobbin and yarn; (2) Phase closed-loop monitoring During the anti-overlapping action, the controller still samples the yarn bobbin phase at a period of T, calculates the cumulative phase lock degree, and when the condition is met... Under certain conditions, the anti-overlapping action is terminated, or the protection is exited after a timeout. When exiting, the controller sends a recovery command, driving the trough cylinder to accelerate to normal speed along a trapezoidal curve.
10. The control method of the anti-overlapping control system for winding machine bobbins according to claim 7 or 8, characterized in that, The parameter adaptive optimization method is as follows: To adapt to different yarn types and working conditions, an online parameter self-tuning method is provided: Threshold self-learning Recording during the normal winding phase Historical data, calculate the mean and standard deviation , The formula for dynamic adaptive adjustment is as follows: ； ② Adaptive velocity disturbance amplitude Adjust as needed according to the diameter of the yarn package. The calculation formula is as follows: ； In the formula: and These are the minimum and maximum diameters of the yarn package.