A yarn tension adaptive synchronous acquisition system and its control method

Abstract

This invention relates to the field of textile machinery control technology, and discloses a yarn tension adaptive synchronous acquisition system and its control method. The system includes a tension sensor module, a signal conditioning module, a control module, and a follow-up comparison module. The tension sensor module is used to acquire and output the yarn tension signal in real time; the signal conditioning module is used to perform gain conditioning on the tension signal; the follow-up comparison module is used to output a trigger pulse signal based on the deviation between the conditioned tension signal and a reference voltage; the control module is also used to determine the sampling delay time based on the first valid trigger pulse signal, and then delay the sampling delay time for each subsequent valid trigger pulse signal so that the sampling time is synchronized with the peak value of the conditioned tension signal before sampling the conditioned tension signal. This invention achieves fully automatic high-precision acquisition of tension signals for a wide range of yarns and various yarn types through a predictive synchronous sampling mechanism, balancing high precision and high energy efficiency.

Description

Technical Field

[0001] This invention relates to the field of textile machinery control technology, specifically to a yarn tension adaptive synchronous acquisition system and its control method. Background Technology

[0002] In the tension control system of a winding machine, real-time and accurate acquisition of yarn tension is crucial. Current mainstream solutions typically use strain gauges or sensors to output analog signals, which are then processed by a fixed-gain conditioning circuit and continuously oversampled at a fixed frequency by a microprocessor's analog-to-digital converter. This approach employs a "resource-for-precision" strategy, with circuit parameters (gain, range) designed to be fixed based on the average tension range of a particular type of yarn.

[0003] Winding machines need to process a wide variety of yarns, from fine denier synthetic filaments to coarse cotton yarns, with an extremely wide tension range (from a few centi-Newtons to hundreds of centi-Newtons). Existing solutions with fixed parameters and fixed frequencies suffer from the following systemic contradictions:

[0004] (1) The contradiction between versatility and high precision: When a large-range circuit designed for high tension acquires low tension signals, the effective signal occupies only a very small part of the ADC range, resulting in low resolution; conversely, a small-range circuit optimized for low tension will saturate and distort under high tension.

[0005] (2) The contradiction between real-time performance and resource efficiency: The high fixed sampling rate set to ensure the capture of tension changes generates a large amount of redundant data when the tension is stable, continuously occupying bus bandwidth and consuming CPU resources and power consumption.

[0006] (3) Low level of intelligence: It relies on manual hardware adjustment and cannot adapt to the flexible production needs of rapid yarn change. Simple trigger sampling may only collect unstable points at the edge of the signal, rather than the most representative peak value, which limits the control accuracy. Summary of the Invention

[0007] In view of this, the present invention provides a yarn tension adaptive synchronous acquisition system and its control method to solve the problem that it is difficult to coordinate high precision, high energy efficiency and process adaptability in existing yarn tension acquisition systems for winding machines.

[0008] In a first aspect, the present invention provides a yarn tension adaptive synchronous acquisition system, comprising: a tension sensor module, a signal conditioning module, a control module, and a follower comparison module. The control module is connected to the signal conditioning module and the follower comparison module, and is used to dynamically configure the gain ratio of the signal conditioning module and the reference voltage of the follower comparison module based on input yarn process parameters. The tension sensor module is connected to the signal conditioning module and is used to acquire and output the yarn tension signal in real time. The signal conditioning module is connected to the follower comparison module and is used to perform gain conditioning on the tension signal. The follower comparison module is used to output a trigger pulse signal based on the deviation between the conditioned tension signal and the reference voltage. The control module is also used to determine the sampling delay time based on the first valid trigger pulse signal, and then, upon the arrival of each subsequent valid trigger pulse signal, delay the sampling delay time so that the sampling time is synchronized with the peak value of the conditioned tension signal before sampling the conditioned tension signal.

[0009] The yarn tension adaptive synchronous acquisition system provided by this invention dynamically configures the gain and reference voltage based on yarn process parameters, directly achieving adaptive high-precision measurement of tension signals across the entire range from fine denier to coarse count yarns. This overcomes the inherent problems of insufficient resolution or saturation distortion in traditional fixed-range circuits under high and low tension conditions. By using predictive synchronization based on the width of the initial trigger pulse to determine the delay for subsequent sampling, the system can intelligently and accurately position each sampling point within the peak stable region of the tension signal. This not only ensures the representativeness and consistency of the sampling from the data source but also significantly enhances anti-interference capabilities by avoiding edges where signal changes drastically and noise is sensitive. By replacing continuous high-speed oversampling with a trigger-delay-sampling rhythm, redundant data is greatly reduced while ensuring the capture of signal characteristics, thus lowering bus bandwidth usage and processor power consumption, and improving system energy efficiency.

[0010] In one optional implementation, the signal conditioning module includes: multiple signal conditioning units and a selection unit, wherein the input terminal of each signal conditioning unit shares a common tension signal, the output terminal of each signal conditioning unit is connected to different input channels of the selection unit, and each signal conditioning unit has a different gain ratio; the control terminal of the selection unit is connected to a control module, the output terminal of the selection unit is connected to a follower comparison module, and the control module controls the selection unit to dynamically select the signal path of the signal conditioning unit with the corresponding gain ratio based on yarn process parameters.

[0011] In one optional implementation, the selection unit is a multiplexer, wherein the control module controls the multiplexer to select the signal path of the signal conditioning unit corresponding to the gain ratio by sending an address signal to the multiplexer.

[0012] In one optional implementation, the follower comparison module includes a signal processing unit and a comparison unit. The signal processing unit is connected to the signal conditioning module, the comparison unit, and the control module. The signal processing unit is used to perform impedance transformation on the conditioned tension signal. The comparison unit is connected to the control module. After the control module dynamically configures the reference voltage of the follower comparison module based on the yarn process parameters, the comparison unit compares the deviation between the impedance-transformed tension signal and the reference voltage and outputs a trigger pulse signal. The control module samples the impedance-transformed tension signal.

[0013] In one optional implementation, the control module includes: a central processing unit and a field-programmable gate array (FPGA), wherein the central processing unit is connected to a follower comparator module and the FPGA, and the central processing unit is used to dynamically output a configuration signal based on the input yarn process parameters; the FPGA is connected to a signal conditioning module and a follower comparator module, and the FPGA is used to configure the gain of the signal conditioning module and the reference voltage of the follower comparator module based on the configuration signal, and after calculating the sampling delay time based on the first valid trigger pulse signal, output a sampling trigger signal after delaying the sampling delay time when each subsequent valid trigger pulse signal arrives; the central processing unit samples the conditioned tension signal based on the sampling trigger signal.

[0014] Secondly, the present invention provides a control method for a yarn tension adaptive synchronous acquisition system, applied to the control module of the first aspect or any corresponding embodiment described above. The method includes: acquiring the yarn's process parameters and tension signal; querying a preset configuration mapping table based on the process parameters to configure the gain ratio of the signal conditioning module and the reference voltage of the follow-up comparison module accordingly; acquiring a trigger pulse signal based on the difference between the conditioned tension signal and the reference voltage; when a valid trigger pulse signal is acquired for the first time, calculating a sampling delay time based on the pulse width of the valid trigger pulse signal; and when each subsequent valid trigger pulse signal arrives, delaying the sampling delay time so that the sampling time is synchronized to the peak position of the corresponding conditioned tension signal, and then acquiring the conditioned tension signal.

[0015] The control method of the yarn tension adaptive synchronous acquisition system provided by this invention, based on process parameter query configuration mapping table and dynamic setting of gain and reference voltage, achieves hardware adaptive matching for different yarn tension signal ranges, ensuring that the signal is in the optimal quantization range throughout the entire process; by capturing the first effective trigger pulse and calculating the delay based on its pulse width, and delaying the sampling by this time after each subsequent trigger, the sampling point is intelligently synchronized from the signal change to the most stable peak position, which not only improves the representativeness and control usability of the sampling data from the source, but also enhances the anti-interference capability by avoiding noise-sensitive areas; this "trigger" Delay The synchronous sampling mechanism replaces the traditional continuous high-speed sampling, which significantly reduces data redundancy and system power consumption while ensuring the complete acquisition of signal characteristics. The entire process realizes a fully automatic closed loop from parameter configuration and signal conditioning to synchronous sampling, providing a directly deployable intelligent solution for high-precision and high-efficiency tension acquisition of winding machines in the production of multiple yarn varieties.

[0016] In one alternative implementation, when the amplitude of the conditioned tension signal is greater than the reference voltage, the trigger pulse signal output by the follow-up comparison module is identified as a valid trigger pulse signal.

[0017] In one alternative implementation, the process of calculating the sampling delay time based on the pulse width of the effective trigger pulse signal includes: measuring the pulse width of the first effective trigger pulse signal; and using half of the pulse width as the sampling delay time.

[0018] In one optional implementation, the method further includes: continuously monitoring the pulse width of the effective trigger pulse signal; if the pulse width of the effective trigger pulse signal exceeds a preset range, then recalculating the sampling delay time based on the current pulse width.

[0019] In one optional implementation, the method further includes: performing data distribution analysis on all the collected conditioned tension signal values ​​to obtain a numerical distribution range; if the numerical distribution range is not within the preset optimal range, dynamically adjusting the gain ratio of the signal conditioning module and / or the reference voltage of the comparison module, and returning to the data distribution analysis step until the numerical distribution range is within the preset optimal range. Attached Figure Description

[0020] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0021] Figure 1 This is a diagram illustrating the composition of a yarn tension adaptive synchronous acquisition system according to an embodiment of the present invention. Figure 2 This is a composition diagram of a signal conditioning module according to an embodiment of the present invention; Figure 3 This is a specific circuit diagram of the signal conditioning unit according to an embodiment of the present invention; Figure 4 This is a composition diagram of the control module according to an embodiment of the present invention; Figure 5This is a specific circuit diagram of the central processing unit according to an embodiment of the present invention; Figure 6 This is a specific circuit diagram of the signal processing unit according to an embodiment of the present invention; Figure 7 This is a specific circuit diagram of the comparison unit according to an embodiment of the present invention; Figure 8 This is a flowchart illustrating the control method of the yarn tension adaptive synchronous acquisition system according to an embodiment of the present invention; Figure 9 This is a detailed flowchart of the control method of the yarn tension adaptive synchronous acquisition system according to an embodiment of the present invention; Figure 10 This is a structural block diagram of the control device of the yarn tension adaptive synchronous acquisition system according to an embodiment of the present invention; Figure 11 This is a schematic diagram of the hardware structure of an electronic device according to an embodiment of the present invention. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] It is understood that before using the technical solutions disclosed in the various embodiments of the present invention, users should be informed of the types, scope of use, and usage scenarios of the personal information involved in the present invention and their authorization should be obtained in accordance with relevant laws and regulations through appropriate means.

[0024] This embodiment provides a yarn tension adaptive synchronous acquisition system, such as... Figure 1 As shown, it includes: tension sensor module 1, signal conditioning module 2, follower comparison module 3, and control module 4.

[0025] Figure 1 In this circuit, the control module 4 is connected to the signal conditioning module 2 and the follower comparison module 3. The control module 4 is used to dynamically configure the gain ratio of the signal conditioning module 2 and the reference voltage of the follower comparison module 3 based on the input yarn process parameters.

[0026] Specifically, Figure 1 In the middle, the control module 4 receives yarn process parameters (such as yarn type, count, target tension value, etc.) from the host computer or human-machine interface, and queries its internally stored "process parameters". The hardware configuration mapping table is used. Based on the query results, control module 4 sends a gain selection command to signal conditioning module 2 through its digital interface (such as GPIO, SPI, or internal registers), for example, selecting one of eight preset gain levels (0.6 to 1.0 times), thereby conditioning the raw signal output by tension sensor 1 to the optimal amplitude range suitable for analog-to-digital converter (ADC) sampling. Simultaneously, control module 4 generates an analog reference voltage matching the current process through its internal pulse width modulation (PWM) module or an external digital-to-analog converter (DAC), and outputs it to follow-up comparator module 3 as a dynamically adjustable trigger threshold. This threshold voltage is set to ensure that the conditioned tension signal can reliably cross the threshold during normal fluctuations, thereby generating stable and regular trigger pulses. This dual-parameter collaborative configuration mechanism ensures that the system can automatically adapt to the tension acquisition needs of a full range of yarns, from fine denier synthetic fibers to coarse cotton yarns.

[0027] Figure 1 In the middle, tension sensor module 1 is connected to signal conditioning module 2. Tension sensor module 1 is used to collect and output the tension signal of the yarn in real time.

[0028] Specifically, Figure 1 In this system, tension sensor module 1 serves as the sensing front end. Internally, it typically uses strain gauges or piezoelectric sensing principles to convert the dynamic tension of the yarn during operation into a proportionally weak analog electrical signal. Tension sensor module 1 is directly connected to the input of signal conditioning module 2 via its output interface, enabling real-time and continuous signal transmission.

[0029] It should be noted that the design of tension sensor module 1 must ensure that its frequency response can cover the fluctuation range of yarn tension (such as from a few hertz to hundreds of hertz), so as to accurately capture tension changes and steady-state signals, and provide a real and original input source for subsequent conditioning, comparison and sampling.

[0030] Figure 1 In the middle, the signal conditioning module 2 is connected to the follower comparison module 3. The signal conditioning module 2 is used to perform gain conditioning on the tension signal.

[0031] Specifically, Figure 1In this process, the signal conditioning module 2 receives the raw, weak signal from the tension sensor module 1 and, based on the gain ratio dynamically configured by the control module 4 (e.g., by switching different feedback resistor networks using a digital potentiometer or multiplexer), precisely amplifies or attenuates the signal to a suitable amplitude range (e.g., 0-3.3V) for subsequent processing. The conditioned signal is then simultaneously sent to the follower comparator module 3.

[0032] Figure 1 In the middle, the follower comparison module 3 is used to output a trigger pulse signal based on the deviation between the conditioned tension signal and the reference voltage.

[0033] Specifically, Figure 1 In this circuit, the comparator module 3 typically includes a voltage follower (used to improve input impedance, enhance drive capability, and isolate the preceding and following stages) and a high-speed voltage comparator. The conditioned tension signal is input to the non-inverting input of the comparator, while the reference voltage generated by the control module 4 is input to its inverting input. When the instantaneous value of the conditioned signal exceeds the reference voltage, the comparator output quickly jumps to a high level; otherwise, it goes low, thus generating a square wave pulse sequence that strictly corresponds to the moment when the tension signal waveform crosses the threshold, i.e., the trigger pulse signal. This pulse signal accurately reflects the moment when the tension signal reaches and exceeds the preset threshold each time, providing a crucial timing reference for subsequent predictive synchronous sampling.

[0034] Figure 1 In addition, the control module 4 is also used to determine the sampling delay time based on the first valid trigger pulse signal, and then delay the sampling delay time when each subsequent valid trigger pulse signal arrives so that the sampling time is synchronized with the peak value of the conditioned tension signal before sampling the conditioned tension signal.

[0035] Specifically, Figure 1 In the process, after receiving the first valid trigger pulse signal output by the follower comparison module 3, the control module 4 immediately starts a high-precision timer to accurately measure the duration of the pulse, i.e., the pulse width. This width represents the typical time span during which the conditioned tension signal exceeds a preset threshold under the current process conditions. Subsequently, the control module 4 uses half of this pulse width as the calculated sampling delay time, corresponding to the theoretical time position of the peak point of the tension signal waveform. After entering steady-state operation, whenever a new valid trigger pulse signal arrives, marking the start of a new tension cycle, the control module 4 does not immediately start sampling the conditioned tension signal in the follower comparison module. Instead, it first starts a delay timer and waits for the aforementioned calculated sampling delay time before sampling.

[0036] The yarn tension adaptive synchronous acquisition system provided in this embodiment dynamically configures the gain and reference voltage based on yarn process parameters, directly achieving adaptive high-precision measurement of tension signals across the entire range from fine denier to coarse count yarns. This overcomes the inherent problems of insufficient resolution or saturation distortion in traditional fixed-range circuits under high and low tension conditions. By using predictive synchronization based on the width of the initial trigger pulse to determine the delay for subsequent sampling, the system can intelligently and accurately position each sampling point within the peak stable region of the tension signal. This not only ensures the representativeness and consistency of the sampling from the data source but also significantly enhances anti-interference capabilities by avoiding edges where signal changes drastically and noise is sensitive. By replacing continuous high-speed oversampling with a trigger-delay-sampling rhythm, redundant data is greatly reduced while ensuring the capture of signal characteristics, thus lowering bus bandwidth usage and processor power consumption, and improving system energy efficiency.

[0037] In some optional implementations, the signal conditioning module 2 includes: multiple signal conditioning units (#211~#21n) and a selection unit 22, wherein the input terminal of each signal conditioning unit 21 is connected to a common tension signal, the output terminal of each signal conditioning unit 21 is connected to different input channels of the selection unit 22, and each signal conditioning unit 21 has a different gain ratio; the control terminal of the selection unit 22 is connected to the control module 4, and the output terminal of the selection unit 22 is connected to the follower comparison module 3. The control module 4 controls the selection unit 22 to dynamically select the signal path of the signal conditioning unit with the corresponding gain ratio based on the yarn process parameters.

[0038] Specifically, Figure 2 In this design, multiple signal conditioning units jointly receive the raw signal input from the tension sensor, each configured with different feedback networks or amplification factors, thus presetting multiple discrete gain ratios. The outputs of all signal conditioning units are connected to different input channels of the selection unit 22, and the control module connects to the control terminal of the selection unit 22 via its digital I / O port. During operation, the control module 4 sends a corresponding selection command to the selection unit 22 based on the optimal gain requirement corresponding to the current yarn process parameters. The selection unit 22, based on this command, selects the output path of the signal conditioning unit with the corresponding gain ratio to its input terminal, while simultaneously disconnecting the paths of other signal conditioning units. The signal from the selected path (i.e., the tension signal after target gain conditioning) is then transmitted to the subsequent follow-up comparison module 3. This design allows the system to switch different measurement ranges within milliseconds via electronic commands without manual hardware replacement or potentiometer adjustment, achieving a fast and accurate adaptive range switching function for tension signals with different amplitude ranges at the hardware level.

[0039] Specifically, Figure 3In this configuration, R1, R8, R2, R9, R3, R10, R4, R11, R5, R12, R6, R13, R7, and R14 are voltage divider resistors with different ratios. Together with the raw tension signal ITence from sensor J1, they form eight gain levels with gain coefficients of 0.6, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, and 1. C1 to C8 are filter capacitors. These signals are input to the decoding and selection unit of the control module. The control unit of the control module selects which channel's gain ratio to use as the sampling gain for the current yarn type via a programmed address.

[0040] Optionally, the selection unit is a multiplexer, wherein the control module controls the multiplexer to select the signal path of the signal conditioning unit with the corresponding gain ratio by sending an address signal to the multiplexer.

[0041] In some alternative implementations, such as Figure 4 As shown, the follower comparison module 3 includes a signal processing unit 31 and a comparison unit 32. The signal processing unit 31 is connected to the signal conditioning module 2, the comparison unit 32, and the control module 4. The signal processing unit 31 is used to perform impedance transformation on the conditioned tension signal. The comparison unit 32 is connected to the control module 4. After the control module 4 dynamically configures the reference voltage of the follower comparison module 3 based on the yarn process parameters, the comparison unit 32 compares the deviation between the impedance-transformed tension signal and the reference voltage and outputs a trigger pulse signal. The control module 4 samples the impedance-transformed tension signal.

[0042] Specifically, Figure 4In this circuit, the input terminal of the signal processing unit 31 is connected to the output terminal of the signal conditioning module 2, receiving the tension signal conditioned to a suitable amplitude. Its core function is to perform impedance transformation and signal buffering. Utilizing the high input impedance and low output impedance characteristics of the voltage follower, it effectively isolates the pre-stage conditioning circuit from the subsequent comparison and sampling circuit, preventing load effects from affecting signal quality and providing sufficient drive current for the subsequent stages. After buffering and stabilization, one path of the signal is directly sent to the control module 4 as the analog signal source to be sampled; the other path is sent to the non-inverting input terminal of the comparison unit 32. Simultaneously, an adjustable reference voltage dynamically generated and output by the control module 4 based on yarn process parameters is applied to the inverting input terminal of the comparison unit 32. The comparison unit 32 compares these two input voltages in real time. When the instantaneous value of the buffered tension signal exceeds the reference voltage, its output terminal immediately flips from low level to high level, generating a precise leading-edge trigger pulse signal, which is fed back to the control module 4 as an event trigger flag. This design ensures that the generation of trigger pulses is strictly based on reliably processed signals, and that the threshold can be flexibly adjusted according to the process, thus providing a stable and accurate timing reference and a high-quality analog signal source for the adaptive and synchronous sampling mechanism of the entire system.

[0043] Specifically, Figure 4 In the control module 4, there are: a central processing unit 41 and a field-programmable gate array 42. The central processing unit 41 is connected to the follower comparator module 3 and the field-programmable gate array 42. The central processing unit 41 is used to dynamically output a configuration signal based on the input yarn process parameters. The field-programmable gate array 42 is connected to the signal conditioning module 2 and the follower comparator module 3. The field-programmable gate array 42 is used to configure the gain of the signal conditioning module 2 and the reference voltage of the follower comparator module 3 based on the configuration signal. After calculating the sampling delay time based on the first valid trigger pulse signal, it outputs a sampling trigger signal after delaying the sampling delay time when each subsequent valid trigger pulse signal arrives. The central processing unit 41 samples the conditioned tension signal based on the sampling trigger signal.

[0044] Specifically, Figure 4In this system, the central processing unit 41, serving as the core decision-making unit, includes a central processing unit and an internal 16-bit high-precision ADC. It internally stores a mapping relationship between "yarn process parameters and hardware configuration parameters." Through its communication interface, it receives yarn process parameters input from the host computer and executes lookup table or calculation algorithms to generate a digital configuration signal containing the target gain level and reference voltage value. This signal is then sent to the field-programmable gate array 42 via a high-speed parallel bus or SPI interface. The field-programmable gate array 42 outputs the address signal of the multiplexer to the signal conditioning module 2 to switch the corresponding gain resistor network. Simultaneously, its internal PWM controller generates pulses with a specific duty cycle, which, after passing through an external filtering circuit, generate the required analog reference voltage and output it to the comparator in the follower comparator module 3.

[0045] Specifically, Figure 4 In the process, the field-programmable gate array 42 directly captures the trigger pulse from the comparator and uses its internal nanosecond-precision counter to accurately measure the high-level duration of the first valid pulse, divide it by two, and calculate the peak sampling delay time. Subsequently, whenever a new trigger pulse rises, the field-programmable gate array 42 starts its internal delay timer. After precisely waiting for the calculated delay time, it outputs a narrow pulse as a sampling trigger signal to the ADC peripheral or external interrupt pin of the central processing unit 41. Upon receiving this hardware trigger signal, the central processing unit 41 immediately starts its built-in ADC to perform a single conversion and acquisition of the conditioned tension signal, which has been sent to its analog input pin through a buffer and is in a stable peak state.

[0046] Specifically, Figure 5 The circuit diagram of the central processing unit shows that the field-programmable gate array (FPGA) selects which channel's gain ratio to use as the sampling gain for the current yarn type through the programming addresses Tension_sel0, Tension_sel1, and Tension_sel2, and then outputs the conditioned tension signal Pp_sel to the signal processing unit 31.

[0047] Specifically, Figure 6 The circuit diagram of the signal processing unit 31 shows that the conditioned tension signal Pp_sel enters the U1 follower, R16, C13 low-pass filter and D1 protection clamping diode, and finally outputs the transformed tension signal V_sense, which enters the sampling pin of the central processing unit.

[0048] Specifically, Figure 7The circuit diagram of the comparator unit shows that V_sense is input to the non-inverting input of comparator U3, and Vref is the reference voltage, which is generated by the PWM module of the field-programmable gate array (FPGA). According to different duty cycles, it is low-pass filtered by R20, C15 and R18, C14 to generate a DC analog voltage of corresponding amplitude, which is input to the inverting input of U3. U3 compares the two voltages V_sense and Vref in real time and generates a square wave signal Samp_cal, which is sent to the FPGA. The FPGA calculates the time by the rising edges of two adjacent square waves and generates a trigger signal at the half position to control the central processing unit to trigger sampling of the transformed tension signal V_sense.

[0049] This embodiment provides a control method for a yarn tension adaptive synchronous acquisition system, applicable to the control module of the above embodiment or any corresponding implementation, such as... Figure 8 As shown, the method includes: Step S1: Obtain the yarn's process parameters and tension signal.

[0050] Specifically, the host computer or human-machine interface sends the process parameters such as the yarn type and count to the control module, while the tension sensor starts to sense the yarn tension in real time and outputs the original tension signal.

[0051] Step S2: After querying the preset configuration mapping table based on the process parameters, configure the gain ratio of the corresponding signal conditioning module and the reference voltage of the follower comparator module.

[0052] Specifically, after receiving the process parameters, the core processing unit of the control module (such as a Digital Signal Processor (DSP)) immediately queries the pre-stored "process parameter-hardware configuration" mapping table in its internal non-volatile memory. This mapping table is a database established in advance through experimental calibration, recording the optimal signal conditioning gain and comparator reference voltage values ​​corresponding to different yarn types. After looking up the table, the control module sends the gain control word to the digital potentiometer or multiplexer in the signal conditioning module through a digital interface (such as SPI or I2C), thereby precisely setting the gain ratio of the amplifier circuit; at the same time, it generates the corresponding analog voltage through its digital-to-analog converter (DAC) or pulse width modulation (PWM) module and sets it as the reference voltage of the comparator in the follow comparator module.

[0053] Step S3: Based on the difference between the conditioned tension signal and the reference voltage, obtain the trigger pulse signal.

[0054] Specifically, after configuration in step S2, the signal conditioning module begins to proportionally amplify or attenuate the original tension signal, adjusting its amplitude to the optimal input range of the analog-to-digital converter (ADC) (e.g., 0-3.3V), and outputs the gain-conditioned tension signal. Within the comparator module, the conditioned tension signal first undergoes buffering and impedance transformation through a voltage follower to improve drive capability and isolate the preceding and following stages, before being fed to the non-inverting input of the high-speed comparator. Simultaneously, the reference voltage set in step S2 is applied to the inverting input of the comparator. The comparator compares these two voltages in real time. When the instantaneous amplitude of the conditioned tension signal exceeds the reference voltage, the comparator output immediately jumps from logic low to high; when the signal amplitude falls back below the reference voltage, the output jumps back to low. Thus, the comparator output generates a square wave, i.e., a trigger pulse signal, that is strictly synchronized with the moment the signal crosses the threshold. Its rising edge precisely marks the moment when the tension signal reaches and crosses the preset threshold each time.

[0055] Step S4: When a valid trigger pulse signal is acquired for the first time, calculate the sampling delay time based on the pulse width of the valid trigger pulse signal.

[0056] Specifically, when the amplitude of the conditioned tension signal is greater than the reference voltage, the trigger pulse signal output by the follow-up comparison module is identified as a valid trigger pulse signal. The process of calculating the sampling delay time based on the pulse width of the valid trigger pulse signal includes: Step S41: Measure the pulse width of the first valid trigger pulse signal.

[0057] Step S42: Use half of the pulse width as the sampling delay time.

[0058] Specifically, the control module continuously monitors the trigger pulse signal from the follow-up comparison module. When a pulse that meets the conditions (i.e., generated by a valid signal exceeding the threshold as described in step S3) appears for the first time, the system identifies it as the first valid trigger pulse signal. The control module immediately starts its internal high-precision timer to capture the rising and falling edges of the pulse and accurately measure the duration for which the pulse remains high, i.e., the pulse width T. This width objectively reflects the typical time span for the tension signal waveform to exceed the trigger threshold under the current process settings. Subsequently, the control module divides the measured pulse width value by 2 to obtain the sampling delay time Δt = T / 2 required for subsequent system operation. For an approximately symmetrical pulse waveform, the midpoint position theoretically corresponds to the time when the peak point of the original tension signal appears.

[0059] Step S5: When each subsequent valid trigger pulse signal arrives, delay the sampling delay time so that the sampling time is synchronized to the peak position of the corresponding conditioned tension signal, and then collect the conditioned tension signal.

[0060] Specifically, after establishing the sampling delay time reference in step S4, the system enters a cyclic operating mode. For each subsequent valid trigger pulse signal (whose identification criteria are the same as the first pulse), the control module no longer immediately starts sampling, but instead performs the following operations: When the rising edge of the trigger pulse arrives, marking the start of a new tension cycle, the timer inside the control module immediately begins counting down using the sampling delay time Δt calculated in step S4. After a precise delay of Δt, the timer generates an internal interrupt or hardware trigger signal. This signal directly controls the analog-to-digital converter (ADC) to initiate a conversion, acquiring the tension signal currently being input from the signal conditioning module. Since the delay Δt is exactly equal to the time from the trigger edge to the signal peak, this sampling action of the ADC is intelligently "synchronized" to the center of the peak position where the tension signal waveform is most stable and the amplitude is most accurate. This mechanism ensures that each acquired data point is the most representative peak tension value, while completely avoiding sampling at the edges of drastic signal changes, thereby fundamentally improving the accuracy and consistency of the data and the system's anti-interference capability.

[0061] The control method of the yarn tension adaptive synchronous acquisition system provided in this embodiment, based on process parameter query configuration mapping table and dynamic setting of gain and reference voltage, achieves hardware adaptive matching for different yarn tension signal ranges, ensuring that the signal is in the optimal quantization range throughout the entire process; by capturing the first effective trigger pulse and calculating the delay based on its pulse width, and delaying the sampling by this time after each subsequent trigger, the sampling point is intelligently synchronized from the signal change to the most stable peak position, which not only improves the representativeness and control usability of the sampling data from the source, but also enhances the anti-interference capability by avoiding noise-sensitive areas; this "trigger" Delay The synchronous sampling mechanism replaces the traditional continuous high-speed sampling, which significantly reduces data redundancy and system power consumption while ensuring the complete acquisition of signal characteristics. The entire process realizes a fully automatic closed loop from parameter configuration and signal conditioning to synchronous sampling, providing a directly deployable intelligent solution for high-precision and high-efficiency tension acquisition of winding machines in the production of multiple yarn varieties.

[0062] In some optional implementations, the method further includes: continuously monitoring the pulse width of the valid trigger pulse signal; if the pulse width of the valid trigger pulse signal exceeds a preset range, then recalculating the sampling delay time based on the current pulse width.

[0063] Specifically, the system possesses timing adaptive capabilities. After completing the initial delay time calculation and entering steady-state synchronous sampling, the control module continuously monitors the pulse width of each valid trigger pulse signal through the monitoring logic within its internal Field-Programmable Gate Array (FPGA). The system presets a reasonable pulse width range, which is set based on the normal fluctuation characteristics of the yarn tension signal. If the width of several consecutive pulses significantly deviates from this preset range (e.g., due to changes in yarn speed, mechanical vibration, or ambient temperature drift causing a slow change in the signal waveform characteristics), the system determines that the current sampling delay reference may no longer accurately correspond to the true peak position of the signal. At this time, the system immediately initiates a recalculation process: using the newly monitored, drifted pulse width as the new input, it executes the "pulse width divided by two" algorithm again to recalculate an updated sampling delay time, and immediately replaces the original value with this new value for subsequent synchronous sampling. This mechanism enables dynamic tracking and compensation of signal waveform characteristic drift, ensuring that the sampling point can be locked on the changing peak value for a long time and automatically, thereby improving the robustness and measurement consistency of the system during long-term operation or changes in operating conditions.

[0064] In some optional implementations, the method further includes: performing data distribution analysis on all the collected conditioned tension signal values ​​to obtain a numerical distribution range; if the numerical distribution range is not within the preset optimal range, dynamically adjusting the gain ratio of the signal conditioning module and / or the reference voltage of the comparison module, and returning to the data distribution analysis step until the numerical distribution range is within the preset optimal range.

[0065] Specifically, the system also possesses amplitude adaptive capability, forming a complete dual-loop optimization system. This function is implemented by the software algorithm of the DSP within the control module: the system statistically analyzes a batch of continuously acquired conditioned tension signal values, calculating their numerical distribution range (e.g., maximum value, minimum value, or distribution range at a certain confidence level). Simultaneously, the system presets an optimal range, corresponding to the core voltage range where the ADC has the highest resolution and best linearity. For example, for a 16-bit ADC with 0-3.3V, the optimal range might be set to 1.0V-3.0V. The algorithm compares the numerical distribution range obtained from real-time analysis with this preset optimal range. If the analysis range is found to be generally too high (approaching saturation) or generally too low (not fully utilizing the range), it is determined that the current hardware configuration has not placed the signal in the optimal quantization state. At this time, the system dynamically adjusts the gain ratio of the signal conditioning module (e.g., lowering the gain if the signal is too high, and increasing the gain if the signal is too low), and / or fine-tunes the reference voltage of the follower comparator module. After adjustment, the system does not immediately terminate but returns to the data distribution analysis step to collect a new round of data and re-determine the distribution range. This process is repeated iteratively until the distribution range of the latest collected signal value falls completely within the preset optimal range. This closed-loop optimization process achieves automatic calibration and continuous optimization of the signal amplitude, ensuring that the ADC always operates in its optimal performance range under any yarn process, thus guaranteeing high measurement accuracy and stability throughout the entire process and under all operating conditions from a hardware perspective.

[0066] For example, Figure 9 A specific control flow implementation of this system is provided, and its steps are consistent with the aforementioned method description, so they will not be repeated here.

[0067] This embodiment also provides a control device for a yarn tension adaptive synchronous acquisition system. This device is used to implement the above embodiments and preferred embodiments, and details already described will not be repeated. As used below, the term "module" can refer to a combination of software and / or hardware that performs a predetermined function. Although the device described in the following embodiments is preferably implemented in software, hardware implementation, or a combination of software and hardware, is also possible and contemplated.

[0068] This embodiment provides a control device for a yarn tension adaptive synchronous acquisition system, such as... Figure 10 As shown, it includes: The acquisition module 1001 is used to acquire the process parameters and tension signals of the yarn.

[0069] The configuration module 1002 is used to query the preset configuration mapping table based on process parameters to determine the gain ratio of the corresponding configuration signal conditioning module and the reference voltage of the follower comparator module.

[0070] The pulse signal acquisition module 1003 is used to acquire the trigger pulse signal based on the difference between the conditioned tension signal and the reference voltage.

[0071] The delay time calculation module 1004 is used to calculate the sampling delay time based on the pulse width of the valid trigger pulse signal when a valid trigger pulse signal is first acquired.

[0072] The acquisition module 1005 is used to delay the sampling delay time when each subsequent valid trigger pulse signal arrives so that the sampling time is synchronized to the peak position of the corresponding conditioned tension signal, and then acquire the conditioned tension signal.

[0073] The control device of the yarn tension adaptive synchronous acquisition system provided in this embodiment of the invention can execute the method provided in any embodiment of the invention, and has the corresponding functional modules and beneficial effects for executing the method. Further functional descriptions of the above modules and units are the same as those in the corresponding embodiments described above, and will not be repeated here.

[0074] Figure 11 This is a schematic diagram of the structure of an electronic device provided in an embodiment of the present invention.

[0075] The following is a detailed reference. Figure 11 The diagram illustrates a structural schematic suitable for implementing an electronic device according to embodiments of the present invention. The electronic device may include a processor (e.g., a central processing unit, graphics processor, etc.) 001, which can perform various appropriate actions and processes according to a program stored in read-only memory (ROM) 002 or a program loaded from memory 008 into random access memory (RAM) 003. The RAM 003 also stores various programs and data required for the operation of the electronic device. The processor 001, ROM 002, and RAM 003 are interconnected via bus 004. An input / output (I / O) interface 005 is also connected to bus 004.

[0076] Typically, the following devices can be connected to I / O interface 005: input devices 006 including, for example, touchscreens, touchpads, keyboards, mice, cameras, microphones, accelerometers, gyroscopes, etc.; output devices 007 including, for example, liquid crystal displays (LCDs), speakers, vibrators, etc.; memory devices 008 including, for example, magnetic tapes, hard disks, etc.; and communication devices 009. Communication device 009 allows electronic devices to exchange data via wireless or wired communication with other devices. Although Figure 11 Electronic devices with various devices are shown, but it should be understood that it is not required to implement or have all of the devices shown, and more or fewer devices may be implemented or have instead.

[0077] In particular, according to embodiments of the present invention, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments of the present invention include a computer program product comprising a computer program carried on a non-transitory computer-readable medium, the computer program containing program code for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via communication device 009, or installed from memory 008, or installed from ROM 002. When the computer program is executed by processor 001, it performs the functions defined in the methods of the embodiments of the present invention.

[0078] Figure 11 The electronic device shown is merely an example and should not be construed as limiting the functionality and scope of use of the embodiments of the present invention.

[0079] This invention also provides a computer-readable storage medium. The methods described above according to embodiments of the invention can be implemented in hardware or firmware, or implemented as computer code that can be recorded on a storage medium, or implemented as computer code downloaded via a network and originally stored on a remote storage medium or a non-transitory machine-readable storage medium and then stored on a local storage medium. Thus, the methods described herein can be processed by software stored on a storage medium using a general-purpose computer, a dedicated processor, or programmable or dedicated hardware. The storage medium can be a magnetic disk, optical disk, read-only memory, random access memory, flash memory, hard disk, or solid-state drive, etc.; further, the storage medium can also include combinations of the above types of memory. It is understood that computers, processors, microprocessor controllers, or programmable hardware include storage components capable of storing or receiving software or computer code, which, when accessed and executed by the computer, processor, or hardware, implements the methods shown in the above embodiments.

[0080] A portion of this invention can be applied as a computer program product, such as computer program instructions, which, when executed by a computer, can invoke or provide the methods and / or technical solutions according to the invention through the operation of the computer. Those skilled in the art will understand that the forms in which computer program instructions exist in a computer-readable medium include, but are not limited to, source files, executable files, installation package files, etc. Correspondingly, the ways in which computer program instructions are executed by a computer include, but are not limited to: the computer directly executing the instructions, or the computer compiling the instructions and then executing the corresponding compiled program, or the computer reading and executing the instructions, or the computer reading and installing the instructions and then executing the corresponding installed program. Here, the computer-readable medium can be any available computer-readable storage medium or communication medium accessible to a computer.

[0081] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A yarn tension adaptive synchronous acquisition system, characterized in that, include: The module includes a tension sensor module, a signal conditioning module, a control module, and a follower comparison module. The control module is connected to the signal conditioning module and the follower comparison module. The control module is used to dynamically configure the gain ratio of the signal conditioning module and the reference voltage of the follower comparison module based on the input yarn process parameters. The tension sensor module is connected to the signal conditioning module, and the tension sensor module is used to acquire and output the tension signal of the yarn in real time. The signal conditioning module is connected to the follower comparison module, and the signal conditioning module is used to perform gain conditioning on the tension signal; The follow-up comparison module is used to output a trigger pulse signal based on the deviation between the conditioned tension signal and the reference voltage; The control module is also used to determine the sampling delay time based on the first valid trigger pulse signal, and then, when each subsequent valid trigger pulse signal arrives, delay the sampling delay time so that the sampling time is synchronized with the peak value of the conditioned tension signal before sampling the conditioned tension signal.

2. The system according to claim 1, characterized in that, The signal conditioning module includes: multiple signal conditioning units and a selection unit, wherein... The tension signal is input to the input terminal of each signal conditioning unit, and the output terminal of each signal conditioning unit is connected to different input channels of the selection unit. Each signal conditioning unit has a different gain ratio. The control terminal of the selection unit is connected to the control module, and the output terminal of the selection unit is connected to the follower comparison module. Based on the yarn process parameters, the control module controls the selection unit to dynamically select the signal path of the signal conditioning unit with the corresponding gain ratio.

3. The system according to claim 2, characterized in that, The selection unit is a multiplexer, wherein, The control module sends an address signal to the multiplexer to control the multiplexer to select the signal path of the signal conditioning unit with the corresponding gain ratio.

4. The system according to claim 1, characterized in that, The follow-up comparison module includes: a signal processing unit and a comparison unit, wherein... The signal processing unit is connected to the signal conditioning module, the comparison unit and the control module, and the signal processing unit is used to perform impedance transformation on the conditioned tension signal. The comparison unit is connected to the control module. After the control module dynamically configures the reference voltage of the following comparison module based on the yarn process parameters, the comparison unit compares the deviation between the tension signal after impedance transformation and the reference voltage, and outputs the trigger pulse signal. The control module samples the tension signal after impedance transformation.

5. The system according to claim 1, characterized in that, The control module includes: a central processing unit and a field-programmable gate array, wherein... The central processing unit is connected to the follow-up comparison module and the field-programmable gate array. The central processing unit is used to dynamically output configuration signals based on the input yarn process parameters. The field-programmable gate array is connected to the signal conditioning module and the follower comparator module. The field-programmable gate array is used to configure the gain of the signal conditioning module and the reference voltage of the follower comparator module based on the configuration signal. After calculating the sampling delay time based on the first valid trigger pulse signal, the sampling trigger signal is output after delaying the sampling delay time when each subsequent valid trigger pulse signal arrives. The central processing unit samples the conditioned tension signal based on the sampling trigger signal.

6. A control method for a yarn tension adaptive synchronous acquisition system, characterized in that, Applied to the control module according to any one of claims 1 to 5, the method comprises: Acquire the yarn's process parameters and tension signals; After querying the preset configuration mapping table based on the process parameters, the gain ratio of the corresponding configuration signal conditioning module and the reference voltage of the follower comparison module are configured accordingly. Based on the difference between the conditioned tension signal and the reference voltage, a trigger pulse signal is obtained; When a valid trigger pulse signal is first acquired, the sampling delay time is calculated based on the pulse width of the valid trigger pulse signal; Upon the arrival of each subsequent valid trigger pulse signal, the sampling delay time is delayed so that the sampling time is synchronized to the peak position of the corresponding conditioned tension signal, and then the conditioned tension signal is acquired.

7. The method according to claim 6, characterized in that, When the amplitude of the conditioned tension signal is greater than the reference voltage, the trigger pulse signal output by the follower comparison module is identified as a valid trigger pulse signal.

8. The method according to claim 6, characterized in that, The process of calculating the sampling delay time based on the pulse width of the effective trigger pulse signal includes: Measure the pulse width of the first valid trigger pulse signal; The sampling delay time is set to half of the pulse width.

9. The method according to claim 6, characterized in that, Also includes: Continuously monitor the pulse width of the effective trigger pulse signal; If the pulse width of the effective trigger pulse signal exceeds the preset range, the sampling delay time is recalculated based on the current pulse width.

10. The method according to claim 6, characterized in that, Also includes: After performing data distribution analysis on all the collected conditioned tension signal values, the numerical distribution range is obtained; If the numerical distribution range is not within the preset optimal range, the gain ratio of the signal conditioning module and / or the reference voltage of the follower comparison module are dynamically adjusted, and the process returns to the data distribution analysis step until the numerical distribution range is within the preset optimal range.

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