A complete control system of composite textile machinery rotary comb guide

Abstract

This invention relates to the field of control technology and provides a complete control system for a composite textile machinery rotary guide bar mechanism. The rotary guide bar mechanism includes a mounting base and a synchronous belt driven to the bottom of the mounting base. Multiple needle rows are mounted on the outer wall of the synchronous belt, and multiple guide needles are equidistantly arranged on the needle rows. The synchronous belt is divided into a first arc segment, a second arc segment, a first straight segment, and a second straight segment. This device solves the problems of traditional loom weaving structures and control methods being fixed, only able to achieve orthogonal warp and weft interlacing, and having a single yarn guiding and weft insertion trajectory. It also solves the problems of insufficient accuracy, single judgment dimension, inability to distinguish defect types, and high false positive and false negative rates in existing single-condition fixed-point camera detection methods. This device replaces the traditional yarn guiding and weft insertion mechanism with a rotary guide bar, improving fabric performance through multi-directional interlacing. Combined with multiple cameras to detect and identify defects in the yarn guiding needles, it improves operational stability.

Description

Technical Field

[0001] This invention relates to the field of control technology, and more specifically, to a complete control system for a composite textile machinery rotary comb mechanism. Background Technology

[0002] Textile weaving involves the interlacing and looping of yarns to form fabrics with specific structures and properties. Warp knitting machines and rapier looms are the two main types of textile machinery.

[0003] In conventional warp knitting machines, multiple fixed guide bars reciprocate linearly along the warp direction, guiding the warp yarns to loop together and form loops. All loops are connected in series along the warp direction. The control system mainly controls the timing of the linear reciprocating motion of the guide bars to synchronize it with the loop-forming and loop-unforming actions of the loom. In conventional rapier looms, fixed guide bars are usually set up, and weft insertion is achieved by the linear reciprocating motion of the rapier along the guide rail. Double-layer rapier looms use two independent sets of fixed guide bars to achieve double-layer weft insertion. The control system controls the reciprocating speed and phase of the rapier according to the knitting speed to ensure the accuracy of the weft insertion action.

[0004] However, in existing weaving structures and control methods, traditional looms can only achieve orthogonal warp and weft interlacing, and the yarn guiding or weft insertion trajectory is singular. This results in the fabric yarns being arranged orthogonally only along the warp and weft directions, leading to low fabric breathability and tensile strength. Furthermore, the warp and weft fixed guide bars, which serve as yarn guiding components, are prone to wear and deformation defects in their guide holes due to the long-term tensile force of the yarn and the impact of reciprocating motion.

[0005] Meanwhile, existing inspection methods for fixed combs typically use single-condition fixed-point cameras to capture images, which can only obtain the instantaneous shape of the needles at a certain moment. They cannot distinguish between different defect types, have a single dimension for deformation judgment, and have a high rate of false positives and false negatives. Even if multiple cameras are used for distributed shooting, it still needs to rely on time-series alternating acquisition and sequential comparison mode, which is difficult to adapt to the dynamic inspection needs under the complex working conditions of rotating comb mechanisms. Summary of the Invention

[0006] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a complete control system for a composite textile machinery rotary combing mechanism.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a complete control system for a composite textile machinery rotary comb mechanism, comprising a rotary comb mechanism, wherein the rotary comb mechanism includes a mounting base and a synchronous belt driven by the bottom of the mounting base, wherein multiple needle rows are mounted on the outer wall of the synchronous belt, and multiple guide needles are equidistantly arranged on the needle rows, and the synchronous belt is divided into a first arc segment, a second arc segment, a first straight segment, and a second straight segment.

[0008] A ring seat is positioned above the rotating comb mechanism and is used for guiding wires.

[0009] The limiting mechanism, located at the bottom of the mounting base, is used to radially limit the pin array at the first arc segment position.

[0010] An arc-shaped camera is installed below the limiting mechanism and is used to collect the deformation data of the pin row at the 90-degree position of the first arc segment. It also moves synchronously with the limiting mechanism to maintain the relative distance and shooting angle with the pin row.

[0011] The mounting base has a first camera and a second camera installed on its bottom sides to collect needle deformation data at two straight line segments.

[0012] The controller acquires the reference data calibrated based on the limit mechanism, sets a comparison method with no alternating order of data, and analyzes the defect status of the same guide needle passing through the same camera during forward and reverse rotation of the synchronous belt by cross comparison of straight segments and arc segments, and comparison of double straight segments and double arc segments.

[0013] The present invention is further configured such that: two pulleys are rotatably connected to the bottom sides of the mounting base, and at least one drive motor is mounted on the top of the mounting base for driving the synchronous belt to rotate, and the synchronous belt is connected to the outer wall of the two pulleys.

[0014] The invention is further configured such that: two synchronous belt baffles are symmetrically installed at the bottom of the mounting base, the two synchronous belt baffles are used to assist in limiting the needle rows on the two straight segments of the synchronous belt; a bearing mounting base is installed at the top of the mounting base; a driven wheel shaft is rotatably mounted inside the bearing mounting base; the driven wheel shaft is connected to a pulley located away from the drive motor.

[0015] The present invention is further configured such that: the limiting mechanism corresponds to the first arc segment, the limiting mechanism includes a housing connected to the bottom of the mounting base and close to the drive motor, the arc segment camera is mounted directly below the housing and the shooting range covers 90 degrees of the first arc segment, the housing has two sets of rollers rotating inside, the rollers are composed of two sets of wheel bodies stacked together, and the outer wall of the wheel body is fitted with a rubber ring.

[0016] The present invention is further configured such that: two elongated holes are provided at the top and bottom of the housing, and a rotating shaft is inserted into each of the two elongated holes on one side of the housing; the two rotating shafts are correspondingly arranged with two rollers, and the rollers are rotatably connected to the outer side wall of the corresponding rotating shaft.

[0017] The invention is further configured such that: two connecting platforms are symmetrically installed inside the housing, and spring rods are hinged to the side walls of the two connecting platforms. The output ends of the spring rods extend between the two wheel bodies of the corresponding rollers and are hinged to the outer side wall of the corresponding rotating shaft.

[0018] The invention is further configured such that: a connecting plate is provided at the bottom of the housing, the connecting plate forms a follower unit between the arc segment camera and the roller, and when the roller moves synchronously with the radial displacement of the needle row, the arc segment camera follows the synchronous displacement, maintaining the relative distance and shooting angle with the needle row, the connecting plate is connected to the bottom of the two rotating shafts, the arc segment camera is connected to the connecting plate through a bracket, and a laser displacement sensor is also installed inside the housing, the detection end of the laser displacement sensor facing the direction of the synchronous belt.

[0019] The present invention is further configured such that: the controller incorporates a rotating comb mechanism operation control method, the operation control method comprising the following steps: S1. Installation and adaptation of the rotating guide bar mechanism: Install the rotating guide bar mechanism on the warp knitting machine or rapier loom, that is, fix the mounting base of the rotating guide bar mechanism to the guide bar mounting beam of the warp knitting machine or rapier loom with bolts, and connect it to the main control system of the warp knitting machine or rapier loom.

[0020] S2. Threading and initial alignment of the ring seat: Fix the ring seat to the preset guide wire position above the rotating comb mechanism using a bracket. Adjust the center of the ring seat to coincide with the center of the synchronous belt track. Thread the lead-out wire through the guide wire holes on the ring seat in sequence, and then thread it through the corresponding guide wire holes on each needle row. Adjust the tension of the wire using the tensioner on the warp knitting machine or rapier loom.

[0021] S3. Rotary comb mechanism cyclic transmission control: During weaving, the controller sends corresponding speed and direction commands to the drive motor according to the weaving speed of the loom. The drive motor drives the pulley connected to it to rotate. The two pulleys cooperate to drive the synchronous belt transmission. The synchronous belt drives multiple sets of needle rows to move synchronously along the track-shaped trajectory. The guide needles on the needle rows pull the yarn to move along the preset trajectory.

[0022] S4. Wire movement synchronization control: The controller controls the movement sequence of the needle row by using the position signal fed back in real time from the encoder, so that the wire movement of the wire needle is synchronized with the loop forming and loop unwinding of the loom. In addition, by using the coordination of the timing belt and the drive motor, it supports multiple operating modes such as forward rotation, reverse rotation, and reciprocating inching. The speed and operating status of the drive motor are dynamically adjusted according to different knitting pattern requirements.

[0023] The present invention is further configured such that: the controller also incorporates a wire needle defect detection method, the detection method performing data processing based on a data comparison method with no alternating order, specifically including the following steps: S01. During the transmission displacement process, the limiting mechanism provides auxiliary limiting for the needle row and synchronous belt of the first arc segment, causing the shooting reference of the arc segment camera to be calibrated. Then, the arc segment camera deformation data acquisition is performed, and the shooting is triggered synchronously based on the drive motor encoder to obtain the deformation characteristics of the wire needle at the 90-degree force position of the first arc segment.

[0024] S02. While the arc segment camera is performing the shooting action, the first camera and the second camera operate and collect the guide needle deformation data of the corresponding range of the first straight segment and the second straight segment.

[0025] S03. The controller acquires data from the circular arc segment camera, the first camera, and the second camera based on a comparison method that does not involve alternating data order. Through cross-comparison of straight segments and circular arc segments, and comparison of data from double straight segments and double circular arc segments, the controller analyzes the defect status of the same guide needle passing through the same camera during forward and reverse rotation of the synchronous belt and outputs the defect judgment result.

[0026] The present invention is further configured such that, in step S03, the comparison method comprises the following specific steps: S031. Establish a status cache recorder for each lead pin on the pin array, allocate an independent status storage unit for each lead pin, and cache the latest collected data and operating status in real time.

[0027] S032. Whenever the arc segment camera collects the deformation data of the guide needle, it updates the latest arc segment deformation data and timestamp of the corresponding status recorder. When the first or second camera collects the guide needle data later, it directly compares it with the most recent arc segment deformation data to generate a cross comparison between the straight segment and the arc segment.

[0028] S033. If multiple straight line segment images of the guide needle are acquired consecutively, the first straight line segment image is used for formal defect determination, and all subsequent straight line segment images are used as supplementary data for the recovery trend curve to calculate the deformation recovery rate of the guide needle.

[0029] S034. If multiple arc segment images appear consecutively for the same wire needle, the deformation data difference between adjacent arc segments is compared sequentially to analyze the deformation stability under this condition. Multiple consecutive sets of arc segment data are used as supplementary basis for defect judgment. S035. If, in the cross-comparison of the straight segment and the arc segment, the straight segment data recovers to the normal threshold and the subsequent data is stable, it is judged as normal elastic deformation; if the straight segment data does not recover, combined with the arc segment data exceeding the limit, it is judged as plastic bending defect; if the arc segment data exceeds the threshold and the straight segment data does not recover, it is judged as needle loosening or fracture defect; if the arc segment data exceeds the threshold and the straight segment data shows partial recovery, it is judged as early fatigue defect of needle microcrack.

[0030] In summary, this application includes at least one of the following beneficial technical effects: (1) The original yarn guiding or weft insertion mechanism of the warp knitting machine and rapier loom is directly replaced by the rotating combing mechanism. Through multi-directional and multi-track yarn transport, a multi-directional interwoven fabric structure is formed. This structure reconstructs the pore morphology inside the fabric, making the pore distribution more uniform and the connectivity better.

[0031] (2) Multi-camera distributed detection is adopted, and deformation data are collected at the arc section of the guide needle and the straight section without stress. The deformation of the guide needle is judged. At the same time, combined with the dynamic comparison method of data without alternation order, it does not need to rely on strict alternation of data collection. It is adapted to the forward, reverse and reciprocating jog operation modes of synchronous belt. By comparing the deformation characteristics of the guide needle under different stress states and at different times, it can distinguish normal elastic deformation, plastic bending, loosening fracture and early fatigue defects of microcracks, reduce the probability of misjudgment and improve the operation stability of the rotating comb mechanism.

[0032] (3) When the arc segment camera is shooting, the roller and spring rod are used to limit the synchronous belt and needle row at the arc segment position, and maintain the stability of the shooting reference in real time. In the process of limiting, the arc segment camera and the roller form a follow-up whole. When the roller moves synchronously with the radial displacement of the needle row, the arc segment camera will also move synchronously, always maintaining the relative distance and shooting angle with the needle row, reducing the shooting reference offset caused by the synchronous belt fluctuation. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the overall structure of a complete control system for a composite textile machinery rotary comb mechanism according to the present invention.

[0034] Figure 2 for Figure 1 A schematic diagram of a localized explosion structure.

[0035] Figure 3 This is a schematic diagram of the needle array structure in this invention.

[0036] Figure 4 This is a bottom view of the rotating comb mechanism in this invention.

[0037] Figure 5 This is a schematic diagram of the limiting mechanism in this invention.

[0038] Figure 6 for Figure 5 A schematic diagram of the structure viewed from below.

[0039] Figure 7 This is a schematic diagram of the internal structure of the limiting mechanism.

[0040] Figure 8This is a schematic diagram of the mounting base, the first camera, and the second camera working together in this invention.

[0041] Figure 9 This is a schematic diagram showing the interaction between the arc-shaped camera, the first camera, the second camera, and the rotating comb mechanism in this invention.

[0042] Figure 10 This is a schematic diagram showing the installation position of the rotating comb mechanism in a warp knitting machine.

[0043] Figure 11 A schematic diagram of a rotary comb mechanism adapted to a rapier loom.

[0044] Figure 12 This is a schematic diagram of a woven fabric produced by a conventional warp knitting machine or rapier loom.

[0045] Figure 13 A schematic diagram of a woven fabric produced using a rotating comb mechanism.

[0046] Explanation of reference numerals in the attached drawings: 1. Rotary comb mechanism; 11. Mounting base; 12. Synchronous belt stop bar; 13. Drive motor; 14. Pulley; 15. Synchronous belt; 16. Bearing mounting base; 17. Driven wheel axle; 18. Needle bar; 2. Circular seat; 3. Limiting mechanism; 31. Housing; 32. Elongated hole; 33. Roller; 34. Rotating shaft; 35. Connecting plate; 36. Connecting platform; 37. Spring rod; 38. Laser displacement sensor; 4. Arc-shaped camera; 5. First camera; 6. Second camera; 7. Fixed comb. Detailed Implementation

[0047] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0048] It should be noted that, unless otherwise specified, all technical and scientific terms used in this application have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0049] Please see Figures 1-13 The present invention provides the following technical solutions: Example 1, see Figure 1 , Figures 10-13A complete control system for a composite textile machinery rotary comb mechanism includes a rotary comb mechanism 1, with an annular seat 2 for guide wires disposed above the rotary comb mechanism 1. The rotary comb mechanism 1 can be adapted to be installed on a warp knitting machine or a rapier loom to replace the original yarn guiding or weft insertion mechanism. By conveying yarn in multiple directions and multiple tracks, it solves the problem that traditional looms can only achieve orthogonal warp and weft interlacing, while optimizing the internal pore structure of the fabric and simultaneously improving air permeability.

[0050] See Figure 10 In a conventional warp knitting machine, multiple fixed guide bars reciprocate in a straight line along the warp direction, guiding the warp yarns to loop together to form loops. All loops are connected in series along the warp direction, ultimately weaving out the yarn as shown in the attached image. Figure 12 The orthogonal plain weave fabric shown has yarns arranged orthogonally only along the warp and weft directions. The fixed comb moves in a straight line, and the yarn guide trajectory is singular, which can only form a warp loop structure. The yarns are arranged in parallel and tightly, and the internal pores of the fabric are mostly isolated small gaps, resulting in poor connectivity, air permeability, and tensile strength.

[0051] See Figure 10 and Figure 13 In this embodiment, the traditional straight reciprocating comb bar in area A of the warp knitting machine is replaced with a rotating comb bar mechanism 1. The rotating comb bar mechanism 1 cooperates with the fixed comb bar of the warp knitting machine. While performing the traditional conductor function, the rotating comb bar mechanism 1 introduces the weft yarn into the warp knitting loop structure to form a composite fabric combining warp and weft knitting. The multi-directional interwoven yarns form a three-dimensional pore structure with uniform size and good connectivity, which improves the transverse tensile strength and breathability of the fabric.

[0052] In a conventional rapier loom, two sets of fixed guide bars 7 are set up. Double-layer weft insertion is achieved through the two sets of independent fixed guide bars 7. The rapier can only move back and forth in a straight line along the guide rail. The weft insertion direction is singular, and only a double-layer fabric with orthogonal warp and weft interlacing can be formed. The upper and lower layers of fabric are tightly attached, and the overall air permeability is poor.

[0053] See Figure 11 and Figure 13 In this embodiment, one set of fixed guide bars 7 in the double-layer rapier loom is replaced with a rotating guide bar mechanism 1. The remaining set of fixed guide bars 7 is responsible for traditional weft insertion, while the rotating guide bar mechanism 1 introduces yarns diagonally and in multiple directions, forming diagonal connecting yarns between the upper and lower layers of fabric, ultimately weaving a multi-directional interlaced yarn as shown in the attached figure. Figure 13 The fabric shown.

[0054] See Figure 1 and Figure 2The rotating comb mechanism 1 includes a mounting base 11 and a synchronous belt 15 driven by the bottom of the mounting base 11. Two pulleys 14 are rotatably connected to the bottom sides of the mounting base 11. At least one drive motor 13 is mounted on the top of the mounting base 11 to drive the synchronous belt 15 to rotate. The synchronous belt 15 is driven by the outer walls of the two pulleys 14. One of the drive motors 13 serves as a power source, controlling the output speed and direction and applying driving force to the pulleys 14.

[0055] This embodiment does not limit the specific structural form of the timing belt 15; it can be a belt, chain, or steel sheet, etc.

[0056] See Figure 2 and Figure 3 Multiple needle rows 18 are installed on the outer wall of the synchronous belt 15. Multiple guide needles are equally spaced on the needle rows 18. The synchronous belt 15 is divided into a first arc segment, a second arc segment, a first straight segment, and a second straight segment. Through the meshing transmission between the pulley 14 and the synchronous belt 15, the synchronous belt 15 adopts a racetrack-shaped trajectory, which converts the rotational motion into the movement of the needle rows 18, so that the needle rows 18 can complete the yarn guiding in the straight segment and complete the reversing action in the arc segment, which is suitable for the continuous cycle knitting needs of warp knitting machines and rapier looms.

[0057] See Figure 2 and Figure 4 Two synchronous belt baffles 12 are symmetrically installed at the bottom of the mounting base 11. The two synchronous belt baffles 12 are used to assist in limiting the needle row 18 on the two straight sections of the synchronous belt 15. The synchronous belt baffles 12 limit the lateral movement of the straight sections of the synchronous belt 15 to prevent the needle row 18 from running off-center and causing the yarn guide to misalign. A bearing mounting base 16 is installed on the top of the mounting base 11. A driven wheel shaft 17 rotates inside the bearing mounting base 16. The driven wheel shaft 17 is connected to a pulley 14 located away from the drive motor 13. The bearing mounting base 16 provides rigid support for the driven wheel shaft 17 to ensure the transmission stability of the two pulleys 14.

[0058] However, when the rotary combing mechanism 1 is running on a racetrack-shaped trajectory, the peak point of the yarn tension is at the midpoint of the 90° arc segment: when the guide needle turns 180° with the synchronous belt 15, it is simultaneously subjected to the dynamic tension of the yarn. The tension will exceed that of the first and second straight segments. Therefore, the arc segment is a high-incidence area for the guide needle to rub, bend, loosen, and break. Moreover, the early micro-deformation is completely invisible to the naked eye. By the time it causes the fabric to break, it has already caused a batch of defective products.

[0059] Existing methods can install one or more cameras to take pictures and determine the degree of deformation of the guide needle. However, regardless of whether one or more cameras are used, it is still only a single-condition shooting method. It can only obtain the instantaneous shape of the needle body and cannot distinguish different defect types such as elastic deformation, plastic deformation, and microcrack fatigue deformation. The deformation judgment dimension is single and it will cause defect misjudgment. Furthermore, the distribution of multiple cameras still requires the use of time-sequential alternating acquisition and sequential comparison mode, which is difficult to adapt to the dynamic detection needs under the complex working conditions of the rotating comb mechanism.

[0060] For this purpose, please refer to Figure 2 , Figure 8 and Figure 9 An arc segment camera 4 is installed below the mounting base 11 and at the first arc segment position of the synchronous belt 15. The arc segment camera 4 is used to collect the deformation data of the needle row 18 at the 90-degree position of the first arc segment. The 90-degree position of the first arc segment is the position where the wire needle is subjected to the greatest tension of the wire, and it is also the position where defects such as needle bending are most likely to appear. The arc segment camera 4 captures the deformation state of the wire needle at the corresponding position, improves the probability of defect detection, and ensures the reliability of the rotating comb mechanism 1 when running at high speed.

[0061] See Figure 2 , Figure 8 and Figure 9 The mounting base 11 has a first camera 5 and a second camera 6 installed on both sides of its bottom. These cameras collect deformation data of the needle row 18 at two straight line segments. The wire needles at the first and second straight line segments are subjected to less tension from the wire, which can reflect the condition of the wire needles in a natural stress-free state. This data is compared with the deformation data of the first arc segment under stress, providing a basis for distinguishing between recoverable elastic deformation and non-recoverable plastic deformation.

[0062] As the core of system control and computation, the controller acquires data from the arc segment camera 4, the first camera 5, and the second camera 6, integrates the data collected from the three stations, and sets up a comparison method with no alternating order of data. Through cross-comparison of straight segments and arc segments, and comparison of data from double straight segments and double arc segments, the controller analyzes the defect status of the same guide pin passing through the same camera when the synchronous belt 15 is rotating in both directions. This breaks through the limitation of traditional single-condition detection, which can only obtain the instantaneous shape of the pin body. By eliminating the error of single-condition detection through multi-dimensional cross-comparison, the controller achieves a comprehensive and accurate analysis of guide pin defects, ensuring the reliability of the system's high-speed operation.

[0063] By setting cameras at the peak position of the arc segment where the guide needle is most sensitive to stress and at the two stress-free straight segments, deformation data of the guide needle under different stress states can be collected.

[0064] After acquiring the data from each workstation, the controller processes it using a comparison method that ensures the data is in a non-overlapping order. Establish a status cache recorder for each lead pin on pin row 18, allocate an independent status storage unit for each lead pin, and cache the latest collected data and operating status in real time.

[0065] Whenever the arc segment camera 4 collects the deformation data of the guide needle, it updates the latest arc segment deformation data and timestamp of the corresponding status recorder. When the first camera 5 or the second camera 6 collects the data of the guide needle in the future, it directly compares it with the most recent arc segment deformation data.

[0066] There are three comparison and analysis methods: cross comparison of straight line segments and circular arc segments, and comparison of data of two straight line segments and two circular arc segments.

[0067] If multiple straight line segment images of the guide pin are acquired consecutively, the first straight line segment image is used for formal defect determination, and all subsequent straight line segment images are used as supplementary data for the recovery trend curve to calculate the deformation recovery rate of the guide pin.

[0068] If multiple arc segment images appear consecutively for the same guide needle, the deformation data difference between adjacent arc segments is compared sequentially to analyze the deformation stability under this condition. Multiple consecutive sets of arc segment data are used as supplementary basis for defect judgment.

[0069] If the data comparison involves a cross comparison of straight segments and circular segments, and the straight segment data recovers to the normal threshold and subsequent data is stable, it is determined to be normal elastic deformation; if the straight segment data does not recover, combined with the out-of-limit characteristics of the circular segment data, it is determined to be a plastic bending defect; if the circular segment data exceeds the threshold and the straight segment data does not recover, it is determined to be a needle loosening or fracture defect; if the circular segment data exceeds the threshold and the straight segment data shows partial recovery, it is determined to be an early fatigue defect of needle microcracks.

[0070] Optionally, two cameras 4 can be configured, which are respectively installed at the 90° peak stress position of the first and second arc segments to realize the synchronous acquisition of bidirectional arc segment deformation data and process it through the comparison method described above.

[0071] The comparison method distinguishes four types of defects—normal elastic deformation, plastic bending, loosening fracture, and early fatigue of microcracks—through cross-comparison analysis of straight segments and circular arc segments, double straight segment comparison analysis, or double circular arc segment comparison analysis. This solves the problem of high misjudgment and omission rate in traditional single-condition detection, making the high-speed operation of the rotating comb mechanism 1 stable and reliable.

[0072] In Example 2, during the rotation of the rotating comb mechanism 1, the centrifugal force generated by the high-speed operation will cause the needle row 18 to undergo outward swing deformation. The swing deformation is an overall mechanical displacement of the needle row 18, not a single needle deformation defect, but it will be identified as needle bending and displacement by the arc segment camera 4. At the same time, the running jump error of the synchronous belt 15 will cause the overall detection reference to shift, introducing fixed system error. As a result, the system cannot distinguish between the overall mechanical vibration shift of the equipment and the real deformation defect of a single needle, and the detection accuracy will be greatly reduced.

[0073] For this purpose, please refer to Figure 2 , Figures 5-7 A limiting mechanism 3 is installed at the bottom of the mounting base 11 and on one side of the drive motor 13. The limiting mechanism 3 is used to radially limit the needle row 18 at the first arc segment position to provide a stable shooting reference. The arc segment camera 4 is installed below the limiting mechanism 3, that is, the radial limit is set at the first arc segment where the centrifugal force of the needle row 18 is the largest, which restricts the overall outward deformation of the needle row 18, so that the deformation of the needle row 18 at the arc segment position is greatly reduced, and the arc segment camera 4 can shoot the needle row 18 position with the smallest deformation at the arc segment position.

[0074] See Figure 2 , Figures 5-7 The limiting mechanism 3 is surrounded by a large number of continuously conveying wires, and the installation space is extremely limited. The installation point of the limiting mechanism 3 must avoid interference with the surrounding conveying lines. The arc segment camera 4 can only take pictures at specific points where the needle row 18 passes through the arc segment. This position is the position with the largest fluctuation during the operation of the needle row 18 with the synchronous belt 15. The data obtained at this position has a high accuracy. If the position is deviated from, the shooting data will be deviated due to changes in the needle row angle and light reflection conditions, and cannot be used for subsequent detection of wire needle defects.

[0075] However, at this position, the synchronous belt 15 experiences the greatest centrifugal force in the arc segment, which also affects the accuracy of the shooting.

[0076] Therefore, the limiting mechanism 3 includes a housing 31 connected to the bottom of the mounting base 11 and close to the drive motor 13. Inside the housing 31, there are two sets of rollers 33 that rotate. The rollers 33 are composed of two sets of stacked wheel bodies. A rubber ring is fitted on the outer wall of the wheel body. The two sets of rollers 33 increase the contact area with the side of the needle row 18, making the limiting force evenly distributed. The rollers 33 and the rubber ring have an elastic buffering effect, which can absorb the small vibrations of the needle row 18. At the same time, it avoids surface scratches and wear caused by rigid contact between the rollers 33 and the needle row 18. The synchronous belt 15 and the needle row 18 at the 90-degree position of the arc segment are limited by the rollers 33, improving the accuracy of data acquisition.

[0077] See Figure 2 , Figures 5-7The top and bottom of the housing 31 are provided with two elongated holes 32. The two elongated holes 32 on one side of the housing 31 are each connected to a rotating shaft 34. The two rotating shafts 34 are correspondingly arranged with two rollers 33. The rollers 33 are rotatably connected to the outer side wall of the corresponding rotating shaft 34. The elongated holes 32 extend radially to provide a moving guide for the rotating shafts 34. When the timing belt 15 jumps, the rollers 33 can adaptively adjust according to the actual position of the needle row 18 to ensure the constant limiting force and avoid the needle row 18 from running stuck due to being too tight or failing to play a limiting role due to being too loose.

[0078] See Figure 2 , Figures 5-7 Two connecting platforms 36 are symmetrically installed inside the housing 31. The side walls of the two connecting platforms 36 are hinged with spring rods 37. The output end of the spring rods 37 extends between the two wheels of the corresponding rollers 33 and is hinged to the outer side wall of the corresponding rotating shaft 34. The spring rods 37 connect and fix the connecting platforms 36 and the rotating shaft 34 by hinge. The spring rods 37 provide elastic preload to the rotating shaft 34 and the rollers 33, so that the rollers 33 always press the side of the needle row 18 with the elastic force of the spring rods 37, reducing the impact of the swing of the synchronous belt 15 and the needle row 18 on the shooting data of the arc segment camera 4.

[0079] Even if the pin array 18 has a slight dimensional deviation or outward deformation, the elastic deformation of the spring rod 37 can automatically compensate, thereby maintaining the limiting effect and setting the shooting reference for the arc segment camera 4.

[0080] See Figure 2 , Figures 5-7 Inside the housing 31, a laser displacement sensor 38 is also installed. The detection end of the laser displacement sensor 38 faces the synchronous belt 15 and is used to detect the radial displacement of the synchronous belt 15 and the corresponding needle row 18 in real time.

[0081] In addition, as a flexible transmission component, the synchronous belt 15 is affected by its own tension fluctuations, manufacturing errors of the pulley 14, and load changes. During transmission, it will generate longitudinal jumps and lateral swaying. The relative distance and angle between the arc-shaped camera 4 and the needle row 18 will change with the swaying of the synchronous belt 15, resulting in distortion of deformation measurement values ​​and exacerbating detection errors.

[0082] A connecting plate 35 is provided at the bottom of the housing 31. The connecting plate 35 is connected to the bottom of the two rotating shafts 34. The arc-shaped camera 4 is connected to the connecting plate 35 through a bracket.

[0083] The circular arc segment camera 4 is rigidly connected to the rotating shaft 34 of the two rollers 33 by the connecting plate 35, so that the circular arc segment camera 4 and the rollers 33 form a follower unit. When the rollers 33 move synchronously with the radial displacement of the needle row 18, the circular arc segment camera 4 will also move synchronously, always maintaining the relative distance and shooting angle with the needle row 18, reducing the shooting reference offset caused by the fluctuation of the synchronous belt 15, and reducing the impact of the swing of the synchronous belt 15 and the needle row 18 on the shooting data of the circular arc segment camera 4.

[0084] Specifically, taking the first arc segment, the first straight segment, and the second straight segment as examples: when the needle row 18 enters the limiting area of ​​the first arc segment, the spring rod 37 applies an elastic preload to the corresponding rotating shaft 34, pushing the two sets of rollers 33 to press the side of the needle row 18, offsetting the centrifugal outward swing deformation generated by the rotation of the needle row 18, providing a stable static shooting reference for the arc segment camera 4, and eliminating the error of misjudging the overall mechanical displacement of the needle row 18 as a defect of the wire needle.

[0085] The circular arc segment camera 4 is rigidly connected to the rotating shaft 34 of the two rollers 33 by the connecting plate 35, so that the circular arc segment camera 4 and the rollers 33 form a rigid follower whole. When the synchronous belt 15 fluctuates longitudinally or the needle row 18 vibrates abnormally, the rollers 33 and the needle row 18 generate radial displacement synchronously, which drives the rotating shaft 34 to slide along the elongated hole 32. Then, through the connecting plate 35, the circular arc segment camera 4 and the needle row 18 maintain the relative position and shooting angle, and compensate for the shooting reference drift caused by the fluctuation of the synchronous belt 15 in real time.

[0086] When the needle row 18 wears out due to long-term use, the timing belt 15 becomes abnormally tensile, or the spring rod 37 fails due to fatigue, the spring rod 37 will push the roller 33 to its limit position. At this time, the laser displacement sensor 38 detects the distance between the needle row 18 and the laser displacement sensor 38. When the distance exceeds the preset distance range, it can be determined that the fluctuation range of the needle row 18 is too large and the roller 33 has not played a limiting role. At this time, the controller sends a warning signal to the operator, prompting to replace the worn needle row 18 or adjust the tension of the timing belt 15 in time to avoid batch defects caused by mechanical component failure.

[0087] Example 3: A method for controlling the operation of the built-in rotating comb mechanism 1 in the controller. The method includes the following steps: S1. Installation and adaptation of the rotating guide bar mechanism 1: Install the rotating guide bar mechanism 1 on the warp knitting machine or rapier loom, that is, fix the mounting base 11 of the rotating guide bar mechanism 1 to the guide bar mounting beam of the warp knitting machine or rapier loom with bolts, and connect it to the main control system of the warp knitting machine or rapier loom.

[0088] S2. Threading and initial alignment of the ring seat 2: Fix the ring seat 2 to the preset guide wire position above the rotating comb mechanism 1 using a bracket. Adjust the center of the ring seat 2 to coincide with the center of the synchronous belt 15 track. Thread the lead-out wire through the guide wire holes on the ring seat 2 in sequence, and then thread it through the corresponding guide wire holes on each needle row 18. Adjust the tension of the wire using a tensioner on the warp knitting machine or rapier loom.

[0089] S3. Rotary comb mechanism 1 cyclic transmission control: During weaving, the controller sends corresponding speed and direction commands to the drive motor 13 according to the weaving speed of the loom. The drive motor 13 drives the pulley 14 connected to it to rotate. The two pulleys 14 cooperate to drive the synchronous belt 15 to drive. The synchronous belt 15 drives multiple sets of needle rows 18 to move synchronously along the track-shaped trajectory. The guide needles on the needle rows 18 pull the thread to move according to the preset trajectory.

[0090] S4. Wire movement synchronization control: The controller controls the movement sequence of the needle row 18 by using the position signal fed back in real time from the encoder, so that the wire movement of the wire needle is synchronized with the loop forming and loop unwinding of the loom. In addition, by using the coordination of the timing belt 15 and the drive motor 13, it supports multiple operating modes such as forward rotation, reverse rotation, and reciprocating inching. The speed and operating status of the drive motor 13 are dynamically adjusted according to different knitting pattern requirements.

[0091] The controller also incorporates a wire needle defect detection method. This method is based on a data processing approach that compares data without any alternation order, and specifically includes the following steps: S01. During the transmission displacement process, the limiting mechanism 3 provides auxiliary limiting for the needle row 18 and the synchronous belt 15 in the first arc segment, causing the shooting reference of the arc segment camera 4 to be calibrated. Then, the deformation data of the arc segment camera 4 is collected, and the shooting is triggered synchronously by the encoder of the drive motor 13 to obtain the deformation characteristics of the wire needle at the 90-degree force position of the first arc segment.

[0092] S02. While the arc segment camera 4 is performing the shooting action, the first camera 5 and the second camera 6 are running and collecting the guide needle deformation data of the corresponding range of the first straight segment and the second straight segment.

[0093] S03. The controller acquires data from the arc segment camera 4, the first camera 5 and the second camera 6 based on a comparison method with no alternating data order. Through cross comparison of straight segments and arc segments, and comparison of data from double straight segments and double arc segments, the controller analyzes the defect status of the same guide needle passing through the same camera when the synchronous belt 15 is rotating forward and backward, and outputs the defect judgment result.

[0094] In step S03, the specific steps of the comparison method are as follows: S031. Establish a status cache recorder for each lead pin on pin row 18, allocate an independent status storage unit for each lead pin, and cache the latest collected data and operating status in real time.

[0095] S032. Whenever the arc segment camera 4 collects the deformation data of the guide needle, it updates the latest arc segment deformation data and timestamp of the corresponding status recorder. When the first camera 5 or the second camera 6 collects the guide needle data later, it directly compares it with the most recent arc segment deformation data to generate a cross comparison between the straight segment and the arc segment.

[0096] S033. If multiple straight line segment images of the guide needle are acquired consecutively, the first straight line segment image is used for formal defect determination, and all subsequent straight line segment images are used as supplementary data for the recovery trend curve to calculate the deformation recovery rate of the guide needle.

[0097] S034. If multiple arc segment images appear consecutively for the same wire needle, the deformation data difference between adjacent arc segments is compared sequentially to analyze the deformation stability under this condition. Multiple consecutive sets of arc segment data are used as supplementary basis for defect judgment.

[0098] S035. If, in the cross-comparison of the straight segment and the arc segment, the straight segment data recovers to the normal threshold and the subsequent data is stable, it is judged as normal elastic deformation; if the straight segment data does not recover, combined with the arc segment data exceeding the limit, it is judged as plastic bending defect; if the arc segment data exceeds the threshold and the straight segment data does not recover, it is judged as needle loosening or fracture defect; if the arc segment data exceeds the threshold and the straight segment data shows partial recovery, it is judged as early fatigue defect of needle microcrack.

[0099] Obviously, the embodiments described above are merely some, not all, embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

Claims

1. A complete control system for a composite textile machine rotary gill mechanism, characterized in that: The system includes a rotating comb mechanism (1), which includes a mounting base (11) and a synchronous belt (15) driven by the bottom of the mounting base (11). The outer wall of the synchronous belt (15) is equipped with multiple needle rows (18), and multiple guide needles are equidistantly arranged on the needle rows (18). The synchronous belt (15) is divided into a first arc segment, a second arc segment, a first straight segment, and a second straight segment. An annular seat (2) is positioned above the rotating comb mechanism (1) and is used for the guide wire; The limiting mechanism (3), located at the bottom of the mounting base (11), is used to radially limit the pin row (18) at the first arc segment position; The arc segment camera (4) is installed below the limiting mechanism (3) and is used to collect the deformation data of the needle row (18) at the 90-degree position of the first arc segment. It moves synchronously with the limiting mechanism (3) to maintain the relative distance and shooting angle with the needle row (18). The mounting base (11) is equipped with a first camera (5) and a second camera (6) on both sides of its bottom, which respectively collect deformation data of the pin array (18) at two straight line segments. The controller acquires the reference data after calibration based on the limit mechanism (3), sets the comparison method of data without alternation order, and analyzes the defect status of the same wire needle passing through the same camera when the synchronous belt (15) is in forward and reverse rotation by cross comparison of straight segment and arc segment, comparison of double straight segment and double arc segment data. The limiting mechanism (3) corresponds to the first arc segment. The limiting mechanism (3) includes a housing (31) connected to the bottom of the mounting base (11) and close to the side of the drive motor (13). The arc segment camera (4) is installed directly below the housing (31) and its shooting range covers 90 degrees of the first arc segment. There are two sets of rollers (33) rotating inside the housing (31). The rollers (33) are composed of two sets of stacked wheel bodies. The outer wall of the wheel body is fitted with a rubber ring. The top and bottom of the housing (31) are provided with two elongated holes (32). A rotating shaft (34) is inserted into each of the two elongated holes (32) on one side of the housing (31). The two rotating shafts (34) are correspondingly arranged with two rollers (33). The rollers (33) are rotatably connected to the outer side wall of the corresponding rotating shaft (34). Two connecting platforms (36) are symmetrically installed inside the housing (31). The side walls of the two connecting platforms (36) are hinged with spring rods (37). The output end of the spring rods (37) extends between the two wheels of the corresponding rollers (33) and is hinged to the outer side wall of the corresponding shaft (34).

2. A complete control system of a composite type textile machinery rotary gill mechanism according to claim 1, characterized in that: The bottom sides of the mounting base (11) are rotatably connected to two pulleys (14), and the top of the mounting base (11) is equipped with at least one drive motor (13) for driving the synchronous belt (15) to rotate. The synchronous belt (15) is connected to the outer wall of the two pulleys (14).

3. A complete control system of a composite type textile machine rotary gill mechanism according to claim 2, characterized in that: Two synchronous belt baffles (12) are symmetrically installed at the bottom of the mounting base (11). The two synchronous belt baffles (12) are used to assist in limiting the needle row (18) on the two straight segments of the synchronous belt (15). A bearing mounting base (16) is installed at the top of the mounting base (11). A passive wheel shaft (17) rotates inside the bearing mounting base (16). The passive wheel shaft (17) is connected to a pulley (14) located away from the drive motor (13).

4. A complete control system for a rotary gill mechanism of a textile machine according to claim 1, characterized in that: A connecting plate (35) is provided at the bottom of the housing (31). The connecting plate (35) forms a follower unit with the arc segment camera (4) and the roller (33). When the roller (33) moves synchronously with the radial displacement of the needle row (18), the arc segment camera (4) follows the synchronous displacement, maintaining the relative distance and shooting angle with the needle row (18). The connecting plate (35) is connected to the bottom of the two rotating shafts (34). The arc segment camera (4) is connected to the connecting plate (35) through the bracket. A laser displacement sensor (38) is also installed inside the housing (31). The detection end of the laser displacement sensor (38) faces the direction of the synchronous belt (15).

5. A complete control system for a rotary gill mechanism of a textile machine according to claim 1, characterized in that: The controller has a built-in rotating comb mechanism (1) operation control method, which includes the following steps: S1. Installation and adaptation of the rotating comb mechanism (1): Install the rotating comb mechanism (1) on the warp knitting machine or rapier loom, that is, fix the mounting seat (11) of the rotating comb mechanism (1) to the comb mounting beam of the warp knitting machine or rapier loom with bolts, and connect it to the main control system of the warp knitting machine or rapier loom. S2. Threading and initial alignment of the ring seat (2): Fix the ring seat (2) above the rotating comb mechanism (1) to the preset wire guide position through the bracket. Adjust the center of the ring seat (2) to coincide with the center of the synchronous belt (15) track. Thread the wires through the wire guide holes on the ring seat (2) in sequence, and then thread them through the wire guide needle holes on each needle row (18). Adjust the tension of the wires through the tensioner on the warp knitting machine or rapier loom. S3, Rotary comb mechanism (1) Cyclic transmission control. During weaving, the controller sends the corresponding speed and direction command to the drive motor (13) according to the weaving speed of the loom. The drive motor (13) drives the pulley (14) connected to it to rotate. The two pulleys (14) cooperate to drive the synchronous belt (15) to drive. The synchronous belt (15) drives multiple sets of needle rows (18) to move synchronously along the track-shaped trajectory. The guide needles on the needle rows (18) pull the thread to move according to the preset trajectory. S4. Wire movement synchronization control: The controller controls the movement sequence of the needle row (18) by using the position signal fed back by the encoder in real time, so that the wire movement of the wire needle is synchronized with the looping and unlooping of the loom. In addition, by using the coordination of the timing belt (15) and the drive motor (13), it supports multiple operating modes such as forward rotation, reverse rotation and reciprocating jogging. According to different weaving pattern requirements, the speed and operating status of the drive motor (13) are dynamically adjusted.

6. A complete control system for a rotary gill mechanism of a textile machine according to claim 5, characterized in that: The controller also incorporates a wire pin defect detection method. This detection method processes data based on a comparison method where data is not in an alternating order, and specifically includes the following steps: S01, During the transmission displacement process of the needle row (18), the limiting mechanism (3) performs auxiliary limiting on the needle row (18) and the synchronous belt (15) of the first arc segment, so that the shooting reference of the arc segment camera (4) is calibrated, and then the deformation data of the arc segment camera (4) is collected. Based on the synchronous triggering of the encoder of the drive motor (13), the shooting is obtained to acquire the deformation characteristics of the wire needle at the 90-degree force position of the first arc segment; S02, while the arc segment camera (4) is performing the shooting action, the first camera (5) and the second camera (6) run and collect the guide needle deformation data of the corresponding range of the first straight segment and the second straight segment; S03. The controller acquires data collected by the arc segment camera (4), the first camera (5) and the second camera (6) based on the comparison method of data without alternation order. Through the cross comparison of straight segment and arc segment, and the comparison of data of double straight segment and double arc segment, the controller analyzes the defect status of the same guide needle passing through the same camera when the synchronous belt (15) is in forward and reverse rotation, and outputs the defect judgment result.

7. A complete control system for a rotary gill mechanism of a textile machine according to claim 6, characterized in that: In step S03, the specific steps of the comparison method are as follows: S031. Establish a status cache recorder for each lead wire pin on the pin array (18), allocate an independent status storage unit for each lead wire pin, and cache the latest collected data and operating status in real time. S032. Whenever the arc segment camera (4) collects the deformation data of the guide needle, it updates the latest arc segment deformation data and timestamp of the corresponding status recorder. When the first camera (5) or the second camera (6) collects the guide needle data, it directly compares it with the most recent arc segment deformation data to generate a cross comparison between the straight segment and the arc segment. S033. If multiple straight line segment images of the guide needle are acquired consecutively, the first straight line segment image is used for formal defect determination, and all subsequent straight line segment images are used as supplementary data for the recovery trend curve to calculate the deformation recovery rate of the guide needle. S034. If multiple arc segment images appear consecutively for the same wire needle, the deformation data difference between adjacent arc segments is compared sequentially to analyze the deformation stability under this condition. Multiple consecutive sets of arc segment data are used as supplementary basis for defect judgment. S035. If, in the cross-comparison of the straight segment and the arc segment, the straight segment data recovers to the normal threshold and the subsequent data is stable, it is judged as normal elastic deformation; if the straight segment data does not recover, combined with the arc segment data exceeding the limit, it is judged as plastic bending defect; if the arc segment data exceeds the threshold and the straight segment data does not recover, it is judged as needle loosening or fracture defect; if the arc segment data exceeds the threshold and the straight segment data shows partial recovery, it is judged as early fatigue defect of needle microcrack.

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