A precise length device and method for a bobbin winder

Abstract

This invention provides a precise yarn length determination device and method for a winding machine, comprising a yarn bobbin, a yarn bobbin winding shaft, a grooved bobbin, a grooved bobbin rotating shaft, a grooved bobbin drive motor, and a control system. Its key features are: a yarn bobbin encoder is installed at the end of the yarn bobbin winding shaft, a grooved bobbin encoder is installed at the end of the grooved bobbin rotating shaft, and an edge sensor is installed at the extreme reciprocating positions of the grooved bobbin's yarn guide to calculate the yarn's lateral velocity. The data processing module in the control system uses a controller as the core for data processing, performing pulse increment statistics and timestamp recording; calculating the angular velocities of the grooved bobbin and the yarn bobbin, deriving the dynamic radius of the yarn bobbin in real time, and calculating the yarn's lateral velocity through the trigger time difference of the edge sensor; integrating and accumulating the real-time composite velocity according to a set control cycle to obtain the total length of the wound yarn, thus achieving precise length determination. This avoids the cumulative effect of slippage errors, is less susceptible to interference from the surrounding environment, has strong adaptability, achieves high-precision length determination, and facilitates real-time acquisition of dynamic parameters.

Description

Technical Field

[0001] This invention belongs to the field of textile machinery technology and relates to the improvement of automatic winding machines, specifically a device and method for accurately determining the length of yarn packages in a winding machine. Background Technology

[0002] As the core equipment for yarn winding and forming in textile production, the automatic winding machine's core functions include not only winding bobbins into uniformly sized and well-formed cones, but also accurately measuring the length of the wound yarn to provide data support for subsequent weaving processes. It is a key link for textile enterprises to achieve refined production.

[0003] Currently, the industry mainly uses three detection methods for calculating yarn length on winding machines: Hall effect detection technology, speed transmission ratio correction technology, and fixed length sensor detection technology. However, these three methods have the following problems and drawbacks, making it difficult to meet the production requirements of high precision and high adaptability.

[0004] (1) Hall effect detection technology involves installing a Hall sensor inside the slotted drum motor and using the characteristic of the motor outputting pulses per revolution to estimate the yarn length in combination with the preset slotted drum radius. This technology has two major problems: First, the Hall sensor has low pulse resolution, and the number of pulses output per revolution of the slotted drum motor is small, resulting in limited accuracy in detecting the rotational speed. This is especially true in high-speed winding or speed fluctuation scenarios, which can easily lead to large speed calculation errors. Second, there is the yarn slippage phenomenon. The frictional transmission between the slotted drum and the yarn bobbin inevitably results in slippage. Directly using the slotted drum motor pulse signal to derive the yarn speed will cause the error caused by slippage to accumulate continuously.

[0005] (2) Speed ​​transmission ratio correction technology, such as the Chinese invention patent application (publication number: CN115258822A), proposes to set up a grooved drum speed sensor and a bobbin speed sensor to calculate the transmission ratio between the grooved drum and the bobbin in real time. The instantaneous value of the transmission ratio is stored at the moment of stopping winding, and the grooved drum speed is calculated based on the stored transmission ratio and the bobbin speed during the restart phase. This technology has three problems: First, the speed transmission ratio correction technology still relies on the grooved drum speed to indirectly calculate the yarn length, without directly measuring the actual displacement of the yarn; second, the transmission ratio is an instantaneous stored value, which cannot reflect the dynamic change of slip ratio during the restart phase; third, a fixed transmission ratio is used during the start-up phase, which deviates from the actual slip situation.

[0006] (3) Fixed-length sensor detection technology often uses contact (such as roller type) or non-contact (such as photoelectric type) fixed-length sensors to directly detect yarn movement. This technology attempts to avoid the indirect estimation defects of Hall effect detection, but there are still insurmountable problems. Contact fixed-length sensors use rollers to rub against the yarn to drive the sensor to count, which can easily cause yarn wear and affect yarn quality. On the other hand, there is also slippage between the roller and the yarn, which is greatly affected by yarn tension fluctuations. When the tension changes, the slippage rate changes abruptly, resulting in unstable measurement accuracy. Non-contact technologies, such as Chinese invention patent applications (publication numbers: CN102701011A, CN118424118A), are based on the principle of photoelectric reflection or transmission to detect yarn displacement. The yarn is irradiated by a parallel light, and the light signal is received on the other side. The undulation of the yarn contour causes a slight change in the signal. Non-contact fixed-length sensors detect yarn displacement based on photoelectric reflection or transmission principles. On the one hand, they are easily affected by environmental interference, such as dust and changes in light in the workshop, which can affect the sensor sensitivity. On the other hand, they have poor adaptability and cannot be adapted to chemical fiber varieties with smooth surfaces and high reflectivity.

[0007] Therefore, there is an urgent need in the field to design a device and method for accurately determining the length of yarn packages in a winding machine, in order to solve the following technical problems:

[0008] (1) Solve the problems of accumulated slip error in existing indirect length measurement technology and poor environmental adaptability of direct length measurement technology.

[0009] (2) Solve the technical problem that the slippage calculation of the groove cylinder and yarn cylinder in the existing detection scheme is inaccurate, which leads to the continuous accumulation of slippage error.

[0010] (3) Solve the problem that the existing testing scheme is easily affected by environmental interference such as workshop dust and light changes, and has poor adaptability.

[0011] (4) To address the technical gap that the existing detection scheme can only output a single result of yarn length and lacks real-time acquisition of core dynamic parameters such as yarn bobbin radius and slip rate, making it difficult to support the optimization of winding machine process and intelligent closed-loop control, so as to meet the intelligent control requirements of the winding process. Summary of the Invention

[0012] To address the aforementioned problems in the prior art, this invention provides a precise yarn length determination device and method for a winding machine, which avoids the cumulative effect of slippage error, is less susceptible to interference from the surrounding environment, has strong adaptability, achieves high-precision length determination, and facilitates real-time acquisition of dynamic parameters.

[0013] The objective of this invention is achieved through the following technical solution:

[0014] A yarn bobbin precision length measuring device for a winding machine includes a yarn bobbin, a yarn bobbin winding shaft, a grooved bobbin, a grooved bobbin rotation shaft, a grooved bobbin drive motor, and a control system. The control system is connected to the control terminal of the grooved bobbin drive motor. The yarn bobbin is mounted on the yarn bobbin winding shaft. The grooved bobbin is driven to rotate by the grooved bobbin drive motor. The yarn bobbin is rotated by surface friction transmission. The device is characterized by having a sensor element added inside the yarn bobbin winding shaft, and a yarn bobbin encoder installed near the sensor element for real-time acquisition of the yarn bobbin rotation angle and rotation speed; and having a sensor element added inside the grooved bobbin rotation shaft, and a grooved bobbin encoder installed near the sensor element. The system includes a device for real-time acquisition of the rotation angle and speed of the yarn guide; an edge sensor is installed at the extreme position of the yarn guide near the yarn guide to calculate the lateral speed of the yarn; the control system includes a data processing module, a dynamic modeling and calculation module, and a length integration calculation module. The data processing module uses a controller as the core of the data processing, and the controller is connected to the yarn guide encoder, the yarn bobbin encoder, and the edge sensor. The dynamic modeling and calculation module is used to derive the dynamic radius of the yarn bobbin in real time; the length integration calculation module is used to integrate and accumulate the real-time composite speed according to a set control cycle to obtain the total length of the wound yarn, thereby achieving precise length determination.

[0015] Improvements to the above technical solution: Both the slotted drum encoder and the yarn drum encoder adopt incremental magnetoelectric encoders.

[0016] Further improvements to the above technical solution: The slotted cylinder drive motor adopts a servo motor or a variable frequency speed control motor; the slotted cylinder encoder outputs A / B phase quadrature pulse signals and Z phase zero-position pulse signals to the controller through a shielded cable as a reference phase reference for the slotted cylinder; the yarn drum encoder outputs A / B phase quadrature pulse signals and Z phase zero-position pulse signals to the controller through a shielded cable.

[0017] Further improvements to the above technical solution: The controller is a programmable logic controller or a digital signal processor. The data processing module has a built-in high-speed counting module that receives pulse signals from the slotted drum encoder and the yarn drum encoder, and performs pulse counting, dynamic modeling and length integration calculation. The controller communicates with the driver of the slotted drum drive motor through an analog output interface or an industrial bus to transmit length information in real time.

[0018] Further improvements to the above technical solution: The controller integrates a CAN communication interface, sets a fixed control cycle, and schedules subsequent dynamic modeling and length integration calculations according to the cycle to ensure the real-time performance of data processing.

[0019] The present invention provides a method for determining the length of yarn in a bobbin using the above-mentioned winding machine, characterized by comprising the following steps:

[0020] Step 1: Before the system starts, the fixed parameters and calculation parameters are preset and stored in the registers of the data processing module as the calculation basis;

[0021] Step 2: After the system starts, the data processing module performs real-time data acquisition through the controller. The data processing module cyclically executes data acquisition operations according to the control cycle, receiving pulse signals from the slotted drum encoder, the yarn drum encoder, and the trigger signal from the edge sensor, and performing pulse increment statistics and timestamp recording; providing continuous and accurate raw data for subsequent calculations.

[0022] Step 3: The dynamic modeling and calculation module calculates the angular velocity of the slotted drum and the yarn drum based on the pulse signals of the slotted drum encoder and the yarn drum encoder. It introduces a slip ratio correction model in combination with the ideal no-slip relationship, derives the dynamic radius of the yarn drum in real time, calculates the transverse velocity of the yarn through the trigger time difference of the edge sensor, and constructs a synthetic velocity model by combining the circumferential velocity.

[0023] Step 4: The length integration calculation module integrates and accumulates the real-time synthesis speed according to the set control cycle to obtain the total length of the wound yarn, thus achieving precise length determination.

[0024] Improvements to the above technical solution: The fixed parameters and calculated parameters include: groove radius: Slotted cylinder pitch: Encoder pulses per revolution: PPR; Yarn bobbin radius: Slip ratio: Angular velocity of the yarn bobbin: Angular velocity of the groove cylinder: Control cycle: Circumferential speed of the yarn bobbin: Yarn transverse speed: Yarn speed: And yarn length L.

[0025] Further improvement to the above technical solution: In step 3, the dynamic modeling calculation module calculates the formula for the angular velocities of the grooved drum and the yarn drum:

[0026] Angular velocity of the groove cylinder:

[0027]

[0028] Yarn bobbin angular velocity:

[0029]

[0030] : Number of pulses in the current cycle of the slotted encoder;

[0031] : Number of encoder pulses for the current cycle yarn bobbin;

[0032] Introducing a slip ratio correction model:

[0033] In actual spinning, the yarn bobbin is driven to rotate by the grooved bobbin through surface friction transmission. When there is no slippage between the two, their linear velocities are equal, that is:

[0034]

[0035] The variation yields:

[0036]

[0037] However, in actual winding, there is frictional slippage between the grooved drum and the yarn bobbin. The linear velocity of the yarn bobbin is slightly lower than that of the grooved drum, introducing a slip ratio. Based on the radius of the yarn bobbin, a dynamic model of the yarn bobbin's dynamic radius and slip ratio is established:

[0038]

[0039] Iterative solution to determine the real-time yarn bobbin radius;

[0040] Calculate the circumferential speed of the yarn based on the real-time radius of the yarn bobbin. :

[0041] The yarn lateral speed is calculated based on the grooved cylinder pitch and the edge sensor timestamp.

[0042] Yarn synthesis speed calculation:

[0043]

[0044] Integral calculation of total yarn length:

[0045] Within each control cycle, the length increment of the yarn winding is the product of the synthesis speed and the cycle duration; the total length is the cumulative sum of the increments in each cycle.

[0046] Cycle length increment:

[0047]

[0048] Total length accumulated:

[0049]

[0050] Initial value:

[0051] .

[0052] Compared with the prior art, the present invention has the following advantages and positive effects:

[0053] 1. The measurement accuracy of this invention is significantly improved: the slotted drum encoder and the yarn drum encoder adopt incremental encoders, which greatly improves the speed detection resolution and avoids the high-speed winding and speed fluctuation errors caused by the low resolution of the Hall sensor; through dynamic modeling of slip ratio, the transmission deviation between the slotted drum and the yarn drum is corrected in real time, solving the problem of slip error accumulation in traditional technology.

[0054] 2. The invention has strong adaptability and environmental tolerance: The sensor is based on the principle of mechanical rotation and stroke triggering, and is not affected by environmental interference such as workshop dust and light changes, making it suitable for harsh working conditions in textile factories; the detection core does not rely on the surface characteristics of yarn and friction transmission, and is seamlessly compatible with various materials such as cotton, linen, and chemical fibers, and the non-contact installation avoids yarn wear and ensures the quality of high-grade yarn.

[0055] 3. This invention supports intelligent production in real time: By updating core parameters such as yarn bobbin radius, slip ratio, and yarn speed in real time according to a preset control cycle, it not only realizes real-time accumulation and visual monitoring of yarn length, but also provides data support for tension adjustment and process optimization of the winding machine, realizes closed-loop control of the winding process, avoids over-winding or under-winding problems, and improves the consistency of yarn bobbin length in batch production. Attached Figure Description

[0056] Figure 1 This is a schematic diagram of the overall architecture and hardware connection structure of a yarn bobbin precision length measuring device for a winding machine according to the present invention;

[0057] Figure 2 This is a schematic diagram of the circular and lateral motion of the yarn as it moves along a spiral path on the surface of the yarn bobbin in the yarn precision length measuring device of a winding machine according to the present invention.

[0058] Figure 3 This is a schematic diagram of the vector synthesis of circular motion and transverse motion when the yarn moves in a spiral motion on the yarn bobbin surface in the yarn precision length measuring device of a winding machine according to the present invention.

[0059] Figure 4 This is a flowchart of a method for determining the length of yarn in a winding machine according to the present invention.

[0060] Figure 5 This is a schematic diagram of the module structure in the control system of the yarn bobbin precision length measuring device of a winding machine according to the present invention.

[0061] The numbers in the diagram are: 1. Yarn bobbin; 2. Yarn bobbin encoder; 3. Grooved drum; 4. Edge sensor; 5. Controller; 6. Grooved drum encoder; 7. Grooved drum drive motor. Detailed Implementation

[0062] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments:

[0063] See Figures 1-5 An embodiment of a yarn bobbin precision length measuring device for a winding machine according to the present invention includes a yarn bobbin 1, a yarn bobbin winding shaft, a grooved cylinder 3, a grooved cylinder rotating shaft, a grooved cylinder drive motor 7, and a control system. The control system is connected to the control end of the grooved cylinder drive motor 7. The yarn bobbin 1 is mounted on the yarn bobbin winding shaft, and the grooved cylinder 3 is mounted on the grooved cylinder rotating shaft and is driven to rotate by the grooved cylinder drive motor 7. The yarn bobbin 1 is driven to rotate by the grooved cylinder 3 through surface friction transmission.

[0064] A sensor is added inside the winding shaft of the aforementioned yarn bobbin, and a yarn bobbin encoder 2 is installed near this sensor to collect the rotation angle and speed of the yarn bobbin in real time. A sensor is also added inside the rotating shaft of the aforementioned slotted drum, and a slotted drum encoder is installed near this sensor to collect the rotation angle and speed of the slotted drum in real time. An edge sensor 4 is placed near the yarn guide limit position of the slotted drum 3 to calculate the lateral speed of the yarn. The aforementioned control system includes a data processing module, a dynamic modeling calculation module, and a length integration calculation module. The data processing module uses a controller as its core, which is connected to the slotted drum encoder 6, the yarn bobbin encoder 2, and the edge sensor 4. The controller receives pulse signals from the slotted drum encoder 6, the yarn bobbin encoder 2, and the trigger signal from the edge sensor 4, and performs pulse increment statistics and timestamp recording. The dynamic modeling calculation module calculates the angular velocity of the slotted drum 3 and the yarn bobbin 1 based on the pulse signals from the slotted drum encoder 6 and the yarn bobbin encoder 2, calculates the lateral speed of the yarn through the trigger time difference of the edge sensor 4, and constructs a composite speed model by combining the circumferential velocity. The aforementioned length integration module is used to integrate and accumulate the real-time synthesis speed according to a set control cycle to obtain the total length of the wound yarn, thus achieving precise length determination. This allows for a control flow of "detection-modeling-calculation".

[0065] Furthermore, both the slotted drum encoder 6 and the yarn drum encoder 2 described above are incremental magnetoelectric encoders. Preferably, an incremental magnetoelectric encoder with at least 4096 pulses per revolution is used.

[0066] Furthermore, the slotted cylinder 3 is directly driven to rotate by the slotted cylinder drive motor 7 via a coupling. The slotted cylinder drive motor 7 is a servo motor or a variable frequency speed control motor. The slotted cylinder encoder 6 outputs A / B phase quadrature pulse signals and Z phase zero-position pulse signals to the controller via a shielded cable, serving as a reference phase reference for the slotted cylinder 3. The yarn bobbin encoder 2 outputs A / B phase quadrature pulse signals and Z phase zero-position pulse signals to the controller via a shielded cable.

[0067] Furthermore, the controller is a programmable logic controller or a digital signal processor. The data processing module has a built-in high-speed counting module that receives pulse signals from the slotted drum encoder 6 and the yarn drum encoder 2, and performs pulse counting, dynamic modeling and length integration calculation. The controller communicates with the driver of the slotted drum drive motor 7 through an analog output interface or an industrial bus to transmit length information in real time.

[0068] Furthermore, the controller integrates a CAN communication interface, sets a fixed control cycle, and schedules subsequent dynamic modeling and length integration calculations according to the cycle to ensure the real-time performance of data processing.

[0069] See Figures 1-5 An embodiment of the yarn length setting method of the above-mentioned winding machine's yarn precision length setting device includes the following steps:

[0070] Step 1: Before the system starts, the fixed parameters and calculation parameters are preset and stored in the registers of the data processing module as the calculation basis;

[0071] Step 2: After the system starts, the data processing module performs real-time data acquisition through the controller. The data processing module cyclically executes data acquisition operations according to the control cycle, receiving pulse signals from the slotted drum encoder 6, the yarn drum encoder 2, and the trigger signal from the edge sensor 4, and performing pulse increment statistics and timestamp recording; providing continuous and accurate raw data for subsequent calculations.

[0072] Step 3: The dynamic modeling and calculation module calculates the angular velocity of the slotted drum 3 and the yarn drum 1 based on the pulse signals of the slotted drum encoder 6 and the yarn drum encoder 2. It introduces a slip ratio correction model in combination with the ideal no-slip relationship, derives the dynamic radius of the yarn drum 1 in real time, calculates the transverse velocity of the yarn through the trigger time difference of the edge sensor 4, and constructs a synthetic velocity model by combining the circumferential velocity.

[0073] Step 4: The length integration calculation module integrates and accumulates the real-time synthesis speed according to the set control cycle to obtain the total length of the wound yarn, thus achieving precise length determination.

[0074] The above steps complete the control process of "detection-modeling-calculation".

[0075] like Figure 5 As shown, a specific embodiment of the yarn bobbin precision length setting device and length setting method of the above-mentioned winding machine according to the present invention includes the following steps:

[0076] (1) System startup;

[0077] (2) Parameter initialization;

[0078] (3) Real-time data acquisition

[0079] (4) Calculation of angular velocity;

[0080] (5) Modeling of slip ratio and dynamic radius of yarn bobbin;

[0081] (6) Determine whether the diameter convergence check is satisfied. If yes, calculate the yarn period and transverse speed. If no, perform iterative calculation and return to step (5).

[0082] (7) Modeling of composite velocity and determination of direction coefficient;

[0083] (8) Calculation of cycle length increment;

[0084] (9) Total length integral accumulation or parameter caching.

[0085] Through the above steps, the total length of the wound yarn is finally obtained, achieving precise length determination.

[0086] Specifically, the above-mentioned fixed and calculated parameters include: slotted drum radius, slotted drum pitch, number of encoder pulses per revolution, yarn drum radius, slip ratio yarn, yarn drum angular velocity, slotted drum angular velocity, control cycle, yarn drum circumferential speed, yarn transverse speed, yarn speed, and yarn length. A comparison of the fixed and calculated parameters with their symbols and sources is shown in Table 1.

[0087]

[0088] This invention is based on the principle of spiral winding. Through the collaborative detection, dynamic modeling, and synthesis speed integration calculation of dual encoders (yarn cylinder encoder 2 and slotted cylinder encoder 6), it achieves accurate measurement of yarn length. The core components include hardware system configuration, data processing module, and modeling and calculation module. The specific implementation scheme is described in detail below:

[0089] I. System Hardware Configuration

[0090] This system includes a signal acquisition module and a data processing module. The hardware components of each module are as follows:

[0091] 1. Signal Acquisition Module

[0092] Slot encoder 6: An incremental magnetic encoder is fixed to the end of the slot shaft and is used to acquire the rotation angle and speed of the slot 3 in real time. The A and B phases of the slot encoder 6 output quadrature pulse signals, and the Z phase outputs a zero-position pulse, which serves as the reference phase reference for the slot 3.

[0093] Yarn cylinder encoder 2: An incremental magnetic encoder is installed at the end of the yarn cylinder winding shaft to collect the rotation angle and speed of yarn cylinder 1 in real time. The A and B phases of the yarn cylinder encoder 2 output quadrature pulse signals, and the Z phase outputs a zero-position pulse.

[0094] Edge sensor 4: Installed near the bottom of the groove cylinder 3 and at the limit position of the reciprocating stroke of the yarn guiding mechanism, it is used to calculate the lateral speed of the yarn.

[0095] 2. Data Processing Module

[0096] It adopts a programmable logic controller, digital signal processor or microcontroller as the core controller, has a built-in high-speed counting module to receive encoder pulse signals, integrates a CAN communication interface, sets a fixed control cycle, and schedules subsequent dynamic modeling and length integration calculations according to the cycle to ensure the real-time performance of data processing.

[0097] II. Parameter Initialization

[0098] Before the system starts, the following parameters need to be preset and stored in the registers of the data processing module as the calculation basis, as detailed in Table 1.

[0099] III. Real-time Data Acquisition Process

[0100] Data processing module according to control cycle The following data acquisition operations are performed repeatedly to provide continuous and accurate raw data for subsequent calculations. The process is as follows:

[0101] Encoder pulse increment acquisition: Records the pulse count of the slotted encoder within the current cycle. Pulse count from the previous cycle Calculate pulse increment .

[0102] 2. Edge Sensor 4-Timestamp Acquisition: Real-time monitoring of the pulse trigger signal of the edge sensor; when the rising edge of the pulse is detected, the current system timestamp is recorded. And calculate the timestamp of the previous pulse. interval If no new pulse is detected in the current cycle, the most recently calculated pulse will be used. .

[0103] IV. Implementation of Core Calculation Modules and Formula Derivation

[0104] 1. Angular velocity calculation

[0105] Angular velocity is calculated from encoder pulses:

[0106] Angular velocity of the groove cylinder:

[0107] Angular velocity of yarn bobbin 1:

[0108] : Number of pulses in the current cycle of the slotted encoder;

[0109] : Number of encoder pulses for the current cycle yarn drum.

[0110] 2. Yarn tube radius 1 and real-time yarn tube radius

[0111] In actual spinning, the yarn bobbin 1 is driven to rotate by the grooved bobbin 3 through surface friction transmission. When there is no slippage between the two, their linear velocities are equal, that is:

[0112]

[0113] The variation yields:

[0114]

[0115] However, in actual winding, frictional slippage exists between the grooved drum 3 and the yarn bobbin 1. The linear velocity of the yarn bobbin 1 is slightly lower than that of the grooved drum 3, introducing slippage rate. Based on the radius of the grooved cylinder 3, a dynamic model of the dynamic radius and slip ratio of the yarn bobbin 1 is established:

[0116]

[0117] Set a convergence threshold and perform diameter convergence verification. If the threshold requirement is not met, iterate to solve the problem and find the real-time yarn tube radius.

[0118] 3. Calculation of yarn synthesis speed

[0119] Calculate the circumferential speed of the yarn based on the real-time radius of the yarn bobbin. :

[0120] The yarn lateral speed is calculated based on the grooved cylinder pitch and the edge sensor timestamp.

[0121] Yarn synthesis speed calculation:

[0122]

[0123] 4. Integral calculation of total yarn length

[0124] The direction of motion is determined by the sign of the circular velocity, and a direction coefficient is introduced to indicate the direction of motion. The core logic is as follows:

[0125] Forward winding: Length accumulation;

[0126] Reverse: Length deducted;

[0127] static state: The length remains unchanged.

[0128] Within each control cycle, the increase in yarn winding length is the product of the synthesis speed and the cycle duration; the total length is the cumulative sum of the increases in each cycle.

[0129] Cycle length increment:

[0130]

[0131] Total length accumulated:

[0132]

[0133] Initial value:

[0134]

[0135] By implementing the above-described technical solution of the present invention, the following technical effects have been achieved:

[0136] (1) The dual-encoder high-resolution detection system adopts an incremental slotted drum encoder and an incremental yarn bobbin encoder. The encoder has 4096 pulses per revolution, which is much higher than that of traditional Hall sensors. This improves the speed detection resolution, effectively avoids errors caused by high-speed winding and speed fluctuations, and achieves accurate synchronous acquisition of the angular velocities of the slotted drum and the yarn bobbin.

[0137] (2) Construction of dynamic modeling and real-time correction technology for slip ratio: A dynamic modeling system with yarn bobbin radius and slip ratio as state variables is constructed, and a slip ratio correction model is introduced. This can reflect the slip changes in the transmission process in real time and completely solve the problem of slip error accumulation.

[0138] (3) Non-contact detection solution suitable for all types of yarns. Based on the mechanical rotation principle, the slotted drum encoder 6, yarn drum encoder 2 and edge sensor 4 are all non-contact installed and do not depend on the surface characteristics of the yarn. They are not affected by environmental factors such as workshop dust and light changes, and can be compatible with various materials such as cotton, linen and chemical fibers.

[0139] The above description is not intended to limit the present invention, nor is the present invention limited to the examples given above. Any changes, modifications, additions, or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A yarn bobbin precision length measuring device for a winding machine, comprising a yarn bobbin, a yarn bobbin winding shaft, a grooved drum, a grooved drum rotating shaft, a grooved drum drive motor, and a control system, wherein the control system is connected to the control terminal of the grooved drum drive motor, the yarn bobbin is disposed on the yarn bobbin winding shaft, the grooved drum is driven to rotate by the grooved drum drive motor, and the yarn bobbin is driven to rotate by the grooved drum through surface friction transmission, characterized in that, A sensor is added inside the yarn bobbin winding shaft, and a yarn bobbin encoder is installed near the sensor to collect the yarn bobbin rotation angle and speed in real time. A sensor is added inside the grooved drum rotation shaft, and a grooved drum encoder is installed near the sensor to collect the grooved drum rotation angle and speed in real time. An edge sensor is set at the yarn guide reciprocating limit position near the grooved drum to calculate the yarn lateral speed. The control system includes a data processing module, a dynamic modeling calculation module, and a length integration calculation module. The data processing module uses a controller as the data processing core, and the controller is connected to the grooved drum encoder, the yarn bobbin encoder, and the edge sensor. The dynamic modeling calculation module is used to derive the dynamic radius of the yarn bobbin in real time. The length integration calculation module is used to integrate and accumulate the real-time synthetic speed according to a set control cycle to obtain the total length of the wound yarn, achieving precise length determination.

2. The precise yarn length determination device for a winding machine according to claim 1, characterized in that, Both the slotted drum encoder and the yarn drum encoder mentioned above are incremental magnetoelectric encoders.

3. The precise yarn length determination device for a winding machine according to claim 1 or 2, characterized in that, The slotted cylinder drive motor is a servo motor or a variable frequency speed control motor. The slotted cylinder encoder outputs A / B phase quadrature pulse signals and Z phase zero position pulse signals to the controller through a shielded cable as a reference phase reference for the slotted cylinder. The yarn drum encoder outputs A / B phase quadrature pulse signals and Z phase zero position pulse signals to the controller through a shielded cable.

4. The precise yarn length determination device for a winding machine according to claim 1 or 2, characterized in that, The controller is a programmable logic controller or a digital signal processor. The data processing module has a built-in high-speed counting module that receives pulse signals from the slotted drum encoder and the yarn drum encoder, and performs pulse counting, dynamic modeling and length integration calculation. The controller communicates with the driver of the slotted drum drive motor through an analog output interface or an industrial bus to transmit length information in real time.

5. The precise yarn length determination device for a winding machine according to claim 3, characterized in that, The controller is a programmable logic controller or a digital signal processor, with a built-in high-speed counting module that receives pulse signals from the slotted drum encoder and the yarn drum encoder, and performs pulse counting, dynamic modeling and length integration calculation; the controller communicates with the driver of the slotted drum drive motor through an analog output interface or an industrial bus to transmit length information in real time.

6. The precise yarn length determination device for a winding machine according to claim 1 or 2, characterized in that, The controller integrates a CAN communication interface, sets a fixed control cycle, and schedules subsequent dynamic modeling and length integration calculations according to the cycle to ensure the real-time performance of data processing.

7. The precise yarn length determination device for a winding machine according to claim 5, characterized in that, The controller integrates a CAN communication interface, sets a fixed control cycle, and schedules subsequent dynamic modeling and length integration calculations according to the cycle to ensure the real-time performance of data processing.

8. A method for determining the length of the yarn package using the precise yarn length determination device of a winding machine as described in any one of claims 1-7, characterized in that, Includes the following steps: Step 1: Before the system starts, the fixed parameters and calculation parameters are preset and stored in the registers of the data processing module as the calculation basis; Step 2: After the system starts, the data processing module performs real-time data acquisition through the controller. The data processing module cyclically executes data acquisition operations according to the control cycle, receiving pulse signals from the slotted drum encoder, the yarn drum encoder, and the trigger signal from the edge sensor, and performing pulse increment statistics and timestamp recording; providing continuous and accurate raw data for subsequent calculations. Step 3: The dynamic modeling and calculation module calculates the angular velocity of the slotted drum and the yarn drum based on the pulse signals of the slotted drum encoder and the yarn drum encoder. It introduces a slip ratio correction model in combination with the ideal no-slip relationship, derives the dynamic radius of the yarn drum in real time, calculates the transverse velocity of the yarn through the trigger time difference of the edge sensor, and constructs a synthetic velocity model by combining the circumferential velocity. Step 4: The length integration calculation module integrates and accumulates the real-time synthesis speed according to the set control cycle to obtain the total length of the wound yarn, thus achieving precise length determination.

9. The method for determining the length of the yarn package using the precise length-determining device of the winding machine according to claim 8, characterized in that, The fixed parameters and calculated parameters include: trough radius: Slotted cylinder pitch: Encoder pulses per revolution: PPR; Yarn bobbin radius: Slip ratio: Angular velocity of the yarn bobbin: Angular velocity of the groove cylinder: Control cycle: Circumferential speed of the yarn bobbin: Yarn transverse speed: Yarn speed: and yarn length L.

10. The method for determining the length of the yarn package using the precise length-determining device of the winding machine according to claim 9, characterized in that, In step 3, the dynamic modeling calculation module calculates the formula for the angular velocities of the grooved drum and the yarn drum: Angular velocity of the groove cylinder: ； Yarn bobbin angular velocity: ； : Number of pulses in the current cycle of the slotted encoder; : Number of encoder pulses for the current cycle yarn bobbin; Introducing a slip ratio correction model: In actual spinning, the yarn bobbin is driven to rotate by the grooved bobbin through surface friction transmission. When there is no slippage between the two, their linear velocities are equal, that is: ； The variation yields: ； However, in actual winding, there is frictional slippage between the grooved drum and the yarn bobbin. The linear velocity of the yarn bobbin is slightly lower than that of the grooved drum, introducing a slip ratio. Based on the radius of the yarn bobbin, a dynamic model of the yarn bobbin's dynamic radius and slip ratio is established: ； Iterative solution to determine the real-time yarn bobbin radius; Calculate the circumferential speed of the yarn based on the real-time radius of the yarn bobbin. : The yarn lateral speed is calculated based on the grooved cylinder pitch and the edge sensor timestamp. ; Yarn synthesis speed calculation: ； Integral calculation of total yarn length: Within each control cycle, the length increment of the yarn winding is the product of the synthesis speed and the cycle duration; the total length is the cumulative sum of the increments in each cycle. Cycle length increment: ； Total length accumulated: ； Initial value: 。

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