A miniature precision monitoring system and method for monitoring the amount of spinning oil used

Abstract

This invention relates to a miniature precision monitoring system and method for the usage of spinning oil, belonging to the field of oil metering technology for textile spinning equipment. It includes a miniature on / off flow sensor, a signal processing module, an alarm module, a PLC linkage module, and an HMI display module, all electrically connected to the signal processing module. It also includes an oil pump and a motor driving the oil pump, located at the inlet end of a miniature output pipeline. The output end of the miniature output pipeline is connected to a spinning oil nozzle. The PLC linkage module is also electrically connected to the oil pump and the alarm module. The miniature on / off flow sensor includes an upper housing and a lower housing fixed by screws. The upper housing has serial tubes with snap-fit ​​interfaces at both ends. A windmill-shaped fluororubber elastic baffle is rotatably installed inside the upper housing, with a miniature magnet at the end of one blade of the baffle. A Hall effect sensor matching the miniature magnet is installed inside the lower housing. The signal processing module includes a signal counting unit and a frequency analysis unit.

Description

Technical Field

[0001] This invention relates to a miniature precision monitoring system and method for monitoring the amount of oil used in spinning, belonging to the field of oil metering technology for textile spinning equipment. Background Technology

[0002] Currently, spinning oil is a core auxiliary material in spinning production. By forming a functional film on the fiber surface, it achieves key functions such as lubrication, antistatic properties, and fiber bundling, directly determining the fiber forming quality and the continuity of spinning production. Currently, the industry commonly uses a 1-in-12-out oil pump to deliver a small amount of oil (approximately 5 mL / min) to the oil nozzle through 12 φ4mm micro-pipes. Existing oil metering technologies mainly rely on traditional mechanical pump estimation and universal flow sensor metering. Both methods have unresolved industry pain points, including: poor compatibility of micro-pipes; universal flow sensors are generally ≥50mm×50mm×60mm in size, requiring compatible pipe diameters ≥10mm, and cannot be installed in the compact space of spinning equipment (φ4mm pumps). Currently, there are no miniaturized flow monitoring sensors specifically designed for micro-pipelines in the spinning industry. Low-flow metering accuracy is insufficient; traditional oil pumps rely on mechanical structural parameters to estimate flow, and mechanical wear and changes in oil viscosity can lead to metering errors of ≥±5% at low flow rates. General-purpose Hall effect sensors use rigid metal baffles, which are easily adhered to by viscous oil and may not reset promptly, further amplifying metering deviations and failing to meet the requirements for precise control of trace amounts of oil. Abnormal operating conditions lack real-time identification capabilities; existing technologies can only achieve oil delivery, lacking real-time monitoring of pipeline leaks and blockages. Abnormal operating conditions can only be detected through manual inspection, with a lag time of ≥5 minutes, easily causing oil waste and leading to quality defects such as fiber breakage, fuzz, and entanglement. There is no equipment linkage control capability; the metering system and the main control system of the spinning equipment do not interact with each other. After an anomaly is detected manually, manual shutdown and flow adjustment are required, resulting in low operational efficiency and potentially expanding the scope of quality losses. Installation and maintenance costs are high; general-purpose sensors require modification of existing spinning pipelines, increasing installation complexity. Traditional oil pumps experience rapid mechanical wear, requiring frequent disassembly and maintenance, increasing production and operating costs.

[0003] While existing technologies include flow detection approaches that combine Hall effect sensors with baffles, these are conventional designs for large-diameter, high-flow-rate pipes. They do not optimize the structure and algorithms to suit the unique scenarios of conveying spinning oils with their viscosity, small volume, and micro-pipelines. Furthermore, they do not integrate flow measurement with anomaly detection and equipment linkage, making them unsuitable for direct application in spinning oil metering scenarios.

[0004] In view of the above-mentioned shortcomings, the present invention aims to create a micro-precision monitoring method for the amount of spinning oil used, so as to make it more valuable for industrial applications. Summary of the Invention

[0005] To solve the above technical problems, the objective of the present invention is to provide a micro-precise monitoring method for the usage amount of spinning oil agent. It can achieve high-precision metering for a φ4mm micro pipeline and a trace oil agent of 3-10 mL / min. At the same time, it can realize real-time identification of oil agent leakage and pipeline blockage, and linkage control with the spinning equipment. Moreover, the device is miniaturized, easy to install, and has low maintenance costs, which can adapt to the compact space of the spinning equipment and the requirements of various spinning processes.

[0006] A micro-precise monitoring system for the usage amount of spinning oil agent of the present invention includes: a micro on-off flow sensor serially installed on the micro output pipeline, a signal processing module electrically connected to the micro on-off flow sensor, an alarm module, a PLC linkage module, and an HMI display module respectively electrically connected to the signal processing module, and an oil agent pump and a motor for driving the oil agent pump arranged at the pipeline inlet end of the micro output pipeline; the output end of the micro output pipeline is connected to a spinning nozzle, and the PLC linkage module is also electrically connected to the oil agent pump and the alarm module;

[0007] The micro on-off flow sensor includes an upper shell and a lower shell fixed by fixing screws. The two ends of the upper shell are provided with series pipes with snap-in interfaces. A windmill-shaped fluororubber elastic baffle is rotatably arranged inside the upper shell. A micro permanent magnet is arranged at the end of one blade of the baffle, and a Hall induction unit matching the micro permanent magnet is arranged inside the lower shell; The signal processing module includes a signal counting unit and a frequency analysis unit.

[0008] Furthermore, the overall volume of the micro on-off flow sensor ≤ 25mm × 25mm × 35mm, and the snap-in interface is an oil-resistant sealing structure; the windmill-shaped fluororubber elastic baffle is a six-piece windmill blade structure or a four-piece cross structure, and the thickness of the fan blade is 2mm. <s

[0009] Furthermore, the micro permanent magnet is a neodymium iron boron micro permanent magnet with a magnetic induction intensity of 800 GS, and the triggering distance from the Hall induction unit is 3-5mm; the Hall induction unit is a linear Hall sensor with an induction frequency of 0-10Hz, a response time ≤ 0.1s, and a power supply voltage of 5V.

[0010] Furthermore, the data update frequency of the signal counting unit is 1 time per second, and the signal frequency calculation period of the frequency analysis unit is 1s.

[0011] A micro-precise monitoring method for the usage amount of spinning oil agent based on the above system includes the following steps: (1) Deployment of the micro on-off flow sensor: The micro on-off flow sensor is serially connected in the φ4mm micro output pipeline between the oil agent pump and the spinning nozzle through the snap-in interface; (2) On / off signal acquisition: The motor drives the oil pump to deliver a small amount of oil. The impact force of the oil pushes the fluororubber elastic baffle of the windmill to swing. The micro magnet moves closer to / away from the Hall sensing unit to form an on / off cycle signal. A single on / off cycle corresponds to a fixed oil volume, i.e., a single on / off threshold. (3) Accurate calculation of oil dosage: The signal counting unit accumulates the number of on / off cycles in real time, and calculates the oil dosage according to the formula: cumulative dosage = number of on / off cycles × single on / off threshold. The data is synchronized to the HMI display module. (4) Dynamic identification of abnormal working conditions: The frequency analysis unit analyzes the frequency of the on / off signal in real time, and determines leakage and blockage abnormalities by combining the preset reference value. The abnormal results are synchronized to the alarm module and PLC linkage module. (5) Abnormal operating condition linkage control: The PLC linkage module sends linkage control commands to the oil pump and alarm module according to the abnormality type; (6) Data archiving and traceability: After the batch production is completed, the signal counting unit automatically stores data such as oil dosage, signal frequency, and abnormal records. The data supports local storage and export.

[0012] Furthermore, the single on / off threshold mentioned in step (2) is calibrated to 0.02 mL / time under standard working conditions of 25℃ room temperature and spinning oil viscosity of 100 cp by a high-precision syringe meter, with a calibration error ≤ ±0.0004 mL, and the metering accuracy of the single on / off threshold after calibration is ≤ ±2%.

[0013] Furthermore, for spinning oils with different viscosities of 50-200cp, a calibration correction coefficient is set through a PLC linkage module and the single on / off threshold is automatically adjusted to ensure that the metering accuracy for oils of different viscosities is ≤±2%.

[0014] Furthermore, the rules for determining abnormal operating conditions in step (4) are as follows: when the average value of the signal frequency for three consecutive calculation cycles increases by ≥30% compared to the benchmark value, it is determined to be a leak in the oil pipeline; when the miniature on / off flow sensor has no on / off signal output for 10 consecutive seconds, it is determined to be a blockage in the oil pipeline.

[0015] Furthermore, the linkage control command in step (5) is as follows: if it is determined that the oil is leaking, the PLC linkage module controls the oil pump to reduce the flow rate by 30% immediately, and the alarm module issues a red audible and visual warning; if it is determined that the pipeline is blocked, the PLC linkage module controls the corresponding spinning position to stop immediately, and the alarm module issues a yellow audible and visual warning.

[0016] Furthermore, the method is suitable for oil delivery flow rates of 3-10 mL / min, is compatible with spinning production processes using φ4 mm micro-tubes, has an abnormal condition identification delay time of ≤10 s, and can restore normal equipment operation via HMI display module touch screen control after the abnormality is resolved.

[0017] By means of the above-described solution, the present invention has at least the following advantages: (1) The overall volume of the miniature on / off flow sensor designed in this invention is ≤25mm×25mm×35mm. It can be directly connected in series with the φ4mm miniature output pipeline through a snap-fit ​​interface, which perfectly fits the compact installation space of the spinning equipment and solves the industry problem that the general flow sensor is large in size and cannot be installed with a pipe diameter ≥10mm. At the same time, the fluororubber elastic baffle is used to replace the traditional metal rigid baffle to avoid signal distortion caused by the adhesion of viscous oil. Combined with standard working condition calibration, 0.02mL / time, the calibration error is ≤±0.0004mL. With the adjustment of the correction coefficient for 50-200cp viscosity oil, the metering accuracy is controlled at ≤±2%. Compared with the traditional mechanical pump estimation, the error is ≥±5%, and the deviation of the general Hall sensor metering is amplified. The metering accuracy is improved by more than 50%, which meets the core requirement of precise control of micro oil in spinning.

[0018] (2) The frequency analysis unit performs real-time analysis of the on / off signal frequency in 1s cycles. Combined with the precise rules of determining leakage if the frequency increases by ≥30% for 3 consecutive cycles and determining blockage if there is no signal for 10s, the abnormal working conditions can be quickly identified in ≤10s. Compared with the ≥5 minutes lag time of manual inspection in the existing technology, the abnormal response efficiency is improved by more than 30 times. Problems can be detected in time at the initial stage of oil leakage and the initial stage of pipeline blockage, effectively avoiding a large amount of oil waste caused by delayed monitoring. At the same time, it can eliminate quality defects such as fiber breakage, fuzz, and entanglement caused by abnormal oil supply from the source, and greatly improve the yield of spinning products.

[0019] (3) This invention establishes a full-link electrical signal interaction between the sensor, signal processing module and oil pump, spinning position and alarm module through PLC linkage module. After abnormal working condition is identified, the control command can be automatically executed: when there is leakage, the oil pump will immediately reduce the flow rate by 30% and issue a red audible and visual warning. When there is blockage, the corresponding spinning position will immediately stop and issue a yellow audible and visual warning. There is no need for manual operation to stop the machine or adjust the flow rate. After the abnormality is resolved, production can be quickly resumed through the touch screen of the HMI display module. This solves the problems of no equipment linkage, low efficiency of manual operation and easy expansion of the scope of quality loss in the existing technology. It realizes the transformation from passive discovery to active prevention and control. The abnormal handling time of a single spinning position is shortened by more than 80%, which significantly improves the continuous operation capability of the spinning production line.

[0020] (4) The miniature on / off flow sensor adopts an oil-resistant and sealed snap-on interface design, which can be directly snapped into the existing φ4mm miniature output pipeline without modifying the original spinning pipeline structure. The installation time of a single sensor is ≤5 minutes, and the overall deployment of multi-station production lines does not require production stoppage, thus solving the problem of high installation complexity of general sensors. At the same time, the fluororubber elastic baffle is oil-resistant and anti-adhesion, and the miniature magnet and Hall sensing unit are non-contact sensing structures with no mechanical wear and loss. Compared with the disadvantages of frequent disassembly and maintenance of traditional oil pumps, it greatly reduces the maintenance frequency and labor costs of the sensor, and reduces the operating cost of the equipment throughout its entire life cycle by more than 60%.

[0021] (5) The signal counting unit automatically stores all-dimensional data such as real-time usage, cumulative usage, signal frequency curve, time of occurrence of abnormal working conditions and processing results of oil agent. The data supports local storage and export, which can realize accurate traceability of oil agent usage in spinning batch production. At the same time, the differentiated data of multi-station monitoring can reflect the flow balance of oil agent pump branches in each spinning station, providing accurate data basis for optimizing the flow parameters of spinning process, setting the maintenance cycle of oil agent pump, and adapting the process of oil agents with different viscosities, thus helping to realize digital and refined management of spinning production.

[0022] (6) The monitoring method of the present invention is adapted to the oil delivery flow range of 3-10 mL / min. By adjusting the baffle structure and viscosity correction coefficient, it can meet the oil metering requirements of mainstream spinning processes such as polyester, nylon and polyester. At the same time, a single oil pump can be adapted to the independent monitoring and control of multiple spinning positions. There is no need to design a separate metering system for different spinning processes. It has strong versatility and scalability and can be quickly implemented in various spinning production lines, promoting the standardization and intelligent upgrading of oil metering technology in the spinning industry.

[0023] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0024] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show a certain embodiment of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the micro-precision monitoring system for the amount of spinning oil used in this invention; Figure 2This is a schematic diagram of the structure of the miniature on / off flow sensor in the miniature precision monitoring system for the amount of spinning oil used in this invention.

[0026] In the diagram: 1. Miniature on / off flow sensor; 10. Upper housing; 11. Lower housing; 12. Series tube; 13. Fixing screw; 101. Windmill-type fluororubber elastic baffle; 102. Miniature magnet; 103. Hall effect sensor unit; 104. Snap-on interface; 2. Signal processing module; 201. Signal counting unit; 202. Frequency analysis unit; 3. Alarm module; 4. PLC linkage module; 5. HMI display module; 6. Oil pump; 61. Motor; 7. Miniature output pipeline; 71. Pipeline inlet end; 8. Spinning oil nozzle. Detailed Implementation

[0027] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0028] See Figure 1 and Figure 2 A preferred embodiment of the present invention discloses a miniature precision monitoring system for the amount of spinning oil used, comprising a miniature on / off flow sensor 1 connected in series on a miniature output pipeline 7. The miniature on / off flow sensor 1 is electrically connected to a signal processing module 2 for collecting and processing the flow signal of a trace amount of oil. A spinning oil nozzle 8 is connected to the output end of the miniature output pipeline 7. An alarm module 3 is also provided on the spinning oil nozzle 8. The alarm module 3 is electrically connected to the miniature on / off flow sensor 1. An HMI display module 5 is also electrically connected to the signal processing module 2. An oil pump 6 and a motor 61 are provided at the pipeline inlet 71 of the miniature output pipeline 7. The motor 61 drives the oil pump 6 to deliver the oil to the spinning oil nozzle 8. The miniature precision monitoring system for the amount of spinning oil used also includes a PLC linkage module 4 electrically connected to the signal processing module 2, the oil pump 6 and the alarm module 3, for receiving and analyzing signals and sending instructions to the oil pump 6 and the alarm module 3.

[0029] The miniature on / off flow sensor 1 includes an upper housing 10 and a lower housing 11, which are fixedly connected to form a whole by fixing screws 13. The upper housing 10 has symmetrically arranged series tubes 12 at both ends, and each series tube 12 has a snap-fit ​​interface 104 at its end. The miniature on / off flow sensor 1 is connected in series to the miniature output pipeline 7 through the snap-fit ​​interface 104. In the middle of the upper housing 10, a windmill-shaped fluororubber elastic baffle 101 is rotatably arranged. The windmill-shaped fluororubber elastic baffle 101 has six windmill blades. A miniature magnet 102 is arranged at the end of one of the windmill blades. The lower housing 11 also has a Hall sensor unit 103. The Hall sensor unit 103 is matched with the windmill-shaped fluororubber elastic baffle 101. When the miniature magnet 102 at the end of the windmill blade rotates to the Hall sensor unit 103, it can trigger an energizing signal. When it rotates past the Hall sensor unit 103, it disconnects the energizing signal. The signal processing module 2 includes a signal counting unit 201 and a frequency analysis unit 202. The signal counting unit 201 records the number of times the miniature magnet 102 at the end of the windmill blade triggers the Hall unit to output on / off electrical signals during the passive rotation of the fluororubber elastic baffle 101 of the windmill blade. Each on / off cycle corresponds to a fixed oil volume, i.e., a single on / off threshold, with an accuracy of ≤±2% after calibration. The signal counting unit 201 accumulates the number of on / off signals, and the real-time oil volume usage is calculated using the formula: Cumulative usage = Number of on / off cycles × Single on / off threshold. The data is updated once per second and synchronized to the spinning equipment control system. The frequency analysis unit 202 is used to analyze the signal frequency.

[0030] A micro-precision monitoring method for the amount of spinning oil used is provided. This method involves deploying a micro-on / off flow sensor 1 in the φ4mm micro-output pipeline 7 of the oil pump 6, and combining on / off signal counting and frequency dynamic analysis logic to achieve precise metering of oil usage, real-time identification of abnormal operating conditions, and equipment linkage control. Specifically, the method includes the following steps: (1) Deployment of miniature on / off flow sensors The miniature on / off flow sensor 1, which integrates a windmill-type fluororubber elastic baffle 101, a miniature magnet 102, and a Hall effect sensing unit 103, is connected in series in the φ4mm miniature output pipeline 7 between the oil pump 6 and the spinning nozzle 8 via a snap-fit ​​interface 104. The overall volume of the miniature on / off flow sensor 1 is ≤25mm×25mm×35mm. The windmill-type fluororubber elastic baffle 101 is made of fluororubber, and the snap-fit ​​interface 104 adopts an oil-resistant sealing structure. It does not require modification of the existing pipeline and is suitable for the compact space of the spinning equipment.

[0031] (2) On / off signal acquisition When the trace amount of oil pumped by the oil pump 6 flows through the miniature on / off flow sensor 1, the impact force of the oil pushes the fluororubber elastic baffle 101 of the wind turbine model to swing towards the outlet side; when the miniature magnet 102 set at the end of the wind turbine blade swings close to the Hall sensing unit 103, it triggers the power-on signal; when the miniature magnet 102 set at the end of the wind turbine blade moves away from the Hall sensing unit 103, it triggers the power-off signal, completing one on / off cycle; each on / off cycle corresponds to a fixed oil volume, i.e., the single on / off threshold, and after calibration, the measurement accuracy of this threshold is ≤±2%.

[0032] (3) Precise calculation of oil dosage The signal counting unit 201 captures and accumulates the number of on / off cycles in real time, and calculates the real-time volume usage of the oil agent according to the following formula: Cumulative usage = Number of on / off cycles × Single on / off threshold; The data update frequency of the signal counting unit 201 is 1 time / second. The calculated real-time usage and cumulative usage are synchronously transmitted to the HMI display module 5 of the spinning equipment to realize the visual monitoring of oil usage.

[0033] (4) Dynamic identification of abnormal operating conditions The frequency analysis unit 202 performs real-time analysis of the on / off signal frequency per unit time. The signal frequency under normal spinning conditions is set as the baseline value, and abnormal conditions are determined according to the following rules: When the signal frequency suddenly increases by ≥30% compared to the reference value, it is determined to be a leak in the oil pipeline; When the miniature on / off flow sensor 1 has no on / off signal output for 10 consecutive seconds, it is determined that the oil pipeline is blocked. The anomaly detection result is transmitted to alarm module 3 and PLC linkage module 4 in real time, triggering audible and visual warnings and initiating equipment linkage control.

[0034] (5) Interlocking control under abnormal operating conditions After receiving the anomaly detection signal, PLC linkage module 4 executes preset linkage control commands according to the anomaly type: If an oil leak is detected, the PLC linkage module 4 controls the oil pump 6 to immediately reduce the current flow rate by 30%, and the alarm module 3 issues a red audible and visual warning to remind staff to check for the leak. If the pipeline is determined to be blocked, the PLC linkage module 4 controls the corresponding spinning position to stop immediately, and the alarm module 3 issues a yellow audible and visual warning to prevent the fiber from having quality defects due to lack of oil. After the abnormal operating condition was resolved, the staff operated the equipment through the HMI display module 5 touch screen, and the equipment returned to normal operation.

[0035] 6. Data archiving and traceability After the spinning batch production is completed, the signal counting unit 201 automatically stores data such as the real-time amount of oil used, the cumulative amount used, the signal frequency curve, the time of occurrence of abnormal working conditions and the handling results of this operation. The data supports local storage and export, providing data support for the traceability of spinning production quality and the optimization of process parameters.

[0036] Furthermore, the wind turbine fluororubber elastic baffle 101 is a cross-shaped fluororubber baffle with 4 blades and a blade thickness of 2mm, which is suitable for pushing micro-oil agents at a rate of 3-10mL / min, thus avoiding the adhesion of sticky oil agents.

[0037] The miniature magnet 102 is a neodymium iron boron miniature magnet with a magnetic induction intensity of 800GS. It is embedded in the end of one of the windmill blades of the fluororubber elastic baffle 101 of the windmill model. The triggering distance between it and the Hall sensing unit 103 is 3-5mm to ensure the stability of signal triggering.

[0038] The Hall sensing unit 103 is a linear Hall sensor with a sensing frequency of 0-10Hz, a response time of ≤0.1s, and a power supply voltage of 5V. It can accurately capture the on / off signal generated by the swing of the baffle, avoiding false triggering caused by equipment vibration.

[0039] The single on / off threshold was calibrated to 0.02 mL / time. The calibration process was completed under standard conditions of 25℃ room temperature and 100cp viscosity of spinning oil. A high-precision syringe meter was used as the calibration equipment, and the calibration error was ≤ ±0.0004 mL.

[0040] For spinning oils with different viscosities of 50-200cp, a calibration correction coefficient is set, and the single on / off threshold is automatically adjusted by PLC to ensure that the metering accuracy for oils of different viscosities is ≤±2%.

[0041] The calculation period for the signal frequency is 1 second. A sudden increase in frequency is determined by the average frequency of three consecutive calculation periods increasing by ≥30% compared to the baseline value, thus avoiding misjudgment caused by instantaneous flow fluctuations.

[0042] The miniature on / off flow sensor is the core actuator, integrating a windmill-type fluororubber elastic baffle 101, a miniature magnet 102, a Hall sensor unit 103, and a snap-fit ​​interface 104, with an overall volume ≤25mm×25mm×35mm.

[0043] Example 1 The high-speed melt spinning production line for polyester staple fiber has an oil viscosity of 100cp at 25℃. The process requires an oil delivery flow rate of 5mL / min. Each oil pump corresponds to 12 spinning positions. Each micro output pipeline has an independently deployed monitoring module with a metering accuracy requirement of ≤±2%.

[0044] (1) Deployment of miniature on / off flow sensor 1 The miniature on / off flow sensor 1, which integrates six windmill-shaped fluororubber elastic baffles 101, 2mm thick 800GS neodymium iron boron miniature magnets 102, and 5V linear Hall effect sensing unit 103, is directly connected in series to the φ4mm miniature output pipeline 7 between the oil pump 6 and the spinning nozzle 8 via its end snap-fit ​​interface 104. The overall volume of the sensor 1 is ≤25mm×25mm×35mm, requiring no modification to the original pipeline. The coaxiality error between the sensor 1 and the pipeline 7 is ≤0.5mm. The upper housing 10 and lower housing 11 of the sensor 1 are fastened with fixing screws 13, and the two end series pipes 12 are seamlessly connected to the snap-fit ​​interface 104 to ensure that the oil flows without leakage.

[0045] (2) On / off signal acquisition The oil pump 6 is driven by motor 61 to deliver oil to the micro output pipeline 7 at a flow rate of 5 mL / min. When the oil flows through the micro on / off flow sensor 1, the impact force pushes the internal windmill-type fluororubber elastic baffle 101 to swing towards the outlet side. When the micro magnet 102 at the end of the baffle 101 swings close to the Hall sensing unit 103 and the trigger distance is 3-5 mm, the power-on signal is triggered. When the magnet 102 moves away from the Hall sensing unit 103, the power-off signal is triggered, completing one on / off cycle.

[0046] This operating condition is the standard calibration condition. The single on / off threshold is calibrated to 0.02 mL / time. The calibration equipment is a high-precision syringe meter with a calibration error of ±0.0003 mL and a measurement accuracy of ±1.5%.

[0047] (3) Precise calculation of oil dosage The on / off signal collected by sensor 1 is transmitted to signal processing module 2, where its internal signal counting unit 201 captures and accumulates the number of on / off cycles in real time at a frequency of 1 time / second, and calculates the real-time / cumulative amount of oil used according to the formula: Cumulative dosage = Number of on / off cycles × Single on / off threshold (0.02 mL / cycle) At a standard flow rate of 5 mL / min, the theoretical number of on-off cycles is 250 times / minute, while the actual monitoring shows a stable rate of 248-252 times / minute. The calculation results are synchronously transmitted to the HMI display module 5, enabling visualized monitoring of real-time and cumulative oil dosage.

[0048] (4) Dynamic identification of abnormal operating conditions The internal frequency analysis unit 202 of the signal processing module 2 performs real-time analysis of the frequency of the on / off signal per unit time with a calculation period of 1 second. The reference value of the signal frequency under this operating condition is set to 4.17Hz (250 times / minute ÷ 60), and anomalies are judged according to the following rules: When the average signal frequency increases by ≥30% or ≥5.42Hz over three consecutive calculation cycles compared to the baseline value, it is determined that there is a leak in oil pipeline 7. If the miniature on / off flow sensor 1 has no on / off signal output for 10 consecutive seconds, it is determined that the oil pipeline 7 is blocked.

[0049] The anomaly detection results are synchronized in real time to alarm module 3 and PLC linkage module 4.

[0050] (5) Interlocking control under abnormal operating conditions After receiving an abnormal signal, the PLC linkage module 4 establishes electrical signal linkage with the oil pump 6, alarm module 3, and spinning nozzle 8, and executes preset instructions according to the abnormality type: If a pipeline leaks, the PLC linkage module 4 sends a command to control the oil pump 6 to immediately reduce the flow rate by 30% to 3.5 mL / min, and at the same time triggers the alarm module 3 to issue a red audible and visual warning at a frequency of 2 times / second. The staff can locate the leaking spinning position through the HMI display module 5 and quickly investigate and repair it. If the pipeline is blocked, the PLC linkage module 4 sends a command to control the corresponding spinning position to stop immediately, and at the same time triggers the alarm module 3 to issue a yellow audible and visual warning at a frequency of 1 time / second to avoid polyester staple fiber breakage and fuzz defects due to lack of oiling agent.

[0051] (6) Data archiving and traceability After the production of polyester staple fiber batch is completed, the signal counting unit 201 automatically stores data such as the real-time oil consumption curve, cumulative consumption, signal frequency curve, occurrence time of abnormal working conditions and handling results of this operation. The data supports local storage and Excel export, providing data support for production quality traceability and process parameter optimization. The average cumulative oil consumption per spinning position in this batch was 12.5L, with 2 minor leakage abnormalities recorded and no blockage abnormalities.

[0052] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A miniature precision monitoring system for the amount of spinning oil used, characterized in that, include: The system comprises a miniature on / off flow sensor, a signal processing module electrically connected to the miniature on / off flow sensor, an alarm module electrically connected to the signal processing module, a PLC linkage module, and an HMI display module, all connected in series on the miniature output pipeline. It also includes an oil pump and a motor driving the oil pump, both located at the pipeline inlet of the miniature output pipeline. The output end of the miniature output pipeline is connected to a spinning nozzle. The PLC linkage module is also electrically connected to the oil pump and the alarm module. The miniature on / off flow sensor includes an upper housing and a lower housing fixed by fixing screws. The upper housing has a series tube with a snap-fit ​​interface at both ends. A windmill-shaped fluororubber elastic baffle is rotatably installed inside the upper housing. A miniature magnet is installed at the end of one blade of the baffle. A Hall sensing unit matching the miniature magnet is installed inside the lower housing. The signal processing module includes a signal counting unit and a frequency analysis unit.

2. The miniature precision monitoring system for the amount of spinning oil used according to claim 1, characterized in that: The overall volume of the miniature on / off flow sensor is ≤25mm×25mm×35mm, and the snap-fit ​​interface is an oil-resistant sealing structure; the wind turbine fluororubber elastic baffle is a six-blade windmill structure or a four-blade cross-shaped structure, and the blade thickness is 2mm.

3. The miniature precision monitoring system for the amount of spinning oil agent used according to claim 1, characterized in that: The miniature magnet is a neodymium iron boron miniature magnet with a magnetic induction intensity of 800GS and a trigger distance of 3-5mm from the Hall sensing unit; the Hall sensing unit is a linear Hall sensor with a sensing frequency of 0-10Hz, a response time of ≤0.1s, and a power supply voltage of 5V.

4. The miniature precision monitoring system for the amount of spinning oil used according to claim 1, characterized in that: The data update frequency of the signal counting unit is 1 time / second, and the signal frequency calculation period of the frequency analysis unit is 1 second.

5. A micro-precision monitoring method for the amount of spinning oil used based on the system described in any one of claims 1-4, characterized in that: Includes the following steps: (1) Deployment of miniature on / off flow sensor: The miniature on / off flow sensor is connected in series in the φ4mm miniature output pipeline between the oil pump and the spinning nozzle through a snap-fit ​​interface; (2) On / off signal acquisition: The motor drives the oil pump to deliver a small amount of oil. The impact force of the oil pushes the fluororubber elastic baffle of the windmill to swing. The micro magnet moves closer to / away from the Hall sensing unit to form an on / off cycle signal. A single on / off cycle corresponds to a fixed oil volume, i.e., a single on / off threshold. (3) Accurate calculation of oil dosage: The signal counting unit accumulates the number of on / off cycles in real time, and calculates the oil dosage according to the formula: cumulative dosage = number of on / off cycles × single on / off threshold. The data is synchronized to the HMI display module. (4) Dynamic identification of abnormal working conditions: The frequency analysis unit analyzes the frequency of the on / off signal in real time, and determines leakage and blockage abnormalities by combining the preset reference value. The abnormal results are synchronized to the alarm module and PLC linkage module. (5) Abnormal operating condition linkage control: The PLC linkage module sends linkage control commands to the oil pump and alarm module according to the abnormality type; (6) Data archiving and traceability: After the batch production is completed, the signal counting unit automatically stores data such as oil dosage, signal frequency, and abnormal records. The data supports local storage and export.

6. The micro-precision monitoring method for the amount of spinning oil agent used according to claim 5, characterized in that: The single on / off threshold mentioned in step (2) is calibrated to 0.02 mL / time under standard working conditions of 25℃ room temperature and 100cp viscosity of spinning oil by a high-precision syringe meter. The calibration error is ≤±0.0004 mL, and the metering accuracy of the single on / off threshold after calibration is ≤±2%.

7. The micro-precision monitoring method for the amount of spinning oil used according to claim 6, characterized in that: For spinning oils with different viscosities of 50-200cp, the calibration correction coefficient is set through the PLC linkage module and the single on / off threshold is automatically adjusted to ensure that the metering accuracy for oils of different viscosities is ≤±2%.

8. The micro-precision monitoring method for the amount of spinning oil agent used according to claim 5, characterized in that: The rules for determining abnormal operating conditions in step (4) are as follows: when the average value of the signal frequency for three consecutive calculation cycles increases by ≥30% compared to the benchmark value, it is determined to be a leak in the oil pipeline; when the miniature on / off flow sensor has no on / off signal output for 10 consecutive seconds, it is determined to be a blockage in the oil pipeline.

9. The micro-precision monitoring method for the amount of spinning oil used according to claim 5, characterized in that: The linkage control command mentioned in step (5) is as follows: if it is determined that the oil is leaking, the PLC linkage module controls the oil pump to reduce the flow rate by 30% immediately, and the alarm module issues a red audible and visual warning; if it is determined that the pipeline is blocked, the PLC linkage module controls the corresponding spinning position to stop immediately, and the alarm module issues a yellow audible and visual warning.

10. The micro-precision monitoring method for the amount of spinning oil used according to any one of claims 5-9, characterized in that: The method is suitable for oil delivery flow rates of 3-10 mL / min, and is compatible with spinning production processes using φ4 mm micro-tubes. The lag time for abnormal condition identification is ≤10 s. After the abnormality is resolved, the equipment can be restored to normal operation via touch screen control of the HMI display module.

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