A production control method and system for high-strength, corrosion-resistant, and durable woven composite geotextiles

Abstract

This invention discloses a production control method and system for high-strength, corrosion-resistant, and durable woven composite geotextiles, relating to the field of geotextile technology. It acquires dual-source data and normalizes it into equivalent and converted rotational speeds, then calculates the deviation change rate. A dual-condition judgment is used to identify slippage trends, and the motor acceleration time parameter is dynamically switched accordingly: when a trend appears, the acceleration is adjusted to a slow value to mitigate impact; when the trend subsides, the acceleration is restored to a fast value to ensure response accuracy. This invention achieves a dynamic optimal balance between fiber protection and production accuracy by using a dual-condition judgment of the deviation change rate and speed ratio deviation rate.

Description

Technical Field

[0001] This invention relates to the field of geotextile technology, specifically to a production control method and system for high-strength, corrosion-resistant, and durable woven composite geotextiles. Background Technology

[0002] In the production of woven composite geotextiles, stretching is necessary because the polymer chains inside the nascent fibers, freshly extruded from the spinneret, are in a disordered and coiled state, possessing almost no practical strength. Only through stretching can these disordered macromolecular chains be forced to stretch, straighten, and compactly stack along the fiber axis, forming a highly oriented crystalline structure. It is this oriented crystallization that transforms the weak van der Waals forces between molecular chains into strong covalent bonds that bear the load, thereby endowing a single fiber with several times higher breaking strength and modulus, enabling it to serve as the backbone of the geotextile and withstand high loads.

[0003] In tension roller drive, if the belt suddenly slips momentarily, the actual linear speed of the roller surface will drop sharply and cause the filament to loosen. After the control system detects the drop in tension, it will immediately increase the motor speed to try to compensate. However, once the belt suddenly regains its grip, the previously accumulated high speed is instantly released to the roller surface, forming an impactful and rapid stretch. This sudden and forceful pull causes the molecular chains inside the fiber to be forcibly broken before they can untangle and slip. The stress is highly concentrated and dense microcracks are generated, which ultimately leads to a significant increase in fiber brittleness, a stiff feel, and the potential for premature breakage. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a production control method and system for high-strength, corrosion-resistant, and durable woven composite geotextiles. This solves the problem that belt slippage causes the system to accelerate compensatingly, and when regaining grip, the high-speed instantaneous release becomes an impactful pull, resulting in the direct breakage of the molecular chains within the fibers, the proliferation of microcracks, a surge in fiber brittleness, and the potential for premature breakage.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a production control method for high-strength, corrosion-resistant, and durable woven composite geotextile, comprising the following specific steps: Step 1: Real-time acquisition of motor speed and roller surface linear velocity, converting this linear velocity into the roller's equivalent speed; and dividing the motor speed by a fixed transmission ratio to obtain the converted speed; Step 2: Calculation based on the roller's equivalent speed and converted speed to obtain the deviation change rate; Step 3: Analysis based on the deviation change rate to determine if the belt exhibits a slippage trend. If a slippage trend is detected, the motor acceleration time parameter is adjusted from a fast acceleration value to a slow acceleration value, and the analysis continues until no slippage trend is detected; if no slippage trend is detected, the motor acceleration time parameter is restored to the fast acceleration value, and the process returns to Step 1 or terminates directly.

[0006] Furthermore, the specific calculation method for the deviation change rate is as follows: The speed ratio deviation rate is obtained by calculating based on the equivalent rotational speed and the converted rotational speed of the roller. In the time series, the first... Speed ​​ratio deviation rate at time t and the first The deviation rate at each speed ratio is used to calculate the difference, and the rate of change of deviation is obtained.

[0007] Furthermore, the specific calculation method for the deviation change rate is as follows: ;in, Indicates the rate of change of deviation. Indicates the first Speed ​​ratio deviation rate at time t. Indicates the first Speed ​​ratio deviation rate at any given time.

[0008] Furthermore, the specific method for obtaining the speed ratio deviation rate is as follows: calculate the difference between the converted speed and the equivalent speed of the roller, take the absolute value to obtain the speed difference, and then calculate the ratio between the speed difference and the converted speed to obtain the speed ratio deviation rate.

[0009] Furthermore, the specific method for obtaining the speed difference is as follows: ;in, Indicates the speed difference. Indicates the converted speed. This represents the equivalent rotational speed of the roller. Further, the specific method for obtaining the speed ratio deviation rate is as follows: ;in, Indicates the speed ratio deviation rate. Indicates the speed difference. This indicates the converted rotational speed.

[0010] Furthermore, the method for analyzing whether the belt has a slippage trend based on the deviation change rate is as follows: a deviation change threshold and a speed ratio deviation threshold are preset, and the deviation change rate is compared with the deviation change threshold. If the deviation change rate is greater than the deviation change threshold, the speed ratio deviation rate is compared with the speed ratio deviation threshold. If the speed ratio deviation rate is greater than the speed ratio deviation threshold, it indicates that there is a slippage trend. If the speed ratio deviation rate is less than or equal to the speed ratio deviation threshold, it indicates that there is no slippage trend. If the deviation change rate is less than or equal to the deviation change threshold, it also indicates that there is no slippage trend.

[0011] Furthermore, the preset method for the deviation change threshold is as follows: under stable process conditions, continuously collect the deviation change rate values ​​of each sampling cycle within a certain period of time to form a fluctuation sample set for normal operation, take the maximum value of the absolute value of the deviation change rate in this sample set, and then multiply it by the safety factor to obtain the deviation change threshold.

[0012] Furthermore, the preset method for the speed ratio deviation threshold is as follows: during normal operation, there is a small steady-state difference between the motor's equivalent speed and the roller's equivalent speed. Historical data of this steady-state difference is collected, its mean is calculated, and three times the standard deviation is added to obtain the speed ratio deviation threshold.

[0013] A production control system for high-strength, corrosion-resistant, and durable woven composite geotextile includes the following specific modules: a data acquisition module: real-time acquisition of motor speed and roller surface linear velocity, converting this linear velocity into the roller's equivalent speed; and dividing the motor speed by a fixed transmission ratio to obtain the converted speed; a deviation calculation module: calculation based on the roller's equivalent speed and converted speed to obtain the deviation change rate; and an analysis and adjustment module: analysis based on the deviation change rate to determine if there is a slippage trend in the belt. If a slippage trend is detected, the motor acceleration time parameter is adjusted from a fast acceleration value to a slow acceleration value, and the analysis continues until no slippage trend is detected. If no slippage trend is detected, the motor acceleration time parameter is restored to the fast acceleration value, and the process returns to the data acquisition module or terminates directly.

[0014] Compared with the prior art, the embodiments of the present invention have at least the following advantages or beneficial effects: 1. By using the deviation change rate obtained from the speed ratio deviation rate through differential calculation between adjacent time steps, the static synchronization error is upgraded to a dynamic degradation rate, enabling the system to capture abnormal acceleration signals in the first sampling period when slippage occurs, rather than reacting only after the deviation has accumulated to an irreversible level. At the same time, the deviation change rate and speed ratio deviation rate are used for dual-condition judgment. The former filters out stable operating conditions, while the latter eliminates sensor noise, fundamentally distinguishing between inherent steady-state errors and sudden slippage trends, and solving the contradiction that a single indicator cannot simultaneously take into account sensitivity and anti-interference capabilities.

[0015] 2. By setting a dynamic two-way adjustment between fast and slow acceleration values ​​for the motor acceleration time parameter based on the presence or absence of slippage trend, the value is immediately rewritten to slow acceleration when slippage trend occurs. The ramp function is used to slow down the speed rise slope, transforming the impactful jerk when the belt regains grip into smooth tension, thus suppressing the generation of fiber microcracks at the source. After the trend is eliminated, the value is immediately restored to fast acceleration, enabling tension control to regain the ability to quickly correct legitimate fluctuations and provide emergency protection against breakage events, achieving a dynamic optimal balance between fiber protection and production accuracy.

[0016] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0017] Figure 1 This is a flowchart of the production control method for woven composite geotextiles according to the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0020] Example 1: like Figure 1 As shown, this embodiment of the invention provides a production control method for high-strength, corrosion-resistant, and durable woven composite geotextiles, comprising the following specific steps: Step 1: Real-time acquisition of motor speed and roller surface linear velocity, followed by data cleaning to remove redundant values ​​and timestamping synchronization. The motor speed is directly read via the encoder feedback interface built into the motor driver. A photoelectric encoder is coaxially mounted at the tail of the servo motor. For each motor revolution, the encoder sends a fixed number of pulse signals to the motor driver. The motor driver is a Siemens SINAMICS. In the S120 series, the high-speed counter inside the motor driver converts these pulses into revolutions per minute in real time and stores them in the speed feedback register, such as the Siemens R0063. The control system of the Siemens S7-1500 series PLC reads the value of this register in each sampling cycle through the analog output port to obtain the motor speed. Since the motor output shaft and the stretching roller are connected by a pulley, there is a fixed speed transmission ratio, which is the transmission ratio. It is usually defined as the ratio of the number of teeth on the motor end to the number of teeth on the roller end. When calculating, the motor speed is directly divided by this transmission ratio and standardized to convert values ​​of different orders of magnitude into a unified numerical range. For example, if the number of teeth on the motor end is 24 and the number of teeth on the roller end is 48, then the transmission ratio is 2, which gives the converted speed, indicating how fast the motor rotates and how fast the roller rotates. The linear velocity of the roller surface is acquired by a rotary encoder, such as the Pepperl+Fuchs EVM58 series, which is coaxially mounted independently of the tension roller. The rotary encoder is directly fixed to the end of the roller shaft and rotates synchronously with the roller, unaffected by intermediate transmission links such as belts or couplings. The pulse signal output from the rotary encoder is input to the PLC. The number of pulses is read in each sampling cycle, and the equivalent rotational speed of the roller is calculated by combining this with the roller diameter, a known mechanical parameter of the equipment. Simultaneously, standardization is performed to eliminate dimensional differences and convert values ​​of different orders of magnitude into a unified numerical range. ;in, Indicates the equivalent rotational speed of the roller. Indicates the linear velocity of the roller surface. Indicates the diameter of the roller. Represents pi (π). This indicates the circumference of the roller.

[0021] Step 2: While calculating based on the equivalent speed and converted speed of the roller, standardization is performed to convert values ​​of different orders of magnitude into a unified numerical range to obtain the deviation change rate; Step 3: Analyze the belt slippage trend based on the deviation change rate. If slippage is detected, adjust the motor acceleration time parameter from a fast acceleration value to a slow acceleration value. This is because when the belt slips, the rollers lose speed, and the system immediately increases the motor speed to try to compensate. Once the belt suddenly regains grip, the high speed accumulated by the motor is released instantly as a powerful, impactful pull, enough to break the molecular chains inside the fiber. Therefore, the time constant register of the ramp function generator built into the motor driver is rewritten from the normal operating value of 50 milliseconds to a protection value of 500 milliseconds. This value determines the time it takes for the speed setpoint to rise from the current value to the target value. The larger the value, the gentler the slope of the speed increase. When the belt regains grip, the motor speed is too high. The driver will force the motor to slowly decrease to synchronous speed along this gentle slope instead of violently swinging within a few milliseconds. This will dissolve the impact energy that would tear the fibers into a gentle tensioning process. The system will continue to analyze whether there is a slippage trend until it is found that there is no slippage trend. If no slippage trend is found, the motor acceleration time parameter will be restored to the fast acceleration value, that is, the 500 millisecond protection value will be restored to the normal operating value of 50 milliseconds. The reason for the restoration is that the motor response is slow in the slow acceleration state and cannot correct the normal small fluctuations in tension in time, which will cause periodic thick and thin spots in the fibers, resulting in loss of production precision. The system will then return to step one or end directly.

[0022] Example 2 differs from Example 1 in that: The specific calculation method for the rate of change of deviation is as follows: The speed ratio deviation rate is calculated based on the equivalent speed and the converted speed of the roller. In the time series, the [missing information] is then [determined]. Speed ​​ratio deviation rate at time t and the first The deviation rate at each speed ratio is calculated by difference to obtain the deviation change rate. That is, only by extracting the rate of change of deviation with time through difference operation between adjacent time points can we distinguish between the inherent deviation that has always existed and the dangerous trend that is rapidly expanding.

[0023] The specific calculation method for the rate of change of deviation is as follows: ; in, Indicates the rate of change of deviation. Indicates the first Speed ​​ratio deviation rate at time t. Indicates the first The speed ratio deviation rate at any given time is directly proportional to the rate of change in a mathematical sense, since the time interval between adjacent samplings is fixed. It has low computational complexity and can output the result without delay in each sampling cycle, without adding any computing power burden to the control system. As soon as the belt begins to slip, this difference will spike, so a fixed threshold can be used to capture it universally across operating conditions without having to frequently adjust the judgment criteria with process speed regulation.

[0024] The specific method for obtaining the speed ratio deviation rate is as follows: The difference between the converted speed and the equivalent speed of the roller is calculated, and the absolute value is taken. Taking the absolute value eliminates the interference of slippage direction on the judgment. Whether the roller lags or abnormally leads, it can be captured uniformly to obtain the speed difference. Then, the speed difference is compared with the converted speed. The ratio processing converts the absolute speed difference into a proportional value relative to the reference speed, eliminating the dimension effect of production speed and obtaining the speed ratio deviation rate.

[0025] The specific method for obtaining the speed difference is as follows: ; in, Indicates the speed difference. Indicates the converted speed. This indicates the equivalent rotational speed of the roller.

[0026] The specific method for obtaining the speed ratio deviation rate is as follows: ; in, Indicates the speed ratio deviation rate. Indicates the speed difference. This indicates the converted rotational speed.

[0027] The method for analyzing whether a belt is slipping based on the rate of change of deviation is as follows: The system presets a deviation change threshold and a speed ratio deviation threshold. It compares the deviation change rate with these thresholds. During normal operation, the deviation change rate is very small, so it is directly determined not to trigger, eliminating the need for a second-level judgment and saving significant redundant calculations. If the deviation change rate is greater than the deviation change threshold, the speed ratio deviation rate is compared with the speed ratio deviation threshold to accurately distinguish between the actual slippage trend and sensor noise. If the speed ratio deviation rate is greater than the speed ratio deviation threshold, it indicates a slippage trend. If the speed ratio deviation rate is less than or equal to the speed ratio deviation threshold, it indicates no slippage trend; that is, although the deviation change rate is large, the speed ratio deviation rate itself is small, and this is considered a signal glitch that is filtered out. If the deviation change rate is less than or equal to the deviation change threshold, it also indicates no slippage trend; that is, the deviation change rate is small during normal operation, and it is directly determined not to trigger.

[0028] The preset method for the deviation change threshold is as follows: Under stable operating conditions, the deviation change rate values ​​of each sampling cycle are continuously collected over a period of time to form a fluctuation sample set for normal operation. The maximum absolute value of the deviation change rate in this sample set is taken and multiplied by the safety factor to obtain the deviation change threshold.

[0029] The preset method for the speed ratio deviation threshold is as follows: During normal operation, there is a small steady-state difference between the motor's equivalent speed and the roller's equivalent speed. Historical data of this steady-state difference are collected, its mean is calculated, and three times the standard deviation is added to obtain the speed ratio deviation threshold.

[0030] Example 3: A production control system for high-strength, corrosion-resistant, and durable woven composite geotextile includes the following specific modules: Data acquisition module: Real-time acquisition of motor speed and roller surface linear velocity, converting this linear velocity into the roller's equivalent speed; and dividing the motor speed by a fixed transmission ratio to obtain the converted speed; Deviation calculation module: Calculates the deviation change rate based on the equivalent speed and converted speed of the roller; Analysis and Adjustment Module: Analyzes whether the belt is slipping based on the deviation change rate. If a slipping trend is found, the motor acceleration time parameter is adjusted from a fast acceleration value to a slow acceleration value, and the analysis continues until no slipping trend is found. If no slipping trend is found, the motor acceleration time parameter is restored to the fast acceleration value, and the process returns to the data acquisition module or terminates directly.

[0031] The preferred embodiments disclosed in this invention are merely illustrative examples of feasible implementation methods and are not intended to exhaustively cover all technical details of the invention, nor do they constitute a limitation on the scope of protection of this invention. In practical applications, those skilled in the art can make appropriate adjustments, combinations, or substitutions to the methods or systems described in these embodiments based on specific production conditions, equipment configurations, and process requirements, without departing from the core concept of this invention. For example, the acquisition method, data processing algorithm, control threshold, or specific implementation form of the execution unit can all be reasonably changed according to the actual situation.

[0032] Furthermore, the technical concepts disclosed in this invention have universal extensibility and adaptability. They are not only applicable to the specific scenarios described in the embodiments, but can also be applied in similar technical fields or related industrial processes through analogy, transplantation, or improvement. Any technical solution formed by making logically equivalent substitutions, reasonable adjustments to the order of steps, or recombination of module functions based on the principles, ideas, or framework disclosed in this specification should be considered to fall within the spirit and scope of this invention.

[0033] It should be further clarified that the specific descriptions and drawings in the patent documents are for the purpose of assisting in understanding the present invention only, and their details should not be interpreted as limitations on the claims. The true scope of protection of the present invention should be determined by the content of the claims recorded in the authorized text, and should cover all equivalent technical solutions that comply with the provisions of patent law under these claims. Any implementation method that has the same or similar function and achieves similar effects through reasonable changes in technical means under the guidance of the concept of the present invention falls within the scope of protection sought by the present invention.

[0034] Therefore, the descriptions in this specification are merely illustrative. Any adjustments to implementation methods, equivalent substitutions of technical features, or further applications based on the concept of this invention, as long as they do not depart from the overall technical approach described in this invention, should be included within the scope of protection of this invention. We encourage those skilled in the art to innovate and optimize based on their understanding of the core of this invention and in conjunction with specific practices, so as to jointly promote the progress and development of related technologies.

Claims

1. A method for controlling the production of high-strength, corrosion-resistant, and durable woven composite geotextiles, characterized in that: The specific steps include the following: Step 1: Real-time acquisition of motor speed and roller surface linear velocity, conversion of this linear velocity into equivalent roller speed; and division of motor speed by fixed transmission ratio to obtain converted speed; Step 2: Calculate the deviation change rate based on the equivalent speed and the converted speed of the roller; Step 3: Analyze whether the belt has a slippage trend based on the deviation change rate. If a slippage trend is found, adjust the motor acceleration time parameter from a fast acceleration value to a slow acceleration value, and continue to analyze whether a slippage trend is found until no slippage trend is found. If the analysis shows no slippage trend, restore the motor acceleration time parameter to the fast acceleration value and return to step one or end directly.

2. The production control method for high-strength, corrosion-resistant, and durable woven composite geotextile according to claim 1, characterized in that: The specific calculation method for the deviation change rate is as follows: The speed ratio deviation rate is calculated based on the equivalent and converted speeds of the rollers. In a time series, the [missing information] is then [determined]. Speed ​​ratio deviation rate at time t and the first The deviation rate at each speed ratio is used to calculate the difference, and the rate of change of deviation is obtained.

3. The production control method for high-strength, corrosion-resistant, and durable woven composite geotextile according to claim 2, characterized in that: The specific calculation method for the deviation change rate is as follows: ； in, Indicates the rate of change of deviation. Indicates the first Speed ​​ratio deviation rate at time t. Indicates the first Speed ​​ratio deviation rate at any given time.

4. The production control method for high-strength, corrosion-resistant, and durable woven composite geotextile according to claim 3, characterized in that: The specific method for obtaining the speed ratio deviation rate is as follows: The difference between the converted speed and the equivalent speed of the roller is calculated, and the absolute value is taken to obtain the speed difference. Then, the speed difference is compared with the converted speed to obtain the speed ratio deviation rate.

5. The production control method for high-strength, corrosion-resistant, and durable woven composite geotextile according to claim 4, characterized in that: The specific method for obtaining the speed difference is as follows: ； in, Indicates the speed difference. Indicates the converted speed. This indicates the equivalent rotational speed of the roller.

6. The production control method for high-strength, corrosion-resistant, and durable woven composite geotextile according to claim 5, characterized in that: The specific method for obtaining the speed ratio deviation rate is as follows: ； in, Indicates the speed ratio deviation rate. Indicates the speed difference. This indicates the converted rotational speed.

7. The production control method for high-strength, corrosion-resistant, and durable woven composite geotextile according to claim 6, characterized in that: The method for analyzing whether the belt has a slippage trend based on the rate of change of deviation is as follows: The system presets a deviation change threshold and a speed ratio deviation threshold. It compares the deviation change rate with the deviation change threshold. If the deviation change rate is greater than the deviation change threshold, it compares the speed ratio deviation rate with the speed ratio deviation threshold. If the speed ratio deviation rate is greater than the speed ratio deviation threshold, it indicates that there is a slippage trend. If the speed ratio deviation rate is less than or equal to the speed ratio deviation threshold, it indicates that there is no slippage trend. Similarly, if the deviation change rate is less than or equal to the deviation change threshold, it also indicates that there is no slippage trend.

8. The production control method for high-strength, corrosion-resistant, and durable woven composite geotextile according to claim 7, characterized in that: The preset method for the deviation change threshold is as follows: Under stable operating conditions, the deviation change rate values ​​of each sampling cycle are continuously collected over a period of time to form a fluctuation sample set for normal operation. The maximum absolute value of the deviation change rate in this sample set is taken and multiplied by the safety factor to obtain the deviation change threshold.

9. The production control method for high-strength, corrosion-resistant, and durable woven composite geotextile according to claim 8, characterized in that: The preset method for the speed ratio deviation threshold is as follows: During normal operation, there is a small steady-state difference between the motor's equivalent speed and the roller's equivalent speed. Historical data of this steady-state difference are collected, its mean is calculated, and three times the standard deviation is added to obtain the speed ratio deviation threshold.

10. A production control system for high-strength, corrosion-resistant, and durable woven composite geotextile, used to implement the production control method for high-strength, corrosion-resistant, and durable woven composite geotextile as described in any one of claims 1-9, characterized in that, The high-strength, corrosion-resistant, and durable woven composite geotextile production control system includes: Data acquisition module: Real-time acquisition of motor speed and roller surface linear velocity, converting this linear velocity into the roller's equivalent speed; and dividing the motor speed by a fixed transmission ratio to obtain the converted speed; Deviation calculation module: Calculates the deviation change rate based on the equivalent speed and converted speed of the roller; Analysis and Adjustment Module: Analyzes whether the belt is slipping based on the deviation change rate. If a slipping trend is found, the motor acceleration time parameter is adjusted from a fast acceleration value to a slow acceleration value, and the analysis continues until no slipping trend is found. If no slipping trend is found, the motor acceleration time parameter is restored to the fast acceleration value, and the process returns to the data acquisition module or terminates directly.

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