LoRa Mesh cluster management method, system, and storage media for looms with non-stop warp beam warp breakage detection devices.

Abstract

This invention discloses a method, system, and storage medium for managing a LoRa Mesh cluster of a loom adapted to a warp breakage detection device for a non-stop warp beam. The method is executed by a system comprising multiple loom node detection units, multiple LoRa Mesh routing nodes, and a cluster management center. Each loom node detection unit integrates a dedicated PCB motherboard for non-stop warp beam warp breakage detection, submitted on the same day, and supports three laser emission modes. The cluster management center can remotely and uniformly switch node operating modes, centrally monitor laser tube lifespan using a lifespan prediction formula, and achieve collaborative operation with a single-machine adaptive calibration module. This invention reduces the average power consumption of loom nodes by 60%, extends the battery life of a single node to over 2 years, increases network throughput by 25%-30%, and maintains a communication success rate of over 99.5%, perfectly meeting the cluster management needs of large textile factories.

Description

Technical Field

[0001] This invention relates to the field of textile machinery automation technology, and in particular to a LoRa Mesh cluster management method, system and storage medium for looms adapted to a warp breakage detection device without a warp stop beam. Same-day application related explanation

[0002] This application is one of a series of invention patents filed by the applicant on the same day, titled "Woven Warp Detection System for Looms with No Stoppages." This series of patents shares the same core inventive concept: using non-contact laser technology to achieve end-to-end reliability assurance for the detection of undisturbed warp pieces on looms. This series of patents includes seven invention patents, each addressing one of the seven interrelated and indispensable technical aspects of the menopause detection system: 1. Dedicated PCB motherboard for detecting warp breaks without stopping on a loom (hardware basics) 2. Adaptive calibration control method, system, and storage medium (calibration algorithm) for the entire lifecycle of warp detection in looms without warp drops. 3. Multi-level anti-interference and error prevention control method, system, and storage medium (anti-interference technology) for the entire chain of warp-stop detection on looms. 4. Hardware-level safety interlock state machine control system for detecting warp breaks without stopping on the loom (safety control) 5. LoRa Mesh cluster management method, system, and storage media for looms with non-stop warp beam warp breakage detection devices (cluster management) 6. A control system and method for main shaft synchronization time slot scheduling and dual-channel hardware split-flow control for warp breakage detection in a non-stop-warp beam loom (lower-level communication). 7. Non-contact intelligent warp breakage detection and end-to-end integrated production management system for all types of shuttleless looms (production integration) There is a clear technical dependency among the various patented technical solutions, which together solve the overall technical problems of the non-stop menstrual fragment detection system, namely "poor real-time performance, low reliability, and weak adaptability", and comply with the patent law's provisions on unity of invention. Background Technology

[0003] With the large-scale development of the textile industry, modern textile factories typically have 100-500 looms, and some large factories even have more than 1,000. Traditional single-machine management methods require workers to inspect and set parameters for each machine, resulting in extremely low management efficiency and failing to meet the needs of modern production.

[0004] The existing loom cluster management system has the following main defects: Outdated communication methods: Most systems use RS485 wired communication, with wiring costs of approximately 300-500 yuan per loom, long construction periods, and difficult maintenance; some systems use WiFi wireless communication, but in the dusty and metal-obstructed environment of textile workshops, the communication success rate is less than 90%, and the power consumption is high. Short node battery life: Existing wireless detection nodes generally adopt a high-power design, with a battery life of only 3-6 months, requiring frequent battery replacements and resulting in high maintenance costs; Unable to be remotely and uniformly managed: It is not possible to remotely switch the working mode of the loom nodes and adjust the detection parameters in batches. It takes 2-3 days to complete the parameter adjustment of 100 looms, resulting in low maintenance efficiency. Lack of preventative maintenance: The lifespan of the laser tube cannot be centrally monitored, and it can only be replaced after the laser tube is damaged, which can easily lead to production downtime; Poor coordination: The cluster mode switching is not synchronized with the single-machine adaptive calibration module, which can easily lead to system anomalies caused by parameter mismatch.

[0005] LoRa Mesh technology has advantages such as long transmission distance, low power consumption, strong anti-interference ability, and flexible networking, making it very suitable for complex industrial environments such as textile factories. However, there is currently no mature LoRa Mesh cluster management solution adapted to the warp breakage detection device without warp stop sheet. Summary of the Invention

[0006] Technical issues The technical problem to be solved by this invention is that existing loom cluster management and control systems suffer from high communication costs, short node endurance, low maintenance efficiency, lack of preventive maintenance, and poor coordination. Technical solution

[0007] To address the aforementioned technical problems, this invention provides a method, system, and storage medium for managing a LoRa Mesh cluster of a loom adapted to a warp breakage detection device without a warp stopper beam.

[0008] The method is executed by a system comprising multiple loom node detection units, multiple LoRa Mesh routing nodes, and a cluster management center. The loom node detection units integrate a dedicated PCB motherboard for detecting non-stop warp segments of the loom, as submitted on the same day as this application, and support three laser emission operating modes. The cluster management center can remotely and uniformly switch the operating modes of the loom nodes to achieve low-power cluster management, while centrally monitoring the laser tube lifespan of all nodes and issuing maintenance warnings in advance. A clear coordination mechanism between cluster management and the single-machine adaptive calibration module is established to ensure parameter synchronization during mode switching. Beneficial effects

[0009] Compared with the prior art, the present invention has the following outstanding and substantial beneficial effects: Significantly reduced node power consumption: Combined with the 2mW low power of the PCB motherboard and the transmission mode with a 5-revolution interval, the average power consumption of the loom node is reduced by 60%, and the battery life of a single node is extended to more than 2 years, eliminating the need for frequent battery replacements. Low communication cost: Utilizing LoRa Mesh wireless communication, no wiring is required, reducing communication costs per loom by over 80% and shortening the construction cycle by 90%; Remote unified management: The cluster control center can automatically switch the working mode of all nodes according to the loom speed, eliminating the need for manual settings for each machine and improving maintenance efficiency by more than 80%. Centralized monitoring of laser tube lifespan: The cluster management center tracks the working time of the laser tubes on each node in real time, calculates the remaining lifespan using a lifespan prediction formula, and issues maintenance warnings in advance to achieve preventative maintenance; Improved collaborative working mechanism: The cluster mode switching command synchronously triggers the parameter update of the single-machine adaptive calibration module, avoiding system anomalies caused by parameter asynchrony; Excellent network performance: Adopting a dynamic routing algorithm based on node remaining energy and link quality, the network's effective throughput is increased by 25%-30%, the average energy consumption of nodes is reduced by 25%, the network self-healing time is shortened to less than 1 second, and the communication success rate remains above 99.5%. Unity of invention fully compliant: All technical features are deeply linked to the PCB motherboard, self-calibration, anti-interference, and safety interlock patents submitted on the same day, sharing the same core inventive concept, and fully complying with the patent unity of invention examination requirements. Attached Figure Description

[0010] Figure 1 is a schematic diagram of the structure of the LoRa Mesh cluster management and control system for looms of the present invention; The diagram shows: 1. Real-time photoelectric signal acquisition, 2. Dual threshold determination, 3. Outlier marking and classification, 4. Outlier data removal processing, and 5. Calibration parameter feedback correction.

[0011] Figure 2 This is an architectural block diagram of the cluster management and control system described in an embodiment of the present invention; In the diagram: 1. System startup, 2. Main control scheduling, 3. Beam signal acquisition, 4. Equipment parameter self-check, 5. System fault diagnosis, 6. Detection data upload, 7. Signal anomaly handling, 8. Dual threshold judgment, 9. Actuator feedback.

[0012] Figure 3 This is a block diagram illustrating the working principle of the beam fracture detection device according to an embodiment of the present invention. In the diagram: 1. Main control processing module, 2. Laser emission module, 3. Optical collimation module, 4. Photoelectric receiving module, 5. Signal conditioning module, 6. Analog-to-digital conversion module, 7. Threshold calculation module, 8. Fault determination module, 9. Alarm execution module. Detailed Implementation

[0013] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is based on the actual working conditions of 500 water-jet looms in a standardized textile factory in Jiangsu Province, and the entire process was tested and verified.

[0014] The LoRa wireless communication module in this embodiment is preferably of type SX1268, SX1278 or LLCC68. Those skilled in the art will understand that other LoRa modules with the same performance parameters can also implement the technical solution of this invention.

[0015] Explanation of the laser tube lifetime prediction formula: The operating mode coefficient is derived based on the inverse relationship between laser tube lifetime and power, and the intermittent emission duty cycle: 2mW continuous mode coefficient: 2 / 5.5≈0.36, take the conservative industrial value of 0.38; Intermittent mode coefficient for 2mW every 5 revolutions: 0.38×(190 / 360) / 5≈0.10, take the conservative industrial value of 0.11; Formula applicable conditions: 2~10mW low power range, textile workshop temperature -10℃ / 45℃, relative humidity 40% / 95% RH.

[0016] Implementation of LoRa Mesh Cluster Management System for Looms

[0017] The LoRa Mesh cluster management system for looms in this embodiment includes 500 loom node detection units 1, 3 LoRa Mesh routing nodes 2, and 1 cluster management center 3.

[0018] Each loom node detection unit 1 integrates a dedicated PCB motherboard for detecting warp segments without stopping on the loom, which was submitted on the same day as this application. It supports three working modes: 2mW multi-level intermittent transmission, 5.5mW constant continuous transmission, and 2mW single-rotation intermittent transmission.

[0019] Each LoRa Mesh routing node 2 uses an STM32F407VET6 microcontroller and an SX1268 LoRa module, supporting LoRa Mesh networking with a transmission distance of up to 500 meters and the ability to penetrate three concrete walls.

[0020] Cluster Control Center 3 uses an Intel Core i5-12400 industrial computer to run cluster control software. It is equipped with a 21-inch LCD screen that can display the operating status of all looms, warp breakage information, and remaining lifespan of laser tubes in real time.

[0021] The specific steps of the control method in this embodiment are as follows: The cluster control center 3 establishes a communication connection with all 500 loom node detection units 1 through the LoRa Mesh routing node 2, and automatically identifies the model and working mode of each node; The loom node detection unit 1 collects warp breakage signals and loom operating status data (including loom speed, spindle angle, laser tube operating current, and operating time) every 10ms, and sends them to the cluster management center 3 through the LoRa Mesh routing node 2; Cluster Management Center 3 processes the received data: When a warp breakage signal is detected, a graded early warning and control command is generated to control the corresponding loom to stop and issue an audible and visual alarm. The operating mode switching command is automatically generated based on the loom speed: when the loom speed is ≥800rpm, it switches to constant continuous transmission mode; when the loom speed is <800rpm, it switches to 2mW intermittent transmission mode every 5 revolutions. The remaining lifespan is calculated based on the laser tube's working time and lifespan prediction formula. When the remaining lifespan is less than 3 months, a maintenance warning is issued. The cluster control center 3 sends control commands to the corresponding loom node detection unit 1 through the LoRa Mesh routing node 2, and the loom node detection unit 1 performs corresponding operations according to the commands; Collaborative working mechanism: After receiving the mode switching command, the loom node detection unit 1 immediately sends a parameter update command to its own adaptive calibration module, and synchronously adjusts the calculation cycle and correction ratio of the light attenuation compensation coefficient to ensure that the calibration parameters match the current working mode; The loom node detection unit 1 feeds back the execution results to the cluster management center 3, and the cluster management center 3 updates the management strategy based on the feedback results.

[0022] The test results of this embodiment show that the system network coverage can reach 500 meters, the communication success rate is 99.6%, the average power consumption of the loom node is 10mA, the battery life of a single node is 2.5 years, the cluster management efficiency is improved by more than 80%, and the effective network throughput is 10kbps.

[0023] Example 2 Centralized monitoring of laser tube lifespan is implemented.

[0024] The database server of the cluster control center 3 stores the laser tube working time data of all loom nodes and predicts the remaining lifespan according to the formula described in claim 9.

[0025] When the remaining lifespan of a laser tube at a certain node is less than 3 months, the cluster control center 3 will display a red warning window on the screen and send an SMS notification to the maintenance personnel to carry out preventive maintenance and avoid production downtime due to laser tube damage.

[0026] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for managing a LoRa Mesh cluster of looms adapted to a warp breakage detection device without a warp stopper beam, characterized in that, The method is executed by a LoRa Mesh cluster management system for looms, which includes multiple loom node detection units, multiple LoRa Mesh routing nodes, and a cluster management center. Each loom node detection unit integrates a dedicated PCB motherboard for detecting non-stop warp segments on a loom, as submitted on the same day as this application. The method includes the following steps: The S1 cluster control center establishes a communication connection with all loom node detection units through the LoRa Mesh routing node; The S2 loom node detection unit collects warp breakage signals and loom operating status data in real time, and sends them to the cluster management center through the LoRa Mesh routing node; The S3 cluster control center generates control instructions based on the received warp breakage signals and loom operating status data; The S4 cluster management center sends management commands to the corresponding loom node detection units through LoRa Mesh routing nodes. The loom node detection units perform corresponding operations according to the management commands, including switching the laser emission working mode, adjusting the detection threshold, and triggering a shutdown alarm.

2. The method according to claim 1, characterized in that, In step S2, the PCB motherboard of the loom node detection unit supports three laser emission working modes: the default 2mW main shaft synchronous multi-level intermittent emission mode, the optional 5.5~10mW constant continuous emission mode, and the optional 2mW low power single-revolution intermittent emission mode. When the 2mW intermittent emission mode with 5 revolutions per cycle is used, the average power consumption of the loom node detection unit is reduced by 60%, and the battery life of a single node is extended to more than 2 years.

3. The method according to claim 1, characterized in that, In step S3, the control instructions generated by the cluster control center include hierarchical early warning control instructions, parameter linkage calibration instructions, working mode switching instructions, and fault diagnosis instructions.

4. The method according to claim 3, characterized in that, The specific working mode switching command is as follows: the cluster control center automatically switches the laser emission working mode according to the loom speed. When the loom speed is higher than the preset speed threshold, it switches to the constant continuous emission mode; when the loom speed is lower than the preset speed threshold, it switches to the 2mW low power multi-level intermittent emission mode.

5. The method according to claim 1, characterized in that, In step S4, the cluster management center sends management commands to the corresponding loom node detection unit via LoRaMesh routing nodes using either broadcast or unicast methods.

6. The method according to claim 1, characterized in that, It also includes step S5: the loom node detection unit feeds back the execution results to the cluster management center through the LoRa Mesh routing node, and the cluster management center updates the management policy based on the feedback results.

7. The method according to claim 1, characterized in that, The LoRa Mesh routing nodes use a dynamic routing algorithm based on the node's remaining energy and link quality for data forwarding.

8. The method according to claim 1, characterized in that, The cluster control center predicts the remaining lifespan of the laser tube using the following formula: Remaining service life (years) = Rated service life (years) - Hours already worked (years) × Working mode coefficient The operating mode coefficient for constant continuous emission mode is 1, the operating mode coefficient for 2mW low-power continuous mode is 0.38, and the operating mode coefficient for 2mW intermittent emission mode every 5 revolutions is 0.

11. This formula is applicable to the 2~10mW low-power range and the normal operating conditions in textile workshops.

9. A LoRa Mesh cluster management system for looms adapted to a warp breakage detection device without a warp stopper beam, characterized in that, include: Multiple loom node detection units, each loom node detection unit integrates a dedicated PCB motherboard for detecting warp breaks in loom sections without warp breaks, which was submitted on the same day as this application, for collecting warp break signals and loom operating status data; Multiple LoRa Mesh routing nodes, each LoRa Mesh routing node includes an STM32 microcontroller, a LoRa wireless communication module and a power module, used to forward data between the loom node detection unit and the cluster management center; A cluster control center, including an industrial computer, display screen, and input devices, is used to receive and process data sent by the loom node detection units, generate control commands, and send them to the corresponding loom node detection units via LoRa Mesh routing nodes.

10. The system according to claim 10, characterized in that, The loom node detection unit also includes a power supply module and a warp break alarm module. The power supply module is used to provide a stable DC power supply to the PCB motherboard, and the warp break alarm module is used to issue an audible and visual alarm when a warp break signal is detected.

11. The system according to claim 10, characterized in that, The LoRa Mesh routing node also includes an Ethernet interface for wired communication with the cluster management center.

12. The system according to claim 10, characterized in that, The cluster control center also includes a database server for storing loom operation data, warp breakage history records, and laser tube life data.

13. A computer-readable storage medium, characterized in that, The computer-readable storage medium is a non-volatile computer-readable storage medium selected from at least one of hard disk, Flash chip, SD card, and eMMC; the storage medium is configured to work in conjunction with the LoRa Mesh cluster management system of claim 10, and stores computer-executable instructions for causing the processor to execute the method described in any one of claims 1-9.

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