A cotton filling and opening integrated machine and a cotton amount automatic control method

Abstract

The present application relates to a kind of control cotton filling amount's cotton filling and picking integrated machine and cotton amount automatic control method, equipment includes the integrated structure of being interconnected cotton filling frame and picking frame, cotton filling frame is provided with cotton storage box and stirring unit, cotton storage box is communicated with the stirring unit in the picking frame in cotton filling unit by suction unit, control early warning unit on cotton filling frame with built-in original current monitoring module stirring motor frequency converter as core control node, without additional installation any external cotton amount detection sensor, directly reuse the current sampling function of frequency converter, by preset negative feedback closed loop algorithm dynamic adjustment upstream cotton motor operating frequency, realize the self-adapting dynamic balance of cotton amount in cotton storage box, trigger overcurrent early warning and overload power-off protection in stages.The present application greatly simplifies equipment hardware structure, improves the level of equipment automation and operating efficiency, effectively avoids stirring motor overload damage, guarantees the continuous stable operation of cotton filling process.

Description

Technical Field

[0001] This invention belongs to the technical field of textile filling equipment, and particularly relates to an integrated filling and opening machine for controlling the amount of cotton fed in and an automatic cotton quantity control method. Background Technology

[0002] The cotton filling machine is the core equipment in the filling process of home textiles and plush toys. At present, the cotton quantity control of the cotton storage box of conventional cotton filling machines generally relies on manual observation and experience, or additional photoelectric and pressure external cotton quantity sensors are installed to realize cotton supply start and stop control. It is necessary to open the cotton storage box body to lay detection probes and independent signal lines, which increases the hardware cost and structural complexity of the equipment, and the equipment failure rate and maintenance cost are relatively high.

[0003] Existing overload protection solutions based on current feedback all require the additional construction of independent detection links such as current transformers and signal amplification circuits. They do not directly reuse the native Hall current detection function built into the frequency converter of the stirring motor, and cannot achieve continuous dynamic balance control of the amount of cotton in the cotton storage box without adding additional hardware. The overall automation level of the cotton filling process is low. Summary of the Invention

[0004] (a) Purpose of the invention To overcome the above shortcomings, the purpose of this invention is to provide an integrated cotton filling and opening machine for controlling the amount of cotton fed in and an automatic cotton quantity control method, so as to solve the above technical problems.

[0005] (II) Technical Solution To achieve the above objectives, the technical solution provided in this application is as follows: A cotton filling and opening integrated machine for controlling the amount of cotton fed in includes a cotton filling frame and a cotton opening frame connected to each other. The cotton filling frame has a cotton storage box, which contains a stirring unit. The cotton storage box is connected to an opening unit within the cotton opening frame via a cotton suction unit. The cotton filling frame is equipped with a control and early warning unit. The control and early warning unit includes a stirring motor frequency converter, a cotton feeding motor frequency converter, a relay, and an early warning indicator light, all interconnected by signal lines. The stirring motor frequency converter has a built-in native current monitoring module, which directly completes the closed-loop control of the entire cotton feeding process based on the current signal.

[0006] Preferably, the stirring unit includes a stirring paddle and a stirring motor. The stirring motor is equipped with a stirring motor frequency converter. The stirring motor is fixedly installed on the cotton filling machine frame. The output shaft extends into the cotton storage box to drive the stirring paddle to rotate. The top or side of the cotton storage box has a cotton inlet that is sealed and connected to the output end of the cotton suction unit.

[0007] Preferably, the cotton suction unit includes a cotton suction fan and a cotton suction pipe.

[0008] Preferably, the cotton opening unit includes a cotton feeding machine and a cotton opening machine connected vertically. The cotton feeding machine includes a cotton feeding hopper as a raw material container, two cotton feeding rollers that mesh and drive each other, and a cotton feeding motor that drives the cotton feeding rollers. The cotton feeding motor is equipped with a cotton feeding motor frequency converter. The cotton feeding port at the bottom of the cotton feeding machine is completely connected to the internal cavity of the cotton opening machine. The cotton opening machine is equipped with a cotton opening roller with a beater inside. A horizontal cotton outlet is opened at the bottom of the cotton opening machine, which is directly sealed and connected to the input end of the cotton suction unit.

[0009] Preferably, the first analog output port of the stirring motor inverter is directly electrically connected to the analog input port of the cotton feeding motor inverter, outputting a 0-10V or 4-20mA standard continuous control signal to the cotton feeding motor inverter to adjust the operating frequency of the cotton feeding motor in real time; the other two output ports of the stirring motor inverter are respectively connected to the AC power supply circuit of the warning signal light and the coil control terminal of the main circuit power contactor of the cotton feeding motor through two independent intermediate relays, so as to realize the automatic control of the start and stop of the warning signal light and the on and off of the main circuit of the cotton feeding motor.

[0010] An automatic cotton quantity control method for a cotton filling and opening integrated machine uses the frequency converter of the stirring motor as the main control node, collects the operating current of the stirring motor in real time, and sets the optimal operating current as preset. To regulate the reference value, the operating frequency of the upstream cotton feeding motor is dynamically adjusted, and the cotton quantity in the cotton storage box is maintained at a stable level through negative feedback closed-loop control, without the need to install any additional external cotton quantity detection sensors.

[0011] Preferably, four gradient current thresholds are pre-configured in the frequency converter of the stirring motor: The minimum current value required to maintain normal cotton filling; The target current value corresponding to the optimal working cotton quantity of the cotton storage box; The corresponding maximum allowable cotton quantity warning current value under normal working conditions; The maximum allowable load limit current value for the corresponding stirring motor.

[0012] The control logic corresponding to different current ranges is as follows: When the real-time current I < I_low, the cotton feeding motor is controlled to run at full speed at the highest set frequency to quickly increase the amount of cotton in the cotton storage box. When I_low≤I<I_high, the target cotton feeding frequency is calculated using an iterative formula, specifically including: ; The maximum change in a single frequency adjustment is limited to no more than 5% of the maximum operating frequency of the cotton feeding motor, ultimately constraining the target frequency to the lowest permissible frequency of the cotton feeding motor. and highest frequency Within the range, the current of the stirring motor gradually increases. convergence; when At the same time, the cotton feeding motor is controlled to run at the lowest frequency, and an audible and visual warning is triggered simultaneously to remind the operator to pay attention to the equipment status; when In such cases, the AC power supply circuit of the cotton feeding motor should be directly cut off to immediately terminate the cotton feeding and subsequent cotton opening process, thus avoiding overload damage to the mixing motor.

[0013] Preferably, after triggering the cotton feeding motor power-off protection, the system will only activate if the real-time monitored stirring motor current remains below a certain level. Only when the frequency converter of the stirring motor outputs a signal to close the power contactor of the cotton feeding motor, will the cotton feeding motor be automatically restarted to resume the cotton supply process.

[0014] Preferably, the triggering logic of the warning signal light is as follows: when the real-time current I is greater than I_high or less than I_low and exceeds the normal operating range, an audible and visual alarm is automatically triggered; when the current returns to the normal range of I_low≤I≤I_high, the alarm signal is automatically turned off.

[0015] Beneficial effects: 1. Simplify system structure and reduce hardware costs: The original current detection module built into the mixer motor frequency converter is reused as the only source of control signal. There is no need to install any external photoelectric or pressure cotton quantity detection sensors, nor is there a need to build an independent current sampling detection circuit. This reduces the space occupied by additional electrical components, avoids the common failure of external sensors due to dust accumulation in the high dust environment of textile production, and greatly reduces the burden of later equipment maintenance.

[0016] 2. Achieve adaptive dynamic balance of cotton quantity in the cotton storage box: Through negative feedback closed-loop regulation, the upstream cotton feeding frequency is dynamically adjusted to follow the actual cotton consumption speed of the cotton filling operation, so as to keep the cotton quantity in the cotton storage box stable within the optimal working range. This avoids the risk of abnormal cotton accumulation leading to overload and damage to the stirring motor under the traditional manual control mode, and also avoids the problem of insufficient cotton supply causing material interruption and idle running of the cotton filling operation, thus ensuring the continuous and stable operation of the cotton filling process.

[0017] 3. Significant energy saving and consumption reduction: The cotton storage box maintains the minimum cotton quantity level corresponding to the optimal working state for a long time, which greatly reduces the running resistance of the stirring paddle rotation and effectively reduces the operating power consumption of the stirring motor. At the same time, the cotton feeding motor adopts continuous variable frequency stepless speed regulation throughout the process, avoiding the impact performance consumption of the traditional industrial frequency start-stop control mode, and the overall operating energy efficiency is significantly improved.

[0018] 4. High degree of equipment integration and automation: The cotton opening unit and the cotton filling unit are integrated on an interconnected integrated frame. The whole machine has a compact structure and occupies a much smaller area than the traditional split cotton opening-filling production line. On-site installation and commissioning are convenient. The entire process can automatically complete the control of cotton supply speed and abnormal status warning without manual intervention. The overall automation level of the equipment is greatly improved. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is an internal structure diagram according to one embodiment of the present invention; Figure 3 This is a flowchart of the method of the present invention. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the following detailed embodiments are described in conjunction with the appendix. Figure 1-3 The present invention will be described in further detail below. It should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0021] The present invention provides an integrated structural design that interconnects the cotton filling frame 1 and the cotton opening frame 8 into a compact whole. The cotton filling frame 1 is equipped with a cotton storage box 2, and a stirring unit is installed inside the cotton storage box 2. The cotton inlet channel of the cotton storage box 2 is directly connected to the cotton opening unit inside the cotton opening frame through the cotton suction unit. All cotton filling, cotton opening, and cotton suction related functional components are integrated on the same frame, which completely solves the pain points of traditional split cotton opening and filling production lines, such as large footprint and complex installation and debugging.

[0022] The mixing unit consists of a mixing paddle 3 and a matching variable frequency mixing motor 12. The mixing motor 12 is fixedly mounted on the cotton filling frame 1, and its output shaft extends into the cotton storage box 2 to drive the mixing paddle 3 to rotate continuously, continuously breaking up the fluffy cotton to prevent clumping and blockage. The cotton inlet on the top or side of the cotton storage box 2 is sealed and connected to the output end of the cotton suction unit. The cotton suction unit consists of a cotton suction fan 13 and a cotton suction pipe 16. The cotton suction fan includes a cotton suction motor and an impeller. During the operation of the whole machine, the suction air volume of the cotton suction fan 13 remains constant. All the fluffy cotton output by the cotton opening unit can be sent into the cotton storage box 2 through the cotton suction pipe 16. The cotton supply speed is completely determined by the cotton feeding speed of the cotton opening unit. Efficient conveying of all the opened cotton material can be achieved without additional adjustment of the fan operating parameters.

[0023] The cotton opening unit consists of a cotton feeding machine and a cotton opening machine connected vertically. The top of the cotton feeding machine is equipped with a cotton feeding hopper 7, which serves as a raw material container. Inside, two cotton feeding rollers 17 with interlocking transmission are installed and driven by an independent cotton feeding motor. The cotton feeding motor is equipped with an independent cotton feeding motor frequency converter. The cotton feeding port at the bottom of the cotton feeding machine is completely connected to the internal cavity of the cotton opening machine. The cotton opening machine is equipped with a rotating cotton opening roller 18 with a hard beater. The bottom of the cotton opening machine has a horizontal cotton outlet that is directly sealed and connected to the input end of the cotton suction unit. The raw cotton is fed into the cotton opening machine at a uniform speed through the cotton feeding roller. After being fully opened into uniform and fluffy cotton by the high-speed tearing action of the cotton opening roller beater, it is then transported to the cotton storage box by the cotton suction unit to complete the subsequent cotton filling process.

[0024] The cotton filling frame 1 is equipped with a control and early warning unit 15. All components inside the control and early warning unit are interconnected through standard signal lines. The core components include the stirring motor frequency converter, the cotton feeding motor frequency converter, the intermediate relay, and the early warning indicator light 4. The stirring motor frequency converter has a built-in native current monitoring module, which can obtain the full operating current of the stirring motor in real time without the need for an additional external sampling circuit. Based on the real-time current signal, the closed-loop control of the cotton feeding process of the whole machine can be directly completed.

[0025] The first analog output port of the stirring motor inverter is directly electrically connected to the analog input port of the cotton feeding motor inverter, outputting an industrial standard 0-10V or 4-20mA continuous control signal to the cotton feeding motor inverter to smoothly adjust the operating frequency of the cotton feeding motor in real time. The other two output ports of the stirring motor inverter are respectively connected to the AC power supply circuit of the warning signal light and the coil control terminal of the main circuit power contactor of the cotton feeding motor through two independent intermediate relays, realizing automatic control of the start and stop of the warning signal light and the on and off of the main circuit of the cotton feeding motor. It fully complies with the industrial electrical safety design specifications, and the low-voltage control signal is completely isolated from the high-voltage power circuit, greatly improving the long-term operational reliability.

[0026] The automatic cotton quantity control method of this invention uses the frequency converter of the stirring motor as the sole main control node, directly calling the built-in native current detection module of the frequency converter to collect the operating current of the stirring motor in real time, and using the preset optimal operating current. As a negative feedback control reference, the operating frequency of the upstream cotton feeding motor is dynamically adjusted. Through negative feedback closed-loop control, the cotton quantity in the storage box is maintained at a stable level. No additional external photoelectric or pressure-type cotton quantity detection sensors are required throughout the process, fundamentally avoiding the common failure of external sensors due to dust accumulation in high-dust textile production environments. Before formal operation, four gradient current thresholds are pre-configured in the parameter area of ​​the stirring motor frequency converter. This corresponds to the minimum current value required to maintain normal cotton filling. The target current value corresponding to the optimal working cotton quantity of the cotton storage box. The corresponding maximum allowable cotton quantity warning current value under normal operation. Based on the maximum allowable load limit current value of the mixing motor, the equipment can automatically enter an unattended closed-loop control process after startup.

[0027] The graded control logic corresponding to different current ranges is executed automatically throughout the entire process: When the real-time current I < I_low, it is determined that the amount of cotton in the cotton storage box is lower than the minimum value required for normal filling. The cotton feeding motor is immediately controlled to run at full speed at the highest set frequency to quickly increase the amount of cotton in the cotton storage box and quickly reach the cotton quantity standard required for normal filling, thus avoiding material shortage and interruption in the filling operation. When I_low≤I<I_high, the system enters the steady-state fine-tuning range, using a preset iterative formula: ; Calculate the target cotton feeding frequency, while limiting the maximum change in a single frequency adjustment to no more than 5% of the maximum operating frequency of the cotton feeding motor. This prevents sudden changes in cotton feeding speed from causing significant fluctuations in the cotton supply. Ultimately, the target frequency is constrained to the lowest allowable frequency of the cotton feeding motor. and highest frequency Within the range, the current of the stirring motor gradually increases. The cotton storage box maintains a stable level within the optimal working range, with smooth convergence. when If the cotton quantity is determined to be too high and close to the overload threshold, the cotton feeding motor is immediately controlled to run at the lowest frequency, and an audible and visual warning is triggered simultaneously to remind the operator to pay attention to the equipment status, so as to prevent the cotton quantity from continuing to rise and triggering the overload protection shutdown. when When the cotton quantity reaches the limit overload threshold, the AC power supply circuit of the cotton feeding motor is directly cut off, and the cotton feeding and subsequent cotton opening process are immediately terminated, thus preventing the mixing motor from being overloaded and damaged at the source.

[0028] After the cotton feeding motor is triggered for power failure protection, the control system will not immediately restart the cotton feeding process. Only when the current of the stirring motor monitored in real time is continuously lower than I_low, and it is confirmed that the amount of cotton in the cotton storage box has returned to the safe range, will the frequency converter of the stirring motor output a signal to close the power contactor of the cotton feeding motor, automatically restart the cotton feeding motor and restore the cotton supply process. This avoids frequent start and stop of the cotton feeding motor caused by current fluctuations and effectively extends the service life of the equipment.

[0029] The triggering logic of the warning signal light is fully linked to the current judgment result: when the real-time current I is greater than I_high or less than I_low and exceeds the normal operating range, an audible and visual alarm is automatically triggered. When the current returns to the normal range of I_low≤I≤I_high, the alarm signal is automatically turned off. The abnormal status reminder is clear and intuitive, and no manual intervention is required.

[0030] This invention achieves adaptive dynamic balance of cotton quantity in the cotton storage box without the need for any external cotton quantity detection components, significantly reducing equipment hardware costs and subsequent maintenance burden. It automatically adjusts the cotton supply rhythm according to the actual cotton filling speed throughout the process, avoiding motor overload failures caused by cotton accumulation under manual control mode, and also preventing the problem of cotton supply interruption and idle running due to insufficient cotton supply. The cotton storage box maintains the optimal low cotton quantity operating state for a long time, greatly reducing the running resistance of the stirring paddle and effectively reducing the power consumption of the whole machine. The machine has a high degree of automation and does not require manual intervention throughout the operation, significantly improving the continuity of cotton filling operation and production efficiency.

[0031] It should be noted that, in this document, relational terms such as "first" and "second" are used only 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. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0032] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A cotton filling and opening integrated machine for controlling the amount of cotton fed, characterized in that, The device includes an interconnected filling frame and a cotton opening frame. The filling frame contains a cotton storage box, which in turn contains a stirring unit. The cotton storage box is connected to an opening unit within the opening frame via a cotton suction unit. The filling frame is equipped with a control and early warning unit. The control and early warning unit includes a stirring motor frequency converter, a cotton feeding motor frequency converter, a relay, and an early warning indicator light, all interconnected by signal lines. The stirring motor frequency converter has a built-in native current monitoring module, which directly completes the closed-loop control of the entire cotton feeding process based on the current signal.

2. The cotton filling and opening integrated machine for controlling the amount of cotton fed according to claim 1, characterized in that, The stirring unit includes a stirring paddle and a stirring motor. The stirring motor is equipped with a stirring motor frequency converter. The stirring motor is fixedly installed on the cotton filling machine frame. The output shaft extends into the cotton storage box to drive the stirring paddle to rotate. The top or side of the cotton storage box has a cotton inlet that is sealed and connected to the output end of the cotton suction unit.

3. The cotton filling and opening integrated machine for controlling the amount of cotton fed according to claim 1, characterized in that, The cotton suction unit includes a cotton suction fan and a cotton suction pipe.

4. The cotton filling and opening integrated machine for controlling the amount of cotton fed according to claim 1, characterized in that, The cotton opening unit includes a cotton feeding machine and a cotton opening machine connected vertically. The cotton feeding machine includes a cotton feeding hopper that serves as a raw material container, two cotton feeding rollers that mesh and drive each other, and a cotton feeding motor that drives the cotton feeding rollers. The cotton feeding motor is equipped with a frequency converter. The cotton feeding port at the bottom of the cotton feeding machine is completely connected to the internal cavity of the cotton opening machine. The cotton opening machine is equipped with a cotton opening roller with a beater inside. A horizontal cotton outlet is opened at the bottom of the cotton opening machine, which is directly and sealed to the input end of the cotton suction unit.

5. The cotton filling and opening integrated machine for controlling the amount of cotton fed according to claim 1, characterized in that, The first analog output port of the stirring motor inverter is directly electrically connected to the analog input port of the cotton feeding motor inverter, outputting a 0-10V or 4-20mA standard continuous control signal to the cotton feeding motor inverter to adjust the operating frequency of the cotton feeding motor in real time. The other two output ports of the stirring motor inverter are respectively connected to the AC power supply circuit of the warning signal light and the coil control terminal of the main circuit power contactor of the cotton feeding motor through two independent intermediate relays, realizing automatic control of the start and stop of the warning signal light and the on and off of the main circuit of the cotton feeding motor.

6. An automatic cotton quantity control method for a cotton filling and opening integrated machine, implemented based on the cotton feeding and opening integrated machine for controlling cotton quantity as described in any one of claims 1-5, characterized in that, Using the frequency converter of the mixing motor as the main control node, the operating current of the mixing motor is collected in real time, and the optimal operating current is preset. To regulate the reference value, the operating frequency of the upstream cotton feeding motor is dynamically adjusted, and the cotton quantity in the cotton storage box is maintained at a stable level through negative feedback closed-loop control, without the need to install any additional external cotton quantity detection sensors.

7. The automatic cotton quantity control method for a cotton filling and opening integrated machine according to claim 6, characterized in that, Four gradient current thresholds are pre-configured in the mixer motor frequency converter: The minimum current value required to maintain normal cotton filling; The target current value corresponding to the optimal working cotton quantity of the cotton storage box; The corresponding maximum allowable cotton quantity warning current value under normal working conditions; The maximum allowable load limit current value for the corresponding stirring motor; The control logic corresponding to different current ranges is as follows: When the real-time current I < I_low, the cotton feeding motor is controlled to run at full speed at the highest set frequency to quickly increase the amount of cotton in the cotton storage box. When I_low≤I<I_high, the target cotton feeding frequency is calculated using an iterative formula, specifically including: ；； The maximum change in a single frequency adjustment is limited to no more than 5% of the maximum operating frequency of the cotton feeding motor, ultimately constraining the target frequency to the lowest permissible frequency of the cotton feeding motor. and highest frequency Within the range, the current of the stirring motor gradually increases. convergence; when At the same time, the cotton feeding motor is controlled to run at the lowest frequency, and an audible and visual warning is triggered simultaneously to remind the operator to pay attention to the equipment status; when In such cases, the AC power supply circuit of the cotton feeding motor should be directly cut off to immediately terminate the cotton feeding and subsequent cotton opening process, thus avoiding overload damage to the mixing motor.

8. The automatic cotton quantity control method for a cotton filling and opening integrated machine according to claim 7, characterized in that, After triggering the cotton feeding motor power-off protection, the stirring motor current will only be lower than the real-time monitored value if it remains below the specified value. Only when the frequency converter of the stirring motor outputs a signal to close the power contactor of the cotton feeding motor, will the cotton feeding motor be automatically restarted to resume the cotton supply process.

9. The automatic cotton quantity control method for a cotton filling and opening integrated machine according to claim 7, characterized in that, The triggering logic of the warning signal light is as follows: when the real-time current I is greater than I_high or less than I_low and exceeds the normal operating range, an audible and visual alarm is automatically triggered. When the current returns to the normal range of I_low≤I≤I_high, the alarm signal is automatically turned off.

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