A functional fabric heat setting process parameter self-adaptive adjusting method

Abstract

The present application belongs to the technical field of fabric heat setting, and particularly relates to a functional fabric heat setting process parameter self-adaptive adjusting method, which comprises the following steps: obtaining the highest temperature of a box and the lowest temperature of the box; calculating a real-time space temperature difference; obtaining a safety temperature difference limit; obtaining a fabric tension data set through a tension detection sensor; obtaining a fabric tension rate; calculating a scratch risk index; obtaining an over-limit temperature value; outputting a target deceleration ratio; obtaining a terminal protection instruction; and generating a dynamic reset instruction after executing the terminal protection instruction. The present application solves the technical problem that the prior art controls temperature and tension separately, uses average temperature calculation to cover up the space temperature difference feature, and causes the system to misjudge the tension increase and incorrectly execute inward force leakage to cause fabric size defects, and high-temperature and high-tension fabric and the support mechanism high-speed friction under fixed speed cause the surface layer coating scratch.

Description

Technical Field

[0001] This invention relates to the field of fabric heat setting technology. More specifically, this invention relates to an adaptive adjustment method for heat setting process parameters of functional fabrics. Background Technology

[0002] In the field of modern textile and functional fabric processing control technology, heat setting is a core process for eliminating internal stress accumulated in fabrics during the weaving process and ensuring the stability of fabric shape and dimensions. Heat setting of functional fabrics is not simply a matter of heating and drying; it is a complex evolutionary process involving the thermoplastic phase transition of polymer fibers, the thermodynamics of spatial fluids, and the deep coupling of dynamic mechanical tension. To ensure the dimensional stability and surface coating quality of functional fabrics after heat setting, accurate multi-dimensional coordinated control of heat distribution, transient tension, and processing speed is required during the heat setting process.

[0003] In related technologies, for example, Chinese patent document CN116145357B discloses a fabric steam setting machine and its control method. The document describes a method that uses a temperature monitoring sensor to acquire the temperature at various points inside the setting chamber and calculates the average value. This average value is then compared with a corresponding standard to control the steam temperature. Simultaneously, a tension detection sensor acquires the support tension. When the tension deviates from the set range, the drive motor is directly controlled to expand or contract the edge support plate outwards or inwards. This control method can achieve basic temperature and tension regulation when processing ordinary fabrics, when the heat field inside the setting chamber is relatively uniform, and when the operating conditions are relatively stable.

[0004] However, analysis of the performance of existing technologies in the actual processing of functional fabric heat setting reveals that this control architecture, which separates temperature control from tension control and relies on global average values ​​and static decoupling, has the drawback of not considering the underlying control conflicts caused by the thermoplastic physical phase transitions and thermodynamic causality of polymer fabrics.

[0005] First, a spatial temperature gradient exists within the actual thermal field of the steam setting chamber. Current technology uses an arithmetic average of multiple temperature measurement points; this mathematical dimensionality reduction masks the unique temperature differences within the chamber. When both localized overheating and undercooling occur simultaneously within the chamber, the calculated average may fall within the normal range, leading the system to misinterpret it as a stable environment. This results in the fabric experiencing repeated thermal shocks from alternating high and low temperatures as it is conveyed through different temperature zones, causing an imbalance in the setting shrinkage rate across different areas.

[0006] Secondly, functional fabrics exhibit thermosensitive shrinkage during the thermoplastic phase transition. When the fabric abruptly transitions from a low-temperature zone to a locally overheated zone, the temperature difference triggers rapid thermal shrinkage of the fibers, directly causing a rapid increase in the absolute tension value collected by the tension sensor. Current technology does not consider this thermodynamic causal sequence. Due to the lack of an underlying mechanism in the control system to sequentially investigate the causal relationship between the localized temperature difference and the sudden increase in tension, the system simply controls the drive motor to perform an inward contraction mechanical force release action as soon as it detects an increase in tension. This simplistic feedback logic not only masks the physical cause of the fabric undergoing thermoplastic distortion in a locally high-temperature zone, but also, due to the mechanical retreat of the mechanical frame, causes the fabric to lose the shaping tension required to maintain its dimensions when it subsequently enters the normal temperature zone.

[0007] Finally, during the high tension caused by the aforementioned transient thermal shrinkage, the speed of the machine in existing solutions is often kept constant. This fixed speed control forces the functional fabric, which is under taut tension and thermoplastic conditions, to engage in prolonged high-speed relative friction with the support structure, ultimately causing abrasions or even coating peeling on the fabric surface structure. Summary of the Invention

[0008] To address the technical problems of existing technologies that separate temperature and tension control, use average temperature calculations to mask spatial temperature difference characteristics, fail to identify fabric thermal shrinkage caused by localized overheating, leading to the system misjudging increased tension and incorrectly executing inward force relief, resulting in fabric dimensional defects, and causing surface coating abrasion due to high-speed friction between the high-temperature, high-tension fabric and the support mechanism at a fixed speed, this invention provides an adaptive adjustment method for heat setting process parameters of functional fabrics, including:

[0009] S1: Collect temperature data within the control cycle to obtain the highest and lowest temperatures of the chamber; S2: Perform algebraic difference calculation on the highest and lowest temperatures of the chamber to calculate the real-time spatial temperature difference; Based on the mean and standard deviation of fluctuations pre-acquired during the steady-state test phase, perform superposition calculation of the natural tolerance distribution to obtain the safe temperature difference limit; Obtain the fabric tension dataset through the tension detection sensor; Based on the fabric tension dataset, perform transient derivative calculation of the fabric force to obtain the fabric tension rate; S3: Based on the real-time spatial temperature difference and fabric tension rate, perform scalar multiplication calculation of multiple factors to calculate the abrasion risk index; Obtain the over-limit temperature value according to the difference between the real-time spatial temperature difference and the safe temperature difference limit; Perform dimensionality reduction proportional mapping on the over-limit temperature value and the safe temperature difference limit to output the target deceleration ratio; S4: Based on the target deceleration ratio, perform cross-layer pipe connection operation of blocking force release and coordinated deceleration compensation to obtain the terminal protection command; After executing the terminal protection command, generate a dynamic reset command.

[0010] Existing heat setting controls for functional fabrics separate temperature and tension control, using average temperature calculations to mask spatial temperature difference characteristics. This fails to identify fabric thermal shrinkage caused by localized overheating, leading to misjudgment of increased tension and incorrect inward force release, resulting in dimensional defects in the fabric. Furthermore, high-speed friction between the high-temperature, high-tension fabric and the support mechanism at a fixed speed causes surface coating abrasion. This invention addresses these shortcomings by extracting the highest and lowest temperatures within the chamber during the same cycle to calculate the real-time spatial temperature difference, and adaptively generating a safe temperature difference limit based on steady-state test data. It calculates the fabric tension rate through tension differential calculation, and integrates temperature difference, tension change rate, and motor speed to generate an abrasion risk index to calculate abrasion risk. Upon confirmation of thermal shrinkage, a cross-layer control system is implemented to block erroneous force release commands to maintain fabric dimensions. Simultaneously, it dynamically reduces speed according to the target reduction ratio and activates localized cooling air, achieving multi-dimensional collaborative protection. After the thermal field recovers, a delayed and stable reset is achieved, and the heating power settings for each temperature zone are dynamically adjusted, ensuring multi-dimensional collaborative protection.

[0011] Preferably, obtaining the highest and lowest temperatures of the enclosure includes: A dedicated data buffer area is created in the controller's memory to establish a real-time data channel between the array temperature detectors inside the molding box and the central processing unit. Temperature data output by each detection node is received synchronously at the sampling rate. At the same time, the temperature data output by each detection node within the same control cycle is compared one by one in the comparison register of the central processing unit, and the current maximum and minimum values ​​are updated in real time. At the end of the control cycle, the current maximum and minimum values ​​are determined as the highest temperature and lowest temperature of the box, respectively.

[0012] Preferably, calculating the real-time spatial temperature difference includes: Using the highest temperature in the chamber as the reference point for the thermal field peak and the lowest temperature in the chamber as the reference point for the thermal field trough, a dimension reduction subtraction operation is performed to calculate the difference in the span between the two in physical space, and the real-time spatial temperature difference is calculated. At the same time, the historical statistical database of the manufacturing execution system is accessed through the communication interface to call the historical average temperature difference of the current fabric batch during the steady-state trial stage, and the standard deviation of the temperature difference corresponding to the historical average temperature difference is extracted simultaneously.

[0013] Preferably, a safe temperature difference limit is obtained, and a fabric tension dataset is acquired using a tension detection sensor, including: The historical average temperature difference, representing the baseline trend, and the standard deviation of the temperature difference, representing the fluctuation amplitude, are linearly superimposed with the same dimensions to obtain the upper limit boundary value covering the background noise of the normal process. The safe temperature difference limit is then calculated. In addition, a hardware feedback link with the tension detection sensor is established to capture the current tension of the fabric in real time. The tension data of the previous frame in the register is cached as the previous tension of the fabric. The underlying hardware clock counter is called synchronously to record the actual time span between the two samplings, which is determined as the data sampling interval. The current tension of the fabric, the previous tension of the fabric, and the data sampling interval are recorded as the fabric tension dataset.

[0014] This invention linearly superimposes the historical average temperature difference with the standard deviation of the temperature difference to obtain the safe temperature difference limit. Simultaneously, it establishes a hardware feedback link for tension sensors, collecting current tension, previous tension, and sampling intervals, and packaging them into a fabric tension dataset. The safe temperature difference limit is adaptively generated based on the actual operating data of the current batch of fabric, replacing the fixed threshold hard-coded at the factory, and can automatically adjust the tolerance range according to the fabric type. The tension dual-frame buffer and timestamp recording provide a time-series data foundation for subsequent tension change rate calculations.

[0015] Preferably, obtaining the fabric tension rate includes: Extract the current fabric tension, previous fabric tension, and data sampling interval from the preceding data. Perform a first-order difference operation in the discrete time domain in the numerical calculation module. First, calculate the incremental feature obtained by subtracting the previous fabric tension from the current fabric tension. Then, project this incremental feature onto the time coordinate system and perform a normalized division operation based on the data sampling interval to obtain the convergence slope mapping value in the unit time dimension. Solve for the fabric tension rate. Simultaneously, establish an industrial communication link with the main drive frequency converter to monitor the drive motor speed fed back by the encoder in real time.

[0016] This invention calculates the tension increment using first-order difference in the discrete time domain, then normalizes it by dividing by the sampling interval to obtain the tension change rate per unit time, i.e., the fabric tension rate. Simultaneously, it monitors the drive motor speed fed back from the main drive inverter in real time. This method upgrades static absolute tension detection to dynamic tension change trend detection, enabling the differentiation between normal process stretching and sudden thermal shock shrinkage. It captures the instantaneous characteristics of thermoplastic deformation of the fabric in high-temperature regions in advance, providing dynamic evidence for determining the cause of thermal shrinkage.

[0017] Preferably, the calculation of the abrasion risk index includes: Extract the real-time spatial temperature difference, fabric tension rate, and drive motor speed obtained in the previous calculation. Perform multi-dimensional risk factor coupling operation in the data calculation module. Perform scalar multiplication operation on the real-time spatial temperature difference, fabric tension rate, and drive motor speed across physical dimensions as independent physical factors. Fold and reconstruct the discrete single-dimensional risk into a unified risk feature quantity, and calculate the abrasion risk index.

[0018] This invention performs a scalar multiplication of three independent risk factors across physical dimensions—real-time spatial temperature difference, fabric tension rate, and drive motor speed—to couple them into a unified abrasion risk index. This method integrates three factors causing fabric coating abrasion—environmental thermal field distortion, sudden fabric shrinkage, and relative mechanical motion speed—into a single index, assessing the risk level of abrasion and peeling of the fabric surface at the system level, thus avoiding omissions and misjudgments inherent in single-factor assessments.

[0019] Preferably, obtaining the over-limit temperature value includes: Extract the real-time spatial temperature difference and the safe temperature difference boundary calculated in the previous step. Perform an out-of-bounds differential operation of the safety margin in the numerical comparison module. Set the real-time spatial temperature difference as the dynamic system input feature and the safe temperature difference boundary as the lower bound of the static truncation envelope. Calculate the scalar redundancy part of the dynamic system input feature minus the lower bound of the static truncation envelope to obtain the out-of-limit temperature value.

[0020] Preferably, the target deceleration ratio is output, including: Extract the over-limit temperature value and the safe temperature difference limit calculated in the previous step. Perform a dimensionality reduction ratio operation for benchmark normalization in the data conversion module. Use the over-limit temperature value as the target deviation feature quantity and the safe temperature difference limit as the full-range benchmark scale. Divide the target deviation feature quantity by the full-range benchmark scale to calculate the relative occupancy weight. Remove the physical dimensions through division logic to obtain the target deceleration ratio.

[0021] This invention uses a normalized division method based on a safe temperature difference limit to map the excessive temperature value into a dimensionless target deceleration ratio. This method achieves a smooth conversion between physical temperature deviation and motor control parameters through proportional dimensionality reduction. It dynamically matches the deceleration amplitude according to the degree of exceeding the limit, which can reduce the relative friction speed under high temperature and high tension to protect the fabric, while avoiding the production cycle loss caused by fixed large deceleration, thus achieving a balance between quality and efficiency.

[0022] Preferably, obtaining the terminal protection command includes: Once it is determined that the real-time spatial temperature difference exceeds the safe temperature difference limit, and simultaneously it is determined that the aforementioned fabric tension rate exceeds the pre-acquired tension rate judgment threshold, the system, in conjunction with the aforementioned abrasion risk index, confirms that the current fabric has encountered an extreme temperature difference and is undergoing thermoplastic shrinkage; the control system initiates takeover, blocking the inward contraction and force release command sent by the original tension control module to the support drive mechanism, and outputs a stop force release command to maintain the existing mechanical support frame to ensure the final size of the fabric; a motor deceleration command is generated according to the target deceleration ratio, and the mechanical operating frequency is reduced to reduce relative friction under high temperature and high tension; and a cold air activation command is simultaneously sent to the local highest temperature zone; at the same time, the over-temperature zone is located according to the spatial position corresponding to the over-limit temperature value, and the heating power setting value of the corresponding temperature zone is dynamically adjusted according to the target deceleration ratio.

[0023] Preferably, generating a dynamic reset command includes: The control system executes the terminal protection command and continuously monitors the real-time space temperature difference. When the real-time space temperature difference recovers to no greater than the safe temperature difference limit, the reset timing begins. After maintaining the protection state for the reset delay time, a dynamic reset command is generated to cancel the stop discharge command, gradually restore the drive motor speed, and shut down the corresponding local cooling device.

[0024] The beneficial effects of this invention are as follows: This invention relies on the array temperature sensor, tension detection sensor and motor encoder data already deployed in the existing heat setting machine to realize all control logic, without the need to install additional hardware equipment such as temperature and speed measuring devices, the equipment modification cost is extremely low, the control algorithm can be directly integrated into the existing heat setting machine PLC control system, and can be quickly deployed on heat setting equipment for functional fabrics of various fiber materials such as cotton, polyester, nylon and spandex. The algorithm automatically generates suitable safety temperature difference limits based on steady-state trial data of each batch of fabrics. This eliminates the need for process engineers to repeatedly adjust temperature and tension threshold parameters manually according to fabric type, significantly reducing reliance on the experience of senior process engineers and minimizing changeover and fabric loss during trial runs. A multi-dimensional collaborative protection mechanism involving temperature, tension, speed, and cooling air ensures the dimensional stability and integrity of the functional fabric coating after heat setting. Proportional speed reduction control avoids production losses caused by sudden shutdowns. This effectively reduces common defects such as fabric abrasions, dimensional deviations, and coating peeling in the heat setting process, while also reducing equipment wear caused by frequent mechanical start-ups and shutdowns. It comprehensively improves the yield, production efficiency, and operational stability of the functional fabric heat setting process, providing a cost-effective and easily implementable reliable technical solution for the intelligent and precise control of heat setting processes in the textile printing and dyeing industry. Attached Figure Description

[0025] Figure 1 This schematically illustrates a flowchart of an adaptive adjustment method for heat setting process parameters of functional fabrics according to the present invention; Figure 2 This diagram illustrates the relationship between the timing of multiple heat setting parameters and the abrasion risk index in this invention. Figure 3 The schematic diagram illustrates the principle of fabric tension rate detection and thermoplastic shrinkage determination in this invention. Detailed Implementation

[0026] This invention discloses an adaptive adjustment method for heat setting process parameters of functional fabrics, referring to... Figure 1 This includes steps S1-S4: S1: Obtain the highest and lowest temperatures of the enclosure.

[0027] It should be noted that in the heat setting process of functional fabrics, the heat flow distribution inside the setting box is dynamically changing. Existing control systems typically only collect the global temperature average. This dimensional reduction in data acquisition loses the physical details of local thermal shocks, leading to misjudgments by the control system when faced with local overheating. This invention extracts extreme value data characterizing the extreme state of the environment, preserving the changing characteristics of the multidimensional physical field from the information source, thus laying a data foundation for subsequent thermodynamic causal deduction and coordinated control.

[0028] Specifically, temperature data is collected during the control cycle to obtain the highest and lowest temperatures of the enclosure, including: A dedicated data buffer area is created in the controller's memory to establish a real-time data channel between the array temperature detectors inside the molding box and the central processing unit. Temperature data output by each detection node is received synchronously at the sampling rate. At the same time, the temperature data output by each detection node within the same control cycle is compared one by one in the comparison register of the central processing unit, and the current maximum and minimum values ​​are updated in real time. At the end of the control cycle, the current maximum and minimum values ​​are determined as the highest temperature and lowest temperature of the box, respectively.

[0029] It should be noted that the highest and lowest temperatures of the enclosure refer to the peak and valley values ​​of the thermal field captured by the array detector within the same control cycle. These values ​​characterize the discrete distribution of the fluid thermodynamics inside the shaping enclosure. Obtaining the highest and lowest temperatures of the enclosure aims to preserve the existing environmental change characteristics from the data source.

[0030] At this point, the highest and lowest temperatures of the enclosure were obtained.

[0031] S2: Obtain the fabric tension rate.

[0032] It should be noted that due to airflow disturbances or differences in the distribution of heating tubes, the steam setting chamber exhibits spatial discontinuities of localized overheating and undercooling, a physical phenomenon present in industrial production. Existing temperature monitoring solutions typically only focus on the global arithmetic mean of the temperature measurement points, resulting in the system's inability to distinguish between stable environments and alternating thermal shocks. This invention overcomes the limitations of mean calculation by directly separating the difference between the highest and lowest temperatures, reconstructing the thermodynamic discontinuity morphology inside the setting chamber in digital space. This ensures that subsequent systems can identify the energy source causing transient thermal shrinkage of the fabric.

[0033] Specifically, an algebraic difference calculation is performed on the highest and lowest temperatures within the enclosure to calculate the real-time temperature difference, including: Using the highest temperature in the chamber as the reference point for the thermal field peak and the lowest temperature in the chamber as the reference point for the thermal field trough, a dimension reduction subtraction operation is performed to calculate the difference in the span between the two in physical space, and the real-time spatial temperature difference is calculated. At the same time, the historical statistical database of the manufacturing execution system is accessed through the communication interface to call the historical average temperature difference of the current fabric batch during the steady-state trial stage, and the standard deviation of the temperature difference corresponding to the historical average temperature difference is extracted simultaneously.

[0034] It should be noted that the real-time spatial temperature difference refers to the difference between the high-temperature zone and the low-temperature zone inside the shaping chamber within the current control cycle. It characterizes the intensity of transient thermodynamic shock suffered by the fabric when it is transported through different temperature zones. Constructing this real-time spatial temperature difference aims to establish the source index of thermodynamic shock. This invention uses algebraic operations in the pure digital domain to remove the masking effect of the arithmetic mean, revealing the local thermal discontinuity hidden behind the mean.

[0035] Thus, the real-time spatial temperature difference, which characterizes the degree of thermal difference inside the shaping chamber and the intensity of transient thermal shock during the current control cycle, was obtained.

[0036] It should be noted that functional fabrics of different materials and thicknesses have varying tolerances to temperature differences in the environment. Existing control systems often use factory-coded static thresholds as alarm lines. This fixed static setting is prone to false alarms or missed alarms when switching between multiple fabric types. This invention does not use manually set empirical constants, but introduces the natural fluctuation statistical laws established by the current fabric batch in a steady state. Through endogenous data, it generates an error-proof envelope that adaptively floats according to the fabric characteristics, providing a physical benchmark for the judgment system.

[0037] Preferably, based on the mean and standard deviation of fluctuations pre-obtained during the steady-state testing phase, a superposition calculation of the natural tolerance distribution is performed to obtain the safe temperature difference limit. Then, a fabric tension dataset is obtained using a tension detection sensor, including: The historical average temperature difference and standard deviation of the temperature difference are extracted from the preceding data. Statistical tolerance offset calculation is performed in the numerical calculation module. The historical average temperature difference, which represents the baseline trend, and the standard deviation of the temperature difference, which represents the fluctuation amplitude, are linearly superimposed with the same dimensions to obtain the upper limit boundary value covering the background noise of the normal process. The safe temperature difference limit is then calculated. In addition, a hardware feedback link with the tension detection sensor is established to capture the current tension of the fabric in real time. The tension data of the previous frame in the register is cached as the previous tension of the fabric. The underlying hardware clock counter is synchronously called to record the actual time span between the two samplings, which is determined as the data sampling interval. The current tension of the fabric, the previous tension of the fabric, and the data sampling interval are recorded as the fabric tension dataset.

[0038] It should be noted that the safe temperature difference limit refers to the upper limit of normal temperature difference fluctuation determined based on historical temperature difference data of the current fabric batch during the steady-state trial phase. It is used to determine whether the real-time spatial temperature difference exceeds the normal process fluctuation range. Constructing this safe temperature difference limit aims to provide a reference system for subsequent adaptive interception. The aforementioned linear superposition is specifically the sum of the historical temperature difference mean and twice the standard deviation of the temperature difference. Taking twice the standard deviation can cover more than 95% of the normal process fluctuation range, filtering out false alarms caused by airflow disturbances and sensor noise, while ensuring that genuine thermal anomalies are not missed, thus providing an adaptive safety judgment boundary for fabrics of different materials.

[0039] Thus, the safe temperature difference limit, which characterizes the upper limit of normal temperature difference fluctuation of the current fabric batch under steady-state processing conditions, was obtained.

[0040] It should be noted that when polymer functional fabrics pass through areas of localized overheating, the spatial temperature difference triggers a thermosensitive shrinkage effect in the fiber's underlying layer, manifesting as an increase in physical tension. Existing monitoring methods only focus on whether the absolute tension value exceeds the standard, lacking dynamic trend recording over time. This makes it impossible for the backend to distinguish whether the tension change originates from normal process stretching or distortion caused by thermal shock. This invention introduces a time micro-element to convert static tension readings into dynamic rate characteristics that characterize the intensity of sudden force changes, enabling the calculation and early warning of the fabric's thermal shock shrinkage trend.

[0041] Preferably, based on the fabric tension dataset, the transient derivative of the fabric stress is calculated to obtain the fabric tension rate, including: Extract the current fabric tension, previous fabric tension, and data sampling interval from the preceding data. Perform a first-order difference operation in the discrete time domain in the numerical calculation module. First, calculate the incremental feature obtained by subtracting the previous fabric tension from the current fabric tension. Then, project this incremental feature onto the time coordinate system and perform a normalized division operation based on the data sampling interval to obtain the convergence slope mapping value in the unit time dimension. Solve for the fabric tension rate. Simultaneously, establish an industrial communication link with the main drive frequency converter to monitor the drive motor speed fed back by the encoder in real time.

[0042] It should be noted that fabric tension rate refers to the force derivative of the fabric within a unit time window. It characterizes the dynamic characteristics of physical shrinkage of the fabric when subjected to localized thermal shock. Constructing this fabric tension rate aims to obtain the characteristics of fabric shrinkage under thermal shock. This invention reconstructs the transient derivative of the fabric force in the time dimension, transforming from numerical monitoring to dynamic trend early warning. The drive motor speed characterizes the current mechanical operating cycle of the equipment, and its early extraction facilitates the subsequent embedding of vehicle speed parameters in the coupling calculation.

[0043] Thus, the fabric tension rate, which characterizes the physical shrinkage under thermal shock, was obtained.

[0044] S3: Output target deceleration ratio.

[0045] It should be noted that mechanical abrasion on the surface coating of functional fabrics is not caused by a single factor, but rather by the combined effects of localized overheating leading to thermoplastic softening and shrinkage of the fabric, resulting in tension, and friction from the supporting mechanism under these conditions. This invention establishes a multi-dimensional coupling feature, integrating environmental thermal field distortion, sudden material stress, and the intensity of relative motion of the equipment at the numerical level to assess system-level risk.

[0046] Specifically, based on real-time spatial temperature difference and fabric tension rate, a scalar multiplication calculation of multiple factors is performed to calculate the abrasion risk index, including: The system extracts the previously calculated real-time spatial temperature difference, fabric tension rate, and drive motor speed. In the data calculation module, it performs a multiplicative coupling operation of multidimensional risk factors. The real-time spatial temperature difference, fabric tension rate, and drive motor speed, spanning multiple physical dimensions, are treated as independent physical factors and subjected to a scalar multiplication operation. This folds and reconstructs the discrete single-dimensional risks into a unified risk characteristic quantity, yielding the abrasion risk index. Before performing the scalar multiplication, the real-time spatial temperature difference, fabric tension rate, and drive motor speed are normalized to a dimensionless range of 0-1 to eliminate differences in dimensions and orders of magnitude between different physical quantities, ultimately obtaining a unitless risk value ranging from 0 to 1. When the abrasion risk index is greater than 0.6, it can be confirmed that the current fabric has a risk of surface coating abrasion, avoiding missed or incorrect judgments in single-factor determinations.

[0047] It should be noted that the abrasion risk index is a safety representation value that integrates the environmental thermal field deterioration, the transient shrinkage rate of the fabric, and the mechanical operating speed. It represents the level of danger of the fabric surface coating peeling off when multiple working conditions are superimposed simultaneously. The purpose of constructing this abrasion risk index is to establish a total safety representation value.

[0048] Thus, an abrasion risk index was obtained, which characterizes the dangerous level of peeling of the fabric surface coating when multiple working conditions are superimposed simultaneously.

[0049] It should be noted that when a thermal shock that breaches the safety barrier is detected inside the shaping chamber, a purely qualitative alarm is insufficient to meet the flexible control requirements of modern precision manufacturing. Existing control systems execute full-on / full-off responses, which can easily lead to over-adjustment and process environment oscillations. This invention introduces a physical source dynamic differential calculation mechanism. By stripping away the safety margin exceeding the natural tolerance, it calculates the severity of the current thermal field runaway, transforming the abstract environmental deterioration state into redundant values ​​with clear physical dimensions. This provides underlying logical support for the subsequent generation of refined and adjustable mechanical coordination commands.

[0050] Preferably, the excess temperature value is obtained based on the difference between the real-time spatial temperature difference and the safe temperature difference limit, including: Extract the real-time spatial temperature difference and the safe temperature difference boundary calculated in the previous step. Perform an out-of-bounds differential operation of the safety margin in the numerical comparison module. Set the real-time spatial temperature difference as the dynamic system input feature and the safe temperature difference boundary as the lower bound of the static truncation envelope. Calculate the scalar redundancy part of the dynamic system input feature minus the lower bound of the static truncation envelope to obtain the out-of-limit temperature value.

[0051] It should be noted that the over-limit temperature value refers to the difference in real-time spatial temperature difference that exceeds the safety line. It represents the redundancy of fabric thermal shrinkage caused by the current local thermal field runaway. The purpose of constructing this over-limit temperature value is to calculate the degree to which the current temperature zone exceeds the safety envelope, which is a prerequisite for proportional compensation.

[0052] Thus, the excess temperature value representing the redundancy of the fabric's thermosensitive shrinkage caused by the current local thermal field runaway was obtained.

[0053] It should be noted that when faced with temperature overflow, how to convert the physical temperature deviation into control parameters for mechanical motors is a logical challenge in moving from the digital domain to physical execution. Direct mapping in existing technologies easily leads to oscillations in the system's operating frequency, affecting the original production line rhythm. This invention uses the concept of proportional dimensionality reduction, normalizing the redundancy representing environmental degradation with a safety tolerance as the denominator, and calculating dimensionless control coefficients. This ensures that subsequent actions can both mitigate relative friction under high-temperature conditions and avoid capacity reduction caused by deceleration.

[0054] Preferably, a dimension reduction scaling mapping is performed on the over-limit temperature value and the safe temperature difference boundary to output the target deceleration rate, including: Extract the over-limit temperature value and the safe temperature difference limit calculated in the previous step. Perform a dimensionality reduction ratio operation for benchmark normalization in the data conversion module. Use the over-limit temperature value as the target deviation feature quantity and the safe temperature difference limit as the full-range benchmark scale. Divide the target deviation feature quantity by the full-range benchmark scale to calculate the relative occupancy weight. Remove the physical dimensions through division logic to obtain the target deceleration ratio.

[0055] It should be noted that the target deceleration ratio refers to a dimensionless deceleration weighting coefficient used to guide mechanical hardware in mitigating friction. It characterizes the deceleration magnitude of the drive motor when facing temperature overflow. Constructing this target deceleration ratio aims to map the overflow amount into a dimensionless control parameter, achieving a reduction in the dimension of physical distortion into mechanical control commands, and avoiding the decrease in production efficiency caused by fixed speed regulation. The target deceleration ratio ranges from 0 to 1, and the target motor operating speed = current operating speed × (1 - target deceleration ratio). That is, the larger the deceleration ratio, the greater the motor deceleration magnitude, achieving a linear match between the degree of exceeding limits and the deceleration magnitude. This ensures that the relative friction speed under high temperature and high tension is reduced to a safe range, while avoiding the production efficiency loss caused by excessive deceleration at a fixed magnitude.

[0056] Thus, the target deceleration ratio, which characterizes the deceleration magnitude performed by the drive motor when facing temperature overflow, was obtained.

[0057] S4: Generate dynamic reset instruction.

[0058] It should be noted that when functional fabrics undergo thermoplastic deformation, if the system detects an increase in tension and immediately performs mechanical stress relief, it will disrupt the skeletal tension that maintains the fabric's intended dimensions, resulting in dimensional defects. This invention constructs a logic interception network that performs physical-level serial identification of extreme temperature differences and transient tension bursts within the same clock cycle. Once the cause of thermal shrinkage is identified, it directly takes over the underlying hardware to block stress relief and simultaneously coordinates vehicle speed and cooling air, achieving a system-level error-proof physical closed-loop protection.

[0059] Specifically, based on the target deceleration ratio, a cross-layer takeover operation is performed to block leakage and coordinate deceleration compensation, thereby obtaining terminal protection instructions, including: Once it is determined that the real-time spatial temperature difference exceeds the safe temperature difference limit, and simultaneously it is determined that the aforementioned fabric tension rate exceeds the pre-acquired tension rate judgment threshold, the system, in conjunction with the aforementioned abrasion risk index, confirms that the current fabric has encountered an extreme temperature difference and is undergoing thermoplastic shrinkage; the control system initiates takeover, blocking the inward contraction and force release command sent by the original tension control module to the support drive mechanism, and outputs a stop force release command to maintain the existing mechanical support frame to ensure the final size of the fabric; a motor deceleration command is generated according to the target deceleration ratio, and the mechanical operating frequency is reduced to reduce relative friction under high temperature and high tension; and a cold air activation command is simultaneously sent to the local highest temperature zone; at the same time, the over-temperature zone is located according to the spatial position corresponding to the over-limit temperature value, and the heating power setting value of the corresponding temperature zone is dynamically adjusted according to the target deceleration ratio.

[0060] It should be noted that the tension rate judgment threshold refers to the tension change anti-shake judgment parameter used to filter the background noise of the sensor hardware. It characterizes the effective stress increment when the fabric undergoes physical shrinkage. The purpose of constructing this tension rate judgment threshold is to establish the authenticity of the tension increase. The specific value range of the tension rate judgment threshold is 0.1 to 0.5, preferably 0.2. The reason for setting this value range is that if the value is less than 0.1, the system is prone to misjudging the slight vibration caused by the airflow disturbance inside the shaping box as thermoplastic shrinkage and thus triggering an alarm interception. If the value is greater than 0.5, it will delay the system's response time to heat-sensitive shrinkage, causing the fabric to be stretched before the protective action is performed. Therefore, this range can achieve a balance between disturbance resistance robustness and error prevention response. Executing cross-layer takeover with logic interception is the exit from the single feedback logic of the traditional system.

[0061] At this point, the terminal protection command to resolve industrial hazards was obtained.

[0062] It should be noted that after multi-dimensional collaborative intervention, the thermodynamic fault inside the shaping box gradually closes. The system needs to cancel the protective action in a timely manner to restore normal production capacity. Existing systems typically use a fixed time delay for mechanical reset. This fixed recovery strategy is prone to causing secondary thermoplastic distortion due to premature cancellation or mechanical efficiency loss due to delayed cancellation when facing thermal shocks of varying severity. This invention couples the initial degree of danger suffered by the system with the magnitude of the speed reduction, calculating an adaptive delay recovery period to ensure a smooth transition of the production line to normal operating conditions.

[0063] Preferably, after executing the terminal protection instruction, a dynamic reset instruction is generated, including: The control system executes the terminal protection command and continuously monitors the real-time space temperature difference. When the real-time space temperature difference recovers to no greater than the safe temperature difference limit, the reset timing begins. After maintaining the protection state for the reset delay time, a dynamic reset command is generated to cancel the stop discharge command, gradually restore the drive motor speed, and shut down the corresponding local cooling device.

[0064] It should be noted that the reset delay time ranges from 5 to 15 seconds, preferably 10 seconds. This time is adaptively adjusted according to the over-limit temperature value. For every 1°C that the over-limit temperature exceeds the safe temperature difference limit, the reset delay time increases by 2 seconds, with a basic reset delay of 5 seconds. This avoids premature protection cancellation that could cause secondary thermal shrinkage deformation, or premature cancellation that could affect production cycle efficiency.

[0065] It should be noted that the complete control process of this invention can be illustrated by a set of typical process parameters: After a batch of polyester functional fabrics is turned on and undergoes a steady-state test for 10 minutes, the historical average temperature difference is 3℃, the standard deviation of the temperature difference is 1℃, and the calculated safe temperature difference limit is 5℃; within a certain control cycle, the array temperature sensor collects the highest temperature of 182℃ and the lowest temperature of 176℃, the real-time spatial temperature difference is 6℃, and the over-limit temperature value is 1℃, and the calculated target reduction rate is 0.2; the current fabric tension rate is 0.3N / s, which is greater than the tension rate threshold of 0.2N / s. After normalization, the abrasion risk index is 0.7, which is greater than the risk threshold of 0.6, thus meeting the protection trigger condition. The system immediately blocks the original tension system's inward contraction release command, reduces the fabric running speed from 20m / min to 16m / min, and simultaneously opens the cold air valve corresponding to the highest temperature zone. According to the adaptive rule, the reset delay time is calculated to be 7 seconds. After continuous monitoring for 7 seconds, the real-time space temperature difference drops back to 4℃. The system linearly increases the speed to the normal operating speed of 20m / min at a slope of 10% of the rated speed per second, closes the cold air valve, and completes a complete protection control process.

[0066] It should be noted that, Figure 2This graph shows the time sequence of multiple parameters in heat setting and the variation of the abrasion risk index. The horizontal axis represents time, covering the complete control cycle from thermal field stabilization to the occurrence of local overheating and then to the protective action. The vertical axis, from top to bottom, represents the real-time spatial temperature difference, fabric tension rate, drive motor speed, and abrasion risk index. The four curves correspond to the real-time changes of each parameter, and the bidirectional arrows indicate the superimposed interval of multi-dimensional working conditions. The real-time spatial temperature difference and fabric tension rate increase synchronously with local overheating. The drive motor speed decreases steadily according to the target reduction ratio after the risk is triggered. The abrasion risk index increases with the coupling of multiple parameters and drops rapidly after the speed reduction protection action. This graph intuitively presents the logic of this invention in calculating the abrasion risk index through the multiplication of multiple factors such as real-time spatial temperature difference, fabric tension rate, and drive motor speed, and reflects the control process of triggering coordinated speed reduction protection when the system is superimposed with multi-dimensional working conditions. Figure 3 This diagram illustrates the principle of fabric tension rate detection and thermoplastic shrinkage determination. The horizontal axis represents time, covering the process from normal operation to thermoplastic shrinkage. The upper vertical axis represents tension, and the lower vertical axis represents fabric tension rate. The two upper curves represent the current and previous fabric tensions, respectively, while the lower curve represents the fabric tension rate. The horizontal dashed line represents the tension rate determination threshold, and the bidirectional arrows indicate the data sampling interval. The system calculates the tension increment by comparing the current and previous fabric tensions at adjacent sampling times, and then normalizes this information using the data sampling interval to obtain the fabric tension rate. When thermoplastic shrinkage occurs, the tension rate rapidly increases and exceeds the tension rate determination threshold, allowing the system to identify the thermoplastic shrinkage condition. This diagram visually demonstrates the principle of upgrading static absolute tension detection to dynamic tension change rate detection, which can distinguish between normal process stretching and sudden thermal shock shrinkage, providing dynamic evidence for determining the cause of thermal shrinkage.

[0067] Thus, the adaptive adjustment method for the heat setting process parameters of functional fabrics was completed.

[0068] While various embodiments of the invention have been shown and described in this specification, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Many modifications, alterations, and alternatives will occur to those skilled in the art without departing from the spirit and essence of the invention.

Claims

1. A method for adaptive adjustment of heat setting process parameters for functional fabrics, characterized in that, include: S1: Collect temperature data within the control cycle to obtain the highest and lowest temperatures of the enclosure; S2: Perform algebraic calculation of the difference between the highest and lowest temperatures in the chamber to calculate the real-time spatial temperature difference; based on the mean and standard deviation of fluctuations obtained in advance during the steady-state test phase, perform superposition calculation of the natural tolerance distribution to obtain the safe temperature difference limit; obtain the fabric tension dataset through the tension detection sensor; based on the fabric tension dataset, perform transient derivative calculation of the fabric stress to obtain the fabric tension rate. S3: Based on real-time spatial temperature difference and fabric tension rate, perform scalar multiplication calculation of multiple factors to calculate the abrasion risk index; obtain the over-limit temperature value according to the difference between real-time spatial temperature difference and safe temperature difference limit; perform dimension reduction proportional mapping on the over-limit temperature value and safe temperature difference limit to output the target deceleration ratio. S4: Based on the target deceleration ratio, perform cross-layer takeover operation of blocking discharge and coordinated deceleration compensation to obtain terminal protection instructions; after executing the terminal protection instructions, generate dynamic reset instructions.

2. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 1, characterized in that, The process of obtaining the highest and lowest temperatures of the enclosure includes: A dedicated data buffer area is created in the controller's memory to establish a real-time data channel between the array temperature detectors inside the molding box and the central processing unit. Temperature data output by each detection node is received synchronously at the sampling rate. At the same time, the temperature data output by each detection node within the same control cycle is compared one by one in the comparison register of the central processing unit, and the current maximum and minimum values ​​are updated in real time. At the end of the control cycle, the current maximum and minimum values ​​are determined as the highest temperature and lowest temperature of the box, respectively.

3. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 1, characterized in that, The calculation of real-time spatial temperature difference includes: Using the highest temperature in the chamber as the reference point for the thermal field peak and the lowest temperature in the chamber as the reference point for the thermal field trough, a dimension reduction subtraction operation is performed to calculate the difference in the span between the two in physical space, and the real-time spatial temperature difference is calculated. At the same time, the historical statistical database of the manufacturing execution system is accessed through the communication interface to call the historical average temperature difference of the current fabric batch during the steady-state trial stage, and the standard deviation of the temperature difference corresponding to the historical average temperature difference is extracted simultaneously.

4. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 1, characterized in that, The process of obtaining the safe temperature difference limit and acquiring a fabric tension dataset via a tension detection sensor includes: The historical average temperature difference, representing the baseline trend, and the standard deviation of the temperature difference, representing the fluctuation amplitude, are linearly superimposed with the same dimensions to obtain the upper limit boundary value covering the background noise of the normal process. The safe temperature difference limit is then calculated. In addition, a hardware feedback link with the tension detection sensor is established to capture the current tension of the fabric in real time. The tension data of the previous frame in the register is cached as the previous tension of the fabric. The underlying hardware clock counter is called synchronously to record the actual time span between the two samplings, which is determined as the data sampling interval. The current tension of the fabric, the previous tension of the fabric, and the data sampling interval are recorded as the fabric tension dataset.

5. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 1, characterized in that, The process of obtaining the fabric tension rate includes: Extract the current fabric tension, previous fabric tension, and data sampling interval from the preceding data. Perform a first-order difference operation in the discrete time domain in the numerical calculation module. First, calculate the incremental feature obtained by subtracting the previous fabric tension from the current fabric tension. Then, project this incremental feature onto the time coordinate system and perform a normalized division operation based on the data sampling interval to obtain the convergence slope mapping value in the unit time dimension. Solve for the fabric tension rate. Simultaneously, establish an industrial communication link with the main drive frequency converter to monitor the drive motor speed fed back by the encoder in real time.

6. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 5, characterized in that, The calculation of the abrasion risk index includes: Extract the real-time spatial temperature difference, fabric tension rate, and drive motor speed obtained in the previous calculation. Perform multi-dimensional risk factor coupling operation in the data calculation module. Perform scalar multiplication operation on the real-time spatial temperature difference, fabric tension rate, and drive motor speed across physical dimensions as independent physical factors. Fold and reconstruct the discrete single-dimensional risk into a unified risk feature quantity, and calculate the abrasion risk index.

7. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 1, characterized in that, The process of obtaining the out-of-limit temperature value includes: Extract the real-time spatial temperature difference and the safe temperature difference boundary calculated in the previous step. Perform an out-of-bounds differential operation of the safety margin in the numerical comparison module. Set the real-time spatial temperature difference as the dynamic system input feature and the safe temperature difference boundary as the lower bound of the static truncation envelope. Calculate the scalar redundancy part of the dynamic system input feature minus the lower bound of the static truncation envelope to obtain the out-of-limit temperature value.

8. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 1, characterized in that, The output target deceleration ratio includes: Extract the over-limit temperature value and the safe temperature difference limit calculated in the previous step. Perform a dimensionality reduction ratio operation for benchmark normalization in the data conversion module. Use the over-limit temperature value as the target deviation feature quantity and the safe temperature difference limit as the full-range benchmark scale. Divide the target deviation feature quantity by the full-range benchmark scale to calculate the relative occupancy weight. Remove the physical dimensions through division logic to obtain the target deceleration ratio.

9. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 1, characterized in that, The method of obtaining terminal protection instructions includes: Once it is determined that the real-time spatial temperature difference exceeds the safe temperature difference limit, and simultaneously it is determined that the aforementioned fabric tension rate exceeds the pre-acquired tension rate judgment threshold, the system, in conjunction with the aforementioned abrasion risk index, confirms that the current fabric has encountered an extreme temperature difference and is undergoing thermoplastic shrinkage; the control system initiates takeover, blocking the inward contraction and force release command sent by the original tension control module to the support drive mechanism, and outputs a stop force release command to maintain the existing mechanical support frame to ensure the final size of the fabric; a motor deceleration command is generated according to the target deceleration ratio, and the mechanical operating frequency is reduced to reduce relative friction under high temperature and high tension; and a cold air activation command is simultaneously sent to the local highest temperature zone; at the same time, the over-temperature zone is located according to the spatial position corresponding to the over-limit temperature value, and the heating power setting value of the corresponding temperature zone is dynamically adjusted according to the target deceleration ratio.

10. The method for adaptive adjustment of heat setting process parameters for functional fabrics according to claim 1, characterized in that, The generation of the dynamic reset command includes: The control system executes the terminal protection command and continuously monitors the real-time space temperature difference. When the real-time space temperature difference recovers to no greater than the safe temperature difference limit, the reset timing begins. After maintaining the protection state for the reset delay time, a dynamic reset command is generated to cancel the stop discharge command, gradually restore the drive motor speed, and shut down the corresponding local cooling device.

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