Waterfall type cloth washing machine and dynamic regulation method thereof

Abstract

The application discloses a waterfall type cloth washing machine and a dynamic regulation method thereof, and belongs to the technical field of washing equipment in the textile field. The waterfall type cloth washing machine is characterized by vertical cabinet type integrated layout and symmetrical continuous sawtooth-shaped flow guide surfaces arranged on the left and right inner walls of a washing channel. Washing water forms multiple layers of waterfall water curtains through the flow guide surfaces, thereby forming countercurrent contact with the vertically upward cloth. The washing liquid replacement efficiency is strengthened, and the downward water flow impact force can offset the upward traction of the cloth, so that the tensile deformation and weft skew are avoided. The fluid clamping effect is formed by the bilateral symmetrical water flow, so that the cloth can be suspended in the center of the channel, and the wall friction pilling defect is eliminated. A transfer unit capable of absorbing water is arranged at the top of the waterfall type cloth washing machine, so that the cloth free water is removed by non-extrusion negative pressure adsorption, and the problem that the traditional mechanical rolling cloth is pressed and wrinkled is avoided. The whole washing process guarantees the stable tension of the cloth, and can be suitable for high-quality continuous washing processing of deformed fabrics such as knitted fabrics and elastic cloth.

Description

Technical Field

[0001] This invention relates to the field of washing equipment technology in the textile industry, specifically to a waterfall-type fabric washing machine and its dynamic control method. Background Technology

[0002] In the textile printing and dyeing process, washing is the core step in removing surface dyes, sizing agents, and impurities from fabrics, directly affecting the color fastness and hand feel of the finished fabric. Existing washing equipment is mainly divided into two categories: flat-width washing machines and rope washing machines. Vertical washing machines are widely used due to their compact size and flexible number of stages. However, in vertical washing machines, the fabric is mostly conveyed vertically upwards. The tension of the traction rollers and the fabric itself overlap, causing the fabric to continuously bear significant axial tension. For low-modulus, easily deformable fabrics such as knitted fabrics and spandex elastic fabrics, long-term tension can easily lead to problems such as warp elongation, weft skew, and poor dimensional stability, potentially even causing product scrap. Furthermore, existing washing channels are mostly open or simple narrow-slit structures, lacking central restraint for the fabric. During high-speed operation, the fabric is prone to lateral shifting, and repeated friction between the edges and the channel walls leads to appearance defects such as pilling, snagging, and abrasion marks, reducing the finished product yield.

[0003] Chinese patent, publication number CN2732790Y, discloses a vertical double-drum knitting washing machine. The machine features a vertical frame structure with two mesh drums arranged vertically, equipped with multiple sets of spray pipes, an expansion edge puller, and rollers. It is a vertical continuous flat-width washing device suitable for low-tension washing of easily deformable fabrics such as elastic fabrics. The washing method uses multiple spray pipes to form a waterfall-like water jet penetration spray, allowing the washing liquid to penetrate the fabric and achieve rapid liquid exchange. It features high washing efficiency and good removal of floating color impurities. The dewatering structure uses a pair of rollers at the discharge end to mechanically extrude water from the washed fabric. However, during the washing process, the fabric is subjected to axial force during transport, and the washing channel is relatively narrow, causing friction and contact between the fabric and the channel, which can easily lead to deformation and pilling defects. Summary of the Invention

[0004] This invention addresses the problems of existing fabric washing machines, which subject fabric to axial force during conveying and have narrow washing channels, leading to fabric deformation and pilling due to friction. It provides a waterfall-style fabric washing machine and its dynamic control method. Through a vertical cabinet-style integrated layout and symmetrically arranged continuous sawtooth-shaped guide surfaces on the left and right inner walls of the washing channel, the washing water forms a multi-layered waterfall curtain, creating a counter-current contact with the vertically ascending fabric. This not only enhances the washing liquid's performance but also... The water flow improves efficiency, and the downward water flow also counteracts the upward traction of the fabric, preventing stretching deformation and weft skew. The symmetrical water flow on both sides creates a fluid clamping effect, allowing the fabric to suspend in the center of the channel and eliminating the defects of pilling caused by wall friction. A water-absorbing transfer unit is also set at the top to absorb and remove free water from the fabric with non-compression negative pressure, avoiding the problem of wrinkling the fabric caused by traditional mechanical pressing. The entire washing process ensures stable fabric tension throughout, making it suitable for high-quality continuous washing of easily deformable fabrics such as knitted fabrics and elastic fabrics.

[0005] In a first aspect, one technical solution provided in the embodiments of the present invention is: a waterfall-type fabric washing machine, including a frame cabinet, a pre-soaking unit, a washing unit, a transfer unit and a drive unit; The prepreg unit is located in the lower cavity of the frame cabinet, and is equipped with a liquid storage tank and a guide roller assembly. The washing unit is installed on the wall panel of the rack cabinet, including a water storage and distribution cavity at the top and a washing channel vertically connected to the bottom of the water storage and distribution cavity. The washing channel is a long strip-shaped slit, and the inner walls on the left and right sides are symmetrically provided with continuous sawtooth-shaped guide surfaces. The transfer unit is located on the top of the frame cabinet and includes a negative pressure water absorption roller and a transmission transfer roller located below the negative pressure water absorption roller. The negative pressure water absorption roller is hollow inside and has water absorption micropores on its roller wall. A fixing device is provided above it. The transmission transfer roller is composed of multiple sets of driven guide rollers spliced ​​together and arches upward in the middle. The drive unit is arranged in parallel next to the transfer unit, including a pair of coaxially arranged drive rollers and a driven roller arranged on the side of the drive rollers. The drive rollers are connected to the transmission gearbox, and the transmission gearbox is connected to the motor.

[0006] In this design, the washing water, after being evenly distributed through the top water storage and distribution chamber, cascades down layer by layer via symmetrically arranged continuous sawtooth-shaped guide surfaces on the left and right inner walls of the washing channel, forming a multi-layered waterfall curtain. This creates a counter-current contact with the vertically ascending fabric, significantly enhancing the washing liquid replacement efficiency. Furthermore, the downward water flow impact counteracts the upward traction force of the fabric. The symmetrical water flow on both sides creates a fluid clamping effect, reducing the axial tensile stress of the fabric, preventing tensile deformation and weft skew, and suspending the fabric in the center of the channel, eliminating wall friction and pilling defects. The top transfer unit... The hollow negative pressure absorbent roller uses non-compression negative pressure to adsorb and remove free moisture from the fabric. Compared with mechanical pressing, it avoids wrinkles and aurora marks, effectively reduces liquid retention and subsequent drying energy consumption. At the same time, the arched transmission and transfer roller in the middle optimizes the fabric wrapping angle and improves the stability of conveying. The lower pre-impregnation unit completes the pre-wetting and initial decontamination of the fabric. Combined with two-stage water washing, the cleanliness is improved step by step. The gear-driven drive unit precisely matches the output traction force, ensuring stable fabric tension throughout the process. It is suitable for high-quality continuous water washing processing of easily deformable fabrics such as knitted fabrics and elastic fabrics.

[0007] Preferably, at least one set of the washing units is provided with a guide arm on the middle side, and the guide arm includes a fixed mounting base, a swing arm and a locking assembly; The fixed mounting base is installed on the crossbeam in the middle of the rack cabinet. One end of the swing arm is rotatably connected to the fixed mounting base, and the other end is provided with a guide roller. The locking component is an arc-shaped adjustment groove opened on the fixed mounting base.

[0008] In this solution, an adjustable guide arm structure is installed between the two washing units. Supported by a fixed mounting base on the frame beam, and equipped with a rotatable swing arm and an arc-shaped adjustment groove locking assembly, the arm angle can be flexibly adjusted and stably locked. This structure can achieve a smooth transition of the fabric between the two washing processes, and can also precisely adjust the fabric entry angle and wrap angle, thereby adapting to the tension requirements of fabrics with different weights and materials. This ensures that the fabric enters the secondary waterfall washing channel in the center, avoids deviation and wrinkling, and effectively improves the overall machine process adaptability and fabric feeding stability.

[0009] Preferably, the water washing unit has an overall T-shaped structure and a water storage and distribution chamber with two parallel compartments at the top; The water storage and distribution chamber is divided into a first chamber and a second chamber from top to bottom by a porous flow equalization baffle. The second cavity is connected to an external water supply pipe, and the first and second cavities are provided with flow guiding layers on their side walls; The outlet of the flow guide jacket is located directly above the sawtooth flow guide surface of the water washing channel, and the inlet is located in the middle of the side wall of the first cavity.

[0010] In this solution, by setting the washing unit as a T-shaped structure and configuring a water storage and distribution chamber with two parallel compartments, combined with the upper and lower double chambers formed by the porous flow equalization baffle and the side wall flow guide layer, multi-level uniform flow and precise guidance of the washing water can be achieved. The porous flow equalization baffle achieves stable pressure and uniform flow of the incoming water, avoids water flow imbalance, and ensures uniform water output in the fabric width direction. The flow guide layer precisely guides the water flow to the top of the sawtooth flow guide surface, and the toothed structure forms a continuous and uniform multi-layer waterfall water curtain, which not only ensures the uniformity of the washing cleanliness across the entire width, but also makes the fluid centering and tension offsetting effect more stable, thereby significantly improving the washing uniformity and fabric processing quality.

[0011] Preferably, the sawtooth-shaped guide surface is composed of multiple sequentially connected water guide surfaces, and the protruding ends of the water guide surfaces all face the center of the water washing channel and are inclined downwards.

[0012] In this solution, a sawtooth-shaped guide surface is formed by multiple sequentially connected water guide surfaces, with the protruding ends of the water guide surfaces facing the center of the washing channel and tilting downwards. This guides the washing water to fall layer by layer to form a continuous waterfall water curtain, which enhances the cleaning effect of countercurrent rinsing. At the same time, the symmetrically tilted water flow forms a downward resultant force and a counter-clamping force, which simultaneously achieves tension cancellation and fabric centering and suspension protection.

[0013] Preferably, both ends of the negative pressure water-absorbing roller are connected to an external air extraction pipe, and the external air extraction pipe is connected to a vacuum generator. When the vacuum generating device is running, a negative pressure cavity is formed inside the negative pressure water absorption roller.

[0014] In this solution, external air extraction pipes and a vacuum generator are connected to both ends of the negative pressure absorbent roller, forming a stable negative pressure chamber inside the roller. The free moisture on the fabric surface can be adsorbed and removed by relying on the micropores in the roller wall. This non-extrusion dewatering method avoids defects such as wrinkles and aurora marks caused by traditional roller extrusion. The dewatering is gentle and uniform, which can effectively reduce the liquid content of the fabric after washing and reduce the energy consumption of subsequent drying. It can meet the high-quality processing needs of easily damaged fabrics such as knitted fabrics and elastic fabrics.

[0015] Secondly, one technical solution provided in this embodiment of the invention is: a dynamic control method for a waterfall-type fabric washing machine, comprising the following steps: S1. Obtain the inherent parameters of the fabric, the structural parameters of the equipment, and the target parameters of the process. Based on the above parameters and in combination with the benchmark parameter calibration rules, obtain the effective tension force of the fabric and the benchmark speed of the motor. S2. Real-time operation signals of the washing machine are collected during operation. Based on the real-time operation signals, inherent parameters of the fabric and structural parameters of the equipment, and combined with the real-time attribute conversion mechanism of the fabric, the real-time attributes of the fabric are calculated to obtain the real-time attributes of the fabric. S3. Calculate the current target tension of the fabric based on the real-time properties and effective tension of the fabric, and construct a compensation driving equation based on the current target tension of the fabric and the real-time operation signal. S4. Calculate the motor speed compensation amount of the drive unit based on the compensation drive equation, determine the target motor speed based on the motor speed compensation amount and the motor reference speed, and generate drive compensation command. Compensate the motor speed based on the drive compensation command.

[0016] This solution employs a four-step closed-loop dynamic control method to maintain a constant effective fabric tension, adaptively offsetting tension imbalances caused by fluctuations in fabric liquid load during washing. First, the method calibrates the effective tension benchmark based on inherent fabric parameters, equipment structural parameters, and process objectives, clearly distinguishing between the required effective tension and the additional tension generated by the weight of the liquid load. Then, it calculates the real-time liquid load properties of the fabric by collecting operating signals in real time, synchronously updating the total tension target under the corresponding working conditions and constructing a compensation driving equation. Finally, it solves for the motor speed compensation and issues the execution order. The entire process is seamlessly integrated, preventing fabric stretching and skew damage caused by excessive tension, as well as fabric relaxation, bulging, and wrinkling due to insufficient tension. Furthermore, it can be deployed using existing sensors without requiring additional equipment modifications, resulting in low implementation costs and effectively improving washing quality and equipment process adaptability.

[0017] Preferably, in step S1, the inherent parameters of the fabric, the structural parameters of the equipment, and the target parameters of the process are obtained. Based on the above parameters and in conjunction with the benchmark parameter calibration rules, the effective tension force of the fabric and the benchmark speed of the motor are obtained, including the following steps: The dry fabric mass per unit length and fabric width are obtained as inherent parameters of the fabric; the drive unit transmission ratio, the radius of the active drive roller, the fabric length in the vertical section of the washing channel, and the no-load torque are obtained as equipment structural parameters; the effective tension force per unit width of the fabric and the reference running linear speed are obtained as process target parameters. The effective tension force of the fabric is obtained by multiplying the effective tension force per unit width of the fabric by the fabric width, and the reference speed of the motor is calculated based on the reference running linear velocity.

[0018] In this scheme, by clearly defining three categories of input parameters—inherent fabric parameters, equipment structure parameters, and process target parameters—in the benchmark calibration step, and establishing standardized parameter conversion rules, a precise and unified calculation benchmark is provided for the entire dynamic control system. Converting the effective tension force per unit width to the fabric width to obtain the total effective tension force clearly identifies the core tension force indicators required by the process, laying a logical foundation for subsequently distinguishing the additional tension force due to liquid self-weight and dynamically updating the total tension target. By deriving the motor benchmark speed from the benchmark operating linear velocity, a standardized mapping from process requirements to drive parameters is achieved, thereby ensuring the consistency and accuracy of the control benchmark and improving the reliability of subsequent compensation calculations.

[0019] Preferably, in step S2, real-time operating signals of the washing machine are collected during operation. Based on the real-time operating signals, inherent fabric parameters, and equipment structural parameters, and combined with a real-time fabric attribute conversion mechanism, the real-time attributes of the fabric are calculated, including the following steps: The measured torque, measured fabric tension, and measured fabric linear speed at the motor output are collected as real-time operating signals. The total tension is obtained by multiplying the difference between the measured torque and the no-load torque by the transmission ratio of the drive unit and comparing it with the radius of the drive roller; the total tension is then calculated by weighted averaging the total tension and the measured fabric tension to obtain the target total tension. The measured linear velocity of the fabric is integrated to obtain the fabric running position. The fabric running position is substituted into the liquid carrying rate formula to obtain the real-time liquid carrying rate of the fabric. The real-time liquid carrying rate is multiplied by the dry fabric mass per unit length and the fabric length of the vertical section of the washing channel, and then multiplied by the gravitational acceleration to obtain the additional tensile force of the liquid carrying self-weight. Real-time liquid retention rate and additional tensile force due to liquid retention weight are used as real-time properties of the fabric.

[0020] In this solution, considering that the liquid carry-over rate is related to the previous state under actual working conditions, the liquid carry-over rate is solved by the previous feedback of the fabric position and the correction of historical deviations, which fits the actual working conditions and ensures the effect of subsequent drive compensation.

[0021] Preferably, in step S3, the current target tension of the fabric is calculated based on the real-time properties and effective tension of the fabric, and a compensation driving equation is constructed based on the current target tension of the fabric and the real-time operating signal, including the following steps: With the goal of stabilizing the effective tension of the fabric, the additional tension due to the self-weight of the liquid-laden material is superimposed with the effective tension per unit width of the fabric to obtain the current target tension related to the real-time liquid-laden rate, and the allowable fluctuation range of the target effective tension is set as a tension constraint. The difference between the current target tension and the total target tension is used as the compensation driving variable; The PID algorithm is used, and the compensation driving equation is constructed based on the compensation driving variables. The formula is expressed as follows:

[0022] in, , , These are the proportional gain coefficient, integral gain coefficient, and differential gain coefficient, which are adaptively adjusted according to the liquid carryover rate. To compensate for the driving variables.

[0023] In this scheme, the core objective of maintaining a constant effective tension of the fabric is to superimpose the real-time liquid-laden self-weight additional tension with the effective tension to obtain a dynamic target tension that matches the current liquid-laden rate. An allowable fluctuation range is also set as a tension constraint. This method breaks the limitations of a fixed tension target and can adaptively adjust the total tension threshold according to changes in the fabric's water content, thus mitigating the interference of self-weight fluctuations on the process tension. A compensation driving equation is constructed using the tension difference as the compensation driving variable combined with a PID algorithm. The control logic is clear and the response is fast. The range constraint also avoids tension oscillations caused by over-adjustment, ensuring a smooth and continuous fabric feeding process.

[0024] Preferably, in step S4, the motor speed compensation amount of the drive unit is calculated based on the compensation drive equation, and the target motor speed is determined based on the motor speed compensation amount and the motor reference speed, including the following steps: The compensation drive variables are calculated in real time, and the compensation drive variables are substituted into the compensation drive equation to calculate the motor speed compensation amount; The target motor speed is obtained by superimposing the motor speed compensation amount with the motor reference speed.

[0025] In this solution, by substituting the real-time compensation drive variables into the compensation drive equation to solve for the motor speed compensation amount, and then superimposing it with the motor reference speed to obtain the final target speed, the tension deviation can be directly and accurately converted into drive adjustment commands, ensuring the timeliness and accuracy of the control response. By superimposing the compensation amount based on the reference speed, the impact of large speed changes on the fabric can be avoided, ensuring a smooth and stable fabric feeding process. At the same time, it forms a complete closed loop with the previous dynamic target tension calculation, effectively maintaining the stability of the effective tension of the fabric and avoiding quality problems such as excessive stretching or loose bulging caused by fluctuations in the liquid content.

[0026] The beneficial effects of this invention are as follows: This invention utilizes a vertical cabinet-style integrated layout with symmetrically arranged continuous sawtooth-shaped guide surfaces on the left and right inner walls of the washing channel. The washing water forms a multi-layered waterfall curtain through the guide surfaces, thus creating a counter-current contact with the vertically ascending fabric. This not only enhances the efficiency of washing liquid replacement, but also counteracts the upward traction force of the fabric with the downward water flow impact, avoiding stretching deformation and weft skew. Furthermore, the symmetrical water flow on both sides creates a fluid clamping effect, allowing the fabric to suspend in the center of the channel and eliminating the defects of pilling caused by wall friction. A water-absorbing transfer unit is also installed at the top, using non-compression negative pressure to absorb and remove free water from the fabric, avoiding the problem of wrinkling the fabric caused by traditional mechanical pressing. The entire washing process ensures stable fabric tension throughout, making it suitable for high-quality continuous washing processing of easily deformable fabrics such as knitted fabrics and elastic fabrics.

[0027] The above description of the invention is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and in order to make the above and other objects, features and advantages of the present invention more apparent and understandable, specific embodiments of the present invention are described below. Attached Figure Description

[0028] Other features, objects, and advantages of the invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings. The drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings.

[0029] Figure 1 This is a cross-sectional axonometric schematic diagram of the internal structure of a waterfall-type fabric washing machine according to the present invention; Figure 2 This is a front axonometric view of the entire waterfall-type fabric washing machine of the present invention; Figure 3 This is a schematic diagram of the rear of a waterfall-type fabric washing machine according to the present invention. Figure 4 This is a schematic diagram of the internal structure of a waterfall-type fabric washing machine according to the present invention. Figure 5 This is a partially enlarged isometric view of the transfer unit of a waterfall-type fabric washing machine according to the present invention; Figure 6 This is a schematic diagram of the fabric walking path of a waterfall-type fabric washing machine according to the present invention; Figure 7 This is a three-dimensional structural diagram of the washing unit of a waterfall-type fabric washing machine according to the present invention; Figure 8 This is a schematic diagram of the front structure of the washing unit of a waterfall-type fabric washing machine according to the present invention; Figure 9 This is a partially enlarged isometric view of the negative pressure absorbent roller of a waterfall-type fabric washing machine according to the present invention; Figure 10 This is an isometric view of the overall assembly of the negative pressure water absorption roller of a waterfall-type fabric washing machine according to the present invention; Figure 11 This is a flowchart of a dynamic control method for a waterfall-type fabric washing machine according to the present invention; In the diagram: 1. Frame cabinet; 2. Pre-impregnation unit; 201. Liquid storage tank; 202. Guide roller assembly; 3. Washing unit; 301. Water storage and distribution chamber; 302. Washing channel; 303. First chamber; 304. Second chamber; 305. Water guide surface; 306. Flow guide interlayer; 307. Porous flow equalization baffle; 4. Transfer unit; 401. Negative pressure water absorption roller; 402. Transmission transfer roller; 403. Fixing device; 5. Drive unit; 501. Active transmission roller; 502. Driven roller; 6. Guide arm; 601. Fixed mounting base; 602. Swing arm; 603. Guide roller. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only one preferred embodiment of this invention and are only used to explain this invention. They do not limit the scope of protection of this invention. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0031] Before discussing the exemplary embodiments in more detail, it should be mentioned that some exemplary embodiments are described as processes or methods depicted as flowcharts. Although the flowcharts describe the operations (or steps) as sequential processes, many of the operations (or steps) can be performed in parallel, concurrently, or simultaneously. Furthermore, the order of the operations can be rearranged. The process can be terminated when its operation is completed, but it may also have additional steps not included in the figures; the process may correspond to a method, function, procedure, subroutine, subroutine, etc.

[0032] Example 1: To address the problems of existing fabric washing machines causing axial stress on the fabric during transport, and the relatively narrow washing channel 302 leading to frictional contact between the fabric and the channel, resulting in fabric deformation and pilling defects, this example provides a waterfall-type fabric washing machine. Figure 1 As shown, it includes a rack cabinet 1, a pre-prep unit 2, a washing unit 3, a transfer unit 4, and a drive unit 5; The prepreg unit 2 is located in the lower cavity of the frame cabinet 1, and is equipped with a liquid storage tank 201 and a guide roller group 202. The washing unit 3 is installed on the wall panel of the rack cabinet 1, including a water storage and distribution cavity 301 set above and a washing channel 302 vertically connected below the water storage and distribution cavity 301. The washing channel 302 is a long strip-shaped slit, and the inner walls on the left and right sides are symmetrically provided with continuous sawtooth-shaped guide surfaces. like Figure 5As shown, the transfer unit 4 is located on the top of the frame cabinet 1, including a negative pressure water absorption roller 401 and a transmission transfer roller 402 located below the negative pressure water absorption roller 401. The negative pressure water absorption roller 401 is hollow inside, and water absorption micropores are provided on the roller wall. A fixing device 403 is provided above it. The transmission transfer roller 402 is composed of multiple sets of driven guide rollers spliced ​​together, and the middle part is arched upward. The drive unit 5 is arranged in parallel next to the transfer unit 4, and includes a pair of active drive rollers 501 arranged coaxially and a driven roller 502 arranged on the side of the active drive rollers 501. The active drive rollers 501 are connected to the transmission gearbox, and the transmission gearbox is connected to the motor.

[0033] Specifically, such as Figure 2 and Figure 3 As shown, the frame cabinet 1 is welded from stainless steel square tubing, forming a vertical rectangular cabinet with sufficient structural rigidity to support the internal roller assembly, water channels, and fluid loads. The outside of the frame is covered with stainless steel sealing plates, and two symmetrical maintenance doors are opened on the front. The doors are equipped with quick-opening locking handles and observation windows. The doors correspond to the internal washing unit 3 and roller assembly positions, and can be opened to complete fabric insertion, maintenance, and cleaning operations. Several sets of lifting rings are evenly arranged on the top of the frame for overall equipment transportation and installation. Multiple sets of adjustable support feet are provided at the bottom, and the equipment level can be adjusted by bolts to adapt to different installation surfaces. Fluid interfaces, transmission holes, and cable trays are reserved on the side walls of the frame corresponding to the positions of each functional unit.

[0034] The pre-impregnation unit 2 is located in the lower cavity of the frame and serves as the pre-treatment station for washing. It guides the fabric entry and performs pre-impregnation and initial stain removal. The liquid storage tank 201 can be an open tank welded from stainless steel. The side walls of the tank are equipped with an inlet, a circulation outlet, an overflow outlet, and a drain outlet. It can be connected to an external washing liquid circulation filtration system and a heating system to maintain the temperature and cleanliness of the washing liquid. The guide roller group 202 is arranged sequentially along the fabric path inside the tank, including the inlet guide roller and the immersion roller. The inlet guide roller is located on the inlet side of the tank and is used to guide the fabric entry. The immersion roller is located at the bottom of the tank, and the fabric is completely immersed below the washing liquid surface after passing around the roller, achieving sufficient pre-impregnation. The tank is also equipped with a liquid level control component, which can use a liquid level sensor in conjunction with the inlet valve to achieve automatic and constant control of the washing liquid level.

[0035] In this embodiment, at least one set of the washing unit 3 is provided with a guide arm 6 on the side of the middle part. The guide arm 6 includes a fixed mounting base 601, a swing arm 602 and a locking assembly. Figure 4 The second set of guide arms 6 is located at the upper right corner of the second set of washing units 3. Figure 1 The second set of guide arms 6 is arranged on the right side of the middle part of the second set of washing units 3. The installation position of the guide arms 6 can be adjusted according to the actual layout of the equipment. The fixed mounting base 601 is installed on the crossbeam in the middle of the rack cabinet 1. One end of the swing arm 602 is rotatably connected to the fixed mounting base 601, and the other end is provided with a guide roller 603. The locking component is an arc-shaped adjustment groove opened on the fixed mounting base 601.

[0036] Specifically, the washing machine in this embodiment is equipped with two sets of washing units 3. Guide arms 6 are provided in the middle of both sets of washing units 3 and on the right side of the second set of washing units 3. These guide arms primarily function to facilitate the transition of the fabric, allowing the fabric to move from the first-stage washing unit 3 to the second-stage washing unit 3. They also provide tension fine-tuning and fabric entry angle adjustment functions. One end of the swing arm 602 is rotatably connected to the fixed mounting base 601 via a hinge shaft, allowing it to swing around the hinge shaft in a vertical plane. Two to three sets of guide rollers 603 are spaced along the length of the arm, and the fabric sequentially passes around the guide rollers 603 to change its direction of movement. The fixed mounting base 601 has an arc-shaped adjustment groove centered on the hinge shaft. A corresponding locking bolt is provided on the swing arm 602. The bolt passes through the arc-shaped adjustment groove; loosening the bolt adjusts the swing angle of the arm, with an adjustment range of 20° to 70°. Tightening the bolt locks the angle. The guide arm 6 can change the entry angle of the fabric into the secondary washing unit 3 by adjusting the arm angle, ensuring that the fabric enters the washing channel 302 in the center. At the same time, it can finely adjust the overall wrap angle of the fabric, thereby achieving precise control of the tension throughout the entire line to adapt to the processing needs of fabrics with different weights and materials.

[0037] This embodiment features an adjustable guide arm 6 structure between two washing units 3, supported by a fixed mounting base 601 on the frame beam. Combined with a rotatable swing arm 602 and an arc-shaped adjustment groove locking assembly, the arm angle can be flexibly adjusted and stably locked. This structure enables a smooth transition of the fabric between the two washing stages and allows for precise adjustment of the fabric entry angle and wrap angle, thus adapting to the tension requirements of fabrics with different weights and materials. It ensures the fabric enters the secondary waterfall washing channel 302 centered, preventing deviation and wrinkling, and effectively improving the overall machine's process adaptability and fabric feeding stability.

[0038] In this embodiment, as Figure 7 As shown, the water washing unit 3 has an overall T-shaped structure and a water storage and distribution cavity 301 with two parallel compartments at the top; The water storage and distribution cavity 301 is divided into a first cavity 303 and a second cavity 304 from top to bottom by a porous flow equalization baffle 307. The second cavity 304 is connected to an external water supply pipe, and the first cavity 303 and the second cavity 304 are provided with a flow guiding interlayer 306 on their side walls; The outlet of the flow guide layer 306 is located directly above the sawtooth flow guide surface of the water washing channel 302, and the inlet is located in the middle of the side wall of the first cavity 303.

[0039] Specifically, the upper part of the washing unit 3 is a closed water storage cavity. Each unit has a built-in double-cell parallel water storage and distribution cavity 301, which corresponds to the left and right areas in the fabric width direction. The second cavity 304 is equipped with a water inlet flange interface, which is connected to the external water supply pipeline. The cavity is equipped with a porous flow equalization baffle 307. The baffle is evenly opened with water permeable holes with a diameter of 3~5mm. The washing water first enters the second cavity 304. After the second cavity 304 is filled with water, it enters the first cavity 303 after being evenly pressured and stabilized through the water permeable holes. This ensures that the water flow rate is uniform along the fabric width direction and avoids local water flow imbalance.

[0040] In this embodiment, by setting the washing unit 3 as a T-shaped structure and configuring a water storage and distribution chamber 301 with two parallel compartments, and combining it with the upper and lower double chambers formed by the porous flow equalization baffle 307 and the side wall flow guiding interlayer 306, multi-level uniform flow and precise guidance of washing water can be achieved. The porous flow equalization baffle 307 realizes the pressure stabilization and uniform flow of the incoming water, avoids water flow imbalance, and ensures that the water output is uniform in the fabric width direction. The flow guiding interlayer 306 precisely guides the water flow to the top of the sawtooth flow guiding surface, and with the tooth structure, a continuous and uniform multi-layer waterfall water curtain is formed. This not only ensures the uniformity of the washing cleanliness across the entire width, but also makes the fluid centering and tension offsetting effect more stable, thereby significantly improving the washing uniformity and fabric processing quality.

[0041] In this embodiment, as Figure 8 As shown, the sawtooth-shaped guide surface is composed of multiple sequentially connected water guide surfaces 305, and the protruding ends of the water guide surfaces 305 all face the center of the water washing channel 302 and are inclined downward.

[0042] Specifically, the angle between the water guide surface 305 and the vertical direction can be set to 30°~60°. When the washing unit 3 is working, the washing water flows downward from the water storage and distribution chamber 301 into the channel, and then flows layer by layer along the water guide surface 305 to form a thin water curtain. The multiple water curtains are continuously distributed along the height direction of the channel, forming a "waterfall" flushing effect. The fabric is transported from bottom to top and forms a countercurrent contact with the water flow from top to bottom, which greatly improves the washing liquid replacement efficiency.

[0043] In this embodiment, a sawtooth-shaped guide surface is formed by multiple sequentially connected water guide surfaces 305, with the protruding end of the water guide surface 305 facing the center of the washing channel 302 and tilting downwards. This guides the washing water to fall layer by layer to form a continuous waterfall water curtain, which enhances the cleaning effect of countercurrent rinsing. At the same time, the symmetrically tilted water flow forms a downward resultant force and a counter-clamping force, which simultaneously achieves tension cancellation and fabric centering and suspension protection.

[0044] In this embodiment, the two ends of the negative pressure water absorption roller 401 are connected to an external air extraction pipe, and the external air extraction pipe is connected to a vacuum generator. When the vacuum generating device is running, a negative pressure cavity is formed inside the negative pressure water absorption roller 401.

[0045] Specifically, such as Figure 9 and Figure 10 As shown, the negative pressure absorbent roller 401 in the transfer unit 4 is the core dehydration component. The roller body has a hollow structure, forming a negative pressure chamber inside. The roller wall is evenly covered with absorbent micropores with a diameter of 0.5~2mm, arranged in a matrix or spiral pattern. Both ends of the roller body are connected to an external air extraction pipe through rotary joints. The air extraction pipe is connected to a vacuum generator, which can maintain a stable negative pressure of -0.02~-0.08MPa in the negative pressure chamber. When the fabric is attached to the roller surface, the free water carried on the surface is drawn into the roller through the micropores under the action of negative pressure, and then collected and discharged through the air extraction pipe, realizing non-compression dehydration and avoiding fabric wrinkling and deformation caused by mechanical compression.

[0046] The transmission transfer roller 402 is matched with the negative pressure water suction roller 401 to provide traction for fabric conveying. The water suction roller and the transmission roller are arranged in a coordinated manner. The fabric is first dehydrated by the water suction roller and then pulled and reversed by the transmission roller to ensure the dehydration effect and conveying stability. The ends of the roller group are equipped with seated bearings and are fixedly installed in the mounting holes of the frame wall panel. The transmission gear is equipped with a protective cover to ensure operational safety.

[0047] In this embodiment, the negative pressure absorbent roller 401 is connected to an external air extraction pipe and a vacuum generator at both ends, so that a stable negative pressure chamber is formed inside the roller body. The free water on the surface of the fabric can be adsorbed and removed by relying on the micropores of the roller wall. This non-extrusion dehydration method avoids the defects such as wrinkles and aurora marks on the fabric caused by traditional roller extrusion. The dehydration is gentle and uniform, which can effectively reduce the liquid content of the fabric after washing and reduce the energy consumption of subsequent drying. It can meet the high-quality processing requirements of easily damaged fabrics such as knitted fabrics and elastic fabrics.

[0048] When the body is working, such as Figure 6As shown, taking a washing machine with two sets of washing units 3 in this embodiment as an example, the fabric to be washed is fed into the inlet at the lower left corner of the frame cabinet 1 of the washing machine. After being guided by the guide rollers set at the inlet, it enters the liquid storage tank 201 of the bottom pre-soaking unit 2. After passing around the guide roller group 202, it is completely immersed in the washing liquid, completing the pre-soaking and preliminary cleaning. Then, under the traction, the fabric enters the sawtooth channel of the first set of washing units 3 on the left vertically from bottom to top. The washing water overflows from the water storage and distribution chamber 301 at the top and forms multiple layers along the sawtooth wall. The water curtain continues to flow against the current, continuously washing both sides of the fabric. The downward impact of the water flow counteracts part of the upward traction force, while the fluid clamping force keeps the fabric suspended in the center. Then, the fabric passes through the top of the first washing unit 3 and immediately adheres to the negative pressure suction roller 401. The negative pressure inside the roller adsorbs and removes the free washing liquid from the surface of the fabric, reducing the liquid content of the fabric. After dehydration, the fabric passes through the adjustable-angle guide arm 6, completing the change of the fabric direction, transitioning from the top of the left station to the bottom of the right station, and enters the secondary washing inlet.

[0049] After entering the secondary washing inlet, the fabric enters the second washing unit 3 on the right side from bottom to top again, repeating the waterfall counter-current rinsing process to complete the second-stage deep washing, further improving the cleanliness of the fabric. Finally, the fabric after the second-stage washing is output from the top of the washing unit 3 on the right side. After the top roller group is reversed and adjusted, it is sent out of the machine from the fabric outlet on the right side of the frame and enters the subsequent process.

[0050] Example 2: In the operation of a waterfall-style fabric washing machine, the fabric is continuously conveyed vertically, sequentially undergoing processes such as soaking, waterfall rinsing, and negative pressure dewatering. Existing drive systems mostly employ a preset fixed speed or fixed torque open-loop control mode, where process parameters remain unchanged throughout the entire process once set. In actual production, after the fabric enters the washing unit from a dry state, it continuously absorbs washing liquid as the washing process progresses, gradually increasing the liquid content and significantly increasing the fabric's weight. After passing through the negative pressure absorption unit, the liquid content decreases, and the weight decreases accordingly. Under fixed drive parameters, the total axial tension of the fabric fluctuates significantly with changes in its weight. For example, when the liquid content increases and the weight increases, if the drive traction force remains constant, part of the fabric's effective tension will be offset by its own weight, resulting in insufficient effective tension. This can easily lead to problems such as fabric slack and bulging, deviation and wrinkling, and friction with the channel wall, thus compromising washing uniformity and fabric movement stability. When the liquid content decreases and the weight decreases, the drive traction force will act more on the fabric itself, resulting in an abnormally large increase in effective tension. This can cause excessive stretching of easily deformable fabrics such as knitted fabrics and elastic fabrics, leading to quality defects such as warp elongation, weft skew, and dimensional instability. Conventional tension closed-loop solutions often use a fixed total tension as the control target, failing to distinguish between the effective tension required for the distribution process and the additional tension generated by the weight of the liquid content. The control target is out of sync with the actual process requirements, and it cannot fundamentally offset the tension fluctuations caused by changes in the liquid content. Both the control accuracy and process adaptability are significantly insufficient.

[0051] To address the aforementioned problems, this embodiment also provides a dynamic control method for a waterfall-type fabric washing machine, such as... Figure 11 As shown, it includes the following steps: S1: Obtain the inherent parameters of the fabric, the structural parameters of the equipment, and the target parameters of the process. Based on the above parameters and in combination with the benchmark parameter calibration rules, obtain the effective tension of the fabric and the benchmark speed of the motor.

[0052] In this embodiment, the inherent parameters of the fabric, the structural parameters of the equipment, and the target parameters of the process are obtained. Based on the above parameters and in combination with the benchmark parameter calibration rules, the effective tension of the fabric and the benchmark speed of the motor are obtained, including the following steps: The dry fabric mass per unit length and fabric width are obtained as inherent parameters of the fabric; the drive unit transmission ratio, the radius of the active drive roller, the fabric length in the vertical section of the washing channel, and the no-load torque are obtained as equipment structural parameters; the effective tension force per unit width of the fabric and the reference running linear speed are obtained as process target parameters. The effective tension force of the fabric is obtained by multiplying the effective tension force per unit width of the fabric by the fabric width, and the reference speed of the motor is calculated based on the reference running linear velocity.

[0053] Specifically, the formulas for calculating the effective fabric tension and the motor's reference speed are as follows:

[0054]

[0055] in, For the effective tension of the fabric, Effective tension per unit width of fabric, For the width of the fabric, This is the reference speed of the motor. As the baseline operating linear velocity, For the transmission ratio of the drive unit, The radius of the drive roller.

[0056] Specifically, the reference total tension under dry cloth conditions can also be calculated, which can be used as a benchmark quantity for evaluating the operating status of equipment. The calculation formula is as follows:

[0057] in, The reference total tension is given under dry fabric conditions. The mass of dry fabric per unit length. It is the length of the fabric in the vertical section of the washing channel. It is gravitational acceleration.

[0058] This embodiment provides a precise and unified calculation benchmark for the entire dynamic control system by clearly defining three categories of input parameters in the benchmark calibration step: inherent fabric parameters, equipment structure parameters, and process objectives parameters, and establishing standardized parameter conversion rules. By converting the effective tension force per unit width to the fabric width to obtain the total effective tension force, the core tension force indicators required by the process can be clearly identified, laying a logical foundation for subsequently distinguishing the additional tension force due to liquid self-weight and dynamically updating the total tension target. By deriving the motor benchmark speed from the benchmark operating linear velocity, a standardized mapping from process requirements to drive parameters is achieved, thereby ensuring the consistency and accuracy of the control benchmark and improving the reliability of subsequent compensation calculations.

[0059] S2: Real-time acquisition of operating signals during the operation of the washing machine; based on the real-time operating signals, inherent parameters of the fabric, and structural parameters of the equipment, and combined with the real-time fabric attribute conversion mechanism, the real-time attributes of the fabric are calculated.

[0060] In this embodiment, real-time operating signals of the washing machine are collected in real time. Based on the real-time operating signals, inherent parameters of the fabric, and structural parameters of the equipment, and combined with the real-time fabric attribute conversion mechanism, the real-time attributes of the fabric are calculated to obtain the real-time attributes of the fabric. This includes the following steps: The measured torque, measured fabric tension, and measured fabric linear speed at the motor output are collected as real-time operating signals. The total tension is obtained by multiplying the difference between the measured torque and the no-load torque by the transmission ratio of the drive unit and comparing it with the radius of the drive roller; the total tension is then calculated by weighted averaging the total tension and the measured fabric tension to obtain the target total tension. The measured linear velocity of the fabric is integrated to obtain the fabric running position. The fabric running position is substituted into the liquid carrying rate formula to obtain the real-time liquid carrying rate of the fabric. The real-time liquid carrying rate is multiplied by the dry fabric mass per unit length and the fabric length of the vertical section of the washing channel, and then multiplied by the gravitational acceleration to obtain the additional tensile force of the liquid carrying self-weight. Real-time liquid retention rate and additional tensile force due to liquid retention weight are used as real-time properties of the fabric.

[0061] Specifically, the calculation process for verifying the total tension is expressed by the following formula:

[0062] in, To verify the total tension, This represents the measured torque at the motor output. This is the no-load torque; The calculation process for the total target tension is expressed by the following formula:

[0063] in, For the target total tension, This is the weighting coefficient, and its value can be set to 0.6-0.8.

[0064] The liquid carryover rate can be calculated using two methods in this embodiment. One method involves less computation, and its formula is as follows:

[0065] in, For the fabric's running position, To determine the baseline liquid carry-over rate of the fabric under ideal conditions at different operating positions, experiments can be conducted. However, under actual operating conditions, the liquid carry-over rate of the fabric fluctuates relatively little within the same process section (in this embodiment, the waterfall washing machine mainly includes a pre-soaking section, a primary washing section, a dewatering section, and a secondary washing section). Therefore, for convenience, the fabric is considered to be in the pre-soaking section when s = 0 - s1, in the primary washing section when s = s1 - s2, in the dewatering section when s = s2 - s3, and in the secondary washing section when s = s3 - s4. The baseline liquid carry-over rate for each section is approximately considered constant, and s1, s2, s3, and s4 can be obtained through experimental measurement. Let t be the real-time liquid carryover rate of the fabric. By using the reference liquid carryover rate of different process sections as the target, the subsequent PID adjustment is made to make the measured total target tension tend to the target effective tension corresponding to the reference liquid carryover rate, thereby making the actual working condition tend to the ideal steady state. The calculation is small and the response speed during adjustment is fast. However, it does not consider the influence of various measurement errors and actual dynamic working conditions, so the accuracy is low. Therefore, this embodiment also has a solution formula with a larger calculation but higher accuracy, which is expressed as follows:

[0066]

[0067]

[0068]

[0069] For historical cumulative deviation, The sampling interval is... This is the liquid carryover rate correction factor. This method involves subtracting the fabric's weight from the measured total target tension using an estimated value of the current liquid carryover rate, thus obtaining an estimated value of the fabric's effective tension. The difference between this estimated value and the target effective tension is used to obtain the correction deviation. If the estimated liquid content is too low, the estimated fabric weight will be too low, and the estimated effective tension of the fabric will be too low. It's a bit too big, at this point A value less than 0 reduces the integral term in the formula for calculating the liquid carryover rate, resulting in a smaller integral term being subtracted during correction. This leads to a larger corrected liquid carryover rate, which in turn increases the estimated fabric weight. Consequently, the estimated effective tension of the fabric is... As the value decreases, it gradually converges towards the target value. The entire process is a negative feedback loop, with the deviation gradually decreasing until it stabilizes within the target range. To prevent divergence caused by abrupt changes in the process stage, a correction deviation is applied to each calculation of the liquid carryover rate. Limitations are imposed if the calculated correction deviation is... If the value is greater than or equal to the maximum limit / less than or equal to the minimum limit, then the correction deviation for that moment... Take the maximum / minimum value as a limit, and correct the deviation over n consecutive sampling times. If all values ​​exceed the limit, the operation will be suspended. The formula for calculating the additional tensile force due to the liquid's own weight is as follows: ;in, It is the additional tensile force due to the weight of the liquid.

[0070] This embodiment takes into account that the liquid carry-over rate is related to the previous state under actual working conditions. Therefore, the liquid carry-over rate is solved by the previous feedback of the fabric position and the correction of historical deviations, which fits the actual working conditions and ensures the effect of subsequent drive compensation.

[0071] S3: Calculate the current target tension of the fabric based on the real-time properties and effective tension of the fabric, and construct a compensation driving equation based on the current target tension of the fabric and the real-time operation signal.

[0072] In this embodiment, the current target tension of the fabric is calculated based on the real-time properties and effective tension of the fabric. A compensation driving equation is then constructed based on the current target tension of the fabric and the real-time operating signal, including the following steps: With the goal of stabilizing the effective tension of the fabric, the additional tension due to the self-weight of the liquid-laden material is superimposed with the effective tension per unit width of the fabric to obtain the current target tension related to the real-time liquid-laden rate, and the allowable fluctuation range of the target effective tension is set as a tension constraint. The difference between the current target tension and the total target tension is used as the compensation driving variable; The PID algorithm is used, and the compensation driving equation is constructed based on the compensation driving variables. The formula is expressed as follows:

[0073] in, , , These are the proportional gain coefficient, integral gain coefficient, and differential gain coefficient, which are adaptively adjusted according to the liquid carryover rate. To compensate for the driving variables.

[0074] Specifically, the calculation process for the current target tension is expressed by the following formula:

[0075] The permissible fluctuation range of the target effective tension is:

[0076] in, This is the deviation coefficient, which can be set according to actual needs; The formula for calculating the compensation driving variable is as follows: .

[0077] This embodiment takes the constant effective tension of the fabric as the core objective in the target tension construction stage. It superimposes the real-time liquid-laden self-weight additional tension with the effective tension to obtain a dynamic target tension that matches the current liquid-laden rate, and sets an allowable fluctuation range as a tension constraint. This method breaks the limitation of a fixed tension target and can adaptively adjust the total tension threshold according to the change of fabric water content, thus offsetting the interference of self-weight fluctuations on process tension from a mechanistic perspective. The compensation driving equation is constructed by using the tension difference as the compensation driving variable and combining it with the PID algorithm. The control logic is clear and the response is fast. The range constraint can also avoid tension oscillation caused by over-adjustment, ensuring a smooth and continuous fabric feeding process.

[0078] S4: Calculate the motor speed compensation amount of the drive unit based on the compensation drive equation, determine the target motor speed based on the motor speed compensation amount and the motor reference speed, generate drive compensation command, and compensate the motor speed based on the drive compensation command.

[0079] In this embodiment, the motor speed compensation amount of the drive unit is calculated based on the compensation drive equation, and the target motor speed is determined based on the motor speed compensation amount and the motor reference speed, including the following steps: The compensation drive variables are calculated in real time, and the compensation drive variables are substituted into the compensation drive equation to calculate the motor speed compensation amount; The target motor speed is obtained by superimposing the motor speed compensation amount with the motor reference speed.

[0080] Specifically, the formula for calculating the target speed of the motor is as follows: .

[0081] This embodiment solves for the motor speed compensation by substituting the real-time compensation drive variable into the compensation drive equation, and then superimposing it with the motor reference speed to obtain the final target speed. This execution method can directly and accurately convert tension deviation into drive adjustment commands, ensuring the timeliness and accuracy of the control response. By superimposing the compensation amount based on the reference speed, it can avoid the impact of large speed changes on the fabric, ensuring a smooth and stable fabric feeding process. At the same time, it forms a complete closed loop with the previous dynamic target tension calculation, effectively maintaining the stability of the effective tension of the fabric and avoiding quality problems such as excessive stretching or loose bulging caused by fluctuations in the liquid content.

[0082] After the drive command is issued, the drive motor adjusts its output speed and torque according to the drive command, changes the traction force of the fabric, and makes the total tension converge toward the target value. After one sampling cycle, it returns to step S2 to carry out a new round of data acquisition and calculation, forming a continuous closed-loop iterative control.

[0083] As can be seen from the above embodiments, it has at least the following substantial effects: (1) The present invention uses a continuous sawtooth-shaped guide surface symmetrically arranged on the left and right inner walls of the water washing channel. After the washing water is evenly distributed in the top water storage and distribution cavity, it falls from top to bottom layer by layer to form a multi-layer waterfall water curtain. It forms a counter-current contact with the vertically upward fabric, which not only significantly enhances the washing liquid replacement efficiency, but also the downward water flow impact force can offset the upward traction force of the fabric. The symmetrical water flow on both sides forms a fluid clamping effect, which not only reduces the axial tensile stress of the fabric and avoids tensile deformation and weft skew, but also makes the fabric suspend in the center of the channel, eliminating the wall friction and fuzzing defects. (2) The present invention uses the hollow negative pressure water absorption roller of the top transfer unit to adsorb and remove the free water of the fabric without squeezing negative pressure. Compared with mechanical pressing, it avoids wrinkling and aurora printing, effectively reduces the liquid content and reduces the energy consumption of subsequent drying. At the same time, the arched transmission transfer roller in the middle can optimize the fabric wrapping angle and improve the stability of conveying. (3) The present invention completes the pre-wetting and initial cleaning of the fabric through the lower pre-soaking unit, and improves the cleanliness step by step with the two-stage water washing. The drive unit with gear transmission accurately matches the output traction force, ensuring the stability of the fabric tension throughout the process. It is suitable for high-quality continuous water washing processing of easily deformable fabrics such as knitted fabrics and elastic fabrics. (4) This invention uses a four-step closed-loop dynamic control method to maintain the constant effective tension of the fabric as the core objective, which can adaptively offset the tension imbalance caused by the fluctuation of the fabric liquid rate during the washing process. The method first calibrates the effective tension benchmark based on the inherent parameters of the fabric, the structural parameters of the equipment and the process target, and clearly distinguishes the effective tension required by the process from the additional tension generated by the self-weight of the liquid. Then, it calculates the real-time liquid properties of the fabric by collecting the running signal in real time, updates the total tension target under the corresponding working condition and constructs the compensation driving equation, and finally solves the motor speed compensation amount and sends it out for execution. The input and output of the whole process are connected step by step, which can avoid the fabric stretching deformation and weft skew damage caused by excessive tension, and also prevent the fabric from loosening and wrinkling due to insufficient tension. Moreover, it can be deployed based on the existing sensors of the equipment without additional modifications to the equipment, resulting in low implementation cost and effectively improving the washing quality and equipment process adaptability.

[0084] The specific embodiments described above are preferred embodiments of the present invention and are not intended to limit the specific scope of the present invention. The scope of the present invention includes, but is not limited to, these specific embodiments. All equivalent changes made in accordance with the shape and structure of the present invention are within the protection scope of the present invention.

Claims

1. A waterfall-type fabric washing machine, characterized in that: Includes rack cabinet, pre-prep unit, washing unit, transfer unit and drive unit; The prepreg unit is located in the lower cavity of the frame cabinet, and is equipped with a liquid storage tank and a guide roller assembly. The washing unit is installed on the wall panel of the rack cabinet, including a water storage and distribution cavity at the top and a washing channel vertically connected to the bottom of the water storage and distribution cavity. The washing channel is a long strip-shaped slit, and the inner walls on the left and right sides are symmetrically provided with continuous sawtooth-shaped guide surfaces. The transfer unit is located on the top of the frame cabinet and includes a negative pressure water absorption roller and a transmission transfer roller located below the negative pressure water absorption roller. The negative pressure water absorption roller is hollow inside and has water absorption micropores on its roller wall. A fixing device is provided above it. The transmission transfer roller is composed of multiple sets of driven guide rollers spliced ​​together and arches upward in the middle. The drive unit is arranged in parallel next to the transfer unit, including a pair of coaxially arranged drive rollers and a driven roller arranged on the side of the drive rollers. The drive rollers are connected to the transmission gearbox, and the transmission gearbox is connected to the motor.

2. The waterfall-type fabric washing machine according to claim 1, characterized in that: At least one set of the washing units is provided with a guide arm on the middle side, and the guide arm includes a fixed mounting base, a swing arm and a locking assembly; The fixed mounting base is installed on the crossbeam in the middle of the rack cabinet. One end of the swing arm is rotatably connected to the fixed mounting base, and the other end is provided with a guide roller. The locking component is an arc-shaped adjustment groove opened on the fixed mounting base.

3. The waterfall-type fabric washing machine according to claim 1, characterized in that: The water washing unit has an overall T-shaped structure and a water storage and distribution chamber with two parallel compartments at the top; The water storage and distribution chamber is divided into a first chamber and a second chamber from top to bottom by a porous flow equalization baffle. The second cavity is connected to an external water supply pipe, and the first and second cavities are provided with flow guiding layers on their side walls; The outlet of the flow guide jacket is located directly above the sawtooth flow guide surface of the water washing channel, and the inlet is located in the middle of the side wall of the first cavity.

4. A waterfall-type fabric washing machine according to claim 1, characterized in that: The sawtooth-shaped guide surface is composed of multiple sequentially connected water guide surfaces, and the protruding ends of the water guide surfaces all face the center of the water washing channel and are inclined downwards.

5. A waterfall-type fabric washing machine according to claim 1, characterized in that: The two ends of the negative pressure water absorption roller are connected to an external air extraction pipe, and the external air extraction pipe is connected to a vacuum generator. When the vacuum generating device is running, a negative pressure cavity is formed inside the negative pressure water absorption roller.

6. A dynamic control method for a waterfall-type fabric washing machine, applicable to the waterfall-type fabric washing machine described in any one of claims 1-5, characterized in that: Includes the following steps: S1. Obtain the inherent parameters of the fabric, the structural parameters of the equipment, and the target parameters of the process. Based on the above parameters and in combination with the benchmark parameter calibration rules, obtain the effective tension force of the fabric and the benchmark speed of the motor. S2. Real-time operation signals of the washing machine are collected during operation. Based on the real-time operation signals, inherent parameters of the fabric and structural parameters of the equipment, and combined with the real-time attribute conversion mechanism of the fabric, the real-time attributes of the fabric are calculated to obtain the real-time attributes of the fabric. S3. Calculate the current target tension of the fabric based on the real-time properties and effective tension of the fabric, and construct a compensation driving equation based on the current target tension of the fabric and the real-time operation signal. S4. Calculate the motor speed compensation amount of the drive unit based on the compensation drive equation, determine the target motor speed based on the motor speed compensation amount and the motor reference speed, and generate drive compensation command. Compensate the motor speed based on the drive compensation command.

7. The dynamic control method for a waterfall-type fabric washing machine according to claim 6, characterized in that: In step S1, the inherent parameters of the fabric, the structural parameters of the equipment, and the target parameters of the process are obtained. Based on the above parameters and in conjunction with the benchmark parameter calibration rules, the effective tension of the fabric and the benchmark speed of the motor are obtained, including the following steps: The dry fabric mass per unit length and fabric width are obtained as inherent parameters of the fabric; the drive unit transmission ratio, the radius of the active drive roller, the fabric length in the vertical section of the washing channel, and the no-load torque are obtained as equipment structural parameters; the effective tension force per unit width of the fabric and the reference running linear speed are obtained as process target parameters. The effective tension force of the fabric is obtained by multiplying the effective tension force per unit width of the fabric by the fabric width, and the reference speed of the motor is calculated based on the reference running linear velocity.

8. The dynamic control method for a waterfall-type fabric washing machine according to claim 7, characterized in that: In S2, real-time operating signals of the washing machine are collected during operation. Based on the real-time operating signals, inherent fabric parameters, and equipment structural parameters, and combined with a real-time fabric attribute conversion mechanism, the real-time attributes of the fabric are calculated, including the following steps: The measured torque, measured fabric tension, and measured fabric linear speed at the motor output are collected as real-time operating signals. The total tension is obtained by multiplying the difference between the measured torque and the no-load torque by the transmission ratio of the drive unit and comparing it with the radius of the drive roller; the total tension is then calculated by weighted averaging the total tension and the measured fabric tension to obtain the target total tension. The fabric running position is obtained by integrating the measured fabric linear velocity, and the real-time liquid carry-over rate of the fabric is obtained by substituting the fabric running position into the liquid carry-over rate calculation formula. The additional tensile force due to the liquid-carrying rate is obtained by multiplying the real-time liquid-carrying rate by the mass of dry fabric per unit length and the length of fabric in the vertical section of the washing channel, and then multiplying by the gravitational acceleration. Real-time liquid retention rate and additional tensile force due to liquid retention weight are used as real-time properties of the fabric.

9. The dynamic control method for a waterfall-type fabric washing machine according to claim 8, characterized in that: In S3, the current target tension of the fabric is calculated based on the real-time properties and effective tension of the fabric. A compensation driving equation is then constructed based on the current target tension of the fabric and the real-time operating signal, including the following steps: With the goal of stabilizing the effective tension of the fabric, the additional tension due to the self-weight of the liquid-laden material is superimposed with the effective tension per unit width of the fabric to obtain the current target tension related to the real-time liquid-laden rate, and the allowable fluctuation range of the target effective tension is set as a tension constraint. The difference between the current target tension and the total target tension is used as the compensation driving variable; The PID algorithm is used, and the compensation driving equation is constructed based on the compensation driving variables. The formula is expressed as follows: in, , , These are the proportional gain coefficient, integral gain coefficient, and differential gain coefficient, which are adaptively adjusted according to the liquid carryover rate. To compensate for the driving variables.

10. The dynamic control method for a waterfall-type fabric washing machine according to claim 9, characterized in that: In S4, the motor speed compensation amount of the drive unit is calculated based on the compensation drive equation, and the target motor speed is determined based on the motor speed compensation amount and the motor reference speed, including the following steps: The compensation drive variables are calculated in real time, and the compensation drive variables are substituted into the compensation drive equation to calculate the motor speed compensation amount; The target motor speed is obtained by superimposing the motor speed compensation amount with the motor reference speed.

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