Multi-dimensional data sensing intelligent carding machine

Abstract

The utility model relates to the technical field of carding machines, in particular to a multi-dimensional data sensing intelligent carding machine, which comprises a multi-dimensional data acquisition module, a data fusion and processing module, an intelligent control module and a motor driving module, the multi-dimensional data acquisition module, the data fusion and processing module and the motor driving module are electrically connected with the intelligent control module respectively; the multi-dimensional data acquisition module is provided with a high-precision electromagnetic rotating speed sensor, a capacitive pressure sensor, a thickness sensor and a strain gauge type tension sensor; the data fusion and processing module comprises a data preprocessing unit and a data fusion unit, and the intelligent control module comprises a programmable logic controller and a control circuit. According to the utility model, the production efficiency is obviously improved, the quality of fiber products is effectively improved, the problems of non-uniform carding, fiber damage and the like are reduced, the equipment maintenance cost is reduced, and the production continuity is improved.

Description

Technical Field

[0001] This utility model relates to the field of combing machine technology, specifically to an intelligent combing machine with multi-dimensional data sensing. Background Technology

[0002] In the textile and fiber processing industry, carding machines are core equipment, undertaking the crucial task of carding, removing impurities from fiber raw materials, and forming a uniform fiber web. However, carding machines currently on the market have revealed many drawbacks in actual operation.

[0003] Traditional carding machines rely primarily on single-dimensional data for control, such as monitoring only the drive shaft speed. This one-sided monitoring cannot comprehensively and accurately reflect the fiber carding status. Key factors such as fiber conveying pressure, fiber web thickness, and fiber tension are often overlooked, making it difficult to precisely control the carding process. This results in large fluctuations in the quality of fiber products, leading to problems such as uneven carding and fiber damage, which affect product quality.

[0004] Existing carding machines are simple to control and lack intelligence and adaptability. Faced with different fiber raw materials and varying production process requirements, they cannot dynamically adjust carding parameters in real time, resulting in low production efficiency and difficulty in meeting diverse market demands. Therefore, there is an urgent need for an intelligent carding machine with multi-dimensional data sensing to solve the above-mentioned technical problems. Summary of the Invention

[0005] The purpose of this invention is to provide a multi-dimensional data-sensing intelligent carding machine to solve the problems mentioned in the background art, such as the simple control of existing carding machines, lack of intelligence and adaptive capabilities, and inability to dynamically adjust carding parameters in real time, resulting in low production efficiency.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a multi-dimensional data sensing intelligent sorting machine, comprising a multi-dimensional data acquisition module, a data fusion and processing module, an intelligent control module, and a motor drive module, wherein the multi-dimensional data acquisition module, the data fusion and processing module, and the motor drive module are electrically connected to the intelligent control module respectively;

[0007] The multi-dimensional data acquisition module is equipped with a high-precision electromagnetic speed sensor, a capacitive pressure sensor, a thickness sensor, and a strain gauge tension sensor. The high-precision electromagnetic speed sensor, capacitive pressure sensor, thickness sensor, and strain gauge tension sensor are electrically connected to the intelligent control module.

[0008] The data fusion and processing module includes a data preprocessing unit and a data fusion unit, which are electrically connected.

[0009] The intelligent control module includes a programmable logic controller and a control circuit, with the programmable logic controller and the control circuit being electrically connected.

[0010] The motor drive module includes a large cylinder drive unit, a work roll drive unit, a stripping roll drive unit, and a doffer drive unit, which are electrically connected to the intelligent control module.

[0011] Preferably, high-precision electromagnetic speed sensors are installed at each drive shaft of the carding machine and rigidly connected to the drive shaft via couplings.

[0012] Preferably, the capacitive pressure sensor is installed on the fiber conveying pipe and is tightly connected to the pipe through a threaded interface.

[0013] Preferably, the capacitive pressure sensor includes a fine filter device, which is disposed at the front end of the capacitive pressure sensor.

[0014] Preferably, the thickness sensor is mounted on an adjustable bracket in the fiber web forming area.

[0015] Preferably, the strain gauge tension sensor is located at the contact point between the fiber combing component and the fiber, and is connected to the combing component by means of adhesive or bolt fixing.

[0016] Preferably, it also includes a fault diagnosis and alarm module, which is electrically connected to the intelligent control module.

[0017] Preferably, it also includes an automatic cleaning device, which is electrically connected to the intelligent control module.

[0018] Preferably, it also includes an automatic dust collection device located at the bottom of the carding machine, which is electrically connected to the intelligent control module.

[0019] Compared with existing technologies, the beneficial effects of this utility model are as follows: This utility model collects multi-dimensional data from all directions, uses an advanced hardware system for data fusion and processing, and coordinates with intelligent control hardware to achieve precise control of the carding process, significantly improving the quality and production efficiency of fiber products. This utility model comprehensively and accurately grasps fiber carding status information, and the intelligent fuzzy control core combined with hardware circuitry achieves precise adjustment of the carding machine speed ratio, effectively improving the quality of fiber products and reducing problems such as uneven carding and fiber damage. The high-performance AC servo motor and servo driver in the motor drive module can quickly respond to control signals, adjust motor operating parameters, and improve production efficiency. Simultaneously, it can automatically adjust carding parameters according to different fiber characteristics and production process requirements, further improving production efficiency. When processing raw materials of different fiber thicknesses, the system can automatically adjust the carding machine speed and the coordination parameters of each component, improving production efficiency while ensuring product quality. The fault diagnosis and alarm module facilitates timely detection and resolution of problems by operators, reducing equipment maintenance costs and improving production continuity. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of this utility model. Detailed Implementation

[0021] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0022] Example 1: Please refer to Figure 1 This utility model provides a multi-dimensional data sensing intelligent sorting machine, including a multi-dimensional data acquisition module, a data fusion and processing module, an intelligent control module, and a motor drive module. The multi-dimensional data acquisition module, the data fusion and processing module, and the motor drive module are electrically connected to the intelligent control module.

[0023] The multi-dimensional data acquisition module is equipped with a high-precision electromagnetic speed sensor, a capacitive pressure sensor, a thickness sensor, and a strain gauge tension sensor. These sensors are electrically connected to the intelligent control module.

[0024] Preferably, high-precision electromagnetic speed sensors are installed at each drive shaft of the carding machine and rigidly connected to the drive shaft via couplings. Their housings are made of high-strength aluminum alloy, offering excellent heat dissipation and protection, resisting corrosion from dust, oil, and other contaminants, ensuring accurate capture of component speeds with a measurement accuracy of ±0.1%FS. The signal cable uses shielded cable with an outer tinned copper wire braided shielding layer to reduce external electromagnetic interference. Shock-absorbing rubber pads are added to the mounting location to reduce the impact of equipment vibration on speed measurement. The mounting bracket is made of high-strength, high-rigidity steel to ensure stable sensor installation during equipment operation and prevent measurement errors caused by bracket deformation.

[0025] Preferably, the capacitive pressure sensor is mounted on the fiber conveying pipeline and tightly connected to the pipeline via a threaded interface; its accuracy is ±0.05N, enabling real-time monitoring of changes in fiber conveying pressure. The signal conditioning circuit is integrated into a small metal shielded box to reduce external interference and improve measurement stability. Preferably, the capacitive pressure sensor includes a fine filter device located at the front end of the capacitive pressure sensor, thereby preventing fibers and impurities from entering the sensor and affecting measurement accuracy and service life.

[0026] Preferably, the thickness sensor is mounted on an adjustable bracket in the fiber web forming area. By adjusting its height and angle, it can be precisely aligned with the fiber web, achieving accurate measurement of the fiber web thickness with an accuracy of ±0.03mm. The laser emission and reception modules are integrated into a single design, with a stainless steel casing providing excellent corrosion resistance. A transparent protective plate made of high-strength acrylic material surrounds the sensor, preventing fiber scattering without affecting laser emission and reception. The optical path system employs advanced optical lenses and reflectors to improve laser emission intensity and reception sensitivity, thereby enhancing the accuracy and stability of thickness measurement.

[0027] Preferably, the strain gauge tension sensor is positioned at the contact point between the fiber combing component and the fiber, and is connected to the combing component by adhesive or bolt fixing. It accurately monitors tension changes during the fiber combing process. The strain gauge uses a high-precision metal foil strain gauge, offering high sensitivity and stability. The signal output line uses a twisted-pair cable with strong anti-interference capabilities to ensure accurate transmission of tension data. The surface is coated with a wear-resistant and corrosion-resistant protective coating to extend its service life. Strictly standardized strain gauge bonding processes are employed, using professional adhesive and high-precision bonding equipment to ensure a tight fit between the strain gauge and the combing component, improving measurement accuracy and reliability.

[0028] Multiple types of sensors are deployed comprehensively in key areas of the carding machine, each tightly connected to the machine through specific mechanical structures and electrical connections. All data collected by the sensors is transmitted to a data concentrator via high-speed shielded twisted-pair cables. The high-speed shielded twisted-pair cables use high-purity oxygen-free copper cores and polytetrafluoroethylene (PTFE) insulation, offering low loss and high transmission rates. The data concentrator employs an industrial-grade embedded computer, boasting powerful processing capabilities and high stability, with a metal casing providing excellent electromagnetic shielding. The data concentrator then utilizes industrial Ethernet to transmit the data to the data processing center. Industrial Ethernet uses fiber optic cables as the transmission medium, offering strong anti-interference capabilities and long transmission distances. A signal amplifier is added between the data concentrator and the sensors to ensure no signal attenuation over long distances, optimizing the data transmission line layout and reducing signal interference.

[0029] The data fusion and processing module includes a data preprocessing unit and a data fusion unit, which are electrically connected. The data preprocessing unit consists of a dedicated signal conditioning chip and an analog-to-digital converter (ADC). The dedicated signal conditioning chip uses a high-precision operational amplifier and filters to amplify and filter the analog signal, improving signal quality. The ADC uses a high-resolution A / D converter to convert the analog signal into a digital signal. The data fusion unit is powered by a dedicated digital signal processor (DSP). This processor features high-speed computing power and low power consumption, and can fuse data such as rotation speed, pressure, thickness, and tension from different sensors to eliminate noise and errors, obtaining more accurate and comprehensive fiber combing status information. The analog signals output from the sensors first enter the dedicated signal conditioning chip, are processed, converted into digital signals by the ADC, and then transmitted to the DSP for data fusion. All chips are connected via a high-speed data bus to ensure fast and stable data transmission.

[0030] The intelligent control module includes a programmable logic controller (PLC) and control circuitry, with the PLC electrically connected to the control circuitry. The PLC employs a high-performance industrial-grade processor, boasting powerful logic processing capabilities and high reliability. It is equipped with dedicated input / output modules to receive data from the data fusion and processing module and transmit control signals to the intelligent motor drive and control system. The fused data is collected through the input / output modules, and parameters such as the speed ratio of the combing machine are adjusted according to preset fuzzy rules. These fuzzy rules are stored in the PLC's memory, enabling rapid data processing and logical judgment through hardware circuitry. A distributed architecture is adopted, using industrial Ethernet as the data transmission backbone to connect various sensor nodes, fuzzy controllers, motor drivers, and other devices. Industrial-grade industrial Ethernet switches ensure fast and accurate data transmission. The core of the control system is a high-performance industrial computer, housed in a ruggedized chassis, providing dustproof, moisture-proof, and vibration-resistant capabilities to withstand harsh industrial environments. Redundant power supplies and data backup devices are provided. The redundant power supply uses a dual-power module hot-backup method, and the data backup device employs a large-capacity hard disk array. The internal circuitry of the industrial computer incorporates multiple layers of shielding and filtering circuits to reduce external electromagnetic interference.

[0031] The motor drive module includes a large cylinder drive unit, a work roll drive unit, a stripping roll drive unit, and a doffer drive unit, all of which are electrically connected to the intelligent control module. Key components of the carding machine, such as the large cylinder, work roll, stripping roll, and doffer, are all driven by independent high-performance AC servo motors. These motors utilize permanent magnet synchronous motor technology, offering fast response, stable torque output, and a wide speed range. The internal windings use high-purity copper and advanced winding technology to reduce winding resistance and improve motor efficiency and performance. Each motor is equipped with a servo driver employing vector control technology and a modular design, integrating a power module, control module, and protection module. The power module uses high-performance IGBT power devices for efficient motor drive; the control module uses an advanced microprocessor to precisely adjust motor speed, torque, and direction based on control signals; and the protection module provides overcurrent protection, overvoltage protection, and overheat protection to protect the motor and driver from damage. The power module uses new heat dissipation materials and structures, such as silicon carbide-based heat sinks, to improve heat dissipation efficiency.

[0032] Preferably, the system also includes a fault diagnosis and alarm module, which is electrically connected to the intelligent control module. System fault diagnosis is implemented by fault diagnosis hardware circuitry in the industrial computer. When a system anomaly occurs, the hardware circuitry triggers an audible and visual alarm, and the cause of the fault is displayed on the human-machine interface. The audible and visual alarm is installed on the control panel for prominent notification to the operator.

[0033] Preferably, the system also includes an automatic cleaning device electrically connected to the intelligent control module. The automatic cleaning device has multiple automatic cleaning nozzles inside the carding machine, which periodically perform high-pressure air jet cleaning of the equipment's interior. Preferably, the system also includes an automatic dust collection device located at the bottom of the carding machine, electrically connected to the intelligent control module. This allows for the timely removal of dust and impurities generated during the cleaning process. The device features a removable cleaning filter with a multi-layer filtration structure and a quick-release design for easy cleaning and replacement by staff.

[0034] In implementing this utility model, the cylinder is made of high-strength alloy steel and undergoes a special heat treatment process, such as carburizing and quenching, to improve the wear resistance and service life of the cylinder needle cloth. The doffer employs high-precision machining technology to ensure minimal surface flatness and roundness errors, guaranteeing uniform fiber web output. The working roller and stripping roller surfaces use novel coating materials, such as nano-coatings with special microstructures, to enhance fiber gripping and combing capabilities, reducing fiber entanglement and damage. A combination of high-precision synchronous belt drive and gear drive replaces traditional belt and chain drives. Synchronous belt drive offers high precision, low noise, and requires no lubrication, while gear drive transmits high torque and offers good stability. The synchronous belt and gears are installed using high-precision positioning and tensioning devices, such as automatic tensioning devices, to ensure no loosening or slippage during transmission.

[0035] The working principle of this invention is as follows: Data collected by various sensors in the multi-dimensional data acquisition module is transmitted to a data concentrator via high-speed shielded twisted-pair cable, and then transmitted to a data processing center via industrial Ethernet. The data fusion and processing module processes the collected data. The analog signals output by the sensors are first amplified and filtered by a dedicated signal conditioning chip in the data preprocessing unit, and then converted into digital signals by an analog-to-digital converter chip. Subsequently, they are transmitted to a digital signal processor (DSP) for fusion processing to eliminate noise and errors, obtaining more accurate and comprehensive fiber combing status information. The programmable logic controller (PLC) in the intelligent control module receives the fused data through the input / output module. Based on the fuzzy rules preset in memory, it performs rapid processing and logical judgment by hardware circuitry to adjust parameters such as the speed ratio of the combing machine, and transmits control signals to the motor drive module. The motor drive module, in conjunction with a servo driver employing vector control technology, precisely adjusts the motor speed, torque, and direction, achieving efficient driving of key components of the combing machine.

[0036] This invention provides a multi-dimensional data-sensing intelligent carding machine. By comprehensively collecting multi-dimensional data and using an advanced hardware system for data fusion and processing, combined with intelligent control hardware, it achieves precise control of the carding process, significantly improving the quality and production efficiency of fiber products. This invention comprehensively and accurately grasps fiber carding status information. The intelligent fuzzy control core, combined with hardware circuitry, enables precise adjustment of the carding machine's speed ratio, effectively improving the quality of fiber products and reducing problems such as uneven carding and fiber damage. For example, by real-time monitoring and precise control of fiber conveying pressure and tension, it avoids fiber damage due to uneven force, improving the strength and uniformity of fiber products. The high-performance AC servo motor and servo driver in the motor drive module can quickly respond to control signals, adjust motor operating parameters, and improve production efficiency. Simultaneously, it can automatically adjust carding parameters according to different fiber characteristics and production process requirements, further enhancing production efficiency. For example, when processing raw materials of different fiber thicknesses, the system can automatically adjust the carding machine speed and the coordination parameters of various components, improving production efficiency while ensuring product quality. The fault diagnosis and alarm module facilitates timely problem detection and resolution by operators, reducing equipment maintenance costs and improving production continuity.

[0037] The above are merely preferred embodiments of this utility model and are not intended to limit the utility model in any way. Those skilled in the art can readily implement this utility model based on the accompanying drawings and the description above. However, any modifications, alterations, or variations made by those skilled in the art without departing from the scope of the utility model's technical solution, utilizing the disclosed technical content, are equivalent embodiments of this utility model. Furthermore, any equivalent changes, alterations, or variations made to the above embodiments based on the essential technology of this utility model are still within the protection scope of this utility model's technical solution.

Claims

1. A multi-dimensional data-sensing intelligent sorting machine, characterized in that: It includes a multi-dimensional data acquisition module, a data fusion and processing module, an intelligent control module, and a motor drive module. The multi-dimensional data acquisition module, the data fusion and processing module, and the motor drive module are all electrically connected to the intelligent control module. The multi-dimensional data acquisition module is equipped with a high-precision electromagnetic speed sensor, a capacitive pressure sensor, a thickness sensor, and a strain gauge tension sensor. The high-precision electromagnetic speed sensor, capacitive pressure sensor, thickness sensor, and strain gauge tension sensor are electrically connected to the intelligent control module. The data fusion and processing module includes a data preprocessing unit and a data fusion unit, which are electrically connected. The intelligent control module includes a programmable logic controller and a control circuit, with the programmable logic controller and the control circuit being electrically connected. The motor drive module includes a large cylinder drive unit, a work roll drive unit, a stripping roll drive unit, and a doffer drive unit, which are electrically connected to the intelligent control module.

2. The intelligent sorting machine with multi-dimensional data perception according to claim 1, characterized in that: High-precision electromagnetic speed sensors are installed at each drive shaft of the carding machine and are rigidly connected to the drive shaft via couplings.

3. The intelligent sorting machine with multi-dimensional data perception according to claim 1 or 2, characterized in that: The capacitive pressure sensor is installed on the fiber conveying pipeline and is tightly connected to the pipeline through a threaded interface.

4. The intelligent sorting machine with multi-dimensional data perception according to claim 3, characterized in that: The capacitive pressure sensor includes a fine filter device, which is located at the front end of the capacitive pressure sensor.

5. A multi-dimensional data-sensing intelligent sorting machine according to claim 1, 2, or 4, characterized in that: The thickness sensor is mounted on an adjustable bracket in the fiber web forming area.

6. A multi-dimensional data-sensing intelligent combing machine according to claim 1, 2, or 4, characterized in that: The strain gauge tension sensor is installed at the contact point between the fiber combing component and the fiber, and is connected to the combing component by means of adhesive or bolt fixing.

7. The intelligent sorting machine with multi-dimensional data perception according to claim 1, characterized in that: It also includes a fault diagnosis and alarm module, which is electrically connected to the intelligent control module.

8. A multi-dimensional data-sensing intelligent sorting machine according to claim 1, 2, 4, or 7, characterized in that: It also includes an automatic cleaning device, which is electrically connected to the intelligent control module.

9. A multi-dimensional data-sensing intelligent sorting machine according to claim 1, 2, 4, or 7, characterized in that: It also includes an automatic dust collection device located at the bottom of the carding machine, which is electrically connected to the intelligent control module.

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