High precision tension electric control system for a spinning machine

Abstract

The utility model discloses a high accuracy tension electrical control system of spinning machine relates to spinning machine technical field. The utility model discloses through high accuracy optical fiber type tension detection, kalman filter signal processing, double core ARM high speed operation, absolute value encoder servo drive and closed loop magnetic powder brake cooperative control and industrial ethernet data synchronization and sound light alarm etc. design, has realized yarn tension's non -contact accurate detection, high -speed response control and whole process data visual monitoring, effectively avoided because of yarn breakage, hair increase quality problem etc. that yarn tension is abnormal, has greatly promoted spinning product's quality stability and production efficiency, satisfied the demand of high accuracy, intelligentization tension control to textile industry.

Description

Technical Field

[0001] This utility model relates to the field of spinning machine technology, specifically to a high-precision tension electrical control system for spinning machines. Background Technology

[0002] Spinning machines are core pieces of machinery in the textile industry, used to process fibers into yarn. Their core function is to transform loose fibers into continuous yarns with a certain strength, fineness, and uniformity through processes such as carding, drafting, and twisting, providing the basic raw materials for subsequent processes such as weaving and dyeing.

[0003] With the continuous advancement of the textile industry, the requirements for tension control of warp yarns in various woven three-dimensional fabrics are becoming increasingly stringent. Existing tension electrical control systems for spinning machines have limitations in terms of control precision and stability. For example, it is difficult to dynamically adjust the tension in real time and accurately based on variations in yarn material, thickness, and weaving process, leading to uneven tension during yarn processing. This not only affects yarn quality, causing problems such as uneven thickness and inconsistent strength, but may also lead to yarn breakage, skipped threads, and other malfunctions during subsequent weaving, reducing production efficiency and product quality. Furthermore, existing control systems have poor adaptability to complex and changing working conditions. When faced with high-speed operation and frequent start-stop cycles, they cannot quickly and effectively adjust the tension, preventing the spinning machine from fully realizing its performance. In addition, traditional tension electrical control systems lack intelligence, lacking real-time monitoring and analysis of tension data, and cannot promptly detect potential problems and provide early warnings and solutions, hindering enterprises from achieving refined management and intelligent production. Therefore, we propose a high-precision tension electrical control system for spinning machines. Utility Model Content

[0004] The purpose of this utility model is to provide a high-precision tension electrical control system for spinning machines in order to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model specifically adopts the following technical solution: A high-precision tension electrical control system for a spinning machine includes: Tension detection module, which is installed at key nodes in the yarn path of the spinning machine, is used to collect yarn tension signals in real time; A signal processing module, wherein the signal processing module is connected to the tension detection module via optical fiber communication; The main control module is connected to the signal processing module, receives real-time tension values, compares them with a preset target tension range, and is connected to a host computer system via a network communication interface. An execution drive module is provided, which works in conjunction with the main control module. The execution drive module includes a servo drive unit and a magnetic powder braking unit. The servo drive unit is used to drive the drafting roller to adjust its rotation speed and change the yarn drafting tension. The magnetic powder braking unit controls the yarn winding tension by adjusting the braking torque through adjusting the current. The human-computer interaction module is connected to the main control module via serial communication, and the human-computer interaction module has a built-in storage module. The communication and early warning module is connected to the main control module, the execution drive module, and the human-machine interaction module via an industrial Ethernet. The power management module is connected to the tension detection module, the signal processing module, the main control module, the execution drive module, the human-machine interaction module, and the communication and early warning module via wires.

[0006] Furthermore, the tension detection module employs a high-precision fiber optic tension sensor.

[0007] Furthermore, the signal processing module incorporates a gain amplifier, a Kalman filter, and an A / D converter.

[0008] Furthermore, the main control module uses an ARM Cortex-A72 processor as its core.

[0009] Furthermore, the servo drive unit adopts an absolute encoder servo motor; the magnetic powder braking unit adopts a closed-loop controlled magnetic powder brake.

[0010] Furthermore, the human-computer interaction module is a 12-inch capacitive touchscreen, integrating a physical button for emergency stop.

[0011] Furthermore, the communication and early warning module includes a data synchronization unit and an alarm handling unit.

[0012] Furthermore, the power management module adopts a redundant design, with an input of AC 90-250V and outputs of DC 24V / 10A, DC 12V / 5A, and DC 5V / 3A.

[0013] The beneficial effects of this utility model are as follows: 1. This utility model achieves real-time detection, precise control, intelligent early warning, and data traceability of yarn tension through the coordinated work of various modules. It effectively solves the problems of low tension control accuracy, poor stability, weak adaptability to working conditions, and insufficient intelligence in the existing technology, improves yarn quality and production efficiency, and meets the textile industry's demand for high-precision and intelligent tension control.

[0014] 2. This utility model achieves non-contact precise detection of yarn tension, high-speed response control within 0.5ms, and full-process data visualization monitoring through high-precision fiber optic tension detection, Kalman filter signal processing, dual-core ARM high-speed operation, absolute encoder servo drive and closed-loop magnetic powder braking coordinated control, and industrial Ethernet data synchronization and audible and visual alarms. It effectively avoids quality problems such as yarn breakage and increased hairiness caused by abnormal tension, and greatly improves the quality stability and production efficiency of spinning products. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the control structure of this utility model.

[0016] Reference numerals in the attached diagram: 1. Tension detection module; 2. Signal processing module; 3. Main control module; 4. Execution drive module; 41. Servo drive unit; 42. Magnetic powder braking unit; 5. Human-machine interaction module; 6. Storage module; 7. Communication and early warning module; 71. Data synchronization unit; 72. Alarm handling unit; 8. Power management module. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings.

[0018] Please see Figure 1 This utility model provides a high-precision tension electrical control system for a spinning machine, comprising: Tension detection module 1 is installed at key nodes in the yarn path of the spinning machine to collect yarn tension signals in real time, thereby enabling timely and accurate acquisition of yarn tension changes at different positions and in different states.

[0019] Signal processing module 2 is connected to tension detection module 1 via optical fiber communication. The signal processing module 2, connected to tension detection module 1, can filter, amplify, and process the acquired yarn tension signal to remove interference signals and improve signal quality and stability, so that subsequent modules can analyze and process it more accurately.

[0020] The main control module 3 is connected to the signal processing module 2, receives the real-time tension value, and compares it with the preset target tension range. The main control module 3 is also connected to the host computer system through a network communication interface. The main control module 3 receives the processed tension signal, performs calculations and analysis based on the preset tension control strategy and algorithm, and determines whether the yarn tension is within the normal range.

[0021] The execution drive module 4 works in conjunction with the main control module 3, and includes a servo drive unit 41 and a magnetic powder braking unit 42. The servo drive unit 41 drives the drafting roller to adjust its speed, thereby changing the yarn drafting tension. The magnetic powder braking unit 42 adjusts the braking torque by changing the current, controlling the yarn winding tension. When the main control module 3 detects an abnormal tension, the execution drive module 4 starts working. The servo drive unit 41 can precisely control the movement speed and position of relevant components of the spinning machine, changing the yarn tension by adjusting the operating state of the components. The magnetic powder braking unit 42 utilizes the characteristics of magnetic powder to provide appropriate braking force, further adjusting the yarn tension and quickly restoring it to a normal level.

[0022] The human-machine interface module 5 is connected to the main control module 3 via serial communication, and the human-machine interface module 5 has a built-in storage module 6. The human-machine interface module 5 facilitates interaction between the operator and the control system. The operator can use this module to set tension control parameters, view the system's operating status and tension data, etc., to achieve real-time monitoring and adjustment of the spinning process. The storage module 6 is used to store various data during system operation, including collected tension signals, control parameters, operation logs, etc., which can be used for subsequent data analysis and system optimization.

[0023] The communication and early warning module 7 is connected to the main control module 3, the execution drive module 4, and the human-machine interaction module 5 via an industrial Ethernet. The data synchronization unit 71 can synchronize the system's data with other relevant equipment or management systems to achieve data sharing and interaction; the alarm handling unit 72 promptly issues an alarm signal when the yarn tension is severely abnormal, reminding operators to take appropriate measures to avoid quality problems and equipment failures.

[0024] The power management module 8 is connected to the tension detection module 1, signal processing module 2, main control module 3, execution drive module 4, human-machine interaction module 5, and communication and early warning module 7 via wires. The power management module 8 provides a stable and reliable power supply for the entire control system, ensuring that each module can work normally. It also has overvoltage, overcurrent, and undervoltage protection functions to ensure the safety and stability of the system.

[0025] In this embodiment, preferably, the tension detection module 1 adopts a high-precision fiber optic tension sensor; it adopts a non-contact measurement method to avoid damage to the yarn surface, with a resolution of 0.05N and a linear error of less than 0.3%, which can accurately capture the minute tension fluctuations of the yarn when it is running at high speed.

[0026] In this embodiment, preferably, the signal processing module 2 has a built-in gain amplifier, Kalman filter, and A / D converter. Through the cooperation of the gain amplifier, Kalman filter, and A / D converter, the acquired optical signal is subjected to photoelectric conversion, gain adjustment, and noise suppression. The tension signal is converted into a digital quantity and then transmitted to the main control module 3. The signal-to-noise ratio is greater than 80dB, which can effectively remove external interference and ensure that the signal transmitted to the main control module 3 is accurate.

[0027] In this embodiment, preferably, the main control module 3 uses a dual-core ARM Cortex-A72 processor as its core. The dual-core ARM Cortex-A72 processor has powerful computing capabilities, with a main frequency of up to 2.0GHz. The single-core performance is about 35% higher than the previous generation ARM Cortex-A57. The dual-core concurrent processing architecture can simultaneously carry out multiple tasks such as real-time analysis of tension signals, calculation of control strategies, and scheduling of multi-module communication. It can complete more than 150,000 tension data comparisons and logical judgments per second, ensuring that even under high-speed conditions with yarn speeds of up to 1,500 meters per minute, the control command output delay can still be within 0.5ms.

[0028] In this embodiment, preferably, the servo drive unit 41 adopts an absolute encoder servo motor; the magnetic powder braking unit 42 adopts a closed-loop control magnetic powder brake; the absolute encoder servo motor has an absolute position feedback function, eliminating the need for origin calibration every time it starts, with a resolution of up to 17 bits (i.e., 131072 pulses / revolution), a speed control accuracy of ±0.01%, and a torque response time of less than 1ms. It can accurately follow the speed adjustment command issued by the main control module, ensuring the linearity and stability of the drafting roller speed change, and effectively avoiding sudden changes in yarn tension caused by speed fluctuations; the closed-loop control magnetic powder brake has a built-in torque sensor, which can provide real-time feedback of the current braking torque value. The main control module dynamically adjusts the input current by comparing the target torque with the actual torque, achieving a torque control accuracy of ±0.5%, and the torque range can be continuously adjusted between 0.1 N·m and 100 N·m. Furthermore, the magnetic hysteresis effect of the magnetic powder is small, and the braking response time is less than 20ms. Even when the yarn winding speed changes rapidly, it can maintain the consistency of the braking torque, preventing over-adjustment or under-adjustment of the winding tension.

[0029] In this embodiment, preferably, the human-machine interaction module 5 is a 12-inch capacitive touch screen, which integrates physical buttons for emergency stop; the interface displays the target tension value, current tension value, tension deviation percentage, equipment operating status (such as normal, alarm) and historical tension curve (data within 7 days can be queried), supports one-click switching between automatic and manual modes, and the tension can be adjusted by the knob in manual mode, making operation convenient.

[0030] In this embodiment, preferably, the communication and early warning module 7 includes a data synchronization unit 71 and an alarm handling unit 72. The data synchronization unit 71 synchronously uploads the real-time tension curve generated by the main control module 3, the working parameters of the execution drive module 4 (such as servo speed and braking current), and the operation records of the human-machine interaction module 5 to the host computer to realize remote monitoring. When the alarm handling unit 72 receives abnormal signals such as tension exceeding the preset range (such as target tension ±3%), signal loss of the tension detection module 1, or overload of the servo drive unit 41 sent by the main control module 3, it immediately triggers the audible and visual alarm of the human-machine interaction module 5 (such as continuous buzzer beeping and red fault code displayed on the screen). At the same time, it stores information such as abnormal time, fault type, and current parameter value in the storage module 6 and sends an alarm notification containing fault location to the host computer to facilitate rapid response by maintenance personnel.

[0031] In this embodiment, preferably, the power management module 8 adopts a redundant design, with an input of AC 90-250V and outputs of DC24V / 10A, DC 12V / 5A, and DC 5V / 3A; it has surge protection (10kV) and electromagnetic compatibility (EMC) level meeting the IEC 61000-4-2 standard, ensuring stable operation of the system in industrial environments and supporting hot-swappable replacement.

[0032] The working principle and usage process of this utility model are as follows: After the system starts up, the power management module 8 outputs stable DC24V / 10A, DC 12V / 5A, and DC 5V / 3A voltages, and each module completes initialization: the main control module 3 enters the multi-task scheduling state, the signal processing module 2 starts the signal processing process, the tension detection module 1 starts to collect yarn tension signals in real time, and transmits them to the signal processing module 2 through optical fiber. After photoelectric conversion, gain adjustment and noise suppression, the signal is converted into a digital quantity and transmitted to the main control module 3.

[0033] The main control module 3 receives the processed tension signal and compares it with the target tension value in real time. If the current tension is within the allowable range, the system maintains the current state. If the deviation exceeds the range, the main control module 3 issues a control command within 0.5ms: the servo drive unit 41 adjusts the speed of the drafting roller (reduces the speed to reduce the yarn drafting tension, with a speed control accuracy of ±0.01% and a torque response time of less than 1ms), and the magnetic powder braking unit 42 adjusts the input current (increases the current to increase the braking torque, with a torque control accuracy of ±0.5% and a braking response time of less than 20ms). The two work together to quickly restore the tension to the target range (e.g., 10.1N, deviation +1%).

[0034] During operation, the human-machine interaction module 5 displays the target tension, current tension, deviation percentage, equipment status and historical tension curve in real time, and simultaneously displays the rotation speed of the servo drive unit 41 and the current of the magnetic powder braking unit 42. The operator can switch to manual mode with one click and adjust the tension by turning the knob.

[0035] If an abnormality occurs, such as tension exceeding ±3%, loss of tension detection signal, or servo overload, the communication and early warning module 7 immediately triggers an audible and visual alarm. At the same time, it stores the abnormal time, fault type, and current parameters in the storage module 6 and sends an alarm notification containing fault location to the host computer. After receiving the notification, the maintenance personnel can remotely view the fault details through the host computer, confirm the fault time point on-site through the historical records of the human-machine interaction module, repair the fiber optic cable, reset the alarm, and the system returns to normal.

[0036] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A high-precision tension electrical control system for a spinning machine, characterized in that, include: Tension detection module (1), the tension detection module (1) is installed at a key node of the yarn path of the spinning machine, and is used to collect yarn tension signals in real time; The signal processing module (2) is connected to the tension detection module (1) via optical fiber communication. The main control module (3) is connected to the signal processing module (2), receives the real-time tension value, and compares it with the preset target tension range. The main control module (3) is connected to the host computer system through the network communication interface. The execution drive module (4) works in conjunction with the main control module (3), and the execution drive module (4) includes a servo drive unit (41) and a magnetic powder braking unit (42); wherein, the servo drive unit (41) is used to drive the drafting roller to adjust the speed and change the yarn drafting tension, and the magnetic powder braking unit (42) controls the yarn winding tension by adjusting the braking torque through adjusting the current. The human-computer interaction module (5) is connected to the main control module (3) via serial communication, and the human-computer interaction module (5) has a built-in storage module (6). The communication and early warning module (7) is connected to the main control module (3), the execution drive module (4) and the human-machine interaction module (5) via an industrial Ethernet. The power management module (8) is connected to the tension detection module (1), the signal processing module (2), the main control module (3), the execution drive module (4), the human-machine interaction module (5), and the communication and early warning module (7) via wires.

2. The high-precision tension electrical control system for a spinning machine according to claim 1, characterized in that, The tension detection module (1) adopts a high-precision fiber optic tension sensor.

3. The high-precision tension electrical control system for a spinning machine according to claim 1, characterized in that, The signal processing module (2) has a built-in gain amplifier, Kalman filter and A / D converter.

4. The high-precision tension electrical control system for a spinning machine according to claim 1, characterized in that, The main control module (3) uses a dual-core ARM Cortex-A72 processor as its core.

5. The high-precision tension electrical control system for a spinning machine according to claim 1, characterized in that, The servo drive unit (41) adopts an absolute encoder servo motor; the magnetic powder braking unit (42) adopts a closed-loop controlled magnetic powder brake.

6. The high-precision tension electrical control system for a spinning machine according to claim 1, characterized in that, The human-computer interaction module (5) is a 12-inch capacitive touch screen, which integrates physical buttons for emergency stop.

7. The high-precision tension electrical control system for a spinning machine according to claim 1, characterized in that, The communication and early warning module (7) includes a data synchronization unit (71) and an alarm handling unit (72).

8. A high-precision tension electrical control system for a spinning machine according to claim 1, characterized in that, The power management module (8) adopts a redundant design, with an input of AC 90-250V and outputs of DC 24V / 10A, DC 12V / 5A, and DC 5V / 3A.

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