CN110004607B - Method for finding and stopping needle position when industrial sewing machine is started - Google Patents
Method for finding and stopping needle position when industrial sewing machine is started Download PDFInfo
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- CN110004607B CN110004607B CN201910393912.2A CN201910393912A CN110004607B CN 110004607 B CN110004607 B CN 110004607B CN 201910393912 A CN201910393912 A CN 201910393912A CN 110004607 B CN110004607 B CN 110004607B
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Abstract
The invention provides a method for finding and stopping needle position when an industrial sewing machine is started, which comprises a motor, a detection module and a control module; the method comprises the following steps: after the industrial sewing machine is started and powered on, when the detection sensor outputs a first signal, the control module firstly controls the motor to rotate forwards by a first preset angle; then the control module judges whether the motor is positioned at the reference position according to the output signal of the detection sensor, if so, the control module controls the motor to rotate reversely by alpha degrees so as to stop the motor at the upper needle stop position; if not, the control module controls the motor to rotate forwards by a second preset angle, so that the motor stops at the upper needle stop position; when the detection sensor outputs a second signal, the control module controls the motor to rotate reversely until the control module judges that the motor is located at the reference position according to the output signal of the detection sensor; and then, the control module controls the motor to rotate reversely by alpha degrees so as to stop the motor at the upper needle stop position. The sewing machine can avoid one to two needles to be moved when the needle stop position is found at the starting, and the potential safety hazard of operators is eliminated.
Description
Technical Field
The invention relates to the field of sewing machines, in particular to a method for finding and stopping needle positions when an industrial sewing machine is started.
Background
At present, with the development of industrial sewing machines, low-efficiency alternating current induction motors are gradually eliminated in the industrial sewing machines, and permanent magnet synchronous motors which save coil excitation and can save more than 10% of energy theoretically are adopted. For the control of a permanent magnet synchronous motor, it is important to know the position of its rotor. At present, a position sensor is generally adopted to obtain the position of a rotor of a permanent magnet synchronous motor, and the commonly used position sensors mainly comprise the following parts: hall sensor, magnetoelectric encoder, resolver, absolute type photoelectric encoder, increment formula photoelectric encoder etc.. Based on the comprehensive consideration of performance and price, the incremental photoelectric encoder is widely applied to the industrial sewing machine market at present, the basic working principle of the incremental photoelectric encoder is to find an initial electric angle by methods such as dichotomy and the like, and the current position is obtained by obtaining the increment of a sensor signal on the basis of finding an absolute reference position by a permanent magnet synchronous motor. Therefore, when the method is adopted to find the needle stopping position during starting, the reference position needs to be found by rotating a circle to know the current mechanical angle, so that the needle stopping position can be found, the situation that the sewing machine moves one to two more needles during starting is caused, operators are easily stabbed, and potential safety hazards exist.
Disclosure of Invention
In view of the above-mentioned shortcomings of the prior art, it is an object of the present invention to provide a method for locating a needle position when starting up an industrial sewing machine, which can avoid the sewing machine from walking one or two more needles when locating the needle position when starting up the industrial sewing machine.
In order to achieve the aim, the invention provides a method for finding and stopping needle positions when an industrial sewing machine is started, which comprises a motor, a detection module and a control module, wherein the motor is used for the industrial sewing machine, the detection module is provided with a detection sensor and an induction piece which synchronously rotates along with the motor and can be induced by the detection sensor, and the motor and the detection sensor are connected with the control module; the method for finding and stopping the needle position when the industrial sewing machine is started comprises the following steps:
1) and performing the following settings: the mechanical angle of the upper needle stop position of the sewing machine corresponding to the motor is 0 degree; when the motor rotates forwards for a circle from 0 degrees to 360 degrees in a mechanical angle, the detection sensor outputs a first signal, a second signal and a first signal in sequence, the first signal and the second signal are two different signals, the position of the output signal of the detection sensor changed from the first signal to the second signal is a reference position, and an included angle between the reference position and the upper needle-stopping position is alpha degrees;
2) after the industrial sewing machine is started and powered on, the control module performs the following control according to the output signal of the detection sensor:
A. when the detection sensor outputs a first signal, the control module firstly controls the motor to rotate forwards by a first preset angle; then the control module judges whether the motor is positioned at the reference position according to the output signal of the detection sensor, if so, the control module controls the motor to rotate reversely by alpha degrees so as to stop the motor at the upper needle stop position; if not, the control module controls the motor to rotate forwards by a second preset angle, so that the motor stops at the upper needle stop position;
B. when the detection sensor outputs a second signal, the control module controls the motor to rotate reversely until the control module judges that the motor is located at the reference position according to the output signal of the detection sensor; and then, the control module controls the motor to rotate reversely by alpha degrees so as to stop the motor at the upper needle stop position.
Further, the motor is a permanent magnet synchronous motor.
Further, the detection sensor is an encoder, and the sensing element is a grating sheet.
Further, the first signal is at a high level, and the second signal is at a low level; when the output signal of the detection sensor generates a falling edge, the control module judges that the motor is located at the reference position.
Further, the number of pole pairs of the motor is p; the included angle between the 0-degree electric angle of the motor and the reference position is beta degrees; when the motor rotates forwards for one circle, a first signal output by the detection sensor corresponds to the mechanical angle of the motor and is X degrees, and a second signal output by the detection sensor corresponds to the mechanical angle of the motor and is Y degrees; in the step a, the first preset angle and the second preset angle are calculated as follows:
the control module acquires an electrical angle theta degree of the motor;
when (theta/p) is less than or equal to beta, the first preset angle is beta- (theta/p), and the second preset angle is Y-alpha + beta- (theta/p);
when (theta DEG/p) > beta DEG, the first predetermined angle is Y DEG + beta DEG- (theta DEG/p) and the second predetermined angle is [ X DEG-alpha DEG + beta DEG- (theta DEG/p) ] - [ Y DEG + beta DEG- (theta DEG/p) ].
As mentioned above, the method for finding and stopping the needle position when the industrial sewing machine is started has the following beneficial effects:
this application can accurately control motor corotation or certain angle of reversal after industrial sewing machine starts, make the motor stop at last needle location, and rotate the output signal that the in-process at the motor can find the reference position through detecting the sensor, this process does not need the rotatory round of motor, thereby it goes to look for needle location again to avoid needing to go after the rotatory round of motor among the prior art, so this application can avoid sewing machine to walk the phenomenon of two needles more when the needle location is looked for in the start, eliminate the potential safety hazard of stabbing the operator.
Drawings
FIG. 1 is a flow chart of a method for locating a needle position during start-up of an industrial sewing machine according to the present application.
Fig. 2 is a corresponding relationship diagram of mechanical angles at various positions in the present application.
Fig. 3 is a diagram illustrating a correspondence relationship between mechanical angles at various positions in an embodiment of the present application.
Fig. 4 is a corresponding relationship diagram of mechanical angles of various positions in the second embodiment of the present application.
Detailed Description
The following description of the embodiments of the present invention is provided for illustrative purposes, and other advantages and effects of the present invention will become apparent to those skilled in the art from the present disclosure.
It should be understood that the structures, proportions, and dimensions shown in the drawings and described herein are for illustrative purposes only and are not intended to limit the scope of the present invention, which is defined by the claims, but rather by the claims. In addition, the terms such as "upper", "lower", "left", "right", "middle" and "one" used in the present specification are for convenience of description only and are not intended to limit the scope of the present invention, and changes or modifications of the relative relationship thereof may be made without substantial technical changes and modifications.
The application provides a method for finding and stopping a needle position when an industrial sewing machine is started, which comprises a motor, a detection module and a control module, wherein the motor, the detection module and the control module are used for the industrial sewing machine, the industrial sewing machine can be an industrial flat sewing machine, the detection module is provided with a detection sensor and an induction piece which synchronously rotates along with the motor and can be induced by the detection sensor, and the motor and the detection sensor are connected with the control module. As shown in FIG. 1, the method for finding and stopping the needle position when the industrial sewing machine is started comprises the following steps:
1) and performing the following settings: the mechanical angle of the upper needle stop position of the sewing machine corresponding to the motor is 0 degree and is also a point C in figure 2; when the motor rotates clockwise from 0 ° to 360 ° in mechanical angle (the forward rotation direction is clockwise in fig. 2), or clockwise in fig. 2, the detection sensor sequentially outputs a first signal, a second signal and the first signal, the first signal and the second signal are two different signals, the position where the output signal of the detection sensor is changed from the first signal to the second signal is a reference position and is also a point D in fig. 2, and the position where the output signal of the detection sensor is changed from the second signal to the first signal is a point F in fig. 2, so that, in the forward rotation direction of the motor, when the motor is located at a position between the point D and the point F, the detection sensor outputs the second signal; when the motor is positioned between the points C to D and between the points F to C, the detection sensor outputs a first signal; the included angle between the reference position and the upper needle stopping position is alpha degrees. The settings in the step 1) are determined by the installation process of the industrial sewing machine, so that after the industrial sewing machine leaves a factory, the reference position of the motor in the industrial sewing machine and the included angle alpha degrees between the reference position and the upper needle stop position are determined. In addition, the lower needle stop position of the sewing machine is a point E in FIG. 2, and the point E is between a point D and a point F in the embodiment. The positive rotation direction of the motor is also the direction of the hand wheel in the industrial sewing machine rotating towards the operator, and the reverse direction is vice versa.
2) After the industrial sewing machine is started and powered on, the control module performs the following control according to the output signal of the detection sensor:
A. when the detection sensor outputs a first signal, the mechanical angle of the motor is between a point C and a point D or between a point F and a point C, and the control module firstly controls the motor to rotate forwards by a first preset angle; and then the control module judges whether the motor is positioned at the reference position according to the output signal of the detection sensor: if the current position of the motor is closer to the reference position D point after the industrial sewing machine is started and powered on, the control module controls the motor to rotate forwards for a first preset angle and then the motor is located at the reference position D point, at the moment, the output signal of the detection sensor is changed into a second signal from a first signal, and the control module controls the motor to rotate backwards for alpha degrees so that the motor is stopped at the upper needle stop position; if the current position of the motor after the industrial sewing machine is started and powered on is closer to a point F in the graph 2, the control module controls the motor to rotate forwards for a first preset angle and then the motor cannot be located at a reference position point D, at the moment, the output signal of the detection sensor is still a first signal, and the control module controls the motor to rotate forwards for a second preset angle continuously to stop the motor at the upper needle stop position.
B. When the detection sensor outputs a second signal, the motor is positioned at a position between the point D and the point F, and the control module controls the motor to rotate reversely until the control module judges the reference position of the motor according to the output signal of the detection sensor; and then, the control module controls the motor to rotate reversely by alpha degrees so as to stop the motor at the upper needle stop position.
This application can accurately control motor corotation or certain angle of reversal after industrial sewing machine starts, make the motor stop at last needle location, and rotate the output signal that the in-process at the motor can find the reference position through detecting the sensor, this process does not need the rotatory round of motor, thereby it goes to look for needle location again to avoid needing to go after the rotatory round of motor among the prior art, so this application can avoid sewing machine to walk the phenomenon of two needles more when the needle location is looked for in the start, eliminate the potential safety hazard of stabbing the operator.
Furthermore, the detection module is a position sensor, the detection sensor is an encoder, preferably an incremental photoelectric encoder, the sensing element is a grating sheet, and the grating sheet is fixed on the rotor of the motor and synchronously rotates along with the rotor of the motor; when the motor rotates for 360 degrees for one circle, the detection sensor feeds back a square wave signal of one period to the control module, so that the first signal is at a high level, and the second signal is at a low level. The motor is a permanent magnet synchronous motor. Along the positive rotation direction of the motor, when the output signal of the detection sensor generates a falling edge, the control module judges that the motor is positioned at a reference position; alternatively, at point D in fig. 2, the output signal of the detection sensor generates a falling edge, and at point F in fig. 2, the output signal of the detection sensor generates a rising edge. Along the motor reverse direction, when the output signal of the detection sensor generates a rising edge, the control module judges that the motor is positioned at a reference position; alternatively, the output signal of the detection sensor generates a rising edge at point D in fig. 2, and the output signal of the detection sensor generates a falling edge at point F in fig. 2. Therefore, the control module can judge whether the motor is positioned at the reference position according to the rotating direction of the motor and whether the output signal of the detection sensor generates a falling edge or a rising edge in the process.
Further, in the step a of the step 2), the first preset angle and the second preset angle are automatically calculated and obtained by the control module according to the current electrical angle of the motor after the industrial sewing machine is powered on. The concrete mode is as follows: as shown in fig. 2, the number of pole pairs of the motor is p; the included angle between the 0-degree electric angle of the motor and the reference position is beta degrees; when the motor rotates forwards for 360 degrees in a circle, the mechanical angle of the motor corresponding to the high level output by the detection sensor is X degrees, and the mechanical angle of the motor corresponding to the low level output by the detection sensor is Y degrees. Therefore, in fig. 2, in the clockwise direction, the mechanical angle corresponding to the upper needle stop position C is 0 °, the mechanical angle corresponding to the reference position D is α °, and the mechanical angle corresponding to the F point at which the detection sensor starts outputting the high level is α ° + Y °. The number p of the pole pairs is determined by the structural characteristics of the motor, and the included angle beta, the mechanical angle X of the motor corresponding to the first signal and the mechanical angle Y of the motor corresponding to the second signal are determined by the installation process of the industrial sewing machine, so that after the industrial sewing machine leaves a factory, the number p of the pole pairs of the motor in the industrial sewing machine, the included angle beta between the 0-degree electrical angle of the motor and the reference position, the mechanical angle X of the motor corresponding to the first signal and the mechanical angle Y of the motor corresponding to the second signal are determined. In the step a of the step 2), the first preset angle and the second preset angle are calculated as follows: a1, the control module obtains the electrical angle theta degree of the motor; a2, when (theta/p) is less than or equal to beta, the first preset angle is beta- (theta/p), and the second preset angle is Y-alpha + beta- (theta/p); when (theta DEG/p) > beta DEG, the first predetermined angle is Y DEG + beta DEG- (theta DEG/p) and the second predetermined angle is [ X DEG-alpha DEG + beta DEG- (theta DEG/p) ] - [ Y DEG + beta DEG- (theta DEG/p) ].
Therefore, as shown in fig. 1, the method for finding and stopping the needle position when the industrial sewing machine is started comprises the following steps:
after the industrial sewing machine is started and powered on, the control module judges the range of the mechanical angle corresponding to the electrical angle theta DEG according to the output signal of the detection sensor. When the detection sensor outputs a low level, the mechanical angle corresponding to the electrical angle theta is within the range of alpha to alpha plus Y, that is, within the range of points D to F in fig. 2, at this time, the control module controls the motor to rotate reversely until the control module judges that the output signal of the detection sensor generates a rising edge, the control module can judge that the motor rotates reversely to the reference position, and then the control module controls the motor to rotate reversely by alpha degrees so that the motor reaches and stops at the point C of the needle-stopping position. When the detection sensor outputs high level, the mechanical angle corresponding to the electrical angle theta DEG is in the range of 0-alpha DEG or alpha DEG + Y-360 DEG, namely in the range of C point-D point or F point-C point of FIG. 2, and then the control module judges whether (theta DEG/p) is less than or equal to beta DEG; if (theta °/p) is less than or equal to beta °, the control module firstly controls the motor to rotate forward for beta ° - (theta °/p) and then judges whether the motor reaches a reference position D point, if so, the control module controls the motor to rotate backward for alpha °, so that the motor reaches and stops at an upper needle stop position C point, and if not, the control module controls the motor to rotate forward for Y ° -alpha ° + beta- (theta °/p) again, so that the motor reaches and stops at the upper needle stop position C point; if (theta DEG/p) > beta DEG, the control module firstly controls the motor to rotate forwards for Y DEG + beta DEG- (theta DEG/p) and then judges whether the motor reaches a reference position D point, if so, the control module controls the motor to rotate backwards for alpha DEG so that the motor reaches and stops at an upper needle-stopping position C point, and if not, the control module controls the motor to rotate forwards for [ X DEG-alpha DEG + beta DEG- (theta DEG/p) ] - [ Y DEG + beta DEG- (theta DEG/p) ], so that the motor reaches and stops at the upper needle-stopping position C point.
Two preferred embodiments of the method for finding the needle position for starting up the industrial sewing machine are provided below, wherein in both embodiments, the motor has 3 pairs of pole pairs, and accordingly, there are three corresponding 0 ° electrical angles, namely a first 0 ° electrical angle d1, a second 0 ° electrical angle d2, and a third 0 ° electrical angle d3 in fig. 3 or 4; in the normal rotation direction of the motor, a region between the first 0 ° electrical angle d1 and the second 0 ° electrical angle d2 is defined as a first region, a region between the second 0 ° electrical angle d2 and the third 0 ° electrical angle d3 is defined as a second region, and a region between the third 0 ° electrical angle d3 and the first 0 ° electrical angle d1 is defined as a third region; the electrical angle in the first region is defined as a first electrical angle p1, the electrical angle in the second region is defined as a second electrical angle p2, and the electrical angle in the third region is defined as a third electrical angle p 3. The high level output from the detection sensor corresponds to a mechanical angle of the motor of 240 °, and the low level output from the detection sensor corresponds to a mechanical angle of the motor of 120 °.
In the first embodiment, as shown in fig. 3, an included angle α ° between the reference position D point and the upper needle stop position C point is 75 °, an included angle β ° between the 0 ° electrical angle D1 of the motor and the reference position D point is 38 °, the industrial sewing machine is a thick material machine H5-4, and the electrical angle Θ ° is 90 °. In the first embodiment, (Θ °/3) ≦ β °, so the first predetermined angle is 8 °, and the second predetermined angle is 53 °. Based on this, after the industrial sewing machine is powered on, the electrical angle is 90 degrees, which may be a first electrical angle p1 in the first region, a second electrical angle p2 in the second region, or a third electrical angle p3 in the third region. When the detection sensor outputs a low level, the electronic control module judges that the electrical angle is 90 degrees and is a second electrical angle p2, at the moment, the control module controls the motor to rotate reversely to a reference position D point, and then the control module controls the motor to rotate reversely by 75 degrees to reach an upper needle stop position C point. When the detection sensor outputs a high level, the electric control module judges that the electric angle is 90 degrees and is a first electric angle p1 or a third electric angle p3, the control module firstly controls the motor to rotate forwards by 8 degrees and then judges whether the motor reaches a reference position D point, if so, the electric angle is the first electric angle p1, and at the moment, the control module controls the motor to rotate backwards by 75 degrees and reaches an upper needle stopping position C point; if not, the third electrical angle is p3, and the control module firstly controls the motor to continue to rotate forwards by 53 degrees to reach the point C of the upper needle stop position.
Example two, as shown in fig. 4, the angle α ° between the reference position D point and the upper needle stop position C point is 65 °, the angle β ° between the 0 ° electrical angle D1 of the motor and the reference position D point is 10 °, and the electrical angle Θ ° is 105 °. In this second embodiment, (Θ °/p) > β °, the first predetermined angle is 95 ° and the second predetermined angle is 55 °. Based on this, after the industrial sewing machine is powered on, the electrical angle is 90 degrees, which may be a first electrical angle p1 in the first region, a second electrical angle p2 in the second region, or a third electrical angle p3 in the third region. When the detection sensor outputs a low level, the electronic control module judges that the electric angle is 90 degrees and is a first electric angle p1, at the moment, the control module controls the motor to rotate reversely to a reference position D point, and then the control module controls the motor to rotate reversely by 65 degrees to reach an upper needle stop position C point. When the detection sensor outputs a high level, the electric control module judges that the electric angle is 90 degrees and is a second electric angle p2 or a third electric angle p3, the control module firstly controls the motor to rotate forwards for 95 degrees and then judges whether the motor reaches a reference position D point, if so, the electric angle is a third electric angle p3, and at the moment, the control module controls the motor to rotate backwards for 65 degrees and reaches an upper needle stop position C point; if not, the second electrical angle p2 is obtained, and the control module firstly controls the motor to continuously rotate forwards by 55 degrees to reach the point C of the upper needle stop position.
In summary, the upper needle stop position can be accurately found in the shortest distance after the industrial sewing machine is started, the implementation cost is low, the specific operation mode is simple, the understanding is easy, the development period is shortened, the development efficiency is improved, and the upper needle stop position can be directly implemented through software without adding peripheral detection equipment; particularly, the condition that the industrial sewing machine walks one to two more needles is avoided when the needle stop position is found during starting, and potential safety hazards are eliminated. Therefore, the invention effectively overcomes various defects in the prior art and has high industrial utilization value.
The foregoing embodiments are merely illustrative of the principles and utilities of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or change the above-mentioned embodiments without departing from the spirit and scope of the present invention. Accordingly, it is intended that all equivalent modifications or changes which can be made by those skilled in the art without departing from the spirit and technical spirit of the present invention be covered by the claims of the present invention.
Claims (5)
1. A method for finding and stopping needle position when an industrial sewing machine is started comprises a motor, a detection module and a control module, wherein the motor, the detection module and the control module are used for the industrial sewing machine, the detection module is provided with a detection sensor and an induction piece which synchronously rotates along with the motor and can be induced by the detection sensor, and the motor and the detection sensor are both connected with the control module; the method is characterized in that: the method for finding and stopping the needle position when the industrial sewing machine is started comprises the following steps:
1) and performing the following settings: the mechanical angle of the upper needle stop position of the sewing machine corresponding to the motor is 0 degree; when the motor rotates forwards for a circle from 0 degrees to 360 degrees in a mechanical angle, the detection sensor outputs a first signal, a second signal and a first signal in sequence, the first signal and the second signal are two different signals, the position of the output signal of the detection sensor changed from the first signal to the second signal is a reference position, and an included angle between the reference position and the upper needle-stopping position is alpha degrees;
2) after the industrial sewing machine is started and powered on, the control module performs the following control according to the output signal of the detection sensor:
A. when the detection sensor outputs a first signal, the control module firstly controls the motor to rotate forwards by a first preset angle; then the control module judges whether the motor is positioned at the reference position according to the output signal of the detection sensor, if so, the control module controls the motor to rotate reversely by alpha degrees so as to stop the motor at the upper needle stop position; if not, the control module controls the motor to rotate forwards by a second preset angle, so that the motor stops at the upper needle stop position;
B. when the detection sensor outputs a second signal, the control module controls the motor to rotate reversely until the control module judges that the motor is located at the reference position according to the output signal of the detection sensor; and then, the control module controls the motor to rotate reversely by alpha degrees so as to stop the motor at the upper needle stop position.
2. The method of claim 1, wherein: the motor is a permanent magnet synchronous motor.
3. The method of claim 1, wherein: the detection sensor is an encoder, and the sensing piece is a grating sheet.
4. The method of claim 3, wherein: the first signal is at a high level and the second signal is at a low level; when the output signal of the detection sensor generates a falling edge, the control module judges that the motor is located at the reference position.
5. The method of claim 1, wherein: the number of pole pairs of the motor is p; the included angle between the 0-degree electric angle of the motor and the reference position is beta degrees; when the motor rotates forwards for one circle, a first signal output by the detection sensor corresponds to the mechanical angle of the motor and is X degrees, and a second signal output by the detection sensor corresponds to the mechanical angle of the motor and is Y degrees; in the step a, the first preset angle and the second preset angle are calculated as follows:
the control module acquires an electrical angle theta degree of the motor;
when (theta/p) is less than or equal to beta, the first preset angle is beta- (theta/p), and the second preset angle is Y-alpha + beta- (theta/p);
when (theta DEG/p) > beta DEG, the first predetermined angle is Y DEG + beta DEG- (theta DEG/p) and the second predetermined angle is [ X DEG-alpha DEG + beta DEG- (theta DEG/p) ] - [ Y DEG + beta DEG- (theta DEG/p) ].
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| CN110670259A (en) * | 2019-09-30 | 2020-01-10 | 浙江众邦机电科技有限公司 | Cloth puncturing method, device, equipment and medium for thick material flat sewing machine |
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| US4513676A (en) * | 1982-08-30 | 1985-04-30 | Microdynamics, Inc. | Method and apparatus for automatically decelerating and stopping a sewing machine motor |
| JPH105474A (en) * | 1996-06-26 | 1998-01-13 | Matsushita Electric Ind Co Ltd | Sewing maching driving unit |
| CN102162177B (en) * | 2011-05-10 | 2013-01-23 | 浙江美机缝纫机有限公司 | Control method of bar tacking machine with needle position safety detection sensor |
| CN203462262U (en) * | 2013-08-29 | 2014-03-05 | 台州拓卡奔马机电科技有限公司 | Control device for supplying upper pin-stopping position of sewing machine |
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