CN112626772A - Method, system and device for controlling fabric density in real time - Google Patents
Method, system and device for controlling fabric density in real time Download PDFInfo
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- CN112626772A CN112626772A CN202011498123.4A CN202011498123A CN112626772A CN 112626772 A CN112626772 A CN 112626772A CN 202011498123 A CN202011498123 A CN 202011498123A CN 112626772 A CN112626772 A CN 112626772A
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C7/00—Heating or cooling textile fabrics
- D06C7/02—Setting
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C3/00—Stretching, tentering or spreading textile fabrics; Producing elasticity in textile fabrics
- D06C3/02—Stretching, tentering or spreading textile fabrics; Producing elasticity in textile fabrics by endless chain or like apparatus
- D06C3/04—Tentering clips
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C3/00—Stretching, tentering or spreading textile fabrics; Producing elasticity in textile fabrics
- D06C3/10—Hooks, pin-blocks, or like apparatus
Abstract
The invention belongs to the technical field of textile printing and dyeing processes, and particularly relates to a method, a system and a device for controlling the density of a fabric in real time, wherein the method comprises the following steps: determining and keeping the overfeed amount constant, determining and configuring the fabric density of the cloth feeding side of an upper overfeed roller to be a constant value P1, and adjusting the fabric density of the cloth feeding side of the upper overfeed roller to reach the constant value P1 in real time, wherein the real-time adjustment method comprises the steps of collecting the real-time fabric density P1 'of the cloth feeding side of the upper overfeed roller, and controlling to increase the cloth feeding speed of the cloth feeding side of the upper overfeed roller if P1' < P1; if P1 ' > P1, the cloth feeding speed of the cloth feeding side of the upper overfeed roller is controlled to be reduced until P1 ' is equal to P1 or the difference value of the P1 ' and the P1 is controlled to be within an error range. The invention can accurately and automatically adjust the fabric density of the cloth feeding side of the upper overfeed roller in real time, so that the density of the shaped fabric does not exceed the process density requirement, the integral level of the textile industry can be improved, and the industry competitiveness can be improved.
Description
Technical Field
The invention belongs to the technical field of textile printing and dyeing, and particularly relates to a method, a system and a device for controlling fabric density in real time.
Background
The heat setting can improve the thermal stability of the size and the quality of the fabric, effectively eliminate crease marks on the fabric and improve hand feeling. The control of the quality of the fabric, such as the fabric surface density, can be realized by controlling the parameters of the heating temperature, the vehicle speed, the overfeeding amount and the like in the heat setting machine. Where the primary manipulated variable for control surface density is overfeed, increased overfeed causes increased fiber density, resulting in increased fabric density. The overfeeding is essentially to adjust the cloth feeding speed of the upper overfeeding roller, overcome the unstable state that the cloth is stretched and the breadth is narrowed because of tension in the heat setting processing of the fabric, ensure the stable and consistent size of the finished product after the setting of the textile and the surface density of the textile, and achieve and not exceed the requirements of customers, so the accurate control of the overfeeding amount is very important, and the overfeeding is the basis for realizing the accurate control of the surface density of the textile.
Some of the prior textile industry production processes control the surface density of the fabric by manpower. And adjusting the overfeed amount of the heat setting machine according to the average value of the multiple sampling measurements and the density difference value required by the customer order, and repeatedly adjusting to obtain the overfeed parameter value within the required density range. Obviously, the manual detection control scheme has no timeliness, continuous measurement in the production process of the fabric cannot be realized, and if the density of the fabric in the production process is required to be ensured to meet the requirement, multiple times of sampling are needed to monitor the change of the density of the fabric, so that a large amount of labor is consumed, and the integrity of the fabric is seriously damaged; the measuring accuracy is reduced due to different degrees of stretching of the fabric in the manual measuring and sampling process, overfeeding ratios are set by different operators according to experience, the randomness is high, the production process is actually in a subjective state lacking data standards, and only when the product quality has obvious problems, the operators can realize the error of the overfeeding control scheme and then adjust the overfeeding control scheme. This not only causes severe hysteresis in control, but also causes resource waste and energy loss. Furthermore, when the vehicle speed changes or certain external interference exists, the originally set overfeeding amount does not adapt to the change any more, so that the quality of the cloth is directly degraded and unqualified, and great trouble is brought to enterprises.
It is known that the deviation of the head and tail gram weights is large due to the weaving machine in the weaving process of the fabric, and the density deviation of the fabric woven by the weaving machines with the same specification and different varieties is large. In addition, the fabric is not uniformly tensioned in the processing process, so that density errors are caused.
Chinese patent ZL202020018193.4 discloses a real-time control device for density of heat-set fabric, which comprises a heat-setting machine, an upper overfeeding roller and an electric controller, wherein a fabric speed detection mechanism and an industrial camera are arranged in front of the upper overfeeding roller, the industrial camera acquires a fabric image and transmits the fabric image to the electric controller, the electric controller processes the acquired fabric image to obtain the real-time density P1 of the fabric before the fabric enters the upper overfeeding roller, and the real-time density P1, the running speed V0 and the process density P0 of the fabric are regulated and controlled according to the real-time density P1 of the fabric, and the electric controller calculates the running speed Vsc of the fabric meeting the process density P36; the electric controller adjusts the rotating speed of the motor of the upper overfeed roller according to the Vsc, so that the running speed of the fabric reaches the Vsc, and the density of the fabric before shaping can reach the process density. The patent has the following problems in specific working condition application:
(1) the fabric speed detection mechanism and the industrial camera are arranged in front of the upper overfeeding roller, the change situation of the fabric density in front of the upper overfeeding roller is detected in real time, the real fabric density at the needle clip position of the fabric cannot be reflected well, because the fabric between the upper overfeeding roller and the lower overfeeding roller is in a stretching state generally, the fabric is not only subjected to stretching elastic force Fn and self gravity FMg, but also subjected to static friction force of the roller on the fabric at each contact position of the fabric and the upper overfeeding roller and the lower overfeeding roller, the rotational inertia of the upper overfeeding roller, the angular acceleration of the upper overfeeding roller and the lower overfeeding roller during running and accelerating and decelerating, the elastic deformation of the fabric and the like, and the fabric density measured by the patent can be greatly influenced, and therefore the overfeeding amount of the overfeeding roller can not be controlled accurately and automatically.
(2) This patent fabric density sampling point is longer with last between the overfeed roller fabric movement path, on the one hand, can not confirm the error position accurately, lead to can not accurate correction, can not accurate control, on the other hand, fabric end to end joint department density error changes greatly, prior art can't guarantee to correct fast in the short distance, in addition, there are the resistance distance of fabric guide roller during the time, the elastic elongation of fabric etc. factor, the required functioning speed of fabric is obviously not the Vsc that calculates, can exert an influence to the control accuracy of fabric density in the actual production.
(3) The control in the prior art is open-loop control, the detection signal is to control the rotating speed of the upper overfeed roller, and once abnormal phenomena such as slipping and the like occur between the upper overfeed roller and the fabric, the actual fabric density control precision error is directly caused to be larger.
(4) In the prior art, the density of the fabric is controlled to be constant by adjusting the relative speed between an upper overfeed roller and a chain (the overfeed amount is adjusted), the overfeed amount is large in fluctuation caused by large density change of the fabric before shaping, and serious abnormal phenomena of fabric falling, fabric hanging or fabric rolling can occur at a fabric outlet, so that the normal production of a shaping machine is seriously influenced.
(5) The fabric density at the joint of the fabric seam can generate large fluctuation, and because the path is too long, the prior art can not carry out real-time quick adjustment, so that the error between the fabric density at the seam and the standard density is large, and the quality of the product is seriously influenced.
In view of this, the problem that exists in the fabric density control when current operating mode fabric is stereotyped must be solved.
Disclosure of Invention
The invention aims to solve the problem that the control precision of the fabric density is not high during the tentering setting of the fabric in the prior art, and provides a real-time control method, a real-time control system and a real-time control device for the fabric density.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows: a real-time control method for fabric density is used for a setting machine, the setting machine comprises an upper overfeeding roller and a chain provided with a needle plate or a cloth clip, and the fabric is conveyed to the needle plate or the cloth clip on the chain through the upper overfeeding roller, and the control method comprises the following steps:
the cloth feeding side of the upper overfeeding roller is provided with at least one active adjusting roller and a density detection unit, and the active adjusting roller and the density detection unit are matched with each other to adjust the density of the fabric at the cloth feeding side of the upper overfeeding roller in real time to enable the density of the fabric to reach a constant value P1.
Preferably, the real-time adjusting method comprises the steps of acquiring the real-time density P1 'of the fabric on the fabric feeding side of the upper overfeeding roller, and controlling to increase the fabric feeding speed of the fabric feeding side of the upper overfeeding roller if P1' < P1; if P1 '> P1, controlling to reduce the cloth feeding speed of the cloth feeding side of the upper overfeed roller until P1' is equal to P1;
or, the real-time adjusting method comprises the step of acquiring the real-time fabric density P1 'on the cloth feeding side of the upper overfeeding roller, and controlling the difference value between P1' and P1 within an error range.
Preferably, the fabric real-time density P1' is taken between the feed side of the upper overfeed roll and the active dancer roll.
Preferably, obtaining a fabric setting process density P0, if the fabric density at the cropping position cannot reach the process density P0, adjusting the overfeeding amount until the fabric density at the cropping position reaches the process density P0, and then keeping the current overfeeding amount constant;
or, acquiring a fabric heat-setting target gram weight G0, if the fabric gram weight at the cropping position cannot reach the target gram weight G0, adjusting the overfeeding amount until the fabric gram weight at the cropping position reaches the target gram weight G0, and then keeping the current overfeeding amount constant.
Preferably, if the fabric tension on the cloth feeding side of the upper overfeed roller exceeds the set tension range, the constant value P1 is corrected again to obtain a corrected constant value P10 until the fabric tension on the cloth feeding side of the upper overfeed roller meets the set tension range.
A real-time fabric density control system is used for the real-time fabric density control method and comprises the following steps:
and the adjusting module is used for adjusting the fabric density of the cloth feeding side of the upper overfeeding roller to reach the constant value P1 in real time.
Preferably, the adjusting module comprises:
the collecting unit is used for collecting the real-time density P1' of the fabric at the cloth feeding side of the upper overfeeding roller;
the control unit is used for adjusting the real-time density P1 'of the fabric on the cloth feeding side of the upper overfeeding roller, and controlling and increasing the cloth feeding speed of the cloth feeding side of the upper overfeeding roller if P1' < P1; if P1 '> P1, controlling to reduce the cloth feeding speed of the upper overfeeding cloth side until P1' is equal to P1;
or, the difference value between the P1' and the P1 is controlled within an error range.
A fabric density real-time control device is used for a setting machine, the setting machine comprises an upper overfeeding roller and a chain provided with a needle plate or a cloth clip, and fabrics are conveyed to the needle plate or the cloth clip on the chain through the upper overfeeding roller, and the fabric density real-time control device further comprises:
the driving adjusting roller is positioned on the cloth feeding side of the upper overfeeding roller, and the linear speed of the upper overfeeding roller and the chain is relatively constant;
the density detection unit is arranged on the cloth feeding side of the upper overfeed roller and is used for acquiring fabric density information and transmitting the fabric density information to the controller;
and the controller controls the active adjusting roller to adjust the fabric density of the cloth feeding side of the upper overfeeding roller to reach a constant value in real time according to the fabric density information.
Preferably, the density detection unit is located between the upper overfeed roller and the active dancer roller.
Preferably, the controller is a controller of the setting machine or a separately provided controller.
After the technical scheme is adopted, the method, the system and the device for controlling the fabric density in real time have the following beneficial effects:
1) according to the invention, the density change condition of the fabric on the fabric feeding side of the upper overfeeding roller is detected in real time, and at least one active adjusting roller is arranged to adjust the running speed of the fabric so as to adjust the density of the fabric on the fabric feeding side of the upper overfeeding roller in real time, so that the aim of accurately and automatically controlling the overfeeding amount of the upper overfeeding roller according to the process density is achieved, the density of the fabric after being shaped can be kept consistent with the process density, and the high quality of the fabric is ensured;
2) according to the invention, the real-time density P1' of the fabric is collected from the upper overfeed roller and the active adjusting roller which is away from the upper overfeed roller by no more than three meters, and is compared with the density P1 of the fabric, so that the linear speed of the active adjusting roller is adjusted in real time, and by adopting the design, the problem that the running path of the fabric between the sampling point and the upper overfeed roller is too long to influence the control precision can be avoided, and the high quality of the fabric is further ensured;
3) according to the invention, through the design that the linear velocity of the active adjusting roller is less than that of the upper overfeed roller, the problem that the fabric slips at the upper overfeed roller can be avoided; through the control design of the fabric tension at the cloth feeding side of the upper overfeeding roller, the influence of the fabric tension on the real-time density of the fabric at the cloth feeding side of the upper overfeeding roller can be avoided, and the control precision is further ensured;
4) the invention can prevent and predict the fluctuation condition of the fabric density in advance, and well realize the stable control of the fabric density;
5) the invention can accurately control the setting density of the fabric, because the invention directly detects and controls the cloth feeding side of the upper overfeeding roller, and then the running speed of the upper overfeeding roller and the setting machine is kept constant, the invention overcomes the technical problem that the adjustment is only carried out after the detection in the prior art goes through a overlong path, and overcomes the problem that the control error is uncertain because whether the fabric is correct or not can not be determined after the fabric density is adjusted under the open-loop control in the prior art, and the invention greatly improves the control precision;
6) the invention can quickly adjust the setting density of the fabric and quickly adjust and respond to improve the product quality, and because the invention directly detects and controls the cloth feeding side of the upper overfeeding roller, and then the running speed of the upper overfeeding roller and the setting machine keeps constant, the invention effectively solves the technical problem of low correction speed caused by adjustment after detection in the prior art through too long paths, and especially solves the problem that the parts with large fabric density change, such as the seam head, are difficult to correct well;
7) the invention realizes intelligent monitoring of fabric density and reduces labor cost;
8) the invention is convenient to implement, is beneficial to improving the integral level of the textile industry and improving the industry competitiveness.
Drawings
FIG. 1 is a schematic flow chart of a method for real-time control of fabric density according to the present invention;
FIG. 2 is a schematic flow chart of another method for real-time control of fabric density according to the present invention;
FIG. 3 is a block diagram of a fabric density real-time control system according to the present invention;
fig. 4 is a schematic structural diagram of a fabric density real-time control device according to the present invention.
Wherein: the automatic cloth feeding device comprises a boarding machine 1, an upper overfeeding roller 2, an active adjusting roller 3, an industrial camera 4, an illuminating light source 5, an external speed measuring device 6, a cloth guide roller 7, a tensioning roller 8, a swing arm 9, an air cylinder 10 and a fabric 11.
Detailed Description
The present invention now will be described more fully hereinafter with reference to the accompanying drawings and detailed description, in which it is to be understood that the embodiments described are merely illustrative of some, but not all embodiments of the invention. The following description of at least one exemplary embodiment is merely illustrative in nature and is in no way intended to limit the invention, its application, or uses. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The relative arrangement of the components and steps, the numerical expressions and numerical values set forth in these embodiments do not limit the scope of the present invention unless specifically stated otherwise. Meanwhile, it should be understood that the sizes of the respective portions shown in the drawings are not drawn in an actual proportional relationship for the convenience of description. Techniques, methods, and apparatus known to those of ordinary skill in the relevant art may not be discussed in detail but are intended to be part of the specification where appropriate. In all examples shown and discussed herein, any particular value should be construed as merely illustrative, and not limiting. Thus, other examples of the exemplary embodiments may have different values. It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, further discussion thereof is not required in subsequent figures.
In the description of the present invention, it is to be understood that the orientation or positional relationship indicated by the orientation words such as "front, rear, upper, lower, left, right", "lateral, vertical, horizontal" and "top, bottom", etc. are usually based on the orientation or positional relationship shown in the drawings, and are only for convenience of description and simplicity of description, and in the case of not making a reverse description, these orientation words do not indicate and imply that the device or element being referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore, should not be considered as limiting the scope of the present invention; the terms "inner and outer" refer to the inner and outer relative to the profile of the respective component itself.
Spatially relative terms, such as "above … …," "above … …," "above … …," "above," and the like, may be used herein for ease of description to describe one device or feature's spatial relationship to another device or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is turned over, devices described as "above" or "on" other devices or configurations would then be oriented "below" or "under" the other devices or configurations. Thus, the exemplary term "above … …" can include both an orientation of "above … …" and "below … …". The device may be otherwise variously oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
It should be noted that the terms "first", "second", and the like are used to define the components, and are only used for convenience of distinguishing the corresponding components, and the terms have no special meanings unless otherwise stated, and therefore, the scope of the present invention should not be construed as being limited.
The invention provides a fabric density real-time control method, which is used for a setting machine, the setting machine belongs to dyeing and finishing equipment, the setting machine can also be a setting machine, a dryer or a stentering setting machine, the setting machine comprises an upper overfeeding roller and a chain equipped with a needle plate or a cloth clip, the fabric is conveyed to the needle plate or the cloth clip on the chain through the upper overfeeding roller for setting treatment, in order to enable the fabric on the needle plate or the cloth clip on the chain to reach a fabric setting process density P0, the fabric density fed into the needle plate or the cloth clip is generally adjusted through adjusting the upper overfeeding roller in the prior art, the fabric density control method has various technical problems as described in the background technology, therefore, the embodiment provides a fabric density real-time control method, the upper overfeeding roller is not adjusted, but the fabric density on the fabric feeding side of the upper overfeeding roller is adjusted, in particular, the control method comprises the following steps:
the fabric density of the fabric feeding side of the upper overfeeding roller is adjusted to a constant value P1 in real time by the aid of the active adjusting roller and the density detection unit which are matched, namely the linear speed of the active adjusting roller is controlled in real time according to detection results of the density detection unit, so that the fabric density of the fabric feeding side of the upper overfeeding roller reaches a constant value P1, the upper overfeeding amount can reach the fabric sizing process density P0 only by the aid of the active adjusting roller and the density detection unit, and then the current overfeeding amount is kept constant without adjusting the upper overfeeding roller.
As is well known to those skilled in the art, overfeeding refers to providing a specific proportion of required overfeeding, positive, negative or zero, according to the requirements of the next process, and the required proportion may be represented by speed, quantity, quality, etc., and the method for determining the overfeeding in this embodiment may be implemented in various ways, for example, the overfeeding may be determined through experience, historical data or experimental data, etc.
According to one embodiment of the method for determining the overfeed amount of the present invention, a fabric setting process density P0 is obtained, and if the fabric density at the drop fails to reach the process density P0, the overfeed amount is adjusted until the fabric density at the drop reaches the process density P0. Wherein, the fabric density at the cropping position can be manually measured or online detection is adopted.
According to another embodiment of the overfeed amount determination method of the present invention, a target grammage G0 for heat setting of the fabric is obtained, and if the grammage of the fabric at the drop fails to reach the target grammage G0, the overfeed amount is adjusted until the grammage of the fabric at the drop reaches the target grammage G0. The gram weight of the fabric at the cropping position can be manually measured or online detection is adopted.
In the present embodiment, the constant value P1 may be determined in the following manner: after the overfeeding amount is determined, the average value of the density of any section of the fabric to be determined is obtained, and the constant value P1 of the fabric density on the cloth feeding side of the upper overfeeding roller is determined according to the average value, wherein the constant value P1 of the embodiment can be determined through manual visual inspection, historical data, experimental data or actual measurement data of field operation.
Preferably, if the fabric tension on the fabric feeding side of the upper overfeeding roller exceeds a set tension range (the preferable tension range is 0-150N), the constant value P1 is corrected again to obtain a corrected constant value P10 until the fabric tension on the fabric feeding side of the upper overfeeding roller conforms to the set tension range, so that the linear speed of the active adjusting roller is smaller than that of the upper overfeeding roller, the problem that the fabric slips at the upper overfeeding roller can be avoided, the influence of the fabric tension on the real-time density of the fabric on the fabric feeding side of the upper overfeeding roller can be avoided through the control design of the fabric tension on the fabric feeding side of the upper overfeeding roller, and the control precision is further ensured.
According to one embodiment of the invention, the method for adjusting the fabric density of the cloth feeding side of the upper overfeed roller to reach the constant value P1 in real time comprises the following steps: acquiring real-time fabric density P1 'on the cloth feeding side of the upper overfeeding roller in real time, and controlling and increasing the cloth feeding speed on the cloth feeding side of the upper overfeeding roller if P1' is less than P1; if P1 '> P1, controlling to reduce the cloth feeding speed of the cloth feeding side of the upper overfeed roller until P1' is equal to P1; alternatively, the difference between P1' and P1 is controlled within an error range, preferably within 5%.
It should be noted that the density of the fabric to be shaped changes in the feeding process, and in this embodiment, the real-time adjustment of the fabric real-time density at the fabric feeding side of the upper overfeeding roller means that the controller adjusts the fabric feeding speed at the fabric feeding side of the upper overfeeding roller in real time, so as to adjust the fabric real-time density at the fabric feeding side of the upper overfeeding roller, so as to ensure that the density of the fabric to be shaped is equal to the target fabric density in the feeding process or the difference between the density and the target fabric density is controlled within an error range, and the error range is preferably within 5%.
Further, the real-time fabric density P1' is acquired from the position between the upper overfeed roller and the real-time adjusting position, and the distance between the upper overfeed roller and the real-time adjusting position is not more than 3M, preferably not more than 1.5M.
As shown in fig. 1, the fabric density real-time control method of the present invention may be performed according to the following steps:
s1: determining the overfeed amount and keeping the overfeed amount constant;
s2: determining a constant value P1 of the fabric density of the cloth feeding side of the upper overfeed roller;
s3: and adjusting the fabric density of the cloth feeding side of the upper overfeed roller to a constant value P1 in real time.
As shown in fig. 2, it is of course possible to change the above-described process and perform it as follows:
sa: determining a constant value P1 of the fabric density of the cloth feeding side of the upper overfeed roller;
sb: adjusting the overfeeding amount according to a constant value P1 until the density of the fabric at the cropping position reaches a process density P0 or the gram weight of the fabric at the cropping position reaches a target gram weight G0;
and (C) Sc: and adjusting the fabric density of the cloth feeding side of the upper overfeed roller to a constant value P1 in real time.
According to the invention, the key point is that the density of the fabric on the cloth feeding side of the upper overfeeding roller is adjusted to reach a constant value P1 in real time, and the upper overfeeding amount is not required to be actively adjusted once being determined, so that the aim of accurately and automatically controlling the overfeeding amount of the upper overfeeding roller according to the process density can be achieved, the density of the fabric after being shaped can be consistent with the process density, and the high quality of the fabric is ensured.
Example two:
as shown in fig. 3, the present embodiment provides a real-time fabric density control system, which is used in the real-time fabric density control method, and includes:
and the adjusting module is used for adjusting the fabric density of the cloth feeding side of the upper overfeeding roller to reach the constant value P1 in real time.
Further, the adjustment module includes:
the collecting unit is used for collecting the real-time density P1' of the fabric at the cloth feeding side of the upper overfeeding roller;
the control unit is used for adjusting the real-time density P1 'of the fabric on the cloth feeding side of the upper overfeeding roller, and controlling and increasing the cloth feeding speed of the cloth feeding side of the upper overfeeding roller if P1' < P1; if P1 '> P1, the cloth feeding speed of the upper overfeeding cloth side is controlled to be reduced until P1' is equal to P1 or the difference value of the two is controlled within an error range, and the error range is preferably within 5%.
Example three:
as shown in fig. 4, the present embodiment provides a fabric density real-time control device, which is used for a setting machine, the setting machine belongs to a dyeing and finishing device, the setting machine can also be a setting machine, a drying machine or a tentering setting machine, the setting machine includes an upper overfeeding roller 2 and a chain equipped with a needle plate or a cloth clip, the upper overfeeding roller 2 transfers a fabric 11 to the needle plate or the cloth clip on the chain, the fabric density real-time control device of the present embodiment further includes at least one active adjusting roller, a density detection unit and a controller.
The active adjusting roller of the embodiment is located at the cloth feeding side of the upper overfeeding roller and is used for adjusting the fabric density of the cloth feeding side of the upper overfeeding roller 2 in real time, the rotating speed of the upper overfeeding roller 2 and the rotating speed of the active adjusting roller 3 are respectively controlled by a controller, the controller can be a controller of the setting machine 1 or an independently arranged controller, and in the invention, the controller is preferably a commercially available industrial controller or an industrial personal computer. The controller drives the motor through a motor driver, for example, a variable frequency driver or a variable frequency motor is adopted, or a servo driver drives and a servo motor is adopted.
The density detection unit of the embodiment is arranged on the cloth feeding side of the upper overfeed roller 2 and used for collecting the density of the fabric and transmitting information to the controller, the density detection unit comprises but is not limited to an intelligent camera, an industrial camera and photoelectric detection, and the density detection unit is an intelligent camera and can automatically process the obtained image to obtain data and then transmit the data to the controller; or the density detection unit is an industrial camera, the industrial camera directly transmits the acquired image to the controller, and the controller processes the image to acquire data; or photoelectric detection is adopted to acquire the fabric density and then the information is transmitted to the controller.
Preferably, the density detecting unit is disposed between the upper overfeed roller 2 and the active dancer 3 adjacent to the upper overfeed roller 2, and the distance between the upper overfeed roller 2 and the active dancer 3 is controlled to be generally within a range of not more than 3m, preferably within a range of not more than 1.5 m.
Further, the density detection unit comprises an industrial camera 4 and an illumination light source 5 which are arranged on one side or two sides of the fabric, the industrial camera 4 is a linear array or an area array industrial camera, and the illumination light source 5 comprises a positive light source and/or a backlight source.
The controller of this embodiment controls the active adjusting roller to adjust the fabric density of the upper overfeeding roller on the fabric feeding side to a constant value in real time according to the fabric density information, wherein the constant value is a standard value or a range value, and further, the controller needs to collect the rotation speed signals of the upper overfeeding roller 2 and the active adjusting roller 3 in the control process, and the rotation speed signals include the rotation speed output signal of the driver or the rotation speed output signal of the external speed measuring device.
For example, an external speed measuring device 6 is adopted to collect a rotating speed output signal, the external speed measuring device 6 can be a roller encoder, and after the controller receives data of the roller encoder, the data can be converted into a linear speed which exceeds the linear speed of the feeding roller, namely the running speed of the fabric passing through the feeding roller assembly; or an infrared velocimeter which is arranged at the peripheral fabric of the upper overfeed roller and is used for measuring the linear velocity of the upper overfeed roller; or a motor encoder arranged on the upper overfeed roller, and the controller can convert the data received by the motor encoder into the linear speed of the upper overfeed roller and the like because the diameter of the upper overfeed roller is known.
Further, a fabric adjusting module used for adjusting the tension and the position of the fabric is arranged in front of the upper overfeeding roller and used for enabling the setting machine to obtain the fabric with proper tension and centered, the fabric adjusting module comprises a tension detecting unit and a cloth guiding unit, the tension detecting unit detects the tension of the fabric in front of the upper overfeeding roller, and the controller receives the detection data of the fabric tension detecting unit and adjusts the tension of the fabric through the cloth guiding unit; it is specific, the fabric guide unit includes a plurality of fabric guide rollers 7, and the driving motor of fabric guide roller 7 is connected with the controller electricity, tension detecting element is including setting up the tensioning roller 8 between fabric guide roller 7, tensioning roller 8 passes through the rotatable connection of swing arm 9 in the frame, and is equipped with cylinder 10 between swing arm 9 and the frame, still be equipped with the sensor of being connected with the controller electricity on swing arm 9, the during operation, the swing angle of sensor perception swing arm detects fabric tension, thereby the controller adjusts fabric tension according to the rotational speed that detects signal real-time change fabric guide roller driving motor.
It should be noted that the tension detecting unit may also adopt other structures, for example, two cloth guide rollers and a fabric tension sensor which are arranged at intervals are adopted, the fabric tension is detected by the fabric tension sensor, and the controller changes the cloth feeding speeds of the two cloth guide rollers in real time according to the detection signal so as to adjust the fabric tension.
When the real-time fabric density control device is used, the fabric heat setting process density P0/target gram weight G0 is obtained, the overfeeding amount is set according to the density of the fabric before setting, then the output fabric density/fabric gram weight is calculated, and if the output fabric density reaches the process density P0 or the output fabric gram weight reaches the target gram weight G0, the overfeeding amount is determined and the overfeeding amount is kept constant; after the overfeeding amount is determined, obtaining the average value of the density of any section of the fabric to be determined, determining the target fabric density P1 on the fabric feeding side of the upper overfeeding roller according to the average value, for example, taking 10 meters of the fabric to be determined, then performing density detection, calculating the average value, and determining the constant fabric density value P1 on the fabric feeding side of the upper overfeeding roller according to the average value; the density detection unit collects fabric density information of the cloth feeding side of the upper overfeeding roller and transmits the fabric density information to the controller, the controller carries out judgment control according to the acquired real-time fabric density P1 ', if P1 ' is less than P1, the linear speed of the active adjusting roller is controlled to be increased, if P1 ' is more than P1, the linear speed of the active adjusting roller is controlled to be decreased until P1 ' is equal to P1 or the difference value of the P1 ' and the P1 is controlled within an error range, and the error range is preferably within 5%.
It should be noted that the constant value P1 of the fabric density on the cloth feeding side of the upper overfeeding roller can be determined before the upper overfeeding amount is determined.
After trial, the method can quickly, accurately and automatically adjust the fabric density of the cloth feeding side of the upper overfeed roller, so that the density of the shaped fabric well meets the requirement of process density, the high quality of the fabric is ensured, the one-time success rate is greatly improved, the implementation is convenient, the cost is low, the high-quality development of the textile printing and dyeing industry is facilitated, and the international competitiveness of the textile printing and dyeing industry in China is improved.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art should be considered to be within the technical scope of the present invention, and the technical solutions and the inventive concepts thereof according to the present invention should be equivalent or changed within the scope of the present invention.
Claims (10)
1. A real-time control method for the density of a fabric, which is used for a setting machine comprising an upper overfeed roller and a chain equipped with a needle plate or a cloth clip, the fabric is conveyed to the needle plate or the cloth clip on the chain by the upper overfeed roller, and is characterized in that the control method comprises the following steps:
the cloth feeding side of the upper overfeeding roller is provided with at least one active adjusting roller and a density detection unit, and the active adjusting roller and the density detection unit are matched with each other to adjust the density of the fabric at the cloth feeding side of the upper overfeeding roller in real time to enable the density of the fabric to reach a constant value P1.
2. The method for controlling the fabric density in real time according to the claim 1, wherein the method for adjusting the fabric density in real time comprises the steps of acquiring the real-time fabric density P1 'on the cloth feeding side of the upper overfeeding roller, and controlling to increase the cloth feeding speed on the cloth feeding side of the upper overfeeding roller if P1' < P1; if P1 '> P1, controlling to reduce the cloth feeding speed of the cloth feeding side of the upper overfeed roller until P1' is equal to P1;
or, the real-time adjusting method comprises the step of acquiring the real-time fabric density P1 'on the cloth feeding side of the upper overfeeding roller, and controlling the difference value between P1' and P1 within an error range.
3. The method as claimed in claim 2, wherein the real-time fabric density P1' is collected from between the feeding side of the upper overfeed roller and the active dancer.
4. The real-time fabric density control method according to claim 1, characterized in that a fabric sizing process density P0 is obtained, if the fabric density at the doffing cannot reach the process density P0, the overfeeding amount is adjusted until the fabric density at the doffing reaches the process density P0, and then the current overfeeding amount is kept constant;
or, acquiring a fabric heat-setting target gram weight G0, if the fabric gram weight at the cropping position cannot reach the target gram weight G0, adjusting the overfeeding amount until the fabric gram weight at the cropping position reaches the target gram weight G0, and then keeping the current overfeeding amount constant.
5. The method for controlling the fabric density in real time according to claim 1, wherein if the fabric tension on the cloth feeding side of the upper overfeed roller exceeds the set tension range, the constant value P1 is revised again to obtain the revised constant value P10 until the fabric tension on the cloth feeding side of the upper overfeed roller meets the set tension range.
6. A real-time fabric density control system for a real-time fabric density control method according to any one of claims 1 to 5, comprising:
and the adjusting module is used for adjusting the fabric density of the cloth feeding side of the upper overfeeding roller to reach the constant value P1 in real time.
7. The fabric density real-time control system of claim 6, wherein the adjustment module comprises:
the collecting unit is used for collecting the real-time density P1' of the fabric at the cloth feeding side of the upper overfeeding roller;
the control unit is used for adjusting the real-time density P1 'of the fabric on the cloth feeding side of the upper overfeeding roller, and controlling and increasing the cloth feeding speed of the cloth feeding side of the upper overfeeding roller if P1' < P1; if P1 '> P1, controlling to reduce the cloth feeding speed of the upper overfeeding cloth side until P1' is equal to P1; or, the difference value between the P1' and the P1 is controlled within an error range.
8. A fabric density real-time control device is used for a setting machine, the setting machine comprises an upper overfeeding roller and a chain provided with a needle plate or a cloth clip, and fabrics are conveyed to the needle plate or the cloth clip on the chain through the upper overfeeding roller, and the fabric density real-time control device is characterized by further comprising:
the active adjusting roller is positioned on the cloth feeding side of the upper overfeeding roller and is used for adjusting the fabric density of the cloth feeding side of the upper overfeeding roller in real time;
the density detection unit is arranged on the cloth feeding side of the upper overfeed roller and is used for acquiring fabric density information and transmitting the fabric density information to the controller;
and the controller controls the active adjusting roller to adjust the fabric density of the cloth feeding side of the upper overfeeding roller to reach a constant value in real time according to the fabric density information.
9. The fabric density real-time control device according to claim 8, wherein: the density detection unit is positioned between the upper overfeed roller and the active adjusting roller.
10. The fabric density real-time control device according to claim 8, wherein: the controller is a controller of the setting machine or an independently arranged controller.
Priority Applications (1)
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|---|---|---|---|
| CN202011498123.4A CN112626772A (en) | 2020-12-17 | 2020-12-17 | Method, system and device for controlling fabric density in real time |
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| CN202011498123.4A CN112626772A (en) | 2020-12-17 | 2020-12-17 | Method, system and device for controlling fabric density in real time |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113699727A (en) * | 2021-09-17 | 2021-11-26 | 浙江中纺控股集团有限公司 | Forming machine with overfeeding device |
| CN114293332A (en) * | 2021-11-29 | 2022-04-08 | 信泰(福建)科技有限公司 | Method for calculating overfeeding input value of setting machine |
-
2020
- 2020-12-17 CN CN202011498123.4A patent/CN112626772A/en active Pending
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113699727A (en) * | 2021-09-17 | 2021-11-26 | 浙江中纺控股集团有限公司 | Forming machine with overfeeding device |
| CN114293332A (en) * | 2021-11-29 | 2022-04-08 | 信泰(福建)科技有限公司 | Method for calculating overfeeding input value of setting machine |
| CN114293332B (en) * | 2021-11-29 | 2024-01-02 | 信泰(福建)科技有限公司 | Method for calculating overfeeding input value of setting machine |
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