CN115573047A - Control system and control method for master batch adding machine with spinning function - Google Patents
Control system and control method for master batch adding machine with spinning function Download PDFInfo
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- CN115573047A CN115573047A CN202211229674.XA CN202211229674A CN115573047A CN 115573047 A CN115573047 A CN 115573047A CN 202211229674 A CN202211229674 A CN 202211229674A CN 115573047 A CN115573047 A CN 115573047A
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D1/00—Treatment of filament-forming or like material
- D01D1/06—Feeding liquid to the spinning head
- D01D1/065—Addition and mixing of substances to the spinning solution or to the melt; Homogenising
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D1/00—Treatment of filament-forming or like material
- D01D1/04—Melting filament-forming substances
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B21/00—Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
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- G08B21/182—Level alarms, e.g. alarms responsive to variables exceeding a threshold
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Abstract
The invention discloses a control system and a control method for a spinning functional master batch adder, and the control system further comprises the following steps: the first frequency converter module is used for controlling the flow of the melt flow pump, and the first frequency converter module corresponds to the melt flow pump one by one; the second frequency converter module is used for controlling the rotating speed of the master batch adding machine; the first communication ports of the controller are electrically connected with the first frequency converter module and the second frequency converter module; the invention provides a control system and a control method of a spinning functional master batch adding machine, wherein the control system comprises a first frequency converter module, a second frequency converter module, a controller, a melt flow pump, a master batch adding machine control system and a master batch adding machine control system.
Description
Technical Field
The invention relates to the technical field of spinning, in particular to a spinning functional master batch adder control system and a control method thereof.
Background
The spinning production line of the spinnable functional fiber has 4 or 8 parts, and each part controls the rotating speed of a spinning melt flow pump shaft through an asynchronous motor by a frequency converter. According to the prior art, the production line is originally provided with a functional master batch adding machine, and a controller of the functional master batch adding machine is connected with a pair of lines of each spinning melt flow pump frequency converter. Because the electrical signal output by the Y1 terminal of each frequency converter changes when the output frequency of each frequency converter reaches the preset operating frequency, the control mode of the original controller is to obtain the Y1 terminal signal of each melt flow pump frequency converter through a connecting line, then the on-off basis of each melt flow pump is judged according to the high and low of the electrical signal, and finally the rotating speed of the master batch adding machine is determined according to the on-off number of the melt flow pumps of the whole production line, so that the adding amount of functional master batches is controlled (the structure of a control system is shown in figure 1), and the controller obtains the corresponding on-off signals of each frequency converter before and after the frequency converter reaches the preset frequency from the four melt flow pump frequency converters; and then the controller sends corresponding output frequency signals to the master batch adding machine frequency converter through the communication port according to the received on-off signals of the four melt flow pump frequency converters, and then the rotating speed of the master batch adding machine is controlled by the motor. This control scheme has the following disadvantages:
1. in the spinning production process, when a winding process of a certain part stops due to faults, if a melt flow pump of the part continues to operate, spinning melt discharged by the melt flow pump becomes waste, but if the winding process fails, the corresponding melt flow pump is stopped to reduce the discharge of the waste, and the pressure fluctuation of an extruder head is easily caused due to frequent starting and stopping of the melt flow pump, so that the product quality problem is caused. Therefore, in actual production, on the premise of ensuring the product quality, when the winding process of a certain part is stopped, a production workshop requires a technologist to reduce the rotating speed of the melt flow pump shaft of the part so as to achieve the purpose of reducing waste discharge. However, when the master batch adding machine control mode is adopted, the speed of the melt flow pump shaft at the position is only reduced but not stopped, so that the rotating speed of the master batch adding machine in the mode cannot be reduced along with the reduction speed of the melt flow pump, and the mixing ratio of the functional master batches and the main raw material before and after the reduction speed of the melt flow pump is uneven. Therefore, in this mode, the purpose of reducing waste discharge cannot be achieved by reducing the rotation speed of the melt flow pump shaft when winding fails;
2. in the test process of developing new functional fibers, the rotating speed of a melt flow pump shaft is often required to be adjusted according to the physical indexes of the product. Under the original master batch adding machine control mode, after the speed of a melt flow pump shaft is adjusted every time, in order to ensure that the mixing ratio of the functional master batches and the main raw material is uniform before and after speed adjustment, master batch flow coefficients of corresponding parts need to be calculated and reset by process personnel, so that the working efficiency of the process personnel is influenced. The above situations can be met when the speed of the melt flow pump needs to be regulated in the new product development process;
3. the existing controller is an early product, the minimum adjusting weight of master batches in the program is 0.1g, but with the continuous development of new varieties of master batches, some functional fibers are found to be sensitive to the addition amount of the master batches in production, the minimum adjusting weight of the master batches is required to be less than 0.1g, and the existing controller cannot meet the production requirement;
4. after the frequency converter of the melt flow pump is started, the output signal of the Y1 terminal of the frequency converter does not change immediately, when the output frequency rises to be close to the operation frequency, the output signal of the Y1 terminal changes, and at the moment, the master batch adding machine responds to the operation of the melt flow pump, namely, the response of the master batch adding machine is lagged in the acceleration process (generally more than 10 seconds) of the melt flow pump, and the process can influence the product quality;
5. the original control mode does not monitor and record the control process, and is not beneficial to the tracing of the product quality.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: the defects of the prior art are overcome, and the spinning functional master batch adding machine control system and the control method thereof are provided, wherein the rotating speed of the master batch adding machine can be changed along with the change of a melt flow pump, so that the production efficiency is high, and the purpose of reducing waste material emission is achieved.
In order to realize the purpose, the technical scheme of the invention is as follows: a control system of a spinning functional master batch adder further comprises:
the first frequency converter module is used for controlling the flow of the melt flow pump, and the first frequency converter module corresponds to the melt flow pump one by one;
the second frequency converter module is used for controlling the rotating speed of the master batch adding machine;
the first communication ports of the controller are electrically connected with the first frequency converter module and the second frequency converter module;
after the controller collects the current operating frequency signal of the first frequency converter module, the controller transmits the fed-back output frequency signal to the second frequency converter module after calculation, and the second frequency converter module controls the rotating speed of the master batch adding machine.
After adopting the structure, compared with the prior art, the invention has the following advantages: the first communication port of the controller is electrically connected with the first frequency converter module and the second frequency converter module through a network cable, namely the controller is connected with the frequency converter communication ends of each melt flow pump and the master batch adding machine, the controller continuously and circularly reads the current operating frequency of each melt flow pump frequency converter, the corresponding frequency value is sent to the master batch adding machine frequency converter after calculation of the controller, and then the rotating speed of the master batch adding machine is controlled through an asynchronous motor and a reduction gearbox, so that the rotating speed of the master batch adding machine can automatically follow the change of the speed of each melt flow pump shaft, when winding fails, the purpose of reducing waste discharge can be achieved by reducing the rotating speed of the melt flow pump shaft, and meanwhile, when the rotating speed of the melt flow pump shaft is regulated, master batch flow coefficients of corresponding parts do not need to be calculated and reset through process personnel, and the production efficiency is high.
Preferably, the monitoring system further comprises a monitoring module, wherein the first communication port of the monitoring module is electrically connected with the first frequency converter module, the second frequency converter module and the communication line of the controller, the monitoring module is used for receiving a current operating frequency signal of the first frequency converter module and an output frequency signal of the second frequency converter module, and when the controller reads the frequency of each melt flow pump frequency converter and sends the frequency to the second frequency converter module in the production process, the monitoring module obtains the current operating frequency of each melt flow pump frequency converter and the current operating frequency of the second frequency converter module in a passive receiving mode through a monitoring program, records the frequency value of each frequency converter in a curve form, which is equivalent to recording the input and output signals of the controller, so that a manager can conveniently check the working condition of the controller.
Preferably, the master batch adding machine further comprises a speed measuring plate and a speed sensor module for detecting the rotating speed of the master batch adding machine, the speed measuring plate is electrically connected with the speed sensor module, the speed sensor module transmits the collected rotating speed signal of the master batch adding machine to the speed measuring plate for processing, the speed sensor module detects the rotating shaft speed of the master batch adding machine, and the speed measuring plate processes the signal from the speed sensor module and temporarily stores the processing result.
Preferably, the second communication port of the controller is electrically connected with the second communication port of the monitoring module and the speed measuring board, the controller circularly reads the operating frequency of each melt flow pump frequency converter through the first communication port of the controller, continuously reads the speed signal of the rotating shaft of the master batch adding machine in the speed measuring board through the second communication port, comprehensively processes the received frequency signal of the melt flow pump frequency converter and the speed signal of the rotating shaft of the master batch adding machine, controls the frequency of the second frequency converter module, and further controls the rotating speed of the master batch adding machine. The monitoring module obtains the current operating frequency of each melt flow pump frequency converter and the second frequency converter module through a first communication port of the monitoring module in a passive receiving mode; through the second communication port, the speed signal of the master batch adding machine rotating shaft is passively received and curve recording is carried out, so that the monitoring module can record the frequency of each frequency converter and the speed of the adding machine rotating shaft.
Preferably, the master batch adding machine further comprises an alarm module, wherein the alarm module is electrically connected with the controller, and an alarm is given when the controller detects that the operating frequency of the first frequency converter module is unchanged and the speed of the rotating shaft of the master batch adding machine is abnormal.
A control method comprises any one of the above control systems for the spinning functional master batch adding machine, and comprises the following steps:
1. when the production is started, setting the operating frequencies of the first frequency converter module and the second frequency converter module according to the process requirements;
2. after each melt flow pump operates stably, starting the master batch adding machine and enabling the master batch adding machine to operate in a manual mode, and respectively finishing the steps of waste discharging, small spinning and wire coiling, detection and the like of an extruder;
3. when the quality of the small silk rolls in the second step meets the process requirements through detection, pressing a manual/automatic switching key, and enabling the controller to enter an automatic control mode;
4. during automatic control, the controller reads the running frequency of a first frequency converter module every 100-300 ms through the first communication port, continuously reads a speed signal of a master batch adding machine rotating shaft in the speed measuring board through the second communication port, and when the controller detects that the running frequency of the first frequency converter module changes, the controller executes main control to realize active regulation of the rotating speed of the master batch adding machine; when the controller detects that the operating frequencies of the first frequency converter module are not changed, executing the next step;
5. and executing negative feedback control and alarm functions: the negative feedback control is used for correcting the speed of the rotating shaft of the master batch adding machine when the speed changes slowly due to external factors, and the alarm function is used for early warning when the master batch adding machine breaks down;
6. the monitoring module obtains the current operating frequency of the first frequency converter module and the current operating frequency of the second frequency converter module in a passive receiving mode through a first communication port of the monitoring module; passively receiving a speed signal of a rotating shaft of the master batch adding machine through a second communication port;
7. and repeating the steps from four to six until the machine is stopped.
After adopting the technical scheme, compared with the prior art, the invention has the following advantages: 1. the controller reads the frequency of the frequency converter of each melt flow pump and calculates the theoretical operating frequency value f of the second frequency converter module S And target speed V of the rotating shaft Eyes of a user Automatic following is performed, and when winding fails, the purpose of reducing waste discharge can be achieved by reducing the rotating speed of a melt flow pump shaft; 2. the master control is utilized to realize the active regulation of the rotating speed of the master batch adding machine, and the master control is used in the occasions needing to regulate the speed of a melt flow pump, so that the uniform mixing ratio of the functional master batches and the main raw materials before and after speed regulation is ensured; 3. the controller reads the frequency of one melt flow pump frequency converter every 100-300 ms, and the frequency of four frequency converters needs 0.4-1.2 s, so that the aim of quickly responding to the frequency change of each melt flow pump frequency converter is fulfilled, the response of the master batch adding machine is quick, and the influence on the product quality during the speed increasing or reducing of the frequency converters can be ignored; 4. the monitoring module is used for monitoring and recording the control process, and the product quality tracing is facilitated.
Preferably, the main control in the fourth step means that the controller cyclically reads the operating frequency of each first frequency converter module through the first communication port, continuously reads the speed signal of the master batch adding machine rotating shaft in the speed measuring board through the second communication port, then performs comprehensive processing on the received frequency signal of the first frequency converter module and the speed signal of the master batch adding machine rotating shaft, then controls the frequency of the second frequency converter module, and further controls the rotating speed of the master batch adding machine, and when the operating frequency of the first frequency converter module changes, that is, the speed of the melt flow pump changes, the controller immediately performs quick and accurate applicability control on the rotating speed of the master batch adding machine.
Preferably, the negative feedback control means that the operating frequency output to the second frequency converter module for the first time when the controller changes the manual control into the automatic control is taken as the reference output frequency F S Then, the frequency value of each first frequency converter module is read, and the whole frequency converter module is obtained according to a formulaReference flow L of production line R Simultaneously reading the speed signal of the rotating shaft of the master batch adding machine in the speed measuring plate, and taking the speed signal as the reference output frequency F of the second frequency converter module S Corresponding reference speed V of rotating shaft Base (C) After the three reference quantities are determined, the controller enters a continuous control state, and the actual flow Lr of the production line and the theoretical operating frequency value f of the second frequency converter module are determined according to a formula by reading the frequency of each frequency converter S And target speed V of the rotating shaft Eyes of a user Reading the speed signal of the rotating shaft of the master batch adding machine in the speedometer and taking the speed signal as the actual speed V Fruit of Chinese wolfberry And comparing the actual operating frequency f with the target speed V, determining the actual operating frequency f of the second frequency converter module according to the speed deviation value, and responding to the slow change and small amplitude change of the rotating speed of the master batch adding machine rotating shaft caused by the change of the resistance, so that the correction can be performed in time, and the reliability is high.
Preferably, the alarm function means that the controller detects that the operating frequency of the first frequency converter module is not changed, but the actual speed V of the rotating shaft of the master batch adding machine read from the speed measuring board Fruit of Chinese wolfberry And a target speed V Eyes of a person Starting a timer which is timed for N minutes when the absolute value of the difference is DeltaV | M, and if the controller reads the actual speed V of the rotating shaft of the master batch adding machine every time within N minutes Fruit of Chinese wolfberry Then, the | DeltaV | M is always true, and the controller can drive the alarm module to alarm after N minutes; if the < M > Delta V | appears in N minutes or the controller detects that the operating frequency of the first frequency converter module is changed, the timer is stopped and cleared, an alarm can be given when the rotating shaft speed of the master batch adding machine is abnormal, the master batch adding machine can find and process in time if a fault occurs in the production process, defective products or waste products of production are reduced, and the whole production cost is lower.
Preferably, in the fourth step, when the controller detects that none of the operating frequencies of the first inverter module has changed, the controller detects that none of the operating frequencies of the first inverter module has changed five times continuously, and the reliability is high.
Drawings
Fig. 1 is a schematic circuit diagram of the prior art.
Fig. 2 is a circuit schematic diagram of a control system of the spinning functional master batch adder.
Fig. 3 is a schematic diagram of a controller structure of a control system of a spinning functional master batch adder.
FIG. 4 is a control flow chart of the control system of the spinning functional master batch adding machine.
FIG. 5 is an alarm flow chart of the control system of the spinning functional masterbatch adding machine of the present invention.
FIG. 6 is a wiring diagram between the controller of the control system of the spinning function masterbatch adding machine, the monitoring module and the speed measuring plate.
FIG. 7 is a wiring diagram of a speed measuring board of a control system of a spinning functional master batch adding machine.
The device comprises a first frequency converter module, a second frequency converter module, a controller, a monitoring module, a speed measuring board, a speed sensor module, a controller, a speed sensor module and an alarm module, wherein the first frequency converter module 1, the second frequency converter module 2, the controller, the monitoring module 5, the speed measuring board 6 and the speed sensor module 7.
Detailed Description
The invention is further described with reference to the following figures and detailed description.
As shown in fig. 2, the invention provides a control system for a spinning functional master batch adding machine, which comprises a controller 3, a first frequency converter module 1 and a second frequency converter module 2, wherein the first frequency converter module 1 corresponds to a melt flow pump one by one and is used for controlling the flow of the melt flow pump, also called as a melt flow pump frequency converter, and the melt flow pump controls the flow by controlling the speed of a pump shaft; the second frequency converter module 2 is used for controlling the rotating speed of the master batch adding machine, is also called a master batch adding machine frequency converter, and particularly controls the rotating speed of the master batch adding machine through an asynchronous motor and a reduction gearbox; the controller 3 is electrically connected with the first frequency converter module 1 and the second frequency converter module 2 through the first communication port, the controller 3 reads the current running frequency of each first frequency converter module 1 through the first communication port, the controller 3 calculates the current running frequency and sends an output frequency signal to the second frequency converter module 2 through the first communication port, and then the rotating speed of the master batch adding machine is controlled through the motor, so that the rotating speed of the master batch adding machine can automatically follow the change of the speed of each melt flow pump shaft. Specifically, taking four melt flow pumps as an example, in order to solve the problem that the melt flow pump in the prior art responds only after delaying for at least ten seconds in the speed-up process, the controller 3 reads the frequency of one melt flow pump frequency converter every 200ms, and the frequency of four frequency converters is read and processed and delayed for about 1s, so as to achieve the purpose of rapidly responding to the frequency change of each melt flow pump frequency converter. In addition, in the internal calculation process of the controller 3, enough digits, at least three digits, are reserved after decimal points of each datum, so that the frequency precision of the datum finally sent to the second frequency converter module 2 is 0.01Hz, and when the functional fiber product is sensitive to the addition amount of master batches, the controller 3 can meet the production requirement.
Specifically, as shown in fig. 3, the controller 3 is composed of two parts: one part is used for reading external signals, internal operation and outputting control signals; the other part is key input and data display, and the information exchange between the two parts is realized through I 2 And finishing the bus C, the interrupt connecting wire and the timing reset wire. And a communication port of the controller 3 is connected with communication ends of the frequency converters of the melt flow pumps and the master batch adding machine through a network cable. Four connecting lines of the left and right parts of the controller 3 are two I of SCL and SDA from top to bottom respectively 2 The bus C, the interrupt connecting wire INT and the timing reset wire RST.
Specifically, the controller 3 works as follows: the controller 3 is first powered on or pressed from E after the reset key is pressed in operation 2 Reading the pump supply data of each melt flow pump from the ROM, taking the minimum pump supply number (not zero) as a denominator and the pump supply data of each melt flow pump as a numerator, calculating the pump supply coefficients K1, K2, K3 and K4 of each melt flow pump, and sequentially displaying the pump supply coefficients in a display for process personnel to confirm; then from E 2 The ROM reads out the running frequency of the master batch adding machine stored by the controller at the latest time, and sends the running frequency to the second frequency converter module 2. The monitoring module 4 comprises a computer with a monitoring program and two communication interface conversion plates, wherein one communication interface conversion module is used for receiving the frequency signals of each frequency converter and is an RS232/485 conversion plate; another communication interface conversion module for receiving the additionThe model of the machine rotating shaft speed signal is an RS232/422 conversion plate.
Specifically, the manual/automatic switching process of the controller 3: when the production is started, a craftsman sets the operation frequency of each melt flow pump and the second frequency converter module 2 according to the process requirements according to the results obtained by tests, starts the master batch adding machine and enables the master batch adding machine to operate in a manual mode after each melt flow pump operates stably, and completes the steps of discharging waste materials, spinning small coiled wires, detecting and the like of the extruding machine respectively, when the quality of the spun small coiled wires reaches the process requirements through detection (the small coiled wires are not fully coiled wires), a manual/automatic switching key is pressed, and the controller 3 enters an automatic control mode: the controller 3 firstly sends the currently set control frequency to the second frequency converter module 2, and then completely and accurately reads the running frequency of each melt flow pump frequency converter as the reference running frequency F of each frequency converter R Each frequency value F R Multiplying with corresponding pump supply coefficient K to obtain the reference flow of each part, adding the reference flows of each part to obtain the reference flow L of the whole production line R (formula 1); in addition, when the manual control is converted into the automatic control, the operation frequency output to the second frequency converter module for the first time is used as the reference output frequency F S Thus, the determination of the reference value required for the automatic operation of the controller is completed. Then circularly reading the current operating frequency f of each melt flow pump frequency converter r The actual flow L of the whole production line can be obtained by calculation r (equation 2), the theoretical operating frequency f of the second frequency converter module 2 can be calculated according to equation 3 S . The controller continuously and circularly reads the current operating frequency of each melt flow pump frequency converter, and the corresponding frequency value f is calculated by formula 1 and formula 3 S And the speed of the master batch adding machine is controlled by an asynchronous motor and a reduction gearbox, so that the speed of the master batch adding machine can automatically follow the change of the speed of each melt flow pump shaft.
L R ＝F R 1*K1+F R 2*K2+F R 3*K3+F R 4 × k4 formula 1
L r ＝f r 1*K1+f r 2*K2+f r 3*K3+f r 4 × k4 formula 2
f S ＝L r /L R *F S Equation 3
In the above formula: l is R : the reference flow of the whole production line;
L r : actual flow of the whole production line;
F R 1-F R 4: the reference frequencies of the four melt flow pump frequency converters;
f r 1-f r 4: the current frequencies of the four melt flow pump frequency converters;
k1 to K4: pump supply coefficients of the four melt flow pumps;
F S : the reference frequency of the second frequency converter module 2;
f S : and calculating the theoretical operating frequency of the second frequency converter module 2 according to the current actual operating frequencies of the four melt flow pump frequency converters.
As an embodiment, in order to verify whether the working process of the controller 3 is normal, the controller further includes a monitoring module 4, a first communication port of the monitoring module 4 is electrically connected to communication lines of the first frequency converter module 1, the second frequency converter module 2 and the controller 3, the first communication port of the monitoring module 4 is connected to communication lines of each melt flow pump frequency converter, the second frequency converter module 2 and the controller 3 through a network cable, during the production process, when the controller 3 reads the frequency of each melt flow pump frequency converter and sends the frequency to the second frequency converter module 2, the monitoring module 4 obtains the current operating frequency of each melt flow pump frequency converter and the second frequency converter module 2 through a monitoring program in a passive receiving mode, and records the frequency value of each frequency converter in a curve form, which is equivalent to recording the input and output signals of the controller 3, thereby facilitating a manager to check the working condition of a new controller. Specifically, passive receiving means that the controller 3 sends an instruction for reading the operating frequency of the frequency converter through a network cable, and the frequency converter sends a frequency value to the controller 3, but because the communication port of the monitoring module 4 is connected to the controller 3 and the communication port of the frequency converter through the network cable and the setting of the communication parameters is the same, the instruction sent by the controller 3 and the frequency value monitoring device sent by the frequency converter can both be received, because the controller 3 and the frequency converter actively send information, and the monitoring module 4 does not send information, but only receives information, it is passive.
As an embodiment, in order to facilitate the process personnel to know the rotation condition of the master batch adding machine and determine the actual execution effect of the control system, the master batch adding machine further comprises a speed measuring plate 5 and a speed sensor module 6, wherein the speed measuring plate 5 is electrically connected with the speed sensor module 6, the speed sensor module 6 is used for collecting a rotating shaft speed signal of the master batch adding machine and then transmitting the signal to the speed measuring plate 5, and the speed measuring plate 5 can process the signal from the speed sensor module 6 by using a speed measuring program and temporarily store the processing result. Specifically, the speed measuring board 5 is a speed signal detection circuit board, which comprises a single chip microcomputer (model: STC12C5616 AD) and two communication chips (model SN75176 BP), and also comprises a direct current 5V voltage stabilizing and filtering element, an optical coupling isolation device and an input interference resistant resistance-capacitance element, and can detect and process speed pulse signals through a program of the single chip microcomputer. When the speedometer 5 receives an inquiry signal of the monitoring module 4 or the controller 3, the speedometer 5 sends the processed speed signal to the monitoring module 4 or the controller 3. Specifically, the speed sensor module 6 is a hall speed sensor, and a magnet facing the hall speed sensor is arranged on the outer circumference of the rotating shaft of the master batch adding machine.
As an embodiment, in order to monitor the rotating shaft speed of the master batch adding machine, the monitoring module 4 is connected with the speed measuring board 5 through the second communication port at the initial development stage, and the monitoring module 4 continuously reads the master batch adding machine rotating shaft speed signal temporarily stored in the speed measuring board 5 through the second communication port through the monitoring program and performs curve recording, so that the monitoring module 4 can record the frequency of each frequency converter and the rotating shaft speed of the adding machine. Specifically, the monitoring module 4 is a computer with a monitoring program and two communication interface conversion boards, one of which is used for receiving signals of the frequency converter, and the other is used for receiving the feedback speed of the rotating shaft in the speed measuring board 5. ( Description of the drawings: since it is impossible for the modified monitoring module in fig. 2 to actively read the signal of the tachometer board 5, the "initial development stage" is that the connection mode of fig. 2 is not adopted at last, or the monitoring module 4 reads the tachometer board signal, that is, when the controller 3 is not connected to the test board 5, the monitoring module 4 actively reads the tachometer board 5 signal. When the controller 3 is connected with the speed measuring board 5, the monitoring module 4 passively receives the signal of the speed measuring board 5 )
As an example, in use it was found that: even if the output frequency of the second frequency converter module 2 is not changed, the speed of the rotating shaft of the master batch adding machine sometimes changes slowly due to the change of external factors (such as resistance), when the speed deviation lasts for a period of time and cannot be corrected, the quality of a product is affected, in order to solve the problem, the controller 3 is changed into a control chip with a dual communication port, the second communication port of the controller 3 is connected with the speed measuring plate 5 and the second communication port of the monitoring module 4, and meanwhile, the control program and the monitoring program are also modified, so that the monitoring module 4 does not send an instruction for reading the speed of the rotating shaft to the speed measuring plate 5 any more, and the controller 3 actively reads the speed. The modified control system is shown in fig. 2, wherein the controller 3 circularly reads the operating frequency of each melt flow pump frequency converter through a first communication port of the controller, continuously reads the speed signal of the rotating shaft of the master batch adding machine in the speed measuring plate through a second communication port, comprehensively processes the received frequency signal of the melt flow pump frequency converter and the speed signal of the rotating shaft of the master batch adding machine, controls the frequency of the second frequency converter module 2, and further controls the rotating speed of the master batch adding machine. The monitoring module 4 obtains the current operating frequency of each melt flow pump frequency converter and the second frequency converter module 2 through a first communication port of the monitoring module in a passive receiving mode; and passively receiving a speed signal of the rotating shaft of the master batch adding machine through a second communication port. Specifically, the controller 3 is a single chip microcomputer with the model of STC12C5a60S2.
Specifically, in order to realize the correction of the speed of the rotating shaft of the master batch adding machine, the controller 3 is set to be in a manual mode during starting, when the control and execution equipment normally and stably runs and the product index meets the requirement, a manual/automatic switching key is pressed, and the controller 3 enters an automatic control mode: the controller 3 takes the operating frequency output to the second inverter module 2 for the first time when the manual control is changed into the automatic control as the reference output frequency F S Then reading the frequency value of the frequency converter of each melt flow pump, and obtaining the reference flow L of the whole production line according to the formula 1 R Simultaneously reading the speed signal of the rotating shaft of the master batch adding machine in the speed measuring plate, and taking the speed signal as the reference frequency F of the second frequency converter module 2 S Corresponding reference speed V of rotating shaft Base of . After determining the three reference quantities, the controller 3 enters a continuous control state, and the actual flow L of the production line is determined according to the formulas 2 to 4 by reading the frequency of each frequency converter r Theoretical operating frequency f of the second frequency converter module 2 S And target speed V of the rotating shaft Eyes of a user Reading the speed signal of the rotating shaft of the master batch adding machine in the speedometer 5, and taking the speed signal as the actual speed V Fruit of Chinese wolfberry With target speed V Eyes of a user The comparison is carried out and the actual operating frequency f of the second frequency converter block 2 is determined on the basis of the deviation value of the speed (cf. Equations 5-8).
V Eyes of a user ＝f S /F S *V Base of Equation 4
ΔV＝V Fruit of Chinese wolfberry –V Eyes of a person Equation 5
When Δ V =0, f = f S Equation 6
When Δ V<At 0, f = f S + Δ f equation 7
When Δ V>At 0, f = f S - Δ f equation 8
In equations (4) to (8):
F S : under the condition that the whole production line normally produces, the controller 3 outputs the running frequency, namely the reference frequency, to the second frequency converter module 2 for the first time when the manual operation is just changed into the automatic control;
V base of : the controller 3 just switches from manual control to automatic control, and the rotating shaft speed of the master batch adding machine in normal operation is the reference speed;
f S : in the automatic control process, the theoretical operating frequency of the second frequency converter module 2 is calculated according to the current actual operating frequencies of the four melt flow pump frequency converters;
V eyes of a user : corresponding to the theory of the second frequency converter module 2Operating frequency f S Calculating the speed of the rotating shaft, namely the target speed;
V fruit of Chinese wolfberry : under the automatic control mode, the actual speed of the rotating shaft is controlled when the master batch adding machine works for a long time;
Δ V: the difference value between the actual speed and the target speed of the rotating shaft of the master batch adding machine;
Δ f: a frequency correction value of the second frequency converter module 2;
f: the actual operating frequency of the second frequency converter module 2.
Of the above parameters, the frequency correction value Δ f of the second frequency converter module 2 is set by the craftsman according to the actual production situation and stored in E of the controller 3 2 In the ROM.
Specifically, in the production process of functional fibers, operations such as starting or stopping, increasing or decreasing of each melt flow pump belong to large operations, and if the master batch adding machine cannot respond in time, the influence on the product quality is large, and as can be seen from the above: during the automatic control of the controller 3, corresponding to these large operations, the controller reads the frequency of the frequency converter of each melt flow pump and calculates the theoretical operating frequency f of the second frequency converter module 2 according to the formulas 1 to 4 S And target speed V of the rotating shaft Eyes of a person Automatic following is made, which is the main control function of the controller 3. While from the actual production it can be observed: the rotating speed of the rotating shaft of the master batch adding machine is changed slowly and has small amplitude due to the change of the resistance. Therefore, the negative feedback control of the controller 3 on the slow speed change of the rotating shaft of the master batch adding machine according to the formulas 5 to 8 is driven relative to the main control that the controller 3 follows the speed change of the pump shafts of all melt flow rates: when the controller 3 detects that the operating frequency of each melt flow pump frequency converter is changed, the theoretical operating frequency value f of the second frequency converter module 2 obtained by the formula 3 is directly used S The actual operating frequency is sent to the second frequency converter module 2, and negative feedback control on the speed of the rotating shaft of the master batch adding machine is not executed any more; when the controller detects that the running frequency of each melt flow pump frequency converter is not changed for five times (four flow pump frequency converters, the frequency of one flow pump frequency converter is read every 200ms, and the frequency converters I to IV detect once in sequence andabout 1 second after treatment and delay, and about 5 seconds after 5 times of circular detection), not executing main control, but executing negative feedback control on the speed of the rotating shaft of the master batch adding machine according to the results of formulas 4-8. The controller 3 can better meet the actual requirements of production control through the design of combining the master control with the negative feedback control of the slave. The control flow of the controller 3 is shown in fig. 4.
As an embodiment, because the price of the functional master batch is generally expensive, if the master batch adding machine fails and is not found and processed in time in the production process, the number of produced inferior-quality products or waste products is increased, and the whole production cost is higher, the controller 3 also has an alarm function, and the controller also comprises an alarm module 7, wherein the alarm module 7 is electrically connected with the controller 3, and when the controller 3 detects that the operating frequency of each melt flow pump frequency converter is not changed, an alarm is given when the rotating shaft of the master batch adding machine read from the speed measuring board 5 is abnormal. Specifically, the controller 3 detects that the running frequency of each melt flow pump frequency converter is not changed, but the actual speed V of the rotating shaft of the master batch adding machine read from the speed measuring board Fruit of Chinese wolfberry With target speed V Eyes of a person Starting a timer which is timed for N minutes when the absolute value of the difference is DeltaV | M, and if the controller 3 reads the actual speed V of the rotating shaft of the master batch adding machine every time within N minutes Fruit of Chinese wolfberry Then, the | Δ V | M is always true, and the controller drives the alarm module 7 to alarm after N minutes; and if the < M > Delta V | appears in the timing time or the controller 3 detects that the running frequency of the melt flow pump frequency converter is changed, stopping the timer and resetting the timer. M is the actual speed V of the rotating shaft of the master batch adding machine Fruit of Chinese wolfberry And a target speed V Eyes of a user The alarm threshold value of the difference, N is the time timed by the timer, and M and N are set by the craftsman according to the requirement of the variety of the produced functional fiber and stored in the E of the controller 2 In the ROM. The alarm flow of the controller 3 is shown in fig. 5.
The controller 3 has the following functions: setting and distinguishing operation authority; setting the supply quantity of a melt flow pump; setting and controlling the frequency of the controller during manual operation; setting a frequency correction value delta f of the second frequency converter module 2, a master batch adding machine rotating shaft speed alarm threshold value M and the timing time N of a timer; the automatic control is carried out by main control following the frequency change of the frequency converter of each melt flow pump and negative feedback control following the main control; and alarming the abnormal speed of the rotating shaft of the master batch adding machine.
Specifically, the wiring diagram of the controller 3 is shown in fig. 6, and the wiring diagram of the speed measuring board 5 is shown in fig. 7, wherein 75176 refers to a communication chip with model number SN75176 BP.
Specifically, the principle of the invention is that a first communication port of a controller 3 is electrically connected with a first frequency converter module 1 and a second frequency converter module 2 through a network cable, that is, the controller 3 is connected with frequency converter communication ends of each melt flow pump and a master batch adding machine, the controller 3 continuously and circularly reads the current operating frequency of each melt flow pump frequency converter, the corresponding frequency value is sent to the second frequency converter module 2 after being calculated by the controller, and then the rotating speed of the master batch adding machine is controlled through an asynchronous motor and a reduction gearbox, so that the rotating speed of the master batch adding machine can automatically follow the change of the speed of each melt flow pump shaft, when winding fails, the purpose of reducing waste discharge can be achieved by reducing the rotating speed of the melt flow pump shaft, and when the rotating speed of the melt flow pump shaft is regulated, the master batch flow coefficient of the corresponding part does not need to be calculated and reset by process personnel, and the production efficiency is high.
Compared with the prior art, the technical scheme has the advantages that the speed sensor module 6, the speed measuring plate 5 and the monitoring module 4 are additionally arranged, the speed measuring program and the monitoring program are correspondingly added, and the controller 3 has a main control function of following the frequency change of the frequency converter of each melt flow pump, so that 5 problems existing in the use of an old control system are solved. In addition, according to the technical scheme, the negative feedback control and alarm function developed aiming at the rotating speed of the rotating shaft of the master batch adding machine is realized according to the actual use condition, so that the control function of the controller 3 is more perfect, the actual problem in production can be solved, and meanwhile, the production cost is reduced, which is just what other master batch adding machine control systems may lack. In addition, according to different production varieties, the technical scheme can set corresponding frequency correction value delta f, alarm threshold value M and timing time N, so that the flexibility and the adaptability are improved.
The action process comprises the following steps: 1. when the production is started, the operation frequency of each melt flow pump and the second frequency converter module 2 is set according to the process requirements. 2. And after the melt flow pumps stably operate, starting the master batch adding machine and enabling the master batch adding machine to operate in a manual mode, and respectively finishing the steps of waste discharging, small spinning and wire coiling, detection and the like of the extruding machine. The physical indexes of the product are detected every time the product is produced, wherein, the fineness and the tensile strength are basic detection items, different products have other detection requirements, and the continuous and batch production is started only after the detection indexes meet the requirements. Because the silk quantity required by detection is not large, the detection requirement can be met by spinning small rolls of silk, the silk does not need to fall to be detected when the rolls are fully rolled, and the detection result can be obtained quickly. 3. When the product quality meets the requirement, pressing a manual/automatic switching key, the controller enters an automatic control mode, and follows the main control of the frequency change of the frequency converter of each melt flow pump and the negative feedback control driven by the main control; and alarming the abnormal speed of the rotating shaft of the master batch adding machine.
Examples
A control method comprises any one of the above control systems for the spinning functional master batch adding machine, and comprises the following steps:
1. when the production is started, the operating frequencies of the first frequency converter module 1 and the second frequency converter module 2 are set according to the process requirements, and at least three digits are reserved behind decimal points of each datum in the internal calculation process of the controller 3, so that the frequency precision of the data finally sent to the second frequency converter module 2 is 0.01Hz;
2. after each melt flow pump operates stably, starting the master batch adding machine and enabling the master batch adding machine to operate in a manual mode, and respectively finishing the steps of waste discharging, small spinning and wire coiling, detection and the like of an extruder;
3. when the quality of the small rolled silk in the step two meets the process requirements through detection, pressing a manual/automatic switching key, and enabling a controller to enter an automatic control mode;
4. the controller 3 reads the running frequency (100 ms, 200ms or 300ms can be selected) of one first frequency converter module 1 every 100ms to 300ms, when the controller 3 detects that the running frequency of the first frequency converter module 1 is changed, the controller 3 executes main control to realize active adjustment of the rotating speed of the master batch adding machine, specifically, the controller 3 circularly reads the running frequency of each first frequency converter module 1 through a first communication port, continuously reads a speed signal of a master batch adding machine rotating shaft in the speed measuring plate 5 through a second communication port, then carries out comprehensive processing on the received frequency signal of the first frequency converter module 1 and the speed signal of the master batch adding machine rotating shaft, then controls the frequency of the second frequency converter module 2, and further controls the rotating speed of the master batch adding machine; when the controller 3 detects that the operating frequencies of the first frequency converter module 1 are not changed, the next step is executed;
5. and (3) executing negative feedback control and alarm functions: the negative feedback control is used for correcting the speed of the rotating shaft of the master batch adding machine when the speed changes slowly due to external factors, and the alarm function is used for early warning when the master batch adding machine breaks down; the negative feedback control means that the operating frequency output to the second inverter module 2 for the first time when the controller 3 changes the manual control to the automatic control is taken as the reference output frequency F S Then, the frequency value of each first frequency converter module 1 is read, and the reference flow L of the whole production line is obtained according to a formula R Simultaneously, the speed signal of the rotating shaft of the master batch adding machine in the speed measuring plate 5 is read and is used as the reference frequency F of the second frequency converter module 2 S Corresponding reference speed V of rotating shaft Base of After the three reference quantities are determined, the controller 3 enters a continuous control state, and the actual flow Lr of the production line and the theoretical operating frequency value f of the second frequency converter module 2 are determined according to a formula by reading the frequency of each frequency converter S And target speed V of the rotating shaft Eyes of a user Reading the speed signal of the rotating shaft of the master batch adding machine in the speed measuring plate 5, and taking the speed signal as the actual speed V Fruit of Chinese wolfberry And a target speed V Eyes of a user Comparing, and determining the actual operating frequency f of the second frequency converter module 2 according to the deviation value of the speed; the alarm function refers to the actual speed V of the rotating shaft of the master batch adding machine read from the speed measuring plate 5 Fruit of Chinese wolfberry And a target speed V Eyes of a person Starting a timer which is timed for N minutes when the absolute value of the difference is DeltaV | M, and if the controller 3 reads the actual speed V of the rotating shaft of the master batch adding machine every time within N minutes Fruit of Chinese wolfberry Then, | Δ V | M is always true, and the controller 3 drives the alarm module 7 to alarm after N minutes; if the | Δ V | is < M in N minutes or the controller 3 detects that the operating frequency of the first frequency converter module 1 is changed, stopping the timer and resetting the timer; (alarm function is performed only in case of running negative feedback control)
6. The monitoring module 4 obtains the current operating frequencies of the first frequency converter module 1 and the second frequency converter module 2 through a first communication port of the monitoring module in a passive receiving mode; passively receiving a speed signal of a rotating shaft of the master batch adding machine through a second communication port;
7. and repeating the steps four to six until the machine is stopped.
After adopting the technical scheme, compared with the prior art, the invention has the following advantages: 1. the controller reads the frequency of the frequency converter of each melt flow pump and calculates the theoretical operating frequency value f of the second frequency converter module 2 S And target speed V of the rotating shaft Eyes of a user Automatic following is performed, and when winding fails, the purpose of reducing waste discharge can be achieved by reducing the rotating speed of a melt flow pump shaft; 2. the master control is utilized to realize the active regulation of the rotating speed of the master batch adding machine, and the master control is used in the occasions needing to regulate the speed of a melt flow pump, so that the uniform mixing ratio of the functional master batches and the main raw materials before and after speed regulation is ensured; 3. the controller reads the frequency of one melt flow pump frequency converter every 100-300 ms, and the frequency of four frequency converters is required to be read for 0.4-1.2 s, so that the purpose of quickly responding to the frequency change of each melt flow pump frequency converter is achieved, the response of the master batch adding machine is quick, and the influence on the product quality during the speed increasing or reducing of the frequency converters can be ignored; 4. the monitoring module is used for monitoring and recording the control process, so that the product quality can be traced conveniently; 5. in the internal calculation process of the controller 3, enough digits are reserved behind the decimal point of each datum, at least three digits are reserved, the frequency precision of the data finally sent to the second frequency converter module 2 is 0.01Hz, and when the functional fiber product is sensitive to the addition amount of master batches, the controller 3 can meet the production requirements.
On the basis of the above-mentioned scheme, if various changes or modifications to the invention do not depart from the spirit and scope of the invention, the invention is also intended to include those changes and modifications, provided they come within the scope of the claims and the equivalent technology of the invention.
Claims (9)
1. A control system for a spinning functional master batch adder is characterized in that: it still includes:
the first frequency converter modules (1) are used for controlling the flow of the melt flow pump, and the first frequency converter modules (1) correspond to the melt flow pump one by one;
the second frequency converter module (2) is used for controlling the rotating speed of the master batch adding machine;
the first communication ports of the controller (3) are electrically connected with the first frequency converter module (1) and the second frequency converter module (2);
after the controller (3) collects the current operating frequency signal of the first frequency converter module (1), the controller (3) calculates and then transmits the fed-back output frequency signal to the second frequency converter module (2), and the second frequency converter module (2) controls the rotating speed of the master batch adding machine.
2. The control system of the spinning functional masterbatch adding machine according to claim 1, characterized in that: the frequency converter is characterized by further comprising a monitoring module (4), wherein a first communication port of the monitoring module (4) is electrically connected with communication lines of the first frequency converter module (1), the second frequency converter module (2) and the controller (3), and the monitoring module (4) is used for receiving a current running frequency signal of the first frequency converter module (1) and an output frequency signal of the second frequency converter module (2).
3. The control system of the spinning functional masterbatch adding machine according to claim 2, characterized in that: it still includes speed measuring board (5) and is used for detecting speed sensor module (6) of master batch interpolation machine rotational speed, speed measuring board (5) be connected with speed sensor module (6) electricity, speed sensor module (6) transmit the rotational speed signal of the master batch interpolation machine who gathers for speed measuring board (5) and handle.
4. The control system of the spinning functional masterbatch adding machine according to claim 3, characterized in that: and a second communication port of the controller (3) is electrically connected with a second communication port of the monitoring module (4) and the speed measuring board (5).
5. The control system of the spinning functional masterbatch adding machine according to claim 1, characterized in that: the intelligent alarm device also comprises an alarm module (7), wherein the alarm module (7) is electrically connected with the controller (3).
6. A control method comprising the control system of the spinning functional masterbatch adding machine of any one of claims 1-5, characterized in that: it comprises the following steps:
1. when the production is started, setting the operating frequencies of the first frequency converter module (1) and the second frequency converter module (2) according to the process requirements;
2. after each melt flow pump operates stably, starting the master batch adding machine and enabling the master batch adding machine to operate in a manual mode, and respectively finishing the steps of waste discharging, small spinning and wire coiling, detection and the like of an extruder;
3. when the quality of the small silk rolls in the second step meets the process requirements through detection, pressing a manual/automatic switching key, and enabling the controller to enter an automatic control mode;
4. during automatic control, the controller (3) reads the operating frequency of a first frequency converter module (1) through a first communication port every 100-300 ms, the speed signal of the master batch adding machine rotating shaft in the speed measuring board (5) is continuously read through a second communication port, and when the controller (3) detects that the operating frequency of the first frequency converter module (1) changes, the controller (3) executes main control to realize active adjustment of the rotating speed of the master batch adding machine; when the controller (3) detects that the operating frequencies of the first frequency converter module (1) are not changed, executing the next step;
5. and (3) executing negative feedback control and alarm functions: the negative feedback control is used for correcting the speed of the rotating shaft of the master batch adding machine when the speed changes slowly due to external factors, and the alarm function is used for early warning when the master batch adding machine breaks down;
6. the monitoring module (4) obtains the current operating frequency of the first frequency converter module (1) and the current operating frequency of the second frequency converter module (2) through a first communication port of the monitoring module in a passive receiving mode; passively receiving a speed signal of a rotating shaft of the master batch adding machine through a second communication port;
7. and repeating the steps from four to six until the machine is stopped.
7. The control system method of claim 6, wherein: the master control in the fourth step means that the controller (3) circularly reads the running frequency of each first frequency converter module (1) through the first communication port, continuously reads the speed signal of the master batch adding machine rotating shaft in the speed measuring board (5) through the second communication port, comprehensively processes the received frequency signal of the first frequency converter module (1) and the received speed signal of the master batch adding machine rotating shaft, controls the frequency of the second frequency converter module (2), and further controls the rotating speed of the master batch adding machine.
8. The control system method of claim 6, wherein: the negative feedback control means that the running frequency output to the second frequency converter module (2) for the first time when the controller (3) converts the manual control into the automatic control is taken as the reference output frequency F S Then reading the frequency value of each first frequency converter module (1) and obtaining the reference flow L of the whole production line according to a formula R Simultaneously, the speed signal of the rotating shaft of the master batch adding machine in the speed measuring plate (5) is read, and the speed signal is used as the reference output frequency F of the second frequency converter module (2) S Corresponding reference speed V of rotating shaft Base of After the three reference quantities are determined, the controller (3) enters a continuous control state, and the actual flow Lr of the production line and the theoretical operating frequency value f of the second frequency converter module (2) are determined according to a formula by reading the frequency of each frequency converter S And target speed V of the rotating shaft Eyes of a user Then reading the speed signal of the rotating shaft of the master batch adding machine in the speedometer (5) and taking the speed signal as the actual speed V Fruit of Chinese wolfberry And a target speed V Eyes of a person And comparing, and determining the actual operating frequency f of the second frequency converter module (2) according to the deviation value of the speed.
9. The control system method of claim 6, wherein: the alarm function means that the controller (3) detects that the operating frequency of the first frequency converter module (1) is unchanged, but the actual speed V of the rotating shaft of the master batch adding machine read from the speed measuring plate (5) Fruit of Chinese wolfberry With target speed V Eyes of a user When the absolute value of the difference is DeltaV | > M, a timer which is timed for N minutes is started, if the controller (3) reads the actual speed V of the rotating shaft of the master batch adding machine every time within N minutes Fruit of Chinese wolfberry After that, the | DeltaV | M is always true, and the controller (3) drives the alarm module (7) to alarm after N minutes; and if the < M > Delta V < occurs in N minutes or the controller (3) detects that the running frequency of the first frequency converter module (1) is changed, stopping the timer and resetting the timer.
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| CN202211229674.XA CN115573047A (en) | 2022-10-08 | 2022-10-08 | Control system and control method for master batch adding machine with spinning function |
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