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Machinery control applications in the modern textile industry
Some years, as people more conscious of the aesthetic and living standards, high-grade yarn-dyed products are increasingly popular. Not real silk, chemical fiber, rayon, cotton yarn, also can be blended and Silk weaving, dyeing bobbins which led the industry in the yarn is widely available. General yarn before dyeing tube blanks need to be purchased to suit the yarn package dyeing contact with the "pine-style cheese" for the next procedure to use, so slack increasing demand for precision winding
Existing domestic slack winding machine structure is generally focused on single-spindle drive mode, usually including winding, yarn, over-feed, such as several sports, the use of mechanical gears and cam completion, for a variety of yarns of different winding process, equipment is more difficult to adjust; yarn organizations to adopt a grooved drum and rotary wing, for some high-end yarn is easy to produce injury; the same time as the structure is used in mechanical transmission, winding speed is not high. This pine-style winding currently abroad has been completely based on electronic gear and all digital electronic cam winding structure, namely, the independent single spindle drive; winding, traversing yarn guide, yarn over-feed, tension compensation are used separate motor control the movement of the relationship between the motor can be described by parameter setting, flexible response to various characteristics of the yarn winding process needs; traversing yarn guide used the "yarn guide", commonly known as "rabbit head" , damage to the yarn is very small, especially for high-grade yarn-dyed yarn winding; In addition, as the motor drive there is no direct mechanical connection, combined with high-speed precision motion control software algorithms, can easily achieve high precision cross-winding, winding speed of winding is much larger than mechanical slack, greatly improving the efficiency of the winding
Beijing and Li Technology Co., Ltd. through the motor and domestic well-known textile machinery group co slack for precision winding process characteristics, in their many years of accumulation of the servo and motion control technology, based on the successful development of the country for the first time round with their own Intellectual property rights of high-speed precision slack winding electrical control program. The scheme has good performance and low cost, greatly enhancing the domestic slack winder automation level, the major technical indicators have reached the level of similar foreign equipment.
System control program profiles
Single-spindle control, for example, a system control program shown in Figure principle, traverse the motor shaft connected to a wire wheel, wire wheel through the positive and negative spin-driven fastening the wire yarn guide and move around, to achieve cross-yarn Fixed cable movement; winding yarn tube direct-drive rotary motor, to achieve the yarn winding movement, the horizontal motion and the synthesis of the two movements after winding yarn showed the shape of a spiral wire wound on bobbins surface back and forth . Tension compensation and over-feed motor is mainly used to control the motor in the process of yarn winding tension.
The yarn guide traverse the program uses a motor through the unique design of the ultra-small inertia servo motor, motor winding, and over-feed is also used in custom designed high-speed brushless DC motor, the tension motor uses a common step motor. Figure in the "single-spindle control driver" is and the benefits of the motor development in its own all-digital AC servo drive, based on the embedded high-speed electronic yarn winder precision motion control algorithms, winding brushless motors speed control and special yarn tension control strategy based motor drive control system. The whole system is simple, functional and communication through the adjustment of the keyboard or the "single-spindle control driver" parameter can be easily set up the internal memory of yarn winding forming the geometric parameters (full tube diameter, to close edge amplitude, etc.), winding the line speed , the winding ratio, traverse the length of yarn, hard-edged trim tube differential amplitude, differential cycle, the cam curve of the differential parameters, along with RS232, RS485, CAN bus communication interface of three, can easily complete networked multi-spindle control, the full realization of flexible digital winding. The main technical parameters are listed below:
Than the control winding 2.000 ~ 12.000;
????? Traverse to the acceleration of the servo motor for up to 8000r/s2, reciprocating frequency of the maximum is 800 beats / minute, 160 per minute
0 commutation;
???? Traverse servo motor function with dynamic range automatically give change, no external zero position sensor;
???? Embedded winding and compensation for the three over-feed and tension motor control, can drive, brushless DC motor driver, stepper motor driver interface, easy to realize the winding motor, over-feed motor and motor control tension compensation ;
Embedded winding and compensation for the three over-feed and tension motor control, can drive, brushless DC motor driver, stepper motor driver interface, easy to realize the winding motor, over-feed motor and motor control tension compensation ;
???? ???? A variety of real-time parameter display, such as the actual line speed, yarn diameter cylinder, reciprocating frequency;
???? Multiple fault protection measures, such as abnormal parameters, motor speed, dynamic range tolerance, hardware fault, etc.;
Operating parameters in real time with power-down protection functions, such as the length of winding, winding diameter;
Introduction to traverse servo motor contro
To ensure the bobbins with good dyeing properties, need to start winding to the full tube diameter between any point on the yarn on the cheese into the interchange in space, not parallel to each other to ensure that each yarn is no overlap That is the need for winding bobbins for precise control over. The so-called winding ratio, is the yarn guide traverse back and forth each time, the number of laps winding bobbins. The traditional cross-grooved drum winding winding (any winding), a constant winding ratio of precision winding, three forms of NC layer winding, the program mainly to achieve a constant winding ratio, and numerical precision cross-winding layer Winding two functions
In order to achieve precision cross-winding, "Control of single spindle drive " real-time collection through the winding motor feedback encoder pulse signal calculation of real-time speed, precision winding process according to the requirements come with a unique numerical algorithm traverse servo motor speed reference Instructions to ensure the traverse servo motor speed and the winding ratio of the motor speed according to the definition of the winding to maintain a certain relationship, so that the yarn helix shape of space around the bobbins on the back and forth. Winding through the precise control over, winding the yarn back and forth to each other cross, do not overlap, that clever use of electronic gear and electronics to replace mechanical cam and cam gear to achieve precision yarn winding tube
In addition to differential electronic cam algorithm to eliminate hard-edged technology, the program has achieved full of original yarn guide for minimum arc length control algorithm to take full advantage of the high-speed DSP digital signal processor computing power, real-time calculation and correction Yarn guide traverse servo motor and the motor drive winding bobbins cam curve law, ensure that in any winding speed and winding diameter state, the yarn guide to the arc length for the minimum, maximum cylinder to eliminate winding yarn Hard-edged phenomenon.
Introduction to the winding wire speed control
Theoretically, the line speed winding bobbins with yarn winding tube radius changes, and changes in velocity fluctuations directly caused by the winding tension, which will affect the yarn quality and yarn tube forming the mechanical and physical properties . If the outer yarn yarn tension greater than the inner tension, it is easy to produce cheese yarn extrusion outer edge of the inner bulge phenomenon of yarn; if the yarn tension during the change is too large, may easily lead to a result of winding yarn Stretch yarn tension there different rates in different, which requires the winding process to minimize tension and pressure fluctuations. Therefore, apart from ensuring a constant pressure on bobbins to ensure the relative stability of the control of winding speed is an important measure tension fluctuation
About Tension Control
Processing precision winding yarn tension directly affects the size of the tightness of winding bobbin, thus affecting the capacity of cheese around the yarn and the difficulty of dyeing and processing of yarn breakage rate, so all kinds of precision winding winding machines are part of the yarn tension control, especially for the yarn package dyeing process with tension, not be too big to get the slack drum, is conducive to staining. In addition to taking measures to ensure the program is relatively constant yarn winding speed, but also another design of a tension adjustment device decreases, the use of a stepper motor control of the tension lever. Online Speed up Process, by adjusting the stepper motor rotation status, control the angle of the tension lever to change the yarn strength by holding the door of the gate in order to ensure constant tension winding; Also in accordance with the special bobbins "in tight outside Song, "the process requirements, the radius can be adjusted according to yarn winding tension rod tube angle, to ensure that small-diameter tube when winding yarn winding tension, winding tension and large diameter
Precision winding, yarn, textile machinery textile process to improve the quality of key equipment, high-speed precision digital winding program successfully mastered the high-speed precision yarn winding process in the "KNOW HOW", all with permanent magnet motor drive technology, machine energy consumption is far lower than the conventional variable frequency motor drive equipment. At the same time the flexible use of digital control technology, is ideal for high-grade fabric in many varieties, small batch production of bobbins, with good social and economic benefits. And facilitate the development of the motor technology company involved in the innovative electronic control solutions, digital servo motor and drive, precision motion control, and computer network communication technology, is a typical high-tech mechanical and electrical integration of control programs is to use digital control a typical case of the transformation of traditional industries
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機械控制在現(xiàn)代紡織工業(yè)的應用
些年，隨著人們審美意識增強和生活水平的提高，高檔色織產(chǎn)品愈加受到人們喜愛。不僅僅真絲綢，化纖絲、人造絲、混紡紗和棉紗等也可采用色絲織造，這就促使紗筒染色工藝在色織行業(yè)獲得廣泛應用。一般紗筒染色前需要將外購的坯紗絡成適合于筒子染色用的“松式筒子”供下道工序用，因此松式精密絡筒機的需求日益增加。
國內(nèi)現(xiàn)有的松式絡筒機整機結(jié)構(gòu)一般采用單錠集中傳動方式，通常包括卷繞、導紗、超喂等幾種運動，采用機械齒輪和凸輪機構(gòu)完成，針對各種紗線不同的絡筒工藝，設備調(diào)整比較困難；導紗機構(gòu)采用的是槽筒和旋轉(zhuǎn)翼片，對一些高檔紗線易產(chǎn)生損傷；同時由于采用的是機械傳動結(jié)構(gòu)，卷繞速度不高。目前國外這種松式絡筒機已經(jīng)完全采用基于電子齒輪和電子凸輪的全數(shù)碼卷繞結(jié)構(gòu)，即單錠獨立傳動；卷繞、橫動導紗、紗線超喂、張力補償均采用單獨電機控制，各電機之間的運動關系可通過參數(shù)設置進行描述，靈活應對各種特性的紗線卷繞工藝的需要；橫動導紗采用的是“導紗器”，即俗稱的“兔子頭”，對紗線的損傷很小，特別適用于高檔色織紗線的卷繞；另外由于各電機在機械上沒有直接的傳動連接，輔以高速精密運動控制軟件算法，可以很方便地實現(xiàn)高速精密交叉卷繞，絡紗速度遠大于機械式松式絡筒機，大大提高了絡紗效率。
北京和利時電機技術有限公司通過和國內(nèi)著名紡機集團合作，針對精密松式絡筒機的工藝特點，在自身多年伺服和運動控制技術積累的基礎上，在國內(nèi)首次開發(fā)成功全面擁有自主知識產(chǎn)權的高速精密松式絡筒機電氣控制方案。整個方案具有良好的性能價格比，大大提升了國產(chǎn)松式絡筒機的自動化水平，主要技術指標達到了國外同類設備的水平。
系統(tǒng)控制方案簡介
???以單錠控制為例，系統(tǒng)控制方案原理如圖一所示，橫動電機軸連接一個鋼絲輪，通過鋼絲輪的正反旋轉(zhuǎn)驅(qū)動緊固在鋼絲上導紗器左右移動，實現(xiàn)紗線的橫動排線運動；卷繞電機直接驅(qū)動紗筒旋轉(zhuǎn)，實現(xiàn)紗線的卷繞運動，上述橫動和卷繞兩個運動合成后即表現(xiàn)為紗線以螺旋線的形狀來回卷繞在紗筒表面。張力補償電機和超喂電機則主要用于控制紗線卷繞過程中的張力。
?本方案中橫動導紗電機采用了一臺經(jīng)過獨特設計的超小慣量伺服電機，卷繞和超喂電機采用的也是專門設計定制的高速無刷直流電機，張力電機采用了一臺普通步進電機。圖中的“單錠控制驅(qū)動器”是和利時電機公司在自有開發(fā)的全數(shù)字永磁交流伺服驅(qū)動器的基礎上，嵌入了精密絡筒機高速電子導紗運動控制算法、卷繞無刷電機速度控制和紗線張力控制策略的專用型電機驅(qū)動控制系統(tǒng)。整個系統(tǒng)結(jié)構(gòu)簡單，功能齊全，通過鍵盤或通信方式調(diào)整“單錠控制驅(qū)動器”內(nèi)部存儲器參數(shù)可以方便設置紗線卷繞成形的幾何參數(shù)（滿筒直徑，收邊幅度等），卷繞的線速度，卷繞比，往復動程長度，紗筒硬邊修整的差動幅度、差動周期、差動凸輪曲線等各項工藝參數(shù)，同時具備RS232、RS485、CAN總線三種通信接口，可以很方便完成多錠聯(lián)網(wǎng)控制，完全實現(xiàn)柔性化數(shù)碼卷繞。主要技術參數(shù)列舉如下：
?卷繞比控制范圍2.000～12.000；?
? 橫動伺服電機換向加速度高達8000r/s2，往復頻率最大為800次/分鐘，即每分鐘160
0次換向；?
????橫動伺服電機具備動程自動找零功能，無需外接零位傳感器；?
????內(nèi)嵌有卷繞、超喂和張力補償三個電機的控制功能，可與變頻器、直流無刷電機驅(qū)動器、步進電機驅(qū)動器方便接口，實現(xiàn)卷繞電機、超喂電機和張力補償電機的控制；?
????具備空筒直徑校準功能；?
????多種實時參數(shù)顯示，如實際線速度、紗筒直徑、往復頻率等；?
????多種故障保護措施，如參數(shù)異常、電機超速、動程超差、硬件故障等；?
實時工作參數(shù)具備掉電保護功能，如卷繞長度、卷繞直徑等；
橫動伺服電機控制簡介
為了保證紗筒具備良好的染色性能，需要從開始卷繞到滿筒之間任何直徑點上，筒子上的紗線在空間上成立體交叉，彼此都不平行，保證每層紗線沒有重疊，就是說需要對紗筒的卷繞比進行精密控制。所謂卷繞比，就是橫動導紗鉤每往復一次，紗筒卷繞的圈數(shù)。交叉卷繞有傳統(tǒng)的槽筒卷繞（任意卷繞）、恒定卷繞比精密卷繞、數(shù)控分層卷繞三種形式，本方案主要實現(xiàn)了恒定卷繞比精密交叉卷繞和數(shù)控分層卷繞兩種功能。
???? 為了實現(xiàn)精密交叉卷繞，“單錠控制驅(qū)動器”通過實時采集卷繞電機反饋編碼器脈沖信號計算其實時速度，根據(jù)精密卷繞工藝要求，用獨特數(shù)控算法得出橫動伺服電機的速度給定指令，以保證橫動伺服電機轉(zhuǎn)速與卷繞電機轉(zhuǎn)速按照卷繞比的定義保持一定關系，讓紗線以空間螺旋線的形狀往復繞在紗筒上。通過精密控制卷繞比，往復卷繞的紗線彼此交叉，不重疊，也就是說巧妙采用電子齒輪和電子凸輪取代機械齒輪和凸輪傳動實現(xiàn)紗筒的精密卷繞。
???? 為了實現(xiàn)精密卷繞的高速性能，需要橫動伺服電機在做往復運動時，能夠快速換向，這就要求伺服電機具備較高的轉(zhuǎn)矩慣量比，為此對橫動伺服電機進行了獨特優(yōu)化設計，以保證電機轉(zhuǎn)子慣量盡可能小。同時伺服驅(qū)動器的電機控制算法在高動態(tài)響應性方面也做了針對性的設計，采用PID控制結(jié)合模糊控制算法，保證伺服電機速度在不產(chǎn)生超調(diào)的情況下，盡可能短時間內(nèi)完成換向。
由于橫動電機換向時，不論多快，都會因為換向加減速造成有硬邊現(xiàn)象出現(xiàn)，按照機械式絡筒機硬邊消除原理，在“單錠控制驅(qū)動器”中嵌入了差動凸輪運動規(guī)律算法，周期性地實時變換橫動導紗器的換向點，完成硬邊消除功能。同時可以根據(jù)不同紗線特性，選擇不同的差動凸輪曲線，設置差動周期和幅度。
????除了采取差動電子凸輪算法消除硬邊技術外，本方案還富有獨創(chuàng)性地實現(xiàn)了導紗器最小換向弧長的控制算法，充分利用了DSP數(shù)字信號處理器高速運算能力，實時計算和修正橫動導紗伺服電機與紗筒卷繞電機傳動的凸輪曲線規(guī)律，保證在任何卷繞轉(zhuǎn)速和卷繞直徑狀態(tài)下，導紗器換向的弧長最小，最大限度地消除卷繞紗筒的硬邊現(xiàn)象。
???卷繞線速度控制簡介
理論上分析，紗筒卷繞的線速度隨紗筒的卷繞半徑變化而變化，而線速度的變化直接引起卷繞張力的波動，從而會影響紗筒的成形質(zhì)量和紗線的機械物理性能。如果外層紗的張力大于內(nèi)層紗的張力，就容易產(chǎn)生筒子外層紗擠壓內(nèi)層紗的脹邊現(xiàn)象；如果絡紗過程中張力變化過大，也會容易造成紗線因絡紗張力不同出現(xiàn)紗線拉伸率不同，這就要求在絡筒過程中盡量減小張力及壓力的波動。所以除保證恒定紗筒壓力外，保證卷繞速度相對穩(wěn)定是控制張力波動的一項重要措施。
??? ?張力控制簡介
精密卷繞加工時紗線張力的大小直接影響筒子卷繞的松緊度，從而影響筒子繞紗的容量和染色的難易，并影響紗線加工的斷頭率，因而各種精密卷繞絡筒機都有紗線的張力控制環(huán)節(jié)，特別是供筒子染色用的紗線的加工張力，不宜過大，以獲得松式卷筒，有利于染色。本方案除了采取措施保證相對恒定的紗線卷繞線速度外，還另外設計有一個張力遞減調(diào)節(jié)裝置，采用一個步進電機控制的張力調(diào)節(jié)桿。在線速度升速過程中，通過調(diào)節(jié)步進電機的轉(zhuǎn)角狀態(tài)，控制張力調(diào)節(jié)桿的角度，改變紗線通過的門柵夾持力度，以保證卷繞張力恒定；另外按照特殊紗筒“里緊外松”的工藝要求，可以根據(jù)紗筒卷繞半徑調(diào)節(jié)張力桿的角度，保證卷繞紗筒小直徑時卷繞張力大，大直徑時卷繞張力小。
? 超喂電機控制簡介
精密卷繞過程中紗線線速度肯定大于紗筒退繞線速度，張力值也因此增大，而過大的張力不但得不到優(yōu)質(zhì)紗筒，而且會增加紗線的斷頭，降低生產(chǎn)效率。因此，本方案采用了所謂“超喂”的辦法，即送出紗線的速度大于卷取紗線的速度，將紗線卷繞時筒子“硬拖”紗線的狀況改變成緩和地卷取紗線的狀況，從而減少斷頭，獲得滿意的松式卷繞筒子。紗線在超喂?jié)L筒上環(huán)繞的圈數(shù)取決于超喂量的大小，一般的超喂量控制值在1．02～1．06（一圈情況下）之間。
? ???精密絡筒、絡絲機器是紡織工藝中提高紡織品質(zhì)量的關鍵設備，高速精密數(shù)碼卷繞方案成功掌握了紗線高速精密卷繞工藝中的“KNOW?HOW”，全部采用永磁電機驅(qū)動技術，機器能耗遠遠低于傳統(tǒng)的變頻電機傳動設備。同時由于采用了柔性化數(shù)碼控制技術，非常適合于高檔織物的多品種、小批量紗筒生產(chǎn)，具有良好的社會經(jīng)濟效益。和利時電機技術公司開發(fā)的該創(chuàng)新解決方案涉及了電子控制，數(shù)字伺服電機和驅(qū)動、精密運動控制、和計算機網(wǎng)絡通信等技術，是典型的高技術機電一體化控制方案，也是采用數(shù)字控制技術改造傳統(tǒng)產(chǎn)業(yè)的典型案例