CN108914264B - An intelligent control method and device for a carding machine based on online carding force - Google Patents

Abstract

The present invention relates to an intelligent control method and device for a carding machine based on online carding force. When the absolute value of the difference between the real-time carding force of the carding machine and the real-time theoretical standard carding force is greater than the threshold value, the carding machine is controlled to stop, otherwise, the original running state is maintained to realize intelligent control. The device includes a cylinder, a main motor, a power detection device, an analog/data converter chip, a CPU operation processor and a control shutdown mechanism. The main motor is connected to the cylinder, and the power detection device is respectively connected to the main motor and the analog/data converter chip. The wires are connected, and the CPU operation processor is respectively connected with the analog/data converter chip and the control shutdown mechanism. The method and the device of the invention use the online detection technology to monitor and give feedback to the carding machine in real time, improve the production efficiency, reduce the production cost, and have great application prospects.

Description

An intelligent control method and device for a carding machine based on online carding force

technical field

The invention belongs to the field of online carding force control, and relates to an intelligent control method and device for a carding machine based on the online carding force.

Background technique

Metal card clothing is the core component of the carding machine. During the carding process, the state change of the metal card clothing in a service cycle will directly affect the carding effect of the carding machine. In daily production, people often use the detection method of metal card clothing to control the carding process of the carding machine and improve its carding effect. The detection of card clothing generally occurs in the following two processes: (1) in the production of card clothing Detect it during the process; (2) Detect it during the use of the card clothing. Most of the existing technologies for detecting card clothing during the production process use optical technology as the technical basis to improve the quality of the card clothing produced, thereby ensuring the carding effect during carding. For example, patent ZL200820237541.6 uses a camera Image detection on the card clothing on the punching and quenching line to achieve the purpose of quality inspection; patent ZL201120239523.3 realizes no breakpoint joints in the production process of the entire roll of card clothing by performing quenching hardness testing on the metal card clothing punching and quenching line, so that The metal card clothing has good consistency, stability and integrity, but the above method can only guarantee the quality of the metal card clothing before carding. During the carding process of the carding machine, the metal card clothing is often worn. The carding effect of the cotton machine will decline, and the above method cannot continuously and effectively guarantee the carding effect of the carding machine. There are two ways to detect card clothing during use: direct and indirect methods: the direct method needs to dismantle the machine to subjectively sense the sharpness and uniformity of the card clothing wrapped on the surface of the cylinder or licker-in roller, and stop the machine when testing The production is interrupted, and the human factors in the test results are relatively large; the indirect method reflects the use status of the card clothing by regularly sampling and testing the raw sliver. The representativeness of the sample is not high and the failure response is lagging, so that a large number of unqualified raw sliver flows into the next process. In addition, due to the small and relatively closed carding area of the carding machine, the detection of the use status of the card clothing has not yet been realized through online detection. At present, the intelligent control method of the carding machine is mainly the intelligent control of the autoleveling process of the carding machine, and the intelligent control method of the carding machine based on the service cycle of the metal card clothing has not yet appeared.

Therefore, there is an urgent need to study an intelligent control method for carding machines based on the life cycle of card clothing that can continuously and effectively ensure the carding effect of the carding machine.

Contents of the invention

The purpose of the present invention is to overcome the deficiencies in the prior art, and provide an intelligent control method of a carding machine based on online carding force and a device for realizing the method. The present invention detects the card clothing in the working state after being put on the machine, and by tracking the online carding force of the carding machine and comparing the theoretical standard carding force curve, the carding state and changes of the carding card clothing of the carding machine can be characterized, and then Real-time control of the running status of the carding machine to achieve intelligent control.

In order to achieve the above object, the present invention adopts following technical scheme:

An intelligent control method for a carding machine based on online carding force. The real-time carding force of the carding machine is tested online, compared with the real-time theoretical standard carding force, and the operating state of the carding machine is adjusted according to the comparison results to realize intelligent control;

The real-time theoretical standard carding force is calculated by the use time and functional equation of the carding machine corresponding to the real-time carding force, and the functional equation is:

F=ab(x-1)+c(x-1) ² -d(x-1) ³ -e(x-1) ⁴ ;

In the formula, F is the real-time theoretical standard carding force, the unit is N, x is the use time of the carding machine, the unit is day, a, b, c, d and e are the control parameters of the equation, and the value ranges are [30 ,80], [0,0.05], [2×10 ^-5 ,8×10 ^-5 ], [10 ^-8 ,10 ^-7 ] and [2×10 ^-13 ,6×10 ^-13 ], the units are respectively It is N, N/day, N/day ² , N/day ³ and N/day ⁴ ; the parameters in the function are related to the operating parameters of the carding machine and the use time, and the real-time carding force is the carding force obtained through power conversion . In the above function equation, the specific values of the control parameters a, b, c, d and e are mainly related to the following factors: the value of a is based on the average value of the carding force within 24 hours of the new card clothing; b is related to the surface of the card clothing The shape (smoothness, tooth tip angle, etc.) parameters are positively correlated; c is positively correlated with the cylinder speed; d is positively correlated with the card clothing material parameters (such as hardness, etc.); Production per unit time is positively correlated.

The control of the running state of the carding machine according to the comparison results means that when the absolute value of the difference between the real-time carding force of the carding machine and the real-time theoretical standard carding force is greater than a threshold value during a continuous period of use, the carding machine is controlled to stop, and vice versa , the original operating state is maintained.

As a preferred technical solution:

As mentioned above, a carding machine intelligent control method based on online carding force. In the carding machine, the main motor drives the cylinder, and the cylinder belt drives the licker-in roller and the pulley of the cover plate. The change of the power of the main motor can represent the carding process. Therefore, the real-time carding force of the online test carding machine is obtained by continuously detecting the power of the cylinder (that is, the power of the main motor), specifically: the present invention first Test the power N ₀ when the cylinder is running empty when the carding machine is running. When the fiber starts to be carded, measure the carding power N at each time point again. The work consumed to overcome fiber resistance is then converted into real-time combing force. The specific calculation formula is as follows:

F _x = (N-N ₀ )×999.6/V _c ;

In the formula, F _x is the real-time combing force, the unit is N, N is the real-time load power of the cylinder, the unit is kW, N ₀ is the load power of the cylinder when it is empty, the unit is kW, V _c is the linear speed of the cylinder, the unit is is m/s.

As mentioned above, an intelligent control method for carding machines based on online carding force, if the absolute value of the difference between the real-time carding force of the carding machine and the real-time theoretical standard carding force is greater than the threshold for more than 5 minutes continuously, it can fully explain the carding The machine is already in an abnormal operating state, which can effectively avoid the unexpected shutdown of the carding machine due to other accidental conditions, and can record enough real-time carding force data for problem analysis; the real-time carding force and real-time theory of the carding machine If the absolute value of the standard carding force difference is greater than the threshold for more than 30 minutes in a row, the machine will run for too long in an abnormal state, which will easily cause damage to the carding machine. Therefore, the continuous period of use is 5 to 30 minutes.

According to an intelligent control method for a carding machine based on online carding force as described above, the threshold is 10% of the real-time theoretical standard carding force. During the carding process, the threshold value changes adaptively according to the value of the reference real-time theoretical standard carding force, so that the method of the present invention can better adjust the carding process of the carding machine.

The present invention also provides an intelligent control device for a carding machine that adopts an intelligent control method for a carding machine based on an online carding force as described above, including a cylinder, a main motor, a power detection device, an analog/data converter chip, and a CPU Arithmetic processor and control shutdown mechanism;

The main motor is connected to the cylinder, the main motor drives the cylinder, and the cylinder belt drives the licker-in roller and the pulley of the cover plate, and the power detection device is respectively connected with the main motor and the analog/data converter chip through wires, and the power detection device Detect the real-time power of the main motor (that is, the real-time load power of the cylinder) and convert it into a voltage signal and transmit it to the analog/data converter chip. The CPU operation processor is respectively connected with the analog/data converter chip and the control shutdown mechanism. The voltage signal After conditioning by the analog/data (A/D) converter chip, it is converted into data that can be read by the CPU computing processor. The theoretical standard carding force is compared. If the absolute value of the difference between the real-time carding force and the real-time theoretical standard carding force is greater than the threshold, the control stop mechanism is used to control the carding machine to stop, otherwise, the original operating state is maintained.

As a preferred technical solution:

According to the intelligent control device of the carding machine mentioned above, the power detection device is a power detection standard instrument or a digital power meter. The power detection device is mainly used to detect the power of the main motor (i.e. the real-time load power of the cylinder) and convert it into a voltage signal and transmit it to the analog/data converter chip. The power detection devices that can meet the above functional requirements are all suitable for the present invention .

According to the intelligent control device of the carding machine mentioned above, the CPU operation processor is connected to the keyboard through wires. Workshop personnel enters the concrete value of the relevant influence parameter of each control parameter (a, b, c, d and e) of the functional equation of the real-time theoretical standard carding force such as real-time theoretical standard carding force by keyboard, so that the intelligent control method of the present invention is more sufficient Better adapt to different carding situations.

According to the intelligent control device of the carding machine described above, the CPU operation processor is connected to the alarm device through wires. The alarm device is used to notify the operator to overhaul or replace the card clothing.

The intelligent control device for the carding machine as described above also includes a display device, which is connected to the CPU computing processor, and the display device is used to display the current real-time combing force and the real-time combing force at historical moments, which can more intuitively and quickly indicate the current And the state of historical combing force fluctuations.

According to the intelligent control device of the carding machine described above, the display device is installed on the carding machine operation panel. Invention Mechanism:

After the fiber is fed into the carding machine, it is subjected to multiple forces, mainly due to the friction on the surface of the metal card clothing in the carding area overcome by the fiber, which is the main force that causes the fiber bundle to decompose into a single fiber state, which is called the carding force. And affect the combing effect. At the same time, wear occurs during the frictional contact between the metal card clothing and the fiber. As time goes by, the card clothing wear gradually accumulates, and the surface state and even the shape of the card clothing will change, thereby affecting the carding effect on the fiber. Therefore, the carding effect can be characterized by the wear condition of the clothing surface. The wear condition of the card clothing surface conforms to the wear rule of the metal surface. The wear process diagram of the metal card clothing surface is shown in Figure 1. In the figure, the abscissa indicates the metal wear time, and the ordinate indicates the amount of metal wear. The initial wear stage of the metal card clothing is O～A stage, normal wear stage is A～B stage, severe wear stage is B～C stage. According to Figure 1, it can be seen that: (1) initial wear stage: the wear of the microstructure and special geometry of the card clothing surface is faster; (2) normal wear stage: after the initial wear, the contact surface increases and the unit pressure decreases. (3) Rapid wear stage: the condition of the contact surface deteriorates and the wear rate increases.

The service cycle of metal card clothing is generally 3-5 years, and the specific service cycle fluctuates with the use history. In production, it is necessary for the operator to determine the actual carding ability of a set of card clothing through regular inspection of raw sliver quality and machine maintenance, resulting in Production was interrupted. In order to generate sufficient combing force on the fibers, the main motor that drives the cylinder to rotate needs to provide enough power to overcome the changing combing force. Therefore, the change in carding force can be characterized by detecting the power change of the main motor.

The present invention establishes the standard curve of card clothing carding force changing with time, as shown in Figure 2, the comparison between the absolute value of the difference between the real-time carding force obtained by conversion and the real-time theoretical standard carding force and the threshold value, in the state of non-stop Determine the running status of the card clothing, so as to achieve the purpose of timely replacement of the card clothing, and even predict possible accidents in production in advance. In the figure, L _max represents the upper limit of the real-time theoretical standard combing force threshold, L _min represents the lower limit of the real-time theoretical standard combing force threshold, and L _std represents the real-time theoretical standard combing force. When the value of the real-time combing force is between the maximum value (L _max ) and When the minimum value (L _min ) is within the range, it indicates that the card clothing is running normally. When it exceeds the range, it indicates that there is a problem with the carding parts and needs to be shut down for maintenance; in addition, the carding force curve can estimate the service life of the current card clothing, and carding in real time Before the carding force is less than the required carding force, the workshop staff can predict in time and replace the card clothing.

Beneficial effect:

(1) A kind of carding machine intelligent control method based on online carding force of the present invention realizes the tracking of the service cycle of carding accessories (such as card clothing) and machine parts by tracking the change of carding force in the carding area And it can be used to achieve the purpose of timely maintenance and replacement of metal card clothing. Its detection is the detection of real-time carding force, with rapid and timely response, which can maximize production efficiency and reduce production costs;

(2) A kind of carding machine intelligent control device based on online carding force of the present invention does not need to stop for inspection, and the detection device is outside the carding area, so the detection process does not affect the carding process and is easy to install;

(3) The intelligent control method of a carding machine based on online carding force of the present invention can continuously and effectively guarantee the carding effect in the fiber carding process, ensure the quality of the produced products, and have excellent promotional value.

Description of drawings

Figure 1 is a diagram of the wear process on the surface of the metal card clothing;

Fig. 2 is a graph showing the variation of the standard curve of the carding force of the metal card clothing over time;

Fig. 3 is a flow chart of the intelligent control method of the carding machine based on the online carding force of the present invention.

Detailed ways

The present invention will be further described below in combination with specific embodiments. It should be understood that these examples are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the teachings of the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms also fall within the scope defined by the appended claims of the present application.

A carding machine intelligent control device based on an online carding force intelligent control method for a carding machine, including a cylinder, a main motor, a power detection device, an analog/data converter chip, a CPU operation processor, a control stop mechanism, a keyboard, Alarm device and display device.

The main motor is connected to the cylinder, the power detection device is respectively connected to the main motor and the analog/data converter chip through wires, the CPU operation processor is respectively connected to the analog/data converter chip and the control stop mechanism, and the keyboard and alarm device are connected to the main motor through wires. The CPU operation processor is connected, wherein the power detection device is a power detection standard instrument or a digital power meter, and the display device is installed on the carding machine operation panel and connected with the CPU operation processor.

The carding machine intelligent control method based on the online carding force utilizing the above-mentioned device is specifically:

(1) Drive the load power N ₀ when measuring the cylinder with no load in the empty state;

(2) On the first day when the new card clothing is replaced, the average value of the carding force within 24 hours of the new card clothing is measured, and input into the CPU operation processor through keyboard commands, the purpose of which is to further determine the real-time theoretical standard carding force function equation in the follow-up The specific values of a, b, c, d and e;

(3) After the preparatory work is completed, online tracking of the use status of the card clothing is carried out according to the flow chart shown in Figure 3, as follows:

(3.1) First, connect the power detection standard instrument or digital power meter to the main motor circuit of the carding machine, collect the real-time power of the main motor (that is, the real-time load power of the cylinder) through it and convert it into a voltage signal, and the voltage signal passes through The analog/data (A/D) converter chip conditioning is converted into data that can be read by the CPU computing processor;

(3.2) The CPU operation processor reads the test data and converts it into real-time combing force according to the relevant formula and displays it on the display screen. The relevant formula is as follows:

F _x = (N-N ₀ )×999.6/V _c ;

In the formula, F _x is the real-time combing force, the unit is N, N is the real-time load power of the cylinder, the unit is kW, N ₀ is the load power of the cylinder when it is empty, the unit is kW, V _c is the linear speed of the cylinder, the unit is is m/s;

(3.3) Compare the real-time carding force with the real-time theoretical standard carding force, and determine the running state of the card clothing without stopping the machine. The real-time theoretical standard carding force is calculated by the use time and functional equation of the carding machine corresponding to the real-time carding force , the function equation is:

F=ab(x-1)+c(x-1) ² -d(x-1) ³ -e(x-1) ⁴ ;

In the formula, F is the real-time theoretical standard carding force, the unit is N, x is the use time of the carding machine, the unit is day, a, b, c, d and e are the control parameters of the equation, and the value ranges are [30 ,80], [0,0.05], [2×10 ^-5 ,8×10 ^-5 ], [10 ^-8 ,10 ^-7 ] and [2×10 ^-13 ,6×10 ^-13 ], the specific The value is further determined according to the keyboard command entered in step ( ² ), and the units are N, N/day, N/day2, N/ ^day3 and N/ ^day4 , where the value of a is based on the new card clothing on the machine for 24 hours The average value of the carding force within is subject to; b is positively correlated with the surface shape (smoothness, tip angle, etc.) parameters of the card clothing; c is positively correlated with the cylinder speed; d is positively correlated with the card clothing material parameters (such as hardness, etc.); e It is negatively correlated with the processed fiber grade value and positively correlated with the current output per unit time of the carding machine;

(3.4) When the absolute value of the difference between the real-time carding force of the carding machine and the real-time theoretical standard carding force is greater than 10% of the real-time theoretical standard carding force within 5 to 30 minutes, the alarm device will send out an alarm, and the control stop mechanism will stop immediately and report an error , to remind the operator to dismantle the machine for inspection, otherwise, it means that the card clothing is running normally, and the original running state will be maintained.

It has been verified that the present invention uses online detection technology to monitor and give feedback to the carding machine in real time, which can guide production well, improve production efficiency, reduce manpower, and reduce production costs, and has great application prospects.

Claims (10)

1. a kind of carding machine intelligent control method based on online carding force, it is characterized in that: the real-time comb of on-line testing carding machine Power is managed, and it is compared with real-time theoretical standard carding force, the operating status of carding machine is regulated and controled according to comparing result, realizes intelligence Control；

The real-time theoretical standard carding force is calculated by the corresponding carding machine of real-time carding force using time and functional equation It arrives, the functional equation are as follows:

F=a-b (x-1)+c (x-1)²-d(x-1)³-e(x-1)⁴；

In formula, F is real-time theoretical standard carding force, and unit N, x are the time that uses of carding machine, and unit is day, a, b, c, d and E is the control parameter of equation, and value range is respectively [30,80], [0,0.05], [2 × 10^-5,8×10^-5]、[10^-8,10^-7] and [2×10^-13,6×10^-13], unit is respectively N, N/ days, N/ days², N/ days³With N/ days⁴；

The operating status for regulating and controlling carding machine according to comparing result refers to when in the continuous one section reality using carding machine in the time When carding force and real-time theoretical standard carding force absolute value of the difference be greater than threshold value when, control carding machine shut down, conversely, then maintaining Former operating status.

2. a kind of carding machine intelligent control method based on online carding force according to claim 1, which is characterized in that institute The real-time carding force for stating on-line testing carding machine is obtained by continuously detecting the power of cylinder, and specific formula for calculation is as follows:

F_x=(N-N₀)×999.6/V_c；

In formula, F_xFor real-time carding force, unit N, N are cylinder real-time load power, unit kW, N₀To be born when cylinder zero load Lotus power, unit kW, V_cFor cylinder linear velocity, unit m/s.

3. a kind of carding machine intelligent control method based on online carding force according to claim 1 or 2, feature exist In described continuous one section is 5~30min using the time.

4. a kind of carding machine intelligent control method based on online carding force according to claim 3, which is characterized in that institute State 10% that threshold value is real-time theoretical standard carding force.

5. using such as a kind of described in any item carding machine intelligent control methods based on online carding force of Claims 1 to 4 Carding machine intelligent controlling device, it is characterized in that: including cylinder, main motor, power detection device, simulation/data converter core Piece, CPU arithmetic processor and control knock-off gear；

The main motor is connect with cylinder, the power detection device respectively with main motor and simulation/data converter core Piece is connected by conducting wire, and CPU arithmetic processor is connect with simulation/data converter chip and control knock-off gear respectively.

6. carding machine intelligent controlling device according to claim 5, which is characterized in that the power detection device is power Examination criteria instrument or digital power meter.

7. carding machine intelligent controlling device according to claim 5, which is characterized in that the CPU arithmetic processor passes through Conducting wire connects keyboard.

8. carding machine intelligent controlling device according to claim 7, which is characterized in that the CPU arithmetic processor passes through Conducting wire connects warning device.

9. carding machine intelligent controlling device according to claim 5, which is characterized in that it further include display device, display dress It sets and is connect with CPU arithmetic processor.

10. carding machine intelligent controlling device according to claim 9, which is characterized in that the display device is mounted on comb On cotton machine operation panel.