Abstract: With the diversification and personalization of market demands, multi-variety, small-batch production has become one of the main production methods for industrial enterprises today. Traditional mechanical twisting machines cannot meet this requirement. This control system, employing a servo-driven, fully electronic electrical control system, solves this problem.
Abstract: With the diversification and individualization of market demand, many varieties of small batch production have become one of the main production methods so find trial enterprises. This problem is solved by the servo control system, which is unable to adapt to this requirement.
Keywords: servo molding, control, twisting
Keywords:servoforming,control,twisting
1. Research Background and Significance
Servo-driven twisting machines will gradually replace all mechanical gear-driven twisting machines in the textile industry. Their efficiency is several times higher than traditional twisting machines, with increased package capacity and significantly improved quality. The high-quality spindles maintain stability at high speeds, and the two-stage transmission mechanism ensures more rational force distribution and a wider range of applications. The elimination of the oil bath gearbox makes maintenance easier, resulting in better winding and easier unwinding of soft edges.
With the rapid development of modern technology, the automation level of China's textile equipment industry is relatively low compared to other industries. Therefore, applying mechatronics, intelligentization, and networking to textile equipment is imperative. The development of doubling machines has progressed from traditional mechanical types to multi-motor types, and then to single-spindle drive control, improving production efficiency and reducing energy consumption. In the production management of doubling machines, the idea of using networked management to achieve an "unmanned workshop" is also feasible. In the operation of doubling machines, achieving multi-parameter operation management, improving yarn quality, and facilitating quality changes are also essential. Developing new doubling machines will lay a solid foundation for the company to further increase its market share in this field and create conditions for innovation to build the Rifeng Twisting brand.
2 Electrical Design Framework
Due to limitations in speed, molding effect, and maintenance of traditional mechanical molding, many textile machinery manufacturers have been dedicated to developing electronic molding twisting machines in recent years. However, limitations in molding control precision and anti-winding algorithms have hindered the development of mature electronically manufactured equipment. Rifeng Textile Machinery's independently developed servo molding electrical control system has been sold in large quantities and has achieved significant economic and social benefits.
Figure 1 Electrical System Block Diagram
3 Electrical Design Scheme
3.1 Hardware Design
This control system uses a Modicon M241 programmable controller and a 10.1” touchscreen. The M241 PLC is suitable for high-performance integrated equipment with speed and position control functions. This product has a built-in Ethernet communication port, providing FTP and web server functionality, allowing for easier integration into the control system architecture. Remote monitoring and maintenance can be achieved through smartphones, tablets, and computers. The product's rich built-in functions significantly reduce your equipment costs. Built-in functions include a Modbus serial communication port, a dedicated USB programming port, CANopen fieldbus for distributed architectures, and position control functions (high-speed counters and pulse outputs for servo motor control). Modicon™3 expansion modules include a safety module, a motor starter control module, and a remote expansion system. The Modicon™4 communication module and the M241 controller's CPU processing power and memory capacity are well-suited to its target performance applications.
3.2 Software Design
SoMachine software is a solution software for equipment manufacturers, used to develop, configure, and debug entire devices within a single software environment, including logic control, motion control, HMI, and related network automation functions. SoMachine software allows you to program and debug all components on Schneider Electric's flexible and scalable control platform, providing a comprehensive solution for equipment manufacturers and helping you optimize automation control solutions according to the requirements of each device.
DOPSoft 1.01.04 software is used in Delta's HMI products. This product boasts a high-speed hardware architecture, providing you with a powerful and stable HMI product, enabling the DOP-B series products to have even more powerful functions.
4. Design of Servo Molding System
The forming quality of yarn bobbins has a significant impact on subsequent processing. The yarn winding distribution must be uniform, with moderate hardness and no protrusions. This requires the forming mechanism of textile equipment to possess multiple functions to meet process requirements, such as anti-overlap and anti-protrusion. During the yarn bobbin winding process, the bobbin is driven by friction rollers below. As the amount of yarn wound on the bobbin increases, its diameter continuously increases, but the rotational speed of the friction rollers remains constant, so the bobbin's rotational speed gradually decreases. If the traverse speed of the guide rod is fixed, then after a period of time, yarn overlap will occur at multiple locations on the bobbin.
Figure 2 Schematic diagram of yarn forming
Figure 2 shows a schematic diagram of the yarn bobbin after one round trip during the winding process. A1 is the starting position when the yarn is guided from left to right, A2 is the ending position when the yarn is guided from right to left, and α is the angle between the two turning points. Assuming that after M yarn guides, the turning point is AM, and the angle between AM and A1 is β, then...
β = M × α − L × 180 (L and M are integers, M > L, and 0 ≤ β ≤ 180°)
Values L and M are chosen such that 0 ≤ β ≤ 180º. When β is 0, point AM returns to position A1, meaning the yarn has overlapped. As the yarn bobbin continues to wind, points A1 continuously overlap, resulting in dense, raised stripes, thus forming the yarn overlap phenomenon. This yarn overlap not only causes unevenness on the surface of the winding bobbin, affecting its stability during winding and causing yarn disorder during take-up, but also leads to uneven dyeing in the next dyeing process and yarn breakage and tangles during unwinding. Therefore, the yarn overlap phenomenon has a serious impact on the yarn in subsequent processes.
Here, this paper proposes a method to avoid yarn overlap by changing the traversing speed of the yarn guide rod after each traversing motion and repeating the above motion after the Mth traversing cycle.
4 Outlook
Currently, most yarn companies in China are facing challenges in technological improvement and increasing production efficiency. At the same time, yarn manufacturers are demanding increasingly higher quality twisted yarns and more diversified forming requirements. Many domestic twisted yarn manufacturers have begun to use servo forming twisting machines. Therefore, Rifeng's servo forming twisting machine, with its superior performance, has gained recognition in the twisting market and will become a new profit growth point for the company, with a promising market prospect.
References:
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[2] Wang Yingquan. Advantages of foreign doubling twisters and my country's development strategies [J]. Silk Technology, 1995, 3(2): 40-42
[3] Liu Rongqing. Yarn twisting and product development [J]. Shanghai Textile Technology, 2003, 31(1): 55-60
[4]TakemuraHidetakesect.Multipletwistspindledoublesproductionandsavespower.Advanceintextilestechnology.2002,(5):50-51
[5]Swordwardridesonwaveoffancyyarnboom,TheIndiantextilejournal,109,No.7,(1999):146-146
About the Author
Sheng Liangjun (1984-), male, electrical engineer, master's degree, mainly engaged in the development of electrical control systems for modern intelligent textile machinery.
