CN104217085B - Computer-assisted combing process design and combed web quality prediction method - Google Patents
Computer-assisted combing process design and combed web quality prediction method Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 81
- 239000000835 fiber Substances 0.000 claims abstract description 124
- 229920000742 Cotton Polymers 0.000 claims abstract description 73
- 238000009826 distribution Methods 0.000 claims abstract description 31
- 238000006073 displacement reaction Methods 0.000 claims abstract description 30
- 238000013178 mathematical model Methods 0.000 claims abstract description 10
- 230000005540 biological transmission Effects 0.000 claims abstract description 7
- 238000000926 separation method Methods 0.000 claims description 52
- 238000009960 carding Methods 0.000 claims description 9
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- 241000347389 Serranus cabrilla Species 0.000 claims description 7
- 238000005457 optimization Methods 0.000 claims description 7
- 238000005304 joining Methods 0.000 claims description 6
- 238000009987 spinning Methods 0.000 description 4
- 210000001520 comb Anatomy 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 102100029469 WD repeat and HMG-box DNA-binding protein 1 Human genes 0.000 description 1
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Abstract
The invention discloses a computer-assisted combing process design and combed web quality prediction method. The method comprises the following steps: establishing a mathematical model for a nipper mechanism and a detaching roller transmission mechanism of a combing machine, and fitting corresponding displacement and speed equations at a detaching-jointing stage respectively; measuring the fiber length distribution density in a combed cotton small roll; simulating a fiber layer which is the same as the fiber length distribution density in a practical combed cotton small roll; simulating a fiber layer which is about to be detached and jointed after cylinder combing; simulating a single detached bundle state after detaching and jointing; simulating the form of an output web of the combing machine after six detached fiber bundles are overlapped; calculating the CV (Variable Coefficient) value of the output web, and predicting the web quality; optimally designing a combing process. By adopting the computer-assisted combing process design and combed web quality prediction method, optimal process parameter configuration during combing of different combed small loops can be found out rapidly and accurately, the CV value of the combing web can be predicted, the efficiency of the combing machine is increased greatly, and a basis is laid for improvement on the overall quality of a combing product.
Description
Technical Field
The invention relates to the technical field of cotton spinning combing, in particular to a method for computer-aided combing process design and combed cotton web quality prediction.
Background
The cotton spinning combing machine is one of the most complex machines in all cotton spinning devices, and the working process of the cotton spinning combing machine is as follows: when the swing shaft of the nipper swings forwards and backwards, the nipper swings forwards and backwards through the swing arm and the lower nipper seat. When the nipper retreats, the upper nipper gradually closes the mouth, and after the nipper closes the mouth, the cylinder card wire just turns to the lower part of the jaw, combs the cotton layer, combs short fiber and impurity. After the cylinder carding is finished, the nipper gradually opens, meanwhile swings forwards, the separating roller reverses at the moment, and the cotton web circularly output in the previous time is poured into the machine and is lapped with the cotton web sent by the nipper. At a certain moment, the separating roller is changed from reverse rotation to clockwise rotation, the lapped new and old cotton layers are sent into a separating jaw for jointing, meanwhile, a top comb is inserted into the cotton layers to carry out carding and impurity removal on the tail ends of cotton flocks, the separating roller continues to clockwise rotate, the nipper is changed from front swing to rear swing, the cotton layers are torn off, meanwhile, the upper nipper is gradually closed, and the cylinder card wire rotates below the jaw again to start the next working cycle.
In the working process of the combing machine, the components (such as nippers, cylinders and detaching rollers) are required to have very precise matching relation, if the process setting is slightly improper in production, the components are slightly matched with errors, the quality of combed products is affected if the result is light, the equipment cannot work normally if the result is heavy, and the effect is more and more serious along with the improvement of the speed of the combing equipment.
Currently, the setting of the combing process only depends on the experience and the feeling of workers, so that the quality of products processed by the same equipment and different cotton mills is very different, and the optimal performance and the optimal efficiency of the combing machine are difficult to exert.
Along with the annual increase of the proportion of combed yarns, the grade and the length of combed cotton are reduced, when the quality index of combed raw materials is changed, the setting of a combing process is also correspondingly changed, and no proper process change countermeasures are provided for the poor quality of the raw materials in the current factory.
Aiming at the high requirement of the process matching of the combing machine parts, a scientific and reasonable process parameter selection configuration method is lacked at present, and the prediction capability of the quality of the output combed cotton net is lacked.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a method for computer-aided combing process design and combed cotton web quality prediction, and provide a method for computer-aided process design and combed cotton web quality prediction aiming at the problems of combing process setting and quality prediction. The method can obviously improve the performance of the combing machine and improve the quality of combed products.
In order to achieve the purpose, the technical scheme of the invention is as follows: a method for computer aided combing process design and combed web quality prediction is implemented according to the following steps:
establishing a mathematical model for a nipper mechanism of a comber, calculating displacement and speed parameters of a lower nipper at different noil spacings of the comber by using a computer, and fitting a corresponding displacement and speed equation of the lower nipper at a separation and joint stage;
secondly, establishing a mathematical model for a detaching roller transmission mechanism of the combing machine, calculating detaching roller displacement and speed parameters at different detaching roller clockwise rotation timings by using a computer, and fitting out corresponding displacement and speed equations of the detaching roller at a detaching and jointing stage;
(III) determining experimentally the fiber length distribution density in combed cotton rolls, the steps comprising: testing the fiber length distribution density condition of the small combed cotton roll to be processed by using a nep and short fiber tester, and making fiber length distribution density images at intervals of 2 mm;
establishing a corresponding mathematical model aiming at the measured fiber length distribution density of the small combed cotton roll, and simulating a fiber layer with the same fiber length distribution density as that in the actual small combed cotton roll by utilizing a computer;
(V) simulating the fiber layer to be separated and jointed after the cylinder is carded by utilizing a computer simulation according to the combing process, wherein the step comprises the following steps: boundary fiber length during cylinder carding can be known according to combing processL f =B+(0.5-K)×G(ii) a Setting upB、K、GDetermining the demarcation fiber lengthL f The length of the fiber layer generated in the step (IV) is less thanL f Removing all the fiber layers to obtain the fiber layers carded by the cylinder;
wherein,Bin order to separate the gauge length, the distance between the two rollers is less than the set distance,Kin order to obtain the coefficient of cotton feeding,Gfor cotton-feeding length, length less than dividing fibre lengthL f All the fibers are swept down by the cylinder and enter the noil, and the length of the fibers is more than or equal to the length of the boundary fibersL f The fibers of (a) enter the separate bonded fiber layer;
sixthly, simulating the form of a single separation cluster after separation and bonding by using a computer simulation by using displacement and speed equations of the nipper mechanism and the transmission mechanism of the separation roller, which are fitted in the step (I) and the step (II), wherein the step (III) comprises the following steps: it is known from combing principle that the length of each nipped separation of the combing machine is equal to the length of the cotton layer fed by the feeding roller, and the distance between the fiber head end and the separating nip is equal to the cotton feeding length from the beginning of the separation jointGThe inner fibers are all output by the detaching roller; solving the division number of the fiber head end when the fiber head end reaches the separating jaw by using the displacement fitting equation of the nipper mechanism in the step (I); using the speed fitting equation of the detaching roller in the step (II), taking the division number of the fiber head end reaching the detaching jaw as the integral lower limit, and taking the 24 division at the detaching and jointing end as the integral upper limit, and calculating the displacement of the fiber in the detaching and jointing process; calculating the displacement of each fiber involved in the separation and joining process by using a computer to obtain the separation cluster form after the separation and joining;
(VII) simulating lapping of 6 separated fiber bundles by using a computer to obtain the shape of the output web of the combing machine, wherein the step comprises the following steps: repeating the steps (one) to (six), generating different random combing separation bundles, and setting the effective output length of the combing machine to beSThe subsequent separation clump is stacked on top of the previous separation clump, and the head end of the subsequent separation clump is at a distance ofSStacking 6 separating clusters in sequence to obtain output cotton of combing machineMesh form;
(VIII) calculating variation coefficient of output web of combing machineCVValue, to perform web quality prediction, comprising: dividing the output web lengthwise intonRespectively counting the number of fibers in each segmentw iAnd calculate outnAverage fiber number of segments w0By usingCVFor obtaining output webs by value calculationCVThe value:
（1）
obtained by calculationCVPredicting the quality of the cotton net;
(nine) optimization design of combing process, the steps include: when the fiber length distribution density of the small combed cotton roll is constant, the noil gauge in the combing process, the clockwise rotation of the detaching roller and the cotton feeding length are respectively changed, and the output web shape when different process parameters are simulated by utilizing the steps (I) to (eight) to calculate the web shapeCVValue and pairCVComparing the values to find outCVConfiguring combing process parameters with the minimum value, thereby realizing computer-aided optimization design of the combing process;
in the step (I), when the noil scale is 8 and the cotton feeding length is 5.2mm, the displacement fitting equation of the lower nipper in the separation and joining process is as follows:
（2）
wherein,yin order to displace the lower nipper, the lower nipper is moved,xis indexing;
when the clockwise rotation of the detaching roller in the step (II) is +0.5, the speed fitting equation of the detaching roller in the detaching and jointing process is as follows:
（3）
wherein,vin order to set the speed of the lower nipper,tfor indexing purposes.
The method can quickly and accurately find out the optimal process parameter configuration when different combing rings are combed, can predict the CV value of the combed cotton net, greatly improves the efficiency of the comber, and lays a foundation for improving the overall quality of combed products.
Drawings
FIG. 1 is a graph of the fiber length distribution density of a small roll of combed cotton.
FIG. 2 is a fiber layer prior to simulated cylinder carding.
FIG. 3 is a fiber layer after simulated cylinder carding.
FIG. 4 is a single separation tuft after simulated separation splicing.
FIG. 5 is a plot of the number distribution of individual discrete mat fibers.
FIG. 6 is a graph simulating a fiber layer after stacking of 6 separate tufts.
Fig. 7 is a graph of the output web fiber count distribution.
Detailed Description
The invention is described in further detail below with reference to the figures and examples.
A method for computer aided combing process design and combed web quality prediction is implemented according to the following steps:
firstly, a mathematical model is established for a nipper mechanism of the comber, displacement and speed parameters of a lower nipper are calculated by using a computer when the comber has different noil spacings, and corresponding displacement and speed equations of the lower nipper in a separation and joint stage are fitted.
For example: the displacement fitting equation of the lower nipper in the separation and jointing process (18 graduation-24 graduation) when the noil graduation is 8 and the cotton feeding length is 5.2mm is calculated by a computer:
（2）
wherein,yin order to displace the lower nipper, the lower nipper is moved,xfor indexing purposes.
And (II) establishing a mathematical model for a detaching roller transmission mechanism of the combing machine, calculating detaching roller displacement and speed parameters at different detaching roller clockwise rotation timings by using a computer, and fitting out corresponding displacement and speed equations of the detaching roller at a detaching and jointing stage.
For example: when the clockwise rotation of the detaching roller is +0.5, the speed fitting equation of the detaching roller in the detaching and jointing process (18 graduation-24 graduation) is calculated by a computer as follows:
（3）
wherein,vin order to set the speed of the lower nipper,tfor indexing purposes.
(III) the fiber length distribution density in the combed cotton small roll is measured by an experiment, and the specific method comprises the following steps: the fiber length distribution density of the small rolls of combed cotton to be processed was measured using a nep and staple tester, and fiber length distribution density images were made at 2mm intervals.
The fiber length distribution density image is shown in fig. 1, and the height of each column represents the percentage of the corresponding length of fiber.
And (IV) establishing a corresponding mathematical model aiming at the measured fiber length distribution density condition of the small combed cotton roll, and simulating a fiber layer with the same fiber length distribution density as that in the actual small combed cotton roll by utilizing a computer.
The specific process is as follows: the cotton fiber length is expressed as Li(wherein i is an integer of 1 to 20), LiThe length ranges of (A) are respectively: 2(i-1)0<Li1<=2i, i.e. (0)<L1<=2，2<L2<=4，4<L3<=6，6<L4<=8，8<L5<=10，10<L6<=12，12<L7<=14，14<L8<=16，16<L9<=18，18<L10<=20，20<L11<=22，22<L12<=24，24<L13<=26，26<L14<=28，28<L15<=30，30<L16<=32，32<L17<=34，34<L18<=36，36<L19<=38，38<L20<=40。
Length LiThe proportion of the fiber number of the combed cotton lap to the total fiber number of the combed cotton lap is ai，a1+a2+…a20=1, and aiThe specific value of (c) is determined by the experiment of the step (three), that is, the length is less than or equal to L when the percentage proportion of the corresponding length fiber in figure 1 isiThe proportion of the fiber number of the combed cotton lap to the total fiber number of the combed cotton lap is a1+a2+…ai. Let Ai=a1+a2+ … ai, known length LiThe ratio of the fibers of (A)i-Ai-1。
A random number between 0 and 1 is generated by using a random command rand (1) in matlab software if Ai-1<rand(1)<=AiThen generate a root length LiThe fibers of (a); the rand (1) command is repeated, for example 300 times, to produce 300 fibres of between 0 and 40mm length.
For example: when the fiber length distribution density of the combed cotton lap is shown in fig. 1, the fiber layer before the cylinder carding simulated by the computer simulation is shown in fig. 2, and the fiber layer length distribution density is consistent with that shown in fig. 1. From the above process, the fiber length distribution density produced is consistent with the actual cotton lap fiber length distribution density.
And (V) simulating the fiber layer to be separated and jointed after the cylinder is carded by utilizing a computer simulation according to the combing process.
The specific process is as follows: taking forward cotton feeding as an example, the boundary fiber length L during cylinder carding can be known according to the combing processf= B + (0.5-K). times.G; setting B, K, G parameter value, determining boundary fiber length LfThe length of the fiber layer generated in the step (IV) is less than LfRemoving all the fiber layers to obtain the fiber layers carded by the cylinder;
wherein B is separation distance, K is cotton feeding coefficient, G is cotton feeding length, and the length is less than length L of boundary fiberfAll the fibers are swept down by the cylinder and enter the noil, and the length of the fibers is more than or equal to the length L of the boundary fibersfInto the separate bonded fiber layers.
For example: when the cotton is fed forward, the cotton feeding coefficient is 0.526, the noil scale, the cotton feeding length and the clockwise rotation of the detaching roller are set in the same steps (I) to (IV), and the computer is used for simulating the fiber layer to be detached and jointed after the cylinder carding, as shown in figure 3.
And sixthly, simulating the form of the single separation cluster after separation and connection by using a computer simulation by using displacement and speed equations of the nipper mechanism and the transmission mechanism of the separation roller which are fitted in the step (I) and the step (II). The specific process is as follows: according to the combing principle, the length of each nipped separation of the combing machine is equal to the length of a cotton layer fed by a cotton feeding roller, and from the beginning of separation and connection, fibers with the fiber head end within the cotton feeding length G from a separating jaw are all output by the separating roller; solving the division number of the fiber head end when the fiber head end reaches the separating jaw by using the displacement fitting equation of the nipper mechanism in the step (I); using the speed fitting equation of the detaching roller in the step (II), taking the division number of the fiber head end reaching the detaching jaw as the integral lower limit, and taking the 24 division at the detaching and jointing end as the integral upper limit, and calculating the displacement of the fiber in the detaching and jointing process; and calculating the displacement of each fiber participating in the separation and jointing process by using a computer to obtain the separation bundle form after the separation and jointing.
For example: the speed of the combing machine is 400 nippers per minute, when one fiber participating in separation and jointing is in 18 divisions, the distance from the head end to the separation nip is 3.9981mm, and the moment when the fiber head end reaches the separation nip is calculated to be 21.5 divisions by utilizing a displacement fitting equation (2) of a nipper mechanism; and (3) performing fixed integral operation on a speed fitting equation (3) of the separating roller by taking 21.5 divisions as the lower integral limit and 24 divisions as the upper integral limit, calculating to obtain the displacement of 20.016mm which is walked in the fiber separating and jointing process, performing the operation on all fibers participating in the separating and jointing process to obtain the form of a separating bundle after the separating and jointing process, and counting the fiber numbers of different positions of the separating bundle to obtain the fiber number distribution curve of a single separating bundle as shown in fig. 5.
And (seventhly), simulating the lapping of 6 separated fiber bundles by using a computer simulation, namely the shape of the output cotton web of the combing machine. The specific process is as follows: and (5) repeatedly utilizing the steps (I) - (VI) to generate different random combing separation clusters, setting the effective output length of the combing machine as S, stacking the next separation cluster on the previous separation cluster, setting the distance from the head end of the next separation cluster to the head end of the previous separation cluster as S, and sequentially stacking 6 separation clusters to obtain the output web shape of the combing machine.
For example: when the effective output length S is 26.48mm, the output web formed by sequentially overlapping the 6 separation bundles is shown in fig. 6, and the fiber root numbers of different positions of the output web are counted to obtain a fiber root number distribution curve of the output web shown in fig. 7.
And (eighthly), calculating the CV value of the variation coefficient of the cotton net output by the combing machine, and predicting the quality of the cotton net. Detailed description of the inventionThe process is as follows: dividing the output web lengthwise intonRespectively counting the number of fibers in each segmentw iAnd calculate outnAverage fiber number of segmentsw 0By usingCVFor obtaining output webs by value calculationCVThe value:
（1）
obtained by calculationCVValues predict web quality.
For example: utilization of the above-mentioned webCVValue is calculated by a value calculation formulaCV=4.3（%）。
(nine) optimization design of combing process. The specific process is as follows: when the fiber length distribution density of the small combed cotton roll is constant, the noil gauge in the combing process, the clockwise rotation of the detaching roller and the cotton feeding length are respectively changed, and the output web shape when different process parameters are simulated by utilizing the steps (I) to (eight) to calculate the web shapeCVValue and pairCVComparing the values to find outCVAnd configuring combing process parameters with the minimum value, thereby realizing the computer-aided optimization design of the combing process.
For example: when a single variable influence factor is taken as a simulation optimization basis, the noil scales are respectively taken as 5, 6, 7, 8, 9, 10, 11 and 12, the clockwise rotation time of the detaching roller is +1, +0.5, 0, -0.5 and-1, and the cotton feeding length is 4.3mm, 4.7mm, 5.2mm and 5.9 mm; using computer to simulate output web and calculate webCVAnd comparing the values, and finding that when the distribution density of the length of the fiber of the small combed lap is shown in figure 1, the optimal process configuration scheme is as follows: the noil scale is 5, the clockwise rotation time of the detaching roller is 0, the cotton feeding length is 4.7mm, and the calculation is carried out at the momentCVThe minimum value is 3.74%.
The above description is only for the preferred embodiment of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (1)
1. A method for computer-aided combing process design and combed web quality prediction, characterized by comprising the steps of:
establishing a mathematical model for a nipper mechanism of a comber, calculating displacement and speed parameters of a lower nipper at different noil spacings of the comber by using a computer, and fitting a corresponding displacement and speed equation of the lower nipper at a separation and joint stage;
secondly, establishing a mathematical model for a detaching roller transmission mechanism of the combing machine, calculating detaching roller displacement and speed parameters at different detaching roller clockwise rotation timings by using a computer, and fitting out corresponding displacement and speed equations of the detaching roller at a detaching and jointing stage;
(III) determining experimentally the fiber length distribution density in combed cotton rolls, the steps comprising: testing the fiber length distribution density condition of the small combed cotton roll to be processed by using a nep and short fiber tester, and making fiber length distribution density images at intervals of 2 mm;
establishing a corresponding mathematical model aiming at the measured fiber length distribution density of the small combed cotton roll, and simulating a fiber layer with the same fiber length distribution density as that in the actual small combed cotton roll by utilizing a computer;
(V) simulating the fiber layer to be separated and jointed after the cylinder is carded by utilizing a computer simulation according to the combing process, wherein the step comprises the following steps: boundary fiber length during cylinder carding can be known according to combing processL f =B+(0.5-K)×G(ii) a Setting upB、K、GDetermining the demarcation fiber lengthL f The length of the fiber layer generated in the step (IV) is less thanL f Removing all the fiber layers to obtain the fiber layers carded by the cylinder;
wherein,Bin order to separate the gauge length, the distance between the two rollers is less than the set distance,Kin order to obtain the coefficient of cotton feeding,Gfor cotton-feeding length, length less than dividing fibre lengthL f All the fibers are swept down by the cylinder and enter the noil, and the length of the fibers is more than or equal to the length of the boundary fibersL f The fibers of (a) enter the separate bonded fiber layer;
sixthly, simulating the form of a single separation cluster after separation and bonding by using a computer simulation by using displacement and speed equations of the nipper mechanism and the transmission mechanism of the separation roller, which are fitted in the step (I) and the step (II), wherein the step (III) comprises the following steps: it is known from combing principle that the length of each nipped separation of the combing machine is equal to the length of the cotton layer fed by the feeding roller, and the distance between the fiber head end and the separating nip is equal to the cotton feeding length from the beginning of the separation jointGThe inner fibers are all output by the detaching roller; solving the fiber head end to the fiber head end by using the displacement fitting equation of the nipper mechanism in the step (I)The number of divisions when the jaws are separated; using the speed fitting equation of the detaching roller in the step (II), taking the division number of the fiber head end reaching the detaching jaw as the integral lower limit, and taking the 24 division at the detaching and jointing end as the integral upper limit, and calculating the displacement of the fiber in the detaching and jointing process; calculating the displacement of each fiber involved in the separation and joining process by using a computer to obtain the separation cluster form after the separation and joining;
(VII) simulating lapping of 6 separated fiber bundles by using a computer to obtain the shape of the output web of the combing machine, wherein the step comprises the following steps: repeating the steps (one) to (six), generating different random combing separation bundles, and setting the effective output length of the combing machine to beSThe subsequent separation clump is stacked on top of the previous separation clump, and the head end of the subsequent separation clump is at a distance ofSSequentially stacking 6 separation clusters to obtain the output web shape of the combing machine;
(VIII) calculating variation coefficient of output web of combing machineCVValue, to perform web quality prediction, comprising: dividing the output web lengthwise intonRespectively counting the number of fibers in each segmentw iAnd calculate outnAverage fiber number of segments w0By usingCVFor obtaining output webs by value calculationCVThe value:
（1）
obtained by calculationCVPredicting the quality of the cotton net;
(nine) optimization design of combing process, the steps include: when the fiber length distribution density of the small combed cotton roll is constant, the noil gauge in the combing process, the clockwise rotation of the detaching roller and the cotton feeding length are respectively changed, and the output web shape when different process parameters are simulated by utilizing the steps (I) to (eight) to calculate the web shapeCVValue and pairCVComparing the values to find outCVConfiguring combing process parameters with the minimum value, thereby realizing computer-aided optimization design of the combing process;
in the step (I), when the noil scale is 8 and the cotton feeding length is 5.2mm, the displacement fitting equation of the lower nipper in the separation and joining process is as follows:
（2）
wherein,yin order to displace the lower nipper, the lower nipper is moved,xis indexing;
when the clockwise rotation of the detaching roller in the step (II) is +0.5, the speed fitting equation of the detaching roller in the detaching and jointing process is as follows:
（3）
wherein,vin order to set the speed of the lower nipper,tfor indexing purposes.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN1963824A (en) * | 2006-11-17 | 2007-05-16 | 东华大学 | Method for forecasting diameter of fibre of unwoven cloth based on extrusion method of polymer of NN |
| CN100999836A (en) * | 2006-12-25 | 2007-07-18 | 东台纺织机械有限责任公司 | Multi-driving linking comber |
| CN103577668A (en) * | 2012-07-26 | 2014-02-12 | 中原工学院 | Calculation method for cotton linter elimination factor of cotton combing machine |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1963824A (en) * | 2006-11-17 | 2007-05-16 | 东华大学 | Method for forecasting diameter of fibre of unwoven cloth based on extrusion method of polymer of NN |
| CN100999836A (en) * | 2006-12-25 | 2007-07-18 | 东台纺织机械有限责任公司 | Multi-driving linking comber |
| CN103577668A (en) * | 2012-07-26 | 2014-02-12 | 中原工学院 | Calculation method for cotton linter elimination factor of cotton combing machine |
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