EP4159655B1 - Procédé de commande de tension de fil pour dispositifs d'alimentation positive motorisés de fil - Google Patents

Procédé de commande de tension de fil pour dispositifs d'alimentation positive motorisés de fil

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Publication number
EP4159655B1
EP4159655B1 EP22198457.8A EP22198457A EP4159655B1 EP 4159655 B1 EP4159655 B1 EP 4159655B1 EP 22198457 A EP22198457 A EP 22198457A EP 4159655 B1 EP4159655 B1 EP 4159655B1
Authority
EP
European Patent Office
Prior art keywords
constant
tension
yarn
integrative
performance index
Prior art date
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Application number
EP22198457.8A
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German (de)
English (en)
Other versions
EP4159655A1 (fr
Inventor
Mirko Ruggeri
Giorgio Bertocchi
Davide PREVITALI
Fabio Previdi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
LGL Electronics SpA
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LGL Electronics SpA
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Publication of EP4159655A1 publication Critical patent/EP4159655A1/fr
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B15/00—Details of, or auxiliary devices incorporated in, weft knitting machines, restricted to machines of this kind
    • D04B15/38—Devices for supplying, feeding, or guiding threads to needles
    • D04B15/44—Tensioning devices for individual threads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H59/00—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators
    • B65H59/38—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by regulating speed of driving mechanism of unwinding, paying-out, forwarding, winding, or depositing devices, e.g. automatically in response to variations in tension
    • B65H59/384—Adjusting or controlling tension in filamentary material, e.g. for preventing snarling; Applications of tension indicators by regulating speed of driving mechanism of unwinding, paying-out, forwarding, winding, or depositing devices, e.g. automatically in response to variations in tension using electronic means
    • B65H59/388—Regulating forwarding speed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/30—Handled filamentary material
    • B65H2701/31—Textiles threads or artificial strands of filaments

Definitions

  • a yarn can be fed toward a downstream textile machine, such as in particular a knitting machine, by a motorized yarn feeder of what is called the "positive" type.
  • a control unit modulates the rotation rate of the reel by closed loop on the basis of the signal received from a tension sensor, in order to stabilize the tension of the yarn fed to the knitting machine at a fixed value or at a profile set by the user.
  • One of the factors that most affects yarn tension is the difference between the speed at which the yarn exits from the feeder and the speed at which it is drawn by the knitting machine.
  • control unit makes it possible to select manually some adjustment parameters as a function of the type of yarn and, indirectly, of the distance between the feeder and the knitting machine.
  • US 6,079,656 discloses a yarn supply apparatus for elastic yarns in knitting machines having abruptly fluctuating yarn consumption.
  • a yarn wheel around which the yarn to be supplied is wrapped, furnishes the yarn to a yarn store located between a knitting station and the yarn wheel.
  • a closed-loop controller responsive to yarn tension operates the yarn wheel via a low-inertia drive motor.
  • the yarn store is embodied as an essentially straight segment of yarn in the yarn path in which yarn is guided so it can expand freely.
  • the combination of a low-inertia drive motor, a yarn store that utilizes the intrinsic elasticity of the yarn, and a closed-loop controller that monitors the yarn tension by means of a sensor device makes it possible to use the yarn supply apparatus for supplying elastic yarns and to keep the yarn tension essentially constant even when the demand for yarn fluctuates abruptly.
  • a method for self-calibrating parameters of a PID regulator following a Fuzzy reasoning, in order to improve the tension signal sensor is known from ZHAO HAI XIA ET AL: "Application of Fuzzy PID Control in Yarn Tension Control System", APPLIED MECHANICS AND MATERIALS, vol. 321-324, 1 June 2013 (2013-06-01), pages 1748- 1752 .
  • the aim of the present invention is to provide a method that makes it possible to control the tension of the yarn in a manner that is more precise and more reliable than known solutions, optimizing automatically the performance during work in relation to the various factors involved, particularly the type of yarn, the speed variations of the knitting machine and the distance between the feeder and the knitting machine.
  • Figure 1 is a schematic view of a motorized positive yarn feeder 10 which feeds a yarn Y to a textile machine, particularly a knitting machine KM.
  • the feeder 10 comprises a motorized reel 12 on which the yarn Y is wound repeatedly (for example, 3 or 4 turns) so that it adheres to the reel by friction. By turning the reel 12, the yarn Y unwinds from an upstream spool S and is fed to the downstream knitting machine KM.
  • a control unit CU which can be integrated in the feeder 10, is connected to adjust the rotation speed of the reel 12 by closed loop on the basis of the signal received from a tension sensor 14 (also, optionally, integrated in the feeder 10), so as to stabilize the tension of the yarn fed to the machine on a fixed value or on a profile set by the user.
  • the feeder 10 is also provided with means (not shown) for measuring the angular speed ⁇ R of the reel 12, which can generally comprise an encoder, a series of Hall sensors, or other similar known devices.
  • the release speed V R of the yarn Y can be assumed to be equal to the product of the angular speed ⁇ R of the reel 12 and the radius of the reel 12.
  • the feeder 10 is arranged at a distance L from the knitting machine KM, which draws yarn at a drawing speed V KM .
  • the distance L and the drawing speed V KM are assumed to be unknown, as are the mechanical characteristics (in particular the stiffness) of the yarn Y.
  • the drawing speed V KM can vary widely, for example during the provision of a design.
  • the closed loop control system has the purpose of limiting the tension variations of the yarn Y which result from said variations in the drawing speed V KM by the knitting machine.
  • Figure 2 shows the architecture of the closed loop control system.
  • control system comprises generally a yarn tension control loop YTL, a reel speed control loop RSL, and a control loop of the current that crosses the electric motor (not shown), which is contained within the speed control loop RSL.
  • the speed control loop RSL and the current control loop are preferably controlled in a conventional manner by means of constant parameter linear regulators, so as to receive in input a reference angular speed ⁇ R ref and return in output the release speed V R .
  • the difference between the release speed V R and the drawing speed V KM generates a tension T on the yarn Y.
  • the tension T is measured by the tension sensor 14 and compared with a desired tension Tdes in a subtractor node N of the tension control loop YTL, so as to generate a tension error Terr.
  • the desired tension Tdes can have a constant value or a profile that is variable over time.
  • the reference angular speed ⁇ R ref is generated by a proportional-integral-derivative regulator PID which receives in input the tension error Terr and has an integrative constant K I that is not constant but is instead updated iteratively through a self-calibration procedure 18 adapted to minimize a performance index (or cost function) of the signal generated by the tension sensor 14.
  • the variance of the tension signal is used as performance index.
  • the self-calibration procedure comprises the following steps:
  • the proportional-integral-derivative regulator PID with integrative constant which is updated iteratively in the abovementioned manner has the effect of minimizing the magnitude of the tension peaks caused by the speed changes of the knitting machine and at the same time of avoiding excessive oscillations of the tension signal.
  • the described self-calibration procedure is particularly effective in the system described here because, as is known, knitting machines conventionally have periodic speed profiles, therefore making the comparison between variances obtained with different successive integrative constants significant.
  • the variance be calculated over a time interval that has a longer duration than the period of the knitting machine.
  • Figure 3 shows an example of the trend of the mean variance E[Var(K I )] as the integrative constant K I varies for an intermediate yarn at a certain working point, as well as the trend of the tension T and of the release speed V R at the minimum value K Imin and at the maximum value K Imax of the integrative constant within the domain portion considered, and also the value that minimizes the mean variance E[Var(K I )].
  • the minimum safeguard value K Imin and the maximum safeguard value K Imax are defined based on the threshold values that can be represented by the control unit CU, considering also the fact that the integrative constant K I can assume only negative values in order to prevent the system from becoming unstable.
  • black-box optimization algorithm used in the method according to the invention provides for:
  • the passive tests are performed by closed loop without ever interrupting tension adjustment.
  • the first derivative and the second derivative is calculated, according to the invention, by means of what is called the central difference formula: dV K I dK I ⁇ V K I + ⁇ K I ⁇ V K I ⁇ ⁇ K I 2 ⁇ ⁇ K I d 2 V K I dK I 2 ⁇ V K I + ⁇ K I ⁇ 2 V K I + V K I ⁇ ⁇ K I ⁇ K I 2
  • the algorithm calculates the direction of the movement p, checking whether one between V(K I + ⁇ K I ) - V(K I ) or V(K I - ⁇ K I ) - V(K I ) returns a result ⁇ 0.
  • the value in the chart of Figure 3 the value is to the left of the minimum of the variance and, therefore, with a sufficiently short "positive” step it is possible to approach the minimum value; in the second case, the value is to the right of the minimum of the variance and with a sufficiently short "negative” step it is possible to approach the minimum value.
  • the direction of the movement p is given by the negative ratio between the first derivative and the second derivative (Newton direction).
  • step ⁇ can be derived by a procedure known as line search.
  • line search a procedure known as line search.
  • the procedure is repeated using the same integrative constant K I without performing any step. Under ideal conditions of no measurement noise, this would mean that the variance is already very close to the minimum value, and therefore a step in any direction would offer a worse result. In the presence of noise (or because of numerical accuracy problems), the procedure may be unable to derive a movement direction. In that case, the optimization step, i.e., the three tests for the variances, is repeated.
  • an additional safeguard criterion is applied according to which ⁇ K I ⁇ ⁇ p ⁇ ⁇ K I where ⁇ maxstep being an experimentally determined maximum step coefficient, which can be comprised typically between 1 and 5.
  • the starting integrative coefficient, K I the number of samples N to be used in calculating the variance (given the sampling rate, this is equivalent to defining the time interval to be considered), the number of intervals M over which to calculate the mean variance, as well as the coefficients for calculating the minimum step and the maximum step, ⁇ minstep and ⁇ maxstep , respectively, can be determined on the basis of experimental tests.
  • K I the starting integrative coefficient
  • K I the starting integrative coefficient
  • These initial calibrations can be used as a starting point during work in order to speed up the convergence to the variance minimum V(K I ).
  • the variance calculation can be performed incrementally in order to avoid the need to store a number N of samples, so as to limit the memory capacity required to perform the self-calibration procedure.
  • the time constant of the integral part T I and the time constant of the derivative part T D of the proportional-integral-derivative regulator PID are kept constant and calibrated starting from an estimated model for the speed control loop.
  • the reel speed control loop RSL includes a Kalman filter for estimating the angular rotation rate of the motor, which is performed starting from the measurement of the angular position.
  • this estimate can be exploited advantageously by a proportional-integral controller in order to control the angular speed ⁇ R of the reel.
  • the Kalman filter allows to improve the performance of the speed control loop RSL and, accordingly, of the entire adjustment procedure, simplifying the implementation of the tension adjustment loop YTL.
  • the variance (or the mean variance) has been used as performance index.
  • performance index As the person skilled in the art will easily understand, it will be possible to use other performance indices calculated directly from the measured value (as in the case of the variance) or from the error (difference between setpoint and measured value).
  • MSE Mean Squared Error
  • RMSE Root Mean Squared Error
  • Integral Performance Indices such as the Integral Squared Error (ISE), the Integral Absolute Error (IAE), the Integral of the Time weighted Absolute Error (ITAE), or even the Integral of the Time weighted Squared Error (ITSE).
  • performance indices are normalized versions or various combinations of those defined above. Each performance index substantially defines a different trade-off between peak rejection and oscillations and must be calculated over a certain measurement period.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Tension Adjustment In Filamentary Materials (AREA)
  • Knitting Machines (AREA)

Claims (10)

  1. Procédé de commande de tension d'un fil dans un dispositif d'alimentation en fil du type muni d'une bobine (12) qui est adaptée pour porter un fil (Y) enroulé sur celle-ci et qui est entraînée en rotation par un moteur afin de tirer ledit fil (Y) d'une bobine (S) et de l'alimenter vers une machine à tricoter (KM), dans lequel une unité de commande (CU) ajuste la vitesse de rotation de la bobine (12) en boucle fermée sur la base du signal reçu d'un capteur de tension (14), afin de stabiliser la tension du fil (Y) à une valeur souhaitée (Tdes) qui est fixe ou variable dans le temps selon un profil prédéfini, où la tension (T) mesurée par ledit capteur de tension (14) est comparée à ladite valeur souhaitée (Tdes) afin d'obtenir une erreur (Terr) qui, au moyen d'un régulateur proportionnel-intégral-dérivé (PID), génère une vitesse angulaire de référence (ωRref) à envoyer à une boucle de régulation de vitesse de bobine (RSL), où
    ledit régulateur proportionnel-intégral-dérivé (PID) comporte une constante d'intégration (KI) qui est mise à jour de manière itérative au moyen d'une procédure d'auto-étalonnage (18) adaptée pour minimiser un indice de performance du signal généré par ledit capteur de tension (14), qui est calculé directement à partir de la valeur mesurée ou de l'erreur comme différence entre la valeur de consigne et la valeur mesurée, où ladite procédure d'auto-étalonnage comprend les étapes suivantes :
    - calculer ledit indice de performance sur un nombre prédéfini d'échantillons (N) du signal de tension (T) en appliquant la constante d'intégration actuelle (KI),
    - sélectionner une nouvelle constante d'intégration KI' au moyen d'un algorithme d'optimisation de type « boîte noire »,
    - si la nouvelle constante d'intégration (KI') se situe dans un intervalle de sécurité compris entre une valeur de sécurité minimale (KImin) et une valeur de sécurité maximale (KImax) qui sont prédéterminées, répéter la procédure en utilisant la nouvelle constante d'intégration (KI'), sinon répéter la procédure en utilisant la constante d'intégration actuelle (KI), où ledit algorithme d'optimisation de boîte noire comprend les étapes suivantes :
    - réalisation d'un premier test passif, dans lequel une constante d'intégration courante fixe (KI) est utilisée pendant un intervalle de temps prédéterminé, puis l'indice de performance du signal de tension dans cet intervalle de temps est calculé,
    - calcul du pas minimum (δKI) de la constante d'intégration courante (KI) selon la formule δ K I = KI γ minstep où γminstep est un coefficient de pas minimum déterminé expérimentalement,
    - réalisation d'un deuxième test passif, dans lequel une constante intégrative augmentée, égale à KI + δKI, est utilisée pendant le même intervalle de temps, puis l'indice de performance est calculé sur le nombre prédéfini (N) d'échantillons du signal de tension (T) dans cet intervalle de temps,
    - réalisation d'un troisième test passif, dans lequel une constante intégrative réduite est utilisée, qui est égale à KI - δKI pour le même intervalle de temps, puis calcul de l'indice de performance sur le nombre prédéfini (N) d'échantillons du signal de tension (T) dans cet intervalle de temps,
    lesdits tests passifs étant réalisés en boucle fermée sans jamais interrompre le réglage de la tension,
    - calcul de la dérivée première et de la dérivée seconde selon la formule suivante : dV Kj dK , = V K I + δ K I − V K , − O ¨ K , 2 bK , d 2 V K I _ V K I + bK I − 2 N Kj + V K r bK , dK ∼ bKjf
    - calcul de la direction du mouvement (p), en vérifiant si l'un des éléments V(KI + δKI) - V(KI) ou V(KI- δKI) - V(KI) renvoie un résultat < 0 et,
    - si c'est le cas, après avoir effectué un contrôle de sécurité, choisir l'amplitude d'un pas α de manière à améliorer la variance et appliquer la nouvelle constante d'intégration (KI') à la boucle de contrôle de tension (YTL) selon la formule Ki'= KI+ αp,
    - si ce n'est pas le cas, répéter la procédure en utilisant la constante d'intégration courante (KI) sans effectuer aucune étape.
  2. Procédé selon la revendication 1, caractérisé en ce que ledit indice de performance est la variance (V(KI)) du signal de tension.
  3. Procédé selon la revendication 1, caractérisé en ce que ledit indice de performance est la variance moyenne (E[Var(KI)]) du signal de tension, calculée sur un nombre prédéfini d'intervalles consécutifs (M).
  4. Procédé selon la revendication 1, caractérisé en ce que ledit coefficient de pas minimum (γminstep) est compris entre 5 et 50.
  5. Procédé selon la revendication 1, caractérisé en ce que l'amplitude du pas (α) est déterminée au moyen d'une procédure de recherche par retour en arrière.
  6. Procédé selon une ou plusieurs des revendications 1 à 5, caractérisé en ce qu'un critère de sécurité supplémentaire est appliqué selon lequel 5 Ki < a p < AKi où γmaxstep étant un coefficient de pas maximal déterminé expérimentalement.
  7. Procédé selon la revendication 6, caractérisé en ce que ledit coefficient de pas maximal (γmaxstep) est compris entre 1 et 5.
  8. Procédé selon une ou plusieurs des revendications 1 à 7, caractérisé en ce que le calcul de l'indice de performance est effectué de manière incrémentielle afin de limiter la capacité mémoire nécessaire pour exécuter la procédure d'auto-étalonnage.
  9. Procédé selon une ou plusieurs des revendications 1 à 8, caractérisé en ce qu'une constante de temps d'une partie intégrale (TI) et une constante de temps d'une partie dérivée (TD) dudit régulateur proportionnel-intégral-dérivé (PID) sont maintenues constantes et calibrées à partir d'un modèle estimé pour la boucle de régulation de la vitesse de la bobine (RSL).
  10. Procédé selon une ou plusieurs des revendications 1 à 9, caractérisé en ce que la boucle de régulation de vitesse de bobine (RSL) comprend un filtre de Kalman pour l'estimation de la vitesse de rotation angulaire du moteur, qui est effectuée à partir de la mesure de la position angulaire.
EP22198457.8A 2021-09-30 2022-09-28 Procédé de commande de tension de fil pour dispositifs d'alimentation positive motorisés de fil Active EP4159655B1 (fr)

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EP4159655B1 true EP4159655B1 (fr) 2025-10-29

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CN116767962B (zh) * 2023-05-19 2025-04-25 东华大学 一种自反馈式纱线张力控制方法
CN116812640B (zh) * 2023-07-27 2026-03-06 苏州迈为科技股份有限公司 张力控制方法和装置
CN118192656A (zh) * 2024-03-15 2024-06-14 国网河北省电力有限公司雄安新区供电公司 一种四轴无人机分数阶pid控制器参数设计方法
CN118502229B (zh) * 2024-07-12 2024-10-29 钛玛科（北京）工业科技有限公司 一种基于自整定pid的纠偏控制系统
CN119190945B (zh) * 2024-11-26 2025-05-27 江苏龙达纺织科技有限公司 一种数码转印纸高速分切装置

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DE19537215C2 (de) * 1995-10-06 1999-09-02 Memminger Iro Gmbh Fadenliefergerät für elastische Garne

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