Design And Implementation Of Tension Control Sysytem For Cold Pad Batch Dyeing Machine

Knitted fabrics are widely used in garment industry due to their characteristics of softness and breathability.Dyeing is one of the important processing steps of knitted fabrics.The advantages of cold pad-batch dyeing process contains low energy consumption,short process flow and high production efficiency,and occupies an important part in the dyeing and finishing process.Knitted fabrics are sensitive to tension,cold pad-batch dyeing machine as knitted fabric dyeing equipment,the quality of its tension control system can directly impact on the quality of knitted fabric dyeing,especially in the case of the tension is not properly controlled while winding,stacked knitted fabric is easy to produce seam prints or wrinkles,which will directly result in color difference.The research content of this paper is the tension control system of cold pad-batch dyeing machine,which mainly includes the following parts:(1)The work flow of cold pad-batch dyeing machine is analyzed.According to the different requirements of knitted fabric tension in cold pad-batch dyeing process,a distributed tension control system is established,and the main factors causing tension fluctuation are briefly analyzed.(2)Fuzzy adaptive PID control algorithm is used to control the tension in order to improve the performance of the tension control system of cold pad-batch dyeing machine.The simulation experiments of constant tension transmission system based on Simulink are carried out to compare the advantages and disadvantages of conventional PID control algorithm and fuzzy adaptive PID control algorithm.The results show that the fuzzy adaptive PID algorithm is better in tension control.(3)In view of the problem that knitted fabrics are sensitive to tension,the constant tension winding method is easy to produce seam-end printing,which will cause color difference in dyeing.The power function variable tension winding method is introduced to reduce the production of seam-end printing and wrinkles.The tension control strategy of power function variable tension winding is determined,and the simulation experiment of power function variable tension winding tension control system is carried out.The simulation results show that the tension fluctuates sharply at the beginning of winding,and the winding tension tends to stabilize gradually with the increase of winding layers.(4)The experimental device of knitted fabric winding tension control is built.The experimental results show that the fuzzy adaptive PID control algorithm can improve the performance of the tension control system and reduce the tension fluctuation rate.Based on fuzzy adaptive PID control algorithm,constant tension winding experiment and power function variable tension winding experiment of knitted fabric are carried out.The results show that the power function variable tension winding can effectively avoid wrinkles in the inner layer.(5)The interface of tension control system of cold pad-batch dyeing machine is designed based on Labview development environment.The communication between Labview and PLC is realized by OPC standard communication interface.Finally,the tension control system of cold pad-batch dyeing machine is tested.The results show that the tension control system can basically meet the requirements of cold pad-batch dyeing process.