Design Of Electric Spindle Operation Status Monitoring System Based On Internet Of Things

As an important process in spinning mills,the spinning process has a crucial impact on spinning quality,production efficiency and cost.The spinning frame directly driven by the brushless DC motor affects the production efficiency of the spinning yarn,and the main performance is that the breakage in the operation directly affects the quality of the yarn and the yarn forming rate.With the demand for information management of factories,traditional methods of manually recording breakage and other conditions of electric spindle are difficult to meet the demand.For this reason,this paper uses wireless ad hoc network,GPRS(General Packet Radio Service)and database technology to design an electric spindle operating status monitoring system based on the Internet of Things.The system first transmits the collected information of the working status of the individual electric spindle to the total monitoring system of the electric spindle spinning frame through the wireless ad hoc network.Then,it is transmitted to the server through GPRS technology.Finally,the server store the information about the working status of the electric spindle in the corresponding database for subsequent data analysis.The main work completed in this paper includes the following aspects.1.Based on the analysis of the performance requirements of the electric spindle operating status monitoring system,the overall network structure of the system based on the Internet of Things is designed.The network structure is divided into three layers: single spindle condition detection(including breakage detection and human-computer interaction,etc.)and wireless ad hoc network module as the sensing layer;GPRS module and Internet as the network layer;server side as the application layer.The mesh structure covers all the spindle positions of the spinning frame,so that each spindle position is connected to the network to accurately locate the breakage.2.According to the actual running condition of the electric spindle spinning frame and the user’s demand,this paper adopts a master multi-slave hardware circuit design for its working condition monitoring end.As the slave system,the single-spindle operation status acquisition terminal is mainly responsible for collecting information such as the breakage,repair and replacement of the single spindle.The collecting system judges the breakage by collecting and analyzing the phase current data of the electric spindle motor,and reserves the interface of the breakage detecting and the vibration measuring sensor signal according to the user’s demand.The main monitoring system of the spinning frame is used as the master system to collect the data information of the single spindle through the wireless self-organizing network module,and then transmit the data to the server through the GPRS module,and at the same time in the TFT-LCD(Thin Film TransistorLiquid Crystal Display)a bar graph showing the operating status of the system and the number of times the spindle breaks are displayed.3.The software for the single electric spindle acquisition terminal and the master monitoring system was designed.The single electric spindle collecting terminal transmits the collected spindle data information to the master monitoring system according to the user’s needs.The master monitoring system has many functions.This paper uses the μC/OS-Ⅲ real-time operating system to complete the software design of the master monitoring system.System functions are divided into main tasks,TFT-LCD display tasks,buttons and LED tasks,independent watchdog tasks,and starting tasks.According to the task requirements,the main task realizes the transmission of data and the update of the working status of the electric spindle.The TFT-LCD display task displays the working status of the system and the bar graph of the spindle breakage.4.A server application was developed to mainly implement information exchange between the server and the master monitoring system.The application analyzes the information of the operating status of the electric spindle and stores it in the corresponding database,which realizes the effective storage of the electric spindle data and facilitates the offline analysis of the subsequent electric spindle data.At the same time,the control of the spun yarn electric spindle spinning frame terminal is realized by transmitting a command from the transmission area of the application.Finally,this paper conducted an experimental test of system performance.Mainly tested the single spindle data acquisition breakage detection,TFT-LCD display and wireless transmission module data transmission,as well as GPRS and server-side data transmission storage.The experimental results show that the system meets the requirements of monitoring the operation status of the electric spindle spinning frame,and provides data support for the subsequent analysis and decision of the management personnel.