BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates generally to a shedding control method and a shedding
control apparatus for a weaving machine or loom. More specifically, the invention
is concerned with a shedding control for allowing shedding operation to follow rotation
of a loom with enhanced accuracy.
2. Description of Related Art
[0002] For having better understanding of the invention, the technical background thereof
will first be described in some detail. There are disclosed in Japanese Unexamined
Patent Application Publications Nos. 25751/1993 (JP-A-5-25751) and 322644/1994 (JP-A-6-322644)
such shedding control apparatuses in which a plurality of heald frames are driven
separately from one another by means of electric motors which are dedicated to the
heald frames, respectively, wherein each of the heald frames is operatively connected
to the dedicated motor in one-to-one correspondence relation.
[0003] In either one of the shedding control apparatuses disclosed in JP-A-5-25751 and JP-A-6-322644,
difference or deviation between a target or desired rotation of the drive motor given
in terms of a rotation angle of a main shaft of the loom and an actual rotation thereof
is detected for controlling the rotation of the drive motor so that the difference
as detected makes disappearance. In this conjunction, it is however noted that in
the case of the shedding control apparatus disclosed in JP-A-5-25751, a control loop
gain is regulated in dependence on the deviation, whereas in the case of the shedding
control apparatus disclosed in JP-A-6-322644, the control loop gain is regulated on
the basis of the information concerning the operating position of the heald frame.
[0004] More specifically, in the case of the shedding control apparatus disclosed in JP-A-5-25751,
the control loop gain is adjusted in dependence on magnitude of the deviation so that
the drive motor can follow the rotation of the main shaft of the loom with high accuracy.
However, rotation of the main shaft of the loom is susceptible to fluctuations due
to the beating, change in the tension of warps or for the like cause. Consequently,
when rotation speed of the main shaft of the loom changes or varies, rotation of the
drive motor is so controlled as to follow such variations. However, such control will
necessarily be accompanied with repetition of acceleration and deceleration, which
is of source undesirable. Needless to say, such operation of the electric motor will
incur increasing of the power consumption.
[0005] On the other hand, in the case of the shedding control apparatus disclosed in JP-A-6-322644,
the control loop gain is increased upon closing of the shed defined by the warps which
requires a high-accuracy control, while in the shed Opening operation (i.e., shedding)
in which requirement imposed on the control is not so severe, the loop gain is deceased.
However, changing-over of the control accuracy in the steady operation state of the
loom will lead to poor stability of the control system, giving rise to a problem in
respect to the smoothness of motion of the heald frame assembly.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is an object of the present invention to provide for a shedding apparatus
of a loom in which a heald frame assembly is driven by a shedding drive motor provided
independent of a loom drive motor a shedding control method which can ensure enhanced
stability of motion of the heald frame assembly while suppressing the electric power
consumption to a possible minimum.
[0007] Another object of the present invention is to provide a shedding control apparatus
for carrying out the control method mentioned above.
[0008] In view of the above and other objects which will become apparent as the description
proceeds, there is provided according to one aspect of the present invention a shedding
control method according to which a rotation control pattern for controlling the shedding
drive motor as a function of a time as a variable, is generated on the basis of rotation
speed of a loom as detected, wherein operation of the shedding drive motor is controlled
in accordance with the rotation control pattern.
[0009] With the shedding control method mentioned above, the shedding drive motor is operated
in accordance with the rotation control pattern as a function of the time lapse given
as a variable during the operation phase of the loom in which synchronism of high
accuracy is not required between the rotation angle of the loom and the operating
position of the heald frame assembly. Thus, smooth motion of the heald frame assembly
can be realized. The rotation control pattern based on the time as the variable is
generated on the actual rotation speed of the loom. Thus, with the method of controlling
the shedding drive motor by using the rotation control pattern generated on the basis
of the rotation speed of the loom as detected, there can be realized a stabilized
motion of the heald frame assembly while suppressing the electric power consumption
to a possible minimum.
[0010] According to another aspect of the present invention, there is provided a shedding
control method according to which a first rotation control pattern for controlling
a shedding drive motor as a function of rotation angle of the loom as a variable and
a second rotation control pattern for controlling the shedding drive motor as a function
of time as a variable are generated or prepared, wherein operation of the shedding
drive motor is controlled in accordance with the first rotation control pattern during
a speed-variable operation phase of the loom, while controlling the shedding drive
motor in accordance with the second rotation control pattern during a constant-speed
operation phase of the loom.
[0011] In an operation phase in which the motion speed of the loom rises up to a steady
operation speed or during a period in which the loom is decelerated from the steady
operation state to the stationary state, it is required to establish synchronism with
high accuracy between the rotation angle of the loom and the operating position of
the heald frame assembly. In this conjunction, it should be noted that according to
the shedding control method mentioned above, the shedding drive motor is operated
in accordance with the first rotation control pattern during the speed-changing operation
phase of the loom such as a period during which the loom speed is increased up to
a steady operation speed or a period in which the loom is decelerated to the stationary
state, in order to establish synchronism between the rotation angle of the loom and
the operating position of the heald frame assembly. On the other hand, in the steady
operation state of the loom in which high-accuracy synchronism is not required to
be established between the rotation angle of the loom and the operating position of
the heald frame assembly, the shedding drive motor is operated in accordance with
the second rotation control pattern in order to ensure smooth motion of the heald
frame assembly. Thus, with the method mentioned just above, the stability of operation
or motion of the heald frame assembly can be enhanced while suppressing the power
consumption to a minimum.
[0012] According to yet another aspect of the present invention, there is provided a shedding
control method according to which a first rotation control pattern for controlling
the shedding drive motor as a function of rotation angle of the loom as a variable
and a second rotation control pattern for controlling the shedding drive motor as
a function of time as a variable are generated or prepared, wherein the first rotation
control pattern and the second rotation control pattern may concurrently be employed
in combination for controlling the shedding drive motor.
[0013] More specifically, according to the shedding control method described just above,
X % of the first rotation control pattern and (100 - X) % of the second rotation control
pattern are employed in combination for controlling the shedding drive motor. Thus,
when the rotation speed according to the first rotation control pattern is represented
by V1 with the rotation speed according to the second rotation control pattern being
represented by V2, then the shedding drive motor is driven at a combined or synthesized
speed given by

By virtue of such combined control as mentioned above, there can be realized the
shedding control which satisfies both requirements imposed on the follow-up motion
of the heald frame assembly and the stability of motion of the heald frame assembly.
[0014] In a preferred mode for carrying out the method mentioned just above, the second
rotation control pattern may preferably be generated on the basis of an actual rotation
speed of the loom as detected.
[0015] According to a further aspect of the present invention, there is provided a shedding
control apparatus which includes a first rotation control pattern setting means for
setting a first rotation control pattern for controlling a shedding drive motor as
a function of rotation angle of the loom as a variable, a second rotation control
pattern setting means for setting a second rotation control pattern for controlling
the shedding drive motor as a function of time lapse as a variable, an operation speed
detecting means for detecting an operation speed of the loom, and a selecting means
for selecting at least one of the first rotation control pattern and the second rotation
control pattern on the basis of operation speed state detected by the operation speed
detecting means.
[0016] According to the shedding control apparatus mentioned above, the shedding drive motor
is operated in accordance with the first rotation control pattern during the speed-changing
operation phase of the loom such as a period during which the loom speed is increased
up to a steady operation speed or a period in which the loom is decelerated to the
stationary state, in order to establish synchronism or matching between the rotation
angle of the loom and the operating position of the heald frame assembly. On the other
hand, in the steady operation state of the loom in which high-accuracy synchronism
is not required to be established between the rotation angle of the loom and the operating
position of the heald frame assembly, the shedding drive motor is operated in accordance
with the second rotation control pattern in order to ensure smooth motion of the heald
frame assembly.
[0017] The above and other objects, features and attendant advantages of the present invention
will more easily be understood by reading the following description of the preferred
embodiments thereof taken, only by way of example, in conjunction with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the course of the description which follows, reference is made to the drawings,
in which:
Fig. 1 is a view showing schematically a shedding mechanism together with a shedding
control apparatus according to an embodiment of the present invention;
Fig. 2 is a view for graphically illustrating a first rotation control pattern employed
in the control performed by the shedding control apparatus;
Fig. 3 is a view for graphically illustrating a second rotation control pattern employed
in the control performed by the shedding control apparatus;
Fig. 4 is a flow chart for illustrating a shedding control method according to a first
embodiment of the invention;
Fig. 5 is a flow chart for illustrating a shedding control method according to the
first embodiment of the invention;
Fig. 6 is a flow chart for illustrating a shedding control method according to a second
embodiment of the invention; and
Fig. 7 is a flow chart for illustrating a shedding control method according to a third
embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] Now, the present invention will be described in detail in conjunction with what is
presently considered as preferred or typical embodiments thereof by reference to the
drawings. In the following description, like reference characters designate like or
corresponding parts throughout the several views.
Embodiment 1
[0020] A first embodiment of the present invention will be described by reference to Figs.
1 to 5.
[0021] Referring to Fig. 1, a shedding drive motor 12 is disposed underneath a heald frame
assembly 11. The shedding drive motor 12 may be constituted by a variable-speed electric
motor of a servo-motor type. A crank disk 13 is fixedly mounted on an output shaft
of the shedding drive motor 12, wherein the crank disk 13 is operatively coupled to
a lower heald frame of the heald frame assembly 11 by means of a connecting rod 14.
The crank disk 13 constitutes a crank mechanism in cooperation with the connecting
rod 14, wherein the rotation of the shedding drive motor 12 in one direction is translated
to upward/downward motions of the heald frame assembly 11 by means of the crank mechanism.
The shedding drive motor 12 is controlled under the command of a shedding control
apparatus generally designated by reference character C1. The shedding control apparatus
C1 is so designed as to control the shedding drive motor 12 through a feedback loop
on the basis of the rotation angle information which can be obtained from a rotary
encoder 121 incorporated in or provided in association with the shedding drive motor
12.
[0022] The shedding control apparatus C1 is comprised of a first rotation control pattern
storing unit 16 for storing a first rotation control pattern which is inputted through
an input unit 15, a second rotation control pattern storing unit 17 for storing a
second rotation control pattern, a control pattern generating circuit 18 for generating
the second rotation control pattern, and a selecting circuit 19 for selecting either
the first rotation control pattern or the second rotation control pattern. In this
conjunction, it should be mentioned that the input unit 15 and the first rotation
control pattern storing unit 16 cooperate to constitute a first rotation control pattern
setting means, while the second rotation control pattern storing unit 17 and the control
pattern generating circuit 18 constitute a second rotation control pattern setting
means. The control pattern generating circuit 18 generates the second rotation control
pattern on the basis of the rotation speed information obtained from the rotary encoder
20 which serves as a means for detecting a rotation angle of the loom. The selecting
circuit 19 constituting the selecting means is so designed as to select either one
of the first and second rotation control patterns on the basis of the rotation speed
information obtained from the rotary encoder 20 which constitutes an operation speed
detecting means.
[0023] The selecting circuit 19 controls the operation of the shedding drive motor 12 through
a feedback loop on the basis of the rotation control pattern as selected and rotation
angle information obtained from the rotary encoder 121 provided in association with
the shedding drive motor 12. In other words, the selecting circuit 19 issues a speed
command signal in accordance with a difference between the rotation angle obtained
from the rotary encoder 121 and the rotation angle determined by the rotation control
pattern.
[0024] Further provided is a loom control computer C2 which is in charge of controlling
the operation of a loom driving motor 21. The loom control computer C2 is so implemented
as to start operation of the loom driving motor 21 in response to a closing operation
of a starting switch (not shown) to thereby output a loom operation start signal to
both the control pattern generating circuit 18 and the selecting circuit 19. Furthermore,
in case abnormality such as weft insertion failure or error, warp breakage or the
like takes place, the loom control computer C2 stops operation of the loom driving
motor 21 and at the same time outputs a weaving operation stop signal to both the
control pattern generating circuit 18 and the selecting circuit 19.
[0025] Now, referring to Fig. 2, a curve D shown therein represents a shedding motion pattern
of the heald frame assembly 11, while a curve E1 represent a first rotation control
pattern corresponding to the shedding motion pattern of the heald frame assembly 11.
In this conjunction, it is to be noted that in the coordinate system for the curve
D, the rotation angle of the loom is taken along the abscissa, while the height of
the heald frame assembly 11 is taken along the ordinate. Similarly, as for the curve
E1, the rotation angle of the loom is taken along the abscissa, while that of the
shedding drive motor 12 is taken along the ordinate. Further referring to Fig. 3,
each of pulse-like waveforms F1, F2, F3 and F4 represents an origin signal outputted
from the rotary encoder 20 upon every complete rotation of the loom. Additionally,
a curve E2 represents the second rotation control pattern is generated by the control
pattern generating circuit 18 on the basis of rotation speeds of the loom determined
on the basis of the time lapses intervening between the origin signals F1, ···, F4.
In the coordinate system for the curve E2, time is taken along the abscissa with the
rotation angle of the shedding drive motor 12 being taken along the ordinate. For
generating the second rotation control pattern between the origin signals F4 and F3,
the rotation speed between the origin signals F3 and F2 is utilized, while for generation
of the rotation control pattern section between the origin signals F3 and F2, the
rotation speed between the origin signals F2 and F1 is employed. To say in another
way, for generation of the rotation control pattern between given origin signals,
the rotation speed during a period defined by an immediately preceding origin signals
is utilized. In this conjunction, it should be noted that the rotation speed in the
second rotation control pattern between the origin signals F1 and F3 is constant,
while during the period between the origin signals F3 and F4, the rotation speed remains
equal to zero.
[0026] Figures 4 and 5 are flow charts for illustrating shedding control operation carried
out by the shedding control apparatus C1. Referring tho the figures, the selecting
circuit 19 arithmetically determines change of the rotation speed (i.e., acceleration
or deceleration) of the loom on the basis of the rotation angle detection information
derived from the output of the rotary encoder 20. When the change of the rotation
speed is equal to or greater than a predetermined value, the selecting circuit 19
decides that the rotation speed of the loom is changing (Fig. 4, step S1, "YES"),
to read out the first rotation control pattern from the first rotation control pattern
storing unit 16 (step S2). Thus, operation of the shedding drive motor 12 is controlled
through the feedback loop in accordance with the first rotation control pattern selected
by the selecting circuit 19 and on the basis of the rotation angle information derived
from the output of the rotary encoder 121 provided in association with the shedding
drive motor 12. By virtue of this feedback control, it is possible to allow the shedding
drive motor 12 to follow the change of the rotation speed of the loom.
[0027] Concurrently, the control pattern generating circuit 18 starts generation of the
second rotation control pattern in response to the input of a weaving operation start
signal (Fig. 5, step S7, "YES"). More specifically, the control pattern generating
circuit 18 arithmetically determines the rotation speed of the loom on the basis of
the origin signals as inputted from the rotary encoder 20 (Fig. 5, steps S8 and S9),
and then generates the second rotation control pattern on the basis of the rotation
speed as determined arithmetically (Fig. 5, step S10).
[0028] On the other hand, when the decision step S2 shown in Fig. 4 results in negation
"NO", the selecting circuit 19 decides that the loom is operating in a steady operation
mode, to thereby select the second rotation control pattern read out from the second
rotation control pattern storing unit 17 (Fig. 4, step S3). Thus, the shedding drive
motor 12 is controlled through a feedback loop in accordance with the second rotation
control pattern as selected and on the basis of the rotation angle information derived
from the rotary encoder 121 provided in association with the shedding drive motor
12. Furthermore, when the weaving operation stop signal is inputted (Fig. 4, step
S4, "YES"), the selecting circuit 19 controls operation of the shedding drive motor
12 through the feedback loop in accordance with the second rotation control pattern
and on the basis of the rotation angle information derived from the output of the
rotary encoder 121 incorporated in the shedding drive motor 12 (Fig. 4, steps S4,
S1, S2). Parenthetically, in the case of the feedback control in accordance with the
second rotation control pattern, the shedding drive motor 12 can rotate smoothly without
being affected by change in the rotation speed of the loom during one complete rotation.
[0029] As will now be appreciated from the above description, upon acceleration or deceleration
of the rotation speed of the loom which requires that the shedding drive motor 12
be controlled in following the rotation speed of the loom with high accuracy, the
first rotation control pattern is selected so that the shedding operation of the heald
frame assembly 11 can follow the acceleration or deceleration of the loom. By contrast,
in the steady operation of the loom in which the rotation speed of the loom need not
be followed up with high accuracy, the second rotation control pattern is selected.
Thus, the shedding motion or operation of the heald frame assembly 11 can be carried
out smoothly nevertheless of occurrence of change in the speed of the loom during
every complete rotation of the loom. Such smooth operation or motion of the heald
frame assembly 11 contributes significantly to lowering or reduction of the electric
power consumption. Additionally, the control system for the loom is stabilized, whereby
the shedding motion performed by the heald frame assembly 11 can be effected in a
stable state.
[0030] At this juncture, it should be mentioned that even when a change in the rotation
speed of the loom occurs, the rotational position in the first rotation control pattern
will necessarily intersect the rotational position in the second rotation control
pattern. The position of such intersect can be arithmetically determined on the basis
of the first rotation control pattern and the second rotation control pattern which
is generated during every complete rotation of the loom. In this conjunction, it should
be noted that change-over between the first rotation control pattern and the second
rotation control pattern is performed at a time point at which the above-mentioned
rotational positions in both the rotation control patterns intersect each other. By
setting the timing for changing over the first and second rotation control patterns
in this manner, shock which may occur upon changing-over of the rotation control patterns
can be suppressed to a possible minimum, which is very advantageous for stable operation
of the control system.
Embodiment 2
[0031] A second embodiment of the present invention will be described by reference to Fig.
6. Although the general configuration of the loom control system is same as the first
embodiment described above, the function of the selecting circuit 19 differs from
that of the first embodiment. Parenthetically, generation of the second rotation control
pattern is same as in the case of the first embodiment. According to the teaching
of the invention incarnated in the instant embodiment, the selecting circuit 19 is
so implemented as to select a combination of X % of the first rotation control pattern
and (100 - X) % of the second rotation control pattern, wherein X represents a weighting
factor for the first rotation control pattern and (100 - X) represents a weighting
factor for the second rotation control pattern. When the rotation speed in the operation
effected in accordance with the first rotation control pattern is represented by V1,
while representing the rotation speed in the second rotation control pattern mode
by V2, the selecting circuit 19 is so implemented as to select a combined or synthesized
speed given by the following expression (1) (see Fig. 6, S13) when the operation speed
of the loom is changing (Fig. 6, S12, "YES"):

where coefficients α1 and α2 represent, respectively, the weighting factors which
are so determined as to satisfy the conditions that α1 + α2 = 1 and that α1 ≧ α2.
[0032] On the other hand, when the loom is operated in a steady mode (Fig. 6, S12, "NO"),
the selecting circuit 19 selects a combined or synthesized speed given by the following
expression (2) (Fig. 6, S14):

where coefficients α1 and α2 represent, respectively, the weighting factors which
meet the conditions that β1 < β2. Thus, the motion stability of the heald frame assembly
is enhanced as the weighting factor 2 is selected greater. As will be appreciated
from the above description, owing to the combined control using the weighting factors
as described above, not only the capability of the heald frame assembly 11 to follow
the rotational positions of the loom with accuracy as well as the stability of operation
of the heald frame assembly 11 can be realized satisfactorily.
Embodiment 3
[0033] A third embodiment of the present invention will be described by reference to a flow
chart shown in Fig. 7. Although the general configuration of the loom control system
is same as the first embodiment described above, the function of the selecting circuit
differs from that of the selecting circuit 19 of the first embodiment. Generation
of the second rotation control pattern is same as in the case of the first embodiment.
When the loom control computer C2 outputs the weaving operation start signal to the
selecting circuit 19 (Fig. 7, S22), the first rotation control pattern is selected
by the selecting circuit 19 (Fig. 7, S23). Upon lapse of a predetermined time t from
the outputting of the weaving operation start signal (Fig. 7, decision step S24),
the selecting circuit 19 selects the second rotation control pattern (Fig. 7, S25).
At this juncture, the predetermined time or period t is so set as to correspond substantially
to a rise-up time taken for the loom to attain the steady operation state. When the
loom control computer C2 outputs the weaving operation stop signal to the selecting
circuit 19 (Fig. 7, S26), the first rotation control pattern is selected by the selecting
circuit 19 (Fig. 7, step S27).
[0034] In the case of the third embodiment of the invention, the first rotation control
pattern is selected only during a period intervening between the start of the loom
operation and the steady operation state thereof and a period intervening between
the steady operation state and stoppage of the loom operation. However, in the instant
embodiment, substantially same advantageous effects as those described hereinbefore
in conjunction with the first embodiment can be obtained. In addition, because the
arithmetic processing for determining change in the rotation speed is rendered unnecessary
according to the instant embodiment of the invention, the control or procedure for
detecting change in the rotation speed of the loom can be much simplified, to a further
advantage.
[0035] Many features and advantages of the present invention are apparent from the detailed
description and thus it is intended by the appended claims to cover all such features
and advantages of the system which fall within the true spirit and scope of the invention.
Further, since numerous modifications and combinations will readily occur to those
skilled in the art, it is not intended to limit the invention to the exact construction
and operation illustrated and described.
[0036] By way of example, in the case of the loom in which the operation speed thereof changes
only during the weaving operation, the first rotation control pattern may be selected
only during the weaving operation. Further, the second rotation control pattern may
be prepared on the basis of the rotation speed of the loom set previously for the
steady operation.
[0037] Further, the first embodiment may be so modified that the first rotation control
pattern is selected during a predetermined period starting from the time point at
which the loom start signal is inputted. With such modification, detection of the
rotation speed change of the loom can be spared, whereby the control system can correspondingly
be simplified. To this end, the first rotation control pattern may be selected in
response to the input of the loom operation stop signal.
[0038] Besides, change-over between the first rotation control pattern and the second rotation
control pattern may be performed at a time point at which the rotational positions
of the shedding drive motor in both patterns intersect with each other. In that case,
the shock which may occur upon changing-over of the first and second rotation control
patterns can be mitigated, which in turn means that stability of the control system
can be enhanced.
[0039] Accordingly, all suitable modifications and equivalents may be resorted to, falling
within the spirit and scope of the invention.
[0040] In a shedding apparatus for driving a heald frame assembly of a loom by a shedding
drive motor installed independent of a loom driving motor, a shedding control apparatus
which can ensure enhanced stability of motion of the heald frame while suppressing
the power consumption to a minimum. The shedding control apparatus for controlling
the shedding drive motor through a feedback loop includes a first rotation control
pattern storing unit for storing a first rotation control pattern, a second rotation
control pattern storing unit for storing a second one, a control pattern generating
circuit for generating the second rotation control pattern and a selecting circuit.
The control pattern generating circuit generates the second rotation control pattern
on the basis of the rotation speed information obtained from a rotary encoder. The
selecting circuit is so designed as to select the first or second rotation control
patterns on the basis of the rotation speed changing information obtained from the
rotary encoder.