This study aimed to develop a dynamic model of a roller carding machine. The roller carding machine used in this study comprised one set each of feed conveyors, feed rollers, licker-in rollers, clothing rollers, a set consisting of a cylinder and doffer and two sets of carding rollers/stripping rollers. In order to establish a dynamic mathematical model of a roller carding machine, this study derived the transfer rate and collecting power of cotton web from the mode of movement, relative velocity, clothing tooth angle and friction force of the main rollers of the system. The transfer delay time of the cotton web was deduced from the clearance among working rollers, corresponding angle of roller center, and angular velocity. Finally, the correctness of the dynamic mathematical model of the roller carding machine derived in this study has been proved from the experiment.
The current roller carding machine control methods lack in the theoretical basis of using an auto-leveler, and are limited to the control of the cotton web layer thickness or the input amount of fibers. When the input amount changes, the output response is relatively slow, thus resulting in considerable impact on fiber web quality. Therefore, this study first established the theoretical modeling, and validated the dynamic mathematical model of the roller carding machine. This study used the sliding mode control in the design of the controller to control uniformity of the output fiber web of the roller carding machine. The sliding mode control used in this study was to allow the system to move in the dynamic process according to the pre-determined sliding mode trajectory, and then use the preset approximation conditions and switching conditions as the control law to navigate the system, in order to achieve the control objectives. Under the sliding mode control, with robust performance to suppress external disturbances and appropriate design of the sliding surface and boundary layer, dynamic model analysis and control adjustment for the system can be implemented to achieve the control objectives and uniform fiber web output. The experimental results confirmed that sliding mode control can effectively control fiber web uniformity of the roller carding machine.
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