CN114411428A - Closed-loop control device and method based on point laser cloth seam detection - Google Patents

Closed-loop control device and method based on point laser cloth seam detection Download PDF

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Publication number
CN114411428A
CN114411428A CN202111650931.2A CN202111650931A CN114411428A CN 114411428 A CN114411428 A CN 114411428A CN 202111650931 A CN202111650931 A CN 202111650931A CN 114411428 A CN114411428 A CN 114411428A
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cloth
module
detected
height
seam
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CN114411428B (en
Inventor
陈一信
陈浙泊
叶雪旺
余建安
陈镇元
陈龙威
张一航
林建宇
潘凌锋
陈逸宸
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Research Institute of Zhejiang University Taizhou
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Research Institute of Zhejiang University Taizhou
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Priority to CN202111650931.2A priority Critical patent/CN114411428B/en
Priority to CN202311000639.5A priority patent/CN117030727A/en
Priority to CN202310993859.6A priority patent/CN117030725A/en
Publication of CN114411428A publication Critical patent/CN114411428A/en
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/8914—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the material examined
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/02—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/06—Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness for measuring thickness ; e.g. of sheet material
    • G01B11/0608—Height gauges
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/01—Arrangements or apparatus for facilitating the optical investigation
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/8901—Optical details; Scanning details
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01V—GEOPHYSICS; GRAVITATIONAL MEASUREMENTS; DETECTING MASSES OR OBJECTS; TAGS
    • G01V8/00—Prospecting or detecting by optical means
    • G01V8/10—Detecting, e.g. by using light barriers
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D3/00—Control of position or direction
    • G05D3/12—Control of position or direction using feedback
    • G05D3/20—Control of position or direction using feedback using a digital comparing device
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/01—Arrangements or apparatus for facilitating the optical investigation
    • G01N2021/0106—General arrangement of respective parts
    • G01N2021/0112—Apparatus in one mechanical, optical or electronic block
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The invention relates to a closed-loop control device and a closed-loop control method based on point laser cloth seam detection, wherein the device part comprises a transmission assembly line, a laser detection module, a polishing module, an image acquisition module, a speed detection module, an installation frame and a processing module; the mounting frame is arranged relative to the transmission assembly line; the mounting frame comprises an upper layer and a lower layer, wherein the lower layer mounting frame is fixedly connected with the external support structure, the upper layer mounting frame is arranged on the lower layer mounting frame in a sliding manner, and a driving module is arranged between the upper layer mounting frame and the lower layer mounting frame; the laser detection module and the speed detection module are arranged on the mounting frame; the polishing module and the image acquisition module are close to the position of the transmission production line, and the image acquisition module faces the cloth; the processing module is respectively connected with the laser detection module and the image acquisition module; the invention improves the automation degree of the transmission assembly line, avoids the defect of manual detection of cloth seams and avoids the harm of toxic gas emitted by the cloth and glue to personnel.

Description

Closed-loop control device and method based on point laser cloth seam detection
Technical Field
The invention relates to the field of point laser detection, in particular to a closed-loop control device and method based on point laser cloth seam detection.
Background
Synthetic leather is an artificial leather that requires a dye on the surface of a piece of cloth. In the existing production technology, the process of coating the dye is to scrape the dye on the surface of the cloth through a pressing knife, wherein the scraping knife keeps a certain distance from the cloth; in order to ensure the continuity of a cloth production line, adjacent cloth is connected through a joint, when the joint passes through the scraper, the scraper needs to be lifted for a certain distance, and the joint part of the cloth is prevented from being broken by the scraper. In the current factory, the timing of the blade raising and lowering is achieved by manually observing the position of the joint and manually operating the jump switch button.
In the process of manually controlling the jump cutter key, due to the problems of single color or rich color of cloth, close color of the cloth and the joint, unstable transmission speed of a production line and the like, the problems easily cause visual fatigue of human eyes and influence on judgment of the jump cutter opportunity. On the other hand, when people are changed or other off duty situations occur, the engineering accidents of false triggering and missed detection are easily caused, the production progress of a factory is seriously delayed, and properties are seriously lost. Furthermore, manual operation of the jump blade requires sufficient experience because the production line is running continuously, wherein the width of the seam is about 1-2CM, if the jump blade is too early, the synthetic leather part close to the seam is not coated with glue or dye, and if the jump blade is too late, the joint is cut off, and the cloth is torn off.
Furthermore, the angle of the seam is ideally 90 degrees, but sometimes the angle of the cloth seam may deviate by more than 10 degrees, so that the effect of controlling the fixed distance of the knife is not ideal and the knife is easily interfered by the scraper at the position where the seam starts or ends. Therefore, a machine vision algorithm is needed to help realize the detection of the seam and assist in judging the time of the cutter jump.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a closed-loop control device and a closed-loop control method based on point laser cloth seam detection.
In order to solve the problems, the invention adopts the following technical scheme:
a closed-loop control device based on point laser cloth seam detection comprises a transmission assembly line, a laser detection module, a polishing module, an image acquisition module, a speed detection module, an installation frame and a processing module; wherein the mounting frame is arranged relative to the transmission assembly line; the mounting frame comprises an upper layer and a lower layer, wherein the lower layer mounting frame is fixedly connected with the external supporting structure, the upper layer mounting frame is arranged on the lower layer mounting frame in a sliding manner, a driving module is also arranged between the upper layer mounting frame and the lower layer mounting frame, and the driving module is used for controlling the displacement of the upper layer mounting frame relative to the lower layer mounting frame; the laser detection module and the speed detection module are arranged on the mounting frame; the polishing module and the image acquisition module are close to the transmission assembly line, the image acquisition module faces the cloth, and the polishing module is used for polishing the image acquisition module; the processing module is respectively connected with the laser detection module and the image acquisition module.
Further, the transport pipeline includes a drum; the cloth is driven by the rotation of the roller; the mounting bracket totally is two, and two mounting brackets set up side by side, and wherein two mounting brackets correspond the left part and the right part of cylinder respectively.
Furthermore, the driving module on the mounting rack is of a lead screw transmission structure, wherein a lead screw in the lead screw transmission structure is fixedly arranged on the lower mounting rack, and one end of the lead screw is also connected with the motor; a sliding block in the lead screw transmission structure is fixedly connected with the upper mounting rack; along with the rotation of motor, the slider can drive and produce relative movement between upper mounting bracket and the lower floor's mounting bracket.
A closed-loop control method based on point laser cloth seam detection comprises the following steps:
step 1: starting a start-up processing module to complete system self-checking and data initialization;
step 2: judging whether the edges of the left side and the right side of the cloth are out of range or not through a laser detection module; if the border of the cloth is not out of range, recording the edges of the left side and the right side of the cloth; if not, marking the corresponding edge as out-of-range, and ending the step;
and step 3: acquiring the movement speed of the cloth through a roller encoder of a speed detection module;
and 4, step 4: judging whether the cloth height mutation part is induced or not through a laser detection module; if the highly mutated part is detected, entering step 5; otherwise, returning to the step 3;
and 5: judging the cause of the highly abrupt change part, including seams and flaws, through the detection numerical difference of the laser detection module; if judging that the joint is a seam, entering a step 6; if the defect is judged, controlling a phase image acquisition module to acquire an image of the defect part, recording the position and the photographing time of the defect part, and returning to the step 3;
step 6: the processing module obtains a lifting time point, a lifting height and a lifting cutter holding time of the scraper according to the transmission speed of the cloth, the transmission distance from the hanging cutter to the laser detection module, the detection value and the compensation value of the laser detection module; and controlling the scraper to act;
and 7: the camera module collects images lifted by the scraper and transmits the images to the processing module;
and 8: and the processing module acquires the image of the lifted scraper, calibrates the image, acquires the compensation of the lifting action of the scraper, including the compensation value of the cutter lifting holding time, and returns to the step 3.
Further, in the step 2, judging whether the left and right edges of the cloth are out of range includes the following steps:
step 21: whether a deviation rectifying module on the mounting frame receives a signal or not; if the signal is received, go to step 22; if the signal is not received, returning to the step 21;
step 22: the deviation rectifying module receives the signal and judges whether the deviation rectifying module of the left part mounting frame is the deviation rectifying module of the right part mounting frame; if the deviation correcting module is the deviation correcting module of the left mounting frame, the step 23 is carried out; if the deviation correcting module is the deviation correcting module of the right part mounting rack, the step 24 is carried out;
step 23: when the deviation rectifying module on the left part mounting rack receives signal input, the screw rod transmission structure on the left part mounting rack is started to control the upper layer mounting rack to move, and whether the edge of the left cloth is detected or not is judged through the deviation rectifying module on the upper layer mounting rack; if the left cloth edge is detected, controlling the screw transmission structure to enable the left cloth edge to be located between the detection parts of the two deviation correction sensors of the deviation correction module, and entering step 24; if the left cloth edge is not detected, go to step 27;
step 24: acquiring the position of the left edge according to the transmission length of the lead screw transmission structure, recording and entering step 211;
step 25: when the deviation rectifying module on the right part mounting rack receives signal input, the screw rod transmission structure on the right part mounting rack is started to control the upper layer mounting rack to move, and whether the edge of the right cloth is detected or not is judged through the deviation rectifying module on the upper layer mounting rack; if the edge of the right cloth is detected, controlling the screw transmission structure to enable the edge of the right cloth to be located between the detection parts of the two deviation rectifying sensors of the deviation rectifying module, and entering step 26; if the left cloth edge is not detected, go to step 27;
step 26: acquiring the position of the left edge according to the transmission length of the lead screw transmission structure, recording and entering step 211;
step 27: if the cloth edge of one side is not detected, continuing to detect the cloth edge of the side, alarming if the cloth edge is not detected for a set duration, and entering step 28;
step 28: if the edge of one side is not detected within the duration set time, judging whether the side detects cloth or not; if the cloth is detected, go to step 29; if no piece of cloth is detected, go to step 210;
step 29: if the cloth is detected on the side but the edge is not detected, judging whether the cloth is detected on the other side; if the cloth on the other side is not detected, the cloth is considered to be out of bounds at the side edge, and the step is finished; if the other side detects cloth, the sensor is considered to be in fault, and the step is ended;
step 210: if the cloth and the cloth edge are not detected on the side, judging whether the cloth is detected on the other side; if the cloth on the other side is not detected, the sensor is considered to be in fault or the cloth is not transmitted, and the step is ended; if the cloth on the other side is detected, the cloth is considered to be out of bounds at the edge of the other side, and the step is finished;
step 211: and acquiring the position of the other side edge of the cloth, and converting the positions of the two side edges to obtain the width of the cloth, and ending the step.
Further, the process of judging whether the cloth height mutation part is sensed in the step 4 comprises the following steps:
step 41: recording height signal values detected by two laser detection modules on the same side of the mounting rack;
step 42: the two laser detection modules on the same side of the mounting rack are differenced to obtain the cloth height;
step 43: judging whether the cloth height value is suddenly changed or not; if mutation occurs, go to step 44; otherwise, returning to step 41;
step 44: judging whether the amplitude and the width of the abrupt change region of the cloth height meet set requirements or not; if the set requirement is met, recording a cloth signal of the mutation area, and ending the step; if the setting requirements are not satisfied, the process returns to step 41.
Further, the step 5 of judging the cause of the cloth mutation part comprises the following steps:
step 51: acquiring a cloth height mutation area, and storing a cloth height difference value into a PLC storage bit; in the mutation area, storing each piece of cloth height data, numbering until the piece of cloth height data is stored to a set upper limit of the number, and restarting numbering;
step 52: using adjacent values in the PLC storage bit to make difference to obtain A, then dividing the difference by the sampling period of the adjacent values, and calculating a catastrophe point k of the cloth height variation waveform; wherein, the mutation point of the cloth height variation waveform represents the time when the waveform changes from negative to positive, namely the time when the cloth height is the highest;
step 53: obtaining the cloth height at the corresponding moment according to the time axis of the catastrophe point k;
step 54: according to the set seam width, x mutation area sampling points are respectively taken before and after a mutation point k;
step 55: obtaining the integral area of the cloth height waveform corresponding to the sampling point part in the step 54;
step 56: judging whether the signal width of the mutation region is larger than a set seam width A or not; if yes, go to step 57; otherwise, go to step 510;
and 57: judging whether the cloth height corresponding to a mutation point k of the mutation region is greater than a set seam height L or not; if yes, go to step 58; otherwise, go to step 510;
step 58: judging whether the integral area obtained in step 55 is larger than a set value M; if yes, go to step 59; otherwise, go to step 510;
step 59: judging whether the mounting racks on the left side and the right side detect sudden changes of the cloth height within a set time length T or not; if so, considering the abrupt change area of the cloth height as a seam, and ending the step; otherwise, go to step 510;
step 510: and (5) finishing the step when the mutation area of the cloth height is a flaw.
Further, the step 6 of controlling the scraper action comprises the following steps:
step 61: judging the height change of the cloth as a seam, and acquiring the lifting time of the scraper according to the transmission speed of the cloth and the transmission distance from the hanging knife to the laser detection module;
step 62: according to the time difference of the seam detected by the left mounting rack and the right mounting rack, combining the distance between the left mounting rack and the right mounting rack to obtain the angle of the seam;
and step 63: obtaining the projection length of the seam in the cloth conveying direction according to the angle of the seam and the width of the cloth;
step 64: obtaining the cutter lifting holding time according to the projection length of the cloth in the cloth conveying direction and the cloth conveying speed;
step 65: obtaining the lifting height of the scraper according to the detected cloth height;
and step 66: and compensating the obtained cutter lifting holding time, and controlling the scraper to act according to the compensated numerical value and by combining the scraper lifting time and the scraper lifting height.
Further, the obtaining of the compensation value of the blade lifting action by the processing module specifically includes the following steps:
step 81: the image acquisition module acquires an image and transmits the image to the processing module for storage and recording;
step 82: according to the time difference of the seam detected by the left mounting rack and the right mounting rack, combining the distance between the left mounting rack and the right mounting rack to obtain the angle of the seam;
step 83: and obtaining a calculation compensation value of the cutter lifting holding time according to the angle of the joint.
The invention has the beneficial effects that:
the laser detection module is arranged on the mounting frame and faces the cloth, so that the cloth transmission is detected, the automation degree of a transmission assembly line is improved, the defect of manual detection is avoided, and the harm of toxic gas emitted by the cloth and glue to personnel is also avoided;
the method comprises the steps that the difference is made between the numerical values detected by two laser detection modules on the same mounting frame to obtain the height of the cloth, the change of the height of the cloth is monitored to obtain a mutation area, and then seams or flaws of the cloth are obtained;
obtaining a compensation value of the scraper lifting action through the angle of the joint to form closed-loop control and ensure the accuracy of the cutter lifting action;
by detecting the edge of the cloth, the cloth is alarmed in time when the cloth is out of bounds and is not transmitted.
Drawings
FIG. 1 is a schematic structural diagram of an apparatus according to a first embodiment of the present invention;
FIG. 2 is a schematic diagram of a second apparatus according to a first embodiment of the present invention;
FIG. 3 is a flowchart illustrating a seam detection process according to a first embodiment of the present invention;
FIG. 4 is a flowchart illustrating a process of determining cause of highly abrupt change portions of cloth according to a first embodiment of the present invention;
FIG. 5 is a flowchart illustrating the operation of the scraper control apparatus according to the first embodiment of the present invention;
FIG. 6 is a flowchart illustrating a compensation value obtaining process according to a first embodiment of the present invention;
FIG. 7 is a schematic diagram illustrating a relationship between a piece of cloth and a scraper and a laser detection module according to a first embodiment of the present invention;
FIG. 8 is a schematic view of a piece goods seam according to a first embodiment of the present invention being inclined;
fig. 9 is a flowchart illustrating the acquisition of the compensation value of the blade lifting time according to the first embodiment of the present invention.
The attached drawings indicate the following: the device comprises a transmission assembly line 1, a laser detection module 2, a mounting rack 3, an upper mounting rack 31, a lower mounting rack 32, a driving module 33, a deviation correction module 34, a deviation correction sensor 341, an image acquisition module 4 and a scraper 5.
Detailed Description
The embodiments of the present invention are described below with reference to specific embodiments, and other advantages and effects of the present invention will be easily understood by those skilled in the art from the disclosure of the present specification. The invention is capable of other and different embodiments and of being practiced or of being carried out in various ways, and its several details are capable of modification in various respects, all without departing from the spirit and scope of the present invention. It is to be noted that the features in the following embodiments and examples may be combined with each other without conflict.
It should be noted that the drawings provided in the following embodiments are only for illustrating the basic idea of the present invention, and the components related to the present invention are only shown in the drawings rather than drawn according to the number, shape and size of the components in actual implementation, and the type, quantity and proportion of the components in actual implementation may be changed freely, and the layout of the components may be more complicated.
The first embodiment is as follows:
as shown in fig. 1 and 2, a closed-loop control device based on point laser cloth seam detection comprises a transmission assembly line 1, a laser detection module 2, a polishing module, an image acquisition module 4, a speed detection module, an installation frame 3 and a processing module; wherein the mounting frame is arranged relative to the transmission assembly line; the mounting frame comprises an upper layer and a lower layer, wherein the lower layer mounting frame 32 is fixedly connected with an external supporting structure, the upper layer mounting frame 31 is arranged on the lower layer mounting frame 32 in a sliding manner, a driving module 33 is also arranged between the upper layer mounting frame and the lower layer mounting frame, and the driving module 33 is used for controlling the displacement of the upper layer mounting frame relative to the lower layer mounting frame; the laser detection module and the speed detection module are arranged on the mounting frame; the polishing module and the image acquisition module are close to the position of the transmission production line, the image acquisition module 4 faces the cloth, and the polishing module is used for polishing the image acquisition module; the processing module is respectively connected with the laser detection module and the image acquisition module.
The transport pipeline comprises a drum; the cloth is driven by the rotation of the roller on the transmission production line. Wherein cloth all can carry out face contact with the cylinder in transmission process, and the tensioning of cloth is guaranteed to the one of them, avoids cloth fold, and its two reinforcing cloth and cylinder frictional force avoid cloth to skid in transmission process. In this case, the mounting frame is arranged at a roller location on the transport line and the roller is spaced from the doctor blade 5 by a set transport length.
The mounting bracket totally two, two mounting brackets set up side by side, and wherein two mounting brackets correspond the left part and the right part of cylinder respectively. The driving module on the mounting rack is of a lead screw transmission structure, wherein a lead screw in the lead screw transmission structure is fixedly arranged on the lower mounting rack, and one end of the lead screw is also connected with the motor; and a sliding block in the lead screw transmission structure is fixedly connected with the upper mounting rack. Along with the rotation of motor, the slider can drive and produce relative movement between upper mounting bracket and the lower floor's mounting bracket, and the edge of cloth is tracked to the laser detection module on the mounting bracket of the lower floor of being convenient for.
The laser detection modules comprise high-precision point lasers, in the embodiment, the number of the laser detection modules is four, and the four laser detection modules are respectively arranged at the upper layer and the lower layer of the two mounting frames; the laser detection module positioned on the upper layer is arranged close to the middle part of the roller and used for detecting the distance of the cloth, so that the seam position can be conveniently found; the two laser detection modules positioned on the lower layer are arranged close to two ends of the roller and used for detecting the distance of the roller. The thickness of the cloth can be obtained by making a difference in the distance value of the laser detection module. It should be noted that the detection positions of the four laser detection modules on the cloth are located on the same straight line, and the straight line is perpendicular to the conveying direction of the cloth.
The polishing module comprises an industrial light source and faces the cloth.
The speed detection module comprises a roller encoder for detecting the transmission speed of the cloth.
The image acquisition module 4 comprises a visual camera, and the image acquired by the image acquisition module is transmitted to a processing module, wherein the processing module is a computer in the example; the image acquisition module is used for acquiring images. The image acquisition module is in this case directed towards the nip area between the blade 5 and the cloth.
Still be provided with on the mounting bracket and rectify module 34, wherein rectify module 34 and set up in the edge of upper mounting bracket, rectify the module and be located the one end that is close to the cloth edge on the upper mounting bracket, for example correspond the module of rectifying on the upper mounting bracket of cylinder left part and be located leftmost side. One deviation rectifying module comprises two deviation rectifying sensors 341, one of which is arranged at the inner side, the other one is arranged at the outer side, and the two deviation rectifying sensors 341 of one deviation rectifying module are spaced by a set distance and face to the cloth.
As shown in fig. 3-9, a closed-loop control method based on spot laser cloth seam detection includes the following steps:
step 1: starting a start-up processing module to complete system self-checking and data initialization;
step 2: judging whether the edges of the left side and the right side of the cloth are out of range or not through a laser detection module; if the border of the cloth is not out of range, recording the edges of the left side and the right side of the cloth; if not, marking the corresponding edge as out-of-range, and ending the step;
and step 3: acquiring the movement speed of the cloth through a roller encoder of a speed detection module;
and 4, step 4: judging whether the cloth height mutation part is induced or not through a laser detection module; if the highly mutated part is detected, entering step 5; otherwise, returning to the step 3;
and 5: judging the cause of the highly abrupt change part, including seams and flaws, through the detection numerical difference of the laser detection module; if judging that the joint is a seam, entering a step 6; if the defect is judged, controlling a phase image acquisition module to acquire an image of the defect part, recording the position and the photographing time of the defect part, and returning to the step 3;
step 6: the processing module obtains a lifting time point, a lifting height and a lifting cutter holding time of the scraper according to the transmission speed of the cloth, the transmission distance from the hanging cutter to the laser detection module, the detection value and the compensation value of the laser detection module and the like; and controlling the scraper to act;
and 7: the camera module collects images lifted by the scraper and transmits the images to the processing module;
and 8: and the processing module acquires the image of the lifted scraper, calibrates the image, acquires the compensation of the lifting action of the scraper, including the compensation value of the cutter lifting holding time, and returns to the step 3.
In the step 2, judging whether the edges of the left side and the right side of the cloth are out of range or not comprises the following steps:
step 21: whether a deviation rectifying module on the mounting frame receives a signal or not; if the signal is received, go to step 22; if the signal is not received, returning to the step 21;
step 22: the deviation rectifying module receives the signal and judges whether the deviation rectifying module of the left part mounting frame is the deviation rectifying module of the right part mounting frame; if the deviation correcting module is the deviation correcting module of the left mounting frame, the step 23 is carried out; if the deviation correcting module is the deviation correcting module of the right part mounting rack, the step 24 is carried out;
step 23: when the deviation rectifying module on the left part mounting rack receives signal input, the screw rod transmission structure on the left part mounting rack is started to control the upper layer mounting rack to move, and whether the edge of the left cloth is detected or not is judged through the deviation rectifying module on the upper layer mounting rack; if the left cloth edge is detected, controlling the screw transmission structure to enable the left cloth edge to be located between the detection parts of the two deviation correction sensors of the deviation correction module, and entering step 24; if the left cloth edge is not detected, go to step 27;
step 24: acquiring the position of the left edge according to the transmission length of the lead screw transmission structure, recording and entering step 211;
step 25: when the deviation rectifying module on the right part mounting rack receives signal input, the screw rod transmission structure on the right part mounting rack is started to control the upper layer mounting rack to move, and whether the edge of the right cloth is detected or not is judged through the deviation rectifying module on the upper layer mounting rack; if the edge of the right cloth is detected, controlling the screw transmission structure to enable the edge of the right cloth to be located between the detection parts of the two deviation rectifying sensors of the deviation rectifying module, and entering step 26; if the left cloth edge is not detected, go to step 27;
step 26: acquiring the position of the left edge according to the transmission length of the lead screw transmission structure, recording and entering step 211;
step 27: if the cloth edge of one side is not detected, continuing to detect the cloth edge of the side, alarming if the cloth edge is not detected for a set duration, and entering step 28; in this example, the set time period is 1 minute;
step 28: if the edge of one side is not detected within the duration set time, judging whether the side detects cloth or not; if the cloth is detected, go to step 29; if no piece of cloth is detected, go to step 210;
step 29: if the cloth is detected on the side but the edge is not detected, judging whether the cloth is detected on the other side; if the cloth on the other side is not detected, the cloth is considered to be out of bounds at the side edge, and the step is finished; if the other side detects cloth, the sensor is considered to be in fault, and the step is ended;
step 210: if the cloth and the cloth edge are not detected on the side, judging whether the cloth is detected on the other side; if the cloth on the other side is not detected, the sensor is considered to be in fault or the cloth is not transmitted, and the step is ended; if the cloth on the other side is detected, the cloth is considered to be out of bounds at the edge of the other side, and the step is finished;
step 211: and acquiring the position of the other side edge of the cloth, and converting the positions of the two side edges to obtain the width of the cloth, and ending the step.
In step 211, the converted cloth width is compared with an input cloth width set value, and if the difference value is greater than a set positive threshold value, the sensor is considered to be abnormal, and an alarm is given; if the difference value is smaller than the set negative threshold value, the cloth is considered to be curled, and an alarm is given.
The process of judging whether the highly mutation part of the cloth is induced in the step 4 comprises the following steps:
step 41: recording height signal values detected by two laser detection modules on the same side of the mounting rack;
step 42: the two laser detection modules on the same side of the mounting rack are differenced to obtain the cloth height;
step 43: judging whether the cloth height value is suddenly changed or not; if mutation occurs, go to step 44; otherwise, returning to step 41;
step 44: judging whether the amplitude and the width of the abrupt change region of the cloth height meet set requirements or not; if the set requirement is met, recording a cloth signal of the mutation area, and ending the step; if the setting requirements are not satisfied, the process returns to step 41.
The step 5 of judging the cause of the cloth mutation part comprises the following steps:
step 51: acquiring a cloth height mutation area, and storing a cloth height difference value into a PLC storage bit; in the mutation area, storing each piece of cloth height data, numbering until the piece of cloth height data is stored to a set upper limit of the number, and restarting numbering;
step 52: using adjacent values in the PLC storage bit to make difference to obtain A, then dividing the difference by the sampling period of the adjacent values, and calculating a catastrophe point k of the cloth height variation waveform; wherein, the mutation point of the cloth height variation waveform represents the time when the waveform changes from negative to positive, namely the time when the cloth height is the highest;
step 53: obtaining the cloth height at the corresponding moment according to the time axis of the catastrophe point k;
step 54: according to the set seam width, x mutation area sampling points are respectively taken before and after a mutation point k;
step 55: obtaining the integral area of the cloth height waveform corresponding to the sampling point part in the step 54;
step 56: judging whether the signal width of the mutation region is larger than a set seam width A or not; if yes, go to step 57; otherwise, go to step 510;
and 57: judging whether the cloth height corresponding to a mutation point k of the mutation region is greater than a set seam height L or not; if yes, go to step 58; otherwise, go to step 510;
step 58: judging whether the integral area obtained in step 55 is larger than a set value M; if yes, go to step 59; otherwise, go to step 510;
step 59: judging whether the mounting racks on the left side and the right side detect sudden changes of the cloth height within a set time length T or not; if so, considering the abrupt change area of the cloth height as a seam, and ending the step; otherwise, go to step 510;
step 510: and (5) finishing the step when the mutation area of the cloth height is a flaw.
The step 6 of controlling the scraper action comprises the following steps:
step 61: judging the height change of the cloth as a seam, and acquiring the lifting time of the scraper according to the transmission speed of the cloth and the transmission distance from the hanging knife to the laser detection module;
step 62: according to the time difference of the seam detected by the left mounting rack and the right mounting rack, combining the distance between the left mounting rack and the right mounting rack to obtain the angle of the seam;
and step 63: obtaining the projection length of the seam in the cloth conveying direction according to the angle of the seam and the width of the cloth;
step 64: obtaining the cutter lifting holding time according to the projection length of the cloth in the cloth conveying direction and the cloth conveying speed;
step 65: obtaining the lifting height of the scraper according to the detected cloth height;
and step 66: and compensating the obtained cutter lifting holding time, and controlling the scraper to act according to the compensated numerical value, the lifting time of the scraper and the lifting height of the scraper.
The cloth height in said step 65 is the highest height in the cloth height variation waveform.
In step 6, the lifting time point t of the blade is calculated by the following formula:
Figure BDA0003444467270000111
s represents the transmission distance from the cloth position detected by the laser detection module to the scraper position; b represents the width of the part without glue before and after the set joint, namely the distance of the cloth moving when the scraper is lifted; v represents the cloth transport speed; t represents the time interval from the detection of the seam by the laser detection module to the blade lift.
In the step 8, the processing module obtains the compensation of the blade lifting action, in this example, the compensation value of the blade lifting time is included, and the obtaining of the compensation value specifically includes the following steps:
step 81: the image acquisition module acquires an image and transmits the image to the processing module for storage and recording;
step 82: according to the time difference of the seam detected by the left mounting rack and the right mounting rack, combining the distance between the left mounting rack and the right mounting rack to obtain the angle of the seam;
step 83: and obtaining a calculation compensation value of the cutter lifting holding time according to the angle of the joint.
In the step 83, a calculated compensation value of the cutter lifting holding time is obtained through the following processes:
firstly, acquiring a distance AB between a right laser detection module on the upper layer of a left mounting frame and a laser detection module on the upper layer of a right mounting frame, and detecting a time difference delta t of a seam; the distance AB can be obtained through the transmission distance of the driving module;
and obtaining a distance difference AF when the laser detection modules at two sides detect the seam through the time difference delta t and the cloth transmission speed V:
AF＝Δt*V
and obtaining the projection length CD of the seam in the conveying direction according to the distance difference AF and the set cloth width ED:
Figure BDA0003444467270000121
according to the projection length CD, the obtained compensation distance L is:
L＝(CD+b)-Hvision
Wherein HVisionShowing the movement length of the cloth during the cutter lifting process obtained by visual calculation, namely the length of the non-glued area before and after the seam of the cloth; finally obtaining the compensation value t of the cutter lifting timeSupplement deviceComprises the following steps:
Figure BDA0003444467270000122
in the implementation process, on the basis of the last cutter lifting holding time, the angle factor of the joint is introduced, the compensation of the cutter lifting time is realized, and the accuracy of the cutter lifting time is ensured.
The acquisition of the cloth movement length during the blade lifting comprises the following steps:
step 831: the processing module acquires a cloth image after the scraper falls;
step 832: preprocessing the image, including mean filtering processing, dynamic threshold processing and the like;
step 833: extracting a bright area in the image and obtaining a skeleton of the bright area; the framework area comprises a boundary line and a seam line of the glue coating area and the non-glue coating area after the scraper is lifted;
step 834: fitting the skeleton into a straight line, and obtaining a normal vector of the straight line;
step 835: judging the number of straight lines contained in the obtained image; if 0 or one straight line is included, go back to step 831; if two straight lines are included, proceed to step 836: if three straight lines are included, indicating that the skeleton-fitted straight line of the seam line is also extracted, the second straight line in the middle is removed, and the process proceeds to step 836;
step 836: acquiring two straight lines on the image, and acquiring the distance between the two straight lines according to the normal vector;
step 837: and obtaining the actual cloth motion length during the cutter lifting period according to the linear distance in the image and the proportional relation between the image and the actual scene, and ending the step.
In step 833, since the width, height, etc. of the seam are different, the skeleton of the seam line image cannot necessarily be extracted; if the skeleton of the seam region is extracted, it is considered a disturbance and is removed in step 835.
The above description is only one specific example of the present invention and should not be construed as limiting the invention in any way. It will be apparent to persons skilled in the relevant art(s) that, having the benefit of this disclosure and its principles, various modifications and changes in form and detail can be made without departing from the principles and structures of the invention, which are, however, encompassed by the appended claims.

Claims (10)

1. A closed-loop control device based on point laser cloth seam detection is characterized by comprising a transmission assembly line, a laser detection module, a polishing module, an image acquisition module, a speed detection module, an installation frame and a processing module; wherein the mounting frame is arranged relative to the transmission assembly line; the mounting frame comprises an upper layer and a lower layer, wherein the lower layer mounting frame is fixedly connected with the external supporting structure, the upper layer mounting frame is arranged on the lower layer mounting frame in a sliding manner, a driving module is also arranged between the upper layer mounting frame and the lower layer mounting frame, and the driving module is used for controlling the displacement of the upper layer mounting frame relative to the lower layer mounting frame; the laser detection module and the speed detection module are arranged on the mounting frame; the polishing module and the image acquisition module are close to the transmission assembly line, the image acquisition module faces the cloth, and the polishing module is used for polishing the image acquisition module; the processing module is respectively connected with the laser detection module and the image acquisition module.
2. The closed loop control device based on point laser cloth seam detection as claimed in claim 1, wherein the transport line comprises a drum; the cloth is driven by the rotation of the roller; the mounting bracket totally is two, and two mounting brackets set up side by side, and wherein two mounting brackets correspond the left part and the right part of cylinder respectively.
3. The closed-loop control device based on point laser cloth seam detection as claimed in claim 2, wherein the driving module on the mounting rack is a lead screw transmission structure, wherein a lead screw in the lead screw transmission structure is fixedly arranged on the lower mounting rack, and one end of the lead screw is further connected with a motor; a sliding block in the lead screw transmission structure is fixedly connected with the upper mounting rack; along with the rotation of motor, the slider can drive and produce relative movement between upper mounting bracket and the lower floor's mounting bracket.
4. A closed-loop control method based on point laser cloth seam detection is characterized by comprising the following steps:
step 1: starting a start-up processing module to complete system self-checking and data initialization;
step 2: judging whether the edges of the left side and the right side of the cloth are out of range or not through a laser detection module; if the border of the cloth is not out of range, recording the edges of the left side and the right side of the cloth; if not, marking the corresponding edge as out-of-range, and ending the step;
and step 3: acquiring the movement speed of the cloth through a roller encoder of a speed detection module;
and 4, step 4: judging whether the cloth height mutation part is induced or not through a laser detection module; if the highly mutated part is detected, entering step 5; otherwise, returning to the step 3;
and 5: judging the cause of the highly abrupt change part, including seams and flaws, through the detection numerical difference of the laser detection module; if judging that the joint is a seam, entering a step 6; if the defect is judged, controlling a phase image acquisition module to acquire an image of the defect part, recording the position and the photographing time of the defect part, and returning to the step 3;
step 6: the processing module obtains a lifting time point, a lifting height and a lifting cutter holding time of the scraper according to the transmission speed of the cloth, the transmission distance from the hanging cutter to the laser detection module, the detection value and the compensation value of the laser detection module; and controlling the scraper to act;
and 7: the camera module collects images lifted by the scraper and transmits the images to the processing module;
and 8: and the processing module acquires the image of the lifted scraper, calibrates the image, acquires the compensation of the lifting action of the scraper, including the compensation value of the cutter lifting holding time, and returns to the step 3.
5. The closed-loop control method based on point laser cloth seam detection as claimed in claim 4, wherein in the step 2, judging whether the left and right edges of the cloth are out of range comprises the following steps:
step 21: whether a deviation rectifying module on the mounting frame receives a signal or not; if the signal is received, go to step 22;
if the signal is not received, returning to the step 21;
step 22: the deviation rectifying module receives the signal and judges whether the deviation rectifying module of the left part mounting frame is the deviation rectifying module of the right part mounting frame; if the deviation correcting module is the deviation correcting module of the left mounting frame, the step 23 is carried out; if the deviation correcting module is the deviation correcting module of the right part mounting rack, the step 24 is carried out;
step 23: when the deviation rectifying module on the left part mounting rack receives signal input, the screw rod transmission structure on the left part mounting rack is started to control the upper layer mounting rack to move, and whether the edge of the left cloth is detected or not is judged through the deviation rectifying module on the upper layer mounting rack; if the left cloth edge is detected, controlling the screw transmission structure to enable the left cloth edge to be located between the detection parts of the two deviation correction sensors of the deviation correction module, and entering step 24; if the left cloth edge is not detected, go to step 27;
step 24: acquiring the position of the left edge according to the transmission length of the lead screw transmission structure, recording and entering step 211;
step 25: when the deviation rectifying module on the right part mounting rack receives signal input, the screw rod transmission structure on the right part mounting rack is started to control the upper layer mounting rack to move, and whether the edge of the right cloth is detected or not is judged through the deviation rectifying module on the upper layer mounting rack; if the edge of the right cloth is detected, controlling the screw transmission structure to enable the edge of the right cloth to be located between the detection parts of the two deviation rectifying sensors of the deviation rectifying module, and entering step 26; if the left cloth edge is not detected, go to step 27;
step 26: acquiring the position of the left edge according to the transmission length of the lead screw transmission structure, recording and entering step 211;
step 27: if the cloth edge of one side is not detected, continuing to detect the cloth edge of the side, alarming if the cloth edge is not detected for a set duration, and entering step 28;
step 28: if the edge of one side is not detected within the duration set time, judging whether the side detects cloth or not;
if the cloth is detected, go to step 29; if no piece of cloth is detected, go to step 210;
step 29: if the cloth is detected on the side but the edge is not detected, judging whether the cloth is detected on the other side; if the cloth on the other side is not detected, the cloth is considered to be out of bounds at the side edge, and the step is finished; if the other side detects cloth, the sensor is considered to be in fault, and the step is ended;
step 210: if the cloth and the cloth edge are not detected on the side, judging whether the cloth is detected on the other side;
if the cloth on the other side is not detected, the sensor is considered to be in fault or the cloth is not transmitted, and the step is ended;
if the cloth on the other side is detected, the cloth is considered to be out of bounds at the edge of the other side, and the step is finished;
step 211: and acquiring the position of the other side edge of the cloth, and converting the positions of the two side edges to obtain the width of the cloth, and ending the step.
6. In step 211, the converted cloth width is compared with an input cloth width set value, and if the difference value is greater than a set positive threshold value, the sensor is considered to be abnormal, and an alarm is given; if the difference value is smaller than the set negative threshold value, the cloth is considered to be curled, and an alarm is given.
7. The closed-loop control method based on point laser cloth seam detection as claimed in claim 5, wherein the process of determining whether the cloth height mutation part is sensed in the step 4 comprises the following steps:
step 41: recording height signal values detected by two laser detection modules on the same side of the mounting rack;
step 42: the two laser detection modules on the same side of the mounting rack are differenced to obtain the cloth height;
step 43: judging whether the cloth height value is suddenly changed or not; if mutation occurs, go to step 44; otherwise, returning to step 41;
step 44: judging whether the amplitude and the width of the abrupt change region of the cloth height meet set requirements or not; if the set requirement is met, recording a cloth signal of the mutation area, and ending the step; if the setting requirements are not satisfied, the process returns to step 41.
8. The closed-loop control method based on point laser cloth seam detection as claimed in claim 6, wherein the step 5 of judging the cause of the cloth mutation position comprises the following steps:
step 51: acquiring a cloth height mutation area, and storing a cloth height difference value into a PLC storage bit; wherein
In the mutation area, storing each piece of cloth height data, numbering until the piece of cloth height data is stored to a set upper limit of the number, and restarting numbering;
step 52: using adjacent values in the PLC storage bit to make difference to obtain A, then dividing the difference by the sampling period of the adjacent values, and calculating a catastrophe point k of the cloth height variation waveform; wherein, the mutation point of the cloth height variation waveform represents the time when the waveform changes from negative to positive, namely the time when the cloth height is the highest;
step 53: obtaining the cloth height at the corresponding moment according to the time axis of the catastrophe point k;
step 54: according to the set seam width, x mutation area sampling points are respectively taken before and after a mutation point k;
step 55: obtaining the integral area of the cloth height waveform corresponding to the sampling point part in the step 54;
step 56: judging whether the signal width of the mutation region is larger than a set seam width A or not; if yes, go to step 57; otherwise, go to step 510;
and 57: judging whether the cloth height corresponding to a mutation point k of the mutation region is greater than a set seam height L or not;
if yes, go to step 58; otherwise, go to step 510;
step 58: judging whether the integral area obtained in step 55 is larger than a set value M; if yes, go to step 59; otherwise, go to step 510;
step 59: judging whether the mounting racks on the left side and the right side detect sudden changes of the cloth height within a set time length T or not;
if so, considering the abrupt change area of the cloth height as a seam, and ending the step; otherwise, go to step 510; step 510: and (5) finishing the step when the mutation area of the cloth height is a flaw.
9. The closed-loop control method based on spot laser cloth seam detection as claimed in claim 7, wherein the step 6 of controlling the scraper action comprises the following steps:
step 61: judging the height change of the cloth as a seam, and acquiring the lifting time of the scraper according to the transmission speed of the cloth and the transmission distance from the hanging knife to the laser detection module;
step 62: according to the time difference of the seam detected by the left mounting rack and the right mounting rack, combining the distance between the left mounting rack and the right mounting rack to obtain the angle of the seam;
and step 63: obtaining the projection length of the seam in the cloth conveying direction according to the angle of the seam and the width of the cloth;
step 64: obtaining the cutter lifting holding time according to the projection length of the cloth in the cloth conveying direction and the cloth conveying speed;
step 65: obtaining the lifting height of the scraper according to the detected cloth height;
and step 66: and compensating the obtained cutter lifting holding time, and controlling the scraper to act according to the compensated numerical value and by combining the scraper lifting time and the scraper lifting height.
10. The closed-loop control method based on spot laser cloth seam detection as claimed in claim 8, wherein the obtaining of the compensation value of the blade lifting action by the processing module specifically comprises the steps of:
step 81: the image acquisition module acquires an image and transmits the image to the processing module for storage and recording;
step 82: according to the time difference of the seam detected by the left mounting rack and the right mounting rack, combining the distance between the left mounting rack and the right mounting rack to obtain the angle of the seam;
step 83: and obtaining a calculation compensation value of the cutter lifting holding time according to the angle of the joint.
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