CN202175829U - On-line real-time detection system for gray fabric flaw based on machine vision - Google Patents
On-line real-time detection system for gray fabric flaw based on machine vision Download PDFInfo
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- CN202175829U CN202175829U CN2011202775815U CN201120277581U CN202175829U CN 202175829 U CN202175829 U CN 202175829U CN 2011202775815 U CN2011202775815 U CN 2011202775815U CN 201120277581 U CN201120277581 U CN 201120277581U CN 202175829 U CN202175829 U CN 202175829U
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B35/00—Details of, or auxiliary devices incorporated in, knitting machines, not otherwise provided for
- D04B35/10—Indicating, warning, or safety devices, e.g. stop motions
- D04B35/20—Indicating, warning, or safety devices, e.g. stop motions responsive to defects, e.g. holes, in knitted products
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Abstract
The utility model relates to an on-line real-time detection system for gray fabric flaw based on machine vision, which comprises a cross beam device. A light source device and one or a plurality of industrial cameras are fixedly arranged on the cross beam device, an imaging area of one industrial camera or an imaging area formed by splicing the plurality of industrial cameras covers a to-be-detected area through which detected gray fabric can pass during spinning, the industrial camera(s) is/are connected with an image acquiring, processing and analyzing device, the image acquiring, processing and analyzing device is connected with a control unit used for controlling a warp knitting machine or a spandex machine, and the control unit is connected with a flaw position area display device. The on-line real-time detection system is simple in structure, low in power consumption and lower in use and maintenance cost, and is safe and reliable, on-line operation of workers is not affected, and the product quality and the efficiency of the warp knitting machine or the spandex machine are greatly improved; therefore, the on-line real-time detection system is applicable for being widely popularized during gray fabric production of the warp knitting machine or the spandex machine and is adapted to the development trend of automatic and unmanned spinning.
Description
Technical field
The utility model relates to warp knitting machine, spandex machine grey cloth online production field, especially a kind of grey cloth fault Real-time and On-line based on machine vision.
Background technology
In the process of warp knitting machine, spandex machine braiding cloth, Fabric Defects Inspection can appear after yarn ruptured, and the fault of the type is to estimate the main parameter of a warp knitting cloth credit rating.In the prior art, the auxiliary detection technology is main with zlasing mode and photoelectricity sensing array scan pattern mainly.It detects principle: (1) zlasing mode: a pair of laser diode emitters and receiver relatively are installed on loom, are made the horizontal cloth surface of plunderring of laser beam, laser beam is vertical with the trend of cloth.When fault takes place; Correspondence has yarn and ruptures; When yarn was broken, under the air-flow effect of air blast and the generation of air guide pipeline, thereby yarn can waft into disturbance in the laser rays; Produce the subtle disruption of light, light-sensitive element and subsequent conditioning circuit are accomplished a defect detection through catching this interference.The verification and measurement ratio of this pattern is about 50～60%, and is and powerless to the broken string defect detection behind the knitting needle.(2) scan pattern: the integrated array that adopts 16-64 photoelectric tube; This array and the cloth surface 8-10cm place that is separated by is moved reciprocatingly perpendicular to the cloth direction of motion; In the motion process; Photovoltaic array obtains the light and shade information of cloth surface light from limited zone interior (about 5*8cm2), thereby judges through the digital processing unit system whether yarn fracture takes place produce fault.The verification and measurement ratio of this pattern is about 80%～85%, and is lower to the fault recall rate at cloth two ends.Above-mentioned two kinds of mode device power consumptions are big, and its auxiliary equipment is installed complicacy, maintenance workload is big.
Meanwhile, the develop rapidly of large scale integrated circuit technology and the further maturation of image processing algorithm, machine vision technique is in the application of online detection range more and more widely.
The utility model content
The utility model will solve the shortcoming of above-mentioned prior art, and a kind of grey cloth fault Real-time and On-line based on machine vision simple in structure, low in energy consumption is provided.
The utility model solves the technical scheme that its technical problem adopts: a kind of grey cloth fault Real-time and On-line based on machine vision; Comprise beam device; Be fixed with light supply apparatus and one or several industrial cameras on the beam device; The imaging region that the imaging region of an industrial camera or several industrial cameras are spliced cover grey cloth weaving to be detected walk about the district to be detected of process; Industrial camera is connected with IMAQ, processing and analytical equipment, and IMAQ, processing and analytical equipment are connected with the control module that can control warp knitting machine or spandex machine, and control module is connected with defect position zone display unit.
As preferably, said defect position zone display unit comprises the grey cloth whole range position indication as exclusive regional defect detection state indication of the camera of the sound and light alarm indication of total indication, corresponding each industrial camera and indication precise position information.
As preferably, said light supply apparatus is conventional fluorescent lamps or the DC light source for driving through dc source.
As preferably; Described conventional fluorescent lamps or DC light source comprise one group of linearly aligned tubulose illuminator; Adjacent tubulose illuminator has lap in the field of illumination of grey cloth to be detected; And all tubulose illuminators cover whole district to be detected in the field of illumination that grey cloth to be detected is spliced to form, and are even with the image chiaroscuro effect that guarantees the industrial camera collection.
As preferably, 1～1.2m place is horizontal above grey cloth to be detected plunders grey cloth width to be detected and is provided with at least 3 tubulose illuminator.
As preferably, said beam device is cross section 40x70mm, the back-shaped aluminium alloy crossbeam of thickness 3mm.
As preferably, said industrial camera is the CCD industrial camera of mega pixel level.
As preferably; Said IMAQ, processing and analytical equipment comprise trigger module when gathering, image processing and analysis module; Trigger module is connected with industrial camera when wherein gathering; Provide poll according to the pattern difference of gathering and gather signal or synchronous acquisition signal, make and carry out collection of poll picture signal or synchronous images signals collecting under the driving of industrial camera flip flop equipment when gathering.
The effect that the utility model is useful is: adopted this grey cloth fault Real-time and On-line based on machine vision; Can online in real time effectively detect the fault that exists when warp knitting machine or spandex machine are produced grey cloth; And can report to the police to fault in time and demonstration, the record of regional location; Control module through said grey cloth fault Real-time and On-line based on machine vision sends halt instruction to the electric control system of warp knitting machine or spandex machine simultaneously; Suspend the machine action of weaving cotton cloth, with artificial naked eyes itinerant monitor system cloth surface-defect, its use greatly reduces the intensity that the workman works; Avoided the tired long problem of grey cloth fault that occurs, promoted the quality of grey cloth greatly because of the workman.Compare with the product of two kinds of know-whies described in the background technology; Said grey cloth fault Real-time and On-line based on machine vision can also provide the most directly foundation for the evaluation of grey quality grade in the next process through the record to defect position.Moreover; The said system architecture of the utility model is simple, low in energy consumption, and the operation and maintenance cost is lower, and safe and reliable; Do not influence workman's on-line operation; Promote the quality of production and the efficient of warp knitting machine or spandex machine greatly, thereby be adapted in warp knitting machine or the spandex machine grey cloth factory promoting comparatively widely, adapted to weaving automation, unmanned development trend.
Description of drawings
Fig. 1 is the system architecture diagram of the utility model;
Fig. 2 is the testing process figure of the utility model;
Description of reference numerals: beam device 1, light supply apparatus 2, industrial camera 3, grey cloth 4 to be detected; District 5 to be detected, IMAQ, processing and analytical equipment 6, control module 7; Sound and light alarm indication 8-1, the exclusive regional defect detection state indication 8-2 of camera, grey cloth whole range position indication 8-3.
The specific embodiment
Below in conjunction with accompanying drawing the utility model is described further:
Embodiment: like Fig. 1; This grey cloth fault Real-time and On-line based on machine vision; Comprise beam device 1, be fixed with light supply apparatus 2 and industrial camera 3 on the beam device 1, industrial camera 3 is connected with IMAQ, processing and analytical equipment 6; IMAQ, processing and analytical equipment 6 are connected with the control module 7 that can control warp knitting machine or spandex machine, and control module 7 is connected with defect position zone display unit.
Wherein said beam device 1 is generally warp knitting machine or the spandex machine carries; Mainly as supporting mounting bracket; Crossbearer has just been accomplished above the grey cloth of weaving or oblique upper at warp knitting machine or spandex machine; General employing cross section is that 40mmx70mm, thickness are the back-shaped aluminium alloy crossbeam of 3mm, and as light source and industrial camera usefulness are installed, light supply apparatus 2 and industrial camera 3 all are set to the corresponding position in district 5 to be detected.
Said light supply apparatus 2 is conventional fluorescent lamps or the DC light source for driving through dc source; Be included in that 1～1.2m place, grey cloth to be detected 4 tops is horizontal plunders at least 3 the tubulose illuminator that grey cloth 4 widths to be detected are provided with; Adjacent tubulose illuminator has lap in the field of illumination of grey cloth 4 to be detected; And all tubulose illuminators cover whole district to be detected in the field of illumination that grey cloth 4 to be detected is spliced to form; Be used to provide comparatively constant, even, the sufficient lighting source in grey cloth to be detected zone 5, the breadth width that this light source is weaved cotton cloth according to different warp knitting machines or spandex machine is different, and the quantity of setting is difference also; Need to guarantee that adjacent lighting source engages the brightness that forms district to be detected 5 images that illuminated and has uniformity, and the image chiaroscuro effect that assurance industrial camera 3 is gathered is even.
Simultaneously, industrial camera 3 is the CCD industrial camera of mega pixel level, the target surface size of ccd sensor chip in the choose reasonable camera; The imaging precision of camera lens and the visual angle of camera lens; The height and position of adjustment beam device 1 is set the reasonable object distance of industrial camera 3, the suitable imaging area that the assurance system is required, and the precision of desired image was a starting point when selection of this area was discerned with fault; (being the width of grey cloth) guarantees the precision of images on the camera length direction; (being the direction that grey cloth weaving is walked about) guarantees the length that institute can definitely discern when fault occurred on the camera width, and generally value is at 5cm, and district 5 to be detected is the target of these system's industrial camera 3 IMAQs among Fig. 1; Industrial camera 3 comprises one or several; Imaging region is whole to be detected regional 5 when being one, and when being several, the imaging region that these several cameras are spliced to form on grey cloth 5 to be detected has covered whole to be detected regional 5; And when adjusting, guarantee that generally the imaging region of each camera intersects to some extent in system.
Said IMAQ, processing and analytical equipment 6 and control module 7 constitute the master control core of native system, and digital signal processing chip DSP commonly used and scm system chip such as arm chip constitute in practical implementation, also can adopt the industry PC structure.The trigger module of said IMAQ, processing and analytical equipment 6 is through the ordered control of software trigger or hardware timing triggering mode control industrial camera IMAQ.After said IMAQ, processing and analytical equipment 6 are accomplished IMAQ through SECO; Utilizing image processing module that the image of being gathered is carried out corresponding image algorithm handles; Grey cloth for different cultivars; By the generic of workman through the man-machine interface operation setting grey cloth of this device; Image processing module can select preset algorithm to carry out the image processing from database, and the analysis module of said IMAQ, processing and analytical equipment 6 can judge according to the fault judgment rule whether fault takes place according to processing result image, thus driving control unit 7.Said control module 7 links to each other with IMAQ, processing and analytical equipment 6; This device is also reported to the police with warp knitting machine or spandex machine and fault and is connected with defect position zone display unit simultaneously, and whether said control module 7 exists the alarm indication of driving fault warning device according to fault and control warp knitting machine or whether the spandex machine suspends.Said IMAQ, processing and analytical equipment 6 are when fault takes place; Testing that can Break-Up System; When warp knitting machine or spandex machine and native system time-out; Said control module 7 can be caught the enabling signal of warp knitting machine or spandex machine, and after predetermined time-delay, the enabling signal that native system can capture according to control module 7 is from the halted state to the detected state.
Said defect position zone display unit links to each other with control module 7, and said defect position zone display unit comprises sound and light alarm indication 8-1, the exclusive regional defect detection state indication 8-2 of camera and grey cloth whole range position indication 8-3.Said sound and light alarm indication 8-1 is total indication; Represent with acoustooptic form whether full width face grey cloth to be detected fault occurs; The exclusive regional defect detection state indication of the camera of each industrial camera 3 of said correspondence 8-2 mainly shows that with the indicator lamp form corresponding work camera monitored the fault generation behavior in the breadth; Make things convenient for the workman in time to locate defect position; Mainly with the precise position information of LED display indication whole range fault, this information is recorded to the grey quality data file that is generated in IMAQ, processing and the analytical equipment 6 to said grey cloth whole range position indication 8-3.
The detection system of the utility model is operated under the situation of warp knitting machine or the online production of spandex machine, because the weaving campaign of warp knitting machine or spandex machine is to constitute the important behavior that detection system detects in real time.
Said grey cloth fault Real-time and On-line based on machine vision accomplish on the warp knitting machine rationally install after; The grey cloth in district 5 to be detected shown in the accompanying drawing 1 moves backward edge very near the knitting needle of warp knitting machine or spandex machine; The grey cloth that this installation requirement can guarantee to be formed by weaving on silk thread was promptly adopted into image by industrial camera 3 in the very first time that produces fault, thereby can guarantee to detect the real-time of fault.The testing process of the detection system of the utility model is as shown in Figure 2:
Behind the machine startup; The master control core is that the system's computing that constitutes of IMAQ, processing and analytical equipment 6 and control module 7 and control core are that the industrial camera configuration file of packing into is automatically accomplished to get into after the initialization and detected circulation; Image capture module control flip flop equipment sends the signal of collection of industrial camera poll or parallel acquisition; The image of gathering is followed the memory module that standard transmission protocol transfers to IMAQ, processing and analytical equipment 6; When industrial camera 3 was operated in the poll drainage pattern, the image of each camera collection was stored among the view data formation that storage of real time opens up according to triggering sequential, and image is handled with analysis module and carried out fault inspection and analysis successively according to the order of image in the formation; When native system uses on warp knitting machine; Normal this pattern that adopts because the cloth speed of production of warp knitting machine generally is not more than 6cm/s, therefore adopts this poll pattern can reach the effect that real-time fault is differentiated; When said industrial camera 3 was operated in the parallel acquisition pattern, each camera was gathered image simultaneously under the synchronous triggering signal of the trigger module of said IMAQ, processing and analytical equipment 6; If N industrial camera 3 arranged; The memory module of IMAQ, processing and analytical equipment 6 can be opened up N queue stores space automatically for each camera, and image is handled and analysis module takes out view data from individual queue, in N concurrent process, carries out the fault of image and differentiates; This mode field is used in the defect detection system of spandex machine; Because the cloth speed of production of spandex machine is than fast many of warp knitting machine,, need to adopt the parallel acquisition pattern for reaching real-time differentiation effect.The system architecture of said poll pattern and parallel schema is identical, but the performance indications of system module are different, and under the identical scale condition of system, the system resource of said parallel module requires to require much bigger than the system resource of poll pattern.
After obtaining view data, IMAQ, processing and analytical equipment 6 utilize built-in algorithms to carry out defect detection, and for guaranteeing real-time, the algorithm that said image is handled will be accomplished in the gap between the triggering signal of said different trigger modes.When fault takes place when; IMAQ, processing and analytical equipment 6 suspend collection, processing and analytic process, and send the alarm response signal to control module 7, and said fault is reported to the police and the sound and light alarm of defect position zone display unit indicates 8-1 to send total warning; The alert grey cloth has fault to occur; Bright or the flicker of the responsive state lamp of the exclusive regional defect detection status indicator lamp 8-2 of the camera of said each industrial camera of correspondence, the regional location that the prompting fault takes place, the pilot operationp personnel locate fault fast; Said grey cloth whole range position indicator panel 8-3 shows the exact position that fault takes place, and this positional information is recorded to the grey quality data file; Simultaneously, when fault took place, warp knitting machine or spandex machine automatic pause under the control of control module 7 was repaired fault up to operating personnel and is restarted.When warp knitting machine or spandex machine restart; The enabling signal that is taken place is controlled unit 7 seizure and is received by IMAQ, processing and analytical equipment 6; Detection system is after predetermined time-delay; Automatically return to detected state from halted state, thereby guarantee that native system exempts from continuous operation under the situation of intervention the operator.
Except that the foregoing description, the utility model can also have other embodiments.All employings are equal to the technical scheme of replacement or equivalent transformation formation, all drop on the protection domain of the utility model requirement.
Claims (8)
1. grey cloth fault Real-time and On-line based on machine vision; Comprise beam device (1); It is characterized in that: be fixed with light supply apparatus (2) and one or several industrial cameras (3) on the beam device (1); The imaging region that the imaging region of an industrial camera (3) or several industrial cameras (3) are spliced cover grey cloth to be detected (4) weaving walk about the district to be detected (5) of process; Industrial camera (3) is connected with IMAQ, processing and analytical equipment (6), and IMAQ, processing and analytical equipment (6) are connected with the control module (7) that can control warp knitting machine or spandex machine, and control module (7) is connected with defect position zone display unit.
2. the grey cloth fault Real-time and On-line based on machine vision according to claim 1 is characterized in that: said defect position zone display unit comprises the sound and light alarm indication (8-1) as total indication, the exclusive regional defect detection state indication of camera (8-2) of corresponding each industrial camera (3) and the grey cloth whole range position indication (8-3) of indication precise position information.
3. the grey cloth fault Real-time and On-line based on machine vision according to claim 1 is characterized in that: said light supply apparatus (2) is conventional fluorescent lamps or the DC light source for driving through dc source.
4. the grey cloth fault Real-time and On-line based on machine vision according to claim 3; It is characterized in that: described conventional fluorescent lamps or DC light source comprise one group of linearly aligned tubulose illuminator; Adjacent tubulose illuminator has lap in the field of illumination of grey cloth to be detected (4); And all tubulose illuminators cover whole district to be detected (5) in the field of illumination that grey cloth to be detected (4) is spliced to form, and are even with the image chiaroscuro effect that guarantees industrial camera (3) collection.
5. the grey cloth fault Real-time and On-line based on machine vision according to claim 4 is characterized in that: horizontal grey cloth to be detected (4) width of plunderring is provided with at least 3 tubulose illuminator at grey cloth to be detected (4) 1～1.2m place, top.
6. the grey cloth fault Real-time and On-line based on machine vision according to claim 1 is characterized in that: said beam device (1) is cross section 40x70mm, the back-shaped aluminium alloy crossbeam of thickness 3mm.
7. the grey cloth fault Real-time and On-line based on machine vision according to claim 1, it is characterized in that: said industrial camera (3) is the CCD industrial camera of mega pixel level.
8. the grey cloth fault Real-time and On-line based on machine vision according to claim 1; It is characterized in that: said IMAQ, processing and analytical equipment (6) comprise trigger module when gathering, image processing and analysis module; Trigger module is connected with industrial camera (3) when wherein gathering; Provide poll according to the pattern difference of gathering and gather signal or synchronous acquisition signal, make industrial camera (3) under the driving of trigger module, carry out collection of poll picture signal or synchronous images signals collecting.
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| CN102704078A (en) * | 2012-07-06 | 2012-10-03 | 常熟市石油固井工具有限公司 | Textile machine with image pick-up function |
| CN102818809A (en) * | 2012-09-05 | 2012-12-12 | 杭州瑞利测控技术有限公司 | Gray cloth defect on-line detecting system based on machine vision and achieving method |
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