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CN115639143B - A cloth detection device and method suitable for an open-width cloth winding machine - Google Patents

A cloth detection device and method suitable for an open-width cloth winding machine Download PDF

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Publication number
CN115639143B
CN115639143B CN202210870238.4A CN202210870238A CN115639143B CN 115639143 B CN115639143 B CN 115639143B CN 202210870238 A CN202210870238 A CN 202210870238A CN 115639143 B CN115639143 B CN 115639143B
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cloth
time
image
rubber roller
camera module
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CN115639143A (en
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廖进成
黄凯乾
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Xiamen Xingquanlong Machinery Co ltd
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Xiamen Xingquanlong Machinery Co ltd
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/01Arrangements or apparatus for facilitating the optical investigation
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84Systems specially adapted for particular applications
    • G01N21/88Investigating the presence of flaws or contamination
    • G01N21/89Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/892Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
    • G01N21/898Irregularities in textured or patterned surfaces, e.g. textiles, wood
    • G01N21/8983Irregularities in textured or patterned surfaces, e.g. textiles, wood for testing textile webs, i.e. woven material

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Immunology (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Physics & Mathematics (AREA)
  • Pathology (AREA)
  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
  • Registering, Tensioning, Guiding Webs, And Rollers Therefor (AREA)

Abstract

Cloth detection device suitable for scutching cloth rewinder includes: the machine frame is provided with a first rubber roller group and a second rubber roller group at intervals in parallel, one side of the second rubber roller group is provided with a cloth rolling roller, an image acquisition module is arranged between the first rubber roller group and the second rubber roller group, the image acquisition module comprises a mounting seat and at least two camera modules, the length direction of the mounting seat is basically parallel to the axial direction of the first rubber roller group, the at least two camera modules are arranged along the length direction of the mounting seat, and the lenses of the camera modules face towards cloth to acquire images; the invention has the beneficial effects that the transmission distance of the cloth and the at least two camera modules arranged along the length direction of the mounting seat are arranged through the first rubber roller group and the second rubber roller group, so that the production state of the cloth can be monitored in real time, the accuracy and the comprehensiveness of monitoring are further improved, the labor intensity of workers is effectively reduced, and the quality of products is ensured.

Description

Cloth detection device and method suitable for open-width cloth winding machine
Technical Field
The application relates to the field of textile machinery, in particular to a cloth detection device and method suitable for an open-width cloth winding machine.
Background
The open width cloth rolling machine is a cloth rolling device applied to a knitting circular knitting machine, the inner space of the existing circular knitting machine is limited, the cloth detection mode of production is mainly two modes, wherein one mode is manual detection in the production process, namely, a worker checks the cloth with naked eyes at regular time, and the other mode is off-line detection, namely, after cloth production is finished, the cloth is additionally detected by using a cloth inspection machine, the two modes are time-consuming and labor-consuming, and the accuracy of human eye identification and the instantaneity of the cloth inspection machine are insufficient, so that the problem of bad batch quality is often caused.
Therefore, the patent with the application publication number of CN214572888U discloses a cloth image real-time acquisition processing mechanism based on a circular knitting machine, wherein a camera and a light source are arranged on the inner side wall of a circular knitting platform, so that the real-time performance of cloth detection is improved. However, when the camera detects, the cloth is wound on the cloth drum, most of the cloth in the image shot by the camera is in a curved surface state, the comparison of the real-time image and the template is not facilitated, the position of the camera is relatively fixed, flaws in a region far away from the camera such as flaws at the edge are difficult to detect, misjudgment is easy to occur, and therefore, the accuracy and the comprehensiveness of detection are required to be further improved.
In view of the above, the present inventors have made intensive studies to solve the above-mentioned drawbacks of the prior art.
Disclosure of Invention
The cloth detection device is simple in structure, can finish image detection of the front surface of the cloth while conveying the cloth, and effectively improves accuracy and comprehensiveness of cloth detection.
The second object of the application is to provide a cloth detection device, which can finish image detection of the front surface and the back surface of cloth while conveying the cloth, thereby further improving the comprehensiveness of cloth detection.
The third object of the application is to provide a cloth detection method, by matching the detection method with a corresponding detection device, flaws on the front surface of the cloth can be effectively detected, and no missed detection can occur.
The fourth object of the application is to provide a cloth detection method, by matching with corresponding detection devices, flaws on the front surface and the back surface of the cloth can be effectively detected, and no missing detection can occur.
To achieve the first object, the present invention discloses a cloth inspection device for a open width cloth rewinder, which is rotatably operated in a circular knitting machine, comprising: the frame, frame parallel interval is provided with first rubber roll group and second rubber roll group, one side of second rubber roll group is equipped with the batching roller, the discharge end of first rubber roll group corresponds the feed end of second rubber roll group, the discharge end of second rubber roll group corresponds the feed end of batching roller, be provided with image acquisition module between first rubber roll group and the second rubber roll group, image acquisition module includes mount pad and two at least camera modules, the length direction of mount pad is on a parallel with first rubber roll group axial direction the mount pad arranges N camera modules along length direction, and N is more than or equal to 2 positive integer, and its camera module's camera lens carries out image acquisition towards the cloth, and the effective view finding area that the camera module's lens gathered respectively can each other seamless connection and can cover cloth's width, and its camera module's camera lens carries out image acquisition towards the cloth, camera module electricity is connected with control system, control system is used for receiving the real-time image information that the camera module gathered to compare this real-time image information with preset, send out the analysis to its quality analysis in case that the template is failed to send out the feedback instruction.
Further, the distance between the discharge end of the first rubber roller group and the feeding end of the second rubber roller group is a transmission distance, and the lens of the camera shooting module is arranged above the direction vertical to the front of the cloth.
Further, the camera module is provided with a plurality of first light sources at the outer diameter end of the lens, a light guide cover is additionally arranged at the outer periphery of the first light sources, and the side wall of the light guide cover is used for projecting light paths of the plurality of first light sources to the front of the lens of the camera module.
By adopting the structure, at least two camera modules are arranged along the length direction of the mounting seat, on one hand, the range shot by at least part of camera modules can be accurately covered on two edges in the width direction of cloth, so that detection is more comprehensive, and on the other hand, the local details of the cloth can be more highlighted by the images shot by the camera modules, namely, the detection precision is higher.
In order to achieve the second object, the invention discloses a cloth detection device suitable for a scutcher, which is based on the cloth detection device of the first object, and the image acquisition module further comprises a shading piece which is arranged on a frame and is positioned on one side of a tensioning section far away from a camera module, wherein the shading piece is provided with a shading main body matched with the width of the cloth, the shading main body is arranged in parallel with a mounting seat, and at least a shading main body at a corresponding position exists in a lens corresponding effective view finding area of each camera module. The shading main body is provided with a groove, at least a plurality of second light sources are arranged in the groove, and the second light sources are electrically connected with the control system and are configured to assist the camera module in collecting the back side images of the cloth.
By adopting the structure, the shading piece effectively reduces background noise on the front face of the cloth collected by the camera module, improves image contrast, and can enable the camera module on the front face of the cloth to collect images on the back face of the cloth by setting the second light source and turning on the second light source under the state that the first light source is turned off.
In order to achieve the third object, the invention discloses a cloth detection method suitable for a scutching cloth winding machine, which is applied to a first object cloth detection device and comprises the following steps:
S1: in a preset running time T1, based on a preset cloth roller running speed V, conveying the cloth from a first rubber roller group to a second rubber roller group for L1 length, when an imaging module is provided with a first light source, the first light source is in a normally-on state, the first light source at least keeps normally-on when a lens is in a working state, a control system is used for setting the shooting waiting time T2 of the imaging module, the effective view finding areas of the imaging modules are mutually overlapped to form a sub-strip-shaped aggregate image area, and a mother strip-shaped aggregate image area commonly constructed by the sub-strip-shaped aggregate image areas can fully cover the area of the cloth with the length L1, which is slipped downwards;
S2: transmitting the real-time cloth image acquired by the camera module to a control system;
S3: based on a qualified template and a threshold value which are preset in a control system, analyzing and comparing the template with the real-time cloth image, calculating the similarity between the real-time cloth image and the qualified template, and comparing the similarity with the threshold value;
If the similarity is greater than the threshold value, the real-time cloth image analysis result is qualified, and the cloth rolling machine continuously operates;
If the similarity is smaller than the threshold value, the real-time cloth image analysis result is unqualified, and the cloth winding machine stops and alarms.
By adopting the method, in the preset running time T1, the mother strip-shaped collection image area collected by the camera module can cover the area of the length L1 of cloth conveying, the front detection of the cloth can be automatically and comprehensively completed, and when the detection is unqualified, the cloth winding machine can automatically alarm, so that the labor intensity of workers is effectively reduced, and the quality of products is ensured.
In order to achieve the fourth object, the invention discloses a cloth detection method suitable for a scutching cloth winding machine, which is applied to a second object cloth detection device and comprises the following steps:
S1: in a preset running time T1, based on a preset cloth roller running speed V, conveying cloth from a first rubber roller group to a second rubber roller group for L1 length, when the first light source of the camera module is lightened, the second light source is turned off, and at the moment, the effective view finding areas acquired by the lenses of each camera module are mutually overlapped to form a forward bar-shaped collection image area; when the second light source is lightened, the first light source is turned off, and the lens acquisition effective view finding areas of the camera modules are mutually overlapped to form a reverse bar-shaped aggregate image area; the overlapping part of the forward strip-shaped aggregate image area and the reverse strip-shaped aggregate image area is a sub-overlapping area S, the shooting waiting time T4 of the shooting module is set through the control system, and at least the sub-overlapping area S is ensured to fully cover the area with the length of L1, wherein the area can slide cloth downwards;
S2: transmitting the real-time cloth image acquired by the camera module to a control system;
S3: based on a qualified template and a threshold value which are preset in a control system, analyzing and comparing the template with the real-time cloth image, calculating the similarity between the real-time cloth image and the qualified template, and comparing the similarity with the threshold value;
If the similarity is greater than the threshold value, the real-time cloth image analysis result is qualified, and the cloth rolling machine continuously operates;
If the similarity is smaller than the threshold value, the real-time cloth image analysis result is unqualified, and the cloth winding machine stops and alarms.
By adopting the method, in the preset running time T1, the sub-overlapping area S collected by the camera module can cover the area of the length L1 of cloth conveying, the detection of the front surface and the back surface of the cloth can be automatically and comprehensively completed, and when the detection is unqualified, the cloth winding machine can automatically give an alarm, so that the labor intensity of workers is effectively reduced, and the quality of products is ensured.
Drawings
The detailed description given as non-limiting examples better explain what the application comprises and can be implemented with reference to the accompanying drawings, in which:
fig. 1 is a schematic perspective view of a cloth detecting device according to an embodiment of the present invention;
Fig. 2 is a schematic side view of a cloth inspection device according to an embodiment of the present invention, in which a side plate of a frame is omitted and a light shielding member is located at a first position;
FIG. 3 is a schematic side view of the image capturing module shown in FIG. 2;
fig. 4 is a schematic view of a partial perspective structure of an image acquisition module according to an embodiment of the present invention;
Fig. 5 is a schematic perspective view of a light shielding member according to an embodiment of the present invention;
FIG. 6 is a detail view of a side plate portion of the shade of FIG. 5;
fig. 7 is a schematic side view of a cloth inspection device according to an embodiment of the present invention, in which a side plate of a frame is omitted and a light shielding member is located at a second position;
FIG. 8 is a schematic diagram illustrating a first position and a second position of a light shielding member according to an embodiment of the present invention;
FIG. 9 is a schematic diagram of a three-dimensional structure of an image detection module according to an embodiment of the present invention;
FIG. 10 is a second schematic diagram of a three-dimensional structure of an image detection module according to an embodiment of the present invention, wherein cloth is omitted in the diagram;
Fig. 11a is a schematic diagram of a mother strip-shaped set image area of a single photographing time period according to an embodiment of the present invention;
FIG. 11b is a schematic diagram of an overlay alignment of the image area of the master strip set of FIG. 11a with the area of the web feed width L2;
fig. 12 is a schematic diagram of an acquisition principle of a camera module according to an embodiment of the present invention;
FIGS. 13 a-13 c illustrate three positional relationships of adjacent parent bar aggregate image areas provided by embodiments of the present invention;
Fig. 14a to fig. 14c are schematic views of three states of the sub-overlapping area S in which the sub-overlapping area S is displayed separately in four consecutive photographing periods according to the embodiment of the present invention, where the forward bar-shaped aggregate image area and the reverse bar-shaped aggregate image area are framed separately at intervals of photographing waiting time T4;
Fig. 15a to 15c are schematic views of three states of combined display of the sub-overlapping area S in four consecutive photographing periods according to the embodiment of the present invention, where the forward bar-shaped aggregate image area and the reverse bar-shaped aggregate image area are separately framed at intervals of photographing waiting time T4;
Fig. 16 is a schematic diagram of a positional relationship between each forward bar-shaped set image area and each reverse bar-shaped set image area in an adjacent photographing time period according to an embodiment of the present invention, where the forward bar-shaped set image area and the reverse bar-shaped set image area are continuously acquired.
Description of the reference numerals:
1. a frame; 11. a rotating shaft; 12. a fastener; 13. a first limiting member; 14. a second limiting piece; 2. a first rubber roller group; 3. the second rubber roller group; 4. a cloth roller; 5. an image acquisition module; 51. a mounting base; 52. a camera module; 521. a lens; 522. a first light source; 523. a light guide cover; 53. a light shielding member; 531. a light shielding body; 532. a groove; 533. a second light source; 534. a side plate; 535. an open slot.
Detailed Description
The application is described in detail below with reference to the accompanying drawings and specific embodiments.
It is to be understood that, according to the technical solution of the present application, those skilled in the art may propose various alternative structural modes and implementation modes without changing the true spirit of the present application. Accordingly, the following detailed description and drawings are merely illustrative of the application and are not intended to be exhaustive or to limit the application to the precise form disclosed.
Terms of orientation such as up, down, left, right, front, rear, front, back, top, bottom, etc. mentioned or possible to be mentioned in the present specification are defined with respect to the configurations described in the drawings, and are relative concepts, so that they may be changed according to different positions and different use states of the same. These and other directional terms should not be construed as limiting terms.
Example 1
Referring to fig. 1, a cloth detecting device for a cloth open-width winding machine according to the present embodiment will be described, where the winding machine is a winding device that rotates on a circular knitting machine, so that the cloth detecting device rotates synchronously with the winding machine and performs cloth detection.
Referring further to fig. 2 to 4, in this embodiment, the cloth detecting apparatus includes: the cloth rolling machine comprises a frame 1, wherein a first rubber roller set 2 and a second rubber roller set 3 are arranged on the frame 1 at intervals in parallel, the intervals in parallel refer to intervals of the first rubber roller set 2 and the second rubber roller set 3 which are basically parallel in the axial direction and are separated by a preset length along the preset direction, specifically, as shown in fig. 3, the intervals are respectively arranged on the basis that the first rubber roller set 2 and the second rubber roller set 3 are basically parallel in the axial direction, a cloth rolling roller 4 is arranged on one side of the second rubber roller set 3, the discharge end of the first rubber roller set 2 corresponds to the feed end of the second rubber roller set 3, the discharge end of the second rubber roller set 3 corresponds to the feed end of the cloth rolling roller set 4, namely, a cloth rolling path of cloth is firstly pulled through the first rubber roller set 2 and then pulled through the second rubber roller set 3, and finally the cloth rolling roller set 4 is wound on the power output end of a cloth rolling motor, and tensioning of the cloth is achieved through winding and pulling of the cloth rolling motor.
The image acquisition module 5 is arranged between the first rubber roll set 2 and the second rubber roll set 3, the image acquisition module 5 comprises an installation seat 51 and at least two camera modules 52, the length direction of the installation seat 51 is basically parallel to the axial direction of the first rubber roll set 2, N camera modules 52 are arranged along the length direction of the installation seat 51, N is a positive integer greater than or equal to 2, the lenses 521 of the camera modules 52 perform image acquisition towards cloth, at least the effective view-finding areas acquired by the lenses 521 of the N camera modules 52 can be connected with each other in a seamless manner and can completely cover the width of the cloth, seamless connection means that no gap exists between the effective view-finding areas of the cloth acquired by the lenses 521 of the adjacent camera modules 52, namely the edges of the effective view-finding areas of the cloth acquired by the lenses 521 of the adjacent camera modules 52 can be exactly overlapped, or the effective view-finding areas of the cloth acquired by the lenses 521 of the adjacent camera modules 52 can be mutually overlapped, the camera modules 52 are electrically connected with a control system, and the control system is used for receiving image information acquired by the camera modules 52 and sending preset real-time feedback information to a real-time analysis result of the image information. Wherein the failed cloth flaw form comprises: broken needles, oil yarns, greasy dirt, holes, crossbars and the like, particularly, the broken needles are shown to split along warp direction lines on a cloth cover, a hole is formed at the tail end in general, the greasy dirt is black oil points caused by pollution of the cloth cover by oil or air floating dust on a machine, the oil yarns are generated by oil agents or dirt carried by raw yarns, weft long strip-shaped defects are formed on the cloth cover, the broken holes are shown to be broken yarns on the cloth cover, holes exist, and the crossbars are shown to be abnormal continuous interlateral circulation in the tubular knitted fabric; the object of sending feedback instructions outwards here is an electrical device that needs to respond when it is detected that it is not acceptable, such as an alarm, a cloth winding motor, etc., the feedback instructions include but are not limited to start-stop signals of the electrical device, such as an alarm start signal, a motor stop signal of the winding machine.
It will be appreciated that the cloth is a material for making a garment, the garment has an outer surface and an inner surface in contact with a human body, the outer surface of the garment directly affects the look and feel of a viewer, so that the outer surface has a higher aesthetic requirement relative to the inner surface, i.e. the control of flaws is also more severe, and the front surfaces of the cloth mentioned in this embodiment all refer to the surfaces of the cloth used as the outer surfaces of the garment; further, the lens 521 of the camera module 52 is disposed above the direction perpendicular to the front surface of the cloth, and the lens 521 is disposed vertically on the cloth, which has the advantage that the image of the cloth does not enter the lens 521 to be inclined angularly, and the image captured by the camera module 52 can restore the actual image, which is beneficial to finding the flaw point on the cloth surface.
In this embodiment, as shown in fig. 3, the distance between the discharge end of the first rubber roll set 2 and the feed end of the second rubber roll set 3 is the transmission distance, in the prior art, based on the fact that the two rubber roll sets only play roles of traction and guiding, the transmission distance between the discharge end of the first rubber roll set 2 and the feed end of the second rubber roll set 3 is generally shorter, in this case, due to the addition of the image acquisition module 5, it is required to ensure that a long enough time is required when the cloth is transmitted from the discharge end of the first rubber roll set 2 to the feed end of the second rubber roll set 3 at a certain speed, in this long enough time, the image pickup module 52 can pick up an image of the cloth in a flat state, meanwhile, because the image acquisition module 5 occupies a certain space, the transmission distance between the discharge end of the first rubber roll set 2 and the feed end of the second rubber roll set 3 is required to be properly enlarged, so that an operator can wind the cloth from the first rubber roll set 2 to the second rubber roll set 3 for winding the cloth.
Compared with the prior art, the cloth detection device provided by the embodiment sets up the transmission interval of cloth and at least two camera modules 52 arranged along the length direction of the mounting seat 51 through the first rubber roller group 2 and the second rubber roller group 3, so that the continuous and smooth cloth cover image can be shot by the camera modules 52 when the cloth is continuously conveyed, and the two edges on the cloth width direction can be accurately covered, the production state of the cloth can be monitored in real time, and the monitoring precision and the comprehensive degree are further improved.
Referring to fig. 2-3 again, a transmission section is constructed by connecting a section between a section of the discharge end of the first rubber roll set 2 and a section of the feed end of the second rubber roll set 3, and the image acquisition module 5 is located between the transmission section and the cloth roller 4, and it should be noted that the front surface of the cloth conveyed by the existing open width cloth rolling machine faces the direction of the cloth roller 4, so that the image acquisition module 5 is arranged on the inner side, and is also based on the consideration of front surface detection of the cloth. In addition, the interval between the feeding end of the first rubber roller group 2 and the axis of the cloth roller 4 in the X direction is smaller than the interval between the discharging end of the second rubber roller group 3 and the axis of the cloth roller 4 in the X direction, so that the front detection of the cloth is met, and meanwhile, the structure of the cloth detection device is more compact.
As shown in fig. 4, in this embodiment, the image capturing module 52 is disposed at an outer diameter end of the lens 521, a plurality of first light sources 522 may be symmetrically disposed around an axis of the lens 521, the number of the first light sources 522 may be at least three, for example, 10-24, and a light guide cover 523 is further disposed at an outer periphery of the first light sources 522, the light guide cover 523 covers a front end of the lens 521 to avoid influence of stray light at other positions on the lens 521, and the light guide cover 523 further has a side wall for projecting light paths of the plurality of first light sources 522 to a position right in front of the lens 521 of the image capturing module 52, that is, a light path of the first light sources 522 covers a path area between the lens 521 and a piece of cloth, so that a pure light path is additionally provided to the lens 521, and a clear piece of image can be obtained by the lens 521.
Referring to fig. 11 a-11 b, fig. 12 and fig. 13 a-13 c, the present embodiment further provides a cloth detecting method suitable for an open width cloth winding machine, which is applied to the cloth detecting device, and includes the following steps:
S1: in the preset running time T1, based on the preset running speed V of the cloth winding drum 4, the cloth is conveyed from the first rubber roll set 2 to the second rubber roll set 3 for a length L1, for example, the preset running time T1 in this embodiment is one minute, the conveying length L1 is 195mm, although not limited thereto, when the image capturing module 52 is provided with the first light source 522, the first light source 522 is in a normally-on state, the first light source 522 at least ensures that the lens 521 remains normally on when in the working state, and the control system sets the capturing waiting time T2 of the image capturing module 52, and it can be understood that the capturing waiting time T2 is the time interval between adjacent capturing time periods of the image capturing module 52; in the photographing time period, the effective view finding areas of the photographing modules 52 are mutually overlapped to form sub-strip-shaped aggregate image areas, and the mother strip-shaped aggregate image areas commonly constructed by the sub-strip-shaped aggregate image areas can fully cover the area with the length of L1, where cloth slides downwards;
S2: transmitting the real-time cloth image acquired by the camera module 52 to a control system;
The camera module 52 and the control system can realize data transmission through a special data line, the control system can be an upper computer and is configured to process and display the acquisition result of the image, and when the image detection is unqualified, a feedback instruction is output to an external electric device, so that the cloth winding machine is stopped.
S3: based on a qualified template and a threshold value which are preset in a control system, wherein the qualified template refers to a normal produced flawless cloth image, the threshold value refers to the minimum similarity value of the image qualification, the minimum similarity value is analyzed and compared with a real-time cloth image, the similarity between the real-time cloth image and the qualified template is calculated, and the similarity is compared with the threshold value;
If the similarity is greater than the threshold value, the real-time cloth image analysis result is qualified, and the cloth rolling machine continuously operates;
If the similarity is smaller than the threshold value, the real-time cloth image analysis result is unqualified, and the cloth winding machine stops and alarms.
By adopting the method, in the preset running time T1, the mother strip-shaped collection image area collected by the camera module 52 can cover the area of the length L1 of cloth conveying, the front detection of the cloth can be automatically and comprehensively completed, and when the detection is unqualified, the cloth winding machine can automatically alarm, so that the labor intensity of workers is effectively reduced, and the quality of products is ensured.
The following mainly describes the step S1:
The working principle of the image acquisition module 5 is as follows, in the working process, the image pickup module 52 is stationary, the cloth is conveyed downwards, in a single photographing period, the image pickup module 52 is used for explaining a mother strip set image area photographed by the cloth as shown in fig. 11a, in this embodiment, taking two image pickup modules 52 as examples, of course, the number of the image pickup modules 52 is not limited, a first rubber roll set 2 and a second rubber roll set 3 are respectively arranged up and down in fig. 11a, a cloth is arranged between the first rubber roll set 2 and the second rubber roll set 3, a frame line in the middle of the cloth comprises a left sub strip set image area and a right sub strip set image area, the two sub strip set image areas are respectively formed by overlapping effective viewfinder areas photographed by the two image pickup modules 52, further, the longitudinal length of the mother strip set image area is equal to the longitudinal length of the first rubber roll set 2 and the second rubber roll set 3, the longitudinal length of the vertical detection area of the mother strip set image area is equal to the longitudinal length of the camera lens 521, and the transverse length of the transverse detection area of the two pieces of the camera lens is equal to the practical length of the vertical detection window W of the camera lens is equal to the transverse length of the two pieces of the camera lens W. As shown in fig. 11b, if the conveying length of the preset cloth in the single shooting waiting time T2 is L2, as long as the mother strip aggregate image area can fully cover the area of the cloth sliding downwards by the length of L2, no missed detection occurs.
Referring to fig. 13 a-13 c, fig. 13 a-13 c show schematic positional relationships between the image areas of the mother strip set in the adjacent photographing time period, where the adjacent photographing time period includes an upper mother strip set image area and a lower mother strip set image area, the lower mother strip set image area is an image set acquired in the previous photographing time period and is represented by a solid line frame, the upper mother strip set image area is an image set acquired in the subsequent photographing time period and is represented by a dashed line frame, and there are three positional relationships between the upper mother strip set image area and the lower mother strip set image area in total according to the difference between the running speed V of the cloth roller 4 and the photographing waiting time T2. In fig. 13a, there is a gap between the lower boundary line of the upper mother strip set image area and the upper boundary line of the lower mother strip set image area, and there is a case where the conveying length L2 of the cloth at the photographing waiting time T2 is longer than the visual field longitudinal detection distance H, and there is a miss; in fig. 13b, the lower boundary line of the upper mother strip image area coincides with the upper boundary line of the lower mother strip image area, there is no gap, and the conveying length L2 of the cloth in the shooting waiting time T2 is equal to the vertical detection distance H of the visual field, that is, no missed detection happens; in fig. 13c, the lower boundary line of the upper mother strip image area is lower than the upper boundary line of the lower mother strip image area, the upper mother strip image area and the lower mother strip image area overlap each other, and the conveying length L2 of the cloth in the photographing waiting time T2 is smaller than the vertical detection distance H of the field of view, that is, no miss detection occurs at all.
Further quantitatively analyzing the running speed V of the cloth rolling roller 4 and the shooting waiting time T2, in step S1, the setting of the shooting waiting time T2 further includes:
as shown in fig. 12, according to the collection principle of the camera module 52, based on the working distance WD between the preset lens 521 and the cloth, the focal length f of the camera module 52, and the side length H of the target surface of the chip of the camera module 52 parallel to the conveying direction of the cloth, the vertical detection distance h=h=wd/f of the field of view of the camera module 52 along the conveying direction of the cloth is obtained, and similarly, the horizontal detection distance w=w=wd/f of the field of view of the camera module 52 along the width direction of the cloth is obtained according to the side length W of the target surface of the chip of the camera module 52 parallel to the width direction of the cloth, which is not described herein, of course, the resolution of the camera module 52 should meet the shooting requirement;
According to the above three results, if no omission occurs, the conveying length L2 of the cloth should be equal to or less than the vertical detection distance H of the field of view at one of the photographing waiting times T2 of the photographing module 52, and similarly, the time for the cloth to pass through the vertical detection distance H of the field of view is T3, and the photographing waiting time T2 should be less than or equal to T3, wherein the time for the cloth to pass through the vertical detection distance H of the field of view is T3, which can be understood as the time taken for the cloth to be detected to reach the bottom edge of the vertical detection area of the field of view from the top edge of the field of view of the lens 521, that is, the travel is the vertical detection distance H of the field of view is T3. It should be noted that the photographing period of the photographing module 52 is very short, and when the photographing period is ignored, the photographing waiting time T2 may be considered to be equal to T3. That is, based on the preset running speed V of the cloth winding roller 4 and the vertical detection distance H of the visual field of the image pickup module 52, the time t3=h/V when the cloth passes through the vertical detection distance H of the visual field is obtained, and the shooting waiting time T2 of the image pickup module 52 is less than or equal to T3. When t2=t3, the number of pictures taken by the image capturing module 52 can be minimized under the condition that no missed detection occurs, which is beneficial to reducing the transmission of data volume and reducing the memory occupation of the control system.
Taking the actual production parameters of a 96-way circular knitting machine as an example, the existing circular knitting machine can be rotated for 13 circles in one minute, the length of cloth woven by the circular knitting machine for one circle is 15mm, meanwhile, the conveying length of cloth in one circle of time of the circular knitting machine is 15mm, when the preset running time T1 is one minute, the conveying length of cloth of the circular knitting machine is L1=15×13=195 mm, the conveying speed of cloth can be further v=195/60=3.25 mm/s, the visual field longitudinal detection distance H=80 mm of the camera module 52 is preset, the time T3=H/V=80/3.25=24.6 s of the cloth passing the visual field longitudinal detection distance H is obtained, and the detection of the front image of the cloth is completed as long as the shooting time interval T2 is less than or equal to T1, in particular, the shooting time interval T2=20 s in the embodiment. In addition, it should be noted that, the adjacent shooting waiting times T2 may be the same value, for example, the shooting waiting times T2 may be 20s, or may be different values, for example, one shooting waiting time T2 is 10s, and the other shooting waiting time T2 is 20s, so long as the master strip-shaped aggregate image area can fully cover the area with the length of L1, where the master strip-shaped aggregate image area is not excessively limited.
Example two
The cloth detecting device provided in this embodiment is a further improvement on the cloth detecting device in the first embodiment, and is characterized in that the image collecting module 5 further includes a light shielding member 53, and a second light source 533 configured to assist the camera module 52 in collecting the back image of the cloth is disposed on the light shielding member 53. It should be noted that, the cloth is formed by mutually intersecting fabrics, and many tiny pores are formed between the fabrics, which do not completely seal the light-tight, so that the real background on the back of the cloth may interfere with the front image of the cloth acquired by the camera module 52. In order to eliminate interference, the light shielding piece 53 is additionally arranged, the light shielding piece 53 can be made of opaque materials such as a wood board and a metal board, or a light absorbing coating such as a black coating is arranged, background noise can be effectively reduced by arranging the light shielding piece 53, image contrast is improved, and the image acquisition of the front face of the cloth is more accurate.
Referring to fig. 5-8, specifically, the light shielding member 53 is disposed on the frame 1 and opposite to the lens 521 of each image capturing module 52, that is, the lens 521 and the light shielding member 53 of the image capturing module 52 are respectively located on two sides of the front and the back of the cloth, the light shielding member 53 has a light shielding main body 531 matched with the width of the cloth, the light shielding main body 531 is disposed parallel to the mounting base 51, and at least the lens 521 of each image capturing module 52 has a light shielding main body 531 at a corresponding position in the effective view-finding area. It will be appreciated that, each camera module 52 is disposed along the length direction of the mounting seat 51, and the view finding areas of the camera modules 52 located at two ends of the mounting seat 51 cover the edges of the cloth in the width direction, and there may be areas not belonging to the cloth, so that the effective view finding area refers to the view finding area of the corresponding cloth, and the effect of enhancing the front face detection of the cloth can be achieved as long as the light shielding main body 531 is disposed in the effective view finding area. Referring to fig. 5, 9 and 10, in this embodiment, the light-shielding main body 531 further has a groove 532, the cross section of the groove 532 is in a U shape, at least a plurality of second light sources 533 are disposed in the groove 532, the plurality of second light sources 533 may be arranged along the length direction of the groove 532, the plurality of second light sources 533 may also be arranged along the width of the groove 532, the second light sources 533 are electrically connected with a control system and configured to assist the image capturing module 52 in capturing images on the back surface of the cloth, the first light source 522 is also electrically connected with the control system, and the light-capturing strategy of the first light source 522 and the second light source 533 is controlled by the control system to capture images on the front surface and the back surface of the cloth by the image capturing module 52.
When the camera module 52 has the first light source 522, the second light source 533 is turned off when the first light source 522 is turned on, and the effective view-finding areas collected by the lenses 521 of the respective camera modules 52 are overlapped with each other to form a forward bar-shaped aggregate image area; when the second light source 533 is turned on, the first light source 522 is turned off, and at this time, the lens 521 of each camera module 52 collects a set image area constructed by overlapping the effective view areas with each other as a reverse bar-shaped set image area; the overlapping portion of the forward strip-shaped aggregate image area and the reverse strip-shaped aggregate image area is a sub-overlapping area S, the control system sets the shooting waiting time T4 of the image capturing module 52, and at least the sub-overlapping area S is ensured to fully cover the area with the length of L1, which is capable of sliding down the cloth, in the preset running time T1, and the setting of the shooting waiting time T4 is described in detail below. In summary, through setting up the second light source 533 on shade 53, on the basis function of camera module 52 collection cloth front image for camera module 52 can also possess cloth reverse image collection's function through the cooperation with first light source 522, second light source 533, has improved the comprehensive degree that the cloth detected greatly, has effectively reduced the probability of missing to examine.
When the cloth is detected poorly, the cloth needs to be processed manually, and in order to facilitate the operation of the staff, the light shielding piece 53 is further arranged to be movably connected with the frame 1 in a position adjustment manner, and at least when the light shielding piece 53 is at the first position, the light shielding piece is located in the effective scenery taking area corresponding to the lens 521 of the camera module 52; when the light shielding member 53 is at the second position, it is moved away from the effective view-taking area corresponding to the lens 521 of the image capturing module 52, so that the worker can conveniently perform the cloth feeding operation from the first rubber roller set 2 to the second rubber roller set 3. The first position refers to a working position of the light shielding member 53 when the image capturing module 5 is operating normally, at this time, the light shielding main body 531 is located in a region corresponding to the effective view-taking region of the lens 521 of the image capturing module 52 and is substantially parallel to the mounting base 51, and the second position refers to a placement position of the light shielding member 53 when the image capturing module 5 is not operating, during the manual distribution process, at least to ensure that the light shielding member 53 is not located in the region corresponding to the effective view-taking region of the lens 521 of the image capturing module 52, so as to facilitate operation.
Specifically, the light shielding member 53 further includes two side plates 534, the light shielding main body 531 is disposed between the two side plates 534, one end of the side plate 534 is rotatably pivoted with the rack 1 by the rotating shaft 11 disposed on the rack 1, in this embodiment, the end of the side plate 534 pivoted with the rack 1 is specifically a lower end of the side plate 534, a communicating open slot 535 is further formed at a position where the light shielding main body 531 abuts against the side plate 534, an opening portion on the light shielding main body 531 is larger than an opening portion on the side plate 534, a fastener 12 is disposed on the rack 1, the opening slot 535 is penetrated by the fastener 12, and the side plate 534 is pressed against the rack 1, so as to fix the light shielding member 53 at the first position. The fastening member 12 may be a locking screw in threaded connection with the rack 1, the opening slot 535 is used for letting out the fastening member 12 when the light shielding member 53 rotates around the rotation axis 11, the opening portion on the light shielding main body 531 is used for letting out the head of the locking screw, and the opening portion on the side plate 534 is used for letting out the stem of the locking screw, so the opening portion on the light shielding main body 531 is larger than the opening portion on the side plate 534, and in addition, by the arrangement of the opening slot 535, the light shielding member 53 does not need to detach the fastening member 12 when rotating, only needs to unscrew the fastening member 12, so that the operation is simple and convenient. Referring to fig. 8, the frame 1 is further provided with a first limiting member 13 and a second limiting member 14, and the first limiting member 13 and the second limiting member 14 respectively abut against and limit two sides of the side plate 534, so that the light shielding member 53 uses the rotating shaft 11 as the center of the rotating shaft 11, and is switched between a first position and a second position. The first limiting member 13 and the second limiting member 14 are first limiting screws and second limiting screws fixedly connected to the frame 1, a rod portion of each limiting screw is in threaded connection with the frame 1, and a head portion of each limiting screw is configured to be abutted against the side plate 534. When the light shielding piece 53 is to be rotated from the first position to the second position, the fastener 12 is only required to be unscrewed, the light shielding piece 53 is rotated to enable the light shielding piece 53 to rotate around the rotating shaft 11, and the locking screw is simultaneously rotated out of the opening slot 535 until the side edge of the light shielding piece abuts against the head of the second limiting screw, so that the limiting of the light shielding piece 53 at the second position can be completed without other additional operations; when the light shielding member 53 is to be rotated from the second position to the first position, the light shielding member 53 is rotated around the rotation shaft 11 until the light shielding side edge abuts against the head of the first limiting screw to complete the preliminary limiting, and meanwhile, the locking screw is turned into the opening slot 535, and then the locking screw is tightened, so that the fastening of the light shielding member 53 is achieved.
The embodiment also provides a cloth detection method suitable for the open-width cloth winding machine, which is suitable for the cloth detection device and comprises the following steps:
S1: in a preset running time T1, based on a preset running speed V of the cloth rolling roller 4, conveying the cloth from the first rubber roller set 2 to the second rubber roller set 3 for a length of L1, when the first light source 522 of the camera module 52 is provided with the first light source 522, the second light source 533 is turned off, and at this time, the effective view finding areas collected by the lenses 521 of each camera module 52 are mutually overlapped to form a forward bar-shaped collection image area; when the second light source 533 is turned on, the first light source 522 is turned off, and the lenses 521 of the respective image capturing modules 52 collect effective view-finding areas and overlap each other to form a reverse bar-shaped aggregate image area; the overlapping part of the forward bar-shaped aggregate image area and the reverse bar-shaped aggregate image area is a sub-overlapping area S, and the shooting waiting time T4 of the camera module 52 is set by the control system, and it is understood that the shooting waiting time T4 is a time interval between adjacent shooting time periods of the camera module 52, and at least the sub-overlapping area S is ensured to fully cover the area with the length of L1, where the cloth slides downwards;
Further, the view-finding method of the forward bar-shaped aggregate image area and the reverse bar-shaped aggregate image area includes two kinds, wherein one kind is that the forward bar-shaped aggregate image area and the reverse bar-shaped aggregate image area are subject to separate view finding at intervals of the photographing waiting time T4, and the other kind is that the forward bar-shaped aggregate image area and the reverse bar-shaped aggregate image area are continuously obtained, and the loop is continuously obtained after the photographing waiting time T4 is further spaced.
S2: transmitting the real-time cloth image acquired by the camera module 52 to a control system;
The camera module 52 and the control system can realize data transmission through a special data line, the control system can be an upper computer and is configured to process and display the acquisition result of the image, and when the image detection is unqualified, a feedback instruction is output to an external electric device, so that the cloth winding machine is stopped.
S3: based on a qualified template and a threshold value which are preset in a control system, wherein the qualified template refers to a normal produced flawless cloth image, the threshold value refers to the minimum similarity value of the image qualification, the minimum similarity value is analyzed and compared with a real-time cloth image, the similarity between the real-time cloth image and the qualified template is calculated, and the similarity is compared with the threshold value;
If the similarity is greater than the threshold value, the real-time cloth image analysis result is qualified, and the cloth rolling machine continuously operates;
If the similarity is smaller than the threshold value, the real-time cloth image analysis result is unqualified, and the cloth winding machine stops and alarms.
By adopting the method, in the preset running time T1, the sub-overlapping area S collected by the camera module 52 can cover the area of the length L1 of cloth conveying, the detection of the front surface and the back surface of the cloth can be automatically and comprehensively completed, and when the detection is unqualified, the cloth rolling machine can automatically give an alarm, so that the labor intensity of workers is effectively reduced, and the quality of products is ensured.
The cloth detection method of the present embodiment differs from the cloth detection method of the first embodiment in that: the image capturing module 52 captures front and back images of the cloth, so that the capturing strategies of the image capturing module 52 are different, and when the image capturing module 52 captures back images of the cloth, the lighting strategy of the first light source 522 and the second light source 533 is different from that when the image capturing module 52 captures front images of the cloth.
Step S1 is described below with reference to fig. 14a to 14c, fig. 15a to 15c, and fig. 16:
In an actual production scenario, the camera module 52 is fixed, the cloth is transported downwards, and for convenience of analysis, it is assumed that the cloth is in a stationary state, and accordingly the camera module 52 is in an upward motion state. Taking two image capturing modules 52 as an example, in the predetermined running time T1, the upward moving speed of the image capturing modules 52 is equal to the running speed V of the cloth roller 4, and the transverse detection distance W and the longitudinal detection distance H of the view unit of the image capturing module are preset, wherein the transverse detection distance W of the view is the actual transverse length of the detection area in the view of the lens 521, and the longitudinal detection distance H of the view is the actual longitudinal length of the detection area in the view of the lens 521.
The first way in step S1 is: the forward bar set image area and the reverse bar set image area are separately framed at intervals of a photographing waiting time T4, specifically, according to different running speeds V and photographing waiting times T4 of the cloth rolling drum 4, three state diagrams of a sub-overlapping area S are given in fig. 14 a-14 c by taking four photographing time periods as an example, each group of diagrams includes two columns of set image areas, as shown in fig. 14a, wherein the area with a solid line frame at the lower left corner and a section line at the left is a forward bar set image area of a first photographing time period, the area with a broken line frame at the upper left corner and a section line at the right is a reverse bar set image area of a second photographing time period, the area with a solid line frame at the lower right corner and a section line at the left is a forward bar set image area of a third photographing time period, the area with a broken line frame at the upper right corner and a section line at the right is a reverse bar set image area of a fourth photographing time period, and the photographing time periods sequentially pass through the first photographing time period, the second photographing time period, the third photographing time period and the fourth photographing time period are sequentially overlapped with each other, namely, the forward bar set image area of the first photographing time period and the fourth photographing time period is a reverse bar set image area of the second photographing time period is obtained, and the second photographing time period is a photographing time period overlapping the fourth photographing time period, and the front bar set image area is a photographing image area of the fourth photographing section is sequentially, i.e. the area of the grid lines represents this area and the front and back sides of the cloth are photographed at the same time. For more direct comparison of the coverage of the cloth, fig. 14a to 14c are divided into two columns, and the sub-overlapping area S only shows the sub-overlapping area S of the first photographing period and the second photographing period, the sub-overlapping area S of the third photographing period and the fourth photographing period, and the sub-overlapping area S of the second photographing period and the third photographing period, and the final two-column merging result are shown in fig. 15a to 15 c.
It will be appreciated that, when the shooting waiting time T4 is preset, the camera module 52 moves up by L3 strokes, and the strokes are compared with the vertical detection distance H of the field of view of the camera module 52 in the following three cases:
As shown in fig. 14a and 15a, after two shooting waiting times T4, the camera module 52 moves up by 2×l3 strokes, wherein 2×l3> h, and the camera module 52 performs four shooting actions at intervals to obtain images of sub-overlapping areas S, wherein gaps exist between adjacent sub-overlapping areas S, and the front and back sides of the cloth cannot be completely detected by the gaps; thus, missed detection can be caused;
As shown in fig. 14b and 15b, after two shooting waiting times T4, the camera module 52 moves up by 2×l3 strokes, where 2×l3=h, and the camera module 52 performs four shooting actions at intervals to obtain images of the sub-overlapping areas S, where there is no gap between adjacent sub-overlapping areas S, the sub-overlapping areas S are just uninterrupted, so that no missing detection occurs as long as the sub-overlapping areas S can continuously slide down the cloth for full coverage in the area L1 length in the preset running time T1;
As shown in fig. 14c and 15c, after the two photographing waiting times T4, the photographing module 52 moves up by 2×l3 strokes, where 2×l3< h, and the photographing module 52 performs four photographing actions at intervals to obtain images of the sub-overlapping areas S, where there is further overlapping between adjacent sub-overlapping areas S, i.e. the density of the sub-overlapping areas S is greater, and no missed inspection occurs.
Further quantifying, the running speed V of the cloth roller 4, and the photographing waiting time T4, in step S1, the setting of the photographing waiting time T4 further includes:
As shown in fig. 12, the shooting principle of the camera module 52 is shown, based on the working distance WD between the preset lens 521 and the cloth, the focal length f of the camera module 52, and the side length H of the target surface of the chip of the camera module 52 parallel to the conveying direction of the cloth, the vertical detection distance h=h×wd/f of the field of view of the camera module 52 along the conveying direction of the cloth is obtained, and similarly, the horizontal detection distance w=w×wd/f of the field of view of the camera module 52 along the width direction of the cloth is obtained according to the side length W of the target surface of the chip of the camera module 52 parallel to the width direction of the cloth;
According to the above three cases, if no missing inspection occurs, the length of the cloth conveyance is 2×l3 after the two photographing waiting times T4, and the upward travel of the image pickup module 52 in the above analysis should be equal to or smaller than the vertical detection distance H of the field of view. Similarly, based on the running speed V of the cloth winding roller 4, the time for the cloth to pass through the visual field longitudinal detection distance H is T3, and the photographing module 52 should at least complete two photographing waiting times T4, and it should be noted that the photographing time period of the photographing module 52 is very short, and when the photographing time period is ignored, the two photographing waiting times T4 can be considered to be equal to T3. That is, based on the preset running speed V of the cloth-rolling drum 4, the vertical detection distance H of the visual field of the image-capturing module 52 is obtained, the time t3=h/V when the cloth passes through the vertical detection distance H of the visual field, and when the forward bar-shaped aggregate image area and the reverse bar-shaped aggregate image area are obtained separately with the interval shooting waiting time T4, the shooting waiting time T4 of the image-capturing module 52 is less than or equal to T3/2. When t4=t3/2, the number of pictures shot by the camera module 52 can be minimized under the condition that no missed detection occurs, which is beneficial to reducing the transmission of data volume and reducing the memory occupation of the control system.
Taking the actual production parameters of a 96-way circular knitting machine as an example, the existing circular knitting machine can be rotated for 13 circles in one minute, the length of cloth woven by the circular knitting machine for one circle is 15mm, meanwhile, the conveying length of cloth in one circle of time of the circular knitting machine is 15mm, when the preset running time T1 is one minute, the conveying length of cloth of the circular knitting machine is L1=15×13=195 mm, the conveying speed of cloth can be further V=195/60=3.25 mm/s, the vertical detection distance H=80 mm of the visual field of the camera module 52 is preset, the time T3=H/V=80/3.25=24.6 s of the vertical detection distance 80mm of the visual field of the cloth is obtained, and the detection of the front image of the cloth is completed only by the shooting time interval T4=T3/2, specifically, the shooting time interval T4=10 s in the embodiment. In addition, it should be noted that the adjacent shooting waiting times T4 may be the same value, for example, the shooting waiting times T4 may all be 10S, or may be different values, for example, one shooting waiting time T4 is 10S, and the other shooting waiting time T4 is 5S, so long as the sub-overlapping area S can fully cover the area of the cloth sliding downward by L1 length in the preset running time T1, and no limitation is made here.
As shown in fig. 16, during the shooting waiting time T4, the cloth is moved down by L4 strokes, and the second mode in step S1: the forward bar-shaped set image area and the reverse bar-shaped set image area are continuously acquired, and the cyclic continuous acquisition is performed after the interval shooting waiting time T4; the camera module 52 shoots the front face of the cloth and then shoots the back face of the cloth by the standing horse, or shoots the back face of the cloth and then shoots the front face of the cloth by the standing horse after shooting the back face of the cloth in a single shooting time period, so that continuous collection of the front face of the cloth and the back face of the cloth is realized. Of course, after photographing the front side of the cloth, Δt may be set, and photographing the back side of the cloth, where Δt is the delay time reserved for switching the first light source 522 and the second light source 533, and the duration of Δt is very short. Because the photographing time is very short, and the forward bar-shaped set image area and the reverse bar-shaped set image area are continuously acquired, the forward bar-shaped set image area and the reverse bar-shaped set image area are basically overlapped, namely, the area of a sub-overlapped area S where the forward bar-shaped set image area and the reverse bar-shaped set image area are overlapped can be considered to be similar to the area of a mother bar-shaped set image area in the first embodiment, so that the detection method in this way has a detection prevention principle similar to that of the first embodiment, namely, the photographing waiting time T4 of the photographing module 52 is equal to or less than the longitudinal detection distance H of the visual field, and the time when the cloth passes through the longitudinal detection distance H of the visual field is equal to or less than T3. According to the detection method in the first embodiment, based on the preset running speed V of the cloth-rolling roller 4, the longitudinal detection distance H of the visual field of the image capturing module 52 is obtained, and the time t3=h/V of the cloth passing through the longitudinal detection distance H of the visual field is obtained, when the forward bar-shaped set image area and the reverse bar-shaped set image area are continuously obtained, and the photographing waiting time T4 of the image capturing module 52 is less than or equal to T3 after the photographing waiting time T4 is further separated and is circularly continuously obtained. In detail, please refer to the first embodiment, and the description is omitted herein.
The first mode and the second mode in the step S1 are related in that both modes can effectively collect the front surface and the back surface of the cloth without missing detection; the difference between the first mode and the second mode in step S1 is that, in the first mode, the forward stripe-shaped aggregate image area and the reverse stripe-shaped aggregate image area are acquired at intervals of the shooting waiting time T4, so that there is more buffer time for switching on and off of the first light source 522 and the second light source 533, and in addition, when the first mode is adopted, the image capturing module 52 can only detect the front image of the cloth in the first shooting time period, so that the part of the forward stripe-shaped aggregate image area except the sub-overlapping area S cannot detect the back surface of the cloth, and after the first shooting time period, no missed detection occurs when various parameters such as the running speed V of the cloth winding roller 4 and the shooting waiting time T4 are matched. In order to enable the first photographing time period of the first mode to detect the front side and the back side of the cloth at the same time, the starting standby time or the slow starting time of the cloth winding machine can be set, or the second mode can be combined in the first photographing time period, wherein the first photographing time period and the second mode refer to that after the first photographing time period directly and continuously acquire the forward bar-shaped set image area and the reverse bar-shaped set image area, the camera module 52 starts to operate in the first mode.
It should be understood that all of the above preferred embodiments are exemplary and not limiting, and that various modifications or variations of the above-described specific embodiments, which are within the spirit of the application, should be made by those skilled in the art within the legal scope of the application.

Claims (8)

1.一种适用于开幅卷布机的布匹检测装置,所述卷布机是旋转运作于针织大圆机的卷布装置;其特征在于,所述布匹检测装置包括:机架(1),所述机架(1)平行间隔设置有第一胶辊组(2)与第二胶辊组(3),所述第二胶辊组(3)的一侧设有卷布辊筒(4),所述第一胶辊组(2)的出料端对应第二胶辊组(3)的进料端,所述第二胶辊组(3)的出料端对应卷布辊筒(4)的进料端,所述第一胶辊组(2)与第二胶辊组(3)间设置有图像采集模组(5),所述图像采集模组(5)包括安装座(51)及至少两个摄像模块(52),所述安装座(51)的长度方向基本平行于第一胶辊组(2)轴向,在所述安装座(51)沿长度方向布置N个摄像模块(52),N为大于等于2的正整数,其摄像模块(52)的镜头(521)朝向布匹进行图像采集,至少保证N个摄像模块(52)的镜头(521)所分别采集的有效取景区域能够相互无缝连接且能够完全覆盖布匹的幅宽,所述摄像模块(52)电连接有控制系统,所述控制系统用于接收摄像模块(52)所采集的实时图像信息,并将该实时图像信息与其预设的合格模板进行比对分析,一旦分析结果不合格,向外发送反馈指令;1. A cloth detection device suitable for an open-width cloth rolling machine, wherein the cloth rolling machine is a cloth rolling device that rotates on a large circular knitting machine; characterized in that the cloth detection device comprises: a frame (1), wherein the frame (1) is provided with a first rubber roller group (2) and a second rubber roller group (3) in parallel and spaced apart, a cloth rolling roller (4) is provided on one side of the second rubber roller group (3), the discharge end of the first rubber roller group (2) corresponds to the feed end of the second rubber roller group (3), and the discharge end of the second rubber roller group (3) corresponds to the feed end of the cloth rolling roller (4), an image acquisition module (5) is provided between the first rubber roller group (2) and the second rubber roller group (3), and the image acquisition module (5) comprises a mounting seat (51) and at least two camera modules (52), The length direction of the mounting seat (51) is substantially parallel to the axial direction of the first rubber roller group (2); N camera modules (52) are arranged along the length direction of the mounting seat (51); N is a positive integer greater than or equal to 2; the lenses (521) of the camera modules (52) face the cloth to collect images, and at least ensure that the effective viewing areas respectively collected by the lenses (521) of the N camera modules (52) can be seamlessly connected to each other and can completely cover the width of the cloth; the camera modules (52) are electrically connected to a control system, and the control system is used to receive real-time image information collected by the camera modules (52), and compare and analyze the real-time image information with a preset qualified template; if the analysis result is unqualified, a feedback instruction is sent to the outside; 所述摄像模块(52)在位于镜头(521)外径端设置有若干第一光源(522),且在第一光源(522)的外周缘增设一导光罩(523),所述导光罩(523)的侧壁用于将若干所述第一光源(522)的光路投射至摄像模块(52)的镜头(521)正前方;The camera module (52) is provided with a plurality of first light sources (522) at the outer diameter end of the lens (521), and a light guide cover (523) is additionally provided at the outer periphery of the first light source (522), and the side wall of the light guide cover (523) is used to project the light paths of the plurality of first light sources (522) to the front of the lens (521) of the camera module (52); 所述图像采集模组(5)还包括遮光件(53),其设置在机架(1)上,并位于张紧切面远离摄像模块(52)的一侧,所述遮光件(53)具有与布匹宽度相匹配的遮光主体(531),且所述遮光主体(531)与安装座(51)平行布置,至少每个所述摄像模块(52)的镜头(521)对应有效取景区域内存在对应位置的遮光主体(531);The image acquisition module (5) further comprises a light shielding member (53), which is arranged on the frame (1) and is located on a side of the tensioning section away from the camera module (52); the light shielding member (53) comprises a light shielding body (531) matching the width of the cloth, and the light shielding body (531) is arranged in parallel with the mounting seat (51); at least a light shielding body (531) is present at a corresponding position within an effective viewing area corresponding to the lens (521) of each camera module (52); 所述遮光主体(531)具有凹槽(532),所述凹槽(532)内至少设置有若干个第二光源(533),所述第二光源(533)与控制系统电连接,且配置为辅助摄像模块(52)进行布匹反面图像的采集;The light shielding body (531) has a groove (532), and at least a plurality of second light sources (533) are arranged in the groove (532). The second light sources (533) are electrically connected to the control system and are configured to assist the camera module (52) in collecting images of the reverse side of the cloth; 所述遮光件(53)被设置成可与机架(1)之间产生位置调整的活动连接,至少当遮光件(53)处于第一位置时,其处于摄像模块(52)的镜头(521)对应有效取景区域内;当遮光件(53)处于第二位置时,其从摄像模块(52)的镜头(521)对应有效取景区域内移开,方便工人从第一胶辊组(2)至第二胶辊组(3)进行上布作业;The shading member (53) is configured to be movably connected to the frame (1) so as to be positionally adjustable, and at least when the shading member (53) is in a first position, it is located within an effective framing area corresponding to the lens (521) of the camera module (52); when the shading member (53) is in a second position, it is moved away from the effective framing area corresponding to the lens (521) of the camera module (52), so as to facilitate workers to carry out cloth loading operations from the first rubber roller group (2) to the second rubber roller group (3); 所述遮光件(53)还包括两侧板(534),两所述侧板(534)之间设置有所述遮光主体(531),所述侧板(534)的一端藉由设置在机架(1)的转轴(11)与机架(1)可旋转地枢接,在所述遮光主体(531)与侧板(534)邻接处开设有连通的开口槽(535),所述遮光主体(531)上的开口部分大于侧板(534)上的开口部分,所述机架(1)上设置有紧固件(12),通过该紧固件(12)穿透开口槽(535),且使侧板(534)压紧于机架(1),以实现遮光件(53)被固定在第一位置;The shading member (53) further comprises two side plates (534), the shading body (531) being arranged between the two side plates (534), one end of the side plate (534) being rotatably pivotally connected to the frame (1) via a rotating shaft (11) arranged on the frame (1), a communicating opening groove (535) being provided at a position adjacent to the shading body (531) and the side plate (534), the opening portion on the shading body (531) being larger than the opening portion on the side plate (534), a fastener (12) being provided on the frame (1), the fastener (12) penetrating the opening groove (535) and causing the side plate (534) to be pressed against the frame (1), so that the shading member (53) is fixed at the first position; 所述机架(1)上还分别设置有第一限位件(13)与第二限位件(14),所述第一限位件(13)及第二限位件(14)分别与侧板(534)的两侧边相互抵靠限位,使所述遮光件(53)以转轴(11)为旋转轴心,在第一位置及第二位置之间进行切换。The frame (1) is also provided with a first limiting member (13) and a second limiting member (14), respectively; the first limiting member (13) and the second limiting member (14) are respectively abutted against two side edges of the side plate (534) to limit each other, so that the shading member (53) is switched between the first position and the second position with the rotating shaft (11) as the rotation axis. 2.如权利要求1所述的一种适用于开幅卷布机的布匹检测装置,其特征在于,所述第一胶辊组(2)出料端与第二胶辊组(3)进料端的间距为传输间距,所述摄像模块(52)的镜头(521)设置在垂直于布匹正面方向的上方。2. A cloth detection device suitable for an open-width cloth winding machine as described in claim 1, characterized in that the distance between the discharge end of the first rubber roller group (2) and the feed end of the second rubber roller group (3) is a transmission distance, and the lens (521) of the camera module (52) is arranged above the cloth in a direction perpendicular to the front direction of the cloth. 3.如权利要求2所述的一种适用于开幅卷布机的布匹检测装置,其特征在于,所述第一胶辊组(2)出料端的切面与第二胶辊组(3)进料端的切面之间的连线构建出传输切面,所述图像采集模组(5)位于传输切面与卷布辊筒(4)之间。3. A cloth detection device suitable for an open-width cloth winding machine as described in claim 2, characterized in that the line connecting the section at the discharge end of the first rubber roller group (2) and the section at the feed end of the second rubber roller group (3) constructs a transmission section, and the image acquisition module (5) is located between the transmission section and the cloth winding roller (4). 4.一种适用于开幅卷布机的布匹检测方法,应用于权利要求1-3任一所述的开幅卷布机的布匹检测装置,其特征在于,包括以下步骤:4. A cloth detection method applicable to an open-width cloth winding machine, applied to the cloth detection device of the open-width cloth winding machine according to any one of claims 1 to 3, characterized in that it comprises the following steps: S1:在预定运行时间T1内,基于预设的卷布辊筒(4)运行速率V,布匹自第一胶辊组(2)向第二胶辊组(3)进行输送L1长度,当摄像模块(52)具备第一光源(522)时,该第一光源(522)处于常亮状态,该第一光源(522)至少保证在镜头(521)处于工作状态时保持常亮,通过控制系统设定摄像模块(52)的拍摄等待时间T2,各所述摄像模块(52)的有效取景区域相互叠加形成子条形集合图像区域,各子条形集合图像区域所共同构建的母条形集合图像区域能够将布匹向下滑移L1长度的区域进行全覆盖;S1: within a predetermined operation time T1, based on a preset cloth rolling roller (4) operation speed V, the cloth is conveyed from the first rubber roller group (2) to the second rubber roller group (3) by a length of L1, when the camera module (52) is provided with a first light source (522), the first light source (522) is in a constant light state, and the first light source (522) is at least guaranteed to remain constant light when the lens (521) is in a working state, and the shooting waiting time T2 of the camera module (52) is set by the control system, and the effective framing areas of the camera modules (52) are superimposed on each other to form a sub-strip collective image area, and the mother strip collective image area jointly constructed by the sub-strip collective image areas can fully cover the area where the cloth slides downward by a length of L1; S2:将摄像模块(52)采集的实时布匹图像传送至控制系统;S2: transmitting the real-time cloth image captured by the camera module (52) to the control system; S3:基于预设在控制系统内的合格模板和阈值,与实时布匹图像进行分析比对,计算出实时布匹图像与合格模板的相似度,并将相似度与阈值进行比较;S3: Based on the qualified template and threshold value preset in the control system, the real-time cloth image is analyzed and compared, the similarity between the real-time cloth image and the qualified template is calculated, and the similarity is compared with the threshold value; 若相似度大于阈值,则实时布匹图像分析结果为合格,卷布机持续运行;If the similarity is greater than the threshold, the real-time cloth image analysis result is qualified and the cloth winding machine continues to operate; 若相似度小于阈值,则实时布匹图像分析结果为不合格,卷布机停机报警。If the similarity is less than the threshold, the real-time cloth image analysis result is unqualified and the cloth winding machine stops and alarms. 5.如权利要求4所述的一种适用于开幅卷布机的布匹检测方法,其特征在于,所述拍摄等待时间T2的设定进一步包括:5. A cloth detection method suitable for an open-width cloth winding machine according to claim 4, characterized in that the setting of the shooting waiting time T2 further comprises: 基于预设的卷布辊筒(4)的运行速率V、摄像模块(52)的视野纵向检测距离H,获取布匹通过视野纵向检测距离H的时间T3=H/V,所述摄像模块(52)的拍摄等待时间T2≤T3。Based on the preset running speed V of the cloth rolling roller (4) and the longitudinal detection distance H of the field of view of the camera module (52), the time T3=H/V for the cloth to pass through the longitudinal detection distance H of the field of view is obtained, and the shooting waiting time T2≤T3 of the camera module (52). 6.一种适用于开幅卷布机的布匹检测方法,应用于权利要求1-3任一所述的开幅卷布机的布匹检测装置,其特征在于,包括以下步骤:6. A cloth detection method applicable to an open-width cloth-winding machine, applied to the cloth detection device of the open-width cloth-winding machine according to any one of claims 1 to 3, characterized in that it comprises the following steps: S1:在预定运行时间T1内,基于预设的卷布辊筒(4)运行速率V,布匹自第一胶辊组(2)向第二胶辊组(3)进行输送L1长度,当摄像模块(52)具备第一光源(522)时,其第一光源(522)点亮时,所述第二光源(533)关闭,此时各个摄像模块(52)的镜头(521)所采集的有效取景区域相互叠加形成正向条形集合图像区域;当第二光源(533)点亮时,所述第一光源(522)关闭,此时各个摄像模块(52)的镜头(521)采集有效取景区域相互叠加形成反向条形集合图像区域;其中正向条形集合图像区域与反向条形集合图像区域相重合的部分为子重叠区域S,通过控制系统设定摄像模块(52)的拍摄等待时间T4,至少保证子重叠区域S能够将布匹向下滑移L1长度的区域进行全覆盖;S1: within a predetermined operation time T1, based on a preset cloth rolling roller (4) operation speed V, the cloth is conveyed from the first rubber roller group (2) to the second rubber roller group (3) by a length of L1, and when the camera module (52) is provided with a first light source (522), when the first light source (522) is turned on, the second light source (533) is turned off, and at this time, the effective framing areas captured by the lenses (521) of the various camera modules (52) are superimposed on each other to form a forward strip-shaped collective image area; when the second light source (533) is turned on, the first light source (522) is turned off, and at this time, the effective framing areas captured by the lenses (521) of the various camera modules (52) are superimposed on each other to form a reverse strip-shaped collective image area; wherein the portion where the forward strip-shaped collective image area overlaps with the reverse strip-shaped collective image area is a sub-overlapping area S, and the control system sets the shooting waiting time T4 of the camera module (52) to at least ensure that the sub-overlapping area S can fully cover the area where the cloth slides downward by a length of L1; S2:将摄像模块(52)采集的实时布匹图像传送至控制系统;S2: transmitting the real-time cloth image captured by the camera module (52) to the control system; S3:基于预设在控制系统内的合格模板和阈值,与实时布匹图像进行分析比对,计算出实时布匹图像与合格模板的相似度,并将相似度与阈值进行比较;S3: Based on the qualified template and threshold value preset in the control system, the real-time cloth image is analyzed and compared, the similarity between the real-time cloth image and the qualified template is calculated, and the similarity is compared with the threshold value; 若相似度大于阈值,则实时布匹图像分析结果为合格,卷布机持续运行;If the similarity is greater than the threshold, the real-time cloth image analysis result is qualified and the cloth winding machine continues to operate; 若相似度小于阈值,则实时布匹图像分析结果为不合格,卷布机停机报警。If the similarity is less than the threshold, the real-time cloth image analysis result is unqualified and the cloth winding machine stops and alarms. 7.如权利要求6所述的一种适用于开幅卷布机的布匹检测方法,其特征在于,所述拍摄等待时间T4的设定进一步包括:7. A cloth detection method suitable for an open-width cloth winding machine according to claim 6, characterized in that the setting of the shooting waiting time T4 further comprises: 基于预设的卷布辊筒(4)的运行速率V,摄像模块(52)的视野纵向检测距离H,获取布匹通过视野纵向检测距离H的时间T3=H/V,当正向条形集合图像区域和反向条形集合图像区域是间隔拍摄等待时间T4分开获取时,所述摄像模块(52)的拍摄等待时间T4≤T3/2。Based on a preset running speed V of the cloth rolling roller (4), a longitudinal detection distance H of the field of view of the camera module (52), and a time T3=H/V for obtaining the cloth passing through the longitudinal detection distance H of the field of view, when the forward strip-shaped collective image area and the reverse strip-shaped collective image area are obtained separately with an interval shooting waiting time T4, the shooting waiting time T4 of the camera module (52) is ≤T3/2. 8.如权利要求6所述的一种适用于开幅卷布机的布匹检测方法,其特征在于,所述拍摄等待时间T4的设定进一步包括:8. A cloth detection method applicable to an open-width cloth winding machine according to claim 6, characterized in that the setting of the shooting waiting time T4 further comprises: 基于预设的卷布辊筒(4)的运行速率V,摄像模块(52)的视野纵向检测距离H,获取布匹通过视野纵向检测距离H的时间T3=H/V,当正向条形集合图像区域和反向条形集合图像区域是连续获取,且间隔拍摄等待时间T4后循环连续获取时,所述摄像模块(52)的拍摄等待时间T4≤T3。Based on a preset running speed V of the cloth rolling roller (4), a longitudinal detection distance H of the field of view of the camera module (52), and a time T3=H/V for obtaining the cloth passing through the longitudinal detection distance H of the field of view, when the forward stripe collection image area and the reverse stripe collection image area are continuously obtained, and the continuous acquisition is cyclically performed after an interval shooting waiting time T4, the shooting waiting time T4 of the camera module (52) is ≤ T3.
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