JPH01296145A - Mat surface inspection method and apparatus - Google Patents

Abstract

PURPOSE:To enable accurate quality inspection of all mat surfaces in a short time, by detecting the weight, moisture, density, uneven color, array, roughness, length and width as main elements for decision of quality while the mat surfaces are moved with rollers in the direction of warp. CONSTITUTION:A mat surface A on a weight sensor 4 is inserted into a pair of roll gaps of conveying rollers 1A on the transport starting end side to be transferred to the transport ending end side being guided with a proper guide. Meanwhile, main elements for decision of quality of the mat surface A are detected with a weight sensor 4, a moisture sensor 5, a density sensor 6, a uneven color detection sensor, an array detection sensor 8, a roughness detection sensor 9, a length sensor 11 and a width sensor 4. For example, the weight for one of mat surfaces A is determined with the sensor 4 on a 10g basis. Then, changes in moisture are measured with the sensor 5 every second to determine an average moisture value and upper and lower limit values on a 0.1% basis. When the mat surface passes through the sensor 6, density or thick between electrodes is detected to judge deficiency of uneven tightening or the like. Then, signals detected with the sensors are converted into voltages to be processed with an operational controller 3 to display the mat surface A involved being ranked.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a tatami mat surface inspection method and apparatus for inspecting the quality of tatami mat surface.

(Prior art) Traditionally, tatami mats, which are woven, finished and dried by rush producers and shipped as long rolls (usually 20.8 m long), are sent to inspection centers (approximately 80% of the tatami mats produced nationwide). There are 30 facilities in Kumamoto Prefecture, which is occupied by industrial associations, that are visually inspected by inspectors and graded.

[Problems to be Solved by the Invention] Incidentally, the actual situation of inspectors at the above-mentioned inspection site is as described below.

A.Due to processing capacity, all inspections are performed on a sample of each vehicle (referred to as one pile, 16 to 20 long vehicles) brought to the inspection site except for weight.

B. Furthermore, since it is a visual inspection, it takes a long time to check various inspection items, so only a part of the tatami surface is inspected.

C0 A group of multiple inspectors patrols each inspection site and conducts inspections, but the inspectors are appointed by voluntary organizations or industry associations, and do not have any equal qualifications.

Therefore, there are the following problems.

a. Defective products may be mixed into items that are not subjected to handling inspection.

b. Even if it is sampled and inspected, only one (20.8m)
Since not everything is inspected, even if there is a defect in the center of the rolled tatami surface, it will be missed.

C1 inspectors conduct inspections based on their experience and intuition, so
There are variations in the judgment and lack of reliability.

This has led to a serious situation in which the return rate for products shipped is as high as 5 to 6%, widening the disparity in quality between production areas, and increasing distrust of inspectors in their inspections.

The present invention aims to solve these problems, and has as its technical object to provide a tatami surface inspection method and apparatus that can perform quality inspections of all tatami surfaces in a short time and accurately.

Means for Solving Problem C) In order to achieve the above object, the present invention detects the main elements for quality judgment while the tatami facing is unfolded and transferred in the warp direction, and immediately after the transfer is finished, the judgment result is detected. This is a tatami mat surface inspection method that displays.

As an apparatus for carrying out the method, a conveying apparatus is provided for spreading the tatami mats and transporting them in the warp direction.

Along this conveying device, a plurality of detection devices are provided for detecting the main elements of quality determination.

C. Furthermore, an arithmetic device and a display device are provided to calculate the quality judgment value of the tatami mat based on the detection signal of each detection device.

This technical measure was taken.

Examples of the detection device include a weight detection device, a moisture detection device, a density detection device, a color unevenness detection device, an alignment detection device, a roughness detection device, a length detection device, a width detection device, and the like.

Further, the conveying device preferably has a pair of rollers arranged in series in the conveying direction of the tatami surface.

[For production]

While the tatami mat is being transferred in the warp direction by rollers, etc., the main elements for quality determination such as weight, moisture, density, uneven color, alignment, roughness, length, width, etc. are detected, and this detection signal is are processed by the arithmetic unit, and the judgment results are immediately displayed as a grade on the display.

(Embodiment of the Invention) A preferred embodiment of the present invention will be described below with reference to FIGS. 1 and 2.

Conveyance rollers 1A to 1D, which are formed by a pair of upper and lower rollers rotatably arranged side by side, are arranged in series at appropriate intervals in the horizontal direction, and one roller of each conveyance roller IA to 1D is , tatami facing A to one side, e.g. 61n/se
c. The feed motors 2A to 2D are connected to each other for feeding at a certain speed. Next, each detection device will be explained in turn.

A weight sensor 4 consisting of a load cell is installed below the conveyance roller 1A on the conveyance start end side.

The weight sensor 4 is connected to the arithmetic and control unit 3 via an amplifier and an A/D converter (not shown), performs measurement in units of 109, and has a so-called auto-zero function.

A moisture sensor 5 is provided between the conveyance roller 1Δ and the conveyance roller 1B. The moisture sensor 5 uses a capacitance method, and an electrode 5a is attached to the surface that comes into contact with the surface of the tatami surface A. The moisture sensor 5 is connected to the arithmetic and control unit 3,
Formed to measure to the nearest 0.1%.

Between the conveyance roller 1B and the conveyance roller 1C,
A density sensor 6 having an electrode 6a similar to the moisture sensor 5 is provided. The density sensor 6 determines the density or thickness of the tatami surface A, and based on this, it is determined whether there is uneven tightening.

Next, the color unevenness detection sensor and alignment detection sensor 8 provided above the rotating drum 7, which has a white peripheral surface and is rotatably supported, will be described. To explain the outline of the color unevenness detection sensor 7, a light source is installed horizontally across the width direction of the tatami surface A, and three light-receiving elements (all of which are not shown) are installed horizontally in parallel to the light source. R for the element
- A G-8 filter is interposed. Further, each light receiving element is processed by being communicated with the arithmetic and control unit 3, data at three locations are compared, and color unevenness is numerically displayed for each light receiving element.

In addition, by making the circumferential surface of the rotating drum 7 white, so-called auto-zero is performed when no tatami surface is passing through.

The alignment detection sensor 8 is the aforementioned color unevenness detection sensor 7.
It compares minute areas, and mainly due to malfunction of the loom that is lining, there is a lining sensor that detects when two or more rushes are woven side by side (also called cannibalism or double weaving). It mainly consists of a contamination sensor that detects contamination (oil stains, dirt), and both have a background (a reference color plate with similar brightness as the tatami surface) installed horizontally across the width of the tatami surface A, and a sensor horizontally parallel to this. A light source is provided (which may be shared), and 80 sensors are installed in series in the width direction of the tatami surface. Then, in the row sensor, each rush is compared with the background over its entire length, and a signal is detected based on the difference in light intensity between the background and abnormal parts such as rows. On the other hand, the pollution sensor is provided with an R-G-B filter or a sensor corresponding to the R-G filter, and the amount of light passing through each filter is compared with a reference threshold, and when it is blacker than the reference or If it is whiter, it is due to contamination, rushes (rushes cut during weaving), woven grass where the base or tip of the grass is gathered only on one side, or withering due to insect damage. It will be counted as a mixed weave).

Next, regarding the roughness detection device 9, the roughness detection device H9 consists of a light emitting side 9A and a light receiving side 9B, and from the light emitting side 9A, a laser beam that is not affected by color is directed onto the tatami surface A. and light receiving side 9
B1. : It is formed so as to detect the amount of reflected light or the angle of reflection of the light-receiving element, and detect the surface roughness based on the difference in the amount of reflected light or the change in the angle of reflection. Incidentally, since both the laser beam and the light receiving element reciprocate in the width direction of the tatami surface A, the locus on the surface of the tatami surface becomes a zigzag shape.

The rotating drum 7 has auxiliary rollers 1 near the upper left and right sides thereof.
0A and 10B are provided, whereby the tatami surface A is pressed against the circumferential surface of the rotating drum 7, and the tatami surface A is pressed against the conveying roller 1A.
When transferred by ~1D, the rotating drum 7
is formed to rotate. A length sensor 11 such as a rotary encoder is provided at the axis of the rotating drum 7, and the length sensor 11 is set depending on the rotation speed of the rotating drum 7 and the angle when stopped.
It is formed to detect the length of the tatami cover A of the book.

Width sensors 12A and 12B made of photosensor diodes and the like are provided at both ends of the tatami mat surface A in the width direction, and the width (am) to the tatami surface A is calculated by detecting the reflected light from both ends of the tatami surface A. Formed to seek.

Note that the arithmetic and control device 3 includes a display device 13 and a printer 1.
4, an alarm device 15, and a sequencer 16 for the feed motors 2A to 2 are connected.

Since this embodiment is configured as described above, the weight sensor 4
The upper tatami surface A is 1 of I@feeding roller 1A on the conveyance start end side.
It is inserted into the gap between the pair of rolls, and is guided by an appropriate guide (it is recommended to have a table-shaped object or roll-shaped object on the back side, and guide plates on both sides to prevent it from coming off the conveyance path). During the transport, various sensors detect the main elements for determining the quality of the tatami surface A.

In other words, the weight sensor 4 detects the weight of one tatami mat A,
lWkg (100 units) is determined, and then the moisture sensor 5 measures the moisture change moment by moment, and the average moisture value,
The upper limit value and lower limit value are determined in the middle of 0.1%.

Next, when the tatami surface A passes through the density sensor 6, the density or thickness between the electrodes is detected, thereby determining irregular tightening defects and the like.

When the tatami surface A reaches the rotating drum 7, the rotating drum 7 rotates and starts length detection, and the color unevenness detection sensor 7 and the alignment detection sensor 8 perform detection. In other words, in the color unevenness detection sensor 7, the light reflected from the light source on the tatami surface A is divided into spectra using an R-G-B filter, processed, and processed, and compared at three locations in the width direction. The degree of uneven color (enclosure) is expressed numerically. On the other hand, in the arrangement detection sensor 8, by comparing the background with the minute area of the tatami surface A (for each rush), it is possible to determine whether the rushes are arranged poorly or if there is contamination.

Next, in the roughness detection sensor 9, the light source (laser light) and the light receiving element are reciprocated left and right, and the amount of reflected light or the position of the reflected light is detected. Inadequate humidification) etc.

When the end of the tatami surface A passes the rotating drum 7, the rotation of the rotating drum 7 stops, and the length sensor 11 detects the angle and number of rotations at the time of stopping. , the width of the tatami surface A is continuously detected.

In this way, the signals detected by each sensor are amplified, A/D converted, and converted into a voltage according to the detection signal, which is then converted into a signal that is easy to process in the performance control device 3 for calculation control. The tatami surface A is processed, ranked, and immediately copied to the display device 13 and printer 14.

Note that in the above embodiment, the tatami mat A is supplied as a long piece), but it is also possible to supply the tatami mats cut into individual pieces.

Preferably, it is configured to be continuously fed by an automatic feeding device.

〔Effect of the invention〕

As described above, according to the present invention, the disadvantages of visual inspection by inspectors are eliminated, and the entire length of the tatami surface is inspected quickly and accurately, making the inspection fair and impartial. Since individual inspection can be carried out in advance, defective products can be easily and completely removed, and the scrap rate can be significantly reduced.

[Brief explanation of the drawing]

FIG. 1 is a conceptual diagram showing an embodiment of the present invention, and FIG. 2 is a control block diagram thereof. 1A to 1D... Conveyance roller, 2A to 2D... Feed motor, 3... Arithmetic control unit, 4... Weight sensor, 5... Moisture sensor, 6... Density sensor-1
7... Color unevenness detection sensor, 8... Line detection sensor, 9... Roughness detection sensor length -110A, 10B...
・Auxiliary roller, 11...Length sensor, 12.12
A, 12B... Width sensor, 13... Display device, 1
4...Printer, 15...Alarm device, 16.
・・Sequencer〇

Claims (4)

[Claims] (1) A tatami facing inspection method characterized by detecting the main elements for quality determination while the tatami facing is unfolded and transported in the warp direction, and immediately displaying the determination results after the completion of the transport. (2) A conveyance device is provided to spread the tatami face and transport it in the warp direction, and along this conveyance device, a plurality of detection devices are provided to detect the main elements of quality judgment. A tatami surface inspection device comprising a calculation device and a display device that calculates a quality judgment value for the tatami surface based on a signal. (3) The detection device comprises a weight detection device, a moisture detection device, a density detection device, an uneven color detection device, an alignment detection device, a roughness detection device, a length detection device, a width detection device, etc. ) tatami surface inspection device. (4) The tatami facing inspection device according to claim 2 or (3), wherein the conveying device comprises a pair of rollers arranged in series in the conveying direction of the tatami facing.