CN103437061A - Real-time monitoring device and real-time monitoring method for knitting needles - Google Patents
Real-time monitoring device and real-time monitoring method for knitting needles Download PDFInfo
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- CN103437061A CN103437061A CN2013103910057A CN201310391005A CN103437061A CN 103437061 A CN103437061 A CN 103437061A CN 2013103910057 A CN2013103910057 A CN 2013103910057A CN 201310391005 A CN201310391005 A CN 201310391005A CN 103437061 A CN103437061 A CN 103437061A
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Abstract
The invention relates to a real-time monitoring device and a real-time monitoring method for knitting needles. The device comprises a Y-shaped optical fiber bundle, a zoom imaging optical lens group, a detection light source module, a photoelectric detector and a signal processing module. The device disclosed by the invention can accurately detect damaged knitting needles in time, such as knitting needles with broken needle hooks and broken or excessively bending needle heads, and give the alarm in time, and the quality of knit goods can be obviously improved; the device has the characteristics of long working distance, small volume, strong real-time performance and low cost.
Description
Technical field
The present invention relates to the knitting machine of textile industry, particularly a kind of knitting needle real-time monitoring device and method, but the damage situation of knitting needle in Real-Time Monitoring knitting machine operation process, comprise pinhock fracture, syringe needle fracture or overbending, and give the alarm in time.
Background technology
Knitting machine is the equipment that modern textile production is generally used.In the operation process of knitting machine, the knitting needle reciprocating motion that on knitting lathe, an end has a pinhock hooks up yarn, and the yarn tractive is entered to coil or various structure and forms knitted fabric.Once damaging appears in knitting needle, for example pinhock, syringe needle fracture or excessively partially curved and undiscovered, hook up with the action of tractive yarn and do not complete, and on fabric, can produce continuous fault or gap, has a strong impact on the fabric quality, the fabric decrease in yield.Therefore, in the knitting machine course of work, be necessary the knitting needle state is monitored in real time, detecting knitting needle damage or the abnormal later operation of reporting to the police immediately and stopping knitting machine, to carry out knitting needle replacing or reinspection.
Formerly technology one is (referring to " fabric defects online automatic detection method and device thereof based on machine vision ", China Patent No. 201110052541.5, inventor Xue Yun is bright, just built merit, Yang Qiwen, Sun Ning, Shen Jidong) to utilize industrial camera online acquisition textile image and compare with the standard picture template, judgement fault type is also reported to the police.After this device produces by fault, shutdown inspection syringe needle state has judged whether to damage the knitting needle appearance, but this method has the following disadvantages:
1, Real-time Feedback a little less than.This technology is by the detection of fabric defects and indirect detection knitting needle state, finds that fabric occurs after fault that shutdown inspection damages knitting needle again, and the reaction time is longer, and the fabric percent defective caused is high.
2, the detection technique difficulty is large.This technology realizes by real time image processing, needs special-purpose algorithm and standard picture template to compare, and needs the special-purpose image processing software of exploitation, and amount of calculation is large, needs large capacity, high speed computer system.
Formerly technology two is (referring to " circular knit knitting machine needle defect detection device ", U.S. Patent No. 3904529, village in the inventor) method detected according to reverberation, an illuminating source is set near knitting machine neilsbed, adopt an optical fiber or fibre bundle as the reverberation receiving transducer, the alignment probe knitting needle pinhock outside, the light of pinhock reflection by optical fiber or fibre bundle short distance reception after, be converted to the signal of telecommunication by photodetector and processed.When pinhock damages, intensity of reflected light changes.Thus, signal processing system is differentiated the knitting needle state.This device has the following disadvantages:
1, operating distance is excessively near.For guaranteeing that more reverberation enters optical fiber, by photodetector, to be received and to process, optical fiber or fibre bundle one end are necessary close apart from knitting needle, and in 3mm, when installing, debug and using, optical fiber easily contacts firmly with knitting needle, causes the damage of optical fiber or knitting needle.
2, adopt Split type structure, installation procedure is more, takes up room large.The knitting needle pinhock outside need to be aimed at due to light source and optical fiber or fibre bundle simultaneously, therefore enough large space placement light source and optical fiber or fibre bundle need to be reserved in the knitting needle pinhock outside.
Summary of the invention
The object of the invention is to overcome the deficiency of above-mentioned formerly technology, a kind of knitting needle real-time monitoring device and method are provided, this device can detect the knitting needle of damage timely and accurately, comprise the knitting needle of pinhock fracture, syringe needle fracture or overbending and give the alarm in time, can significantly improve the quality of knitwear, this device has the advantages that operating distance is long, volume is little, real-time and cost is low.
Technical solution of the present invention is as follows:
A kind of knitting needle real-time monitoring device, characteristics are that this device comprises the Y-shaped fibre bundle, zoom optical imaging lens group, the probe source module, photodetector and signal processing module, described Y-shaped fibre bundle merges other end maintenance three ends separately by an end of the fine bundle of two-beam: fibre bundle merges end, surveying light optical fiber end and reverberation optical fiber end forms, the light beam coupling that the end face of described detection light optical fiber end and probe source module are sent, the end face of reverberation optical fiber end and the coupling of described photodetector, described fibre bundle merges the object plane that the end face of holding is placed in zoom optical imaging lens group.
Rectangular or the strip of the end surface shape of the merging end of described Y-shaped fibre bundle, formed by multifiber end face close-packed arrays, and the end surface shape at the two ends that described fibre bundle separates is rounded, still by multifiber end face close-packed arrays, is formed.
The end surface shape that described fibre bundle merges end be two long limits near rectangle or strip, comprise three kinds of structures:
The fiber end face of described detection light optical fiber end and reverberation optical fiber end close-packed arrays respectively becomes two rectangles;
The optical fiber of described detection light optical fiber end and reverberation optical fiber end is interlaced, and close-packed arrays becomes a rectangle;
Fiber distribution corresponding to described detection light optical fiber end is near the center line that is parallel to long limit, and fiber distribution corresponding to reverberation optical fiber end is in both sides, and close-packed arrays is orthogonal.
Described zoom optical imaging lens group consists of the first convex lens and the second convex lens successively, and described the first convex lens and the second convex lens have the zoom imaging function.
The optical axis of described zoom optical imaging lens group and the shank of knitting needle are 45° angle to be placed, and the hot spot image space is overlapped over against the outer surface of pinhock bending.
Described probe source module comprises light source and light source driving circuit, and the square-wave signal that is sent certain frequency by light source driving circuit carries out intensity modulated to light source.
Described signal processing module comprises comparator, microcontroller, display and alarm, the input of described comparator is connected with the output of microcontroller, the output of photodetector respectively, the output of comparator is connected with the input of microcontroller, the input of described display is connected with the output of microcontroller, and the input of described alarm is connected with the output of microcontroller.
The input of described light source driving circuit is connected with the output of microcontroller, and the control signal of sending according to microcontroller is set frequency and the dutycycle of described square-wave signal.
Utilize described knitting needle real-time monitoring device knitting needle to be carried out to the method for Real-Time Monitoring, its characteristics are that the method comprises the following steps:
1. opening power, the outer surface by the picture of zoom optical imaging lens group preceding article shaped laser spot over against the pinhock bending, make it overlap area and reach maximum;
2. utilize described photodetector to gather the intensity of reflected light signal of a static knitting needle, the signal magnitude shown according to display is finely tuned described zoom optical imaging lens group position, makes the intensity of reflected light signal meet or exceed the measurement threshold value that device is set;
3. the activation pin loom, utilize described photodetector that time dependent intensity of reflected light signal is changed into to time dependent voltage signal, then voltage signal is input to described comparator;
4. to take the threshold voltage of described microcontroller setting be reference voltage to described comparator, and input voltage signal is changed in square-wave signal input microcontroller;
5. described microcontroller judges according to the square-wave signal change in duty cycle whether knitting needle exists the fracture of pinhock, syringe needle or the damage such as excessively partially curved:
When the square-wave signal dutycycle is less than normal duty cycle range, the microprocessor control alarm gives the alarm, and display shows that types of damage is pinhock, syringe needle fracture; When the square-wave signal dutycycle is greater than normal duty cycle range, the microprocessor control alarm gives the alarm, and display shows that types of damage is that syringe needle is excessively partially curved.
With technology formerly, compare, the present invention has following advantage:
1. directly monitor the knitting needle state, real-time is better.Signal processing module mainly carries out signal modulation, voltage ratio and waits work;
2. operating distance is long, is difficult for causing damage.Zoom optical imaging lens group of the present invention has larger optical numerical value aperture, still have longer operating distance on the basis that guarantees reverberation reception Space Angle, far away apart from knitting needle, avoided causing because of maloperation the damage of optical head in installing, debug and using;
3. the optical fiber fabrication cost is low.Optical fiber transmission light beam used herein is regular size, and manufacturing procedure is simple, and cost is lower.
The accompanying drawing explanation
Fig. 1 is knitting needle real-time monitoring device structural representation of the present invention
Fig. 2 is Y-shaped fibre bundle schematic diagram of the present invention
Fig. 3 is optical system schematic diagram of the present invention
Fig. 4 is principles of signal processing figure of the present invention
Fig. 5 is embodiment of the present invention square-wave signal testing result figure
The specific embodiment
Below in conjunction with drawings and Examples, the present invention is described in detail, but should limit the scope of the invention with this.
First refer to Fig. 1, Fig. 1 is the structured flowchart of knitting needle real-time monitoring device embodiment of the present invention.As seen from the figure, knitting needle real-time monitoring device of the present invention, comprise Y-shaped fibre bundle 1, zoom optical imaging lens group 2, probe source module 3, photodetector 4 and signal processing module 5, described Y-shaped fibre bundle 1 merges other end maintenance three ends separately by an end of the fine bundle of two-beam: fibre bundle merges end, surveying light optical fiber end and reverberation optical fiber end forms, the light beam coupling that the end face of described detection light optical fiber end and probe source module 3 are sent, the end face of reverberation optical fiber end and 4 couplings of described photodetector, described fibre bundle merges the object plane that the end face of holding is placed in zoom optical imaging lens group 2.
Described Y-shaped fibre bundle 1 design is as shown in Fig. 2 the first design, the end surface shape that fibre bundle merges end be two long limits near rectangle or strip, each rectangle or strip are formed by multifiber end face close-packed arrays, and the end face of these two rectangles or strip is corresponding light optical fiber end and the reverberation optical fiber end surveyed respectively.The end surface shape of surveying light optical fiber end and reverberation optical fiber end is circular, still by multifiber end face close-packed arrays, is formed.
Described zoom optical imaging lens group 2 consists of the first convex lens 201 and the second convex lens 202 successively.Described the first convex lens 201, the second convex lens 202 have the zoom imaging function in device.For the adjacent knitting needle signal of clear differentiation, the imaging facula width need be less than or equal to the gap length of thickness of the stems and pin and pin.With reference to the textile industry standard FZ/T90105-1999 of the People's Republic of China (PRC), knitting machine plane No. scope is 2 to 50, and the thickness of the stems scope is 0.26mm～2.2mm, and between pin and pin, the space scope is 0.248mm～10.5mm.For mating knitting needle corresponding to different plane No., the imaging multiplying power will be determined according to the gap length of thickness of the stems and pin and pin, can realize the zoom imaging function by changing the different focal lens.Described zoom optical imaging lens group 2 is 45° angle with shank places, and makes the hot spot image space over against the outer surface of pinhock bending and overlaps as far as possible.
Described probe source module 3 comprises light source 301 and light source driving circuit 302.The detection light optical fiber end coupling of the output beam of described light source 301 and described Y-shaped fibre bundle 1, their relative position will guarantee that the light that light source 301 sends enters detection light optical fiber end as much as possible.The effect of described light source driving circuit 302 is to send the square-wave signal of certain frequency light source is carried out to intensity modulated.
The reverberation optical fiber end coupling of the input of described photodetector 4 and described Y-shaped fibre bundle 1, their relative position will guarantee that the light of reverberation optical fiber end enters photodetector 4 as much as possible.
Described signal processing system comprises comparator 501, microcontroller 502, display 503 and alarm 504.The input of described comparator is connected with the output of microcontroller, the output of photodetector respectively, the output of comparator is connected with the input of microcontroller, the input of described display is connected with the output of microcontroller, and the input of described alarm is connected with the output of microcontroller.
Described comparator 501 is transformed into the square-wave signal with different duty for the voltage signal by input, and is input in described microcontroller 502.When a knitting needle from zoom optical imaging lens group 2 through out-of-date, the voltage signal amplitude of input comparator 501 can first be decreased to the reference voltage that is less than comparator, then increase to and be greater than reference voltage, in process, comparator output square wave produces twice saltus step, and the voltage signal of each root knitting needle all will change a square-wave signal with different duty into thus.
Described microcontroller 502 judge according to the square-wave signal change in duty cycle of input whether knitting needle exists pinhock, syringe needle to rupture or the damage such as excessively partially curved.When the square-wave signal dutycycle is less than normal duty cycle range, microcontroller 502 control alarms 504 give the alarm, and display 503 shows that types of damage are pinhock, syringe needle fracture; When the square-wave signal dutycycle is greater than normal duty cycle range, microcontroller 502 control alarms 504 give the alarm, and display 503 shows that types of damage are that syringe needle is excessively partially curved.
Described light source 301, light source driving circuit 302, comparator 501, microcontroller 502, display 503 and alarm 504, because the connection of these circuit and element is all existing routine, I beg your pardon that I do not repeat them here.
As shown in Figure 1, Figure 2, Figure 3, Figure 4, its concrete structure and parameter are as follows for the structure of most preferred embodiment of the present invention:
Utilize above-described embodiment device to carry out Real-Time Monitoring to the knitting needle on the knitting machine neilsbed of 32 pins/inch:
According to single needle static measurement value U
1, the comparator reference voltage U is set
0=U
1* 40%; Arrange according to the plane No. of knitting machine that to differentiate the normal dutycycle dynamic range of knitting needle state be 30%～70%.
Its actual monitor signal as shown in Figure 5, is the square-wave signal of comparator output in figure.Monitoring result shows, described device reaches 100% to the damage knitting needle in the knitting needle on this knitting needle needle bed and the recognition accuracy of askew pin.
Claims (8)
1. a knitting needle real-time monitoring device, be characterised in that this device comprises Y-shaped fibre bundle (1), zoom optical imaging lens group (2), probe source module (3), photodetector (4) and signal processing module (5), described Y-shaped fibre bundle (1) merges other end maintenance three ends separately by an end of the fine bundle of two-beam: fibre bundle merges end, surveying light optical fiber end and reverberation optical fiber end forms, the light beam coupling that the end face of described detection light optical fiber end and probe source module (3) are sent, the end face of reverberation optical fiber end and described photodetector (4) coupling, described fibre bundle merges the object plane that the end face of holding is placed in zoom optical imaging lens group (2), the output of described photodetector (4) is connected with the input of described signal processing module (5).
2. knitting needle real-time monitoring device according to claim 1, it is characterized in that the rectangular or strip of the end surface shape of merging end of described Y-shaped fibre bundle (1), by multifiber end face close-packed arrays, formed, the end surface shape at the two ends that described fibre bundle separates is rounded, still by multifiber end face close-packed arrays, is formed.
3. knitting needle real-time monitoring device according to claim 2, it is characterized in that end surface shape that described fibre bundle merges end be two long limits near rectangle or strip, comprise three kinds of structures:
The fiber end face of described detection light optical fiber end and reverberation optical fiber end close-packed arrays respectively becomes two rectangles;
The optical fiber of described detection light optical fiber end and reverberation optical fiber end is interlaced, and close-packed arrays becomes a rectangle;
Fiber distribution corresponding to described detection light optical fiber end is near the center line that is parallel to long limit, and fiber distribution corresponding to reverberation optical fiber end is in both sides, and close-packed arrays is orthogonal.
4. knitting needle real-time monitoring device according to claim 1, it is characterized in that described zoom optical imaging lens group (2) consists of the first convex lens (201) successively and the second convex lens (202), described the first convex lens (201) and the second convex lens (202) have the zoom imaging function.
5. knitting needle real-time monitoring device according to claim 1, is characterized in that the optical axis of described zoom optical imaging lens group (2) and the shank of knitting needle (6) are the 45° angle placement, make the hot spot image space overlap over against the outer surface of pinhock bending.
6. knitting needle real-time monitoring device according to claim 1, is characterized in that described probe source module (3) comprises light source (301) and light source driving circuit (302).
7. knitting needle real-time monitoring device according to claim 1, it is characterized in that described signal processing module (5) comprises comparator (501), shaping circuit (502), microcontroller (503), display (504) and alarm (505), the input of described comparator is connected with the output of microcontroller, the output of photodetector respectively, the output of comparator is connected with the input of microcontroller, the input of described display is connected with the output of microcontroller, and the input of described alarm is connected with the output of microcontroller.
8. utilize described knitting needle real-time monitoring device knitting needle to be carried out to the method for Real-Time Monitoring, it is characterized in that the method comprises the following steps:
1. opening power, the outer surface by the picture of zoom optical imaging lens group preceding article shaped laser spot over against the pinhock bending, make it overlap area and reach maximum;
2. utilize described photodetector to gather the intensity of reflected light signal of a static knitting needle, the signal magnitude shown according to display is finely tuned described zoom optical imaging lens group position, makes the intensity of reflected light signal meet or exceed the measurement threshold value that device is set;
3. activation pin loom, described photodetector changes time dependent intensity of reflected light signal into time dependent voltage signal, then voltage signal is input to described comparator;
4. to take the threshold voltage of described microcontroller setting be reference voltage to described comparator, and input voltage signal is changed in square-wave signal input microcontroller;
5. described microcontroller judges according to the square-wave signal change in duty cycle whether knitting needle exists the fracture of pinhock, syringe needle or the damage such as excessively partially curved:
When the square-wave signal dutycycle is less than normal duty cycle range, the microprocessor control alarm gives the alarm, and display shows that types of damage is pinhock, syringe needle fracture; When the square-wave signal dutycycle is greater than normal duty cycle range, the microprocessor control alarm gives the alarm, and display shows that types of damage is that syringe needle is excessively partially curved.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109632817A (en) * | 2019-01-15 | 2019-04-16 | 天津大学 | A kind of online defect detection method of fabric knitting based on collimated laser beam |
| CN109881356A (en) * | 2018-12-25 | 2019-06-14 | 西安工程大学 | Hosiery machine knitting needle on-line measuring device and method based on SVM image classification |
| CN112834523A (en) * | 2021-01-03 | 2021-05-25 | 福建省万物智联科技有限公司 | Broken yarn detection circuit |
| EP4394100A1 (en) | 2022-12-31 | 2024-07-03 | Fundació Eurecat | Method for detecting defects in the needles of an automatic knitting machine, and corresponding system and computer program |
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| EP4394100A1 (en) | 2022-12-31 | 2024-07-03 | Fundació Eurecat | Method for detecting defects in the needles of an automatic knitting machine, and corresponding system and computer program |
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| CN103437061B (en) | 2015-02-18 |
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Effective date of registration: 20180322 Address after: 201815 room 3, 3 J665, room 55, Huiyuan Road, Jiading District, Shanghai Patentee after: Shanghai Zhongke Shenguang Photoelectric Industry Co Ltd Address before: 201800 Jiading District 800-211 post office box, Shanghai Patentee before: Shanghai Optical Precision Machinery Inst., Chinese Academy of Sciences |