CN113445201B - Double needle bar warp knitting machine broken yarn on-line detection system based on camera array and method thereof - Google Patents
Double needle bar warp knitting machine broken yarn on-line detection system based on camera array and method thereof Download PDFInfo
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- CN113445201B CN113445201B CN202110818197.XA CN202110818197A CN113445201B CN 113445201 B CN113445201 B CN 113445201B CN 202110818197 A CN202110818197 A CN 202110818197A CN 113445201 B CN113445201 B CN 113445201B
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04B—KNITTING
- D04B35/00—Details of, or auxiliary devices incorporated in, knitting machines, not otherwise provided for
- D04B35/10—Indicating, warning, or safety devices, e.g. stop motions
- D04B35/14—Indicating, warning, or safety devices, e.g. stop motions responsive to thread breakage
Abstract
The invention discloses a double-needle bed warp knitting machine broken yarn on-line detection system based on a camera array, which comprises a processing host, the camera array, a detectable region synchronous sensor, a warp knitting machine control motor and a double-needle bed warp knitting machine, wherein the processing host is electrically connected with the camera array, the detectable region synchronous sensor, the warp knitting machine control motor and the double-needle bed warp knitting machine, the processing host is used for processing information transmitted by a camera and information of the sensor, the camera array is used for photographing the motion process of loop forming and loop releasing of the warp knitting machine, the detectable region synchronous sensor is used for detecting a synchronous hole on a flywheel of the warp knitting machine control motor so as to judge whether a loop forming mechanism is a detectable region or not, the warp knitting machine control motor is used for pushing the loop forming mechanism of the warp knitting machine to work, the camera array comprises a plurality of cameras and illumination light sources which are arranged at equal intervals, the invention has the characteristics of strong practicability and convenient installation.
Description
Technical Field
The invention relates to the technical field of information science and technology of warp knitting machines, in particular to a system and a method for detecting broken filaments of a double-needle-bed warp knitting machine on line based on a camera array.
Background
The warp knitting industry has an important position in the textile industry due to high technological content, excellent productivity and unique product performance, and how to ensure the quality of knitted products is a very critical link. Some scientific and technological enterprises launch related automatic detection equipment, which mainly includes two types: monitoring silk and monitoring cloth cover.
The device for monitoring the filament is represented by blowing infrared automatic stop, the principle is that the filament is blown by wind, once the filament is broken, the filament is blown, the blown filament sweeps through the infrared correlation tube, and the infrared automatic stop device detects shading and stops immediately. The success rate of the equipment is about 80%, the error stop rate is as high as 20%, and the error stop easily causes a stop lever on a cloth cover to cause unnecessary cloth cover flaws.
The automatic stop of the photographing of the cloth cover is monitored by photographing and analyzing whether the photograph has defects or not, and the machine is stopped once the defects are found. Due to the limitation of the installation position of the camera, when broken filaments are detected, the defective cloth is long, and the current market products mainly aim at plain cloth and are limited in detection variety. Therefore, it is necessary to design a device and a method for detecting broken filaments of a double-needle-bed warp knitting machine based on a camera array, which have strong practicability and convenient installation.
Disclosure of Invention
The invention aims to provide a system and a method for detecting broken filaments of a double-needle-bed warp knitting machine on line based on a camera array, so as to solve the problems in the background technology.
In order to solve the technical problems, the invention provides the following technical scheme: the system comprises a processing host, a camera array, a detectable area synchronous sensor, a warp knitting machine control motor and a double-needle-bed warp knitting machine, wherein the processing host is electrically connected with the camera array, the detectable area synchronous sensor, the warp knitting machine control motor and the double-needle-bed warp knitting machine;
the processing host is used for processing information transmitted by the camera and information of the sensor, the camera array is used for photographing the motion process of the warp knitting machine in the looping and the knocking-over, the detectable area synchronous sensor is used for detecting a synchronous hole in a flywheel of a control motor of the warp knitting machine, so that whether a looping mechanism in the warp knitting machine is a detectable area or not is judged, and the control motor of the warp knitting machine is used for pushing the looping mechanism of the warp knitting machine to work.
According to the technical scheme, the processing host comprises a main board, a touch screen, a display, a remote monitor, a single chip microcomputer control board and a warning lamp, wherein the main board is electrically connected with the touch screen, the display screen is electrically connected with the main board, the remote monitor is electrically connected with the main board, the single chip microcomputer control board is electrically connected with the main board, the warning lamp is electrically connected with the main board, a broken yarn analysis module is installed inside the processing host, and the single chip microcomputer control board is electrically connected with the warp knitting machine, the camera and the detectable area sensor;
the main board is used for connecting each part, and simultaneously carries out transmission and data preliminary processing to electronic signal, the touch-sensitive screen is used for carrying out the input of information to handling the host computer, the display screen is used for receiving the signal of main board and forms the image, remote monitoring is used for carrying out remote monitoring to the running state of tricot machine, the singlechip control panel is used for receiving tricot machine start-up shut down signal, camera acquisition start-up signal, detectable area sensor signal, broken yarn analysis module is used for comparing the image of gathering, judges whether broken silk.
According to the technical scheme, the double-needle-bed warp knitting machine comprises a looping mechanism, the looping mechanism comprises a yarn dividing needle, a silk thread penetrates through the inside of the yarn dividing needle, a sinker is arranged below the yarn dividing needle, a knocking-over plate is arranged below the sinker, and the left side of the knocking-over plate is connected with a latch needle in a sliding mode.
The method for detecting broken filaments of the double-needle-bed warp knitting machine on line based on the camera array comprises the following steps:
s1, starting the warp knitting machine, controlling the motor to be electrified by the warp knitting machine, rotating the motor at a specified speed, pushing a looping mechanism of the warp knitting machine to work, and detecting the area sensor to start working;
s2, when the coiling mechanism moves to the state of the detectable area, the sensor of the detectable area can detect the corresponding signal and transmit the signal to the processing host;
s3, when the processing host detects the input of the signal, the processing host transmits an image acquisition starting signal to the camera array, and then the camera array starts to operate to acquire an image;
s4, acquiring images by a camera, sending the images of each frame to a host processor, detecting the image data in each frame by a broken yarn analysis module of the host processor, judging whether a plurality of continuous vacancies exist, sending a stop instruction to the warp knitting machine, and providing an electric signal for a warning lamp to warn if the vacancies exist;
and S5, stopping the warp knitting machine after receiving the stop command, then performing wiring operation by workers, starting the warp knitting machine after the wiring operation is finished, and repeating the step S1.
According to the technical scheme, in the step S2, the detectable area is only silk threads between the settling plate and the yarn guide needle, the latch needle is not beyond the state of the settling plate, the silk threads in the detectable area are photographed, the regularly arranged silk threads appear in an image, if the silk threads are broken, a notch appears, then a signal of the silk thread breaking phenomenon is fed back to the processing host, and the processing host generates a stop signal for the warp knitting machine to prompt the warp knitting machine to stop.
According to the above-mentioned technical means, in the step S2, the detectable area sensor is a proximity switch, and is used for detecting a synchronization hole formed in a flywheel of the warp knitting machine control motor, the synchronization hole corresponds to the detectable area on one side, and the flywheel rotates half a turn and then corresponds to the detectable area on the other side.
According to the above technical solution, in the step S3, when the detectable area sensor detects the synchronous hole on the flywheel of the warp knitting machine control motor, the output waveform is a periodic fluctuation chart and has a synchronous signal, when the processing host detects the synchronous signal, the processing host starts an image capturing signal for the camera array, and after the flywheel rotates for a half turn, the other camera array starts an image capturing trigger signal.
According to the technical scheme, the camera fixing boxes are fixedly installed above the cameras and the illuminating light source, the cameras are placed in the camera fixing boxes to form a camera array, and the camera fixing boxes are fixedly installed between the upright columns on the two sides of the warp knitting machine.
According to the technical scheme, the silk threads are made of a plurality of different types of yarns.
Compared with the prior art, the invention has the following beneficial effects: according to the invention, in the repeated movement process of the looping and the knocking-over of the warp knitting machine, only silk and no other barriers exist between the sinker and the yarn guide needle at the moment of the detectable area. At this specific moment, the photograph automatic stop system triggers and shoots, and neatly arranged silk can appear in the image, if there is disconnected silk to appear, then the breach can appear, and equipment is shut down simultaneously, and the manual work is worked a telephone switchboard, and this photograph automatic stop equipment's advantage is simple to operate, and the defective cloth distance is short, and the rate of accuracy is high, and the variety that detects is many.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic block diagram of the present invention;
FIG. 2 is a schematic diagram of a processing host module of the present invention;
FIG. 3 is a schematic diagram of the motion of the looping mechanism of the present invention;
FIG. 4 is a schematic view of the camera array position of the present invention;
FIG. 5 is a schematic diagram of the output waveform of the detectable area sensor of the present invention;
FIG. 6 is a schematic view of the control motor flywheel of the present invention;
FIG. 7 is a schematic view of a wire notch of the present invention;
in the figure: 1. a yarn guide needle; 2. a settlement plate; 3. latch needles; 4. a silk thread; 5. a knock-over plate; 6. a camera fixing box; 7. a synchronization signal; 8. a flywheel; 9. a synchronization hole; 10. and (4) notches.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
Referring to fig. 1-7, the present invention provides a technical solution: the system comprises a processing host, a camera array, a detectable area synchronous sensor, a warp knitting machine control motor and a double-needle-bed warp knitting machine, wherein the processing host is electrically connected with the camera array, the detectable area synchronous sensor, the warp knitting machine control motor and the double-needle-bed warp knitting machine; the detection signals of the detectable area synchronous sensor can be fed back to the processing host, the processing host can process the signals and feed back the signals to the camera array, the camera array can collect images at the moment, the collected images can be transmitted to the processing host, the images are analyzed, whether the images are broken filaments or not is judged, and when the images are broken filaments, the processing host feeds back the signals to the warp knitting machine to stop the warp knitting machine.
The processing host is used for processing information transmitted by the camera and information of the sensor, the camera array is used for photographing the motion process of the warp knitting machine in the looping and knocking-off process, the detectable area synchronous sensor is used for detecting a synchronous hole in a flywheel of a control motor of the warp knitting machine so as to judge whether the looping mechanism is a detectable area or not, and the control motor of the warp knitting machine is used for pushing the looping mechanism of the warp knitting machine to work.
The camera array comprises a plurality of cameras and illumination light sources which are arranged at equal intervals, the cameras are electrically connected with the illumination light sources, the cameras are electrically connected with the detectable area synchronous sensors, the cameras are used for carrying out image forming on the silk threads, and the illumination light sources are used for providing illumination for the silk thread areas.
The processing host comprises a mainboard, a touch screen, a display, remote monitoring, a single-chip microcomputer control panel and a warning lamp, wherein the mainboard is electrically connected with the touch screen, the display screen is electrically connected with the mainboard, the remote monitoring is electrically connected with the mainboard, the single-chip microcomputer control panel is electrically connected with the mainboard, the warning lamp is electrically connected with the mainboard, a broken yarn analysis module is arranged in the processing host, and the single-chip microcomputer control panel is electrically connected with the warp knitting machine, the camera and the detectable area sensor.
The main board is used for connecting each part, simultaneously carries out transmission and data preliminary treatment to electronic signal, the touch-sensitive screen is used for carrying out the input of information to handling the host computer, the display screen is used for receiving the signal of main board and forms the image, remote monitoring is used for carrying out remote monitoring to the running state of tricot machine, the singlechip control panel is used for receiving tricot machine start-up shut down signal, camera acquisition start-up signal, detectable area sensor signal, broken yarn analysis module is used for comparing the image of gathering, judges whether broken string.
The looping mechanism in the double needle bed warp knitting machine comprises a yarn dividing needle 1, a silk thread 4 penetrates through the yarn dividing needle 1, a sinker 2 is arranged below the yarn dividing needle 1, a knocking-over plate 5 is arranged below the sinker 2, a latch needle 3 is connected to the left side of the knocking-over plate 5 in a sliding mode, in an initial state, such as A, the needle rises and retreats, the sinker 2 moves forwards to press an old coil, in this case, the state is such as B, cloth and the needle rise together, the needle rises to the highest position and needs to pause for a period, in this case, the yarn guide needle swings backwards, in this case, such as C, the yarn swings backwards after traversing a needle distance before the needle, the yarn is wound on the needle, in this case, such as D, yarn laying is completed, in this case, the sinker 2 retreats, the needle descends after yarn laying, and in this case, such as E. The sinker 2 is moved forward, when the needle head is lowered to the upper edge of the grid-like knock-over plate 5, the sinker 2 is moved forward above the grid-like knock-over plate 5, the old loop is dropped off from the needle head, and when the needle is lowered to the lowest position, a new loop is formed, at this time, the state is F, at the state A, E, F, only the thread 4 is between the sinker plate 2 and the yarn guide needle, and the latch needle 3 does not exceed the sinker plate 2, which is called the detectable region.
The method for detecting broken filaments of the double-needle bed warp knitting machine on line based on the camera array comprises the following steps:
s1, starting the warp knitting machine, controlling the motor to be electrified by the warp knitting machine, rotating the motor at a specified speed, pushing a looping mechanism of the warp knitting machine to work, and detecting the area sensor to start working;
s2, when the coiling mechanism moves to the state of the detectable area, the sensor of the detectable area can detect the corresponding signal and transmit the signal to the processing host;
s3, when the processing host detects the input of the signal, the processing host transmits an image acquisition starting signal to the camera array, and then the camera array starts to operate to acquire images;
s4, acquiring images by a camera, sending the images of each frame to a host processor, detecting the image data in each frame by a broken yarn analysis module of the host processor, judging whether a plurality of continuous vacancies exist, sending a stop instruction to the warp knitting machine, and providing an electric signal for a warning lamp to warn if the vacancies exist;
and S5, stopping the warp knitting machine after receiving the stop command, then performing wiring operation by workers, starting the warp knitting machine after the wiring operation is finished, and repeating the step S1.
In the step S2, the detectable region is that only the yarn 4 exists between the settling plate 2 and the yarn guide needle 1, and there is no obstacle, at this time, the latch needle 3 does not exceed the settling plate 2 and does not obstruct the photographing of the camera, when the yarn 4 in the detectable region is photographed, the yarn arranged in order appears in the image, if there is yarn breakage, the phenomenon that the yarn 4 cannot correspond to the image of the yarn will appear in comparison with the image of the yarn, the number of the yarn in the two images is different, the gap 10 will appear in the image, and then the signal of the yarn breakage phenomenon is fed back to the processing host, and the processing host generates a stop signal to the warp knitting machine, so as to prompt the warp knitting machine to stop.
In the step S2, the detectable area sensor is a proximity switch, and is used to detect the synchronous hole 9 on the flywheel 8 of the warp knitting machine control motor, the synchronous hole corresponds to the detectable area on one side, the flywheel 8 rotates half a turn and corresponds to the detectable area on the other side, and when the synchronous hole corresponds to the detectable area on one side, the synchronous signal 7 is generated.
In the step S3, when the detectable area sensor detects the synchronous hole 9 on the flywheel 8 of the warp knitting machine control motor, the output waveform is a periodic fluctuation graph and has a synchronous signal 7, when the processing host detects the synchronous signal 7, the processing host starts an image acquisition signal for the camera array on the detection surface, after the flywheel 8 rotates for a half turn, the processing host sends a trigger signal for starting image acquisition for the camera array on the other surface, and then the camera acquires an image for the silk thread and judges whether there is a phenomenon of silk breakage through comparison and analysis.
The camera fixing boxes are fixedly arranged above the cameras and the illuminating light source, the cameras are placed in the camera fixing boxes to form a camera array, and the camera fixing boxes are fixedly arranged between the upright columns on the two sides of the warp knitting machine.
The silk thread 4 is made of a plurality of different kinds of yarns; more detectable varieties are obtained, and the application range is wide.
It is noted that, herein, relational terms such as first and second, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Also, the terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (1)
1. The broken yarn on-line detection system of the double-needle-bed warp knitting machine based on the camera array comprises a processing host, the camera array, a detectable region synchronous sensor, a warp knitting machine control motor and the double-needle-bed warp knitting machine, and is characterized in that: the processing host is electrically connected with the camera array, the detectable area synchronous sensor, the warp knitting machine control motor and the double-needle bed warp knitting machine;
the processing host is used for processing information transmitted by the camera and information of the sensor, the camera array is used for photographing the motion process of the warp knitting machine in the looping and the knocking-over, the detectable area synchronous sensor is used for detecting a synchronous hole in a flywheel of a control motor of the warp knitting machine so as to judge whether a looping mechanism in the warp knitting machine is a detectable area or not, and the control motor of the warp knitting machine is used for pushing the looping mechanism of the warp knitting machine to work;
the camera array comprises a plurality of cameras and illumination light sources which are arranged at equal intervals, the cameras are electrically connected with the illumination light sources, the cameras are electrically connected with the detectable area synchronous sensors, the cameras are used for carrying out image forming on the silk threads, and the illumination light sources are used for providing illumination for the silk thread areas;
the processing host comprises a main board, a touch screen, a display, a remote monitor, a single-chip microcomputer control board and a warning lamp, wherein the main board is electrically connected with the touch screen, the display is electrically connected with the main board, the remote monitor is electrically connected with the main board, the single-chip microcomputer control board is electrically connected with the main board, the warning lamp is electrically connected with the main board, a broken yarn analysis module is installed in the processing host, and the single-chip microcomputer control board is electrically connected with the warp knitting machine, the camera and the detectable area synchronous sensor;
the system comprises a main board, a touch screen, a display, a singlechip control board, a yarn breakage analysis module, a detection area synchronization sensor and a control module, wherein the main board is used for connecting all parts and simultaneously transmitting electronic signals and primarily processing data, the touch screen is used for inputting information to a processing host, the display is used for receiving signals of the main board and forming images, the remote monitoring is used for remotely monitoring the running state of the warp knitting machine, the singlechip control board is used for receiving signals of starting and stopping the warp knitting machine, signals of collecting and starting a camera and signals of the detection area synchronization sensor, and the yarn breakage analysis module is used for comparing the collected images and judging whether yarn breakage occurs;
the inner part of the double-needle bed warp knitting machine comprises a looping mechanism, the looping mechanism comprises a yarn dividing needle (1), a silk thread (4) penetrates through the inner part of the yarn dividing needle (1), a sinker (2) is arranged below the yarn dividing needle (1), a knocking-over plate (5) is arranged below the sinker (2), and the left side of the knocking-over plate (5) is connected with a latch needle (3) in a sliding manner;
the operation steps of the on-line detection system for broken filaments of the warp knitting machine are as follows:
s1, starting the warp knitting machine, controlling the motor to be electrified by the warp knitting machine, rotating the motor at a specified speed, pushing a looping mechanism of the warp knitting machine to work, and starting the operation of the detectable area synchronous sensor;
s2, when the coiling mechanism moves to the detectable area, the synchronous sensor of the detectable area can detect the corresponding signal and transmit the signal to the processing host;
s3, when the processing host detects the input of the signal, the processing host transmits an image acquisition starting signal to the camera array, and then the camera array starts to operate to acquire images;
s4, acquiring images by a camera, sending the images of each frame to a processing host, detecting whether vacancy exists in the image data of each frame by a broken yarn analysis module of the processing host, if a plurality of continuous vacancies exist, determining that a broken yarn exists, sending a stop instruction to a warp knitting machine, and simultaneously providing an electric signal for a warning lamp to warn the warp knitting machine;
s5, stopping the warp knitting machine after receiving the stop command, then performing wiring operation by workers, and starting the warp knitting machine to repeat the step S1 after the wiring operation is completed;
in the step S2, the detectable area is that only silk threads (4) exist between the sinker (2) and the yarn dividing needle (1) and no obstacle exists, at the moment, the latch needle (3) does not exceed the sinker (2) and cannot block the shooting of the camera, when the silk threads (4) in the detectable area are shot, regularly arranged silk appears in an image, if broken silk appears, the phenomenon that the silk threads (4) cannot correspond to each other can appear in a contrast silk thread image, a gap (10) appears in the image, then a signal with the broken silk phenomenon is fed back to the processing host computer, and the processing host computer generates a stop signal to the warp knitting machine to prompt the warp knitting machine to stop;
in the step S2, the detectable area synchronization sensor is a proximity switch, and is used for detecting a synchronization hole (9) on a flywheel (8) of the warp knitting machine control motor, the synchronization hole corresponds to the detectable area on one side, and the flywheel (8) rotates half a turn and then corresponds to the detectable area on the other side;
in the step S3, when the detectable area synchronization sensor detects the synchronization hole (9) on the flywheel (8) of the warp knitting machine control motor, the output waveform is a periodic fluctuation graph and has a synchronization signal (7), when the processing host detects the synchronization signal (7), the processing host starts an image acquisition signal for the camera array on the detection surface, and after the flywheel (8) rotates for a half circle, the other camera array starts an image acquisition trigger signal;
a camera fixing box is fixedly arranged above the cameras and the illuminating light source, a plurality of cameras are placed in the camera fixing box to form a camera array, and the camera fixing box is fixedly arranged between upright columns on two sides of the warp knitting machine;
the silk thread (4) is made of a plurality of different types of yarns.
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2006299443A (en) * | 2005-04-18 | 2006-11-02 | Tsudakoma Corp | Controlling device of moving member of loom |
| CN202323332U (en) * | 2011-11-28 | 2012-07-11 | 郑文真 | Warp knitting machine device |
| CN102839496A (en) * | 2012-08-30 | 2012-12-26 | 无锡信捷电气股份有限公司 | Visual broken line detection system for warp knitting machine |
| CN102818809A (en) * | 2012-09-05 | 2012-12-12 | 杭州瑞利测控技术有限公司 | Gray cloth defect on-line detecting system based on machine vision and achieving method |
| FI128403B (en) * | 2013-07-05 | 2020-04-30 | Procemex Oy Ltd | Synchronization of imaging |
| CN103451846B (en) * | 2013-09-13 | 2015-11-18 | 福州大学 | A kind of grey cloth broken yarn online test method based on computer vision and system |
| CN103901040B (en) * | 2014-03-27 | 2017-02-01 | 华中科技大学 | Three-dimensional online network defect detection system based on machine vision |
| CN104928837A (en) * | 2015-05-22 | 2015-09-23 | 苏州三立自动化设备有限公司 | Warp knitting machine with thread breakage detection function and thread breakage detection method implemented by aid of warp knitting machine |
| CN104894743B (en) * | 2015-06-17 | 2016-02-24 | 卡尔迈耶（中国）有限公司 | The transmission controlling mechanism of multi-bar jacquard warp |
| CN111433399B (en) * | 2017-11-29 | 2021-11-26 | 乌斯特技术有限公司 | Method and system for triggering fabric inspection on a loom |
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