CN114717832A - Rapid detection method for broken needles for spinning - Google Patents
Rapid detection method for broken needles for spinning Download PDFInfo
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- CN114717832A CN114717832A CN202210405786.XA CN202210405786A CN114717832A CN 114717832 A CN114717832 A CN 114717832A CN 202210405786 A CN202210405786 A CN 202210405786A CN 114717832 A CN114717832 A CN 114717832A
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- needle
- broken
- needling
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06H—MARKING, INSPECTING, SEAMING OR SEVERING TEXTILE MATERIALS
- D06H3/00—Inspecting textile materials
- D06H3/14—Detecting and removing metal particles, e.g. broken needles, or card clothing, from fabrics
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Textile Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Treatment Of Fiber Materials (AREA)
Abstract
The invention relates to the technical field of spinning, in particular to a method for quickly detecting broken needles for spinning. The method specifically comprises the following steps: (1) before needling production, a needle plate is used for needling a blank sample to obtain a standard sample, then digital image processing is carried out on a needle hole of the standard sample, and a coordinate system is established; (2) after needling production is carried out for a plurality of hours, taking another blank sample piece, carrying out needling treatment on the blank sample piece by using a needle plate to obtain a comparison sample piece, extracting and identifying images of pinholes on the comparison sample piece by adopting a digital image processing technology, and establishing a coordinate system; (3) comparing the established coordinate systems, and if the results are different, finding out the corresponding position of the needle plate to replace the broken needle; if the result is the same, the replacement is not needed; (4) in the subsequent production, the steps (2) and (3) are repeated. The invention can quickly and accurately detect the broken needle and the position thereof without increasing the burden of the existing equipment, and can be suitable for fiber fabrics of various materials.
Description
Technical Field
The invention relates to the technical field of spinning, in particular to a method for quickly detecting broken needles for spinning.
Background
In the operation process of the textile machine, when the textile needle is used for a certain time or meets hard substances, the phenomenon of needle breakage can occur, and if the needle breakage is not replaced in time, the effect and the quality of the textile can be influenced. Therefore, monitoring the operating knitting needle, namely detecting broken needles, is an indispensable important component of the knitting needle, and plays a vital role in improving the product quality and reducing defective and defective products.
Application number 202021955530.9's utility model discloses a broken needle check out test set is used in spinning machine processing utilizes the tight power extrusion compression spring of braided wire during operation, and mutually supporting between pressure sensor, control panel and the warning light can reach the effect of real-time supervision broken needle through pressing pressure sensor, and when pressure sensor's pressure coefficient suddenly reduced, the warning light was lighted, reached the purpose that detects. However, as is well known to those skilled in the art, the needles oscillate as they reciprocate up and down with the needle plate during the needling process, and the force generated by the needling process after the needles are broken varies slightly, so that the small variation of the force is disturbed by the oscillation during the reciprocating process and is difficult to be accurately detected by the pressure sensor.
The invention discloses an application number 201710036716.0 patent discloses a damaged needle flaw detection method of a circular knitting machine, which is characterized in that a machine learning method is utilized to detect damaged needles of fabrics, a flaw image is preprocessed through a self-adaptive image enhancement technology, an interested area is effectively segmented, and characteristic information of fabric flaw points is effectively extracted according to a multi-scale pyramid method with consistent phases; in the aspect of classification and identification of fabric defect points, a supergraph regularization attribute learning is utilized to successfully detect fabric broken needle defects. However, this method is not suitable for carbon fiber fabrics, and those skilled in the art know that carbon fibers are black, so that fabrics made of carbon fibers are also black in whole, and an image acquisition system is used for shooting and acquiring, so that even if image enhancement processing is performed, a defect area is difficult to distinguish, and more unreliable, the defect area of the carbon fiber fabrics is also changed correspondingly with the lapse of time in the needling process, so that extracted characteristic information of fabric defect points is difficult to be summarized, and thus broken needles are detected.
Therefore, a new method for rapidly detecting broken needles for spinning needs to be provided through research.
Disclosure of Invention
The invention aims to provide a method for quickly detecting broken needles for spinning, which can quickly and accurately detect the broken needles and the positions of the broken needles without increasing the burden of the conventional equipment and is applicable to fiber fabrics made of various materials.
In order to achieve the above object, the present invention provides the following technical solutions:
the invention provides a method for quickly detecting broken needles for spinning, which comprises the following steps:
(1) before needling production, a needle plate is used for needling a blank sample, the needled blank sample is used as a standard sample, a digital image processing technology is adopted for extracting and identifying an image of a needle hole on the standard sample, and a coordinate system is established;
(2) after needling production is carried out for a plurality of hours, taking another blank sample piece, carrying out needling treatment on the blank sample piece by using a needle plate to obtain a comparison sample piece, extracting and identifying images of pinholes on the comparison sample piece by adopting a digital image processing technology, and establishing a coordinate system;
(3) comparing the coordinate systems established in the steps (1) and (2), if the obtained results are different, determining that the difference is the broken needle, and finding the position corresponding to the needle plate for replacing the broken needle; if the result is the same, the replacement is not needed;
(4) and (3) repeating the steps (2) and (3) to monitor and replace the broken needle in subsequent production.
Furthermore, the needle mounting surface of the needle plate is provided with vertical and horizontal coordinate axis scale marks according to the rows and columns of the mounting holes.
Further, the blank sample is in a shape corresponding to the shape of the needle plate.
Further, the punched surface of the blank is matched with the size of the mounting surface of the needle plate.
Further, the color of the blank sample is light; preferably white, tin white, yellow goose, light pink, fruit green, pink green, light blue and light purple; further preferably white, tin white, goose yellow, light pink, fruit green, pink green; more preferably white.
Furthermore, the blank sample piece is made of one of aluminum foil paper, matt powder paper, paperboard, coated paper, forest paper, offset paper, paperboard and photographic paper.
Further, the needling depth of the step (1) and the step (2) is 0.8-1.2 mm; preferably 1 mm.
Further, the needling depth of the step (1) is the same as that of the step (2).
Further, the plurality of hours in the step (2) is 50-300 hours.
Further, the method for extracting and recognizing the image by using the digital image processing technology in the steps (1) and (2) is as follows: journal of sensor and microsystem 2009, 28 vol, No. 6, 73-79, a system for rapidly detecting micro-holes based on digital image processing technology.
The invention also provides application of the method for rapidly detecting the broken needle for spinning in the needling process of the carbon fiber fabric. Wherein the surface density of the carbon fiber fabric is 15-500 g/m2。
Compared with the prior art, the invention has the following beneficial effects:
1. the method for establishing the coordinate system by combining the blank sample piece with the digital image processing technology is adopted to detect broken needles of the weaving machine, is simple, quick, accurate and reliable, and avoids the problem of unreliable detection results caused by various external factors in pressure sensing detection and direct image scanning detection;
2. the detection method does not need any precision modification on the existing equipment, greatly saves the equipment modification and subsequent maintenance cost, and improves the economic benefit;
3. the detection method of the invention has no any limit to the material and color of the product, and can be widely applied to fiber fabrics of various materials.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the provided drawings without creative efforts.
FIG. 1 is a schematic view of a needle board mounting face;
fig. 2 is a graph established by the standard sample piece and the comparison sample piece in example 1, wherein (a) is a graph established by the standard sample piece, and (b) is a graph established by the comparison sample piece;
fig. 3 is a graph established by the standard sample piece and the comparison sample piece in example 2, wherein (a) is a graph established by the standard sample piece, and (b) is a graph established by the comparison sample piece;
fig. 4 is a coordinate graph established by the standard sample and the comparison sample of example 3, wherein (a) is the coordinate graph established by the standard sample, and (b) is the coordinate graph established by the comparison sample.
Detailed Description
During the needle punching process, the phenomenon of needle breakage often occurs, and an experienced technician generally stops the machine after the pricking pins are used for a certain frequency, touches the puncturing section of each pricking pin to judge the damage of the pricking pin, and then changes the broken needle. As is known to those skilled in the art, the needle plates of weaving machines are equipped with a large number of needles, which are not safe and efficient for each touch detection and which require a certain experience of the operator. However, as described in the background art, the improvement design of the detection equipment is performed on the basis of the original equipment, so that the production cost is greatly increased, the applicability is limited, and the application of sustainable production is not facilitated.
Based on the production process, the breakage of the needle usually occurs at the position of 1-5 mm of the needle point, so that the position of the broken needle can be judged only by detecting the change of a needle hole formed on the fabric when the needle penetrates the fabric by about 1mm before and after the broken needle. However, the collection of the image scanning directly on the pinholes on the fabric is more demanding on the material and color of the fabric, and the fabric which is black like a carbon fiber fabric and the pinholes of which are easy to deform with time is not suitable at all.
Therefore, the application discloses a method for performing comparison monitoring through blank samples, which comprises the following specific steps:
(1) before needling production, needling a blank sample by using a needle plate, wherein the needling depth is 0.8-1.2 mm, the needled blank sample is used as a standard sample, extracting and identifying images of pinholes on the standard sample by adopting a digital image processing technology, and establishing a coordinate system;
(2) after needling production is carried out for a plurality of hours, taking another blank sample piece, carrying out needling treatment on the blank sample piece by using a needle plate to obtain a comparison sample piece, carrying out image extraction and identification on needle holes on the comparison sample piece by adopting a digital image processing technology, and establishing a coordinate system;
(3) comparing the coordinate systems established in the steps (1) and (2), if the obtained results are different, determining that the difference is the broken needle, and finding the position corresponding to the needle plate for replacing the broken needle; if the result is the same, the replacement is not needed;
(4) and (3) repeating the steps (2) and (3) to monitor and replace the broken needle in subsequent production.
Further, in order to find the position of the broken needle on the needle plate more quickly, the vertical and horizontal coordinate axis scale marks are arranged on the needle mounting surface of the needle plate according to the row and the column of the mounting holes, as shown in figure 1.
In the present invention, the blank is shaped to conform to the shape of the needle plate.
In the invention, the size of the needle punching surface of the blank sample piece is consistent with that of the installation surface of the needle plate.
In the invention, the color of the blank sample is light color; preferably white, tin white, yellow goose, light pink, fruit green, pink green, light blue and light purple; further preferably white, tin white, goose yellow, light pink, fruit green, pink green; more preferably white.
In the invention, the blank sample piece is made of a material with a stable aperture after needling, and the blank sample piece is made of one of aluminum foil paper, matt powder paper, paperboard, art paper, forest paper, offset paper, paperboard and photographic paper; preferably one of aluminum foil paper, matt powder paper, paperboard, coated paper, forest paper and offset paper; further preferably, aluminum foil paper.
In the invention, the needling depth of the step (1) and the step (2) is preferably 0.9-1.1 mm; more preferably 1 mm.
In the invention, the needling depth of the step (1) is the same as that of the step (2).
In the invention, the hours in the step (2) are 50-300 hours.
In the present invention, the method for extracting and identifying images by using digital image processing technology is disclosed in the text entitled "micro-cluster-hole rapid detection system based on digital image processing technology" published in sensor and microsystem 2009, volume 28, period 6, 73-79 by zhang sword and the like.
The technical solutions provided by the present invention are described in detail below with reference to examples, but they should not be construed as limiting the scope of the present invention. The surface density of the inventive examples is 15-500 g/m2The carbon fiber fabric of (2) is implemented for a needle-punched production object.
Example 1
A method for quickly detecting broken needles for spinning comprises the following steps:
(1) preparing two blank samples, wherein the two blank samples are white paperboard and the shapes of the two blank samples are consistent with the shapes of the needle plates;
(2) before needling production, a blank sample is used for needling by using a needle plate, the needling depth is 0.8mm, the needled blank sample is used as a standard sample, a digital image processing technology is adopted for extracting and identifying images of pinholes on the standard sample, and a coordinate system shown in figure 2(a) is established;
(3) the density of the film on the opposite surface is 500g/m2After the carbon fiber fabric is produced for 50 hours in a needling mode, another blank sample piece is taken, needling treatment is carried out on the blank sample piece according to the method in the step (1), the needling depth is 0.8mm, a comparison sample piece is obtained, image extraction and identification are carried out on pinholes on the comparison sample piece through a digital image processing technology, and a coordinate system shown in fig. 2(b) is established;
(4) as can be seen by comparing fig. 2(a) and fig. 2(b), the positions of the comparison samples (2, 7), (2, 8), (9, 4), (9, 5), (10, 4), (10, 5) and (21, 6) in the coordinate axes do not have holes identical to those of the standard samples, which indicates that broken needles occur at these positions, and the broken needles can be replaced only by finding the corresponding positions of the needle plate.
Example 2
A method for quickly detecting broken needles for spinning comprises the following steps:
(1) preparing two blank samples which are made of aluminum foil paper and have the shape consistent with that of the needle plate; the needle mounting surface of the needle plate is arranged in a three-coordinate manner according to the mounting hole;
(2) before needling production, taking a blank sample piece, needling by using a needle plate, wherein the needling depth is 1mm, taking the blank sample piece after needling as a standard sample piece, extracting and identifying a pinhole on the standard sample piece by adopting a digital image processing technology, and establishing a coordinate system shown in fig. 3 (a);
(3) the density on the opposite side was 200g/m2After the carbon fiber fabric is produced by needling for 200 hours, taking another blank sample piece, performing needling treatment on the blank sample piece according to the method in the step (1), wherein the needling depth is 1mm to obtain a comparison sample piece, extracting and identifying images of pinholes on the comparison sample piece by adopting a digital image processing technology, and establishing a coordinate system shown in fig. 3 (b);
(4) as can be seen by comparing fig. 3(a) with fig. 2(b), the positions of the comparison samples (2, 3), (2, 4), (2, 7), (7, 4), (8, 7), (10, 1), (12, 8), (14, 4) in the coordinate axes do not have holes identical to those of the standard samples, which indicates that broken needles occur at these positions, and the broken needles can be replaced only by finding the corresponding positions of the needle plates.
Example 3
A method for quickly detecting broken needles for spinning comprises the following steps:
(1) preparing two blank samples, wherein the two blank samples are goose yellow forest paper and the shape of the two blank samples is consistent with that of the needle plate; the needle mounting surface of the needle plate is arranged in a three-coordinate manner according to the mounting hole;
(2) before needling production, taking a blank sample piece, needling by using a needle plate, wherein the needling depth is 1.2mm, taking the blank sample piece after needling as a standard sample piece, extracting and identifying images of needle holes on the standard sample piece by adopting a digital image processing technology, and establishing a coordinate system shown in fig. 4 (a);
(3) the density on the opposite surface was 15g/m2After the carbon fiber fabric is produced for 300 hours in a needling way, another blank sample is taken according to the reference stepPerforming needling treatment on a blank sample by the method in the step (1), wherein the needling depth is 1.2mm to obtain a comparison sample, extracting and identifying images of pinholes on the comparison sample by adopting a digital image processing technology, and establishing a coordinate system shown in fig. 4 (b);
(4) comparing fig. 4(a) and fig. 4(b), it can be seen that the positions of the comparison sample in the coordinate axes (3, 2), (6, 6), (12, 5) do not have holes identical to those of the standard sample, indicating that broken needles are present in these positions, and the broken needles can be replaced only by finding the corresponding positions of the needle plate.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, various modifications and decorations can be made without departing from the principle of the present invention, and these modifications and decorations should also be regarded as the protection scope of the present invention.
Claims (10)
1. A method for rapidly detecting broken needles for spinning is characterized by comprising the following steps:
(1) before needling production, a needle plate is used for needling a blank sample, the needled blank sample is used as a standard sample, a digital image processing technology is adopted for extracting and identifying an image of a needle hole on the standard sample, and a coordinate system is established;
(2) after needling production is carried out for a plurality of hours, taking another blank sample piece, carrying out needling treatment on the blank sample piece by using a needle plate to obtain a comparison sample piece, carrying out image extraction and identification on needle holes on the comparison sample piece by adopting a digital image processing technology, and establishing a coordinate system;
(3) comparing the coordinate systems established in the steps (1) and (2), if the obtained results are different, determining that the difference is the broken needle, and finding the position corresponding to the needle plate for replacing the broken needle; if the result is the same, the replacement is not needed;
(4) and (3) repeating the steps (2) and (3) to monitor and replace the broken needle in subsequent production.
2. The method for rapidly detecting the broken needle for the textile as claimed in claim 1, wherein the needle mounting surface of the needle plate is provided with vertical and horizontal coordinate axis scale marks according to the row of the mounting holes.
3. The method for rapidly detecting broken needles for textile use according to claim 1, wherein the blank sample has a shape corresponding to the shape of the needle plate.
4. The method for rapidly detecting broken needles for textile use according to claim 1 or 3, wherein the size of the needle punching surface of the blank sample piece is consistent with the size of the mounting surface of the needle plate.
5. The method for rapidly detecting the broken needle for spinning according to claim 4, wherein the blank sample is light in color; the blank sample piece is made of one of aluminum foil paper, matte powder paper, paperboard, coated paper, forest paper, offset paper, paperboard and photographic paper.
6. The method for rapidly detecting the broken needle for spinning according to claim 1, wherein the needling depth of the step (1) and the step (2) is 0.8-1.2 mm.
7. The method for rapidly detecting the broken needle for spinning according to claim 1, wherein the needling depth of the step (1) is the same as that of the step (2).
8. The method for rapidly detecting broken needles for textiles according to claim 1, wherein the hours in the step (2) are 50-300 hours.
9. The application of the method for rapidly detecting broken needles for spinning in any one of claims 1 to 8 in the spinning process of carbon fiber fabrics.
10. The application of the method for rapidly detecting the broken needle for textile in the needling process of the carbon fiber fabric according to claim 9, characterized in thatCharacterized in that the surface density of the carbon fiber fabric is 15-500 g/m2。
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