EP2048273B1 - Procédé et dispositif destinés à la détection d'erreurs dans la fabrication de produits de tuftage et machine de tuftage - Google Patents

Procédé et dispositif destinés à la détection d'erreurs dans la fabrication de produits de tuftage et machine de tuftage Download PDF

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Publication number
EP2048273B1
EP2048273B1 EP07017680.5A EP07017680A EP2048273B1 EP 2048273 B1 EP2048273 B1 EP 2048273B1 EP 07017680 A EP07017680 A EP 07017680A EP 2048273 B1 EP2048273 B1 EP 2048273B1
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EP
European Patent Office
Prior art keywords
transverse offset
needle bar
pattern
transverse
tufted product
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
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EP07017680.5A
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German (de)
English (en)
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EP2048273A1 (fr
Inventor
Rainer Dr. Bongratz
Alfred Ferchau
Klaus Greiner-Mai
Torsten Schöne
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Protechna Herbst GmbH and Co KG
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Protechna Herbst GmbH and Co KG
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Priority to EP07017680.5A priority Critical patent/EP2048273B1/fr
Publication of EP2048273A1 publication Critical patent/EP2048273A1/fr
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Expired - Fee Related legal-status Critical Current
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Classifications

    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • D05C15/08—Tufting machines
    • D05C15/10—Tufting machines operating with a plurality of needles, e.g. in one row

Definitions

  • the present invention relates to a device for detecting defects in tufted goods provided with a transverse offset pattern with an optical detection device for monitoring the surface of the tufted goods.
  • Tufting is one of the common production methods for the production of carpet.
  • vertically moving needles arranged on a needle bar pierce a pile material yarn from above into a supplied sheet carrier material, preferably a woven carrier material or a nonwoven carrier material.
  • a loop of a gripper also "looper" is detained.
  • the needles are usually mounted at a distance of a few millimeters on the needle bar extending over several meters and are moved together. If the carpet is produced as a velor, which today makes up about 70-80% of the production, the pile loops are cut by means of at least one cyclically moving knife while they are still on the grippers.
  • the needle bar and the carrier material according to the pattern between the strokes of the needle bar are moved transversely to a conveying direction of the carrier material relative to each other, resulting in a transverse offset of the pile material yarn on the carrier material. Tear a pile material thread, so it is difficult in such a patterned tufted goods to recognize this designated as a thread break error quickly. This is due in particular to the fact that due to the transverse offset of the pile material yarn, the defect in the finished tufted fabric constantly changes its position according to the pattern. In addition, a single missing or faulty sling is not sufficient to reliably detect an actually occurring production error.
  • this object is achieved by a device for detecting production errors in tufted goods provided with a transverse offset pattern, which device is designed with an optical detection device for monitoring the course of tufting threads of the tufted article, the device comprising the tufting threads in the region of the back of the tufted goods during or after processing by a needle bar by means of the optical detection device transversely to a conveying direction of the tufted goods scans line by line and detects at least one line image, further the device at least two line images for detecting production errors, evaluates and wherein the device takes into account the pattern-related transverse offset of the tufting threads in the evaluation.
  • the pattern applied to the carrier material of the tufted article to be produced with the pile material thread is already taken into account during monitoring of the tufted article during or immediately after its production by means of the optical detection device scanning the tufting line by line, so that in the case of actual production error, such as a yarn breakage, a pattern-related position change of the resulting defects can be considered.
  • a line-by-line scanning means that either only individual lines are scanned sequentially transversely to the conveying direction of the tufted goods, or that several lines are scanned simultaneously, wherein the obtained at least two line images are evaluated for detecting production errors respectively ,
  • a production error such as a yarn breakage
  • line scans performed by means of the optical detection device can be reliably assessed whether there is actually a production error. If the optical detection device has registered an error at a certain point in a line scan, and a corresponding error in a subsequent line scan is no longer detected at the point at which the supposedly broken pile material thread would be located according to the applied pattern, then it has the supposed detected error is a detection error of the optical detection device without an actual production error.
  • the device according to the invention also quickly recognizes that in the last-mentioned case it is merely a registration error, ie a purely statistical error, of the optical detection device and that no further precautions need to be taken, since there is actually no production error.
  • the device according to the invention has a control unit which is coupled to the optical detection device.
  • the control unit may for example be formed by a PC or the like and be provided with a corresponding evaluation software and a control logic with which the device and a tufting machine coupled thereto can be controlled.
  • the control unit may also be implemented as control software running on a computer.
  • the control unit utilizes information about a pattern-related transverse offset.
  • it can be coupled to a transverse offset detector, which outputs the information about the pattern-related lateral offset to the control unit.
  • Such information may be based on a detected relative movement between the needle bar and tufted goods are determined.
  • the transverse offset detector has at least one sensor associated with the needle bar, which detects a pattern-related transverse movement of the needle bar and outputs a signal corresponding to the transverse movement of the needle bar to the transverse displacement detector.
  • the desired pattern is applied to the carrier material by a relative movement between the tufted article and the needle bar. This relative movement is achieved according to this embodiment of the invention by a transverse movement of the needle bar with respect to the conveying direction of the carrier material and thus the tufted goods.
  • the transverse offset detector has at least one sensor monitoring the movement of the tufted goods, which detects a pattern-related transverse movement of the tufted goods and corresponding to the transverse movement of the tufted goods Signal to the control unit.
  • control unit does not receive the information about the transverse offset from a direct detection of a relative movement between the needle bar and the tufted goods, but from other sources of information.
  • control unit transmits the information about the transverse offset directly from the control software for creating the pattern to be applied, from an input medium, for example a data carrier reading device or a manual input unit, directly from the thread progression.
  • an input medium for example a data carrier reading device or a manual input unit
  • a further development of the invention can furthermore provide a transverse offset data memory which temporarily stores the current transverse offset data and outputs this to the control unit during the evaluation of the line images corresponding to the transverse offset data. This aspect is used when there is a significant distance between the needle bar and the monitored area of the tufted goods, which requires temporary storage of the data.
  • the device evaluates a predetermined minimum number, for example at least five, successive line images.
  • a camera in particular a cell camera, can be used as the optical detection device.
  • an area camera can be used, which allows simultaneous capture of multiple line images. Because of their cost-effective availability, CMOS or CCD cameras are preferably used.
  • a light source illuminating the tufting threads of the tufted article in the scanning region of the camera is provided. It should be noted that the tufting threads can also be monitored directly during tufting, that is to say when needling into the carrier material, which permits particularly early detection of production errors.
  • a line scan camera or a surface camera scans the back of the tufted goods transversely to their conveying direction, this provides advantages in the detection of production errors, in particular with irradiation of collimated light with radiation direction transversely to the direction of movement of the carpet due to the resulting intensity differences and contrasts. It should be noted in this context that the invention can be reliably detected after a few line scans, whether an actual production error has occurred or not. With an improvement in the illumination of the scanned area of the tufted article, the number of line scans required to reliably detect actual production errors can be further reduced.
  • the term "light” any electromagnetic radiation can be understood. So it is possible to use light in the visible range.
  • the invention preferably provides in a development that the light lies in the infrared range, in particular with a wavelength of 10 -3 m to 7.8 ⁇ 10 -7 m.
  • the light source on the back or on the functional side arranged the tufted goods. In the second case, the tufted goods are irradiated with transmitted light.
  • the light source and detection device are synchronized with the working cycle of a needle bar for needling the pile material into a carrier material of the tufted article.
  • the detection device comprises an electronic signal filter, in particular a digital filter.
  • the needle bar of a single-needle bar a multi-needle bar, for example a double needle bar (English: “double sliding needle barr"), with at least two independently and mutually movable nail bars or by an offset needle bar ( English: "staggered needle barr”) with at least two staggered needle rows.
  • a separate transverse offset detector and / or transverse offset memory is used per row of pins and taken into account in the evaluation of the detected line images.
  • a control unit to be provided for evaluating the line images and to be coupled to a transverse offset detector or a cross-offset information source, wherein the central control unit receives information about a pattern-related transverse offset from the cross-offset detector or via receives the lateral offset information source and takes into account in the evaluation.
  • the transverse offset detector or the transverse offset information source outputs a signal corresponding to a pattern-related transverse movement of the needle bar to the control unit.
  • the cross-offset detector or the cross-offset information source may output a pattern-related transverse movement of the tufting product corresponding signal to the central control unit.
  • transverse offset detector is coupled to an electronic storage unit in which transverse offset data are stored for a pattern to be applied to the tufted article, wherein the transverse offset detector determines the transverse offset data at least with respect to a current pattern-related transverse movement of the needle bar or / and the tufted goods are output to the control unit.
  • the invention also relates to a tufting machine for producing tufted goods, in particular velor carpet goods, with a needle bar for needling pole material in a carrier material of the tufted goods, at least one gripper for holding pole material loops and at least one knife for cutting the pile material loops at the front of the tufted fabric and with a device of the type described above.
  • FIG. 4 the situation of the production of tufted goods is shown schematically in the side view.
  • a tufting goods web 10 moves according to arrow 12 in Fig. 1 in a conveying direction to the left, for example at a speed of 3 m / min.
  • the tufted fabric 10 is composed of a carrier material 14 and a pile material 16, which is fed in a thread-like manner.
  • the pile material 16 is connected via a plurality of needles 18, which at an in Fig. 4 Not shown needle bar are fixed, introduced into the substrate 14, one speaks of "needles”.
  • the individual pile material loops 22, 24, 26, 28, 30 are cut open with a knife 36.
  • the blade 36 moves up and down cyclically as indicated by arrow 37, i. substantially orthogonal to the direction of movement 12 of the tufting fabric 10 to sever the pile material loops 22 to 30 received and held by the gripper 34.
  • a plurality of threads 40 are on overhead loops, which in the following due to their strength nubs 42nd are called on the back 44 each paired together.
  • the threads 40 have a clearly defined cut end on the functional side 38 when the knife 36 is functioning properly, with all filaments of the threads projecting equidistant from the carrier material 14 on the functional side 38.
  • the pile material thread 16 is needled parallel to the conveying direction 12 into the carrier material 14.
  • the pile material yarn 16 in the direction transverse to the conveying direction 12, ie in the direction orthogonal to the plane according to FIG. 4 spiked into the substrate is needled.
  • Fig. 1 shows a perspective view of a tufting machine 50 according to the invention.
  • This has two guide rollers 52 and 54 which guide a substrate material web 14 stretched over a lying between the guide roller 52 and 54 processing area.
  • a needle bar 56 is arranged, which extends transversely to the conveying direction 12 via the carrier material web 14 and has a multiplicity of needles 18.
  • Each of the needles 18 works according to the in Fig. 4 shown and described above functional scheme.
  • the needle bar 56 is moved in the direction of arrow 20 in the direction perpendicular to the carrier material web 14, wherein the needles 18 penetrate into the carrier material 14 and loops 22 accordingly Fig. 4 form.
  • Fig. 1 In the left area puncture holes 19 of the needles 18 in the tufted goods are indicated.
  • the needle bar 56 In order to needle the respective pile material yarns 16 according to a predetermined pattern in the carrier material 14, the needle bar 56 must in each case when reaching its top dead center position according to FIG. 1 , in which the individual needles 18 do not engage in the carrier material 14, are moved according to arrow 58 in its longitudinal direction, ie orthogonal to the conveying direction 12 of the carrier material 14.
  • the extent of this transverse movement - in this context is also spoken by a transverse offset - by the predetermined pattern determines and leads to a thread pattern corresponding to the desired pattern on the tufted goods.
  • the transverse movement according to arrow 58 is applied to the needle bar 56 via a transverse movement drive device 60.
  • the transverse movement drive device 60 may be, for example, a numerically controlled linear motor or a pairing of cam and associated push rod.
  • the transverse movement is transmitted by the transverse movement drive device 60 via a guide rod 62 to the needle bar 56.
  • the needle bar 56 is linearly guided via the guide rod 62 in a linear bearing 64 and provided at its other end with a further guide rod 66 which is linearly guided in a further linear bearing 68.
  • the linear bearings 64 and 68 of the schematic representation according to FIG. 1 allow the movement according to arrow 20.
  • the tufting machine 50 further comprises a permanently installed line scan camera 70, which scans the rear side 44 of the tufted article 10 along the line S in accordance with the field of view drawn with dashed lines.
  • the position of the detection with the line scan camera is also in FIG. 4 using the arrow E 1 , and the indicated line S characterized. Alternatively, however, it is also possible to monitor the pile material threads 16 prior to needling into the support material 14, as indicated by the arrow E 2 .
  • the line scan camera 70 is provided with an electronic control unit 72. Further, a motion sensor 74 is coupled to the electronic control unit 72, which detects the transverse movement of the needle bar 56 according to arrow 58.
  • the detection range is irradiated to improve the detection quality with collimated light.
  • the light source can be arranged either on the back of the needle bar and irradiate the back of the tufted goods 10, as shown by arrows L 1 and L 2 .
  • the light source serves the carrier material 14 as the reflector.
  • the light source is arranged on the opposite side of the tufted goods 10, in which case the tufted goods 10 are transilluminated in the detection area by the irradiated light, as indicated by arrow L 3 .
  • FIG. 2 shows nine pile material threads F1 to F9, which were introduced, for example, by means of the needles from the area 75 in the carrier material 14. More specifically shows Fig. 2 a section of the back 44 of the tufted fabric 10, in which the pile material threads F1 to F9 run. In the Fig. 2 bold points are points where the pile material yarns F1 to F9 penetrate the substrate 14. In the Fig. 2 bold drawn connecting lines between two bold points give the nubs 44 Fig. 4 again. Further shows Fig. 2 a series of line images S1 to S11, as they were successively taken with the line scan camera 70 along the scan line S.
  • the pile material thread F1 it can be seen that this first linear (in the conveying direction) runs on the substrate 14 in the field of line S1, then was needled in the area of line S2 so that it is transversely offset by two thread spacings d to the right runs on the substrate 14, in the sequence in the line S3 again linear in on the substrate 14 and then in the area of row S4 was again geriadelt so that it extends transversely offset by two thread spacings d on the substrate 14.
  • the pile material thread F1 then again runs linearly on the carrier material 14, then it extends in the region of the line S6 by two thread spacings d to the left transversely offset, in the sequence in the area of the line S7 again linearly offset in the carrier material 14 and then in the region of the line S8 again by two thread spacings d to the left transversely.
  • the lines S1 to S8 form the basic pattern, it is also called rapport. From the line S9, the thread pattern is repeated in accordance with the above description with respect to the lines S1 to S8.
  • Fig. 3 the line images of the individual scanning lines S1 to S11 are shown. Corresponding to the nubs formed by the pile material threads F1 to F9 and the gaps between them are in each scanning line in Fig. 3 a group 78 of black pixels for a detected pile thread and a group 80 of white pixels for one of the gaps.
  • the production error 76 appears for the first time in the scanning line S3 and changes its position in accordance with the thread pattern of the thread F5 predetermined by the pattern.
  • This production error 76 is very difficult to detect due to its constantly changing position.
  • Conventional detection devices can detect only after a plurality of detected scan lines that a certain thread is torn. This is because in conventional detection devices for detecting production errors in tufted goods, only the same positions of the scanning lines are compared with each other. Thus, in the production of tufted goods with patterns, a production error can only be actually and reliably detected if it has occurred several times at one and the same location of the acquired scan lines. Thus, a plurality of detected scanning lines are required to detect the error sufficiently often at the same position.
  • the control unit 72 can use the information on the transverse offset present in this line to indicate the production error 82 contained in the line image S4 interpret that it is one and the same pile material thread, namely the thread F5, which was no longer in its desired position due to the thread breakage already in the line image S3.
  • a monitoring device a method for monitoring the production of tufted goods and a tufting machine is provided with which production errors that occur due to a yarn breakage in the production of tufted goods, quickly and reliably at or immediately after their creation can be detected and appropriate action can be taken on the tufting machine before longer material sections of tufing goods of inferior quality are produced.
  • a cross-offset detection and consideration of the transverse offset can also be dispensed with if a pattern-free tufted fabric is produced, that is, if the pile material threads are linearly needled into the substrate.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)

Claims (22)

  1. Dispositif destiné à la détection d'erreurs (76, 82) dans la fabrication d'un produit de tuftage (10) à motif décalé transversalement, lequel dispositif est équipé d'un moyen de détection optique (70) pour surveiller le cheminement des fils de tuftage (16) du produit de tuftage (10), ce dispositif balayant ligne par ligne et perpendiculairement à la direction d'acheminement (12) du produit de tuftage (10) les fils de tuftage (16) sur l'envers du produit de tuftage (10) à l'aide dudit moyen de détection optique (70), pendant ou après une passe de traitement opérée par une barre à aiguilles (56), et détectant ce faisant au moins une image de lignes, ce même dispositif évaluant au moins deux images de lignes pour détecter des erreurs de fabrication et tenant compte, lors de cette évaluation, du décalage transversal des fils de tuftage (16) en fonction du motif à appliquer.
  2. Dispositif selon la revendication 1,
    caractérisé par une unité de commande (72) couplée audit moyen de détection optique (70).
  3. Dispositif selon la revendication 1 ou 2,
    caractérisé en ce que ladite unité de commande (72) est en outre couplée à un détecteur de décalage transversal (74) ou à une source d'information de décalage transversal, lequel ou laquelle envoie à l'unité de commande (72) des informations sur un décalage transversal en fonction du motif à appliquer.
  4. Dispositif selon la revendication 3,
    caractérisé en ce que ledit détecteur de décalage transversal (74) présente au moins un capteur (74) affecté à ladite barre à aiguilles (56), lequel capteur détecte un mouvement transversal de la barre à aiguilles (56) en fonction du motif à appliquer et envoie à l'unité de commande (72) un signal correspondant au mouvement transversal de la barre à aiguilles (56).
  5. Dispositif selon la revendication 3 ou 4,
    caractérisé en ce que le détecteur de décalage transversal présente au moins un capteur surveillant le mouvement du produit de tuftage, lequel capteur détecte un mouvement transversal du produit de tuftage en fonction du motif à appliquer et envoie au détecteur de décalage transversal un signal correspondant au mouvement transversal du produit de tuftage.
  6. Dispositif selon l'une des revendications 3 à 5,
    caractérisé en ce que l'unité de commande est couplée à une unité de mémoire électronique dans laquelle sont mémorisées des données de décalage transversal pour un motif à appliquer sur le produit de tutftage, les données de décalage transversal contenant des informations de l'unité de commande électronique au moins concernant un mouvement transversal de la barre à aiguilles ou/et du produit de tuftage en fonction du motif à appliquer.
  7. Dispositif selon l'une des revendications 3 à 6,
    caractérisé par une mémoire de données de décalage transversal qui mémorise temporairement les données de décalage transversal actuelles et envoie celles-ci à l'unité de commande lors de l'évaluation des images de lignes correspondant aux données de décalage transversal.
  8. Dispositif selon l'une des revendications précédentes,
    caractérisé en ce que ce dispositif évalue un nombre minimal d'images de lignes successives (S1 à S11), par exemple au moins cinq.
  9. Dispositif selon l'une des revendications précédentes,
    caractérisé en ce que le moyen de détection optique comprend une caméra (70), en particulier une caméra linéaire ou une caméra de surface.
  10. Dispositif selon la revendication 9,
    caractérisé par une source de lumière éclairant les fils de tuftage (16) dans la zone de balayage de la caméra (70).
  11. Dispositif selon la revendication 10,
    caractérisé en ce que la lumière émise par ladite source de lumière est dirigée parallèlement et projetée perpendiculairement à la direction d'acheminement du produit de tuftage.
  12. Dispositif selon la revendication 10 ou 11,
    caractérisé en ce que la source de lumière est disposée du côté de l'envers ou du côté fonctionnel du produit de tuftage.
  13. Dispositif selon l'une des revendications 10 à 12,
    caractérisé en ce que la lumière de la source de lumière se situe dans l'infrarouge, en particulier d'une longueur d'onde comprise entre 10-3 et 7,8·10-7 m.
  14. Dispositif selon l'une des revendications précédentes,
    caractérisé en ce que le moyen de détection comprend un filtre de signal électronique, en particulier un filtre numérique.
  15. Dispositif selon l'une des revendications précédentes,
    caractérisé en ce que la source de lumière et/ou le moyen de détection optique sont synchronisés avec la cadence de travail d'une barre à aiguilles (56) pour introduire la matière à poils (16) dans une matière de support (14) du produit de tuftage (10).
  16. Dispositif selon l'une des revendications précédentes,
    caractérisé en ce que la barre à aiguilles est formée par une barre à aiguilles simple, une barre à aiguilles multiple avec au moins deux barres à aiguilles pouvant être déplacées indépendamment l'une de l'autre ou par une barre à aiguilles de décalage avec au moins deux rangées d'aiguilles pouvant être décalées l'une par rapport à l'autre.
  17. Procédé permettant de surveiller la fabrication d'un produit de tuftage (10) à motif décalé transversalement et de détecter des erreurs de fabrication (76, 82) dans le produit de tuftage (10) à l'aide d'un moyen de détection optique (70) destiné à surveiller les fils de tuftage du produit de tuftage (10),
    caractérisé par les étapes suivantes :
    a) balayage ligne par ligne et perpendiculairement à la direction d'acheminement (12) du produit de tuftage (10) des fils de tuftage (16) sur l'envers du produit de tuftage (10) à l'aide du moyen de détection optique (70), pendant ou après une passe de traitement opérée par une barre à aiguilles (56),
    b) détection d'au moins deux images de lignes (S1 à S11),
    c) évaluation desdites deux images de lignes (S1 à S11)
    d) prise en compte d'un décalage transversal en fonction du motif à appliquer dans le produit de tuftage (10) lors de l'évaluation desdites deux images de lignes (S1 à S11) et
    e) émission d'un signal d'erreur en fonction d'au moins une erreur de fabrication détectée (76, 82).
  18. Procédé selon la revendication 17,
    caractérisé en ce qu'une unité de commande (72) est prévue pour l'évaluation des images de lignes (S1 à S11) et couplée avec un détecteur de décalage transversal (74) ou une source d'information de décalage transversal, l'unité de commande centrale (72) recevant du détecteur de décalage transversal (74) ou par l'intermédiaire de la source d'information de décalage transversal des informations sur un décalage transversal en fonction du motif à appliquer et tenant compte de ces informations lors du processus d'évaluation.
  19. Procédé selon la revendication 18,
    caractérisé en ce que le détecteur de décalage transversal (74) envoie à l'unité de commande centrale un signal correspondant à un mouvement transversal de la barre à aiguilles (56) en fonction du motif à appliquer.
  20. Procédé selon la revendication 18 ou 19,
    caractérisé en ce que le détecteur de décalage transversal (74) ou la source d'information de décalage transversal envoie à l'unité de commande centrale un signal correspondant à un mouvement transversal du produit de tuftage (10) en fonction du motif à appliquer.
  21. Procédé selon l'une des revendications 18 à 20,
    caractérisé en ce que des données de décalage transversal actuelles sont mémorisées temporairement dans une mémoire de données de décalage transversal et envoyées à l'unité de commande lors de l'évaluation des images de lignes correspondant aux données de décalage transversal.
  22. Machine de tuftage pour fabriquer des produits de tuftage (10), en particulier des tissus de moquette velours, comportant une barre à aiguilles (56) pour introduire la matière à poils (16) dans une matière de support (14) du produit de tuftage (10), au moins un préhenseur (34) destiné à retenir les boucles de matière à poils (22 à 30) et au moins un couteau (36) destiné à couper les boucles de matière à poil (22 à 30) sur l'endroit (38) du produit de tuftage (10) ainsi qu'un dispositif selon l'une des revendications 1 à 16.
EP07017680.5A 2007-09-10 2007-09-10 Procédé et dispositif destinés à la détection d'erreurs dans la fabrication de produits de tuftage et machine de tuftage Expired - Fee Related EP2048273B1 (fr)

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EP2048273B1 true EP2048273B1 (fr) 2016-11-09

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