EP3732470A2 - Procédés et systèmes de surveillance de la qualité de fils - Google Patents

Procédés et systèmes de surveillance de la qualité de fils

Info

Publication number
EP3732470A2
EP3732470A2 EP18847153.6A EP18847153A EP3732470A2 EP 3732470 A2 EP3732470 A2 EP 3732470A2 EP 18847153 A EP18847153 A EP 18847153A EP 3732470 A2 EP3732470 A2 EP 3732470A2
Authority
EP
European Patent Office
Prior art keywords
yarn
light
image sensor
light source
image
Prior art date
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.)
Withdrawn
Application number
EP18847153.6A
Other languages
German (de)
English (en)
Inventor
Petr Perner
Josef Suska
Ondrej ZELINKA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US15/854,018 external-priority patent/US10605798B2/en
Priority claimed from US15/854,014 external-priority patent/US20190195853A1/en
Application filed by Individual filed Critical Individual
Publication of EP3732470A2 publication Critical patent/EP3732470A2/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G01N21/89—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles
    • G01N21/8914—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the material examined
    • G01N21/8915—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the material examined non-woven textile material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H63/00—Warning or safety devices, e.g. automatic fault detectors, stop-motions ; Quality control of the package
    • B65H63/06—Warning or safety devices, e.g. automatic fault detectors, stop-motions ; Quality control of the package responsive to presence of irregularities in running material, e.g. for severing the material at irregularities ; Control of the correct working of the yarn cleaner
    • B65H63/062—Electronic slub detector
    • B65H63/065—Electronic slub detector using photo-electric sensing means, i.e. the defect signal is a variation of light energy
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01H—SPINNING OR TWISTING
    • D01H13/00—Other common constructional features, details or accessories
    • D01H13/14—Warning or safety devices, e.g. automatic fault detectors, stop motions ; Monitoring the entanglement of slivers in drafting arrangements
    • D01H13/22—Warning or safety devices, e.g. automatic fault detectors, stop motions ; Monitoring the entanglement of slivers in drafting arrangements responsive to presence of irregularities in running material
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00—Measuring arrangements characterised by the use of optical techniques
    • G01B11/08—Measuring arrangements characterised by the use of optical techniques for measuring diameters
    • G01B11/10—Measuring arrangements characterised by the use of optical techniques for measuring diameters of objects while moving
    • G01B11/105—Measuring arrangements characterised by the use of optical techniques for measuring diameters of objects while moving using photoelectric detection means
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N33/00—Investigating or analysing materials by specific methods not covered by groups G01N1/00 - G01N31/00
    • G01N33/36—Textiles
    • G01N33/365—Filiform textiles, e.g. yarns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/30—Handled filamentary material
    • B65H2701/31—Textiles threads or artificial strands of filaments

Definitions

  • the invention relates to a method and device for diameter measuring and color inspection of a linear textile formation such as yarn, thread, textile fibers and slivers.
  • Yarn is a textile formation made by spinning of a relatively short fibrous material into a long continuous unit.
  • Raw cotton is used as one of the many input materials for yarn production.
  • Machine yarns are wound onto coils for easy storage and further processing.
  • Yarn evenness and foreign fibers are important quality parameters in yarn.
  • Yarn evenness refers to the variation in diameter along its length, as yarn has small changes in diameter along its length. There are numerous locations of thick and thin portions along the yarn length. This affects evenness of the yarn.
  • Formign fiber is the presence of foreign particles in the textile yarn. Textile yarn is generally white in color. A presence of foreign fiber interfers with color homogeneity of the yarn. Yarn color analysis detects or determines the presence of foreign fibers. This is one type of monitoring. Yarn evenness and foreign fiber are affected by quality of the materials used.
  • Yarn evenness is also affected during manufacturing by spinning machines. As yarn is produced rapidly and in high volumes, manual inspection by human inspectors is not feasible, but rather impractical, and not possible to an extent required by automated manufacture.
  • the invention provides methods and apparatus, e.g., systems and devices, for monitoring yarn quality for measuring yarn diameter and detecting foreign fibers.
  • the present invention is particularly suitable for mass machine production of yarn, which has increased resistance against accumulated dust particles and which is easily realizable.
  • Embodiments of the invention of claim 11 provide methods for yarn quality monitoring, which are carried out by a primary light source directly illuminating an image sensor through a focusing element.
  • Longitudinally moving yarn is placed as an obstacle between the light source and the image sensor. Images of yarn contours are focused on the image sensor.
  • the longitudinally moving yarn is guided by guiding elements, and is split into small consecutively measured yarn segments whose longitudinal dimension is defined by a longitudinal dimension of a photosensitive area of the image sensor, the speed of yarn movement, and the image sensor sampling rate. Image sensor data for each measured segment is evaluated and the diameter of the yarn is calculated.
  • Embodiments of the invention provide a setup of the yarn, to create an obstacle in the diffused light beam, such that the focusing element creates images with sharp yarn contours suitable for accurate determinations of yarn diameter.
  • the focusing element By using the focusing element, the effects of dust particles accumulated on both optical surfaces (emitter and receiver) placed out of focus are eliminated. Additionally, unwanted ambient light rays coming from the sides are directed outward from the image sensor by the focusing element.
  • two types of light sources are used: a primary light source, which directly illuminates an image sensor, and, a secondary light source, whose rays are reflected from the yarn before they reach the image sensor.
  • a diffraction element is used for diffracting at least portion of light rays.
  • Diffracted light rays create an interference pattern on the image sensor.
  • Undiffracted light rays, originating from the primary light source create a yarn contour image on the image sensor (the "yarn contour image” or “contour image” is created from yarn shadows and non blocked primary light source rays).
  • Undifracted light rays originating from the secondary light source (reflected from the yarn), create a yarn image on the image sensor.
  • Image sensor captured data image data or pixel data is created as any combination of yarn contour image, yarn image and interference patterns.
  • Embodiments of the present invention eliminate problems of prior art, where dust particles and fibers on optical surfaces create sharp shadows on the image sensor. These shadows make accurate yarn diameter evaluation impossible. Embodiments of the present invention are such that particles accumulated on the optical surfaces do not create shadows on the image sensor, even if its size is comparable with the measured yarn itself. Only light intensity on the image sensor will be lower. However, this effect is compensated for by increasing power of the primary light source, see claims 16, 17. Another advantage of using direct image sensor illumination is that significantly lower power of the primary light source is needed to excite the image sensor pixels, than that for configurations where reflected light is captured for yarn diameter processing (not monitoring).
  • measured parts of yarn are illuminated by a secondary light simultaneously with the illumination from the primary light source.
  • the secondary light source is placed on same side of yarn as the image sensor.
  • Light rays from the secondary light source are reflected from the moving yarn and are focused on the image sensor by a focusing element.
  • Secondary light rays reflected by the yarn are diffracted by a diffraction element (placed in front of focusing element or in front of the image sensor), and an interference pattern is created.
  • the focusing element significantly improves image quality. Images of moving yarn contours and its respective interference pattern are simultaneously (see claim 15) captured by the image sensor for further diameter measurements and color analysis of the longitudinally moving yarn.
  • Color analysis may thus be understood as “reflectivity analysis” and is broader in technicals understanding. To include true color analysis and simpler methods too, for example
  • Embodiments of the invention are such that when the diffraction element is employed, the direct color sensing is not used, such that a monochromatic image sensor is used.
  • Measured yarn segment color information is obtained by the processing of light intensity at corresponding pixel positions on the image sensor. Corresponding pixel position depends on color wavelength, yarn diameter, and yarn position.
  • the monochromatic image sensor has high sensitivity and high resolution, while being inexpensive.
  • Embodiments of the invention are such that when using a diffraction element with a zero order mode feature, part of the light rays pass un-diffracted through the diffraction element, and are focused on the image sensor as a yarn image or yarn contour image.
  • the interference pattern created by the diffracted rays is obtained by being captured simultaneously with the yarn image and/or the yarn contour image by the image sensor. Color analysis is obtained by processing of captured interference pattern and yarn diameter is obtained by processing of captured yarn contour image and/or yarn image.
  • Embodiments of the invention of claim 13 are such that monochromatic light, RGB (Red- Green-Blue) light, white light, UV (Ultra-Violet) light, and IR (Infra-Red) light is used as the s secondary light source.
  • RGB Red- Green-Blue
  • white light white light
  • UV Ultra-Violet
  • IR Infra-Red
  • This secondary light source illuminates the yarn, and the image sensor captures light rays reflected from the yarn.
  • Specific light wavelengths are suitable for foreign s fiber detection and monitoring of various yarn materials, e.g. cotton, wool, or synthetic
  • Embodiments of the invention of claim 14 are such that the primary light uses wavelengths different from secondary light. Such wavelength selection in combination with optical filter, which partially covers the image sensor, allows the use of primary light rays only to measure the diameter of the yarn (moved longitudinally). 6
  • parameters of primary light and/or the secondary light source are controlled, preferably via feedback. The feedback is based ons the quality of previously captured images. For example, light intensity is increased when images with low light intensity were previously captured.
  • Embodiments of the invention of claim 1 are directed to an apparatus in the form of a device for yarn quality monitoring.
  • the device includes at least one primary light source illuminating the image sensor, at least one focusing element, at least one image sensor, and a control unit for processing image sensor data.
  • the provided measurement enables monitoring of the yarn quality.
  • the device of claim 1 includes a primary light source, which emits diffusive light, or an additional light diffuser is used.
  • the device also includes at least one optical element in an optical path of primary light for focusing of a yarn contour image on the image sensor.
  • the device has a secondary light source for illuminating the yarn and diffraction element is provided in the optical path.
  • the diffraction element is a diffraction grating.
  • the advantage of the diffraction grating is simplicity and economics.
  • inventions of the device of claim 5 employ monochromatic light, RG B-light, white light, UV-light, IR-light, as a secondary light source.
  • Secondary light source illuminates the yarn and the image sensor captures light reflected from the moving yarn.
  • Specific light wavelengths or its combination are suitable for detection and monitoring of various yarn materials, e.g. cotton, wool or synthetic materials, such as polypropylene.
  • inventions of claim 4 utilize a primary light source with wavelengths different from the secondary light source. Such wavelength selection in combination with an optical filter, covering partially the image sensor, allows for the use of the primary light source only as a single source for measuring the diameter of the yarn.
  • the device includes sources of primary and/or secondary light, which are controlled via e.g., feedback, based on the quality of previously captured images. For example, light intensity is increased when images with low light intensity were previously captured.
  • the focusing element is formed by at least one lens or a combination of lenses, from the group of aspherical lens, mirror lens, convex lens, and concave lens. Lenses or combinations of lenses can be mounted in an M12x0.5 package, see http ://www. m 12 lenses. Board- Lenses-s/12. htm
  • M12x0.5 package allows for the adjustment of a focus distance, and the M12x0.5 package is available at low costs.
  • the image sensor is formed by at least one line or array of light-sensitive pixels. Individual pixels or regions of pixels can be covered with an optical filter layer for specific ranges of light wavelengths. This simplifies further processing of the captured images for diameter measurements and yarn color analysis.
  • the image sensor pixels can include micro lenses for increased sensitivity and limiting of wide angle light rays, such that the image is made sharper.
  • the image sensor is a charge coupled device type. This CCD image sensor is used, as it has high sensitivity and incurs low cost.
  • the device may have an image sensor of a complementary metal oxide semiconductor type.
  • CMOS image sensors have high speed and low power
  • control unit is provided with a programmable logic array (P LA), preferably an FPGA, or an application specific integrated circuit (ASIC), for fast parallel image data processing, microcontroller for yarn quality monitoring, light source control circuits and power supply.
  • P LA programmable logic array
  • ASIC application specific integrated circuit
  • microcontroller for yarn quality monitoring
  • light source control circuits and power supply.
  • an ASIC can be used to integrate image sensor with data processing on one chip.
  • the present invention is an advancement over the prior art, as it allows for accurate yarn measurements and color analysis when significant amounts of dust particles are present. Additionally, the invention provides methods and devices able to measure yarn diameters and :? detect foreign fibers from the same image data, as captured by an image sensor. Embodiments of the invention are directed to a yarn quality monitoring device or system.
  • the device comprises: a primary light source (e.g., a primary light source) for emitting light,6 the light propagation (e.g., travel) defining an optical path; a diffuser proximate to the first light source for diffusing the emitted light; an image sensor illuminated by the diffused lights emitted from the primary light source, for capturing a yarn contour image from illumination of a moving yarn in the optical path; a focusing element in the optical path between the first .14 light source and the image sensor, for focusing the yarn contour image on the image sensor;
  • a primary light source e.g., a primary light source
  • the light propagation e.g., travel
  • a controller in communication with the image sensor for processing the captured yarn contour image, to determine yarn diameter.
  • the device additionally comprises: a secondary light source (e.g., a secondary light source) for illuminating the yarn, the reflected light propagation defining an optical path; a > diffraction element in the optical path, between the yarn and the image sensor, the
  • a secondary light source e.g., a secondary light source
  • the controller is also configured for processing
  • the diffraction element is a diffraction grating.
  • the primary light source and the secondary light source emit light at different wavelengths
  • the device further includes an optical filter at least partially covering the image sensor for blocking light reflected from the yarn illuminated by secondary light source.
  • the secondary light source emits one or more light types including monochromatic light, RG B (Red-Green-Blue) light, white light, UV-light (ultraviolet light) or IR-light (infra-red light).
  • the focusing element includes one or more lenses such as aspherical lenses, s mirror lenses, convex lenses, concave lenses and combinations thereof.
  • the focusing element includes one or more lenses in an M12x0.5 package. The package functionally symbolizes a lens holder with a lens held thereby.
  • the image sensor comprises: one or more lines of photosensitive pixels; and,
  • the image sensor is type of a CMOS (complementary metal oxide semiconductor) sensor or a CCD (charge coupled device).
  • CMOS complementary metal oxide semiconductor
  • CCD charge coupled device
  • the image sensor includes micro-lenses configured to limit wide angle light rays.
  • the controller comprises: a programmable logic array (PLA) fors image data processing, to obtain yarn diameter and/or yarn color analysis; a light control circuit in communication with the PLA, which is controlled by the PLA; and, a microcontroller in communication with the PLA, the microcontroller programmed to evaluate the yarn eveness, and/or the yarn foreign fiber content, from the processed image data.
  • PLA programmable logic array
  • Embodiments of the invention are directed to a method of yarn quality monitoring.
  • the method comprises: illuminating an image sensor with light from a primary light source configured for creating a contour image of a yarn on the image sensor, the primary light > source diffused by a diffuser and focused by a focusing element, on an image sensor,
  • the primary light source, diffuser and focusing element aligned to define an optical path; obtaining a contour image of the yarn by the image sensor, the moving yarn positioned in the optical path between the primary light source and the image sensor; and, processing the yarn contour image to obtain a yarn diameter for the purpose of yarn quality monitoring.
  • the method further comprises: illuminating the moving yarn by a secondary light source, such that the light from the secondary light source is reflected from the moving yarn; focusing the reflected light on the image sensor; diffracting the reflected light from the moving yarn to cause the creation of an interference pattern on the image sensor;
  • the method is such that the secondary light source emits at least one type of light including: monochromatic light, RGB light, white light, UV light, IR light, and combinations thereof.
  • the method is such that the illuminating by the primary light source is at s a wavelength different from a wavelength of light emitted from the secondary light source, and optionally, the method further comprises: covering a portion of the image sensor with s an optical filter; passing the emitted light from the primary light source through the optical filter to a portion of the image sensor; and, blocking light reflected from the yarn, to cause illumination from only the primary light source for measuring a diameter of the moving yarn.
  • the method is such that the capturing of the contour image of the moving yarn and the capturing of the interference pattern is performed simultaneously by the image 4 sensor. 6
  • the method is such that it additionally comprises: controlling the primary light source to emit light at an intensity based on processing results from a previously captureds image from the image sensor in a feedback loop.
  • the method is such that it additionally comprises: controlling the secondary light source to emit light at an intensity based on processing results from previously captured ..3 ⁇ 4 image from the image sensor in a feedback loop.
  • the primary and secondary light may be termed first and second lights (or even light and further light, as used in claim 18 and 28).
  • One light is a > direct light from the light source to the image sensor (inbetween it passes the longitudinally moving yarn).
  • the other one is a reflected light from the moving yarn. Both types of light may be an independent disclosure and claim (or a combination thereof).
  • FIG. 1 is a perspective view of a system in accordance with an
  • FIG. la is a another perspective view of a system in accordance with
  • FIG. 2 is a perspective view of a system in accordance with an
  • FIG. 2a is a perspective view of a system in accordance with another
  • FIG. 3 is a block diagram of the controller of FIGs 1 and 2.
  • FIGs 4A and 4B are flow diagrams of processes performed in the
  • Embodiments of the present invention concern functionally yarn quality monitoring, for example, for all yarns used in the textile industry.
  • FIG. 1 shows a yarn quality monitoring system in an exemplary device, where a primary light source 2 (first light source) directly illuminates an image sensor 3, such that the light propagates along an optical path 100. This through a diffuser 5 and a focusing element 6, for example. Guiding elements 10 (e.g. guided by spaced apart elements 10a and 10b that may be provided for orienting or stabilizing the moving yarn 1) stabilize the longitudinally moving yarn 1. The yarn 1 is guided as an obstacle for diffused light from the light source 2, which illuminate the image sensor 3 behind the yarn.
  • a primary light source 2 first light source
  • a segment or portion of the moving yarn 1 as used in this description is shorter than displayed thick and thin places ly and lx so several measured consecutive segments may represent whole thick or thin place for purpose of monitoring the yarn.
  • FIG. la explains the set-up of FIG 1 and has the longitudinally moving yarn 1 that has in the measuring segment a thick place ly in the yarn 1 and is shown in such a position that contour image of a portion of this thick place ly is focused on the image sensor 3.
  • the image sensor is receiving the light rays from light source 2, diffused by element 5 and focused by element 6.
  • the conversion into an electrical signal is done by the image sensor - and depending on the type of image sensor, CCD-type or CMOS-type, line-oriented or surface oriented, the output 3a conveys a serial signal or a bus signal with several data lines, represented by the "x" along the electrical signal line or path 3a.
  • Segment of the yarn is continuous portion of the yarn which goes through focal point of the focusing element (its image is focused on the image sensor 3) during integration (exposure) time of the image sensor.
  • This time can be for example 37psec (for an exemplary frame rate of 27kFHz of the image sensor 3).
  • a yarn segment has about 0.25mm length (it will indeed be influenced by the focusing element 6 and size of the image sensor pixels, thus the speed Vi of the yarn and sensor sampling rate 1/T 3 (T 3 being the sampling time (interval)) is most important).
  • Information about a yarn segment (in this exemplary implementation it is 0.25 mm of the yarn length) is contained in the pixel data (one frame/image of the image sensor, one line of pixels as sensor 3).
  • Monitoring uses a consecutive measuring of (non-same) yarn segments as to their properties, such as a diameter and/or a color and/or a reflectivity. This as it goes through focal point of the focusing element (the yarn 1 is moving along axis 200). Further evaluation of measured data for yarn quality data logging or immediate actions (for example cut yarn thick place away). The same applies for yarn thin places lx, shown at a position slightly above the thick place ly. With the next sampling, when the thin place lx goes through the focal point, a measuring establishes another data in the log chain. The faster the pixel data sampling (at same speed Vi of the yarn 1) the shorter yarn segments are measured for yarn quality monitoring.
  • the focusing element 6 directs the non-blocked light rays through a diffraction element 8 making an image of yarn contours on the image sensor 3.
  • a diffraction grating can be used as standard and easily available diffraction element 8.
  • a yarn contour image also referred to herein as a contour image, for example, is an image created from a yarn, such as a moving yarn 1, by light from the primary light source 2 not blocked by the yarn, and the shadow(s) of the yarn.
  • Yarn diameter is determined by processing of yarn contour image(s) on the image sensor 3, by the controller 4 (also referred to as control unit).
  • a secondary light source 7 (second light source) is added to the system of
  • This secondary light source 7 emits light at a wavelength different from primary light source 2.
  • the term "primary” and “secondary” are names to identify the light sources, others are 2 and 7 and even other names are first and second light source. Primary and secondary is not meant to give them priorities. And light sources that are employed by technical equipment are generally no natural light origin, but “artificial light”, that is read implicitly when activating light and illuminating a longitudinally moving yarn segment. The disclosure is not meant to switch on the (natural) sun to prepare yarn quality monitoring.
  • This secondary light source 7 is placed on the same side of the moving yarn 1 as the image sensor 3, and serves to illuminate a portion of the moving yarn 1.
  • the secondary light source 7 may be a plurality of the same or different light sources 7.
  • the emitted light reflected from the yarn 1 also propagates along an optical path 100 to the image sensor 3, this along a front portion of this optical path 100.
  • More than one secondary light source(s) 7 are used, for example, for detecting of foreign fiber material(s) or to increase illumination intensity.
  • the full optical path from Light source 7 is of angled nature, starting at light source 7 along a first path portion 120 and after the light illuminates the moving yarn 1 and being reflected therefrom the path is the same as path 100, mentioned earlier. This is the from path portion of the full, straight path 100 starting at the light source 2.
  • the diffraction element 8 serves to diffract at least a portion of secondary light rays reflected from the moving yarn 1, which creates an interference pattern on the image sensor 3. For example, for white light, the diffraction element 8 creates rainbow spectra. The remaining portion of the reflected light rays passes through the diffraction element 8, without being diffracted, and creates a focused yarn image on the image sensor 3. This focused yarn image is, for example, used for diameter measurement of the yarn 1.
  • a color image sensor as the image sensor 3 is s replaced by a monochromatic image sensor, as the image sensor 3.
  • a monochromatic image sensor, as the image sensor 3, allows for high sensitivity and high resolution. Measured yarn s segment color information is obtained from a captured interference pattern by the
  • a portion of the light rays : ? passes un-diffracted through the diffraction element 8, and are focused on the image sensor
  • the interference pattern created by the diffracted rays is obtained by being captured simultaneously with the obtaining by capturing the yarn image and/or yarn contour image by the image sensor 3, and is processed (in the6 controller 4) to obtain a color analysis. This is e.g. helpful for determining foreign fiber(s) in the yarn, e.g., a foreign fiber content moving in the yarn, as well as a determination of yarns diameter.
  • the yarn quality may be monitored, such that color analysis and yarn diameter are obtained from the same yarn segment (or portion).
  • An optical filter 9 may partially cover the image sensor 3, and allows for the passage of only rays from the primary light source 2. These may be used for diameter measurement of the yarn 1, while the optical filter 9 blocks light rays from the secondary light source 7.
  • Interference pattern processing by the controller 4 may be used to determine the presence of foreign fiber(s) in the yarn 1.
  • the yarn contour image and interference pattern are captured by the image sensor 3, contemporaneous in time, and for example, at the same time.
  • the interference pattern may originate from the secondary light source 7, based on light rays reflected from the yarn, while the yarn contour image may originate from the primary light source 2.
  • Processing the light intensity of interference pattern at specific distances from the yarn image on image sensor 3 can be used for color analysis of the yarn 1.
  • the detection of foreign fiber(s) in the yarn 1 is achieved by a color image sensor, as the image sensor 3.
  • a monochromatic image sensor 3 may be used as the image sensor 3.
  • the secondary light source 7 serves to illuminate the yarn contemporaneously, and, for example, simultaneously, with the illumination from the primary light source 2.
  • the secondary light source 7 is placed on same side of yarn 1 as the image sensor 3. Light rays from the secondary light source 7 are reflected from the moving yarn 1 and are focused on the image sensor 3 by the focusing element 6. Light rays from the secondary light source 7 reflected by the yarn 1 are diffracted by a diffraction element 8 (placed in front of focusing element 6 or in front of the image sensor 3). An interference pattern is thus created at the image sensor 3.
  • Images of moving yarn contours and its respective interference pattern are simultaneously captured by the image sensor 3, for further diameter measurements and color analysis.
  • the focusing element 6 improves image quality at the image sensor 3.
  • the secondary light source 7 for illumination is used to create an interference pattern, for example, through the diffraction element 8 (along with processes from the controller 4, as detailed below).
  • the secondary light source 7 is, for example, of specific wavelengths, such as those for monochromatic light, RGB light, white light, UV-light, IR-light or any combination(s) thereof.
  • the focusing element 6 serves to eliminate distortion effects, caused by dust particles or other foreign or ambient particles, accumulated on optical surfaces (light sources 2, 7 and the focusing element 6). Additionally, the focusing element 6 directs unwanted lateral ambient light rays, directing these ambient light rays away or outward from the image sensor 3.
  • the focusing element 6 may be formed as a single lens or a set of lenses, the lens or lenses may include aspherical lenses, mirror lenses, convex lenses, concave lenses, and
  • the focus may be adjustable by rotating a lens housing of the focusing element 6 by manipulating an adjusting thread.
  • M 12x0.5 type of the focusing lens with housing is used, as its thread pitch fully satisfies the application of the apparatus, and such a lens has low acquisition costs.
  • the size and pitch of M 12x0.5 package allows for the adjustment of a focal distance.
  • Several lenses may be used, depending on the image quality for the presently measured yarn 1.
  • the image sensor 3 is formed, for example, by at least one line of light sensitive pixels.
  • Each of the pixels is, for example, a square or rectangular shaped light sensitive area. Individual pixels can be monochromatic or sensitive for specific ranges of wavelengths.
  • the image sensor 3 is, for example, a CCD-type or CMOS-type, and is formed as one or more lines of photosensitive pixels.
  • Each of the pixels of the image sensor 3 includes, for example, a micro lens for increased sensitivity and for limiting wide angle light rays, resulting in sharper images.
  • the light source 7 as shown in FIG. 2a illuminates the moving yarn 1 alone, without illumination from light source 2.
  • the light source 7 is placed on the same side of the yarn 1 as the image sensor 3.
  • this light source 7 Light provided by this light source 7 is reflected from the moving yarn 1 and focused on the image sensor 3 by the focusing element 6. A portion of light rays from the light source 7 is reflected by the moving yarn 1 and diffracted by a diffraction element 8 that is placed in front of focusing element 6 or in front of the image sensor 3. In the drawing the diffraction element 8 is in the optical path between focusing element 6 and image sensor 3.
  • An interference pattern is thus created at the image sensor 3 for moving (running) yarn color analysis. Remaining un-diffracted light rays create a yarn image on the image sensor and is used for diameter processing when only light source 7 applies.
  • An interference pattern is thus created at the image sensor 3 using only yarn reflected light.
  • FIG. 3 shows the function of the controller 4.
  • the controller 4 may include a power supply 38 and a computer, for example a microcontroller 30, having an integrated circuit with a processor core with other embeded functions, such as l/O-peripherals (I/O is input/output), data memory, program memory.
  • the controller 4 may also include an l/O-interface 34, light source control circuits 35 and a programmable logic array module 36 (PLA module).
  • the PLA module 36 functions in yarn diameter calculations and color analysis from captured image data.
  • the program memory of the microcontroller 30 (e.g., ARM, Atmel AVR, Intel 8051, as well as any combinations thereof) stores executable instructions running the algorithms for determining yarn eveness (thick and thin places), see FIG. 4A, and foreign fiber detection, see FIG. 4B.
  • the l/O-interface 34 serves for data exchange with a host system.
  • the host system is, for example, a central unit of a spinning machine yarn quality control system (or the central unit of a winding machine yarn quality control system).
  • the host system can be
  • the host system links to the controller 4 via a communication bus.
  • the controller 4 may include the light source control circuits 35, which may be controlled by the PLA 36.
  • the image sensor 3 and functionalities of the control unit 4 can be integrated in an Application Specific Integrated Circuit (ASIC circuit), to simplify the device and provide a low cost solution to yarn quality measurement.
  • All of the components of the controller 4 may communicate with each other, directly or indirectly. Shown is a bus architecture B that allows communication of the devices in the controller. There may be more such bus architecture, especially for independent communications.
  • the controller may control the parameters of the primary light source 2 and/or the secondary light source 7 via feedback to the PLA 36. The feedback is based on the quality of at least one previously captured image from the image sensor 3, as linked to the PLA 36. Preferably more images are used.
  • FIGs. 4A and 4B show flow diagrams detailing computer- implemented processes in accordance with further embodiments. Reference is also made to elements shown in FIGs. 1 to 3.
  • the process and subprocesses of FIGs. 4A and 4B are computerized processes performed by the controller 4.
  • the aforementioned processes and : ? sub-processes can be, for example, performed manually, automatically, or a combination thereof, and, for example, in real time.
  • yarn diameter analysis and determination begins as pixel data (from the image 6 sensor 3), based on light emitted from the (primary) light source 2, is read by the PLA 36, at block 402, for each yarn segment of a predetermined length.
  • the PLA 36 then applies rules s and policies to the read pixel data, to determine whether the image contrast of the read data is within a predetermined range, at block 404.
  • the process moves to adjusting block 406, where the light source .w intensity, for example, of the primary light source 2, is adjusted to obtain an acceptable image contrast in the next measuring cycle beginning at block 402, by the light source control circuits 35, at block 406. From block 406, the process moves to block 408.
  • the process may continue to block 408.
  • the PLA 36 determines the yarn diameter, by processing the data from the pixels by, for example, a threshold method, such as binarizing the pixel data and counting pixels corresponding to the yarn 1.
  • the process may continue to block 410, where determined yarn diameter value(s) for captured yarn segment image is/are stored in the microcontroller 30.
  • a history of the stored yarn diameter values (previously stored values) fail to meet a predertemined criteria for thickness (e.g., yarn evenness). If yes (fail detected), the yarn diameter is outside of an acceptable range for several consecutive measured yarn segments (for any number of o? predetermined segments designating a sample size of the like), e.g., too thin or too thick, and the l/O-lnterface 34 may send a yarn evenness alert A to the host system, at block 414. If criteria are met (the yarn diameter is within a predetermined thickness range) the process returns to block 402, from where it continues to read another pixel data. The return is also done, when the routine exits from Block 414.
  • a predertemined criteria for thickness e.g., yarn evenness
  • the yarn evenness alert A is a result of monitoring the moving yarn for an acceptable range.
  • the monitoring from the measurement detects the yarn parameter is outside the given range, the A signal as an alert is produced.
  • Locks as shown here may be functioning in a microcontroller software or a PLA
  • yarn foreign fiber analysis and determination begins as pixel data, based on secondary light source 7 light reflected from the yarn, is read by the PLA 36, at block 452, for each yarn segment of a predetermined length.
  • the PLA 36 then applies rules and policies to the read pixel data, to determine whether the image contrast is within a predetermined range, at block 454.
  • the process moves to block 456, where the light source intensity, for example, of the secondary light source 7, is set to result in acceptable image contrast in the next measuring cycle, by the light source control circuits 35, at block 456. From block 456, the process proceeds to block 458. Also, at block 454, should the image contrast be within a predetermined range, the process also moves to block 458. At block 458, the PLA 36 determines RGB (Red-Green-Blue) color values (so called color analysis) for the yarn segment, for example, by processing light intensities of image sensor 3 pixels at specific positions relative to the position of the yarn image.
  • RGB Red-Green-Blue
  • each determined RG B color value is stored in data memory associated with the microcontroller 30. It is then determined by the microcontroller 30, whether the history of the stored yarn RG B color values (currently and previously stored values) meets a predetermined criteria for foreign fibers, at function 462. If "yes”, there are sufficient foreign fibers in the yarn 1 for several consecutive yarn segments to cause the l/O-lnterface 34 to send an foreign fiber alarm to the host system, at block 464. From block 464, or if "no", at block 462, the process returns to block 452, from where it continues.
  • the alarm or alert signal A is the result of monitoring the yarn for the attirbute "foreign fiber present".
  • Implementation of the method and/or system of embodiments of the invention can involve performing or completing selected tasks manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of embodiments of the method and/or system of the invention, several selected tasks could be implemented by hardware, by software or by firmware or by a combination thereof using an operating system.
  • programmable non-transitory storage media for example, compact discs (CDs) or other discs including magnetic, optical, etc., readable by a machine or the like, or other computer usable storage media, including magnetic, optical, or semiconductor storage, or other source of electronic signals.
  • CDs compact discs
  • other discs including magnetic, optical, etc., readable by a machine or the like
  • other computer usable storage media including magnetic, optical, or semiconductor storage, or other source of electronic signals.

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Abstract

La présente invention concerne des procédés de surveillance de qualité de fil textile et des appareils de surveillance de qualité de fil textile. La qualité du fil textile en mouvement (1) est surveillée pour répondre à des critères requis, par exemple l'uniformité ou la présence de fibres étrangères indésirables. La lumière éclairant par les sources de lumière (2) et/ou (7) et un capteur d'image (3) sont utilisés. Le fil (1) est placé en tant qu'obstacle dans la voie (100) d'une lumière (2) diffusée (5), les contours de la lumière étant focalisés (6) pour une capture d'image de contours de fil nets. La lumière (7) est réfléchie par le fil (1) et se propage le long d'un trajet (100) vers le capteur d'image par l'intermédiaire de l'élément de diffraction (8). Une partie de la lumière réfléchie est diffractée (8) et crée un motif d'interférence. La lumière réfléchie restante crée une image de fil. Ainsi, la lumière (2) éclaire directement le capteur d'image. La lumière (7) éclaire le fil en mouvement (1) et la lumière provenant de la source de lumière (7) est réfléchie par le fil et éclaire le capteur d'image. Le diamètre du fil est déterminé par traitement de l'image du contour du fil ou de l'image du fil. L'analyse de couleur du fil (1) est déterminée par traitement de motifs d'interférence capturés. Une évaluation supplémentaire des diamètres de fil est utilisée pour la surveillance d'uniformité de fil et une évaluation de résultats d'analyse de couleur supplémentaire est utilisée pour la surveillance de fibres étrangères.
EP18847153.6A 2017-12-26 2018-12-24 Procédés et systèmes de surveillance de la qualité de fils Withdrawn EP3732470A2 (fr)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US15/854,018 US10605798B2 (en) 2017-12-26 2017-12-26 Method and device for optical yarn quality monitoring
US15/854,014 US20190195853A1 (en) 2017-12-26 2017-12-26 Method and system for yarn quality monitoring
PCT/IB2018/060583 WO2019130209A2 (fr) 2017-12-26 2018-12-24 Procédés et systèmes de surveillance de la qualité de fils

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CN112730235B (zh) * 2020-12-18 2022-04-22 南京大学 一种基于光学衍射的动态细线突结自动化检测装置和方法
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