JP2008280637A - Method and apparatus for detecting width abnormality of crimped fiber bundle - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and apparatus for detecting the width abnormality by which crimp unevenness of a tow band influencing the filter quality can accurately be detected from the width variation of a fiber bundle and the variation state of the fiber bundle can simply be confirmed at any time even by visual checking. <P>SOLUTION: The method for detecting the width abnormality comprises obtaining an image of the fiber bundle with an image-pickup means, detecting both ends of the fiber bundle in the width direction from the change in luminance of the obtained image, computing the distance between both the ends as the width of the fiber bundle with an image processing means (4), calculating variations in the width of the fiber bundle using a computing means (5) at an interval of a prescribed time and issuing an alarm from an alarm device (7) when the variations exceed the threshold value in a step of transporting the crimped fiber bundle (1) to a loading apparatus. The image of the fiber bundle (1) is recorded in a recording/displaying means (6) and can be displayed. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention provides a crimp for detecting whether or not the amount of change in the width of a fiber bundle being conveyed is within a predetermined range in a conveying step of sending a crimped fiber bundle (especially a tow band) to a loading device. The present invention relates to a fiber bundle width abnormality detection method and a detection apparatus.

  Acetate tow (tow band) used for cigarette filters and the like can be produced by generally collecting continuous filaments, and applying a crimped fiber bundle with, for example, a crimper, followed by drying. The tow band is conveyed to a loading device using a feed roll, and after being compressed and packed, is wound up by a filter maker into a rod-shaped plug and then used as a cigarette filter. At this time, it is a well-known fact that the crimping of the tow band plays a very important role in order to develop performance such as filter hardness and ventilation resistance.

  In addition, plugs and filters obtained from continuous tow bands are required to exhibit a certain performance as long as they are wound up under certain conditions.

  However, when the crimped state of the tow band changes partially, if the crimp is strong and finely applied, the ventilation resistance of the plug obtained is high, conversely the crimp is weak and rough In such a case, there arises a problem that the ventilation resistance is lowered. Therefore, there is a need for a toe band that is crimped uniformly in the longitudinal direction.

  The reason for the partial change in the crimped state of the tow band may be various factors such as poor crimper performance, poor fiber bundle alignment, unevenness in the filaments constituting the tow band, and oily spots.

  Until now, take out a part of the tow band that was once pulled up to the loading device, measure the number of crimps offline, actually roll up the plug and measure the variation in ventilation resistance, uniform crimp It was judged whether it was in a state.

  However, such offline determination takes time, resulting in a product loss and the problem that all toe bands cannot be evaluated uniformly.

Therefore, in order to solve the above problems, for example, as disclosed in JP-A-7-207570 (Patent Document 1), light is projected from one side of the fiber bundle and the shadow of the fiber bundle is used. By measuring the thickness and width continuously, calculating the threshold value based on the obtained measurement value, detecting abnormalities in the shape of the fiber bundle from the measurement value and the threshold value, and issuing an alarm A device capable of detection has been proposed.
JP-A-7-207570

  Thus, this device can detect large abnormalities in the shape such as twisting of the fiber bundle, but it can detect even the slightly crimped spots that affect the filter quality of the final product. I couldn't.

  An object of the present invention is to provide an abnormality detection method and apparatus that can accurately detect crimped spots of a tow band that affects filter quality from the fluctuation in the width of the fiber bundle, and can easily check the fluctuation state of the fiber bundle at any time by visual observation. It is to provide.

  A first basic configuration of the present invention is a method for detecting an abnormal width of a fiber bundle to which crimps are applied. In the step of conveying the fiber bundle to a stacking device, an image of the fiber bundle is captured by an imaging unit. Obtaining both ends in the width direction of the fiber bundle from the brightness change amount of the obtained image by the image processing means, calculating a distance between the both ends as a fiber bundle width, and obtaining a fluctuation value of the width. Including calculating using a calculation means at regular intervals, generating an alarm when the fluctuation value exceeds a threshold value, and recording and displaying an image of the fiber bundle on a recording / display means. There exists in the width abnormality detection method of the crimped fiber bundle which becomes.

  Furthermore, a second basic configuration of the present invention is an apparatus for detecting an abnormal width of a fiber bundle to which crimps are applied, an imaging means for acquiring an image of the fiber bundle, and both ends in the width direction of the fiber bundle. The image processing means for calculating the distance between the two ends as the fiber bundle width, the calculating means for calculating the fluctuation value of the width at regular intervals, and when the fluctuation value exceeds a threshold value. An abnormality determining means for determining that the quality is abnormal, an alarm generating means for generating an alarm when the abnormality determining means determines that there is an abnormality, an image of the fiber bundle is recorded, and a recording / recording that can confirm the state of the fiber bundle on the screen A crimped fiber bundle width anomaly detection device comprising display means.

  According to the fiber bundle width abnormality detection method and apparatus of the present invention, crimped spots of a fiber bundle to which crimps are imparted can be accurately and early detected by an image, and product loss can be minimized. In addition, the state of the tow can be confirmed at any time in the recorded image, which can assist in the analysis of the cause of crimp abnormality, and other abnormalities such as cracks and dirt can be detected early.

  In the tow quality monitoring method based on the detection of the tow width according to the present invention, in the step of conveying the fiber bundle to which crimps are applied to the stacking device, an image of the fiber bundle is acquired, and both ends in the width direction of the fiber bundle are imaged. Detecting from the amount of change in luminance, calculating the distance between both ends as a fiber bundle width, calculating the fluctuation value of the width at regular intervals, and generating an alarm when the fluctuation value exceeds a threshold value Thus, crimped spots are detected at an early stage.

  The position where the tow width is detected may be anywhere as long as the fiber bundle to which crimp is applied is from the dryer to the feed roll of the stacking device. However, in order to prevent malfunction due to abnormal shaking of the fiber bundle, it is desirable to detect while the toe position is regulated by a guide such as a roller guide or a bar guide.

The width variation value CV of the fiber bundle can be obtained by the following equation.
CV (%) = SD / AV × 100 (1)
SD = √ (Σ (Xi−AV) ² / (N−1)) (2)
Here, AV is an average value of N measurement values. Xi represents an individual measurement value.

  The width measurement frequency of the fiber bundle can be arbitrarily set. In many cases, the abnormal width due to crimped spots extends over a length of about 50 mm in the longitudinal direction. The conveying speed of the fiber bundle is 300 to 700 m / min. Therefore, in order to detect all 50 mm long abnormal parts, it is necessary to measure the width at a frequency of at least 100 to 250 times / sec. However, in the case of crimped spots in which variation in plug quality is a problem, there are many cases where spots are continuously generated in the longitudinal direction, and the width measured at a certain interval can be obtained without detecting all abnormal parts. By analyzing how much the fluctuation has occurred within a certain period of time, it is possible to identify a crimped spot that is a problem. Specifically, it is possible to identify crimped spots from a fluctuation value within a certain time even at a measurement frequency of about 17 times / sec.

  Arbitrary settings can also be made for the time used as a delimiter when the fluctuation value is obtained. However, if it is divided by too short time, there is a problem that the number of measurement is too small and the number of measurement points is not enough to judge crimped spots, and conversely if it is divided by long time, it takes time to judge crimped spots, and there is a problem. If so, there is a problem that product loss increases. For example, the time may be divided by a time corresponding to a tow length of 6 m corresponding to 50 standard plugs.

  The threshold value for whether or not to generate an alarm may be set in advance, or may be automatically set based on the measured value.

  Further, any method for acquiring an image of the fiber bundle may be used as long as it can be captured. For example, a CCD camera or an infrared camera may be used. During imaging, the tow may be irradiated with light having a color tone different from that of the background so that both ends in the width direction of the fiber bundle can be easily distinguished from the background.

Hereinafter, the present invention will be described more specifically with reference to a representative example. FIG. 1 is a schematic view of an apparatus for detecting an abnormal width of a crimped fiber bundle according to the present invention.
The sorting of the detection device that detects the abnormal width of the crimped fiber bundle is
Camera: Keyence Corporation CV-025 (Lens CA-LH8)
Image processing device: Keyence Corporation CV-2500
Computer: NEC VY13M / RF-R
Monitor: Keyence Corporation CA-MN80
Lighting device: Keyence Corporation CA-R20
Met.

  Is arranged above the fiber bundle so that the width direction of the fiber bundle 1 conveyed along the id 2 can be imaged. The camera 3 must be arranged so that both ends in the width direction of the fiber bundle 1 are included in one image. The image information obtained through the camera 3 is sent to the image processing device 4, where the device 4 detects both ends of the fiber bundle 1 in the width direction from the amount of change in luminance of the image, and the distance between the both ends is defined as the fiber bundle width. Calculated. At this time, an accurate fiber bundle width can be obtained by measuring in advance the scale of the image obtained through the camera 3 and incorporating it into the arithmetic expression. Alternatively, the fiber bundle 1 may be easily identified from the background by illuminating the fiber bundle 1 with the illumination device 8. The computer 5 calculates a fluctuation value for every predetermined time for the tow width calculated by the image processing device 4 and records an image obtained through the camera 3. Further, in the computer 5, when the fluctuation value exceeds the threshold value, a signal is sent from the abnormality determination means so that the alarm device 7 issues an alarm. The image to be recorded may be an image obtained at regular intervals. However, an allowable range may be provided for the toe width, and only an image outside the range may be recorded. The recorded image can be visually confirmed through the monitor 6 at any time.

  Table 1 shows the tow width variation during the conveyance of acetate tow for a filter having a Y-shaped cross-section having a total fineness of 3.9 kilotex and a fineness per single fiber of 3.0 decitex, and the tow was used. Showed plug quality.

  At this time, the tow width was measured at a measurement frequency of 17 times / sec, and the tow width fluctuation value was calculated every minute. The plugs were rolled up at 400 m / min with a plug manufacturing apparatus, and 300 physical properties were measured. From Table 1, it can be seen that the plug variation is large when the tow width variation value is large.

  FIG. 2 shows one image when the tow width is outside the allowable range during measurement of the tow width shown in Table 1. It can be visually confirmed that the crimped state is partially changed and is not uniformly crimped.

  As described above, according to the tow monitoring method of the present invention, crimped spots of the fiber bundle to which crimps are imparted can be found at an early stage, and product loss can be minimized. In addition, the state of the tow can be confirmed with an image, which can assist the analysis of the crimp abnormality factor.

It is a figure which shows the tow quality monitoring apparatus of this invention. It is a figure which shows an example of the image of a fiber bundle.

Explanation of symbols

1 Fiber bundle 2 Guide 3 Camera 4 Image processing device 5 Computer 6 Monitor 7 Alarm device 8 Illumination device

Claims (2)

A method for detecting an abnormal width of a fiber bundle to which crimps are applied,
Acquiring an image of the fiber bundle by the imaging means in the step of conveying the fiber bundle to the loading device;
The image processing means detects both ends in the width direction of the fiber bundle from the luminance change amount of the acquired image, and calculates the distance between the both ends as the fiber bundle width,
Calculating the fluctuation value of the width at regular intervals using a calculation means;
An alarm is generated when the fluctuation value exceeds a threshold value, and a fiber bundle image can be recorded and displayed on a recording / display means.
A method for detecting an abnormal width of a crimped fiber bundle, comprising: An apparatus for detecting an abnormal width of a fiber bundle to which crimps are applied,
An imaging means for acquiring an image of the fiber bundle;
An image processing means for detecting a luminance change amount at both ends in the width direction of the fiber bundle and calculating a distance between the both ends as a fiber bundle width;
A calculation means for calculating a fluctuation value of the width at regular intervals;
An abnormality determining means for determining that the quality value is abnormal when the fluctuation value exceeds a threshold;
An alarm generating means for generating an alarm when it is determined to be abnormal;
Recording / display means for recording an image of the fiber bundle and confirming the state of the fiber bundle on the screen;
An apparatus for detecting an abnormal width of a crimped fiber bundle, comprising:

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