JPH0327156A - Automatic fabric inspection system of woven fabric - Google Patents

Abstract

PURPOSE:To properly detect defects of cloth by analyzing weaving data and warp data in every beam of woven fabric, inputting data specifying kinds of defects of cloth and positions thereof to a fabric inspection condition setting means, selecting a camera and light source of a fabric inspector most suitably and dealing with woven fabric. CONSTITUTION:Weaving data having accumulated stopped position of weaving machine and suspension cause during weaving in each beam of woven fabric and warp data having accumulated trouble occurrence position and content thereof in a preparing process of warp beam corresponding to the beam of woven fabric are outputted to an analyzing means. In the analyzing means, the weaving data and the warp data are analyzed, analyzed data specifying kinds of defects of cloth and positions thereof which are estimated in the beam of woven fabric are outputted to a fabric inspection condition setting means and optimum fabric inspection conditions for making light projection method of light source and camera device in the fabric inspector selectively correspond to kinds of defects of cloth or positions thereof to be estimated are actualized.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application This invention uses a camera device in a textile factory to
The present invention relates to an automatic fabric inspection system for automatically and efficiently carrying out fabric inspection work.

Prior Art In textile factories, the entire length of the woven fabric is inspected for the presence or absence of fabric defects, and the quality of the product is graded; this process is generally referred to as the fabric inspection process. This is an important process.

Various types of fabric defects are known to occur in woven fabrics, depending on the cause of their occurrence, and since these defects are randomly distributed over the entire length of the woven fabric, fabric inspectors need to identify these defects in order to extract them. , forced to perform extremely precise continuous work. Therefore, with the aim of reducing the work burden of such inspection workers, automatic inspection systems using camera devices such as CCD image sensors have been proposed (for example, Japanese Patent Application Laid-Open No. 119259/1983). ).

Here, a data processing system is disclosed for accurately detecting fabric defects present on a woven fabric by scanning the surface of a running woven fabric using a camera device combined with an appropriate light source. .

The problem to be solved by the invention is that when using such conventional technology, it is not possible to detect all fabric defects existing in woven fabric soil with one camera device, and multiple fabric defects can be detected depending on the type of fabric defects. Since it is necessary to use several camera devices, there is a problem that not only the system becomes complicated and expensive, but also the inspection machine itself cannot be made smaller. In other words, fabric defects include those that should be detected by so-called transparent inspection, such as loose warp and weft threads, misthreading, and reed lines, and those that should be detected by so-called reflection inspection, such as weaving steps, moiré, and uneven gloss. There are things that should be detected, such as folded ears, bent ears, etc., that should be detected by so-called local inspection. However, transparent inspection is inspection using a combination of a parallel light source placed on one side of the fabric and a camera device placed on the other side; Local fabric inspection, which combines a parallel light source placed on one side of the fabric with a camera device, refers to a combination of a spot light source and a camera device. Therefore, in order to effectively detect all of these defects, it is necessary to prepare different camera devices for each of these different inspection methods, and it is necessary to use at least three or more camera devices.

Therefore, in view of the actual state of the prior art, it is an object of the present invention to accumulate weaving data in the weaving process, analyze this, and analyze the type and position of fabric defects predicted in the woven fabric beam by using a fabric inspection machine. An object of the present invention is to provide an automatic woven fabric inspection system that can accurately detect all fabric defects using a single camera device by selectively controlling the inspection conditions of the fabric. be.

Means for Solving the Problems The present invention has the following features: a weaving data accumulating means for accumulating weaving data including the stopping position and stopping cause of the loom during weaving for each woven fabric beam;
A data analysis means analyzes the weaving data from this weaving data accumulation means and specifies the type and position of fabric defects predicted in the woven fabric beam, and the analysis data from the data analysis means: The gist thereof is to include a fabric inspection condition setting means for determining fabric inspection conditions.

In addition, a warp data accumulation means is added to each warp beam to accumulate warp data including the content and location of trouble that has occurred in the preparation process, and the warp data from the warp data accumulation means is input to the data analysis means. Furthermore, a drive control means may be added to control the running speed of the fabric inspection machine based on the analysis data from the data analysis means.

With this configuration, when a woven fabric beam is placed in a fabric inspection machine, since the weaving data of the woven fabric beam during weaving has been accumulated by the weaving data accumulating means, the weaving data can be collected by the data analyzing means. Through the analysis, it is possible to specify the types and positions of fabric defects predicted to exist in the woven fabric soil. Therefore, if the inspection conditions of the fabric inspection machine are selectively controlled by the fabric inspection condition setting means in accordance with the type of the fabric defect, the fabric defect can be detected accurately. However, here, the inspection conditions refer to transparent inspection, reflective inspection, and local inspection, and even if the inspection conditions are the same, the position of the camera device, zoom magnification, etc. It is also possible to optimally adjust the inspection mode including the following.

If a warp data accumulation means is added, it is possible to accumulate warp data in the preparation process regarding the warp beam used for the woven fabric beam, so the data analysis means can collect warp data from this warp data via the inspection condition setting means. The inspection conditions can be selected and controlled even for predicted fabric defects, thereby making it possible to detect fabric defects caused by troubles occurring in the preparation process.

In addition, by adding a drive control means, the inspection machine can be quickly moved to areas where fabric defects are not expected.
The inspection efficiency can be greatly improved.

It works as described above.

Example Examples will be described below with reference to the drawings.

The automatic fabric inspection system 10 includes a weaving data accumulation means 1
1, data analysis means 12, and inspection condition setting means 13 as main components (FIG. 1).

The weaving data accumulation means 11 stores the looms L1, L2, and
Receives the operation information signal SL from Ln, accumulates it as weaving data Dll, and then sends the data analysis means 1 to the weaving data Dll.
Output to 2. However, the operating information signal SL is
(f = 1, 2-n) is transmitted from a monitor device (not shown) installed in the machine, and its contents include at least a warp beam identification code for identifying the installed warp beam for each weaving aLi. , the woven fabric beam identification code for identifying the woven fabric beam during weaving, the weaving length and the cause of the stop when the loom stops, when the loom restarts, whether the cause of the stop is restarted after automatic repair or after manual repair It shall include information such as whether to restart or not. Furthermore, the weaving data Dll is obtained by organizing this information for each weaving beam, and its contents may be the same as the operation information signal SL. However, in the weaving data Dll, the weaving length when the loom Li is stopped is converted to the fabric length measured from the end of the winding of the woven fabric beam, and is displayed as the loom stopping position.

Warp data D15 from the warp data accumulation stage 15 is also input to the data analysis means 12, and the warp data accumulation means 15 receives the operation information signal Sp from the preparation machines Pl1P2...Pm.

The preparation machine Pj (j=1, 2...m) is a series of preparation machines such as a warp sizing machine, a partial warping machine, a beam warping machine, a beam rewinding machine, etc. This is to adjust the warp beam that is set on the shaft. Therefore, the operation information signal S
The contents of p include troubles that occur during the operation of the preparation machine Pj and their occurrence positions (indicated by the warping length of the warp beam, the same applies hereinafter), and the warp data D15 is the information organized by each warp beam. It is.

The output of the data analysis means 12 is branched into the inspection condition setting means 13 and the drive control stage 14, and the outputs of the latter two are
They are input to the fabric inspection machine 20 as a fabric inspection control signal Sc and a drive control signal Sd, respectively. Further, the fabric length signal Sv is fed back from the fabric inspection machine 20 to the fabric inspection condition setting means 13.

The inspection machine 20 includes a camera device 21, two parallel light sources 22 and 23, and a spot light source 24 (second
figure).

The camera device 21 uses, for example, a CCD image sensor, and is installed facing the cloth W to be inspected. The camera device 21 has a zoom function, can move along the guide shaft 21a in the width direction of the cloth W (in the direction of arrow K1 in the figure), and can arbitrarily set its elevation angle. (direction of arrow K2 in the figure).

The parallel light source 22 is, for example, a hooded fluorescent light source, and is installed on the same side of the cloth W as the camera device 21, so that the reflected light irradiating the cloth W is reflected onto the camera device 2.
1. The parallel light source 23 is also a similar light source, but this one is disposed on the opposite side of the cloth W from the camera device 21. The light from the parallel light source 23 is reflected by the reflecting mirror 23a, and then passes through the cloth W and enters the camera device 21.

The spot light source 24 is a hooded incandescent light source, and is movable in the width direction of the cloth W via a guide shaft 24a (in the direction of arrow K3 in the figure), and the reflected light projected onto the cloth W is reflected by the camera. The light enters the device 21 .

Setting the position, elevation angle, and zoom magnification of the camera device 21 in the width direction of the cloth W, setting the position of the spot light source 24 in the width direction of the cloth W, and turning on and off the parallel light sources 22 and 23 and the spot light source 24 are all set by It is assumed that the control is performed by a fabric inspection control signal Sc from the fabric inspection condition setting means 13.

The fabric W is unwound from the fabric beam WB installed in the fabric inspection machine 20, runs in front of the camera device 21 (in the direction of arrow K in the figure), and is wound onto the take-up roll WR. During this time, the camera device 21 performs a fabric inspection operation. Note that the winding roll WR is actively driven by a drive source (not shown), while the winding roll WR is actively driven by a drive source (not shown).
A measuring roll MR is provided which rotates passively in contact with the
An encoder WRI is connected to the shaft end.

The encoder WRI measures the traveling length of the cloth W and outputs it to the fabric inspection condition setting means 13 as a cloth length signal Sv (first
figure). Further, the running speed of the cloth W by the take-up roll WR is set and controlled by the drive control means 14 via the drive control signal Sd. Note that the data analysis means 12
It is assumed that the identification code Nw of the fabric beam WB set in the fabric inspection machine 20 is inputted, for example, via a data input device (not shown).

The operation of the automatic fabric inspection system 10 having such a configuration is as follows.

When a woven fabric beam WB to be inspected is mounted on the fabric inspection machine 20 and the identification code Nw of the woven fabric beam WB is inputted to the data analysis means 12, the data analysis means 12 collects the weaving data accumulating means 11 and the warp data accumulating means. Using the weaving data Dll and warp data D15 supplied from 15, the types of fabric defects predicted to exist in the fabric W in the woven fabric beam WB and their positions are specified. That is, since the weaving data Dll includes the cause and stop position of the loom Li that weaved the woven fabric piece WB during weaving, the data analysis means 1
2 can specify the type of predicted cloth defect in accordance with the cause of the stoppage (FIG. 3), and can also specify the position of the cloth defect from the stop position. However, since the stop position included in the weaving data Dll is expressed as the fabric length measured from the end of winding of the fabric beam WB, the position of the fabric defect at this time can be determined by using the stop position as is. It can be displayed based on the running length of the cloth W.

On the other hand, in Fig. 3, it is shown that the cause of the loom stoppage is the weft feeler stoppage, and the fabric defect predicted when the loom is restarted after manual repair is the stop step (
(first row of the same figure). Even if the cause of the stoppage is a weft filler stoppage, if the loom is automatically restarted after mechanical repair by the weft repair device, the operation of the weft repair device is uniform, so the weft "sink" ” and “looseness” may be overlooked and remain (second paragraph).

The weft arrival sensor stop (6th stage) indicates the loom has stopped due to the arrival time of the inserted weft deviating from the predetermined loom machine angle range, and the sizing stop (8th stage) 2) refers to the start/stop operation of the preparation machine Pj during adjustment of the warp beam used for the woven fabric beam WB. The start/stop operation of the preparation machine Pj indicates the occurrence of a trouble during the preparation process, and this is included in the warp data D15 together with the location of the trouble. By analyzing,
It is possible to predict and specify the type and position of warp defects, including those that manifest as fabric defects.

However, when using the warp data D15, the data analysis means 12 considers the shrinkage rate between the warp length before weaving (corresponds to the warping length) and the fabric length after weaving (corresponds to the weaving length). The former shall be converted into the latter.

Note that the weaving start position (seventh stage) refers to the period between the start of weaving and a certain weaving length when a new warp beam is set on the loom. Depending on the type of fabric, noticeable moiré may occur at the beginning of the winding of the fabric beam, and in order to predict this, this is included as a cause for loom stoppage. It is known that such moiré tends to appear in textiles such as ester, taffeta, and mixed yarns.

The data analysis means 12 outputs the analysis data Dl2 regarding the type and position of fabric defects predicted in this way to the inspection condition setting means 13 and the drive control means 14. Drive control signal Sd to reverse machine 20
can be sent to control the running speed of the cloth W set on the fabric inspection machine 20. That is, the drive source of the fabric inspection machine 20 is controlled so as to have a predetermined running speed for fabric inspection at an appropriate length before and after the position where the fabric defect is predicted to exist;
In addition, for other parts where fabric defects are not expected,
The cloth W can be fast forwarded.

On the other hand, the fabric inspection condition setting means 13 can detect the running length of the fabric W set on the fabric inspection machine 20 based on the fabric length signal Sv fed back from the fabric inspection machine 20. Analysis data D1 from analysis means 12
2, a fabric inspection control signal Sc is sent to the fabric inspection machine 20 according to the type of fabric defect predicted next,
The inspection conditions of the fabric inspection machine 20 can be selected and determined. In other words, the next predicted fabric defects are stop, moire, step,
When the gloss is uneven, in order to perform reflection inspection (1st, 7th, and 8th rows in Fig. 3), the parallel light source 22 is turned on, and the camera device 21 is placed at approximately the middle position of the cloth W. It moves and waits at an elevation angle such that the reflected light emitted from the parallel light source 22 and reflected by the cloth W can properly enter. Moreover, the zoom magnification of the camera device 21 is
The setting is made small so that the entire width of the cloth W can be photographed.

Predicted fabric defects include misthreading, loose warp threads, warp threads missing,
If the fabric is loose, etc., in order to perform a transparent inspection, the parallel light source 23 is turned on, and the elevation angle of the camera device 21 is set to standby with the camera device 21 facing the same light source (see 3, 4, and 6 in Fig. 3). step). In addition, if the fabric defect is related to the ears, for local inspection,
The spot light source 24 is turned on, and both the spot light source 24 and the camera device 21 are brought to the end of the cloth W on the side where the cloth defect is predicted to be on standby (fifth stage). However, for selvage-related stops, selvage sensors and yarn end processing sensors are installed at both ends of the woven fabric being woven, and the information on which side of the sensor is activated and stopped is used as operation information. Signal SL, weaving data D
shall be included in ll.

As a result of analyzing the weaving data Dll, it is predicted that two or more types of fabric defects exist at the same position on the fabric W, and different inspection conditions must be selected and realized for the fabric defects. In this case, the fabric inspection condition setting means 13 sets fabric inspection conditions for the fabric inspection machine 20 corresponding to its main defects (fabric defects that have the greatest impact on the quality grading of the fabric; the same applies hereinafter). do it. For example, in the second row of Fig. 3, reflective inspection should be selected for stopping stages and weft dropouts, and transparent inspection should be selected for sinking and loosening. In this case, it is better to focus on the latter and set it to transparent inspection. However, depending on the type of cloth W,
Even sink marks and looseness may appear in a form that can be easily detected by reflective inspection, and in that case, it is better to consider stoppages and weft omissions as the main defects and to set reflective inspection to give better results.

In the above description, it is assumed that the warp data accumulating means 15 may be omitted. That is, since the warp data accumulation means 15 focuses on fabric defects caused by troubles occurring in the preparation machine Pj when adjusting the warp beam used for the woven fabric beam WB, it ignores such fabric defects. If it is acceptable, it is sufficient to analyze only the weaving data Dll.

Furthermore, it goes without saying that the analysis contents of the 1000 steps of data analysis 12 can be arbitrarily determined other than those shown in FIG.

In particular, problems that occur in the warp beam preparation process are not limited to sizing stops, but also data such as fluctuations in the amount of glue applied in the warping machine, changes in the speed of the preparation machine Pj due to some reason, etc. This can be included as a cause.

Another embodiment of the fabric inspection machine 20 uses guide rollers GR, GR, . (Figure 4). When two or more types of fabric defects are predicted at the same position, different inspection conditions should be set for each, or even if the inspection conditions are the same, the zoom magnification of the camera device 21 or the camera When there are optimal conditions for the inspection mode, such as the position of the device 21, the spot light source 24, and the illuminance of the parallel light sources 22 and 23, the inspection conditions and Since the inspection mode can be set individually, even stricter automatic fabric inspection can be carried out. In addition, in the same figure, the parallel light source 23 used for transparent inspection can be used to adjust the angle of reflection of the reflection mirror 23H, so that the parallel light source 23 can be used to detect adjacent groups such as groups A and B, groups B and C, etc. in the figure. Although it is designed to be shared by two groups, it goes without saying that it is also possible to prepare a dedicated one for each group. Also,
The number of groups of camera devices 21 and the like can be determined arbitrarily, regardless of the figure.

Effects of the Invention As explained above, according to the present invention, by combining the weaving data accumulation means, the data analysis means, and the inspection condition setting means, the camera device and light source of the fabric inspection machine can
Selection control can be performed to achieve the optimal inspection conditions according to predicted fabric defects and their positions.
It has an excellent effect that all fabric defects can be accurately detected using one camera device.

[Brief explanation of drawings]

Figures 1 to 3 show examples. Figure 1 is the overall system diagram, Figure 2 is a conceptual diagram of the structure of the fabric inspection machine, and Figure 3 is the correspondence between causes of stoppage, fabric defects, and inspection conditions. It is a table. FIG. 4 is a diagram corresponding to FIG. 2 showing another embodiment. WB...Woven fabric beam Li (i=1, 2...)...Loom Dll...Weaving data Dl2...Analysis data D
15... Warp data 10... Automatic fabric inspection system 11... Weaving data accumulation means 12... Data analysis means 13... Inspection condition setting means 14... Drive control means 15. ... Warp data accumulation means 20 ... Inspection machine

Claims (1)

[Scope of Claims] 1) Weaving data accumulating means for accumulating weaving data including the stopping position and cause of stopping of the loom during weaving for each woven fabric beam, and analyzing the weaving data from the weaving data accumulating means. , a data analysis means for specifying the type and position of fabric defects predicted in a woven fabric beam, and an inspection condition setting means for determining inspection conditions for a fabric inspection machine based on analysis data from the data analysis means. Automatic inspection system for woven fabrics. 2) A warp data accumulation means is added to each warp beam to accumulate warp data including the content and position of trouble that has occurred in the preparation process, and the warp data from the warp data accumulation means is input to the data analysis means. An automatic fabric inspection system according to claim 1, characterized in that: 3) The automatic fabric inspection according to claim 1 or 2, further comprising a drive control means for controlling the traveling speed of the fabric inspection machine based on the analysis data from the data analysis means. system.