WO2023070724A1 - 一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法及其装置 - Google Patents

一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法及其装置 Download PDF

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Publication number
WO2023070724A1
WO2023070724A1 PCT/CN2021/128859 CN2021128859W WO2023070724A1 WO 2023070724 A1 WO2023070724 A1 WO 2023070724A1 CN 2021128859 W CN2021128859 W CN 2021128859W WO 2023070724 A1 WO2023070724 A1 WO 2023070724A1
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WIPO (PCT)
Prior art keywords
shredded tobacco
roller
foreign matter
line
solenoid valve
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PCT/CN2021/128859
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English (en)
French (fr)
Inventor
石吉勇
王月影
邹小波
黄晓玮
李志华
郭志明
申婷婷
张新爱
张迪
梁静
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江苏大学
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Application filed by 江苏大学 filed Critical 江苏大学
Priority to US17/620,074 priority Critical patent/US11825871B2/en
Priority to DE112021000036.5T priority patent/DE112021000036B4/de
Priority to GB2312772.3A priority patent/GB2618044B/en
Publication of WO2023070724A1 publication Critical patent/WO2023070724A1/zh

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    • 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
    • G01N21/17—Systems in which incident light is modified in accordance with the properties of the material investigated
    • G01N21/25—Colour; Spectral properties, i.e. comparison of effect of material on the light at two or more different wavelengths or wavelength bands

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  • the invention belongs to the technical field of foreign matter detection in shredded tobacco, and in particular relates to a pulse spectrum online imaging detection method and device for plastic foreign matter with low chromaticity difference in shredded tobacco.
  • shredded tobacco involves many links such as tobacco harvesting, storage, transportation, and processing, which can easily lead to the mixing of different types of foreign matter, thereby affecting the quality of shredded tobacco products.
  • plastic foreign matter in shredded tobacco can burn synchronously with shredded tobacco due to its low ignition point, and produce irritating, even toxic and harmful gases. It causes invisible chemical hazards to consumers and seriously affects consumers' sensory experience.
  • Plastic is a "zero tolerance" foreign matter in cigarette production. Therefore, the detection of plastic foreign matter in shredded tobacco has become one of the key nodes in cigarette quality control.
  • the purpose of this application is to provide a pulse spectrum online imaging detection method and device for plastic foreign matter with low chromaticity difference in shredded tobacco, which is used to solve the problem of difficult identification and removal of plastic foreign matter with low chromaticity difference in shredded tobacco in the prior art.
  • Step 1 the negative pressure thin layer feeding of shredded tobacco includes the following process:
  • Process 2 The shredded tobacco after being adjusted by the thin layer thickness adjustment roller is transported to the end via the horizontal conveyor belt and falls to the surface of the conveying drum; at the same time, the negative pressure control solenoid valve III connected with the air chamber below the conveying drum surface is opened, and the shredded tobacco is The air hole array on the outer layer of the conveying roller and the negative pressure generated by the airflow from outside to inside in the air holes are adsorbed on the surface of the conveying roller;
  • Step 2 the tobacco pulse line-scan recognition includes the following process:
  • Process 1 encoding the surface of the conveying roller with a width of W and a circumference of L, first divide the surface of the conveying roller into P rectangular strips with a width of W and a length of L/P, and a single rectangular strip is denoted as A_j; Subsequently, the rectangular strip A_j is divided into Q square unit areas with a side length of L/P, and a single square unit area is marked as A_j_k; finally, the surface of the conveying roller is encoded using the coded array C that includes Q rows, P columns, and an initial value of 0.
  • the encoding rule is that C(k, j) corresponds to the square unit area A_j_k; where P and Q are both positive integers, and the value of j is 1, 2,..., P-1, P; where k is The value is 1, 2, ..., Q-1, Q;
  • the conveying drum keeps rotating at a constant speed, and a line scanning area with a width of W is determined on the surface of the drum, and the thin layer of shredded tobacco in the line scanning area is detected by using an LED line array light source containing N characteristic wavelengths of low chromaticity difference plastics combined with a line scanning camera.
  • Step 3 the positive pressure online removal of foreign matter includes the following process:
  • Process 1 Set the foreign matter shredded tobacco removal trigger line directly above the foreign matter collection barrel.
  • the position trigger will signal Transmission to the industrial computer, while the industrial computer reads the corresponding element C(1:Q,j) of the rectangular strip A_j in the encoding array, and reads all the elements C(k,j) in C(1:Q,j) sequentially If C(k, j) is 0, then C(k, j) corresponds to the square unit area A_j_k without foreign matter, and all air holes in the square unit area A_j_k correspond to the air chambers to maintain the original state, so that the square unit area A_j_k The shredded tobacco thin layer maintains a negative pressure adsorption state; if C(k, j) is 1, then C(k, j) corresponds to the square unit area A_j_k with foreign matter on it, and all the
  • the thin-layer thickness adjustment method is to adjust the distance between the thin-layer thickness adjustment roller and the horizontal conveyor belt or the length of the nail teeth.
  • the process of judging whether there is a foreign object in the area corresponding to the matrix strip A_j is: when the absolute value
  • the process of further locating the foreign matter in the square unit area A_j_k of the rectangular strip A_j is as follows: the value of k is 1, 2, ..., Q-1, Q in sequence; the matrix strip A_j is sequentially extracted under ⁇ _i
  • the present invention also provides a device for implementing the above detection method: the device includes a hopper, a regulating valve, a horizontal conveyor belt, a thin layer thickness adjusting roller, shredded tobacco rejecting roller, an ultra-thick shredded tobacco collecting hopper, an LED line array light source, a line scan camera, and an air flow nozzle Array, loose shredded tobacco collecting hopper, conveying roller, air hole array, air chamber, positive pressure control solenoid valve I, positive pressure control solenoid valve II, negative pressure control solenoid valve III, industrial computer, data line, PLC control cabinet, foreign object shredded tobacco removal Trigger line, qualified shredded tobacco cutting trigger line, residual shredded tobacco removal trigger line, foreign matter collection barrel, qualified shredded tobacco collection barrel, residual tobacco collection barrel, high-pressure air bag with air pressure of P1, high-pressure air bag with air pressure of P2, vacuum Air bag, position trigger and solenoid valve control board;
  • the regulating valve is arranged at the opening at the bottom of the hopper for controlling the flow rate of the material
  • the thin-layer thickness adjusting roller, shredded tobacco rejecting roller and ultra-thick shredded tobacco collecting hopper are sequentially arranged above the horizontal conveyor belt, and the thin-layer thickness adjusting roller removes the shredded tobacco exceeding the set thickness from the horizontal conveyor belt and transports it through the shredded tobacco rejecting roller To the ultra-thick shredded tobacco collecting hopper;
  • the delivery roller is docked with the end of the horizontal conveyor belt, and the shredded tobacco falls to the surface of the delivery roller through the end of the horizontal conveyor belt; and a position trigger is provided at the connection between the delivery roller and the horizontal conveyor belt, and is electrically connected to the industrial computer. It is used to realize the positioning of the rotation position of the conveying roller; the conveying roller is provided with a motor, and the output shaft of the motor is connected with the transmission wheel of the roller, and is used to drive the movement of the conveying roller; the surface of the conveying roller is provided with an outer layer of air hole array; and The lower part of the pore array communicates with the air chamber;
  • the single air chamber is electrically connected to the positive pressure control solenoid valve I, the positive pressure control solenoid valve II and the negative pressure control solenoid valve III respectively;
  • the positive pressure control solenoid valve I is electrically connected to the high-pressure air bag whose air pressure is P1
  • the positive pressure control solenoid valve II is electrically connected with the high-pressure air bag whose air pressure is P2
  • the negative pressure control solenoid valve III is electrically connected with the vacuum air bag;
  • the foreign matter shredded tobacco removal trigger line is located above the foreign matter collection barrel.
  • the position trigger transmits the signal to the industrial computer, and the industrial computer judges After the signal, the switch of the solenoid valve is controlled by the solenoid valve control board in the PLC control cabinet, and the shredded tobacco containing foreign matter on the surface of the conveying drum falls to the foreign matter collection barrel through the change of the air chamber;
  • the qualified shredded tobacco blanking trigger line is located above the qualified shredded tobacco collection barrel, and when the area where the qualified shredded tobacco is located enters the top of the qualified shredded tobacco collection barrel and the center line of the area overlaps with the qualified shredded tobacco blanking trigger line, the position trigger transmits a signal to the industrial After the computer and industrial computer discriminate the signal, the switch of the solenoid valve is controlled by the solenoid valve control panel in the PLC control cabinet, and the qualified shredded tobacco on the surface of the conveying drum is dropped to the qualified shredded tobacco collection barrel through the change of the air chamber;
  • the trigger line for removing shredded tobacco is located above the shredded tobacco collection barrel, and when the area where the shredded tobacco is located enters the shredded tobacco residue collecting barrel and the center line of the area overlaps with the shredded tobacco removal trigger line, the position trigger transmits a signal to the industrial computer, After the industrial computer distinguishes the signal, the switch of the solenoid valve is controlled by the solenoid valve control board in the PLC control cabinet, and the residual shredded tobacco on the surface of the conveying drum is dropped to the residual shredded tobacco collection barrel through the change of the air chamber;
  • the PLC control cabinet is provided with a solenoid valve control board, and the solenoid valve control board is electrically connected with the industrial computer, the positive pressure control solenoid valve I, the positive pressure control solenoid valve II and the negative pressure control solenoid valve III;
  • the valve control board controls the opening and closing of the positive pressure control solenoid valve I, the positive pressure control solenoid valve II and the negative pressure control solenoid valve III through the signal fed back by the industrial computer;
  • the opening and closing of the air flow nozzle array is controlled by a PLC control cabinet;
  • the industrial computer is electrically connected to the position trigger, and receives and processes the material position information collected from the position trigger;
  • the industrial computer is electrically connected to the line scan camera, receives and processes the spectral information collected by the line scan camera;
  • both the thin layer thickness adjusting roller and the shredded tobacco rejecting roller rotate clockwise.
  • the surfaces of the thin layer thickness adjusting roller and the shredded tobacco removing roller are provided with spikes, wherein the spiked teeth of the shredded tobacco removing roller and the spiked teeth of the thin layer thickness adjusting roller are in a staggered distribution state.
  • the air flow nozzle array is located above the junction between the conveying roller and the end of the horizontal conveying belt, and the airflow direction of the air flow nozzle array is tangent to the rotation direction of the conveying roller.
  • each group of LEDs emits light independently, it can evenly irradiate the line scanning area on the surface of the conveying roller.
  • the airflow nozzle array and the line scan camera are sequentially arranged along the moving direction of the conveying roller.
  • the qualified shredded tobacco collection barrel is directly below the conveying drum.
  • the caliber of the foreign matter collecting barrel, the qualified shredded tobacco collecting barrel and the remaining shredded tobacco collecting barrel is 2-10 times the length of the discrimination area.
  • the foreign matter shredded tobacco removal trigger line, qualified shredded tobacco discharge trigger line and residual shredded tobacco removal trigger line are respectively located directly above the foreign matter collection barrel, qualified shredded tobacco collection barrel and residual shredded tobacco collection barrel.
  • the present invention forms a fixed and continuous thin layer on the surface of the conveying drum with the shredded tobacco that is in a loose state and has a high degree of cross-crosslinking with each other through negative pressure adsorption force, thereby improving the detection and removal of plastic foreign matter with low chromaticity difference in the shredded tobacco Probability; through area coding on the surface of the drum, the intelligent linkage between pulse line scan recognition and positive pressure online rejection is realized; through pulsed light emission of low chromaticity difference plastic characteristic wavelength LED line array light source, combined with line scan
  • the camera can efficiently and real-time acquire the characteristic signals of plastic foreign objects with low chromaticity difference, which overcomes the limitations of existing conventional technologies in the detection of plastic foreign objects with low chromaticity difference in shredded tobacco. This solution solves the problems of feeding, identification, positioning, rejecting, and unloading in the detection of plastic foreign objects with low chromaticity difference in shredded tobacco, and can realize the efficient removal of plastic foreign objects with low chromaticity difference in shredded tobacco.
  • Fig. 1 is a schematic structural diagram of an on-line imaging detection device for pulse spectrum imaging of shredded tobacco with low chromaticity difference and plastic foreign matter in Example 1 of the present invention
  • Fig. 2 is a three-dimensional schematic diagram of the thin layer thickness adjusting roller, shredded tobacco rejecting roller and ultra-thick shredded tobacco collecting hopper in Example 1 of the present invention
  • Fig. 4 is the planar development view of the surface of the conveying roller in Embodiment 1 of the present invention.
  • FIG. 5 is a schematic diagram of a three-dimensional structure of a conveying roller in Embodiment 1 of the present invention.
  • FIG. 6 is a schematic diagram of the position structure of the control solenoid valve in Embodiment 1 of the present invention.
  • Fig. 7 is a structural schematic diagram of the air chamber and the control solenoid valve in Embodiment 1 of the present invention.
  • Embodiment 9 is a pulse cycle diagram of the LED linear array light source corresponding to the characteristic wavelength in Embodiment 1 of the present invention.
  • a pulse spectrum online imaging detection method for plastic foreign matter with low chromaticity difference in shredded tobacco including three steps: negative pressure thin layer feeding of shredded tobacco, pulse line scanning recognition of shredded tobacco, and positive pressure online removal of foreign matter:
  • Process 2 After the shredded tobacco passes through the bottom of the thin layer thickness adjustment roller 4, it falls to the surface of the conveying drum 11 through the end of the horizontal conveyor belt 3, and the negative pressure control solenoid valve III 16 connected to the air chamber 13 under the surface of the conveying drum 11 is opened, and the shredded tobacco
  • the air hole array 12 on the outer layer of the conveying roller 11 and the negative pressure generated by the airflow from outside to inside in the air chamber 13 are adsorbed on the surface of the conveying roller 11;
  • Process three the loose shredded tobacco that is adsorbed to the surface of the shredded tobacco thin layer on the surface of the conveying drum 11 by negative pressure is blown to the loose shredded tobacco hopper 10 by the tangential airflow on the surface of the conveying drum 11 emitted by the nozzles when passing through the front of the airflow nozzle array 9, and the remaining shredded tobacco A stable thin layer is formed on the surface of the conveying roller 11 .
  • Step 2 the tobacco pulse line-scan recognition includes the following process:
  • Process 1 encoding the surface of the conveying roller 11 whose width W is 100 cm and whose circumference L is 300 cm, first divide the surface of the conveying roller 11 into 30 rectangular strips with a width of 100 cm and a length of 10 cm, and a single rectangular strip is recorded as A_j, then the rectangular strip A_j is divided into 10 square unit areas with a side length of 10cm, and the single square unit area is denoted as A_j_k, and finally the conveyor roller 11 is paired with a coding array C that includes 10 rows, 30 columns and an initial value of 0
  • the surface is encoded, and the encoding rule is that C(k, j) corresponds to the square unit area A_j_k; wherein, the value of j is 1, 2, ..., 29, 30; the value of k is 1, 2, ..., 9, 10;
  • the conveying roller 11 keeps rotating at a constant speed, and a line scanning area with a width of 100 cm is determined on the surface of the conveying roller 11, and an LED line array light source 7 including three characteristic wavelengths of low chromaticity plastics is used to combine line scanning cameras with 8 pairs of line scanning
  • the shredded tobacco thin layer in the area is imaged; as shown in Figure 9, the LED linear array light source corresponding to a single characteristic wavelength ( ⁇ _1, ⁇ _2, ⁇ _3) in the imaging process is in the form of a pulse width of 50 ⁇ s, a pulse interval of 100 ⁇ s, and a pulse period of 150 ⁇ s (as shown in Fig.
  • the line scanning camera 8 obtains the scanning signal I_band_j_i under the irradiation of the i-th characteristic band ⁇ _i corresponding to the rectangular strip A_j in real time; wherein the value of i is 1, 2, 3;
  • the identification process is:
  • Process 1 Set the foreign matter shredded tobacco removal trigger line 20 directly above the foreign matter collection barrel 23.
  • the area corresponding to the rectangular strip A_2 enters the foreign matter collection barrel 23 and the center line of this area overlaps with the foreign matter shredded tobacco removal trigger line 20, the position
  • the trigger 29 transmits the signal to the industrial computer 17, and the industrial computer 17 reads the corresponding element C (1:10, 2) of the rectangular strip A_2 in the coded array, and reads all elements in C (1: 10, 2) sequentially.
  • Process 2 Set the qualified shredded tobacco cutting trigger line 21 directly above the qualified shredded tobacco collection barrel 24, when the area corresponding to the rectangular strip A_1 enters the qualified shredded tobacco collection barrel 24 and the center line of this area is consistent with the qualified shredded tobacco cutting trigger line 21
  • the position trigger 29 transmits the signal to the industrial computer 17, and the industrial computer 17 reads the corresponding element C (1:10, 1) of the rectangular strip A_1 in the encoding array, and reads C (1:10, The values of all elements in 1); if C(1,1) is 0, then C(1,1) corresponds to a thin layer of qualified shredded tobacco on the square unit area A_1_1, and all the air holes in the square unit area A_1_1 correspond to the negative of the air chamber 13.
  • the pressure control solenoid valve III 16 is closed, and the positive pressure control solenoid valve I 14 is continuously opened for 2 seconds and then closed, so that all air holes in the square unit area A_1_1 corresponding to the air chamber 13 enter the positive pressure P1 state and enter the normal pressure P0 state after 2 seconds. Make the thin layer of qualified shredded tobacco on the square unit area A_1_1 fall to the qualified shredded tobacco collecting barrel 24;
  • Process 3 In order to prevent a small amount of shredded tobacco remaining on the surface of the conveying drum 11 after going through the first and second steps of step 3, set the residual shredded tobacco removal trigger line 22 directly above the shredded tobacco collection barrel 25, and when the corresponding area of the rectangular strip A_j enters When the residual shredded tobacco collection barrel 25 is right above and the center line of this area overlaps with the shredded tobacco removal trigger line 22, the position trigger 29 transmits the signal to the industrial computer 17, and the industrial computer 17 controls the rectangular strip A_j to correspond to all square unit areas A_j_k
  • the positive pressure control solenoid valve II 15 of all the air holes corresponding to the air chamber 13 is continuously opened for 2 seconds and then closed.
  • the shredded tobacco thin layer falls to the residual shredded tobacco collecting barrel 25 and all the corresponding elements C(1:10, j) in the coding array are assigned 0.
  • the present invention also provides a device for realizing the pulse spectrum online imaging detection method of plastic foreign matter with low chromaticity difference in shredded tobacco:
  • the device includes hopper 1, regulating valve 2, horizontal conveyor belt 3, thin layer thickness adjusting roller 4, shredded tobacco removing roller 5, ultra-thick shredded tobacco collecting hopper 6, LED line array light source 7, line scan camera 8, air flow nozzle array 9 , Loose shredded tobacco collecting hopper 10, conveying drum 11, air hole array 12, air chamber 13, positive pressure control solenoid valve I 14, positive pressure control solenoid valve II 15, negative pressure control solenoid valve III 16, industrial computer 17, data line 18, PLC Control cabinet 19, foreign matter shredded tobacco removal trigger line 20, qualified shredded tobacco cutting trigger line 21, residual shredded tobacco removal trigger line 22, foreign matter collection barrel 23, qualified shredded tobacco collection barrel 24, residual shredded tobacco collection barrel 25, air pressure of P1 High-pressure air bag 26, high-pressure air bag 27 whose air pressure is P2, vacuum air bag 28, position trigger 29 and solenoid valve control panel 30;
  • the regulating valve 2 is located at the bottom opening of the hopper 1 for controlling the flow rate of the material
  • the thin-layer thickness adjusting roller 4, shredded tobacco removing roller 5, and ultra-thick shredded tobacco collecting hopper 6 are sequentially arranged above the horizontal conveyor belt 3, wherein the thin-layer thickness adjusting roller 4 and the shredded tobacco removing roller 5 all rotate in a clockwise direction; as shown in the figure As shown in 2-3, the surface of the thin-layer thickness adjusting roller 4 and the shredded tobacco removing roller 5 are provided with nail teeth, wherein the nail teeth of the shredded tobacco removing roller 5 and the nail teeth of the thin-layer thickness adjusting roller 4 are in a staggered distribution state;
  • the thin-layer thickness regulating roller 4 and the shredded tobacco rejecting roller 5 are all provided with a motor, and the output shaft of the motor is connected with the transmission wheel of the roller to drive the movement of the roller; the delivery roller 11 is docked with the end of the horizontal conveyor belt 3, The shredded tobacco falls to the surface of the conveying drum 11 through the end of the horizontal conveying belt 3; and a position trigger 29 is provided at the connection between the conveying roller 11 and the horizontal conveying belt 3, and is electrically connected with the industrial computer 17 through the data line 18 for Realize the positioning of the rotating position of the conveying roller 11; the conveying roller 11 is provided with a motor, and the output shaft of the motor is connected with the transmission wheel of the roller for driving the movement of the roller; the width of the conveying roller 11 is 100cm, and the circumference length is 300cm , conveying materials in a clockwise direction; the surface of the conveying roller 11 is provided with an outer layer air hole array 12, specifically as shown in Figure 5; the air hole array 12 is composed of a number of
  • the air flow nozzle array 9 is located above the joint between the conveying drum 11 and the end of the horizontal conveying belt 3, the air flow direction is tangent to the rotation direction of the conveying drum 11, and a loose shredded tobacco collecting hopper 10 is provided on the lower side of the air flow direction , so that the loose shredded tobacco on the surface of the thin layer of shredded tobacco on the conveying drum 11 is blown to the loose shredded tobacco hopper 10 by the tangential airflow of the airflow nozzle array 9;
  • the LED linear light source 7 is located above the conveying roller 11.
  • the LED linear light source 7 is composed of 3 groups of LED lamp beads.
  • the first, second and third groups respectively include 20 LED lamps that can emit light with wavelengths of ⁇ _1, ⁇ _2, and ⁇ _3. Beads; when each group of LEDs emits light independently, it can evenly illuminate the line scanning area on the surface of the conveying roller 11;
  • the line scan camera 8 is arranged behind the airflow nozzle array; the line scan width of the line scan camera 8 is 100 cm, and the thin layer of shredded tobacco in the line scan area can be imaged by the line scan camera 8 , the scanning process of the line scan camera is shown in Figure 8;
  • a foreign matter collecting barrel 23 Along the running direction of the conveying drum 11, a foreign matter collecting barrel 23, a qualified shredded tobacco collecting barrel 24 and a residual shredded tobacco collecting barrel 25 are arranged in sequence, and the qualified shredded tobacco collecting barrel 24 is located directly below the conveying roller 11;
  • the qualified shredded tobacco blanking trigger line 21 is located directly above the qualified shredded tobacco collecting barrel 24.
  • the position trigger The device 29 transmits the signal to the industrial computer 17, and the industrial computer 17 controls the switch of the electromagnetic valve through the electromagnetic valve control panel 30 after discriminating the signal, and the qualified shredded tobacco on the surface of the conveying drum 11 is dropped to the qualified shredded tobacco collection barrel through the change of the air chamber 13 twenty four;
  • the opening and closing of the air flow nozzle array 9 is controlled by a PLC control cabinet 19;
  • the industrial computer 17 is connected with the line scan camera 8 through the data line 18, receives and processes the spectral information collected from the line scan camera 8;
  • the industrial computer 17 has a built-in routine data processing program, a standard database and a processing module, which can perform data processing on the spectral information of shredded tobacco and plastic foreign objects with low chromaticity difference, and realize the discrimination of plastic foreign objects with low chromaticity difference.

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Abstract

一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法及其装置，属于烟丝异物检测技术领域。主要包括烟丝负压薄层上料、烟丝脉冲线扫识别、异物正压在线剔除三个步骤；通过负压吸附力将呈松散状态且彼此间交叉交联度高的烟丝在输送滚筒（11）的表面形成固定、连续的薄层，提高了烟丝中低色度差塑料异物的被检出和剔除的概率；通过对滚筒（11）表面进行区域编码，实现了脉冲线扫识别、正压在线剔除两者间的智能联动；通过对低色度差塑料特征波长LED线阵光源（7）进行脉冲式发光，结合线扫描相机（8）可以高效、实时获取低色度差塑料异物的特征信号，克服了现有常规技术对烟丝中低色度差塑料异物检测的局限性，实现烟丝中低色度差塑料异物的高效剔除。

Description

一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法及其装置 技术领域
本发明属于烟丝异物检测技术领域，具体涉及一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法及其装置。
背景技术
烟丝生产涉及烟叶采收、储运、加工等众多环节，易导致不同类型的异物混入其中，从而影响烟丝产品的质量。与常规食品中异物的摄入会对牙齿、口腔、食道造成有形的物理伤害不同，塑料类烟丝异物由于其燃点较低的特点，能与烟丝同步燃烧，并产生刺激性，甚至有毒有害气体，对消费者造成无形的化学危害，严重影响消费者的感官体验。塑料是卷烟生产的“零容忍”异物，因此，烟丝中塑料异物检测便成了卷烟品质控制的关键节点之一。
根据异物与食品在颜色、密度、被磁化能力等方面存在的差异，目前已建立了异物的计算机视觉检测法、X射线检测法以及磁场检测法等识别方法。如专利CN107330882A公布了一种基于计算机视觉的烟丝异物检测方法，该方法采用预设的异物鉴别器分析异物与烟丝在外观上的差异，可实现烟丝异物的检出；专利CN212059973U公布了一种基于X射线的食品异物检测方法，借助X射线在不同密度介质中传播行为的差异，可实现金属等高密度差类异物的检出；专利CN111871812A公布了一种基于磁场的烟丝异物检测方法，利用金属探测器感知烟丝内可磁化的金属异物，可实现烟丝中金属异物的检测与分拣。然而，由于低色度差塑料异物自身透明度高，颜色、密度与被磁化能力与烟丝差异不显著等特性，导致现有方法难以有效检出。
为了克服现有技术方案的不足，本发明依据低色度差塑料异物与烟丝在化学组分方面存在差异的特性，利用光谱在线成像技术精准、快速捕捉低色度差塑料的光学特征以分析其化学组分的差异，从而实现烟丝中低色度差塑料异物的高效识别及剔除。
发明内容
本申请的目的在于提供一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法及其装置，用于解决现有技术对烟丝中低色度差塑料异物难识别、难剔除的问题。
首先，本发明提供一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法，包含烟丝负压薄层上料、烟丝脉冲线扫识别、异物正压在线剔除三个步骤：
步骤一，所述烟丝负压薄层上料包含以下过程：
过程一，烟丝从料斗中掉落至水平输送带并由水平输送带传输，经过薄层厚度调节滚轮下方时，超过设置厚度的烟丝被薄层厚度调节滚轮移除，转移至烟丝剔除滚轮，然后再经烟 丝剔除滚轮剥离后输送至超厚烟丝集料斗；
过程二，经过薄层厚度调节滚轮调整后的烟丝经水平输送带继续运输至末端并掉落至输送滚筒的表面；同时与输送滚筒表面下方气室相连的负压控制电磁阀III打开，烟丝被输送滚筒外层气孔阵列及气孔内由外向内的气流产生的负压吸附在输送滚筒表面；
过程三，被负压吸附至输送滚筒表面的烟丝，在其薄层表面仍可能会有松散烟丝，此时再通过气流喷嘴阵列喷嘴发出沿输送滚筒表面切向气流，将松散烟丝吹送至松散烟丝集料斗，剩余的烟丝在输送滚筒表面形成稳定的薄层；
步骤二，所述烟丝脉冲线扫识别包含以下过程：
过程一，对宽度为W、圆周长度为L的输送滚筒表面进行编码，首先将输送滚筒表面划分为P条宽度为W、长度为L/P的矩形条带，单个矩形条带记为A_j；随后将矩形条带A_j划分为Q个边长为L/P的正方形单元区域，单个正方形单元区域记为A_j_k；最后利用包含Q行、P列且初始值为0的编码数组C对输送滚筒表面进行编码，编码规则为C(k，j)与正方形单元区域A_j_k对应；其中P和Q均为正整数，j的取值为1，2，……，P-1，P；其中k的取值为1，2，……，Q-1，Q；
所述单个正方形单元区域A_j_k下方置有u个气孔，u个气孔对应1个气室，其中u为正整数；所述矩形条带A_j在不同时间对应的输送滚筒上位置可通过位置触发器及工业计算机进行判断；
过程二，输送滚筒始终保持匀速转动，在滚筒表面确定宽度为W的线扫描区域，利用包含N个低色度差塑料特征波长的LED线阵光源结合线扫描相机对线扫描区域的烟丝薄层进行成像；成像过程中单个特征波长对应的LED线阵光源以脉冲宽度T/N、脉冲间隔T(N-1)/N、脉冲周期T的形式依次循环发光；在矩形条带A_j经过线扫描区域期间，线扫描相机实时获取矩形条带A_j对应的第i个特征波段λ_i照射下的扫描信号I_band_j_i；其中i的取值为1，2，……，N-1，N；其中N为正整数，脉冲周期T的取值范围1.5～3000μs；
过程三，利用N个特征波长λ_i对应的扫描信号的异物鉴别阈值D_i，结合实时获取矩形条带A_j对应的第i个特征波段照射下的扫描信号I_band_j_i，识别矩形条带A_j对应区域是否存在异物；若识别结果为矩形条带A_j对应区域不存在异物，则保持编码数组C中第j列元素C(1：Q，j)的数值不变；若识别结果为矩形条带A_j对应区域存在异物，则进一步定位异物在矩形条带A_j的所属正方形单元区域A_j_k，并将编码数组C对应的C(k，j)设置为1；
步骤三，所述异物正压在线剔除包含以下过程：
过程一，在异物收集料筒正上方设定异物烟丝剔除触发线，当矩形条带A_j对应区域进 入异物收集料筒正上方且该区域中线与异物烟丝剔除触发线重叠时，位置触发器将信号传输至工业计算机，同时工业计算机读取矩形条带A_j在编码数组中的对应元素C(1：Q，j)，依次读取C(1：Q，j)中所有元素C(k，j)的值；若C(k，j)为0，则C(k，j)对应正方形单元区域A_j_k上无异物，正方形单元区域A_j_k内所有气孔对应气室维持原有状态，使得该正方形单元区域上的烟丝薄层维持负压吸附状态；若C(k，j)为1，则C(k，j)对应正方形单元区域A_j_k上有异物，正方形单元区域A_j_k内所有气孔对应气室的负压控制电磁阀III关闭、正压控制电磁阀I持续打开t1秒后关闭，使正方形单元区域A_j_k内所有气孔对应气室进入正压P1状态且持续t1秒后再进入常压P0状态，使得该正方形单元区域A_j_k上的含异物烟丝薄层掉落至异物收集料筒；
过程二，在合格烟丝收集料筒正上方设定合格烟丝下料触发线，当矩形条带A_j对应区域进入合格烟丝收集料筒正上方且该区域中线与合格烟丝下料触发线重叠时，位置触发器将信号传输至工业计算机，同时工业计算机读取矩形条带A_j在编码数组中的对应元素C(1：Q，j)，依次读取C(1：Q，j)中所有元素的值；若C(k，j)为0，则C(k，j)对应正方形单元区域A_j_k上为合格烟丝薄层，正方形单元区域A_j_k内所有气孔对应气室的负压控制电磁阀III关闭、正压控制电磁阀I持续打开t1秒后关闭，使正方形单元区域A_j_k内所有气孔对应气室进入正压P1状态且持续t1秒后进入常压P0状态，使得该正方形单元区域A_j_k上的合格烟丝薄层掉落至合格烟丝收集料筒；若C(k，j)为1，则C(k，j)对应正方形单元区域A_j_k上的含异物烟丝已在步骤三的过程一中被剔除，正方形单元区域A_j_k内所有气孔对应气室在本过程中维持原有状态不变；
过程三，为了防止输送滚筒表面经过步骤三的过程一、二后仍有少量烟丝残留，在残留烟丝收集料筒正上方设定残留烟丝清除触发线，当矩形条带A_j对应区域进入残留烟丝收集料筒正上方且该区域中线与残留烟丝清除触发线重叠时，位置触发器将信号传输至工业计算机，同时工业计算机控制矩形条带A_j对应所有正方形单元区域A_j_k内所有气孔对应气室的正压控制电磁阀II持续打开t1秒后关闭，进气室入正压P2状态且持续t1秒后进入常压P0状态，使得矩形条带A_j对应区域上的残留烟丝薄层掉落至残留烟丝收集料筒并将编码数组中的对应元素C(1：Q，j)全部赋值为0。
优选的，所述薄层厚度调节的方法为调控薄层厚度调节滚轮与水平输送带的间距或钉齿的长度。
优选的，所述判别矩阵条带A_j对应区域是否存在异物过程为：当矩阵条带A_j在λ_i下的扫描信号I_band_j_i的绝对值|I_band_j_i|小于异物鉴别阈值D_i时，识别结果为矩阵条带A_j对应区域不存在异物；当|I_band_j_i|大于或等于异物鉴别阈值D_i时，识别结果为矩阵条 带A_j对应区域存在异物。
优选的，所述进一步定位异物在矩形条带A_j的所属正方形单元区域A_j_k的过程为：k的值依次取1，2，……，Q-1，Q；依次提取矩阵条带A_j在λ_i下的扫描信号I_band_j_i中正方形单元区域A_j_k对应的扫描信号I_band_j_i_k，当扫描信号I_band_j_i_k绝对值|I_band_j_i_k|小于异物鉴别阈值D_i时，识别结果为k值对应的正方形单元区域A_j_k不存在异物；当|I_band_j_i_k|大于等于异物鉴别阈值D_i，识别结果为k值对应的正方形单元区域A_j_k存在异物。
优选的，t1设置为1～20s。
本发明还提供实现上述检测方法的装置：该装置包括料斗、调节阀、水平输送带、薄层厚度调节滚轮、烟丝剔除滚轮、超厚烟丝集料斗、LED线阵光源、线扫描相机、气流喷嘴阵列、松散烟丝集料斗、输送滚筒、气孔阵列、气室、正压控制电磁阀I、正压控制电磁阀Ⅱ、负压控制电磁阀Ⅲ、工业计算机、数据线、PLC控制柜、异物烟丝剔除触发线、合格烟丝下料触发线、残留烟丝清除触发线、异物收集料筒、合格烟丝收集料筒、残留烟丝收集料筒、气压为P1的高压气包、气压为P2的高压气包、真空气包、位置触发器和电磁阀控制板；
所述调节阀设于料斗底部开口处，用于控制物料流速；
所述料斗位于水平输送带的上方，以便经料斗流出的物料掉落至水平输送带；所述水平输送带的一侧设有电机，电机的输出轴与水平输送带的传动轮连接，用于驱动水平输送带的运动；
所述薄层厚度调节滚轮、烟丝剔除滚轮和超厚烟丝集料斗依次设置在水平输送带上方，所述薄层厚度调节滚轮将超过设置厚度的烟丝从水平输送带移除并经烟丝剔除滚轮输送至超厚烟丝集料斗内；
所述薄层厚度调节滚轮和烟丝剔除滚轮均设有电机，电机的输出轴与滚轮的传动轮连接，用于驱动滚轮的运动；
所述输送滚筒与水平输送带的末端对接，烟丝经水平输送带末端掉落至输送滚筒表面；且所述输送滚筒与水平输送带连接处设置有位置触发器，并与工业计算机电性相连，用于实现输送滚筒旋转位置的定位；所述输送滚筒设有电机，电机的输出轴与滚筒的传动轮连接，用于驱动输送滚筒的运动；所述输送滚筒表面设有外层气孔阵列；且所述气孔阵列下方与气室相通；
所述单个气室分别与正压控制电磁阀I、正压控制电磁阀II和负压控制电磁阀III电性相连；所述正压控制电磁阀I与气压为P1的高压气包电性相连，正压控制电磁阀II与气压为P2的高压气包电性相连，负压控制电磁阀Ⅲ与真空气包电性相连；
所述气流喷嘴阵列位于输送滚筒的上方，同时在气流方向的下侧设有松散烟丝集料斗，以便通过气流喷嘴阵列的切向气流将输送滚筒上烟丝薄层表面的松散烟丝吹送至松散烟丝集料斗；
所述LED线阵光源位于输送滚筒上方，LED线阵光源由N组LED灯珠组成，第i组包含E个可发出光线波长为λ_i的LED灯珠；其中E为大于等于1的整数；
所述输送滚筒的上方设有线扫描相机；所述线扫描相机的线扫描宽度为W，利用线扫描相机可对线扫描区域的烟丝薄层进行成像；
沿输送滚筒的运转方向，依次设有异物收集料筒、合格烟丝收集料筒和残留烟丝收集料筒；
所述异物烟丝剔除触发线位于异物收集料筒上方，当异物所在区域进入异物收集料筒上方且该区域中线与异物烟丝剔除触发线重叠时，位置触发器将信号传输至工业计算机，工业计算机判别信号后通过PLC控制柜中的电磁阀控制板控制电磁阀的开关，通过气室的改变使输送滚筒表面的含异物烟丝掉落至异物收集料筒；
所述合格烟丝下料触发线位于合格烟丝收集料筒上方，当合格烟丝所在区域进入合格烟丝收集料筒上方且该区域中线与合格烟丝下料触发线重叠时，位置触发器将信号传输至工业计算机，工业计算机判别信号后通过PLC控制柜中的电磁阀控制板控制电磁阀的开关，通过气室的改变使输送滚筒表面的合格烟丝掉落至合格烟丝收集料筒；
所述残留烟丝清除触发线位于残留烟丝收集料筒上方，当残留烟丝所在区域进入残留烟丝收集料筒上方且该区域中线与残留烟丝清除触发线重叠时，位置触发器将信号传输至工业计算机，工业计算机判别信号后通过PLC控制柜中的电磁阀控制板控制电磁阀的开关，通过气室的改变使输送滚筒表面的残留烟丝掉落至残留烟丝收集料筒；
所述PLC控制柜内设有电磁阀控制板，所述电磁阀控制板与工业计算机、正压控制电磁阀I、正压控制电磁阀II和负压控制电磁阀III电性相连；所述电磁阀控制板通过工业计算机反馈的信号，控制正压控制电磁阀I、正压控制电磁阀II和负压控制电磁阀III的开启与关闭；
所述气流喷嘴阵列的开启与关闭由PLC控制柜控制；
所述工业计算机与位置触发器电性连接，接收并处理来自位置触发器采集的物料位置信息；
所述工业计算机与线扫描相机电性连接，接收并处理来自线扫描相机采集的光谱信息；
所述工业计算机内置常规数据处理程序、标准数据库和处理模块，能对烟丝及低色度差塑料异物的光谱信息进行数据处理，实现低色度差塑料异物的判别。
优选的，所述薄层厚度调节滚轮和烟丝剔除滚轮均按顺时针方向转动。
优选的，所述薄层厚度调节滚轮和烟丝剔除滚轮表面均设有钉齿，其中烟丝剔除滚轮的钉齿与薄层厚度调节滚轮的钉齿呈交错分布状态。
优选的，所述薄层厚度调节滚轮和烟丝剔除滚轮的钉齿为弓齿，且单个钉齿的长度可调。
优选的，所述单个气室与含有1-40个气孔的气孔阵列对应。
优选的，所述气流喷嘴阵列位于输送滚筒与水平输送带的末端对接处的上方，气流喷嘴阵列的气流方向与输送滚筒的转动方向同向相切。
优选的，每组LED单独发光时，可均匀照射输送滚筒表面的线扫描区域。
优选的，所述气流喷嘴阵列、线扫描相机沿着输送滚筒的运动方向依次设置。
优选的，所述输送滚筒正下方为合格烟丝收集料筒。
优选的，所述异物收集料筒、合格烟丝收集料筒和残留烟丝收集料筒的口径为判别区域长度的2-10倍。
优选的，所述异物烟丝剔除触发线、合格烟丝下料触发线和残留烟丝清除触发线分别位于异物收集料筒、合格烟丝收集料筒和残留烟丝收集料筒的正上方。
本发明的有益效果：
本发明通过负压吸附力将呈松散状态且彼此间交叉交联度高的烟丝在输送滚筒的表面形成固定、连续的薄层，提高了烟丝中低色度差塑料异物的被检出和剔除的概率；通过对滚筒表面进行区域编码，实现了脉冲线扫识别、正压在线剔除两者间的智能联动；通过对低色度差塑料特征波长LED线阵光源进行脉冲式发光，结合线扫描相机可以高效、实时获取低色度差塑料异物的特征信号，克服了现有常规技术对烟丝中低色度差塑料异物检测的局限性。本方案解决了烟丝中低色度差塑料异物检测中上料、识别、定位、剔除、下料中的难题，可以实现烟丝中低色度差塑料异物的高效剔除。
附图说明
图1为本发明实施例1中烟丝低色度差塑料异物脉冲光谱在线成像检测装置的结构示意图；
图2为本发明实施例1中薄层厚度调节滚轮、烟丝剔除滚轮和超厚烟丝集料斗的三维示意图；
图3为本发明实施例1中薄层厚度调节滚轮、烟丝剔除滚轮和超厚烟丝集料斗的平面示意图；
图4为本发明实施例1中输送滚筒表面的平面展开图；
图5为本发明实施例1中输送滚筒的三维结构示意图；
图6为本发明实施例1中控制电磁阀位置结构示意图；
图7为本发明实施例1中气室及控制电磁阀结构示意图；
图8为本发明实施例1中线扫描相机扫描区域示意图；
图9为本发明实施例1中特征波长对应的LED线阵光源脉冲周期图；
其中：1.料斗；2.调节阀；3.水平输送带；4.薄层厚度调节滚轮；5.烟丝剔除滚轮；6.超厚烟丝集料斗；7.LED线阵光源；8.线扫描相机；9.气流喷嘴阵列；10.松散烟丝集料斗；11.输送滚筒；12.气孔阵列；13.气室；14.正压控制电磁阀I；15.正压控制电磁阀Ⅱ；16.负压控制电磁阀Ⅲ；17.工业计算机；18.数据线；19.PLC控制柜；20.异物烟丝剔除触发线；21.合格烟丝下料触发线；22.残留烟丝清除触发线；23.异物收集料筒；24.合格烟丝收集料筒；25.残留烟丝收集料筒；26.气压为P1的高压气包；27.气压为P2的高压气包；28.真空气包；29.位置触发器；30.电磁阀控制板。
具体实施方式
下面结合一些具体实施例为本发明进一步详细说明，但本发明的保护范围不仅限于这些实施例。
实施例1：
一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法，包含烟丝负压薄层上料、烟丝脉冲线扫识别、异物正压在线剔除三个步骤：
步骤一，所述烟丝负压薄层上料包含以下过程：
过程一，烟丝从料斗1中掉落至水平输送带3，烟丝在随水平输送带3移动至薄层厚度调节滚轮4下方时，超过设置厚度的烟丝被薄层厚度调节滚轮4移除，通过调控薄层厚度调节滚轮4与水平输送带3间的高度实现对烟丝厚度的调节，再经烟丝剔除滚轮5剥离后输送至超厚烟丝集料斗6；
过程二，烟丝经过薄层厚度调节滚轮4下方之后，经水平输送带3末端掉落至输送滚筒11的表面，与输送滚筒11表面下方气室13相连的负压控制电磁阀III 16打开，烟丝被输送滚筒11外层气孔阵列12及气室13内由外向内的气流产生的负压吸附在输送滚筒11表面；
过程三，被负压吸附至输送滚筒11表面的烟丝薄层表面的松散烟丝，经过气流喷嘴阵列9前方时被喷嘴发出的输送滚筒11表面切向气流吹送至松散烟丝集料斗10，剩余的烟丝在输送滚筒11表面形成稳定的薄层。
步骤二，所述烟丝脉冲线扫识别包含以下过程：
过程一，对宽度W为100cm、圆周长度L为300cm的输送滚筒11表面进行编码，首先将输送滚筒11表面划分为30条宽度为100cm、长度为10cm的矩形条带，单个矩形条带记为A_j，随后将矩形条带A_j划分为10个边长为10cm的正方形单元区域，单个正方形单 元区域记为A_j_k，最后利用包含10行、30列且初始值为0的编码数组C对输送滚筒11表面进行编码，编码规则为C(k，j)与正方形单元区域A_j_k对应；其中，j的取值为1，2，……，29，30；k的取值为1，2，……，9，10；
所述单个正方形单元区域A_j_k下方置有4个气孔(如图4所示)，4个气孔对应1个气室13；其中矩形条带A_j在不同时间对应的输送滚筒11上位置可通过位置触发器29及工业计算机17判断。
过程二，输送滚筒11始终保持匀速转动，在输送滚筒11表面确定宽度为100cm的线扫描区域，利用包含3个低色度差塑料特征波长的LED线阵光源7结合线扫描相机8对线扫描区域的烟丝薄层进行成像；如图9所示，成像过程中单个特征波长(λ_1、λ_2、λ_3)对应的LED线阵光源以脉冲宽度50μs、脉冲间隔100μs、脉冲周期150μs的形式(如图9所示)依次循环发光；在矩形条带A_j经过线扫描区域期间，线扫描相机8实时获取矩形条带A_j对应的第i个特征波段λ_i照射下的扫描信号I_band_j_i；其中i的取值为1，2，3；
过程三，利用3个特征波长λ_1、λ_2、λ_3对应的扫描信号的异物鉴别阈值，分别记为D_1、D_2、D_3)，结合实时获取矩形条带A_j对应的第i个特征波段照射下的扫描信号I_band_j_i，识别矩形条带A_j对应区域是否存在异物；如果识别结果为矩形条带A_j对应区域不存在异物，则保持编码数组C中第j列元素C(1：10，j)的数值不变；如果识别结果为矩形条带A_j对应区域存在异物，则进一步定位异物在矩形条带A_j的所属正方形单元区域A_j_k，并将编码数组C对应的C(k，j)设置为1；
当矩阵条带A_1不存在对λ_1敏感的低色度差塑料异物时，其识别过程为：
将矩阵条带A_1在λ_1下的扫描信号I_band_1_1的绝对值|I_band_1_1|与异物鉴别阈值D_1进行比较，|I_band_1_1|小于D_1，识别结果为矩阵条带A_1对应区域不存在异物，保持编码数组C中第1列元素C(1：10，1)的数值不变；
当矩阵条带A_2中正方形单元区域A_2_1不存在对λ_1敏感的低色度差塑料异物，而正方形单元区域A_2_2存在对λ_1敏感的低色度差塑料异物时，其识别过程为：
将矩阵条带A_2在λ_1下的扫描信号I_band_2_1的绝对值|I_band_2_1|与异物鉴别阈值D_1进行比较，|I_band_2_1|大于D_1，识别结果为矩阵条带A_2对应区域存在异物，则需要进一步定位异物在矩形条带A_2的所属正方形单元区域A_2_k；提取矩阵条带A_2在λ_1下的扫描信号I_band_2_1中正方形单元区域A_2_1对应的扫描信号I_band_2_1_1，当扫描信号I_band_2_1_1绝对值|I_band_2_1_1|小于异物鉴别阈值D_1，识别结果为k＝1时对应的正方形单元区域A_2_1不存在异物，保持编码数组C中C(2，1)的数值不变；提取矩阵条带A_2在λ_1下的扫描信号I_band_2_1中正方形单元区域A_2_2对应的扫描信号I_band_2_1_2，当 扫描信号I_band_2_1_2绝对值|I_band_2_1_2|大于异物鉴别阈值D_1，识别结果为k＝2时对应的正方形单元区域A_2_2存在异物，将编码数组C对应的C(2，2)设置为1。
步骤三，所述异物正压在线剔除包含以下过程：当只有正方形单元区域A_2_2存在低色度差塑料异物时，其识别过程为：
过程一，在异物收集料筒23正上方设定异物烟丝剔除触发线20，当矩形条带A_2对应区域进入异物收集料筒23正上方且该区域中线与异物烟丝剔除触发线20重叠时，位置触发器29将信号传输至工业计算机17，同时工业计算机17读取矩形条带A_2在编码数组中的对应元素C(1：10，2)，依次读取C(1：10，2)中所有元素的值；C(1，2)为0，则表明C(1，2)对应正方形单元区域A_2_1上无异物，正方形单元区域A_2_1内所有气孔对应气室13维持原有状态，使得该正方形单元区域上的烟丝薄层维持负压吸附状态；C(2，2)为1，则表明C(2，2)对应正方形单元区域A_2_2上有异物，正方形单元区域A_2_2内所有气孔对应气室13的负压控制电磁阀III 16关闭、正压控制电磁阀I 14持续打开2秒后关闭，使正方形单元区域A_2_2内所有气孔对应气室13进入正压P1状态且持续2秒后再进入常压P0状态使得该正方形单元区域上A_2_2的含异物烟丝薄层掉落至异物收集料筒23；
过程二，在合格烟丝收集料筒24正上方设定合格烟丝下料触发线21，当矩形条带A_1对应区域进入合格烟丝收集料筒24正上方且该区域中线与合格烟丝下料触发线21重叠时，位置触发器29将信号传输至工业计算机17，同时工业计算机17读取矩形条带A_1在编码数组中的对应元素C(1：10，1)，依次读取C(1：10，1)中所有元素的值；若C(1，1)为0，则C(1，1)对应正方形单元区域A_1_1上为合格烟丝薄层，正方形单元区域A_1_1内所有气孔对应气室13的负压控制电磁阀III 16关闭、正压控制电磁阀I 14持续打开2秒后关闭，使正方形单元区域A_1_1内所有气孔对应气室13进入正压P1状态且持续2秒后进入常压P0状态，使得该正方形单元区域A_1_1上的合格烟丝薄层掉落至合格烟丝收集料筒24；
过程三，为了防止输送滚筒11表面经过步骤三的过程一、二后仍有少量烟丝残留，在残留烟丝收集料筒25正上方设定残留烟丝清除触发线22，当矩形条带A_j对应区域进入残留烟丝收集料筒25正上方且该区域中线与残留烟丝清除触发线22重叠时，位置触发器29将信号传输至工业计算机17，同时工业计算机17控制矩形条带A_j对应所有正方形单元区域A_j_k内全部气孔对应气室13的正压控制电磁阀II 15持续打开2秒后关闭，进气室入正压P2状态且持续2秒后进入常压P0状态，使得矩形条带A_j对应区域上的残留烟丝薄层掉落至残留烟丝收集料筒25并将编码数组中的对应元素C(1：10，j)全部赋值为0。
如图1-8所示，本发明还提供一种实现烟丝低色度差塑料异物的脉冲光谱在线成像检测方法的装置：
该装置包括，料斗1、调节阀2、水平输送带3、薄层厚度调节滚轮4、烟丝剔除滚轮5、超厚烟丝集料斗6、LED线阵光源7、线扫描相机8、气流喷嘴阵列9、松散烟丝集料斗10、输送滚筒11、气孔阵列12、气室13、正压控制电磁阀I 14、正压控制电磁阀Ⅱ15、负压控制电磁阀Ⅲ16、工业计算机17、数据线18、PLC控制柜19、异物烟丝剔除触发线20、合格烟丝下料触发线21、残留烟丝清除触发线22、异物收集料筒23、合格烟丝收集料筒24、残留烟丝收集料筒25、气压为P1的高压气包26、气压为P2的高压气包27、真空气包28、位置触发器29和电磁阀控制板30；
所述调节阀2设于料斗1底部开口处，用于控制物料流速；
所述料斗1垂直于水平输送带3放置，其出口位于水平输送带3的上方，以便经料斗1流出的物料掉落至水平输送带3；所述水平输送带3的一侧设有电机，电机的输出轴与水平输送带3的传动轮连接，用于驱动水平输送带3的运动；
所述薄层厚度调节滚轮4、烟丝剔除滚轮5、超厚烟丝集料斗6依次设置在水平输送带3上方，其中薄层厚度调节滚轮4和烟丝剔除滚轮5均按顺时针方向转动；如图2-3所示，所述薄层厚度调节滚轮4和烟丝剔除滚轮5表面均设有钉齿，其中烟丝剔除滚轮5的钉齿与薄层厚度调节滚轮4的钉齿呈交错分布状态；
所述薄层厚度调节滚轮4和烟丝剔除滚轮5均设有电机，电机的输出轴与滚轮的传动轮连接，用于驱动滚轮的运动；所述输送滚筒11与水平输送带3的末端对接，烟丝经水平输送带3末端掉落至输送滚筒11表面；且所述输送滚筒11与水平输送带3连接处设置有位置触发器29，并通过数据线18与工业计算机17电性相连，用于实现输送滚筒11旋转位置的定位；所述输送滚筒11设有电机，电机的输出轴与滚筒的传动轮连接，用于驱动滚筒的运动；所述输送滚筒11的宽度为100cm，圆周长度为300cm，呈顺时针方向输送物料；所述输送滚筒11表面设有外层气孔阵列12，具体如图5所示；气孔阵列12由若干均匀分布的气孔组成，且所述气孔阵列12下方与气室13相通，4个气孔对应单个气室13；
如图7所示，所述单个气室13分别与正压控制电磁阀I 14、正压控制电磁阀II 15和负压控制电磁阀III 16电性相连；所述正压控制电磁阀I 14与气压为P1的高压气包26电性相连，正压控制电磁阀II 15与气压为P2的高压气包27电性相连，负压控制电磁阀Ⅲ16与真空气包28电性相连；
所述气流喷嘴阵列9位于输送滚筒11与水平输送带3的末端对接处的上方，气流方向与输送滚筒11的转动方向同向相切，同时在气流方向的下侧设有松散烟丝集料斗10，以便通过气流喷嘴阵列9的切向气流将输送滚筒11上烟丝薄层表面的松散烟丝吹送至松散烟丝集料斗10；
所述LED线阵光源7位于输送滚筒11上方，LED线阵光源7由3组LED灯珠组成，第1、2、3组分别包含20个可发出光线波长为λ_1、λ_2、λ_3的LED灯珠；每组LED单独发光时，可均匀照射输送滚筒11表面的线扫描区域；
沿着输送滚筒11的运动方向，线扫描相机8设置在气流喷嘴阵列的后方；所述线扫描相机8的线扫描宽度为100cm，利用线扫描相机8可对线扫描区域的烟丝薄层进行成像，线扫描相机扫描过程如图8所示；
沿输送滚筒11的运转方向，依次设有异物收集料筒23、合格烟丝收集料筒24和残留烟丝收集料筒25，且合格烟丝收集料筒24位于输送滚筒11的正下方；
所述异物烟丝剔除触发线20位于异物收集料筒23正上方，当异物所在区域进入异物收集料筒23正上方且该区域中线与异物烟丝剔除触发线20重叠时，位置触发器29将信号传输至工业计算机17，工业计算机17判别信号后通过电磁阀控制板30控制电磁阀的开关，通过气室13的改变使输送滚筒11表面的含异物烟丝掉落至异物收集料筒23；
所述合格烟丝下料触发线21位于合格烟丝收集料筒24正上方，当合格烟丝所在区域进入合格烟丝收集料筒24正上方且该区域中线与合格烟丝下料触发线21重叠时，位置触发器29将信号传输至工业计算机17，工业计算机17判别信号后通过电磁阀控制板30控制电磁阀的开关，通过气室13的改变使输送滚筒11表面的合格烟丝掉落至合格烟丝收集料筒24；
所述残留烟丝清除触发线22位于残留烟丝收集料筒25正上方，当残留烟丝所在区域进入残留烟丝收集料筒25正上方且该区域中线与残留烟丝清除触发线22重叠时，位置触发器29将信号传输至工业计算机17，工业计算机17判别信号后通过电磁阀控制板30控制电磁阀的开关，通过气室13的改变使输送滚筒11表面的残留烟丝掉落至残留烟丝收集料筒25；
所述PLC控制柜19内设有电磁阀控制板30，所述电磁阀控制板30与工业计算机17、正压控制电磁阀I 14、正压控制电磁阀II 15和负压控制电磁阀III 16电性相连；所述电磁阀控制板30通过工业计算机17反馈的信号，控制正压控制电磁阀I 14、正压控制电磁阀II 15和负压控制电磁阀III 16的开启与关闭；
所述气流喷嘴阵列9的开启与关闭由PLC控制柜19控制；
所述工业计算机17通过数据线18与位置触发器29连接，接收并处理来自位置触发器29采集的物料位置信息；
所述工业计算机17通过数据线18与线扫描相机8连接，接收并处理来自线扫描相机8采集的光谱信息；
所述工业计算机17内置常规数据处理程序、标准数据库和处理模块，能对烟丝及低色度差塑料异物的光谱信息进行数据处理，实现低色度差塑料异物的判别。
说明：以上实施例仅用以说明本发明而并非限制本发明所描述的技术方案；因此，尽管本说明书参照上述的各个实施例对本发明已进行了详细的说明，但是本领域的普通技术人员应当理解，仍然可以对本发明进行修改或等同替换；而一切不脱离本发明的精神和范围的技术方案及其改进，其均应涵盖在本发明的权利要求范围内。

Claims (10)

  1. 一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法，其特征在于，按照下述步骤进行：
    步骤一，所述烟丝负压薄层上料包含以下过程：
    过程一，烟丝从料斗(1)中掉落至水平输送带(3)并由水平输送带(3)传输，经过薄层厚度调节滚轮(4)下方时，超过设置厚度的烟丝被薄层厚度调节滚轮(4)移除，转移至烟丝剔除滚轮(5)，然后再经烟丝剔除滚轮(5)剥离后输送至超厚烟丝集料斗(6)；
    过程二，经过薄层厚度调节滚轮(4)调整后的烟丝经水平输送带(3)继续运输至末端并掉落至输送滚筒(11)的表面；同时与输送滚筒(11)表面下方气室(13)相连的负压控制电磁阀III(16)打开，烟丝被输送滚筒(11)外层气孔阵列(12)及气孔内由外向内的气流产生的负压吸附在输送滚筒(11)表面；
    过程三，被负压吸附至输送滚筒(11)表面的烟丝，在其薄层表面仍可能会有松散烟丝，此时再通过气流喷嘴阵列(9)喷嘴发出沿输送滚筒(11)表面切向气流，将松散烟丝吹送至松散烟丝集料斗(10)，剩余的烟丝在输送滚筒(11)表面形成稳定的薄层；
    步骤二，所述烟丝脉冲线扫识别包含以下过程：
    过程一，对宽度为W、圆周长度为L的输送滚筒(11)表面进行编码，首先将输送滚筒(11)表面划分为P条宽度为W、长度为L/P的矩形条带，单个矩形条带记为A_j；随后将矩形条带A_j划分为Q个边长为L/P的正方形单元区域，单个正方形单元区域记为A_j_k；最后利用包含Q行、P列且初始值为0的编码数组C对输送滚筒(11)表面进行编码，编码规则为C(k，j)与正方形单元区域A_j_k对应；其中P和Q均为正整数，j的取值为1，2，……，P-1，P；其中k的取值为1，2，……，Q-1，Q；
    所述单个正方形单元区域A_j_k下方置有u个气孔，u个气孔对应1个气室(13)，其中u正整数；所述矩形条带A_j在不同时间对应的输送滚筒(11)上位置可通过位置触发器(29)及工业计算机(17)进行判断；
    过程二，输送滚筒(11)始终保持匀速转动，在滚筒表面确定宽度为W的线扫描区域，利用包含N个低色度差塑料特征波长的LED线阵光源(7)结合线扫描相机(8)对线扫描区域的烟丝薄层进行成像；成像过程中单个特征波长对应的LED线阵光源(7)以脉冲宽度T/N、脉冲间隔T(N-1)/N、脉冲周期T的形式依次循环发光；在矩形条带A_j经过线扫描区域期间，线扫描相机(8)实时获取矩形条带A_j对应的第i个特征波段λ_i照射下的扫描信号I_band_j_i；其中i的取值为1，2，……，N-1，N；其中N为正整数；脉冲周期T的取值范围1.5～3000μs；
    过程三，利用N个特征波长λ_i对应的扫描信号的异物鉴别阈值D_i，结合实时获取矩形条带A_j对应的第i个特征波段照射下的扫描信号I_band_j_i，识别矩形条带A_j对应区域是否存在异物；若识别结果为矩形条带A_j对应区域不存在异物，则保持编码数组C中第j列元素C(1：Q，j)的数值不变；若识别结果为矩形条带A_j对应区域存在异物，则进一步定位异物在矩形条带A_j的所属正方形单元区域A_j_k，并将编码数组C对应的C(k，j)设置为1；
    步骤三，所述异物正压在线剔除包含以下过程：
    过程一，在异物收集料筒(23)正上方设定异物烟丝剔除触发线(20)，当矩形条带A_j对应区域进入异物收集料筒(23)正上方且该区域中线与异物烟丝剔除触发线(20)重叠时，位置触发器(29)将信号传输至工业计算机(17)，同时工业计算机(17)读取矩形条带A_j在编码数组中的对应元素C(1：Q，j)，依次读取C(1：Q，j)中所有元素C(k，j)的值；若C(k，j)为0，则C(k，j)对应正方形单元区域A_j_k上无异物，正方形单元区域A_j_k内所有气孔对应气室(13)维持原有状态，使得该正方形单元区域上的烟丝薄层维持负压吸附状态；若C(k，j)为1，则C(k，j)对应正方形单元区域A_j_k上有异物，正方形单元区域A_j_k内所有气孔对应气室(13)的负压控制电磁阀III(16)关闭、正压控制电磁阀I(14)持续打开t1秒后关闭，使正方形单元区域A_j_k内所有气孔对应气室(13)进入正压P1状态且持续t1秒后再进入常压P0状态，使得该正方形单元区域A_j_k上的含异物烟丝薄层掉落至异物收集料筒(23)；
    过程二，在合格烟丝收集料筒(24)正上方设定合格烟丝下料触发线(21)，当矩形条带A_j对应区域进入合格烟丝收集料筒(24)正上方且该区域中线与合格烟丝下料触发线(21)重叠时，位置触发器(29)将信号传输至工业计算机(17)，同时工业计算机(17)读取矩形条带A_j在编码数组中的对应元素C(1：Q，j)，依次读取C(1：Q，j)中所有元素的值；若C(k，j)为0，则C(k，j)对应正方形单元区域A_j_k上为合格烟丝薄层，正方形单元区域A_j_k内所有气孔对应气室(13)的负压控制电磁阀III(16)关闭、正压控制电磁阀I(14)持续打开t1秒后关闭，使正方形单元区域A_j_k内所有气孔对应气室(13)进入正压P1状态且持续t1秒后进入常压P0状态，使得该正方形单元区域A_j_k上的合格烟丝薄层掉落至合格烟丝收集料筒(24)；若C(k，j)为1，则C(k，j)对应正方形单元区域A_j_k上的含异物烟丝已在步骤三的过程一中被剔除，正方形单元区域A_j_k内所有气孔对应气室(13)在本过程中维持原有状态不变；
    过程三，为了防止输送滚筒表面经过步骤三的过程一、二后仍有少量烟丝残留，在残 留烟丝收集料筒(25)正上方设定残留烟丝清除触发线(22)，当矩形条带A_j对应区域进入残留烟丝收集料筒(25)正上方且该区域中线与残留烟丝清除触发线(22)重叠时，位置触发器(29)将信号传输至工业计算机(17)，同时工业计算机(17)控制矩形条带A_j对应所有正方形单元区域A_j_k内所有气孔对应气室(13)的正压控制电磁阀II(15)持续打开t1秒后关闭，进气室入正压P2状态且持续t1秒后进入常压P0状态，使得矩形条带A_j对应区域上的残留烟丝薄层掉落至残留烟丝收集料筒(25)并将编码数组中的对应元素C(1：Q，j)全部赋值为0。
  2. 根据权利要求1所述的一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法，其特征在于，所述薄层厚度调节的方法为调控薄层厚度调节滚轮(4)与水平输送带(3)的间距或钉齿的长度。
  3. 根据权利要求1所述的一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法，其特征在于，所述判别矩阵条带A_j对应区域是否存在异物过程为：当矩阵条带A_j在λ_i下的扫描信号I_band_j_i的绝对值|I_band_j_i|小于异物鉴别阈值D_i时，识别结果为矩阵条带A_j对应区域不存在异物；当|I_band_j_i|大于或等于异物鉴别阈值D_i时，识别结果为矩阵条带A_j对应区域存在异物。
  4. 根据权利要求1一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法，其特征在于，所述进一步定位异物在矩形条带A_j的所属正方形单元区域A_j_k的过程为：k的值依次取1，2，……，Q-1，Q；依次提取矩阵条带A_j在λ_i下的扫描信号I_band_j_i中正方形单元区域A_j_k对应的扫描信号I_band_j_i_k，当扫描信号I_band_j_i_k绝对值|I_band_j_i_k|小于异物鉴别阈值D_i时，识别结果为k值对应的正方形单元区域A_j_k不存在异物；当|I_band_j_i_k|大于等于异物鉴别阈值D_i，识别结果为k值对应的正方形单元区域A_j_k存在异物。
  5. 根据权利要求1所述的一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法，其特征在于，t1设置为1～20s
  6. 实现权利要求1～5任一项所述检测方法的装置，其特征在于，该装置包括料斗(1)、调节阀(2)、水平输送带(3)、薄层厚度调节滚轮(4)、烟丝剔除滚轮(5)、超厚烟丝集料斗(6)、LED线阵光源(7)、线扫描相机(8)、气流喷嘴阵列(9)、松散烟丝集料斗(10)、输送滚筒(11)、气孔阵列(12)、气室(13)、正压控制电磁阀I(14)、正压控制电磁阀Ⅱ(15)、负压控制电磁阀Ⅲ(16)、工业计算机(17)、数据线(18)、PLC控制柜(19)、异物烟丝剔除触发线(20)、合格烟丝下料触发线(21)、残留烟丝清除触发线(22)、异 物收集料筒(23)、合格烟丝收集料筒(24)、残留烟丝收集料筒(25)、气压为P1的高压气包(26)、气压为P2的高压气包(27)、真空气包(28)、位置触发器(29)和电磁阀控制板(30)；
    所述调节阀(2)设于料斗(1)底部开口处，用于控制物料流速；
    所述料斗(1)位于水平输送带(3)的上方，以便经料斗(1)流出的物料掉落至水平输送带(3)；所述水平输送带(3)的一侧设有电机，电机的输出轴与水平输送带(3)的传动轮连接，用于驱动水平输送带(3)的运动；
    所述薄层厚度调节滚轮(4)、烟丝剔除滚轮(5)和超厚烟丝集料斗(6)依次设置在水平输送带(3)上方，所述薄层厚度调节滚轮(4)将超过设置厚度的烟丝从水平输送带(3)移除并经烟丝剔除滚轮(5)输送至超厚烟丝集料斗(6)内；
    所述薄层厚度调节滚轮(4)和烟丝剔除滚轮(5)均设有电机，电机的输出轴与滚轮的传动轮连接，用于驱动滚轮的运动；
    所述输送滚筒(11)与水平输送带(3)的末端对接，烟丝经水平输送带(3)末端掉落至输送滚筒(11)表面；且所述输送滚筒(11)与水平输送带(3)连接处设置有位置触发器(29)，并与工业计算机(17)电性相连，用于实现输送滚筒(11)旋转位置的定位；所述输送滚筒(11)设有电机，电机的输出轴与滚筒的传动轮连接，用于驱动输送滚筒(11)的运动；所述输送滚筒(11)表面设有外层气孔阵列(12)；且所述气孔阵列(12)下方与气室(13)相通；
    所述单个气室(13)分别与正压控制电磁阀I(14)、正压控制电磁阀II(15)和负压控制电磁阀III(16)电性相连；所述正压控制电磁阀I(14)与气压为P1的高压气包(26)电性相连，正压控制电磁阀II(15)与气压为P2的高压气包(27)电性相连，负压控制电磁阀Ⅲ(16)与真空气包(28)电性相连；
    所述气流喷嘴阵列(9)位于输送滚筒(11)的上方，同时在气流方向的下侧设有松散烟丝集料斗(10)，以便通过气流喷嘴阵列(9)的切向气流将输送滚筒(11)上烟丝薄层表面的松散烟丝吹送至松散烟丝集料斗(10)；
    所述LED线阵光源(7)位于输送滚筒(11)上方，LED线阵光源(7)由N组LED灯珠组成，第i组包含E个可发出光线波长为λ_i的LED灯珠；其中E为大于等于1的整数；
    所述输送滚筒(11)的上方设有线扫描相机(8)；所述线扫描相机(8)的线扫描宽度为W，利用线扫描相机(8)可对线扫描区域的烟丝薄层进行成像；
    沿输送滚筒(11)的运转方向，依次设有异物收集料筒(23)、合格烟丝收集料筒(24)和残留烟丝收集料筒(25)；
    所述异物烟丝剔除触发线(20)位于异物收集料筒(23)上方，当异物所在区域进入异物收集料筒(23)上方且该区域中线与异物烟丝剔除触发线(20)重叠时，位置触发器(29)将信号传输至工业计算机(17)，工业计算机(17)判别信号后通过PLC控制柜(19)中的电磁阀控制板(30)控制电磁阀的开关，通过气室(13)的改变使输送滚筒(11)表面的含异物烟丝掉落至异物收集料筒(23)；
    所述合格烟丝下料触发线(21)位于合格烟丝收集料筒(24)上方，当合格烟丝所在区域进入合格烟丝收集料筒(24)上方且该区域中线与合格烟丝下料触发线(21)重叠时，位置触发器(29)将信号传输至工业计算机(17)，工业计算机(17)判别信号后通过PLC控制柜(19)中的电磁阀控制板(30)控制电磁阀的开关，通过气室(13)的改变使输送滚筒(11)表面的合格烟丝掉落至合格烟丝收集料筒(24)；
    所述残留烟丝清除触发线(22)位于残留烟丝收集料筒(25)上方，当残留烟丝所在区域进入残留烟丝收集料筒(25)上方且该区域中线与残留烟丝清除触发线(22)重叠时，位置触发器(29)将信号传输至工业计算机(17)，工业计算机(17)判别信号后通过PLC控制柜(19)中的电磁阀控制板(30)控制电磁阀的开关，通过气室(13)的改变使输送滚筒(11)表面的残留烟丝掉落至残留烟丝收集料筒(25)；
    所述PLC控制柜(19)内设有电磁阀控制板(30)，所述电磁阀控制板(30)与工业计算机(17)、正压控制电磁阀I(14)、正压控制电磁阀II(15)和负压控制电磁阀III(16)电性相连；所述电磁阀控制板(30)通过工业计算机(17)反馈的信号，控制正压控制电磁阀I(14)、正压控制电磁阀II(15)和负压控制电磁阀III(16)的开启与关闭；
    所述气流喷嘴阵列(9)的开启与关闭由PLC控制柜(19)控制；
    所述工业计算机(17)与位置触发器(29)电性连接，接收并处理来自位置触发器(29)采集的物料位置信息；
    所述工业计算机(17)与线扫描相机(8)电性连接，接收并处理来自线扫描相机(8)采集的光谱信息；
    所述工业计算机(17)内置常规数据处理程序、标准数据库和处理模块，能对烟丝及低色度差塑料异物的光谱信息进行数据处理，实现低色度差塑料异物的判别。
  7. 根据权利要求6所述的装置，其特征在于，所述薄层厚度调节滚轮(4)和烟丝剔除滚轮(5)均按顺时针方向转动；所述薄层厚度调节滚轮(4)和烟丝剔除滚轮(5)表 面均设有钉齿，其中烟丝剔除滚轮(5)的钉齿与薄层厚度调节滚轮(4)的钉齿呈交错分布状态；所述薄层厚度调节滚轮(4)和烟丝剔除滚轮(5)的钉齿为弓齿，且单个钉齿的长度可调。
  8. 根据权利要求6所述的装置，其特征在于，所述每组LED单独发光时，可均匀照射输送滚筒(11)表面的线扫描区域；所述单个气室(13)与含有1-40个气孔的气孔阵列(12)对应。
  9. 根据权利要求6所述的装置，其特征在于，所述气流喷嘴阵列(9)位于输送滚筒(11)与水平输送带(3)的末端对接处的上方，气流喷嘴阵列(9)的气流方向与输送滚筒(11)的转动方向同向相切；所述气流喷嘴阵列(9)、线扫描相机(8)沿着输送滚筒(11)的运动方向依次设置。
  10. 根据权利要求6所述的装置，其特征在于，所述输送滚筒(11)正下方为合格烟丝收集料筒(24)；所述异物收集料筒(23)、合格烟丝收集料筒(24)和残留烟丝收集料筒(25)的口径为判别区域长度的2-10倍；所述异物烟丝剔除触发线(20)、合格烟丝下料触发线(21)和残留烟丝清除触发线(22)分别位于异物收集料筒(23)、合格烟丝收集料筒(24)和残留烟丝收集料筒(25)的正上方。
PCT/CN2021/128859 2021-10-27 2021-11-05 一种烟丝低色度差塑料异物的脉冲光谱在线成像检测方法及其装置 WO2023070724A1 (zh)

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