WO2024012438A1 - 一种适用于开幅卷布机的坯布检测装置及检测方法 - Google Patents

一种适用于开幅卷布机的坯布检测装置及检测方法 Download PDF

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Publication number
WO2024012438A1
WO2024012438A1 PCT/CN2023/106737 CN2023106737W WO2024012438A1 WO 2024012438 A1 WO2024012438 A1 WO 2024012438A1 CN 2023106737 W CN2023106737 W CN 2023106737W WO 2024012438 A1 WO2024012438 A1 WO 2024012438A1
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WIPO (PCT)
Prior art keywords
cloth
camera module
gray
control system
light
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PCT/CN2023/106737
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English (en)
French (fr)
Inventor
廖进成
黄凯乾
Original Assignee
厦门兴全龙机械有限公司
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Publication of WO2024012438A1 publication Critical patent/WO2024012438A1/zh

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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
    • G01N21/01—Arrangements or apparatus for facilitating the optical investigation
    • 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
    • G01N21/892—Investigating the presence of flaws or contamination in moving material, e.g. running paper or textiles characterised by the flaw, defect or object feature examined
    • G01N21/898—Irregularities in textured or patterned surfaces, e.g. textiles, wood
    • G01N21/8983—Irregularities in textured or patterned surfaces, e.g. textiles, wood for testing textile webs, i.e. woven material

Definitions

  • the present application relates to the field of knitting machinery, in particular to a gray cloth detection device and detection method suitable for open-width cloth winding machines.
  • the open-width winding machine is a winding device used in circular knitting machines (also known as weft knitting machines and circular knitting machines).
  • the internal space of existing circular knitting machines is relatively limited, and the gray fabrics produced are mainly tested in the following two ways: One of the methods is manual inspection during the production process, that is, arranging for personnel to check regularly with the naked eye.
  • the other method is offline inspection, that is, after the gray fabric production is completed, an additional cloth inspection machine is used for inspection.
  • the above two methods not only It is time-consuming and labor-intensive, and there are deficiencies in the accuracy of the human eye and the real-time performance of the cloth inspection machine, which often leads to problems with poor batch performance.
  • the patent application with publication number CN214572888U discloses a real-time collection and processing mechanism for gray cloth images based on circular knitting machines. It is equipped with cameras and light sources on the inner wall of the knitting circular table to improve the real-time performance of gray cloth detection.
  • the camera detects the gray fabric is wound on the cloth tube.
  • Most of the gray fabric in the images captured by the camera is in a curved state, which is not conducive to the comparison of the real-time image and the template, and the position of the camera is relatively fixed. For Defects in areas far away from the camera, such as edges, are difficult to detect and are prone to misjudgment. Therefore, the accuracy and comprehensiveness of detection need to be further improved.
  • the first purpose of this application is to provide a gray cloth detection device suitable for open-width cloth rolling machines.
  • the gray cloth detection device has a simple structure and can complete the image detection of the front side of the gray cloth while transporting the gray cloth, effectively improving the accuracy of gray cloth detection. degree and comprehensiveness.
  • the second purpose of this application is to provide another gray cloth detection device that can complete image detection of the front and back of the gray cloth while transporting the gray cloth, further improving the comprehensiveness of gray cloth detection.
  • the third purpose of this application is to provide a method for detecting gray fabrics.
  • This detection method in conjunction with a corresponding detection device, defects on the front side of the gray fabrics can be effectively detected, and basically no missed detection will occur.
  • the fourth purpose of this application is to provide a method for detecting gray fabrics.
  • This detection method in conjunction with a corresponding detection device, defects on the front and back of the gray fabric can be effectively detected, and basically no missed detection will occur.
  • the present invention discloses a gray cloth detection device suitable for an open-width cloth rolling machine that rotates on a circular knitting machine and includes a cloth cutting device and a winding device.
  • the cutting device is used to cut and unfold the ring-shaped gray fabric woven by the circular knitting machine.
  • the winding device includes a frame, and a first rubber roller set and a second rubber roller are arranged in parallel on the frame.
  • the second rubber roller group is equipped with a cloth roll roller on one side of the second rubber roller group.
  • the cut and unfolded gray cloth is straightened and flattened by the first rubber roller group and the second rubber roller group in sequence, and is finally rolled up in the cloth roll.
  • roller which includes an image acquisition module and a control system.
  • the image acquisition module includes a guide, a driver and a camera module.
  • the driver and the camera module are electrically connected to a control system.
  • the guide includes a guide rail and a slider.
  • the guide rail is arranged on the frame. and suspended across the transmission surface constructed by the discharge end of the first rubber roller group and the feed end of the second rubber roller group.
  • the driving member drives the slider in forward and reverse directions along the length direction of the guide rail. Reciprocating sliding motion, the camera module has a lens, the camera module is arranged on the slider, the lens faces the transmission surface for image collection, the control system is at least used to receive the real-time image information collected by the camera module, and Determine the defects of the gray fabric. Once the control system determines that the transmitted gray fabric has defects, it will send control instructions to the outside.
  • the guide rail is arranged parallel to the first rubber roller group, and the lens of the camera module is arranged above the direction perpendicular to the front direction of the gray cloth.
  • the camera module is provided with a plurality of first light sources at the outer diameter end of the lens, and a light guide cover is added to the outer periphery of the first light source.
  • the side walls of the light guide cover are used to connect the plurality of first light sources.
  • the light path of the light source is projected directly in front of the lens of the camera module.
  • the camera module slides on the guide rail through the slider.
  • the range captured by the camera module can completely cover the entire width of the gray fabric, making the detection more comprehensive.
  • the camera module by adding a first light source, the camera module The images captured by the module can highlight the details of the gray fabric and increase the accuracy of image recognition.
  • the present invention discloses a gray cloth detection device suitable for an open-width cloth rolling machine.
  • the gray cloth detection device is based on the first purpose gray cloth detection device, and the image acquisition module also includes a light shielding device.
  • the light-shielding part is arranged on the frame and is opposite to the lens of the camera module.
  • the light-shielding part has a light-shielding body that matches the width of the gray cloth, and the light-shielding body is arranged parallel to the guide rail.
  • At least the lens of the camera module There is a light-shielding body at a corresponding position in the corresponding effective viewing area; the light-shielding body has a groove, and at least several second light sources are provided in the groove.
  • the second light source is electrically connected to the control system and is configured to assist in photography
  • the module collects the image of the reverse side of the gray cloth.
  • the light shield effectively reduces the background noise collected by the camera module on the front of the gray cloth and improves the image contrast.
  • the camera located on the front of the gray cloth can be The module can collect images of the reverse side of gray fabric.
  • the present invention discloses a gray cloth detection method suitable for an open-width cloth rolling machine, which is applied to a first-purpose gray cloth detection device and includes the following steps:
  • the sliding cycle time T2 is defined as the time for the camera module to go through the cumulative forward sliding stroke and reverse sliding stroke from one end of the guide rail to the other end.
  • the first light source is at least guaranteed to remain on when the lens is in working condition.
  • each effective viewing area of the forward sliding stroke collected by the camera module is the same.
  • the first forward collective image area is formed by superimposing each other.
  • the effective viewing areas of the reverse sliding stroke collected by the camera module are superimposed on each other to form the first reverse collective image area.
  • the overlapping portion of the forward collection image area and the first reverse collection image area is the first overlapping area, which at least ensures that the first overlapping area can transport the gray fabric downwards to basically fully cover the L1 length area;
  • S2 Transmit the real-time gray cloth image collected by the camera module (53) to the control system for data processing to code the image information characteristics;
  • the control system is preset with sample data and similarity judgment threshold, analyze and compare the image information feature code of the gray cloth collected in real time with the sample data, and adjust the defect points of the gray cloth by adjusting the size of the similarity judgment threshold.
  • the sensitivity of recognition where:
  • the control system will not issue a shutdown command. If the detected gray cloth is If the image information feature code is inconsistent with the sample data, the control system will send a shutdown command;
  • the control system will send a shutdown command; if the image information feature code of the detected gray fabric If the code does not contain sample data, the control system will not send a shutdown command and the cloth rolling machine will continue to run.
  • the first overlapping area collected by the camera module can cover the length of the gray cloth conveying L1, and the front-side detection of the gray cloth can be automatically and comprehensively completed.
  • the cloth rolling machine can automatically alarm. , effectively reducing the labor intensity of workers and ensuring product quality.
  • the present invention discloses a gray cloth detection method suitable for an open-width cloth rolling machine, and is applied to a gray cloth detection device to achieve the second object of the invention, which includes the following steps:
  • the sliding cycle time T2 is defined as the time for the camera module to go through the accumulated stroke of the forward sliding stroke and the reverse sliding stroke from one end of the guide rail to the other end.
  • the first light source of the camera module is turned off, the second light source of the light-shielding body is turned on, and the effective viewing areas of the reverse sliding stroke collected by the camera module are superimposed on each other to form a second reverse set image.
  • the overlapping portion of the second forward collection image area and the second reverse collection image area is the second overlapping area, which at least ensures that the second overlapping area can transport the gray fabric downwards to basically fully cover the L1 length area;
  • S2 Send the real-time gray cloth image collected by the camera module (53) to the control system for data processing to make the image information Coding of information characteristics;
  • the control system is preset with sample data and similarity judgment threshold, analyze and compare the image information feature code of the gray cloth collected in real time with the sample data, and adjust the defect points of the gray cloth by adjusting the size of the similarity judgment threshold.
  • the sensitivity of recognition where:
  • the control system will not issue a shutdown command. If the detected gray cloth is If the image information feature code is inconsistent with the sample data, the control system will send a shutdown command;
  • the control system will send a shutdown command; if the image information feature code of the detected gray fabric If the code does not contain sample data, the control system will not send a stop command and the cloth rolling machine will continue to run.
  • the second overlapping area collected by the camera module can cover the length of the gray cloth conveying L1, and can automatically and comprehensively complete the detection of the front and back of the gray cloth.
  • the cloth rolling machine can automatically alarm, effectively mitigating Reduce the labor intensity of workers and ensure the quality of products.
  • Figure 1 is a schematic three-dimensional structural diagram of a gray cloth detection device provided by an embodiment of the present invention
  • Figure 2 is a schematic side structural diagram of a gray fabric detection device provided by an embodiment of the present invention.
  • the side plate of the frame is omitted, and the light shielding member is located in the first position;
  • Figure 3 is a side structural schematic diagram highlighting the image acquisition module in Figure 2;
  • Figure 4 is a partial three-dimensional structural diagram of an image acquisition module provided by an embodiment of the present invention.
  • Figure 5 is a schematic three-dimensional structural diagram of a light-shielding member provided by an embodiment of the present invention.
  • Figure 6 is a detailed view of the side panel part of the light shield in Figure 5;
  • Figure 7 is a schematic side structural view of a gray fabric detection device provided by an embodiment of the present invention.
  • the side plate of the frame is omitted, and the light shielding member is located in the second position;
  • Figure 8 is a schematic diagram of the transformation between the first position and the second position of the light shield provided by the embodiment of the present invention.
  • Figure 9 is one of the three-dimensional structural schematic diagrams of the image detection module during operation according to the embodiment of the present invention.
  • Figure 10 is the second schematic diagram of the three-dimensional structure of the image detection module during operation according to the embodiment of the present invention.
  • the gray cloth is omitted in this figure;
  • Figure 11a is a schematic diagram of the first forward set image area provided by an embodiment of the present invention.
  • Figure 11b is a schematic diagram of the first overlapping area based on Figure 11a provided by an embodiment of the present invention.
  • Figure 11c is a coverage comparison diagram of the first overlapping area and the gray cloth conveying length L2 area provided by the embodiment of the present invention.
  • Figure 12 is an enlarged schematic diagram of area A in Figure 11a;
  • Figure 13 is a schematic diagram of the acquisition principle of the camera module provided by the embodiment of the present invention.
  • Figures 14a-14c show three states of overlapping areas provided by embodiments of the present invention.
  • Figure 15a is a schematic diagram of the intersection of the second reverse set image area in the first periodic stroke and the second forward set image area in the second periodic stroke provided by the present invention
  • Figure 15b is a schematic diagram of the intersection of the collective image area in the first cycle and the collective image area in the second cycle.
  • the cloth rolling machine is a cloth rolling device that rotates on a circular knitting machine, so the gray cloth detection device is synchronized It rotates with the cloth rolling machine and detects gray cloth.
  • the open-width cloth rolling machine includes a frame 1.
  • the frame 1 is provided with a first rubber roller group 2 and a second rubber roller group 3 in parallel.
  • Parallel arrangement means that the axial directions of the first rubber roller group 2 and the second rubber roller group 3 are substantially parallel and are separated by a predetermined length in a predetermined direction.
  • the first rubber roller group 2 and the second rubber roller group 3 are separated by a predetermined length.
  • the two rubber roller groups 3 are basically parallel in the axial direction, there are also gaps in the X direction and the Y direction respectively.
  • the second rubber roller group 3 is provided with a cloth rolling roller 4 on one side.
  • the discharge end of the roller group 2 corresponds to the feed end of the second rubber roller group 3, and the discharge end of the second rubber roller group 3 corresponds to the feed end of the cloth rolling roller 4, that is, in the first rubber roller group 2
  • a transmission surface for conveying gray cloth is formed between the discharge end of the rubber roller group 3 and the discharge end of the second rubber roller group 3. It is first pulled by the first rubber roller group 2, and then passes through the second rubber roller group. 3 traction, and finally the cloth winding roller 4 is used for winding.
  • the cloth winding roller 4 is set at the power output end of the cloth winding motor, and the gray cloth is tensioned through the winding and traction of the cloth winding motor.
  • An image acquisition module 5 is provided between the first rubber roller group 2 and the second rubber roller group 3.
  • the image acquisition module 5 includes a guide part 51, a driving part 52, and a camera module 53.
  • the driving part 52 and the camera module 53 are The external electrical connection is with a control system.
  • the guide 51 includes a guide rail 511 and a slider 512.
  • the guide rail 511 is arranged on the frame 1 and is suspended across the discharge end of the first rubber roller group 2 and the second rubber roller.
  • the guide rail 511 is arranged parallel to the first rubber roller group 2, and the driving member 52 drives the slider 512 to slide forward or reverse along the length direction of the guide rail 511 Movement, wherein the driving member 52 can be a combination of a motor and a chain, or a combination of a motor and a screw rod.
  • the slider 512 is provided on the chain or screw rod.
  • the motor is a motor with forward and reverse functions, such as a servo motor.
  • forward sliding means that the camera module 53 slides from the rightmost end of the guide rail 511 to the leftmost end of the guide rail 511
  • reverse sliding means that the camera module 53 slides from the leftmost end of the guide rail 511 to the rightmost end of the guide rail 511. It should be noted that the forward and reverse directions are only used to distinguish the two strokes of the camera module 53 sliding back and forth on the guide rail 511.
  • the camera module 53 is arranged on the slider 512, and the lens 531 of the camera module 53 faces the gray cloth to collect images, and the camera module 53
  • the range captured by the camera module 53 can accurately cover both edges of the blank in the width direction, making the detection more comprehensive.
  • the image captured by the camera module 53 can highlight the details of the blank. , that is, the detection accuracy is higher.
  • the control system is at least used to receive the real-time image information collected by the camera module 53, and compare and analyze the real-time image information with its pre-stored template. Once the analysis result is unqualified, it will be sent out. Feedback instructions.
  • the manifestations of defective gray fabrics generally include: one or more of broken needles, oily yarn, oil stains, holes, and horizontal stripes.
  • broken needles refer to cracks along the warp direction on the cloth surface. Generally, a hole will be formed at the end.
  • Oil stain refers to the black oil spots caused by oil on the machine or dust floating in the air contaminating the cloth surface.
  • Oil yarn refers to the original yarn containing oil or dirt, which will appear on the cloth surface. Long strip-like defects are formed in the weft direction. Holes refer to the yarn on the fabric being broken and there are holes.
  • Horizontal strips refer to the occurrence of some abnormal continuous horizontal cycles in the cylindrical knitted fabric; here outwards
  • the objects for sending feedback instructions are electrical devices that need to respond when the test fails, such as the driving component 52, alarm, cloth rolling motor, etc.
  • the control instructions include but are not limited to start and stop signals of electrical devices such as alarm start signals, Winding machine motor stop signal.
  • gray cloth is a material used to make clothes. Clothes have an outer surface and an inner surface that are in contact with the human body. The outer surface of clothes directly affects the perception of the viewer, so the outer surface has higher aesthetic requirements than the inner surface, that is, The control of defects is also more stringent.
  • the front side of the gray cloth mentioned in this embodiment refers to the side of the gray cloth used as the outer surface of the clothes; further, the lens 531 of the camera module 53 is set in a direction perpendicular to the front side of the gray cloth.
  • the advantage of the lens 531 being arranged vertically on the gray cloth is that the image of the gray cloth entering the lens 531 will not be tilted at an angle, and the image captured by the camera module 53 can more accurately restore the actual image, which is helpful for discovering defects on the cloth surface.
  • the distance between the discharge end of the first rubber roller group 2 and the feed end of the second rubber roller group 3 is the transmission distance.
  • the group only plays the role of traction and guidance, so the transmission distance between the discharge end of the first rubber roller group 2 and the feed end of the second rubber roller group 3 is generally relatively short.
  • the image acquisition module 5 It is necessary to ensure that there is a long enough time for the gray cloth to be transferred from the discharge end of the first rubber roller group 2 to the feed end of the second rubber roller group 3 at a certain speed.
  • the camera module 53 can move along the guide rail 511 When sliding in the length direction, the image of the gray fabric in a flat state can be captured.
  • the image acquisition module 5 since the image acquisition module 5 also occupies a certain space, it is necessary to connect the discharge end of the first rubber roller group 2 and the second rubber roller group 3.
  • the transmission distance between the material ends is appropriately enlarged to facilitate the operator to wind the gray cloth from the first rubber roller group 2 to the second rubber roller group 3 for cloth winding operation.
  • the gray cloth detection device sets the transmission distance of the gray cloth through the first rubber roller group 2 and the second rubber roller group 3, and the camera module 53 for sliding viewfinding, so that the gray cloth continuously While being transported, the camera module 53 can capture continuous and flat images of the cloth surface during the reciprocating sliding process, and can accurately cover both edges of the gray cloth in the width direction, which can be used to detect defects in the gray cloth.
  • a transmission surface is constructed between the discharge end of the first rubber roller group 2 and the feed end of the second rubber roller group 3, and the image acquisition module 5 is located between the transmission surface and the cloth rolling roller 4 It should be noted that the front side of the gray cloth transported by the existing open-width cloth winding machine is facing the direction of the cloth rolling roller 4, so the image acquisition module 5 is arranged on the inner side, which is also based on the consideration of the front side detection of the gray cloth.
  • the distance in the X direction between the feed end of the first rubber roller group 2 and the axis center of the cloth roller 4 will be smaller than the distance between the discharge end of the second rubber roller group 3 and the axis center of the cloth roller 4
  • the spacing in the X direction can make the structure of the gray cloth detection device more compact while satisfying the front detection of gray cloth.
  • the camera module 53 is provided with at least two first light sources 532 at the outer diameter end of the lens 531.
  • the first light sources 532 can be arranged symmetrically around the axis of the lens 531.
  • This embodiment shows that 10-24 first light sources 532 are arranged at the circumferential position of the outer diameter end of the lens 531, and a light guide cover 533 is added to the outer periphery of the first light source 532.
  • the light guide cover 533 The front end of the lens 531 is shielded to prevent stray light from other positions from affecting the lens 531.
  • the light guide cover 533 also has side walls, which are used to project the light paths of several first light sources 532 to the camera module 53.
  • Right in front of the lens 531 that is, the optical path of the first light source 532 covers the path area between the lens 531 and the gray cloth, so that the lens 531 can obtain a clearer image of the gray cloth.
  • This implementation also provides a gray cloth detection method suitable for open-width cloth rolling machines, which is applied to the above-mentioned gray cloth detection device.
  • the method is suitable for image collection of the front side of the gray cloth by the camera module 53 during the sliding process, and at least ensures that the gray cloth is in During the transportation process, the camera module 53 will basically not cause the gray fabric to be missed, specifically including the following steps:
  • the sliding cycle time T2 is defined as the forward sliding stroke and reverse sliding stroke of the camera module 53 from one end of the guide rail 511 to the other end.
  • the cumulative stroke time of the sliding stroke that is, the camera module 53 takes one end of the guide rail 511 as the starting point, and after the sliding cycle time T2, the total sliding stroke is the accumulation of the forward sliding stroke and the reverse sliding stroke, and the camera The module 53 returns to the starting point.
  • the first light source 532 is at least guaranteed to remain on when the lens 531 is in the working state.
  • the camera module 53 is in the forward sliding stroke, through the camera module 53
  • the collected effective viewing areas of the forward sliding stroke are superimposed on each other to form the first forward collective image area.
  • the effective viewing areas of the reverse sliding stroke collected by the camera module 53 are mutually exclusive.
  • the first reverse set image area is superimposed to form a first reverse set image area, in which the first forward set image area and the first reverse set image area both capture images of the front side of the gray cloth, and the first forward set image area and the first reverse set image area are mutually exclusive.
  • the overlapping part is the first overlapping area, which at least ensures that the first overlapping area can basically fully cover the area of length L1 of the gray fabric downward.
  • basically full coverage means that within the predetermined running time T1, the first The proportion range of the overlapping area covering the downward conveying L1 length area of the gray fabric is 90%-100%;
  • S2 Send the real-time gray cloth image collected by the camera module 53 to the control system for data processing to code its image features;
  • the control system is preset with sample data and similarity judgment threshold, analyze and compare the image information feature code of the gray cloth collected in real time with the sample data, and adjust the defect points of the gray cloth by adjusting the size of the similarity judgment threshold.
  • the sensitivity of recognition where:
  • the control system will not issue a shutdown command. If the detected gray cloth is If the image information feature code is inconsistent with the sample data, the control system will send a shutdown command;
  • the control system will send a shutdown command; if the image information feature code of the detected gray fabric If the code does not contain sample data, the control system will not send a stop command and the cloth rolling machine will continue to run.
  • the first overlapping area collected by the camera module 53 can basically cover the entire length of the gray cloth conveying L1, and can automatically and comprehensively complete the front-side detection of the gray cloth.
  • the roll The cloth machine can automatically alarm, effectively reducing the labor intensity of workers and ensuring product quality.
  • the first is the establishment of the analysis model.
  • the gray cloth is transported downwards. It is difficult to analyze when both the camera module 53 and the gray cloth are moving. Therefore, assuming that the gray fabric is stationary in the analysis model, it can be understood that the movement of the camera module 53 includes horizontal sliding and movement in the opposite direction of the conveyance direction of the gray fabric, and in general, the camera module 53 The slip rate of module 53 is fixed.
  • the horizontal field of view detection distance W and the vertical field of view detection distance H of the viewing field unit of the camera module 53 are used.
  • the horizontal field of view detection distance W is the actual lateral length of the detection area in the field of view of the lens 531.
  • the longitudinal detection distance H of the field of view is the actual longitudinal length of the detection area in the field of view of the lens 531, and is based on the periodic stroke WS of the sliding movement of the camera module 53.
  • the periodic stroke WS here is defined as the forward sliding direction of the camera module 53 from one end of the guide rail 511 to the other end.
  • the accumulation of the shifting stroke and the reverse sliding stroke requires that the effective viewing area of the camera module 53 at both ends of the guide rail 511 can cover both edges of the gray fabric in the width direction. Therefore, the periodic stroke WS is a floating interval. In this implementation The stroke value of the example cycle stroke WS is twice the value of the gray cloth width WB. Please refer to Figure 10.
  • the camera module 53 is located at the rightmost end of the guide rail 511 as the starting point. The camera module 53 slides from the rightmost end of the guide rail 511 to the leftmost end as the forward direction. Slip, otherwise it is reverse slip.
  • the effective viewing areas collected by the camera module 53 by sliding in the forward direction are superimposed on each other to form a collective image area as the first forward collective image area
  • the effective viewing areas collected by the camera module 53 by sliding in the reverse direction are superimposed on each other to form a collective image area.
  • the first reverse collection image area the first forward collection image area and the first reverse collection image area both collect images of the front side of the gray cloth; as shown in Figure 11a, the upper and lower ends of Figure 11a are the first rubber roller groups respectively. 2 and the second rubber roller group 3.
  • the gray cloth is located between the first rubber roller group 2 and the second rubber roller group 3.
  • the solid path frame in the middle of the gray cloth is the first forward collective image area, as shown in Figure 11b.
  • the solid line path frame in the middle of the gray cloth is the first forward collection image area
  • the dotted line path frame is the first reverse collection image area
  • the first forward collection image area and the second reverse collection image area The section line area where the areas intersect is the first overlapping area, and the conveying length of the gray cloth moving downward at this time is L2, as shown in Figure 11c.
  • the first overlapping area in Figure 11b is intercepted, so that the conveying length of the gray cloth moving downward is The area of L2 is covered and compared. As long as the first overlapping area covers the area with the conveying length of L2 where the gray fabric moves down, detection will not be missed.
  • the first overlapping area which is a special case of the overlap of the first forward set image area and the first reverse set image area in the same slip cycle time T2, to facilitate understanding.
  • the first overlapping area can basically cover the gray cloth and transport it from the discharge end of the first rubber roller group 2 to the feed end of the second rubber roller group 3.
  • L1 the distance between the discharge end of the first rubber roller group 2 and the feed end of the second rubber roller group 3 is directly marked as L1.
  • the length of L1 It depends on the length of the set running time T1 and the cloth unloading speed of the circular knitting machine.
  • Figure 11a shows an enlarged schematic diagram of area A in Figure 11a.
  • the path frame is the first forward collection image area.
  • the adjacent effective viewing areas of the two effective viewing areas in this figure are The edges are overlapping, and the two effective viewing areas are staggered by a small distance from each other in the direction of conveying the gray fabric. Therefore, there are gaps between the bottom and top of the two effective viewing areas and the solid path frame, that is, there are two small triangular areas S respectively.
  • the small triangular area S is a blind area for detection.
  • the small triangular area S accounts for a very small proportion; therefore, when the operating speed V1 of the cloth roller 4 and the slip cycle time T2 are matched, the first overlapping area can move the gray fabric to the predetermined operating time T1.
  • the area with the length of L1 is basically fully covered, and there is basically no missed detection. According to the running speed V1 of the cloth roller 4, the slip cycle time T2, and the above analysis model, it can be concluded that the camera module 53 has three superpositions of the first forward collection image area, the first and the reverse collection area within a cycle. result:
  • Figures 14a-14c show three states of the overlapping area.
  • the first forward set image area of the camera module 53 and Three states of the first overlapping area where the first reverse set image area intersects.
  • the first forward set image area acquired by the forward sliding stroke of the camera module 53 is shown in the solid line path frame in the middle of the gray cloth.
  • the length L3 of the first overlapping area is the length of the perpendicular line between the rightmost end point of the first overlapping area and the leftmost line segment; during a slip cycle time T2, the conveying length L2 of the gray fabric in Figure 14a is greater than the longitudinal detection distance H of the field of view, and the first overlapping area The length L3 is smaller than the width WB of the gray fabric.
  • the slip cycle time T2 of the camera module 53 is controlled through the control system, including: Please refer to Figures 11a-11c, 13, 14a-14c.
  • Figure 13 is the acquisition principle of the camera module 53, based on the width of the gray fabric.
  • WB the default periodic stroke WS of the camera module 53 sliding on the guide rail 511
  • the periodic stroke is defined as the accumulation of the forward sliding stroke and the reverse sliding stroke of the camera module 53 from one end of the guide rail 511 to the other end, where the camera module When 53 is located at the two end points of the periodic stroke WS, the collective image area constructed by the camera module 53 at least includes the edges of the two gray fabrics in the width direction of the gray fabric; based on the working distance WD between the preset lens 531 and the gray fabric and the focal length of the camera module 53 f.
  • the width of the gray cloth can also be determined according to the width of the gray cloth.
  • the horizontal field of view detection distance W and the field of view longitudinal detection distance H of the viewing field of view unit are both determined.
  • the resolution of the camera module 53 should meet the shooting requirements, which will not be described again here;
  • the conveying length L2 of the gray cloth should be equal to or less than the longitudinal detection distance H of the field of view.
  • the camera module 53 should complete at least one slip cycle time T2; that is, based on the preset running speed V1 of the cloth rolling roller 4, due to the operation of the cloth rolling roller 4
  • the speed V1 is adapted to the weaving speed of the circular knitting machine, so the running speed V1 of the cloth rolling roller 4 is predetermined.
  • the vertical field of view detection distance H of the camera module 53 is used to obtain the time for the gray fabric to pass through the vertical field of view detection distance H.
  • T3 H/V1
  • H the time T3 for the gray cloth to pass through the longitudinal detection distance H of the field of view refers to the time it takes for the gray cloth to move down and the conveying length value is H.
  • the slip cycle time T2 ⁇ T3 is the average slip rate of the camera module 53.
  • V2 WS/T2.
  • the frame rate FR of the camera module 53 is set.
  • the frame rate FR of the camera module 53 refers to the number of shots taken by the camera module 53 per second. Therefore, FR is an integer value. In 1/2 of the camera module 53
  • the sliding cycle time T2 means that the camera module 53 can complete the sliding between the rightmost end and the leftmost end of the guide rail 511 and make the first forward collection image area of the camera module 53 cover the width of the gray fabric.
  • the control system needs to continuously calculate, process and compare the output results during the slip cycle time T2. If the hardware computing power The disadvantage is that the control system is not enough to digest the pictures generated by the camera module 53 during the slip cycle time T2, and it is easy to cause the program to crash. Furthermore, the control system also needs to save the pictures, and frequently saving a large number of pictures will occupy a large amount of running memory of the control system. , which will also cause the program to run stuck.
  • the frame rate FR is reasonably set by sacrificing a small area, that is, making the edges of adjacent pictures in the collection image area coincide with each other.
  • the small triangular area S The area will be larger, but in exchange for resource optimization such as data transmission, program computing power, and memory usage, the image acquisition and detection process will be smoother.
  • the width of the gray fabric produced is 1800mm.
  • the default cycle stroke WS of the camera module 53 is 2 times the width, that is, 3600mm.
  • the existing circular knitting machine takes one minute. It can rotate 13 times, and the length of the gray fabric woven by the circular knitting machine in one circle is 15mm. At the same time, the conveying length of the gray fabric in one revolution of the circular knitting machine is 15mm. Then within one minute, the conveying length of the gray fabric in the circular knitting machine is 15mm.
  • the target surface of the image module 53 chip is 4mm long, 2mm wide, has a focal length of 8mm, and the working distance between the lens 531 and the gray cloth is 160mm.
  • the sliding cycle time of the camera module 53 is T2 ⁇ T3.
  • T2 20s, that is, within one minute, the camera module 53 slides back and forth three times to complete the detection of the front image of the gray cloth.
  • the gray cloth detection device provided in this embodiment is further improved on the basis of the gray cloth detection device in Embodiment 1.
  • the image acquisition module 5 also includes a light-shielding member 54, and the light-shielding member 54 is provided with an auxiliary
  • the camera module 53 uses the second light source 543 to collect images of the reverse side of the gray cloth.
  • the gray cloth is formed by cross-woven fabrics. There are many small pores between the fabrics, which are not completely closed and opaque. Therefore, the physical background located on the back of the gray cloth will affect the front side of the gray cloth collected by the camera module 53. Image interference. In order to eliminate interference, a light-shielding member 54 is added.
  • the light-shielding member 54 can be made of an opaque material such as a wooden board or a metal plate, or has a light-absorbing coating such as a black coating. By providing the light-shielding member 54, the light-shielding member 54 can be effectively reduced. It reduces background noise and improves image contrast, making the image collection of the front side of the gray fabric more accurate.
  • the light shielding member 54 is arranged on the frame 1 and is opposite to the lens 531 of the camera module 53. That is, the lens 531 and the light shielding member 54 of the camera module 53 are respectively located on the front and back of the gray cloth.
  • the light-shielding member 54 has a light-shielding body 541 that matches the width of the gray fabric, and the light-shielding body 541 is arranged parallel to the guide rail 511. At least the lens 531 of the camera module 53 has a corresponding position in the effective viewing area.
  • the light shielding body 541 is arranged on the frame 1 and is opposite to the lens 531 of the camera module 53. That is, the lens 531 and the light shielding member 54 of the camera module 53 are respectively located on the front and back of the gray cloth.
  • the light-shielding member 54 has a light-shielding body 541 that matches the width of the gray fabric, and the light-shielding body 541 is arranged parallel to the guide rail 511. At least the lens
  • the camera module 53 slides on the guide rail 511, and its viewing area located at both ends of the guide rail 511 at least covers both edges of the gray fabric in the width direction. There may be areas that do not belong to the gray fabric, so the viewing area is effective. The area refers to the viewing area corresponding to the gray cloth. As long as the light shielding body 541 is arranged in the effective viewing area, it can enhance the front detection of the gray cloth. Please refer to Figure 5, Figure 9 and Figure 10.
  • the light shielding body 541 also has a groove 542, the cross section of the groove 542 is U-shaped, and at least a number of A plurality of second light sources 543 can be arranged along the length direction of the groove 542.
  • a plurality of the second light sources 543 can also be arranged along the width of the groove 542.
  • the second light source 543 is connected to the control
  • the system is electrically connected and configured to assist the camera module 53 in collecting images of the reverse side of the gray fabric. Specifically, when the camera module 53 is in the forward sliding stroke and the camera module 53 is equipped with the first light source 532, the first light source 532 of the camera module 53 is turned on, and the second light source 543 of the light-shielding body 541 is turned off, and the camera is captured through the camera.
  • the effective viewing areas of the forward sliding stroke collected by the module 53 are superimposed on each other to form a forward collective image area, that is, the camera module 53 realizes the image collection of the front side of the gray cloth; when the camera module 53 is in the reverse sliding stroke, the The first light source 532 of the camera module 53 is turned off, the second light source 543 of the light shielding body 541 is turned on, and the effective viewing areas of the reverse sliding stroke collected by the camera module 53 are superimposed on each other to form a reverse collective image area, that is, the camera module 53 Realize the image collection of the reverse side of the gray cloth.
  • the camera module 53 can also have the back side of the gray cloth by cooperating with the first light source 532 and the second light source 543.
  • the image acquisition function greatly improves the comprehensiveness of gray cloth detection and effectively reduces the probability of missed detection.
  • the light-shielding member 54 is set to be movablely connected to the frame 1 for position adjustment. At least when the light-shielding member 54 When 54 is in the first position, it is in the effective viewing area corresponding to the lens 531 of the camera module 53; when the light shield 54 is in the second position, it is moved away from the effective viewing area corresponding to the lens 531 of the camera module 53, making it convenient for workers to move from The first rubber roller group 2 to the second rubber roller group 3 perform cloth loading operations.
  • the first position refers to the working position of the light shielding member 54 when the image acquisition module 5 is operating normally.
  • the light shielding body 541 is in the effective viewing area corresponding to the lens 531 of the camera module 53 and is basically parallel to the guide rail 511.
  • the second position refers to the placement position of the light-shielding member 54 during the manual cloth loading process when the image acquisition module 5 stops operating. At this time, it is at least ensured that the light-shielding member 54 is not within the effective viewing area corresponding to the lens 531 of the camera module 53, so as to Easy to operate.
  • the light shielding member 54 also includes two side plates 544.
  • the light shielding body 541 is disposed between the two side plates 544.
  • One end of the side plate 544 is connected to the machine through the rotating shaft 11 provided on the frame 1.
  • the frame 1 is rotatably connected to the frame 1.
  • one end of the side plate 544 that is pivotally connected to the frame 1 is specifically the lower end of the side plate 544.
  • the opening groove 545 is connected, the opening part on the light shielding body 541 is larger than the opening part on the side plate 544, the frame 1 is provided with a fastener 12, and the fastener 12 penetrates the opening groove 545, and The side plate 544 is pressed against the frame 1 to fix the light shield 54 in the first position.
  • the fastener 12 can be a locking screw threadedly connected to the frame 1, and the opening slot 545 is used to give way to the fastener 12 when the light shielding member 54 rotates around the rotation axis 11.
  • the opening part on the main body 541 is used to give way to the head of the locking screw, and the opening part on the side plate 544 is used to give way to the rod part of the locking screw.
  • the opening part on the light-shielding main body 541 is larger than
  • the opening portion on the side plate 544 and the arrangement of the opening groove 545 allow the light-shielding member 54 to rotate without removing the fastener 12 and only need to loosen the fastener 12, making the operation simple and convenient.
  • the frame 1 is also provided with a first limiting member 13 and a second limiting member 14 respectively.
  • the first limiting member 13 and the second limiting member 14 are respectively connected with the side plate 544.
  • the two sides are limited against each other, so that the light-shielding member 54 switches between the first position and the second position with the rotating shaft 11 as the rotation axis.
  • the first limiter 13 and the second limiter 14 are first limit screws and second limit screws fixed to the frame 1, and the stems of the limit screws are threadedly connected to the frame 1.
  • the head of the limiting screw is configured to abut against the side plate 544 .
  • This embodiment also provides a method for detecting gray cloth suitable for open-width cloth rolling machines.
  • the method is suitable for collecting images of the front and back sides of the gray cloth by the camera module 53 during the sliding process, and at least ensures that the gray cloth is transported during transportation. , the camera module 53 will basically not cause the front and back sides of the gray fabric to be missed, specifically including the following steps:
  • the sliding cycle time T2 is defined as the time that the camera module 53 goes through the accumulated forward sliding stroke and reverse sliding stroke from one end of the guide rail 511 to the other end.
  • the first light source 532 of the camera module 53 is turned off, the second light source 543 of the light shielding body 541 is turned on, and the reflection collected by the camera module 53 is
  • Each effective viewing area in the forward sliding stroke is superimposed on each other to form a second reverse set image area.
  • the overlapped portion of the second forward set image area and the second reverse set image area is the second overlapping area, which at least ensures the second overlapping area.
  • the area can basically fully cover the area of the L1 length of the downward conveying of the gray fabric; in this embodiment, basically full coverage refers to the proportion of the second overlapping area covering the L1 length area of the downward conveying of the gray fabric within the predetermined running time T1
  • the range is 90%-100%;
  • S2 Transmit the real-time gray cloth image collected by the camera module (53) to the control system for data processing to code the image information characteristics;
  • the control system is preset with sample data and similarity judgment threshold, analyze and compare the image information feature code of the gray cloth collected in real time with the sample data, and adjust the defect points of the gray cloth by adjusting the size of the similarity judgment threshold.
  • the sensitivity of recognition where:
  • the control system will not issue a shutdown command. If the detected gray cloth is If the image information feature code is inconsistent with the sample data, the control system will send a shutdown command;
  • the control system will send a shutdown command; if the image information feature code of the detected gray fabric If the code does not contain sample data, the control system will not send a stop command and the cloth rolling machine will continue to run.
  • the collective image area collected by the camera module 53 can cover the area of the gray cloth conveying length L1, and can automatically and comprehensively complete the detection of the front and back of the gray cloth.
  • the cloth rolling machine can automatically alarm, effectively mitigating Reduce the labor intensity of workers and ensure the quality of products.
  • the difference between the gray cloth detection method in this embodiment and the gray cloth detection method in Embodiment 1 is that: the camera module 53 collects images of the front and back sides of the gray cloth, and when the camera module 53 collects images of the back side of the gray cloth, the first light source 532 The lighting strategy of the second light source 543 is different from that when the camera module 53 collects the front image of the gray cloth.
  • the first forward collection image area and the first reverse collection image area are mentioned, while the second embodiment is provided with a second forward collection image area and a third reverse collection image area.
  • Two reverse collection image areas; the connection between the two is that the first forward collection image area and the second forward collection image area are both defined as the collection image areas collected by the camera module 53 during the forward sliding stroke.
  • the first forward collection image area The reverse collection image area and the second reverse collection area are both collection image areas collected by the camera module 53 during the reverse sliding stroke; the difference is that the first forward collection image area and the first reverse collection image area are both collected during the reverse sliding stroke.
  • the second forward collection image area in the second embodiment is in the scene where the first light source 532 is always on and the second light source 543 is turned off.
  • the second reverse collection image area is an image collection of the reverse side of the gray cloth in a scenario where the first light source 532 is turned off and the second light source 543 remains on.
  • Step S1 will be described below with reference to Figures 3, 10, 14a, 14c and 15a-15b:
  • the periodic stroke WS is defined as the accumulation of the forward sliding stroke and the reverse sliding stroke of the camera module 53 from one end of the guide rail 511 to the other end.
  • the sliding period time T2 is the time it takes for the camera module 53 to go through the periodic stroke.
  • the first light source 532 of the camera module 53 is turned on, the second light source 543 is turned off, and the camera module 53 collects Each effective viewing area of the forward sliding stroke is superimposed on each other to form a second forward collective image area.
  • the first light source 532 of the camera module 53 is turned off, and the light shielding body 541 is opened.
  • FIGS 14a-14c show the three states of the overlapping area, and the implementation The description of Example 1 is basically the same, except that in the second forward collection image area of the first cycle, only the front image of the gray cloth is collected, and in the second reverse collection image area, only the back image of the gray cloth is collected. Therefore, the second overlapping area is both covered with gray cloth.
  • Embodiment 2 additionally performs backside detection on the gray fabric
  • the principle of achieving at least basically no missed detection in Embodiment 2 is the same as Embodiment 1, and is therefore also based on the cooperation of the running speed V1 of the cloth roller 4 and the slip cycle time T2
  • the camera module 53 has three superposition results of the second forward collection image area and the reverse collection area within one cycle: the conveying length L3 of the gray cloth in Figure 14a is greater than the longitudinal detection distance H of the field of view, and the length of the second overlapping area L3 is smaller than the width WB of the gray fabric, at this time, there is a gap area between the second reverse collection image area at the upper right end and the second forward collection image area at the lower right end, that is, there is a missed detection area; the gray fabric in Figure 14b
  • the conveying length L3 is equal to the longitudinal detection distance H of the field of view
  • the length L3 of the second overlapping area is equal to the width WB of the gray fabric, but the rightmost end of the second
  • the second reverse set image area above the rightmost end is equal to There is just no gap area in the second forward set image area at the lower right end; however, since there is also detection of the reverse side of the gray fabric, further explanation is given, as shown in Figure 15a, which shows the second positive image area in the first cycle.
  • Figure 15a shows the second positive image area in the first cycle.
  • Schematic diagram of the intersection of the reverse set image area and the second forward set image area in the second cycle is the third point of the cycle.
  • the upper boundary line of the second reverse collection image area, and its lower boundary is the upper boundary line of the second forward collection image area of the periodic stroke.
  • the intersection of the set image area of the itinerary, where the set image area refers to the accumulation of the second forward set image area and the second reverse set image area in the cycle itinerary, and the lower boundary line of the second overlapping area of the second cycle itinerary is Lower than the upper boundary line of the reverse set area of the first periodic trip, that is, the second forward set image area of the second periodic trip can cover the second reverse set image area of the first periodic trip that does not overlap, and basically does not Missed detection will occur; in Figure 14c, the conveying length L3 of the gray cloth is less than the longitudinal detection distance H of the field of view, the length L3 of the second overlapping area is equal to the width WB of the gray cloth, and there are two endpoints at the rightmost end of the second overlapping area.
  • the rightmost end There is no gap area between the upper second reverse set image area and the rightmost lower second forward set image area, and the area of the second overlapping area is larger than the area of the second overlapping area in Figure 14b.
  • the second periodic stroke The second forward set image area can cover the second reverse set image area that does not overlap in the first cycle; that is, at least ensuring that the second overlapping area length L3 can cover the width WB of the gray fabric, it will basically not happen. Missing detection is also applicable in this embodiment.
  • the frame rate FR of the camera module 53 please refer to the corresponding part of the gray fabric detection method in Embodiment 1, which will not be described again here.

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Abstract

一种适用于开幅卷布机的坯布检测装置，旋转运作于针织大圆机，包括机架（1），机架（1）平行间隔设置有第一胶辊组（2）与第二胶辊组（3），第二胶辊组（3）的一侧设有卷布辊筒（4），第一胶辊组（2）与第二胶辊组（3）间设置有图像采集模块（5），图像采集模块（5）包括导向件（51）、驱动件（52）、摄像模块（53），导向件（51）包括导轨（511）及滑块（512），驱动件（52）驱动滑块（512）沿导轨（511）的长度方向上正向或反向滑移运动，摄像模块（53）设置于滑块（512），其摄像模块（53）的镜头（531）朝向坯布进行图像采集。

Description

一种适用于开幅卷布机的坯布检测装置及检测方法 技术领域
本申请涉及针织机械领域，尤其是一种适用于开幅卷布机的坯布检测装置及检测方法。
背景技术
开幅卷布机是应用于针织大圆机(又名针织纬编机、针织圆纬机)的卷布装置，现有的大圆机内部空间较为有限，生产的坯布检测方式主要是以下两种，其中一种方式是在生产过程中进行人工检测，即安排人员使用肉眼定时查看，另一种方式是脱机检测，即当坯布生产完成后，额外使用验布机进行检测，以上两种方式不但费时费力，而且在人眼的精确度与验布机的实时性上存在不足，往往会造成批量性不良的问题。
为此，申请公开号为CN214572888U的专利揭示了一种基于针织圆纬机的坯布图像实时采集处理机构，其在针织圆台内侧壁上设置了相机与光源，提高坯布检测的实时性。但该相机检测时，坯布是卷绕在布筒上的，相机所拍摄的图像中坯布大部分是曲面状态的，不利于实时图像与模板的比对，且相机的位置是相对固定的，对于离相机较远区域的瑕疵如边缘的瑕疵是难以检测的，容易出现误判，因而检测的精准度与全面度有待进一步提高。
有鉴于此，本发明人针对现有技术中的上述缺陷深入研究，遂有本案产生。
发明内容
本申请第一目的是提供一种适用于开幅卷布机的坯布检测装置，该坯布检测装置结构简单，能够在坯布输送的同时，完成坯布正面的图像检测，有效提高了坯布检测的精度准度与全面度。
本申请第二目的是提供另一种坯布检测装置，该坯布检测装置，能够在坯布输送的同时，完成坯布正面及坯布反面的图像检测，进一步提升了坯布检测的全面度。
本申请的第三目的是提供一种坯布检测方法，通过该检测方法配合相应的检测装置，可有效检测坯布正面的瑕疵，基本不会发生漏检。
本申请的第四目的是提供一种坯布检测方法，通过该检测方法配合相应的检测装置，可有效检测坯布正面及坯布反面的瑕疵，基本不会发生漏检。
为实现本申请的第一目的，本发明揭示了一种适用于开幅卷布机的坯布检测装置，所述开幅卷布机旋转运作于针织大圆机，其包括剖布装置和收卷装置，所述剖布装置用于将针织大圆机所织造的环形坯布切割后展开，所述收卷装置包括一机架，所述机架上平行设置有一第一胶辊组与一第二胶辊组，所述第二胶辊组的一侧设有卷布辊筒，被切割后展开的坯布依次经第一胶辊组及第二胶辊组被拉直平整，最终被收卷于卷布辊筒，它包括一图像采集模块 及控制系统，所述图像采集模块包括导向件、驱动件及摄像模块，所述驱动件及摄像模块外部电连接有控制系统，所述导向件包括导轨及滑块，所述导轨设置在机架上并悬空横跨于第一胶辊组的出料端与第二胶辊组的进料端所构建的传输面上，所述驱动件驱动滑块沿导轨的长度方向上正向和反向往复滑移运动，所述摄像模块具有一镜头,所述摄像模块设置在滑块上，其镜头朝向传输面进行图像采集，所述控制系统至少用于接收摄像模块所采集的实时图像信息，并对其进行坯布瑕疵点判断，当控制系统一旦判断出传输的坯布存在瑕疵，向外发送控制指令。
进一步地，所述导轨与第一胶辊组平行设置，所述摄像模块的镜头设置在垂直于坯布正面方向的上方。
进一步地，所述摄像模块在位于镜头的外径端设置若干第一光源，且在第一光源的外周缘增设一导光罩，所述导光罩的侧壁用于将若干所述第一光源的光路投射至摄像模块的镜头正前方。
采用上述结构，摄像模块藉由滑块滑移于导轨，一方面摄像模块所拍摄的范围可以完整地将坯布的幅宽全覆盖，使得检测更为全面，另一方面通过增设第一光源，摄像模块所拍摄的图像可以更加凸显坯布的细节，增加图像识别的准确度。
为实现本申请的第二目的，本发明揭示了一种适用于开幅卷布机的坯布检测装置，该坯布检测装置以第一目的坯布检测装置为基础，且所述图像采集模块还包括遮光件，其设置在机架上，且与摄像模块的镜头相对设置，所述遮光件具有与坯布幅宽相匹配的遮光主体，且所述遮光主体与导轨平行布置，至少所述摄像模块的镜头对应有效取景区域内存在对应位置的遮光主体；所述遮光主体具有凹槽，所述凹槽内至少设置有若干个第二光源，所述第二光源与控制系统电连接，且配置为辅助摄像模块进行坯布反面图像的采集。
采用上述结构，遮光件有效减少摄像模块采集坯布正面的背景噪点，提高图像对比度，再通过第二光源的设置，在第一光源关闭的状态下，开启第二光源，可以使得位于坯布正面的摄像模块能够进行坯布反面的图像采集。
为实现本发明的第三目的，本发明揭示了一种适用于开幅卷布机的坯布检测方法，应用于第一目的坯布检测装置，包括以下步骤：
S1：在预定运行时间T1内，基于预设的卷布辊筒运行速率V1，坯布自第一胶辊组向第二胶辊组进行输送L1长度，通过控制系统控制摄像模块的滑移周期时间T2，所述滑移周期时间T2被定义为摄像模块经过自导轨一端向另一端正向滑移行程及反向滑移行程所累加行程的时间，当摄像模块具备第一光源时，该第一光源至少保证在镜头处于工作状态时保持常亮，当摄像模块处于正向滑移行程，通过摄像模块采集的正向滑移行程各个有效取景区域相 互迭加形成第一正向集合图像区域，当摄像模块处于反向滑移行程，通过摄像模块采集的反向滑移行程各个有效取景区域相互迭加形成第一反向集合图像区域，第一正向集合图像区域及第一反向集合图像区域相互重合的部分为第一重叠区域，至少保证第一重叠区域能够将坯布向下输送L1长度的区域进行基本全覆盖；
S2：将摄像模块(53)采集的实时坯布图像传送至控制系统进行数据处理，使其图像信息特征代码化；
S3：所述控制系统内预设有样本数据和相似度判断阈值，将实时采集的坯布的图像信息特征代码与样本数据进行分析比对，通过调整相似度判断阈值的大小，来调整坯布瑕疵点识别的灵敏度，其中：
如果控制系统存储的样本数据为合格样本数据，若所检测坯布的图像信息特征代码与样本数据具有一致性，则所检测的坯布为合格，控制系统不会下发停机指令，若所检测坯布的图像信息特征代码与样本数据不一致，则控制系统发送停机指令；
如果控制系统存储的样本数据为不合格样本数据，若所检测坯布的图像信息特征代码中包含样本数据，则所检测的坯布不为合格，控制系统发送停机指令；若所检测坯布的图像信息特征代码不包含样本数据，则控制系统不会发送停机指令，卷布机持续运行
采用上述方法，在预定运行时间T1内，摄像模块采集的第一重叠区域可以覆盖坯布输送L1长度的区域，能自动且全面地完成坯布的正面检测，当检测不合格时，卷布机能自动报警，有效减轻了工人的劳作强度，保证了产品的质量。
为实现本发明的第四目的，本发明揭示了一种适用于开幅卷布机的坯布检测方法，应用于实现第二发明目的坯布检测装置，包括以下步骤：
S1：在预定运行时间T1内，基于预设的卷布辊筒运行速率V1，坯布自第一胶辊组向第二胶辊组进行输送L1长度，通过控制系统控制摄像模块的滑移周期时间T2，所述滑移周期时间T2被定义为摄像模块经过自导轨一端向另一端正向滑移行程及反向滑移行程所累加行程的时间，当摄像模块处于正向滑移行程，且摄像模块具备第一光源时，所述第一光源打开，同时第二光源关闭，并通过摄像模块采集的正向滑移行程各个有效取景区域相互迭加形成第二正向集合图像区域，当摄像模块处于反向滑移行程，所述摄像模块的第一光源关闭，打开遮光主体的第二光源，并通过摄像模块采集的反向滑移行程各个有效取景区域相互迭加形成第二反向集合图像区域，第二正向集合图像区域及第二反向集合图像区域相互重合的部分为第二重叠区域，至少保证第二重叠区域能够将坯布向下输送L1长度的区域进行基本全覆盖；
S2：将摄像模块(53)采集的实时坯布图像传送至控制系统进行数据处理，使其图像信 息特征代码化；
S3：所述控制系统内预设有样本数据和相似度判断阈值，将实时采集的坯布的图像信息特征代码与样本数据进行分析比对，通过调整相似度判断阈值的大小，来调整坯布瑕疵点识别的灵敏度，其中：
如果控制系统存储的样本数据为合格样本数据，若所检测坯布的图像信息特征代码与样本数据具有一致性，则所检测的坯布为合格，控制系统不会下发停机指令，若所检测坯布的图像信息特征代码与样本数据不一致，则控制系统发送停机指令；
如果控制系统存储的样本数据为不合格样本数据，若所检测坯布的图像信息特征代码中包含样本数据，则所检测的坯布不为合格，控制系统发送停机指令；若所检测坯布的图像信息特征代码不包含样本数据，则控制系统不会发送停机指令，卷布机持续运行。
采用上述方法，摄像模块采集的第二重叠区域可以覆盖坯布输送L1长度的区域，能自动且全面地完成坯布的正面及坯布反面的检测，当检测不合格时，卷布机能自动报警，有效减轻了工人的劳作强度，保证了产品的质量。
附图说明
作为非限制性例子给出的具体说明更好地解释本申请包括什么以及其可被实施，此外，该说明参考附图，在附图中：
图1为本发明实施例提供的坯布检测装置的立体结构示意图；
图2为本发明实施例提供的坯布检测装置的侧视结构示意图，此图中省略了机架的侧板，且遮光件位于第一位置；
图3为图2中凸显图像采集模块的侧视结构示意图；
图4为本发明实施例提供的图像采集模块的局部立体结构示意图；
图5为本发明实施例提供的遮光件的立体结构示意图；
图6为图5中遮光件的侧板部分的细节图；
图7为本发明实施例提供的坯布检测装置的侧视结构示意图，此图中省略了机架的侧板，且遮光件位于第二位置；
图8为本发明实施例提供的遮光件第一位置与第二位置的变换示意图；
图9为本发明实施例提供的图像检测模块工作时的立体结构示意图之一；
图10为本发明实施例提供的图像检测模块工作时的立体结构示意图之二，此图中省略了坯布；
图11a为本发明实施例提供的第一正向集合图像区域示意图；
图11b为本发明实施例提供的基于图11a的第一重叠区域的示意图；
图11c为本发明实施例提供的第一重叠区域与坯布输送长度L2区域的覆盖比对图；
图12为图11a中A区域的放大示意图；
图13为本发明实施例提供的摄像模块的采集原理示意图；
图14a-图14c为本发明实施例提供的重叠区域的三种状态；
图15a为本发明提供的第一周期行程中第二反向集合图像区域与第二周期行程中第二正向集合图像区域的相交示意图；
图15b为第一周期行程中集合图像区域与第二周期行程中集合图像区域的相交示意图。
具体实施方式
以下结合附图及具体实施例对本申请做详细描述。
容易理解，根据本申请的技术方案，在不变更本申请实质精神下，本领域的一般技术人员可以提出可相互替换的多种结构方式以及实现方式。因此，以下具体实施方式以及附图仅是对本申请的技术方案的示例性说明，而不应当视为本申请的全部或者视为对本申请技术方案的限定或限制。
在本说明书中提到或者可能提到的上、下、左、右、前、后、正面、背面、顶部、底部等方位用语是相对于各附图中所示的构造进行定义的，它们是相对的概念，因此有可能会根据其所处不同位置、不同使用状态而进行相应地变化。所以，也不应当将这些或者其他的方位用语解释为限制性用语。
实施例一
请参考图1，现对本实施例提供的一种适用于开幅卷布机的坯布检测装置进行说明，卷布机是旋转运作于针织大圆机的卷布装置，因而所述坯布检测装置是同步随卷布机旋转并进行坯布检测的。
请进一步参考图2-4，在本实施例中，所述开幅卷布机包括机架1，所述机架1平行设置有第一胶辊组2与第二胶辊组3，此处平行设置指的是第一胶辊组2与第二胶辊组3的轴向基本平行且沿预定方向相隔预定长度的间距，具体地，如图3所示，第一胶辊组2与第二胶辊组3在轴向基本平行的基础上，还分别在X方向和Y方向上存在间距，所述第二胶辊组3的一侧设有卷布辊筒4，所述第一胶辊组2的出料端对应第二胶辊组3的进料端，所述第二胶辊组3的出料端对应卷布辊筒4的进料端，即在第一胶辊组2的出料端与第二胶辊组3的出料端之间形成用于输送坯布的传输面，先经过第一胶辊组2的牵引，后经过第二胶辊组 3牵引，最终再到卷布辊筒4进行收卷，所述卷布辊筒4设置于卷布电机的动力输出端，通过卷布电机的卷绕牵引实现了坯布的张紧。
所述第一胶辊组2与第二胶辊组3间设置有图像采集模块5，所述图像采集模块5包括导向件51、驱动件52、摄像模块53，其驱动件52及摄像模块53外部电连接有控制系统，所述导向件51包括导轨511及滑块512，所述导轨511设置在机架1上并悬空横跨于第一胶辊组2的出料端与第二胶辊组3的进料端所构建的传输面上，所述导轨511与第一胶辊组2平行设置，所述驱动件52驱动滑块512沿导轨511的长度方向上正向或反向滑移运动，其中所述驱动件52可以是电机与链条的组合，也可以是电机与丝杆的组合，滑块512设置在链条或丝杆上，电机是具有正反转功能的电机，如伺服电机、步机电机等；在本实施例中，请参照图10，以摄像模块53位于导轨511最右端为起始点，正向滑移即摄像模块53从导轨511最右端滑至导轨511的最左端，反向滑移即摄像模块53从导轨511最左端滑至导轨511的最右端，需要说明的是正向、反向只是用来区分摄像模块53往复滑移于导轨511的两行程段，当起始参考点不同时，正向、反向亦不同，并不以此为限；所述摄像模块53设置于滑块512，其摄像模块53的镜头531朝向坯布进行图像采集，藉由摄像模块53随滑块512移动，一方面摄像模块53所拍摄的范围可以精准覆盖到坯布幅宽方向上的两边缘，使得检测更为全面，另一方面摄像模块53所拍摄的图像可以更加凸显坯布局部细节，即检测的精度更高，所述控制系统至少用于接收摄像模块53所采集的实时图像信息，并将该实时图像信息与其预存的模板进行比对分析，一旦分析结果不合格，向外发送回馈指令。其中瑕疵坯布的表现形式一般包括：断针、油纱、油污、破洞、横条的一种或多种，具体地，断针指的是在布面上呈现为沿经向纹路裂开，一般在末端会形成一个洞，油污指是机器上的油或空中飘浮的灰尘污染布面所导致的黑色油点，油纱指的是因原纱带有油剂或脏剂产生的，在布面会形成纬向长条状疵点，破洞指是的布面上纱线已断，存在孔洞，横条指的是在圆筒针织物中出现一些不正常的连续的横间循环；此处向外发送回馈指令的对象为当检测不合格时，需要发生响应的电气装置，如驱动件52、报警器、卷布电机等，控制指令包括但不限于电气装置的启停信号如报警器启动信号、卷机电机停止信号。
可以理解的是坯布是用于制作衣服的材料，衣服具有外表面以及与人体接触的内表面，衣服外表面直接影响了视者的观感，因而外表面相对于内表面有着更高的美观要求，即对于瑕疵的把控也更加严苛，本实施例所提及的坯布正面均指的是坯布用作衣服外表面的一面；进一步地，所述摄像模块53的镜头531设置在垂直于坯布正面方向的上方，镜头531垂直设置于坯布的好处在于，坯布的图像进入镜头531不会发生角度倾斜，摄像模块53拍摄的图像能更还原实际的图像，有利于发现布面上的瑕疵点。
在本实施例中，如图3所示，所述第一胶辊组2出料端与第二胶辊组3进料端的间距为传输间距，在现有技术中，基于上述两个胶辊组仅起到牵引及导向的作用，因而第一胶辊组2出料端与第二胶辊组3进料端之间的传输间距一般比较短，而本案中由于增设了图像采集模块5，需要保证坯布以一定速率从第一胶辊组2出料端传输至第二胶辊组3进料端时具有足够长的时间，在这个足够长的时间内，使摄像模块53沿导轨511的长度方向进行滑移时，能拍摄到处于平整状态下坯布的图像，同时由于图像采集模块5也占用了一定的空间，需将第一胶辊组2出料端与第二胶辊组3进料端之间的传输间距适当拉大，便于操作人员将坯布从第一胶辊组2缠绕至第二胶辊组3进行绕布作业。
本实施例提供的坯布检测装置，与现有技术相比，通过第一胶辊组2与第二胶辊组3设置了坯布的传输间距、以及滑移取景的摄像模块53，使得坯布在持续输送的同时，摄像模块53在往复滑移的过程中可以拍摄到连续平整的布面图像，且能精准覆盖到坯布幅宽方向上的两边缘，用于坯布瑕疵点的检测。
再次参考图2-3，所述第一胶辊组2出料端与第二胶辊组3进料端之间构建出传输面，所述图像采集模块5位于传输面与卷布辊筒4之间，需要说明的是，现有的开幅卷布机所输送的坯布正面是朝向卷布辊筒4方向的，因而图像采集模块5设置在里侧，也是基于对坯布正面检测的考虑。此外，第一胶辊组2的进料端与卷布辊筒4轴心间的在X方向上的间距会小于第二胶辊组3的出料端与卷布辊筒4轴心间的在X方向上的间距，如此在满足坯布正面检测的同时，可以使坯布检测装置的结构更加紧凑。
如图4所示，在本实施例中，所述摄像模块53在位于镜头531的外径端设置至少两个第一光源532，所述第一光源532可绕镜头531的轴向对称布置，本实施例给出的是在镜头531的外径端的圆周位置布置10-24颗的第一光源532，且在第一光源532的外周缘还增设一导光罩533，所述导光罩533屏蔽镜头531前端以避免其他位置的杂光对镜头531产生影响，所述导光罩533还具有侧壁，所述侧壁用于将若干所述第一光源532的光路投射至摄像模块53的镜头531正前方，即第一光源532的光路覆盖了镜头531至坯布之间的路径区域，使得镜头531能够获取更加清晰的坯布图像。
本实施还提供一种适用于开幅卷布机的坯布检测方法，应用于上述坯布检测装置，所述方法适用于摄像模块53在滑移过程中对坯布正面的图像采集，且至少保证坯布在输送的过程中，摄像模块53基本不会造成坯布的漏检，具体包括以下步骤：
S1：在预定运行时间T1内，基于预设的卷布辊筒4运行速率V1，坯布自第一胶辊组2向第二胶辊组3进行输送L1长度，通过控制系统控制摄像模块53的滑移周期时间T2，所述滑移周期时间T2被定义为摄像模块53经过自导轨511一端向另一端正向滑移行程及反向 滑移行程所累加行程的时间，即摄像模块53以导轨511的一端为起点，经过滑移周期时间T2，所滑移的总行程是正向滑移行程与反向滑移行程的累加，并且摄像模块53回到起点，当摄像模块53具备第一光源时532，该第一光源532至少保证在镜头531处于工作状态时保持常亮，当摄像模块53处于正向滑移行程，通过摄像模块53采集的正向滑移行程各个有效取景区域相互迭加形成第一正向集合图像区域，当摄像模块53处于反向滑移行程，通过摄像模块53采集的反向滑移行程各个有效取景区域相互迭加形成第一反向集合图像区域，其中第一正向集合图像区域与第一反向集合图像区域均采集坯布正面的图像，第一正向集合图像区域及第一反向集合图像区域相互重合的部分为第一重叠区域，至少保证第一重叠区域能够将坯布向下输送L1长度的区域进行基本全覆盖，本实施例中基本全覆盖指的是，在预定运行时间T1内，第一重叠区域覆盖坯布向下输送L1长度区域的比例区间为90％-100％；
S2：将摄像模块53采集的实时坯布图像传送至控制系统进行数据处理，使其图像特征代码化；
S3：所述控制系统内预设有样本数据和相似度判断阈值，将实时采集的坯布的图像信息特征代码与样本数据进行分析比对，通过调整相似度判断阈值的大小，来调整坯布瑕疵点识别的灵敏度，其中：
如果控制系统存储的样本数据为合格样本数据，若所检测坯布的图像信息特征代码与样本数据具有一致性，则所检测的坯布为合格，控制系统不会下发停机指令，若所检测坯布的图像信息特征代码与样本数据不一致，则控制系统发送停机指令；
如果控制系统存储的样本数据为不合格样本数据，若所检测坯布的图像信息特征代码中包含样本数据，则所检测的坯布不为合格，控制系统发送停机指令；若所检测坯布的图像信息特征代码不包含样本数据，则控制系统不会发送停机指令，卷布机持续运行。
通过采用上述方法，在预定运行时间T1内，摄像模块53采集的第一重叠区域可以基本全覆盖坯布输送L1长度的区域，能自动且全面地完成坯布的正面检测，当检测不合格时，卷布机能自动报警，有效减轻了工人的劳作强度，保证了产品的质量。
下面主要对所述S1步骤进行具体说明：
首先是分析模型的建立，在实际的应用场景下，摄像模块53是沿导轨511水平滑移的同时，坯布是往下输送的，当摄像模块53与坯布都是运动的情况是不易分析。因而，分析模型中假设坯布是静止的，则可以理解的是，所述摄像模块53的运动包括了水平滑移的同时，还有向坯布传输方向的反方向移动，且在一般情况下，摄像模块53的滑移速率是固定的。
其次，是本方法的工作过程及原理剖析，默认摄像模块53取景视野单元的视野横向检测距离W、视野纵向检测距离H，其中视野横向检测距离W为镜头531视野中检测区域的实际横向长度，视野纵向检测距离H为镜头531视野中检测区域的实际纵向长度，再基于摄像模块53滑移的周期行程WS，此处周期行程WS被定义为摄像模块53自导轨511一端向另一端正向滑移行程及反向滑移行程的累加，只要摄像模块53于导轨511两端的有效取景区域只要能覆盖坯布幅宽方向上的两边缘即可，因而周期行程WS是一个可浮动的区间，本实施例周期行程WS的行程数值为坯布幅宽WB数值2倍，请参见图10，以摄像模块53位于导轨511最右端为起始点，摄像模块53从导轨511最右端滑移至最左端作为正向滑移，反之则为反向滑移。则摄像模块53正向滑移采集的各个有效取景区域相互迭加形成集合图像区域作为第一正向集合图像区域，摄像模块53反向滑移采集的各个有效取景区域相互迭加形成集合图像区域作为第一反向集合图像区域，其中第一正向集合图像区域与第一反向集合图像区域均采集坯布正面的图像；如图11a所示，图11a上下两端分别为第一胶辊组2与第二胶辊组3，坯布位于第一胶辊组2与第二胶辊组3间，坯布中部的实线路径框即为第一正向集合图像区域，如图11b所示，在一个滑移周期时间T2中，坯布中部的实线路径框为第一正向集合图像区域，虚线路径框为第一反向集合图像区域，第一正向集合图像区域与第二反向集合图像区域相交的剖面线区域为第一重叠区域，且此时坯布下移的输送长度为L2，如图11c所示，截取如图11b中第一重叠区域，使其与坯布下移的输送长度为L2的区域进行覆盖比对，只要第一重叠区域覆盖坯布下移的输送长度为L2的区域，就不会漏检。当然图11c中给出的是第一重叠区域，是同一个滑移周期时间T2中第一正向集合图像区域与第一反向集合图像区域的重合特例，以助于理解。同理，在预定运行时间T1,存在多个滑移周期时间T2，第一重叠区域能基本覆盖坯布从第一胶辊组2的出料端往第二胶辊组3的进料端方向输送长度为L1的区域，附图中为了便于标记，直接将第一胶辊组2的出料端至第二胶辊组3的进料端之间的间距标记为L1，实际，该L1的长度取决于设定的运行时间T1的长短及针织大圆机下布的速率。
需要说明的是，已知摄像模块53相对于坯布的运动路径是倾斜的，请参考图11a及图12，图12示出了图11a中A区域的放大示意图，此时，图11a中实线路径框为第一正向集合图像区域，图中存在两个方框分别代表滑移过程中相邻的两个有效取景区域，为了有助于理解，此图中两个有效取景区域的相邻边缘是重合的，两个有效取景区域在坯布输送方向上相互错开微小的间距，因而两个有效取景区域的下方和上方与实线路径框间存在间隙，即分别存在两个小三角区域S，小三角区域S是检测的盲区，当卷布辊筒4运行速率V1越慢，摄像模块53的滑移速率越慢，且摄像模块53的帧率FR越大时，小三角区域S就越小。整 体上来说，小三角区域S占比很小；因而，在卷布辊筒4运行速率V1、滑移周期时间T2相适配的情况下，第一重叠区域能够将坯布在预定运行时间T1内向下输送L1长度的区域进行基本全覆盖，基本不会出现漏检的。根据卷布辊筒4运行速率V1、滑移周期时间T2，及上述分析模型，可以得出摄像模块53在一个周期行程内第一正向集合图像区域第一与反向集合区域有三种迭加结果：
请参考图3、图14a-图14c，图14a-图14c示出了重叠区域的三种状态，在实施例中，即在一个周期行程内，摄像模块53的第一正向集合图像区域与第一反向集合图像区域相交的第一重叠区域的三种状态，具体地所述摄像模块53的正向滑移行程所获取的第一正向集合图像区域如图坯布中部实线路径框所示，与其反向滑移行程所获取的第一反向集合图像区域如图坯布中部虚线路径框所示，两者相互重合的部分为第一重叠区域如图坯布中部剖面区域所示，再定义第一重叠区域长度L3为第一重叠区域最右端端点与最左端线段垂线的长度；在一个滑移周期时间T2,图14a中坯布的输送长度L2大于视野纵向检测距离H，第一重叠区域长度L3小于坯布的幅宽WB，此时最右端上部的第一反向集合图像区域与最右端下部的第一正向集合图像区域之间，存在空隙区域，即存在漏检区域；图14b中坯布的输送长度L2等于视野纵向检测距离H，第一重叠区域长度L3等于坯布的幅宽WB，但第一重叠区域的最右端仅有一个端点，此时最右端上部的第一反向集合图像区域与最右端下部的第一正向集合图像区域刚好不存在空隙区域；图14c中坯布的输送长度L2小于视野纵向检测距离H，第一重叠区域长度L3等于坯布的幅宽WB，且第一重叠区域的最右端存在两个端点，此时最右端上部的第一反向集合图像区域与最右端下部的第一正向集合图像区域不存在空隙区域，且第一重叠区域面积大于图14b中第一重叠区域的面积；即至少保证第一重叠区域长度L3能够将坯布的幅宽WB进行覆盖，就基本不会发生漏检。
进一步地,通过控制系统控制摄像模块53的滑移周期时间T2，包括：请参考图11a-图11c、图13、图14a-图14c，图13为摄像模块53的采集原理，基于坯布幅宽WB，默认摄像模块53滑移于导轨511的周期行程WS，所述周期行程被定义为摄像模块53自导轨511一端向另一端正向滑移行程及反向滑移行程的累加，其中摄像模块53位于周期行程WS的两行程端点时，摄像模块53所构建的集合图像区域至少包括坯布幅宽方向上的两坯布边缘；再基于预设镜头531与坯布的工作距离WD、摄像模块53的焦距f、与坯布输送方向相平行的摄像模块53芯片靶面的边长h，获取摄像模块53沿坯布输送方向的视野纵向检测距离H＝h*WD/f，同理还可根据与坯布幅宽方向相平行的摄像模块53芯片靶面的边长w，获取摄像模块53沿坯布幅宽方向的视野横向检测距离W＝w*WD/f，则摄像模块53有效取景区域中 取景视野单元的视野横向检测距离W、视野纵向检测距离H均为确定，当然摄像模块53的分辨率应当满足拍摄需求，在此不再赘述；
根据上述三种结果，若要不发生漏检，则在摄像模块53滑移周期时间T2，坯布的输送长度L2应等于或小于视野纵向检测距离H。同理可得，当坯布输送长度数值为H时，摄像模块53应至少完成一个滑移周期时间T2；即基于预设的卷布辊筒4的运行速率V1，由于卷布辊筒4的运行速率V1是要适应于针织圆纬机的织布速率，因而卷布辊筒4的运行速率V1是预先定好的，摄像模块53的视野纵向检测距离H，获取坯布通过视野纵向检测距离H的时间T3＝H/V1,其中坯布通过视野纵向检测距离H的时间T3，指的是坯布下移输送长度数值为H时所用的时间，滑移周期时间T2≤T3，摄像模块53的平均滑移速率V2＝WS/T2。
进一步地，设置所述摄像模块53的帧率FR，所述摄像模块53的帧率FR指的是摄像模块53每秒拍摄的次数，因而FR为整数值，在摄像模块53的1/2个滑移周期时间T2，即摄像模块53可以完成从导轨511最右端与最左端之间的滑移，并使摄像模块53的第一正向集合图像区域覆盖坯布幅宽，当第一正向集合图像区域中相邻图片是相互间无缝连接的，则第一正向集合图像区域中每张图片的视野横向检测距离W之和，应大于或等于坯布的幅宽，即FR*T2/2*W≥WB，可得FR≥2WB/(W*T2)。在理想的情况下，即卷布辊筒4的运行速率V1及滑移周期时间T2相适配，且帧率足够高的情况下，可以保证第一重叠区域完全覆盖坯布在预定运行时间T1内向下输送L1长度的区域,但用这种方式，相邻图片间的重叠区域比例会很高，虽然完全不会造成漏检，但是会使摄像模块53在滑移周期时间T2采集过程中生成大量的图片，大量的图片意味着将产生大量的数据，一方面会对数据传输造成延迟卡顿，另一方面控制系统需在滑移周期时间T2不断地计算处理比对输出结果，如果硬件算力不足即在滑移周期时间T2控制系统不足以消化摄像模块53生成的图片，还容易造成程序死机，再者控制系统还要将图片保存下来，而频繁保存大量图片会占用控制系统大量的运行内存，同样会造成程序运行卡滞。因而在保证基本全覆盖的基础上，合理设置帧率FR,通过牺牲小部分区域，即让集合图像区域中相邻图片的边缘是相互重合的，此时如图12所示，小三角区域S的面积会大一些，但换取了数据传输、程序算力、内存占用等资源优化，使得图像采集检测过程更加顺畅。
以96路针织大圆机的实际生产参数为例进行公式说明，已知生产的坯布幅宽为1800mm，默认摄像模块53的周期行程WS为幅宽的2倍即3600mm，现有针织大圆机一分钟可以转13圈，且针织大圆机一圈织造的坯布长度为15mm，同时且让针织大圆机转一圈时间内坯布的输送长度为15mm，则在一分钟的时间内，针织大圆机坯布的输送长度L1＝15*13＝195mm，可知卷布辊筒4的运行速率V1＝L1/T1＝195/60＝3.25mm/s，基于默认的摄 像模块53芯片靶面长4mm，宽2mm、焦距8mm、镜头531与坯布的工作距离160mm，可知采用摄像模块53的视野横向检测距离W＝2*160/8＝40mm、视野纵向检测距离H＝4*160/8＝80mm，进一步地，坯布通过视野纵向检测距离H的时间T3＝H/V1＝80/3.25＝24.6s，则摄像模块53的滑移周期时间T2≤T3即可，在实际生产中，滑移周期时间T2＝20s，即在一分种内，摄像模块53往复滑移三次，就能完成坯布正面图像的检测。进一步地，V2＝WS/T2＝3600/20＝180mm/s，FR≥3600/(40*20)＝4.5,取整得FR帧率至少为5FPS。
实施例二
本实施例提供的坯布检测装置是在实施例一坯布检测装置的基础上进一步改进，其区别在于，所述图像采集模块5还包括有遮光件54，所述遮光件54上设置有配置为辅助摄像模块53进行坯布反面图像采集的第二光源543。需要说明的是，坯布是由织物相互交叉编织形成的，织物之间具有许多细小的孔隙，并非完全封闭不透光的，因而位于坯布反面的实物背景，会对摄像模块53所采集的坯布正面图像产生干扰。为了消除干扰，故而增设了遮光件54，所述遮光件54可以采用不透光的材质构成如木板、金属板，又或者具有吸光的涂层如黑色涂层，通过设置遮光件54可以有效减少背景噪点，提高图像对比度，使得摄像对坯布正面的图像采集更加准确。
请参考图5-8，具体地，所述遮光件54设置在机架1上，且与摄像模块53的镜头531相对设置，即摄像模块53镜头531与遮光件54是分别位于坯布正面及反面的两侧，所述遮光件54具有与坯布幅宽相匹配的遮光主体541，且所述遮光主体541与导轨511平行布置，至少所述摄像模块53的镜头531对应有效取景区域内存在对应位置的遮光主体541。可以理解的是，摄像模块53是滑移于导轨511的，其位于导轨511两端点的取景区域是至少涵盖了坯布幅宽方向上的两边缘，可能存在有不属于坯布的区域，因而有效取景区域指的是对应坯布的取景区域，则只要遮光主体541是设置在有效取景区域内，就可以起到增强坯布正面检测的作用。请参考图5、图9及图10，在本实施例中，所述遮光主体541还具有凹槽542，所述凹槽542的横截面呈U型，所述凹槽542内至少设置有若干个第二光源543，若干所述第二光源543可沿凹槽542的长度方向排布，若干所述第二光源543还可沿凹槽542的宽度进行布置，所述第二光源543与控制系统电连接，且配置为辅助摄像模块53进行坯布反面图像的采集。具体地，当摄像模块53处于正向滑移行程，且摄像模块53具备第一光源532时，所述摄像模块53的第一光源532打开，遮光主体541的第二光源543关闭，并通过摄像模块53采集的正向滑移行程各个有效取景区域相互迭加形成正向集合图像区域，即摄像模块53实现对坯布正面的图像采集；当摄像模块53处于反向滑移行程，所述 摄像模块53的第一光源532关闭，打开遮光主体541的第二光源543，并通过摄像模块53采集的反向滑移行程各个有效取景区域相互迭加形成反向集合图像区域，即摄像模块53实现对坯布反面的图像采集。综上，通过在遮光件54上设置第二光源543，在摄像模块53采集坯布正面图像的基础功能上，使得摄像模块53还能通过与第一光源532、第二光源543的配合具备坯布反面图像采集的功能，大大提高了坯布检测的全面度，有效降低了漏检的概率。
当出现坯布检测不良时，需人工对坯布进行处理，为了方便工作人员的操作，进一步地，所述遮光件54被设置成可与机架1之间产生位置调整的活动连接，至少当遮光件54处于第一位置时，其处于摄像模块53的镜头531对应有效取景区域内；当遮光件54处于第二位置时，其从摄像模块53的镜头531对应有效取景区域内移开，方便工人从第一胶辊组2至第二胶辊组3进行上布作业。其中第一位置指的是图像采集模块5正常运作时，所述遮光件54的工作位置，此时遮光主体541处于摄像模块53的镜头531对应有效取景区域内，并与导轨511基本平行，第二位置指的是图像采集模块5停止运作时，人工进行上布过程中，所述遮光件54的放置位置，此时至少保证遮光件54不在摄像模块53的镜头531对应有效取景区域内，以方便操作。
具体地，所述遮光件54还包括两侧板544，两所述侧板544之间设置有所述遮光主体541，所述侧板544的一端藉由设置在机架1的转轴11与机架1可旋转地枢接，在本实施例中，所述侧板544与机架1枢接的一端具体为侧板544的下端，在所述遮光主体541与侧板544邻接处还开设有连通的开口槽545，所述遮光主体541上的开口部分大于侧板544上的开口部分，所述机架1上设置有紧固件12，通过该紧固件12穿透开口槽545，且使侧板544压紧于机架1，以实现遮光件54被固定在第一位置。其中，所述紧固件12可为与机架1螺纹连接的锁紧螺丝，所述开口槽545是用于遮光件54在绕转轴11旋转的过程中让位紧固件12，所述遮光主体541上的开口部分是用于让位锁紧螺丝的头部，所述侧板544上的开口部分是用于让位锁紧螺丝的杆部，因而所述遮光主体541上的开口部分大于侧板544上的开口部分，此外通过开口槽545的设置，使得遮光件54在进行旋转时，无需拆下紧固件12，只需拧松紧固件12即可，使得操作简单方便。请参考图8，所述机架1上还分别设置有第一限位件13与第二限位件14，所述第一限位件13及第二限位件14分别与侧板544的两侧边相互抵靠限位,使所述遮光件54以转轴11为旋转轴心,在第一位置及第二位置之间进行切换。所述第一限位件13、第二限位件14为固接于机架1的第一限位螺丝、第二限位螺丝，所述限位螺丝的杆部与机架1螺纹连接，所述限位螺丝的头部配置为与侧板544相抵接。当遮光件54要从第一位置旋转至第二位置时，只需拧松紧固件12，转动遮光件54，使 遮光件54绕转轴11旋转，同时锁紧螺丝转出开口槽545，直到遮光的侧边抵靠在第二限位螺丝的头部，即可完成遮光件54在第二位置的限位，无需其他额外操作；当遮光件54要从第二位置旋转至第一位置时，只需转动遮光件54，使遮光件54绕转轴11旋转，直到遮光的侧边抵靠在第一限位螺丝的头部完成初步限位，同时锁紧螺丝转入开口槽545，再拧紧锁紧螺丝，实现对遮光件54的紧固。
本实施例还提供一种适用于开幅卷布机的坯布检测方法，所述方法适用于摄像模块53在滑移过程中对坯布正面及反面的图像采集，且至少保证坯布在输送的过程中，摄像模块53基本不会造成坯布正面及反面的漏检，具体包括以下步骤：
S1：在预定运行时间T1内，基于预设的卷布辊筒4运行速率V1，坯布自第一胶辊组2向第二胶辊组3进行输送L1长度，通过控制系统控制摄像模块53的滑移周期时间T2，所述滑移周期时间T2被定义为摄像模块53经过自导轨511一端向另一端正向滑移行程及反向滑移行程所累加行程的时间，当摄像模块53处于正向滑移行程，且摄像模块53具备第一光源532时，所述第一光源532打开，同时第二光源543关闭，并通过摄像模块53采集的正向滑移行程各个有效取景区域相互迭加形成第二正向集合图像区域，当摄像模块53处于反向滑移行程，所述摄像模块53的第一光源532关闭，打开遮光主体541的第二光源543，并通过摄像模块53采集的反向滑移行程各个有效取景区域相互迭加形成第二反向集合图像区域，第二正向集合图像区域及第二反向集合图像区域相互重合的部分为第二重叠区域，至少保证第二重叠区域能够将坯布向下输送L1长度的区域进行基本全覆盖；在本实施例中，基本全覆盖指的是，在预定运行时间T1内，第二重叠区域覆盖坯布向下输送L1长度区域的比例区间为90％-100％；
S2：将摄像模块(53)采集的实时坯布图像传送至控制系统进行数据处理，使其图像信息特征代码化；
S3：所述控制系统内预设有样本数据和相似度判断阈值，将实时采集的坯布的图像信息特征代码与样本数据进行分析比对，通过调整相似度判断阈值的大小，来调整坯布瑕疵点识别的灵敏度，其中：
如果控制系统存储的样本数据为合格样本数据，若所检测坯布的图像信息特征代码与样本数据具有一致性，则所检测的坯布为合格，控制系统不会下发停机指令，若所检测坯布的图像信息特征代码与样本数据不一致，则控制系统发送停机指令；
如果控制系统存储的样本数据为不合格样本数据，若所检测坯布的图像信息特征代码中包含样本数据，则所检测的坯布不为合格，控制系统发送停机指令；若所检测坯布的图像信息特征代码不包含样本数据，则控制系统不会发送停机指令，卷布机持续运行。
采用上述方法，摄像模块53采集的集合图像区域可以覆盖坯布输送L1长度的区域，能自动且全面地完成坯布的正面及坯布反面的检测，当检测不合格时，卷布机能自动报警，有效减轻了工人的劳作强度，保证了产品的质量。
本实施例的坯布检测方法与实施例一坯布检测方法的区别在于：所述摄像模块53进行了坯布正面及反面图像采集，且当摄像模块53进行坯布反面图像采集时，所述第一光源532与第二光源543的打灯策略与摄像模块53进行坯布正面图像采集时不同。
需要说明的是，实施例一的坯布检测方法的说明中，提到了第一正向集合图像区域和第一反向集合图像区域，而本实施例二设有第二正向集合图像区域和第二反向集合图像区域；两者的联系在于，第一正向集合图像区域及第二正向集合图像区域均定义为摄像模块53在正向滑移行程采集的集合图像区域，同理第一反向集合图像区域及第二反集合区域均为摄像模块53在反向滑移行程采集的集合图像区域；区别在于，第一正向集合图像区域和第一反向集合图像区域均是在第一光源532常亮状态下，对坯布正面的图像采集，而实施例二的第二正向集合图像区域是在第一光源532保持常亮，同时第二光源543关闭的场景下，对坯布正面的图像采集，第二反向集合图像区域是在第一光源532关闭，同时第二光源543保持常亮的场景下，对坯布反面的图像采集。
以下结合图3、图10、图14a、图14c和图15a-图15b对步骤S1进行说明：
周期行程WS被定义为摄像模块53自导轨511一端向另一端正向滑移行程及反向滑移行程的累加，滑移周期时间T2,是摄像模块53经过周期行程所用的时间，在第一周期行程中，当摄像模块53处于正向滑移行程，且摄像模块53具备第一光源532时，所述摄像模块53的第一光源532打开，第二光源543关闭，并通过摄像模块53采集的正向滑移行程各个有效取景区域相互迭加形成第二正向集合图像区域，当摄像模块53处于反向滑移行程，所述摄像模块53的第一光源532关闭，打开遮光主体541的第二光源543，并通过摄像模块53采集的反向滑移行程各个有效取景区域相互迭加形成第二反向集合图像区域，图14a-图14c示出了重叠区域的三种状态，与实施例1的描述基本一致，只是在第一周期行程的第二正向集合图像区域只采集坯布正面图像，第二反向集合图像区域只采集坯布反面图像，因而第二重叠区域是均有进行坯布正反面图像采集；如图15a所示，当摄像模块53进行第二周期行程时，第二周期行程的第二正向集合图像区域覆盖第一周期行程未发生重迭的第二反向集合图像区域，以实现该区域的坯布正面图像采集。通过摄像模块53相邻周期行程的正反面图像采集互补，只需第二重叠区域均能够将坯布向下输送L1长度的区域进行基本全覆盖，即可完成坯布的正反面图像采集，且不会造成漏检。
虽然实施例二有额外对坯布进行反面检测，但实施例二达成至少基本不漏检的原理和实施例一是相同的，因而同样基于卷布辊筒4运行速率V1、滑移周期时间T2配合不同，摄像模块53在一个周期行程内第二正向集合图像区域与反向集合区域有三种迭加结果：其中图14a中坯布的输送长度L3大于视野纵向检测距离H，第二重叠区域长度L3小于坯布的幅宽WB，此时最右端上部的第二反向集合图像区域与最右端下部的第二正向集合图像区域之间，存在空隙区域，即存在漏检区域；图14b中坯布的输送长度L3等于视野纵向检测距离H，第二重叠区域长度L3等于坯布的幅宽WB，但第二重叠区域的最右端仅有一个端点，此时最右端上部的第二反向集合图像区域与最右端下部的第二正向集合图像区域刚好不存在空隙区域；但由于还有对坯布反面的检测，因而对此进一步补充说明，如图15a所示，图15a为第一周期行程中第二反向集合图像区域与第二周期行程中第二正向集合图像区域的相交示意图，在第一周期行程中，未发生重迭的第二反向集合图像区域的上边界是该周期行程的第二反向集合图像区域上边界线，而其下边界是该周期行程的第二正向集合图像区域上边界线，由于摄像模块53的取景视野是框图的形式，所以第二周期行程的第二正向集合图像区域的下边界线会低于第一周期行程的第二正向集合图像区域的上边界线，相应地如图15b所示，图15b为第一周期行程集合图像区域与第二周期行程集合图像区域的相交情况，此处集合图像区域是指该周期行程中，第二正向集合图像区域与第二反向集合图像区域的累加，第二周期行程第二重叠区域的下边界线是低于第一周期行程反向集合区域的上边界线的，即第二周期行程的第二正向集合图像区域可以覆盖第一周期行程未发生重迭的第二反向集合图像区域，基本不会发生漏检；图14c中坯布的输送长度L3小于视野纵向检测距离H，第二重叠区域长度L3等于坯布的幅宽WB，且第二重叠区域的最右端存在两个端点，此时最右端上部的第二反向集合图像区域与最右端下部的第二正向集合图像区域不存在空隙区域，且第二重叠区域面积大于图14b中第二重叠区域的面积，同理第二周期行程的第二正向集合图像区域能覆盖第一周期行程未发生重迭的第二反向集合图像区域；即至少保证第二重叠区域长度L3能够将坯布的幅宽WB进行覆盖，就基本不会发生漏检，在本实施例中同样适用。
至于各项参数如卷布辊筒4运行速率V1、滑移周期时间T2的配合，请参考实施例一的相应部分，通过控制系统控制摄像模块53的滑移周期时间T2，进一步包括：基于预设的卷布辊筒4的运行速率V1，摄像模块53的视野纵向检测距离H，获取坯布通过视野纵向检测距离H的时间T3＝H/V1,滑移周期时间T2≤T3。此外，摄像模块53的帧率FR确定，请参考实施例一坯布检测方法中的对应部分，在此不再赘述。
应当理解的是，所有以上的优选实施例都是示例性而非限制性的，本领域技术人员在本申请的构思下对以上描述的具体实施例做出的各种改型或变形都应在本申请的法律保护范围内。

Claims (13)

  1. 一种适用于开幅卷布机的坯布检测装置，所述开幅卷布机旋转运作于针织大圆机，其包括剖布装置和收卷装置，所述剖布装置用于将针织大圆机所织造的环形坯布切割后展开，所述收卷装置包括一机架(1)，所述机架(1)上平行设置有一第一胶辊组(2)与一第二胶辊组(3)，所述第二胶辊组(3)的一侧设有卷布辊筒(4)，被切割后展开的坯布依次经第一胶辊组(2)及第二胶辊组(3)被拉直平整，最终被收卷于卷布辊筒(4)，其特征在于：它包括一图像采集模块(5)及控制系统，所述图像采集模块(5)包括导向件(51)、驱动件(52)及摄像模块(53)，所述驱动件(52)及摄像模块(53)外部电连接有控制系统，所述导向件(51)包括导轨(511)及滑块(512)，所述导轨(511)设置在机架(1)上并悬空横跨于第一胶辊组(2)的出料端与第二胶辊组(3)的进料端之间所构建的传输面上，所述驱动件(52)驱动滑块(512)沿导轨(511)的长度方向上正向和反向往复滑移运动，所述摄像模块(53)具有一镜头(531),所述摄像模块(53)设置在滑块(512)上，其镜头(531)朝向传输面进行图像采集，所述控制系统至少用于接收摄像模块(53)所采集的实时图像信息，并对其进行坯布瑕疵点判断，当控制系统一旦判断出传输的坯布存在瑕疵，向外发送控制指令。
  2. 如权利要求1所述的一种适用于开幅卷布机的坯布检测装置，其特征在于，所述导轨(511)与第一胶辊组(2)平行设置，所述摄像模块(53)的镜头(531)设置在垂直于坯布正面方向的上方。
  3. 如权利要求2所述的一种适用于开幅卷布机的坯布检测装置，其特征在于，所述图像采集模块(5)位于传输面与卷布辊筒(4)之间。
  4. 如权利要求1所述的一种适用于开幅卷布机的坯布检测装置，其特征在于，所述摄像模块(53)在位于镜头(531)的外径端设置至少两个第一光源(532)，且在第一光源(532)的外周缘增设一导光罩(533)，所述导光罩(533)的侧壁用于将所述第一光源(532)的光路投射至摄像模块(53)的镜头(531)正前方。
  5. 如权利要求1-4任一项所述的一种适用于开幅卷布机的坯布检测装置，其特征在于，所述图像采集模块(5)还包括遮光件(54)，其设置在机架(1)上，且与摄像模块(53)的镜头(531)相对设置，所述遮光件(54)具有与坯布幅宽相匹配的遮光主体(541)，且所述遮光主体(541)与导轨(511)平行布置，至少所述摄像模块(53)的镜头(531)对 应有效取景区域内存在对应位置的遮光主体(541)。
  6. 如权利要求5所述的一种适用于开幅卷布机的坯布检测装置，其特征在于，所述遮光主体(541)具有凹槽(542)，所述凹槽(542)内至少设置有若干个第二光源(543)，所述第二光源(543)与控制系统电连接，仅当所述摄像模块(53)用于坯布反面图像采集时，控制系统下发控制指令，点亮所述第二光源(543)。
  7. 如权利要求5或6所述的一种适用于开幅卷布机的坯布检测装置，其特征在于，所述遮光件(54)被设置成可与机架(1)之间产生位置调整的活动连接，至少当遮光件(54)处于第一位置时，其处于摄像模块(53)的镜头(531)对应有效取景区域内；当遮光件(54)处于第二位置时，其从摄像模块(53)的镜头(531)对应有效取景区域内移开，方便工人从第一胶辊组(2)至第二胶辊组(3)进行上布作业。
  8. 如权利要求7所述的一种适用于开幅卷布机的坯布检测装置，其特征在于，所述遮光件(54)还包括两侧板(544)，两所述侧板(544)之间设置有所述遮光主体(541)，所述侧板(544)的一端藉由设置在机架(1)的转轴(11)与机架(1)可旋转地枢接，在所述遮光主体(541)与侧板(544)邻接处开设有连通的开口槽(545)，所述遮光主体(541)上的开口部分大于侧板(544)上的开口部分，所述机架(1)上设置有紧固件(12)，通过该紧固件(12)穿透开口槽(545)，且使侧板(544)压紧于机架(1)，以实现遮光件(54)被固定在第一位置。
  9. 如权利要求8所述的一种适用于开幅卷布机的坯布检测装置，其特征在于，所述机架(1)上还分别设置有第一限位件(13)与第二限位件(14)，所述第一限位件(13)及第二限位件(14)分别与侧板(544)的两侧边相互抵靠限位,使所述遮光件(54)以转轴(11)为旋转轴心,在第一位置及第二位置之间进行切换。
  10. 一种使用权利要求1-4任一项所述开幅卷布机的坯布检测装置进行坯布瑕疵检测的方法，其特征在于，包括以下步骤：
    S1：在预定运行时间T1内，基于预设的卷布辊筒(4)运行速率V1，坯布自第一胶辊组(2)向第二胶辊组(3)进行输送L1长度，通过控制系统控制摄像模块(53)的滑移周期时间T2，所述滑移周期时间T2被定义为摄像模块(53)经过自导轨(511)一端向另一 端正向滑移行程及反向滑移行程所累加行程的时间，当摄像模块(53)具备第一光源(532)时，该第一光源(532)至少保证在镜头(531)处于工作状态时保持常亮，当摄像模块(53)处于正向滑移行程，通过摄像模块(53)采集的正向滑移行程各个有效取景区域相互迭加形成第一正向集合图像区域，当摄像模块(53)处于反向滑移行程，通过摄像模块(53)采集的反向滑移行程各个有效取景区域相互迭加形成第一反向集合图像区域，第一正向集合图像区域及第一反向集合图像区域相互重合的部分为第一重叠区域，至少保证第一重叠区域能够将坯布向下输送L1长度的区域进行基本全覆盖；
    S2：将摄像模块(53)采集的实时坯布图像传送至控制系统进行数据处理，使其图像信息特征代码化；
    S3：所述控制系统内预设有样本数据和相似度判断阈值，将实时采集的坯布的图像信息特征代码与样本数据进行分析比对，通过调整相似度判断阈值的大小，来调整坯布瑕疵点识别的灵敏度，其中：
    如果控制系统存储的样本数据为合格样本数据，若所检测坯布的图像信息特征代码与样本数据具有一致性，则所检测的坯布为合格，控制系统不会下发停机指令，若所检测坯布的图像信息特征代码与样本数据不一致，则控制系统发送停机指令；
    如果控制系统存储的样本数据为不合格样本数据，若所检测坯布的图像信息特征代码中包含样本数据，则所检测的坯布不为合格，控制系统发送停机指令；若所检测坯布的图像信息特征代码不包含样本数据，则控制系统不会发送停机指令，卷布机持续运行。
  11. 一种使用权利要求6-9任一项所述开幅卷布机的坯布检测装置进行坯布瑕疵检测的方法，其特征在于，包括以下步骤：
    S1：在预定运行时间T1内，基于预设的卷布辊筒(4)运行速率V1，坯布自第一胶辊组(2)向第二胶辊组(3)进行输送L1长度，通过控制系统控制摄像模块(53)的滑移周期时间T2，所述滑移周期时间T2被定义为摄像模块(53)经过自导轨(511)一端向另一端正向滑移行程及反向滑移行程所累加行程的时间，当摄像模块(53)处于正向滑移行程，且摄像模块(53)具备第一光源(532)时，所述第一光源(532)打开，同时第二光源(543)关闭，并通过摄像模块(53)采集的正向滑移行程各个有效取景区域相互迭加形成第二正向集合图像区域，当摄像模块(53)处于反向滑移行程，所述摄像模块(53)的第一光源(532)关闭，打开遮光主体(541)的第二光源(543)，并通过摄像模块(53)采集的反向滑移行程各个有效取景区域相互迭加形成第二反向集合图像区域，第二正向集合图像区域及第二反向集合图像区域相互重合的部分为第二重叠区域，至少保证第二重叠区域能够 将坯布向下输送L1长度的区域进行基本全覆盖；
    S2：将摄像模块(53)采集的实时坯布图像传送至控制系统进行数据处理，使其图像信息特征代码化；
    S3：所述控制系统内预设有样本数据和相似度判断阈值，将实时采集的坯布的图像信息特征代码与样本数据进行分析比对，通过调整相似度判断阈值的大小，来调整坯布瑕疵点识别的灵敏度，其中：
    如果控制系统存储的样本数据为合格样本数据，若所检测坯布的图像信息特征代码与样本数据具有一致性，则所检测的坯布为合格，控制系统不会下发停机指令，若所检测坯布的图像信息特征代码与样本数据不一致，则控制系统发送停机指令；
    如果控制系统存储的样本数据为不合格样本数据，若所检测坯布的图像信息特征代码中包含样本数据，则所检测的坯布不为合格，控制系统发送停机指令；若所检测坯布的图像信息特征代码不包含样本数据，则控制系统不会发送停机指令，卷布机持续运行。
  12. 如权利要求10或11所述开幅卷布机的坯布检测装置进行坯布瑕疵检测的方法，其特征在于，通过控制系统控制摄像模块(53)的滑移周期时间T2，进一步包括：
    基于预设的卷布辊筒(4)的运行速率V1，摄像模块(53)的视野纵向检测距离H，获取坯布通过视野纵向检测距离H的时间T3＝H/V1,滑移周期时间T2≤T3。
  13. 如权利要求12所述开幅卷布机的坯布检测装置进行坯布瑕疵检测的方法，其特征在于，基于坯布幅宽WB、摄像模块(53)的视野横向检测距离W、滑移周期时间T2,获取摄像模块(53)的帧率FR,FR为正整数，且FR≥2WB/(W*T2)。
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