阅读说明：本技术 一种基于机器视觉的蕾丝花边缺陷检测装置及使用方法 (Bud thread lace defect detection device based on machine vision and use method ) 是由 李建兴 何志刚 罗堪 马莹 林华良 檀甫贵 苏凌霄 于 2019-12-19 设计创作，主要内容包括：本发明属于纺织生产技术领域,公开一种基于机器视觉的蕾丝花边缺陷检测装置,包括开卷组件(1)和缺陷检测组件(2),其特征在于：所述缺陷检测组件(2),包括检测台(24),所述检测台(24)下方安装有开卷组件(1),所述检测台(24)背面固定安装有收卷组件(3),所述开卷组件(1)和PLC控制器电连接,PLC控制器电连接有收卷组件(3)。其方法将蕾丝花边原料卷放入开卷轴(13)中,蕾丝花边原料卷到达张力控制结构(14),到达检测台(24)；判断缺陷,开始收卷；结束操作。不仅丰富了纺织品行业缺陷检测装置,而且其检测精度高,实时性强。(The invention belongs to the technical field of textile production, and discloses a lace defect detection device based on machine vision, which comprises an uncoiling component (1) and a defect detection component (2), and is characterized in that the defect detection component (2) comprises a detection table (24), the uncoiling component (1) is arranged below the detection table (24), a coiling component (3) is fixedly arranged on the back surface of the detection table (24), the uncoiling component (1) is electrically connected with a P L C controller, and the P L C controller is electrically connected with the coiling component (3).)

1. A bud thread lace defect detection device based on machine vision comprises an uncoiling assembly (1) and a defect detection assembly (2), and is characterized in that the defect detection assembly (2) comprises a detection table (24), an aluminum frame (21) with a set angle is mounted on the detection table (24), a high-speed industrial camera (22) and a lighting source (23) matched with detection are mounted on the aluminum frame (21) to form a machine vision system, the uncoiling assembly (1) is mounted below the detection table (24), a coiling assembly (3) is fixedly mounted on the back of the detection table (24), the uncoiling assembly (1) is electrically connected with a P L C controller, and the P L C controller is electrically connected with the coiling assembly (3).

2. The bud thread lace defect detection device based on the machine vision according to claim 1, wherein the uncoiling component (1) comprises a spindle (11), an uncoiling thin rod (12), an uncoiling shaft (13) and a supporting iron frame (19), the supporting iron frame (19) is provided with the spindle (11), the uncoiling thin rod (12) and the uncoiling shaft (13) from top to bottom, a spindle servo motor (17) and a main servo motor driver (18) are arranged between the spindle (11) and a tension control structure (14), a linear speed encoder is arranged in the main servo motor (17), the spindle (11) is connected with the main servo motor (17) through an uncoiling belt, the tension control structure (14) is arranged at one end of the uncoiling thin rod (12) to control the bud thread lace tension, the uncoiling shaft (13) is connected with the uncoiling servo motor (15) through an uncoiling belt I, the unwinding servomotor (15) is fixed to an unwinding servomotor driver (16).

3. The bud thread lace defect detection device based on the machine vision as claimed in claim 2, wherein the tension control structure comprises a gear (144), a rolling disc (145) and a movable iron rod (146), the movable iron rod (146) connected to the unwinding thin rod (12) rotates to drive the rolling disc (145) and the gear (144) to move, the gear (144) touches an iron rod (143) in the rotation process, the tail end of the iron rod (143) is connected to the front end of a spring (142), and the tail end of the spring (142) is hooked on the lower portion of a movable iron sheet (141) fixed on a support iron frame.

4. The lace defect detection device based on machine vision according to claim 1, wherein the rolling component (3) comprises a rolling support iron frame (34), the rolling support iron frame (34) is fixed with a rolling shaft (31), a rolling servo motor (32) and a rolling servo motor driver (33), the rolling servo motor (32) is fixed above the rolling servo motor driver (33), the rolling shaft (31) and the rolling servo motor (32) are connected through a rolling belt (35), and a tension sensor for detecting lace cloth rolls is installed at the corners of the rolling support iron frame (34) and the detection table.

5. Use of the device for detecting bud thread lace defect based on machine vision according to any one of claims 1 to 4, characterized by comprising the steps of,

the first step is as follows: the detection device is ready, a lace raw material roll is placed in the uncoiling shaft (13), after the operation is finished, the uncoiling component (3) outputs a pulse signal to the uncoiling servo motor (15), and the uncoiling servo motor is conveyed by an uncoiling belt to the uncoiling shaft (13) to operate;

the second step is that: the bud thread lace raw material roll reaches a tension control structure (14), and the speed is obviously different from that of the unwinding roll;

the third step: the uncoiling component receives the pulse signal and outputs the pulse signal to a main shaft servo motor (17), and the lace raw material coil reaches a detection platform (24) after passing through a main shaft (11);

after the collection is finished, another lace with the same color is detected again and is matched with a lace template which is just collected at the same time, MAT L AB software is used for judging whether defects exist, if yes, the fifth step is carried out, otherwise, the device is automatically stopped;

the fifth step: before the bud thread lace raw material roll reaches a winding shaft (31), the winding component outputs a pulse signal to a winding servo motor (32) to start winding;

and a sixth step: and finishing the operation after the rolling is finished.

Technical Field

The invention belongs to the technical field of textile production, and particularly relates to a device for detecting defects of lace based on machine vision and a using method thereof.

Background

In the current textile industry, flaw detection or defect detection plays an important role in improving the quality of textiles, and a lace is no exception. At present, the detection of the lace in China mainly depends on manual detection. The traditional manual detection method is that the inspector makes an assessment according to personal experience. The method has the problems of low detection speed, high omission factor, non-uniform detection standard and the like, so that a novel, rapid and accurate automatic detection method for the fabric defects is urgently needed to be developed.

The existing textile defect detection device has the following schemes: (1) application number 201820594716.2, name a fabrics fault detection test platform, has the test bench, the support is installed to the left and right sides of test bench, and cloth off tracking mechanism is all installed to the both ends head of test bench and is used for making the cloth keep smooth compression roller, and the front end of test bench is installed and is opened a book the mount pad, and the rolling mount pad is installed to its rear end. The device does not have the capability of automatically detecting textile defects. (2) Application number 201721303579.4, name a detect device of fabrics defect, including anti-skidding support callus on the sole, supporting legs connecting rod, workstation support frame, the dustproof safety cover of conveyer belt, control panel, testing result display screen, control button, fabrics detection device main part, conveyer belt anti falling baffle, automatic handling manipulator, fabrics conveyer belt, the fabrics conveyer belt passes through mechanical connection in the middle of workstation support frame top. To above-mentioned scheme, adopt the conveyer belt to detect the fabrics defect, do not open a book subassembly and rolling part, thereby and different elastic material can arouse deformation to influence the testing result. (3) Application number 201820803164.1, title a textile defect detection device based on machine vision, including industry PC, FPGA controller, image acquisition device and textile transport mechanism, industry PC with FPGA controller both-way communication connects, image acquisition device with FPGA controller communication connects. For the third scheme, the resolution of the position and the angle of the light source is not clear, great influence is generated on the acquisition of the image, and the production cost is high and is not suitable for popularization in the market. The data is consulted to know that the main factor influencing the tension of the lace is the change of the linear velocity and the roll diameter. And a large number of simulation experiments show that the change of the linear velocity is the main reason influencing the change of the tension, and the constant of the linear velocity must be kept to keep the constant of the tension.

Disclosure of Invention

The invention aims to solve the problem, provides a device for detecting the defects of the lace based on machine vision and a using method thereof aiming at a series of defects of the lace in flaw detection, and not only enriches the devices for detecting the defects in the textile industry, but also has high detection precision and strong real-time performance. The probability of false detection or missed detection caused by the conventional manual detection of bud thread lace defects is reduced, and meanwhile, the high-speed industrial camera is used for replacing human eyes, so that the labor cost is saved, and the manual labor intensity is reduced.

In order to achieve the purpose, the technical scheme of the invention is as follows:

a bud thread lace defect detection device based on machine vision comprises an uncoiling assembly 1 and a defect detection assembly 2 and is characterized in that the defect detection assembly 2 comprises a detection table 24, an aluminum frame 21 with a set angle is mounted on the detection table 24, a high-speed industrial camera 22 and a lighting source 23 matched with detection are mounted on the aluminum frame 21 to form a machine vision system, the uncoiling assembly 1 is mounted below the detection table, a coiling assembly 3 is fixedly mounted on the back of the detection table, the uncoiling assembly 1 is electrically connected with a P L C controller, and the P L C controller is electrically connected with the coiling assembly 3.

Preferably, the unwinding assembly 1 comprises a main shaft 11, an unwinding thin rod 12, an unwinding shaft 13, a tension control structure 14, an unwinding servo motor 15, an unwinding servo motor driver 16, a main servo motor 17, a main servo motor driver 18, and a support iron stand 19, the supporting iron frame 19 is provided with a main shaft 11, an uncoiling slender rod 12 and an uncoiling shaft 13, a spindle servomotor 17 and a main servomotor driver 18 are installed between the spindle 11 and the tension control structure 14, a linear velocity encoder is installed in the main servo motor 17, the main shaft 11 is connected with the main servo motor 17 through an uncoiling belt two phase, a tension control structure 14 is arranged at the upper end of the uncoiling slender rod 12 to control the tension of the lace, the uncoiling shaft 13 is connected with an uncoiling servo motor 15 through an uncoiling belt I, and the uncoiling servo motor 15 is fixed on an uncoiling servo motor driver 16.

Preferably, the tension control structure comprises a movable iron sheet 141, a spring 142, an iron rod 143, a gear 144, a rolling disc 145 and a movable iron rod 146, wherein the movable iron rod 146 connected to the uncoiling slender rod 12 rotates to drive the rolling disc 145 and the gear 144 to move, the gear 144 touches the iron rod 143 in the rotation process, the tail end of the iron rod 143 is connected to the front end of one spring 142, and the tail end of the spring 142 is hooked on the lower part of the movable iron sheet 141 fixed on the support iron frame.

Preferably, it is the same with the subassembly of opening a book and defect detecting component to rolling subassembly 3, including rolling support iron frame 34, rolling support iron frame 34 is fixed with rolling axle 31, rolling servo motor 32, rolling servo motor driver 33, rolling servo motor 32 is fixed in rolling servo motor driver 33 top, be connected with rolling belt 35 between rolling axle 31, the rolling servo motor 32, install at rolling support iron frame 34 and detection platform corner and detect lace cloth material roll tension force sensor.

The use method of the bud thread lace defect detection device based on machine vision comprises the following steps,

firstly, the defect detection assembly is ready to put a lace raw material roll into the uncoiling shaft 13, after the operation is finished, the uncoiling assembly controls the uncoiling servo motor driver 16 to output a pulse signal to the uncoiling servo motor 15 through the P L C controller, and the uncoiling servo motor is conveyed by an uncoiling belt to the uncoiling shaft 13 to operate;

the second step is that: the bud thread lace material roll reaches the tension control structure 14 at a speed significantly different from the unwinding roll;

thirdly, the uncoiling component controls the main servo motor driver 18 to receive pulse signals through a P L C controller and output the pulse signals to the main shaft servo motor 17, and the lace raw material coil passes through the main shaft 11 and then reaches the detection platform 24;

after the collection is finished, another lace with the same color is detected again and is matched with a lace template which is just collected at the same time, MAT L AB software is used for judging whether defects exist, if yes, the fifth step is carried out, otherwise, the device is automatically stopped;

fifthly, before the bud thread lace raw material roll reaches the winding shaft 31, the winding system controls the winding servo motor driver 33 to output a pulse signal to the winding servo motor 32 through P L C to start winding;

and a sixth step: and finishing the operation after the rolling is finished.

Compared with the prior art, the invention has the beneficial effects that:

the detection part of the device for detecting the lace defects adopts a 120 x 50(cm) detection table, can detect the large-size lace defects, has a certain angle, and well solves the problem that patterns are not clear due to fine manufacturing process. Open a book subassembly structure and increased linear velocity encoder and tension control structure for traditional fabrics defect detection, solved the bud silk lace because the linear velocity undersize causes the raw materials to roll up and piles up and lead to unable detection discernment or raw materials roll to be dragged or even destroy the problem of lace raw materials. The winding part structure increases the tension of the tension sensor for detecting the current lace cloth roll, and realizes the constancy of the tension through the PID controller. The device realizes the cooperative operation of the tension ring and the speed ring to ensure that the motion control is more accurate. Note: image processing: a method and a technique for removing noise, enhancing, restoring, segmenting, and extracting features of an image by a computer. Machine vision mainly uses a computer to simulate the visual function of a human, extracts information from an image of an objective object, processes and understands the information, and is applied to actual detection, measurement and control.

The invention is applied to the production of lace in textile factories, detects whether the lace surface has defects such as missing diameter, broken weft, leak, and the like, plays an important role in improving the quality of the lace for detecting the lace in textile factories, can effectively aim at the characteristics of the lace, namely high elasticity, greatly shorten the product development period, improve the competitiveness of products in the market, fill up the vacancy that the lace defect detection does not exist in the market, realize the constant tension through a PID controller in the detection process of the lace fabric according to the characteristics of the high elasticity of the lace, detect the linear speed of the lace raw material roll in real time through a linear encoder, feed the speed back to P L C, compare the given rotating speed with the actually measured rotating speed through P L C, output pulses to a servo drive to keep the linear speed of the lace raw material roll constant, ensure the whole device to be more stable due to the constant tension and speed, and on the basis that a detected object is the lace, different types of textiles can detect the defects according to the control of the tension and the speed.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and together with the description, serve to explain the principles of the invention.

FIG. 1 is a line speed control schematic in an embodiment of the present invention.

Fig. 2 is a schematic diagram of tension control in an embodiment of the present invention.

FIG. 3 is a schematic structural diagram of a device for detecting a bud thread lace defect based on machine vision according to the present invention.

FIG. 4 is a structural view of an unwinding assembly of the device for detecting bud thread lace defects based on machine vision.

FIG. 5 is a drawing showing a tension control structure of the device for detecting a lace defect according to the present invention.

Fig. 6 is an enlarged view of the tension control structure shown in fig. 5.

FIG. 7 is a structural diagram of a defect detecting assembly of the device for detecting defects of lace based on machine vision according to the present invention.

FIG. 8 is a drawing showing a rolling part of the device for detecting bud thread lace defects based on machine vision according to the present invention.

FIG. 9 is a flowchart of a device for detecting defects in lace based on machine vision according to the present invention.

Detailed Description

The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings.

As shown in fig. 1 and 2, a line speed schematic diagram and a tension control schematic diagram. Compared with the traditional textile detection, a linear speed encoder and a tension control structure are added to the uncoiling assembly, a tension sensor is added to the coiling part, the cooperative control of speed and tension is realized, and the characteristic that high elasticity is achieved in the textile based on lace is achieved.

The control principle of the linear velocity: v0(t) is a given rotating speed, V (t) is an actual rotating speed, E (t) is an error after the two are compared, the error is output to a servo drive, and the error is output to a servo motor through modifying pulses after the servo motor drive is calculated, so that the linear speed is corrected. The encoder is used as a rotating speed feedback device.

Tension control principle: t0(k) is a tension set value, T (k) is actual tension, an error E (k) is obtained after the two are compared, the error is output to a servo drive for calculation, after the servo drive is calculated, a pulse is output to a servo motor to control the rotating speed, the cloth winding speed V (k) is obtained by combining the winding diameter, and then the tension sensor detects the tension T (k) of the current lace cloth roll, so that the tension is constant through a PID controller.

As shown in fig. 3-8, a lace defect detection device based on machine vision comprises an uncoiling assembly 1 and a defect detection assembly 2, wherein the defect detection assembly 2 comprises a detection table 24, an aluminum frame 21 with a set angle is mounted on the detection table 24, a high-speed industrial camera 22 and a lighting source 23 matched with the detection are mounted on the aluminum frame 21 to form a machine vision system, the uncoiling assembly 1 is mounted below the detection table, a coiling assembly 3 is fixedly mounted on the back of the detection table, the uncoiling assembly 1 is electrically connected with a P L C controller, the P L C controller is electrically connected with the coiling assembly 3, the high-speed industrial camera is one or two cameras distributed at equal intervals, the defect detection assembly can replace the two cameras into one by reducing the shooting area, the lighting source is a common fluorescent lamp, and the detection table is a 120 × 50cm detection table.

The uncoiling component 1 is electrically connected with a P L C controller, the P L C controller is electrically connected with a coiling component 3, the uncoiling component 1 comprises a spindle 11, an uncoiling thin rod 12, an uncoiling shaft 13, a tension control structure 14, an uncoiling servo motor 15, an uncoiling servo motor driver 16, a main servo motor 17, a main servo motor driver 18 and a support iron frame 19, the spindle 11, the uncoiling thin rod 12 and the uncoiling shaft 13 are mounted on the support iron frame 19, a spindle servo motor 17 and a main servo motor driver 18 are mounted between the spindle 11 and the tension control structure 14, a linear velocity encoder is mounted in the main servo motor 17, the spindle 11 is connected with the main servo motor 17 through an uncoiling belt, the tension control structure 14 is mounted at the upper end of the uncoiling thin rod 12 to control the tension of a lace, the uncoiling shaft 13 is connected with the uncoiling servo motor 15 through an uncoiling belt I, and the uncoiling servo motor 15 is fixed on the servo motor driver 16.

A worker loads a lace raw material roll into an uncoiling shaft 13, an uncoiling system obtains an error value between a given speed and an actual speed and outputs the error value to an uncoiling servo motor driver 16, the uncoiling servo motor driver 16 outputs the error value to an uncoiling servo motor 15 through modifying pulses after calculation, the uncoiling servo motor 15 drives the uncoiling shaft 13 through an uncoiling belt, the uncoiling shaft 13 starts to uncoil, then is drawn upwards through the unwinding slender rod 12, at the same time triggers the tension control structure 14, continues to be drawn upwards through the support iron frame 19 and winds around the main shaft 11, and the main shaft can obtain an error value between a given speed and an actual speed and outputs the error value to the main servo motor driver 18, the main servo motor driver 18 outputs the error value to the main servo motor 17 through modifying pulses after calculation, the main servo motor 17 drives the main shaft 11 through the uncoiling belt II, and the uncoiling assembly finishes entering the defect detection assembly. Open a book subassembly structure and increased linear velocity encoder and tension control structure for traditional fabrics defect detection, solved the bud silk lace because the linear velocity undersize leads to the raw materials to roll up and piles up and lead to unable detection discernment or the linear velocity undersize leads to the fact the raw materials to roll up and is dragged or even destroy the problem of lace raw materials. The design not only improves the accuracy of detecting the lace by the defect detecting assembly, but also enables the device to become more stable.

The tension control structure comprises a movable iron sheet 141, a spring 142, an iron rod 143, a gear 144, a rolling disc 145 and a movable iron rod 146, wherein the movable iron rod 146 connected to the uncoiling slender rod 12 rotates to drive the rolling disc 145 and the gear 144 to move, the gear 144 touches the iron rod 143 in the rotating process, the tail end of the iron rod 143 is connected to the front end of the spring 142, and the tail end of the spring 142 is hooked at the lower part of the movable iron sheet 141 fixed on a support iron frame.

Is distinguished from previous textile defect detection devices and is a further breakthrough in tension control in unwinding structures. When the lace raw material is stretched to the uncoiling slender rod 12 from the uncoiling shaft 13, the tension control structure 14 is triggered at the same time, the uncoiling slender rod 12 rotates ceaselessly, so that the movable iron rod 146 rotates, the movable iron rod drives the rolling disc 145 to move, the rolling disc 145 drives the gear 144 to move, the gear can touch the iron rod 143 in the rotating process, the tail end of the iron rod 143 is connected with the front end of the spring 142, and the tail end of the spring 142 is tightly hooked on the movable iron sheet 141. This structure has been opened a book the subassembly and has controlled certain tension, has alleviated the degree of difficulty of whole device motion control, and 3 end connection activity iron sheet 1 of iron rod are connected to 2 front ends of spring, and spring 2 plays the effect of a buffering.

As shown in FIG. 7, the lace material from the spindle 11 is extended onto the inspection table 24, an aluminum frame 21 parallel to the inspection table 24 is mounted at a distance of 80 cm from the beginning of the inspection table 24, two high-speed industrial cameras 22 are arranged on the aluminum frame 21 at equal distances, and the aluminum frame 21 is divided into three parts, on which an illumination light source 23 is mounted for detecting the lace defect on the inspection table 24. The two high-speed industrial cameras 22 can detect defects in the range of 80 × 60 (cm) and the size of the object stage 4120 × 50(cm), and the light source is a common fluorescent lamp. The defect detection assembly is different from the traditional textile defect detection device in that a plane detection table is changed into an angle detection table, and the number of high-speed industrial cameras is increased from one to two. The oblique detection platform decomposes the gravity of raw materials perpendicular to the ground, the speed is more constant than that of a planar detection platform, and a large-size lace can be detected by adding one camera.

It is the same with uncoiling subassembly and defect detecting component of rolling subassembly 3, supports iron stand 34 including the rolling, rolling support iron stand 34 is fixed with rolling axle 31, rolling servo motor 32, rolling servo motor driver 33, rolling servo motor 32 is fixed in rolling servo motor driver 33 top, be connected with rolling belt 35 between rolling axle 31, the rolling servo motor 32, install at rolling support iron stand 34 and detection platform corner and detect the lace cloth and roll up tension sensor.

As shown in fig. 8, the device for detecting a lace defect, after detecting a lace defect, stretches from the detecting table 24 to the winding shaft 31, the winding assembly obtains an error value between a given speed and an actual speed, outputs the error value to the winding servo motor driver 33, outputs the calculated error value to the winding servo motor driver 33 through modifying pulses, outputs the calculated error value to the winding servo motor 32, and the winding servo motor 32 drives the winding shaft 31 through the winding belt 35, and these devices are all mounted on the winding support iron frame 34. The tension sensor is additionally arranged to detect the tension of the current lace cloth roll, and the tension is constant through the PID controller.

As shown in fig. 9, the method for using the device for detecting bud thread lace defect based on machine vision comprises the following steps,

the first step is that the defect detection assembly is ready, a lace raw material roll is placed into the unwinding shaft 13, after the operation is finished, the unwinding assembly controls the unwinding servo motor driver 16 to output a pulse signal to the unwinding servo motor 15 through the P L C controller, the pulse signal is transmitted to the unwinding shaft 13 through the unwinding belt to operate, when the defect detection detects that the raw material roll needs to be placed, the unwinding servo motor is halted, the auxiliary relay M506 is arranged at 1, and the auxiliary relay M is used for configuration reminding operators.

The second step is that: the bud thread lace material roll reaches the tension control structure 14 at a speed significantly different from the unwinding roll;

thirdly, the uncoiling component controls the main servo motor driver 18 to receive pulse signals through a P L C controller and output the pulse signals to the main shaft servo motor 17, and the lace raw material coil passes through the main shaft 11 and then reaches the detection platform 24;

after the collection is finished, another lace with the same color is detected again and is matched with a lace template which is just collected at the same time, after a corresponding algorithm program is compiled in MAT L AB software, whether a defect exists is judged, if yes, the fifth step is carried out, otherwise, the device is automatically stopped;

the automatic shutdown working principle is that the P L C is driven to output an instruction, 1 is output to the TXT document, the configuration king reads the value of the TXT document in real time and gives the value to the auxiliary register M504, and when the TXT document is changed from 0 to 1, the register M504 is also changed from power-off to power-on, namely the auxiliary register is powered off in general.

Fifthly, before the bud thread lace raw material roll reaches the winding shaft 31, the winding system controls the winding servo motor driver 33 to output a pulse signal to the winding servo motor 32 through P L C to start winding;

and a sixth step: and finishing the operation after the rolling is finished.

1. Different from textile defect detection, the defect detection device of the lace realizes the cooperative operation of the tension ring and the speed ring to enable the motion control to be more accurate.

2. In the process of matching the two images, firstly, the images are preprocessed, then, the feature points of the two images are extracted, and finally, matching is carried out according to the feature points.

3. The device completes the data cooperation realization of motion control and bud thread lace image matching.

The embodiments described above are only a part of the embodiments of the present invention, and not all of them. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.