阅读说明：本技术 一种经纱绕罗拉断纱检测方法 (Warp yarn winding roller broken yarn detection method ) 是由 谈源 史伟林 刘勇俊 许晴 谢鑫 于 2020-12-17 设计创作，主要内容包括：本发明涉及视觉检测技术领域,尤其涉及一种经纱绕罗拉断纱检测方法,先通过工业相机采集无纱状态下的罗拉装置图像数据,并对其进行特征提取作为标准值；当罗拉装置缠绕经纱并开始运转后,通过工业相机实时采集经纱绕罗拉工作状态下的图像数据,并对实时采集到的图像数据进行预处理并生成新的灰度值数据与标准值进行对比,进而判断经纱罗拉绕丝的实际状态。通过工业相机配合检测系统能够能够实时检测经纱罗拉是否断纱,摆脱了人工监测的局限性,适用于大批量重复性工业生产中,能够在经纱断纱的第一时间检测到并将数据输送至PLC对编织工作进行及时刹停,避免产品出现缺陷。(The invention relates to the technical field of visual detection, in particular to a method for detecting broken yarns of warps wound around a roller, which comprises the steps of firstly collecting image data of the roller device in a yarn-free state through an industrial camera and extracting the characteristics of the image data as standard values; after the roller device winds warps and starts to operate, image data of the warps in the working state of the wound rollers are collected in real time through the industrial camera, the image data collected in real time are preprocessed, new gray value data are generated and compared with a standard value, and then the actual state of the yarn winding of the warp rollers is judged. Whether broken yarn of warp roller can real-time detection through industry camera cooperation detecting system, has broken away from manual monitoring's limitation, is applicable to big repeatability industrial production in batches, can detect and carry data to PLC at the very first time of broken yarn of warp and in time brake and stop weaving work, avoids the product defect to appear.)

1. A method for detecting broken yarns of warp yarns wound on rollers is characterized by comprising the following steps:

s1: an LED light source is arranged on the roller device, an industrial camera is arranged on the support facing the detection area of the roller device, and the industrial camera is connected with the PLC;

s2: acquiring image data of a roller device in a non-yarn state by an industrial camera, extracting characteristics of the image data, and setting the image data as a standard value;

s3: acquiring image data of the warp in a working state of winding the roller in real time through an industrial camera;

s4: preprocessing image data acquired in real time and generating new gray value data;

s5: and calculating and comparing the new gray value data generated after the pretreatment with a standard value, and judging the actual state of the wrap roller wire winding.

2. The warp winding roller yarn breakage detecting method according to claim 1, characterized in that image data is acquired in a state where the roller device is free from yarn, and a gray value of each pixel corresponding to each row and each column in the image is extracted and set as a standard value;

wherein, the standard value is set as t (x, y), and t (a, b) = [ g (a, iy) + h (ix, b) ]/(ix + iy) represents an extracted value representing a pixel point gradation value at the a-th row and the b-th column in a yarn-free state.

3. The method for detecting broken yarns of warp-wound rollers as claimed in claim 2, characterized in that the new gray value data generated after preprocessing is set as f (x, y) and represents the new gray value generated by a pixel point at a certain column and a certain row;

wherein, f (a, b) = [ g (a, iy) + h (ix, b) ]/(ix + iy), which represents new gray value data generated after preprocessing the pixel points at the a-th row and the b-th column.

4. The warp winding roller yarn breakage detection method according to any one of claims 2 to 3, characterized in that g (a, iy) represents a sum of gray value data of all pixel points in the a-th row, h (ix, b) represents a sum of gray value data of all pixel points in the b-th column, and (ix + iy) is a constant value representing a sum of all pixel values included in the image data.

5. The warp-winding roller yarn breakage detecting method according to claim 4, characterized in that the new gray-value data generated after the preprocessing is compared with a standard value;

by: t (x, y) < f (x, y) × A + f (x, y) × B, and the wrap yarn state of the warp roller is judged;

when the inequality is established, the warp yarn is judged to be normal in conveying, otherwise, the warp yarn is in a filament winding state.

6. The warp winding roller yarn breakage detection method according to claim 5, characterized in that A and B are detection coefficients, wherein the value range of the detection coefficient A is 0.2-0.7, and the value range of the detection coefficient B is 0.4-1.4.

7. The method for detecting broken yarns of warp-wound rollers as claimed in claim 1, wherein in the process of collecting the image data of the warp-wound rollers in real time by the industrial camera, the industrial camera extracts one frame of image data every 2 seconds.

8. The method for detecting broken yarns of warp winding rollers according to claim 1, characterized in that the collected wire winding signals of the industrial camera are communicated with a PLC through a modbus protocol.

Technical Field

The invention relates to the technical field of visual detection, in particular to a method for detecting broken yarns of warps wound around rollers.

Background

During the manufacture of the composite material, the warp and weft yarns are moved in an interlacing motion to form the fabric. However, in the weaving process, the palm frame of the loom drives the warp yarns to move up and down in a staggered manner at a frequency of dozens of times per second, and in the process, the warp yarns are frequently broken due to the fact that the physical strength of the warp yarns is not uniform enough. If the warp yarn is broken, the weaving process is not stopped in time, the broken warp defect of the woven cloth surface can occur, the quality of the cloth surface is reduced, even the cloth surface is scrapped, and the broken warp defect in the production process becomes the main defect of the cloth surface.

In the large-batch repetitive industrial production process, the continuity and accuracy of field detection cannot be met by artificial vision, the labor cost is wasted, and the production quality cannot be effectively guaranteed.

In view of the above problems, the designer actively makes research and innovation based on the practical experience and professional knowledge that is abundant for many years in the engineering application of such products, so as to create a cable label pasting device, which is more practical.

Disclosure of Invention

The technical problem to be solved by the invention is as follows: a method for detecting broken warp around a roller is provided, which detects the broken warp at the roller device.

In order to achieve the purpose, the invention adopts the technical scheme that: a method for detecting broken yarns of warp yarns wound on rollers comprises the following steps:

s1: an LED light source is arranged on the roller device, an industrial camera is arranged on the support facing the detection area of the roller device, and the industrial camera is connected with the PLC;

s2: acquiring image data of a roller device in a non-yarn state by an industrial camera, extracting characteristics of the image data, and setting the image data as a standard value;

s3: acquiring image data of the warp in a working state of winding the roller in real time through an industrial camera;

s4: preprocessing image data acquired in real time and generating new gray value data;

s5: and calculating and comparing the new gray value data generated after the pretreatment with a standard value, and judging the actual state of the wrap roller wire winding.

Further, collecting image data under the condition that the roller device has no yarn, and extracting the gray value of each pixel corresponding to each row and each column in the image to be set as a standard value;

wherein, the standard value is set as t (x, y), and t (a, b) = [ g (a, iy) + h (ix, b) ]/(ix + iy) represents an extracted value representing a pixel point gradation value at the a-th row and the b-th column in a yarn-free state.

Further, setting the new gray value data generated after preprocessing as f (x, y) to represent the new gray value generated by a pixel point at a certain column of a certain row;

wherein, f (a, b) = [ g (a, iy) + h (ix, b) ]/(ix + iy), which represents new gray value data generated after preprocessing the pixel points at the a-th row and the b-th column.

Further, g (a, iy) represents the sum of the grayscale values of all the pixel points in the a-th row, h (ix, b) represents the sum of the grayscale values of all the pixel points in the b-th column, and (ix + iy) is a constant value and represents the sum of all the pixel values included in the image data.

Further, comparing the new gray value data generated after the preprocessing with the standard value;

by: t (x, y) < f (x, y) × A + f (x, y) × B, and the wrap yarn state of the warp roller is judged;

when the inequality is established, the warp yarn is judged to be normal in conveying, otherwise, the warp yarn is in a filament winding state.

Further, A and B are detection coefficients, wherein the value range of the detection coefficient A is 0.2-0.7, and the value range of the detection coefficient B is 0.4-1.4.

Further, in the process of acquiring image data of the warp in the operation state of winding the roller in real time through the industrial camera, the industrial camera extracts one frame of image data every 2 seconds.

Further, the collected wire winding signals of the industrial camera are communicated with a PLC through a modbus protocol.

The invention has the beneficial effects that: whether can real-time detection warp roller wire winding through industry camera cooperation detecting system, broken away from manual monitoring's limitation, be applicable to big repeatability industrial production in batches, can detect and carry data to PLC at the very first time of warp broken yarn and in time brake and stop weaving work, avoid the product defect to appear.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments described in the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.

FIG. 1 is a logic block diagram of a method for detecting broken yarns of warp winding rollers in the embodiment of the invention.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments.

It will be understood that when an element is referred to as being "secured to" another element, it can be directly on the other element or intervening elements may also be present. When an element is referred to as being "connected" to another element, it can be directly connected to the other element or intervening elements may also be present. The terms "vertical," "horizontal," "left," "right," and the like as used herein are for illustrative purposes only and do not denote a unique embodiment.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

The invention discloses a method for detecting broken yarns of warps wound on rollers, which comprises the following steps: s1: an LED light source is arranged on the roller device, an industrial camera is arranged on the support facing the detection area of the roller device, and the industrial camera is connected with the PLC; s2: acquiring image data of a roller device in a non-yarn state by an industrial camera, extracting characteristics of the image data, and setting the image data as a standard value; s3: acquiring image data of the warp in a working state of winding the roller in real time through an industrial camera; s4: preprocessing image data acquired in real time and generating new gray value data; s5: and calculating and comparing the new gray value data generated after the pretreatment with a standard value, and judging the actual state of the wrap roller wire winding.

In the specific implementation process, the industrial camera lens shoots vertically downwards, so that dust cannot fall off from the lens; meanwhile, the factors influencing detection, such as broken filaments, are all positioned below the warp yarns and cannot fall into the space between the lens and the warp yarns, so that false detection cannot be caused. Specifically, the method comprises the steps of firstly collecting image data of a roller device in a yarn-free state through an industrial camera, and extracting characteristics of the image data to be used as a standard value; after the roller device winds warps and starts to operate, image data of the warps in the working state of the wound rollers are collected in real time through the industrial camera, the image data collected in real time are preprocessed, new gray value data are generated and compared with a standard value, and then the actual state of the yarn winding of the warp rollers is judged.

As a preferred embodiment of the above operation steps, image data is collected in a state that the roller device has no yarn, and the gray value of each pixel corresponding to each row and each column in the image is extracted and set as a standard value; wherein the standard value is set to t (x, y), wherein:

t(a,b)=[g(a,iy)+h(ix,b)]/(ix+iy)，

and the extracted values of the gray values of the pixels at the a-th row and the b-th column in the non-yarn state are shown.

Setting the new gray value data generated after preprocessing as f (x, y) to represent the new gray value generated by a pixel point at a certain column of a certain row; wherein:

f(a,b)=[g(a,iy)+h(ix,b)]/(ix+iy)，

and new gray value data generated after preprocessing pixel points at the a-th row and the b-th column are represented.

Wherein g (a, iy) represents the gray-value data sum of all the pixel points in the a-th row, h (ix, b) represents the gray-value data sum of all the pixel points in the b-th column, and (ix + iy) is a constant value representing the sum of all the pixel values included in the image data, and is usually a constant value.

As a preferred embodiment of the above operation steps, comparing the new gray-scale value data generated after the preprocessing with the standard value; by:

t(x,y)＜f(x,y)*A+ f(x,y)*B，

judging the winding state of the warp roller; when the inequality is established, the warp yarn is judged to be normal in conveying, otherwise, the warp yarn is in a filament winding state. Specifically, A and B are detection coefficients, wherein the value range of the detection coefficient A is 0.2-0.7, and the value range of the detection coefficient B is 0.4-1.4. The detection coefficients A and B are detection coefficient application ranges summarized by multiple tests.

As a preferred embodiment of the above operation steps, in the process of acquiring the image data of the warp yarn in the operation state around the roller in real time by the industrial camera, the industrial camera extracts one frame of image data every 2 seconds. And the wire winding signals collected by the industrial camera are communicated with the PLC through a modbus protocol. Whether can real-time detection warp roller wire winding through industry camera cooperation detecting system, broken away from manual monitoring's limitation, be applicable to big repeatability industrial production in batches, can detect and carry data to PLC at the very first time of warp broken yarn and in time brake and stop weaving work, avoid the product defect to appear.

It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are described in the specification and illustrated only to illustrate the principle of the present invention, but that various changes and modifications may be made therein without departing from the spirit and scope of the present invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.