Full-automatic spinneret plate microscopic examination system and method

Abstract

The system comprises detection equipment, the equipment is provided with a rack table top, a to-be-detected area is arranged on the rack table top, one side of the to-be-detected area is provided with a rotating mechanism, a mechanical arm, a blowing and sucking device and a line scanning camera array, the mechanical arm, the blowing and sucking device and the line scanning camera array are arranged on the periphery of the rotating mechanism, and a material carrying disc is placed in the to-be-detected area. The rotating mechanism is provided with a plurality of hollowed-out areas used for containing spinneret plates, and the hollowed-out areas correspondingly serve as a feeding station, a discharging station, a blowing and sucking cleaning station and a photographing detection station after the rotating mechanism rotates at a constant speed; the blowing and sucking device cleans micropores of the spinneret plate, the line scanning camera array collects images of the spinneret plate and detects the states of the micropores of the spinneret plate on the basis of a machine vision and machine learning method, and the mechanical arm grabs the spinneret plate to be detected to the feeding station and takes down the spinneret plate passing the detection from the discharging station and places the spinneret plate back to the original position of the material carrying disc. The automatic level of spinneret plate detection is effectively improved, human intervention is reduced, the detection efficiency is improved, and the detection cost is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of spinneret detection in the chemical fiber industry, and in particular to a full-automatic spinneret microscopic inspection system and method. Background Art

[0002] The spinneret is an indispensable precision part in the spinning machine of the chemical fiber industry. In the production process of polyester filament high-speed spinning, mechanical impurities, gel, carbonization, thermal cracking and other particles in the melt often clog the micropores of the spinneret, resulting in uneven fineness of the spun silk, producing products such as "stigma silk", "fine silk" and "hairy silk". Therefore, the spinneret needs to be cleaned and inspected regularly.

[0003] At present, in the actual production process, non-contact semi-automatic microscopic inspection equipment is usually used to inspect spinnerets, such as the SpinTrak spinneret inspection system developed by ASPEX in the United States and the spinneret inspection instrument of ZENTES in Germany. This type of equipment locates and photographs the manually placed spinnerets hole by hole, and uses image processing methods to determine whether each micropore on the spinneret has dirt, wall burrs, and blockage, and marks the problematic micropores for manual processing. This type of microscopic inspection equipment has greatly improved the problems of slow speed, inconsistent standards, missed inspections, and other human factors in manual visual inspection methods, and has greatly improved the efficiency of spinneret inspection and the robustness of the results.

[0004] However, in the actual production process, it was found that the current spinneret microscopic inspection equipment has problems such as low automation and low detection efficiency: (1) The automation level is low, and manual loading and unloading is required, that is, the spinneret to be inspected needs to be placed manually before inspection, and the spinneret needs to be manually taken out, packaged, marked, registered and stored after inspection, or secondary processing and re-inspection; this seriously affects the inspection speed and increases the inspection cost. (2) The microscopic inspection equipment locates, photographs, and inspects the spinneret hole by hole, and the inspection speed is slow and the efficiency is low. (3) The microscopic inspection equipment can only inspect circular holes, but not special-shaped holes, and has certain limitations in use. Summary of the invention

[0005] In order to solve the above technical problems existing in the prior art, the present invention proposes a fully automatic spinneret microscopic inspection system and method, and its specific technical scheme is as follows: A fully automatic spinneret microscopic inspection system comprises an inspection device, wherein the inspection device comprises: a frame table, an inspection area is arranged on the frame table, a rotating mechanism and a manipulator, a blowing and sucking device and a line scanning camera array are installed on one side of the inspection area, the inspection area is used to place a loading tray, a plurality of hollow areas for placing spinnerets are arranged on the rotating mechanism, and the hollow areas correspond to a loading station and an unloading station of the manipulator, a blowing and sucking cleaning station of the blowing and sucking device, and a photo detection station of the line scanning camera array after the rotating mechanism rotates at a uniform speed; the blowing and sucking device is used to clean the spinneret micropores located at the blowing and sucking cleaning station, the line scanning camera array is used to collect the spinneret image located at the photo detection station and detect the state of each micropore of the spinneret based on machine vision and machine learning methods, and the manipulator is used to grab the spinneret to be inspected to the loading station and remove the spinneret that has passed the inspection from the unloading station and put it back to the original position of the loading tray.

[0006] Preferably, the rotating mechanism comprises a high-precision servo motor and a turntable 4 which controls the motor to rotate at a uniform speed. The turntable 4 is provided with the hollow area, which is arranged around the circumference of the turntable.

[0007] Preferably, the robot 3 adopts an XYZ three-axis control platform.

[0008] Preferably, the detection device further comprises an infrared backlight source, which is arranged in cooperation with the line scan camera array 7 .

[0009] Preferably, the line scan camera array 7 is composed of a plurality of line scan high-resolution industrial cameras connected in parallel, using a wide-angle telecentric lens.

[0010] Preferably, the detection equipment also includes a display for outputting the qualified rate of micropore status of different types of spinnerets, different batches of spinnerets and different positions of spinnerets, and evaluating the quality of spinnerets and the content of micropore blockage and production process.

[0011] Preferably, it also includes automatic loading equipment and discharge packaging equipment. The automatic loading equipment identifies the model and number of each spinneret, adjusts its posture based on the snap-on on the back of the spinneret, and places it on the spinneret loading tray 2 in a specified direction. At the same time, the information of each spinneret model to be inspected on the loading tray 2 is registered. The spinnerets are pushed to the inspection area of ​​the inspection equipment in units of loading trays 2 to queue for inspection. The discharge packaging equipment discharges, bags, seals, marks and puts qualified spinnerets on the loading tray 2 into storage.

[0012] A fully automatic spinneret microscopic inspection method, comprising: Step 1, the automatic feeding equipment identifies the model and number of each spinneret, adjusts the posture based on the card slot on the back of the spinneret, and places it on the spinneret loading tray in the specified direction; at the same time, the information of each spinneret model to be inspected on the loading tray is registered; the spinnerets are pushed to the inspection area of ​​the inspection equipment in units of loading trays; Step 2, the robot grabs the spinnerets on the loading tray in turn and places them on the loading station; Step 3, the rotating disk of the rotating mechanism rotates at a constant speed, and the feeding station is switched to the blowing and suction cleaning station after rotation, and the blowing and suction device at the corresponding position of the changed station performs high-pressure gas blowing and suction cleaning on the spinneret; Step 4: The rotating disk of the rotating mechanism continues to rotate at a constant speed, and the blowing and suction cleaning station is switched to the photo detection station. The line scan camera array collects the spinneret image and detects the state of each micropore of the spinneret based on machine vision and machine learning methods; Step 5, when the spinneret is inspected, the rotating mechanism turntable rotates, the photo inspection station is switched to the unloading station, the manipulator grabs the spinneret on the unloading station and puts it back to the original position of the loading tray, and then proceeds to step 2 to continue the inspection until all the spinnerets on the loading tray are inspected, and then proceeds to step 7 for unloading and packaging; If the spinneret test fails, go to step 6; Step 6, the rotating mechanism turntable rotates to switch the photo inspection station to the blowing and suction cleaning station, that is, the spinneret is turned back to the blowing and suction device, and steps 3 and 4 are continued. If the spinneret still fails the inspection, go to step 8; Step 7, transfer the tested material tray to the discharging and packaging equipment, and discharge, bag, seal and mark the qualified spinneret on the material tray; Step 8: The spinnerets that fail the test are discharged to the manual processing area for manual processing.

[0013] The system of the present invention is used to detect whether there are dirt, wall burrs, and blockages in the micropores of various chemical fiber spinnerets, effectively improving the automation level of spinneret detection, reducing human intervention, improving detection efficiency, and reducing detection costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 Schematic diagram of the structure of a detection device of a fully automatic spinneret microscopic inspection system of the present embodiment; In the figure, 1-frame table, 2-loading tray, 3-manipulator, 4-turntable, 41-loading station, 42-blowing and suction cleaning station, 43-photographing and inspection station, 44-unloading station, 5-blowing and suction device, 6-display, 7-line scan camera array. DETAILED DESCRIPTION

[0015] In order to make the purpose, technical scheme and technical effect of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0016] A fully automatic spinneret microscopic inspection system of the present embodiment mainly includes a detection device, on the side of which an automatic loading device and a discharging packaging device are installed, and the devices can be coordinated and controlled through a software program.

[0017] Specifically, the spinneret after cleaning and drying is placed in the loading area of ​​the automatic loading equipment. The automatic loading equipment can also be cascaded with the cleaning and drying equipment to realize automatic transfer of spinnerets between processes. The automatic loading equipment identifies the model and number of each spinneret, and adjusts its posture based on the snap-on on the back of the spinneret, and places it on the spinneret loading tray 2 in the specified direction; at the same time, the information of each spinneret model to be inspected on the loading tray 2 is registered for use in subsequent microscopic inspection, unloading and packaging processes; the spinnerets are pushed to the inspection area of ​​the inspection equipment in units of loading trays 2 to queue for inspection.

[0018] like Figure 1 As shown, the working process of the detection equipment in this embodiment is spinneret loading, micropore blowing and suction cleaning, image analysis, and unloading, so its hardware part includes: a frame table 1, a rotating mechanism is installed on the frame table 1, and a manipulator 3, a blowing and suction device 5, and a line scanning camera array 6 are arranged in sequence around the rotating mechanism. The rotating mechanism includes a high-precision servo motor and a turntable 4 that controls the uniform rotation. A number of hollow areas for placing spinnerets are opened on the turntable 4. Each hollow area is used as a loading station 41, a blowing and suction cleaning station 42, a photo detection station 43, and a unloading station 44 according to its position after rotation. The manipulator 3 is an XYZ three-axis control platform, using 3 sets of servo motors and 3 ball screws.

[0019] The robot 3 grabs the spinnerets on the loading tray 2 in turn and places them on the loading station 41. Under the control of the servo motor, the rotating mechanism controls each spinneret to pass through the blowing and suction cleaning station 42 and the photo detection station 43 at a uniform speed in turn to realize a round of inspection of the spinneret; if the spinneret is qualified in the microscopic inspection, the robot 3 discharges the spinneret to the loading tray 2 at the unloading station 44, and completes the loading of the new spinneret to be inspected at the same time; if the spinneret is unqualified in the microscopic inspection, the spinneret is not unloaded, and the spinneret is directly rotated back to the blowing and suction cleaning station 42, and the subsequent work such as inspection is completed in turn after re-blowing. If it passes, the robot 3 unloads it back to the loading tray 2 and places it in the placement position when loading; after all the spinnerets on the loading tray 2 are inspected, the loading tray 2 is transferred to the unloading packaging equipment, and the unloading packaging equipment discharges, bags, seals, marks and stores the qualified spinnerets on the loading tray 2.

[0020] The number of re-inspections is set, and if the re-inspection fails after the number of re-inspections is reached, the material is discharged to the manual processing area for manual processing. The number of high-pressure gas blowing and suction of the blowing and suction device 5 is set, and after the number of re-inspections is reached, the turntable 4 rotates to rotate the spinneret to the photo inspection station 43.

[0021] The photo detection station 43 is also provided with an infrared backlight source that cooperates with the line scan camera array 7 to realize one-time scanning and imaging of all micropores on the spinneret, thereby improving the imaging and detection efficiency. The line scan camera array 7 is composed of multiple line scan high-resolution industrial cameras in parallel, and adopts a wide-angle telecentric lens, which has the advantages of small distortion and high detection accuracy. The line scan camera array 7 is based on the encoder to associate the camera sampling frequency with the rotation speed of the rotating mechanism, and the average detection speed is less than 50 seconds / plate, and the specific detection speed is related to the number of spinning holes on the plate. The line scan camera array 7 collects the spinneret image, and realizes the state detection of each micropore of the spinneret based on machine vision and machine learning methods. The detection items include micropore dirt, wall burrs, blockage conditions and special shaped hole sizes, etc. The detection accuracy reaches ±0.01mm, the false detection rate is 1%, and the missed detection rate is 1‰. By controlling the brightness of the infrared backlight source, different types of spinnerets can be detected, and the range of detectable micropores is: 0.01mm-5mm.

[0022] The software part of the detection device in this embodiment includes control software, detection software and statistical analysis software. The control software is responsible for the coordinated control of electrical equipment, motion equipment and sensors, realizing operations such as loading and unloading, spinneret displacement, micropore blowing and suction, and cooperates with the detection software to realize spinneret imaging and detection.

[0023] The detection software realizes functions such as spinneret image acquisition, micropore segmentation, edge detection, shape analysis, etc., and completes the task of detecting the micropore status of circular holes or irregular holes.

[0024] The statistical analysis software analyzes and visually outputs the qualified rates of micropores of different types of spinnerets, different batches of spinnerets and different positions of spinnerets based on the recorded detection results of each micropore on the spinneret through the display 6, evaluates the spinneret quality and the correlation between micropore blockage and production process, etc.

[0025] At present, the research and development budget of fully automatic microscopic inspection of a single spinneret is controlled within 1.5 million. The investment recovery period is related to the number of shared workshops. The more shared workshops there are, the better the effect of reducing manpower and the shorter the investment recovery period. If there are 2 to 4 shared workshops, the investment recovery period is about 2 to 6 years. In workshops that are not equipped with a single-machine microscopic inspection instrument, 6 microscopic inspectors are usually assigned, and they only work the day shift; in workshops equipped with a single-machine microscopic inspection instrument, 3 microscopic inspectors are assigned, and 300 to 400 spinnerets can be inspected every day. Spinnerets of different specifications are manually placed in molds of corresponding specifications, and then placed on the automatic microscopic inspection instrument for inspection. The beat of the automatic microscopic inspection instrument is 22 to 30 minutes per 16 plates, and special-shaped holes still need to be manually inspected. After using the fully automatic spinneret microscopic inspection system of the present invention, only one person is retained in each workshop, and the detection beat is ≤14 minutes per 16 plates, and both circular holes and special-shaped holes can be detected, which is more practical and has a wider range of applications.

[0026] In summary, the fully automatic spinneret microscopy system of this embodiment has the following effects: (1) Improve product quality and reduce the production of inferior products. The system can detect and record each hole one by one without omission. The detected spinning holes are judged in a digital way to ensure the correctness of the detection results, so as to achieve the best spinning quality and reduce the production of inferior products and unnecessary losses.

[0027] (2) Improve efficiency and save labor costs. The system automatically completes the entire process of spinneret feeding, microscopic inspection, discharging, packaging, and marking, greatly improving the efficiency of spinneret inspection. For unqualified holes, compressed air is used to automatically clean the dirt; only the spinning holes that cannot be cleaned by compressed air require manual follow-up processing.

[0028] (3) Understand the age and quality of the old spinneret. Since each spinneret has a test history, it is easy to understand the time the spinneret was online and the number of times it was used, and then evaluate the life of the spinneret.

[0029] (4) Evaluate the defect rate of cleaning equipment. Understand the cleaning status of the spinneret, and then improve the scheduling of the front-end cleaning equipment to increase the cleanliness of the spinneret.

[0030] (5) Real-time evaluation and improvement of abnormalities in the spinning process. If the dirty holes of the spinneret are found to be concentrated in a certain area, it may be a temperature problem or other problem in a certain process during the spinning process, and the process can be improved accordingly.

[0031] The above description is only a preferred implementation case of the present invention and does not limit the present invention in any form. Although the implementation process of the present invention is described in detail above, for those familiar with the art, they can still modify the technical solutions recorded in the above examples, or replace some of the technical features therein with equivalents. All modifications, equivalent replacements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A fully automatic spinneret microscopic inspection system, comprising a detection device, characterized in that: The inspection device comprises: a frame table (1), an inspection area is arranged on the frame table (1), a rotating mechanism and a manipulator (3), a blowing and suction device (5) and a line scanning camera array (6) are installed on one side of the inspection area, a loading tray (2) is placed in the inspection area, and a plurality of hollow areas for placing spinnerets are arranged on the rotating mechanism, and the hollow areas correspond to the loading station (41) and unloading station (44) of the manipulator (3) and the blowing and suction cleaning of the blowing and suction device (5) after the rotating mechanism rotates at a uniform speed. The invention relates to a spinneret detection station (42) and a line scan camera array (6) for taking a picture and inspecting the spinneret. The blowing and suction device (5) is used to clean the spinneret micropores at the blowing and suction cleaning station (42). The line scan camera array (6) is used to collect an image of the spinneret at the picture and inspecting station (43) and detect the state of each micropore of the spinneret based on machine vision and machine learning methods. The manipulator (3) is used to grab the spinneret to be inspected to the loading station (41) and remove the spinneret that has passed the inspection from the unloading station (44) and put it back to the original position of the loading tray (2).

2. A fully automatic spinneret microscopic inspection system as claimed in claim 1, characterized in that: The rotating mechanism comprises a high-precision servo motor and a rotating disk (4) which controls the motor to rotate at a constant speed. The rotating disk (4) is provided with the hollowed-out area, which is arranged around the circumference of the rotating disk.

3. A fully automatic spinneret microscopic inspection system as claimed in claim 1, characterized in that: The manipulator (3) adopts an XYZ three-axis control platform.

4. A fully automatic spinneret microscopic inspection system as claimed in claim 1, characterized in that: The detection device also includes an infrared backlight source, which is arranged in cooperation with the line scan camera array (7).

5. A fully automatic spinneret microscopic inspection system as claimed in claim 1, characterized in that: The line scan camera array (7) is composed of a plurality of line scan high-resolution industrial cameras connected in parallel, and uses a wide-angle telecentric lens.

6. A fully automatic spinneret microscopic inspection system as claimed in claim 1, characterized in that: The detection equipment also includes a display for outputting the qualified rates of micropore states of different types of spinnerets, different batches of spinnerets and different positions of spinnerets, and evaluating the quality of spinnerets and the content of micropore blockage and production process.

7. A fully automatic spinneret microscopic inspection system as claimed in claim 1, characterized in that: It also includes automatic loading equipment and material discharging and packaging equipment. The automatic loading equipment identifies the model and number of each spinneret, adjusts the posture based on the latch on the back of the spinneret, and places it on the spinneret loading tray (2) in a specified direction; at the same time, registers the information of the model of each spinneret to be inspected on the loading tray (2); the spinnerets are pushed to the inspection area of ​​the inspection equipment in units of the loading tray (2) to queue for inspection; the material discharging and packaging equipment discharges, bags, seals, marks and stores the qualified spinnerets on the loading tray (2).

8. A spinneret microscopic inspection method using the fully automatic spinneret microscopic inspection system according to any one of claims 1 to 7, characterized in that: include: Step 1, the automatic feeding device identifies the model and number of each spinneret, and adjusts the posture based on the bracket on the back of the spinneret, and places it on the spinneret loading tray (2) in a specified direction; at the same time, the information of each spinneret model to be inspected on the loading tray (2) is registered; the spinnerets are pushed to the inspection area of ​​the inspection device in units of the loading tray (2) to queue; Step 2, the robot (3) sequentially grabs the spinnerets on the loading tray (2) and places them on the loading station (41); Step 3, the rotating mechanism turntable (4) rotates at a constant speed, and the feeding station (41) is switched to the blowing and suction cleaning station (42) after rotation, and the blowing and suction device (5) at the corresponding station performs high-pressure gas blowing and suction cleaning on the spinneret; Step 4, the rotating mechanism turntable (4) continues to rotate at a constant speed, the blowing and suction cleaning station (42) is switched to the photo detection station (43), the line scan camera array (6) collects the spinneret image and detects the state of each micropore of the spinneret based on machine vision and machine learning methods; Step 5, when the spinneret has passed the inspection, the rotating mechanism turntable (4) rotates, the photo inspection station (43) switches to the unloading station (44), the robot (3) grabs the spinneret on the unloading station (44) and puts it back to the original position of the loading tray (2), then proceeds to step 2 to continue the inspection until all the spinnerets on the loading tray (2) have been inspected, and then proceeds to step 7 for unloading and packaging; If the spinneret test fails, go to step 6; Step 6, the rotating mechanism turntable (4) rotates to switch the photographing inspection station (43) to the blowing and suction cleaning station (42), that is, the spinneret is turned back to the blowing and suction device (5), and steps 3 and 4 are continued. If the spinneret still fails the inspection, then go to step 8; Step 7, transferring the tested material carrier (2) to a discharging and packaging device, discharging, bagging, sealing and marking the qualified spinneret on the material carrier (2); Step 8: The spinnerets that fail the test are discharged to the manual processing area for manual processing.

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