Foreign fiber sorting system with quality tracing function and method thereof

Abstract

The invention provides a foreign fiber sorting system and method with a quality tracing function, and the system comprises a first data collection device which is used for collecting the initial information of a cotton raw material; the second data acquisition device is mounted on the foreign fiber machine and is used for recording foreign fiber cleaning data of the cotton raw materials at the corresponding front end; the third data acquisition device is used for acquiring first foreign fiber residual data on the lap on the lap machine; the fourth data acquisition device is used for acquiring second foreign fiber residual data of the electronic yarn clearer on the winding machine; and the fifth data acquisition device is used for acquiring third foreign fiber residue data in the cloth on the cloth inspecting machine. According to the foreign fiber sorting system with the quality tracing function and the method thereof, the work and parameters of the system can be adjusted according to the foreign fiber content (missing foreign fibers in the past) of the rear-end process, and the raw material quality is evaluated by combining the raw material information of the front-end process (cotton formula and batch), so that the optimal raw material and proportion can be given; and the foreign fiber removal rate and the quality control of the whole spinning mill are improved.

Description

Technical Field

[0001] The present invention relates to the field of quality tracing, and in particular to a foreign fiber sorting system and method with a quality tracing function. Background Art

[0002] The detection and control of foreign fibers, commonly known as "three fibers," in spinning mills mainly involves connecting a foreign fiber sorting machine in series behind the cotton blower to remove foreign fibers from the cotton online, as shown in patents CN101246128A and CN102011197A. This type of equipment processes and ejects information based on the image or spectrum of the cotton fibers flowing through it, but it is not linked to the foreign fiber ratio in the raw materials at the front end and the yarn quality at the end.

[0003] The foreign fiber content of the raw material (raw cotton) is marked on the cotton bales by the cotton supplier, but there is no specific classification and content analysis of foreign fibers. The foreign fiber content in the yarn produced by the final winding machine affects the yarn quality and selling price. However, the foreign fiber content in the yarn is fed back to the spinning mill through the foreign fiber removal status of the electronic yarn clearer or the defects on the cloth surface of the yarn woven into the cloth, and the cycle is from one week to one month. If the foreign fiber content of the cloth mill exceeds the standard, the spinning mill will file a quality claim. The spinning mill will conduct manual random inspections on the suppliers or raw materials of the raw cotton blend, or find the foreign fiber inspection status of the foreign fiber inspection equipment at that time, trace the raw cotton supplier, or adjust the foreign fiber inspection equipment. The entire project involves manual labor, including tracking raw materials, numerous foreign fiber inspections, winding machines, and production process technology, which is very inefficient. Summary of the Invention

[0004] The present invention provides a foreign fiber sorting system and method with quality tracing function, which solves the problem of achieving quality tracing by measuring the foreign fiber content in the front-end and back-end processes. The technical solution is as follows:

[0005] A foreign fiber sorting system with quality traceability function, comprising:

[0006] A first data collection device is used to collect initial information of cotton raw materials, wherein the initial information includes cotton variety, origin, batch, foreign fiber content, and cotton ratio;

[0007] A second data acquisition device is installed on the foreign fiber machine and is used to record foreign fiber cleaning data of the cotton raw material at the corresponding front end, wherein the foreign fiber cleaning data includes foreign fiber type, foreign fiber quantity and foreign fiber distribution data;

[0008] a third data collection device for collecting first foreign fiber residue data on the cotton lap on the lap forming machine, wherein the first foreign fiber residue data includes foreign fiber classification and content distribution information;

[0009] a fourth data collection device for collecting second foreign fiber residual data from the electronic yarn clearer on the winding machine, wherein the second foreign fiber residual data includes foreign fiber classification, content, and defect distribution information per million meters;

[0010] The fifth data collection device is used to collect the third foreign fiber residual data in the cloth on the cloth inspection machine, and the third foreign fiber residual data includes foreign fiber classification, content, and defect distribution information.

[0011] Furthermore, there is a first process route between the first data acquisition device and the second data acquisition device. The first process route includes a cotton picker, an axial flow opener, a cotton mixer, and a cotton cleaning machine that process the cotton raw materials in sequence. The foreign fiber machine obtains the production flow information of the cotton raw materials and stores and matches them with batches.

[0012] Furthermore, the foreign fiber machine is provided with a cotton inlet, a cotton outlet, an imaging module, a lighting module, a high-speed ejection and collection module, a waste cotton outlet and a processing display module. The cotton raw material after the cotton cleaning process enters from the cotton inlet, and in the sorting channel provided with the lighting module, the camera of the imaging module takes pictures, the high-speed ejection and collection module ejects the foreign fibers, and discharges the collected foreign fibers through the waste cotton outlet. The cotton without foreign fibers enters the next process through the cotton outlet, and the processing information of the cotton raw material is recorded by the second data acquisition device.

[0013] Furthermore, many spinning mills or foreign fiber machine clusters are connected to cloud or local servers. The servers have the functions of data aggregation and storage, optimization and distribution of algorithm parameters, self-learning and deployment of algorithm models, as well as recording, aggregation and sharing of factory-related production process parameters.

[0014] Furthermore, the foreign fiber machine obtains the initial information of the cotton raw materials at the front end through the firewall, obtains the foreign fiber information of the rolls, the foreign fiber information of the yarn, and the foreign fiber information of the cloth at the back end through the intra-field communication, and combines the foreign fiber classification information detected by the foreign fiber machine to adjust the image processing algorithm or parameters and the classification of the network model to optimize the missed detection.

[0015] Furthermore, the foreign fiber machine is connected to the server via a wide area network. The server performs algorithm optimization calculations and network model training based on the foreign fiber information, working information and defect images fed back by the foreign fiber machine, and deploys them on the foreign fiber machine.

[0016] Furthermore, if users are not allowed to access the cloud or local server, they can form a local area network through the foreign fiber machine cluster to share raw material information, foreign fiber machine sorting information, and back-end foreign fiber information, forming big data of raw material and foreign fiber information. The foreign fiber machine cluster distributes data, adjusts the sensitivity of the corresponding image feature algorithm and sends it down, and trains and deploys the adaptive sorting network model to the foreign fiber machine processing unit according to the specific situation of the foreign fiber machine.

[0017] Furthermore, the foreign fiber machine, foreign fiber machine cluster or server, within the corresponding range, evaluates the batch foreign fiber content and cotton blending of the front-end cotton raw materials, the back-end roll foreign fiber information, the back-end yarn foreign fiber information, and the back-end cloth foreign fiber information, in combination with the first process route and the second process route, and outputs statistical reports. The data storage and calculation are stored in the foreign fiber machine or server in file or database format, and the user is provided with plans and suggestions for the optimal cotton blending and the optimal process route for the corresponding yarn variety.

[0018] The foreign fiber sorting system and method with quality traceability function can adjust its own operation and parameters according to the foreign fiber content (missed foreign fibers) of the back-end process, and evaluate the quality of the raw materials in combination with the raw material information of the front-end process (cotton formula and batch), so as to provide the optimal raw materials and ratios, thereby improving the foreign fiber removal rate and quality control of the entire spinning mill. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic structural diagram of the foreign fiber sorting system with quality traceability function;

[0020] Figure 2 It is a workflow diagram of the foreign fiber sorting method with quality traceability function. DETAILED DESCRIPTION

[0021] like Figure 1 As shown, the foreign fiber sorting system with quality traceability function includes:

[0022] A first data collection device is used to collect initial information of the cotton raw material 104, wherein the initial information includes cotton variety, origin, batch, foreign fiber content, cotton ratio, etc.;

[0023] A second data acquisition device is installed on the foreign fiber machine 102, and is used to record the foreign fiber cleaning data of the front-end cotton raw material 104; the foreign fiber cleaning data includes the type of foreign fibers, the number of foreign fibers and the foreign fiber distribution data;

[0024] a third data collection device for collecting first foreign fiber residue data on the cotton lap on the lap forming machine, wherein the first foreign fiber residue data includes information such as foreign fiber classification and content distribution;

[0025] a fourth data collection device for collecting second foreign fiber residual data from the electronic yarn clearer on the winding machine, wherein the second foreign fiber residual data includes information such as foreign fiber classification, content, and defect distribution per million meters;

[0026] The fifth data collection device is used to collect the third foreign fiber residual data in the cloth on the cloth inspection machine, and the third foreign fiber residual data includes information such as foreign fiber classification, content, and defect distribution.

[0027] The spinning mill purchases cotton raw materials 104, and the user uses a first data acquisition device, which uses a data terminal 107 such as a computer, mobile phone, or pad to enter initial information containing the cotton raw materials 104. The initial information includes cotton variety, origin, batch, foreign fiber content, cotton ratio, etc. The initial information of the cotton raw materials 104 is recorded in a file or database of the foreign fiber machine 102.

[0028] Cotton raw material 104 passes through a first process route 105, which includes a plucker, axial-flow opener, blender, and blower, before entering a foreign matter detector 102. These devices involved in first process route 105 are interconnected with the foreign matter detector 102 on the same production line via a communication protocol or a control console. This allows the foreign matter detector 102 to obtain and record production flow information about the cotton raw material 104.

[0029] The foreign fiber detector 102 records the acquired initial information of the cotton raw material 104 and the production flow information of the cotton raw material 104 through the first process route 105 and performs data recording and batch matching.

[0030] The second data acquisition device is mounted on a foreign fiber machine 102, which is equipped with a cotton inlet 1, a cotton outlet 2, an imaging module 3, a lighting module 4, a high-speed ejection and collection module 5, a waste cotton outlet 6, and a processing and display module 7. The foreign fiber machine 102 captures and images the high-speed cotton flow with a camera. After processing by the processing and display module 7, the high-speed ejection and collection module 5 ejects and collects the foreign fibers. The working process of the foreign fiber machine 102 is briefly described as follows: cotton raw material 104, which has been cleaned and opened by the cotton cleaning machine, enters the cotton inlet 1. In the sorting channel equipped with the lighting module 4, it is photographed by the camera of the imaging module 3. The high-speed ejection and collection module 5 ejects the foreign fibers, and the collected foreign fibers are discharged through the waste cotton outlet 6. Cotton free of foreign fibers passes through the cotton outlet 2 to the next process. The second data acquisition device records the processing information of the cotton raw material.

[0031] A spinning mill has at least one foreign fiber sorting machine, hereinafter referred to as a foreign fiber detector 102. Numerous spinning mills or foreign fiber detector clusters 101 are connected to a server 109. Server 109 performs functions such as data aggregation and storage, algorithm parameter optimization and distribution, algorithm model self-learning and deployment, and recording, aggregation, and sharing of factory-related production process parameters. The foreign fiber detector 102, foreign fiber detector cluster 101, or server 109 can evaluate the foreign fiber content and cotton blending of the cotton raw material 104 at the front end, along with the corresponding back-end roll foreign fiber information 113, yarn foreign fiber information 114, and cloth foreign fiber information 115, in accordance with the first process route 105 and the second process route 106. The machine then generates statistical reports. The data is stored and calculated in a file or database format in the foreign fiber detector 102 or server 109, and the user is provided with solutions and recommendations for the optimal cotton blending and process route for the corresponding yarn variety.

[0032] Specifically, in a spinning mill, if there are multiple production lines equipped with foreign fiber machines 102, they can form a foreign fiber machine cluster 101. The cotton information 104 equipped for each production line is stored in the front-end raw material information. The same or different information such as batches or cotton blends corresponding to multiple foreign fiber machines for different production lines is aggregated (via a local area network). Information such as the same batch or cotton blend, or the same yarn variety, can be combined with the foreign fiber machine 102 and the back-end foreign fiber information such as the roll foreign fiber information 113, the back-end yarn foreign fiber information 114, and the back-end cloth foreign fiber information 115 to increase the defect information and data set for algorithm optimization calculation and network model training. If the user allows access to the server 109 via the wide area network, the server 109 can further increase the defect information and data set through the foreign fiber machine cluster 101 of other factories, realize the robustness of the algorithm optimization and further enhance the data for network model training, ensuring the wide adaptability and characteristics of the equipment detection capability.

[0033] The foreign fiber machine 102 processing display module 7 has the following information acquisition mode:

[0034] (1) It can obtain the intercommunication information of other foreign fiber machines 102 in the same spinning mill, and can communicate with foreign fiber machines of other users through the wide area network and cloud server (with the user's permission);

[0035] (2) connecting to a user's computer, pad, mobile phone, or other data terminal 107 through a firewall (obtaining the initial information of the cotton raw material 104 input by the user), thereby obtaining the foreign fiber content information of the front-end cotton raw material 104 through the first process route 105, and obtaining the back-end roll foreign fiber information 113 for the back-end yarn through the second process route 106 (applicable to the roll process);

[0036] (3) Obtaining the rear-end yarn foreign fiber information 114 or the rear-end cloth foreign fiber information 115 through the second process route 106.

[0037] The foreign fiber machine 102 obtains the initial information of the cotton raw material 104 at the front end through the firewall 108, and obtains the foreign fiber information of the back end roll foreign fiber information 113, the back end yarn foreign fiber information 114, and the back end cloth foreign fiber information 115 through the intra-site communication. Combined with the foreign fiber classification and information detected by the foreign fiber machine 102, the image processing algorithm or parameters, the classification of the network model, etc. are adjusted to optimize missed detection. The foreign fiber machine 102 is connected to the big data training server 109 through the wide area network (user access is allowed) and information. The server 109 performs algorithm optimization calculations and network model training through the foreign fiber information, work information, defect images and other information fed back by the foreign fiber machine 102, and deploys them on the foreign fiber machine 102. After the processing and display module 7 obtains the above information, the processing unit of the processing and display module 7 performs the following processing:

[0038] S1: The foreign fiber machine 102 adjusts the sensitivity of the corresponding image feature algorithm of the processing unit of the foreign fiber machine 102, or the training and deployment of the network model, and performs adaptive adjustment of the algorithm and detection efficiency based on the foreign fiber classification and information of the rear-end roll foreign fiber information 113, the rear-end yarn foreign fiber information 114, and the rear-end cloth foreign fiber information 115, that is, the missed foreign fiber information.

[0039] S2: In the same spinning mill or between different spinning mills, the initial information 104 of cotton raw materials, the pictures of raw materials and foreign fibers collected by the foreign fiber machine 102, the foreign fiber information of the back-end rolls 113, the foreign fiber information of the back-end yarn 114, and the foreign fiber information of the back-end cloth 115 of spinning are shared through the server 109 to form big data of raw material and foreign fiber information, which is stored in the server 109. The server 109 can distribute data to the foreign fiber machine 102 according to the specific situation of the foreign fiber machine 102, adjust the sensitivity and distribution of the corresponding image feature algorithm, and train and deploy the adaptive sorting network model to the processing unit of the foreign fiber machine 102.

[0040] S3: If the user does not allow access to the cloud or locally deployed server 109, the fiber optic machine cluster 101 can form a local area network to complete operations similar to those in the above steps S1 and S2.

[0041] By improving foreign fiber detection, data such as the foreign fiber content in the raw material, cotton blending quality, the optimal cotton blending plan, and a process diagram from blending to yarn are output to the data terminal 107. This process automatically runs and circulates during the production process, replacing manual retrieval, recording, and tracking tasks, thereby increasing the automation and digitization of the factory.

[0042] After the cotton passes through the foreign matter detector 102, it then passes through a second process route 106, which includes equipment such as a draw frame, roving frame, spinning frame, and winder. This second process route 106 combines the cotton raw material 104 with the first process route 105, summarizing the cotton raw material 104's production flow path or foreign matter changes. This information is then recorded in the foreign matter detector 102 or server 109, enabling the traceability of the yarn production process from the same batch of raw material to yarn. In this second process route 106, a third data acquisition device collects foreign matter information 113 (such as foreign matter classification and content) from the final rolls. A fourth data acquisition device collects foreign matter information 114 (including foreign matter classification, content, and defect distribution per million meters) from the yarn produced by the electronic yarn clearer on the winder. Finally, a fifth data acquisition device collects foreign matter information 115 (including foreign matter classification and content, i.e., foreign matter information that has been missed by the previous processing steps) from the final cloth.

[0043] In a spinning mill, the process of moving yarn from the foreign fiber detector 102 to the winding machine (dependent on the production line process) and then to the final yarn and cloth takes more than five days. To record changes in foreign fiber content, factory personnel must transcribe information such as the production flow route and foreign fiber changes. The foreign fiber detector 102, the foreign fiber detector cluster 101, and the server 109 can record the production flow route and foreign fiber changes for the same batch of materials within their respective ranges, compile and analyze the data, and then send it back to the data terminal 107 through the firewall 108, replacing the data transcription and aggregation by factory personnel.

[0044] The spinning mill can input information such as the classification of foreign fibers on the cloth surface (missed foreign fibers) fed back from the weaving process into the system through the data terminal 107 or network communication. The foreign fiber sorting system with quality traceability function performs algorithm and network model optimization, as well as data aggregation and analysis, according to the above working process.

[0045] Through the above-mentioned work process, the foreign fiber sorting machine is combined with the process flow, user input information, cloud server and other interconnections to form a foreign fiber sorting system with quality traceability function.

[0046] By combining the foreign fiber content of the raw materials in the front-end process and the foreign fiber content of the back-end process (which is overlooked), the foreign fiber sorting machine automatically adjusts its own operation and parameters, evaluates the quality of the raw materials and provides the optimal raw material ratio plan, thereby improving the detection effect, eliminating the manual work of recording raw materials, production process routes, yarn foreign fiber tracking, etc., and improving the automation and digitization level of the factory.

Claims

1. A foreign fiber sorting system with quality traceability function, characterized in that: include: A first data collection device is used to collect initial information of cotton raw materials, wherein the initial information includes cotton variety, origin, batch, foreign fiber content, and cotton ratio; A second data acquisition device is installed on the foreign fiber machine and is used to record foreign fiber cleaning data of the cotton raw material at the corresponding front end, wherein the foreign fiber cleaning data includes foreign fiber type, foreign fiber quantity and foreign fiber distribution data; a third data collection device for collecting first foreign fiber residue data on the cotton lap on the lap forming machine, wherein the first foreign fiber residue data includes foreign fiber classification and content distribution information; a fourth data collection device for collecting second foreign fiber residual data from the electronic yarn clearer on the winding machine, wherein the second foreign fiber residual data includes foreign fiber classification, content, and defect distribution information per million meters; The fifth data collection device is used to collect the third foreign fiber residual data in the cloth on the cloth inspection machine, and the third foreign fiber residual data includes foreign fiber classification, content, and defect distribution information.

2. The foreign fiber sorting system with quality traceability function according to claim 1 is characterized by: The first process route is between the first data acquisition device and the second data acquisition device. The first process route includes a cotton picker, an axial flow opener, a cotton mixer, and a cotton cleaning machine that process the cotton raw materials in sequence. The foreign fiber machine obtains the production flow information of the cotton raw materials and stores and batches them.

3. The foreign fiber sorting system with quality traceability function according to claim 1 is characterized by: The foreign fiber machine is provided with a cotton inlet, a cotton outlet, an imaging module, a lighting module, a high-speed ejection and collection module, a waste cotton outlet and a processing display module. The cotton raw material after the cotton cleaning process enters from the cotton inlet, and is photographed by a camera of the imaging module in a sorting channel provided with a lighting module. The high-speed ejection and collection module ejects the foreign fibers, and discharges the collected foreign fibers through the waste cotton outlet. The cotton without foreign fibers enters the next process through the cotton outlet, and the processing information of the cotton raw material is recorded by the second data acquisition device.

4. The foreign fiber sorting system with quality traceability function according to claim 1 is characterized by: Numerous spinning mills or foreign fiber machine clusters are connected to cloud or local servers. The servers have the functions of data aggregation and storage, optimization and distribution of algorithm parameters, self-learning and deployment of algorithm models, as well as recording, aggregation and sharing of factory-related production process parameters.

5. The foreign fiber sorting system with quality traceability function according to claim 1 is characterized in that: The foreign fiber machine obtains the initial information of the cotton raw materials at the front end through the firewall, and obtains the foreign fiber information of the rolls, the foreign fiber information of the yarn, and the foreign fiber information of the cloth at the back end through the intra-field communication. Combined with the foreign fiber classification information detected by the foreign fiber machine, the image processing algorithm or parameters and the classification of the network model are adjusted to optimize the missed detection.

6. The foreign fiber sorting system with quality traceability function according to claim 1 is characterized by: The foreign fiber machine is connected to the server via a wide area network. The server performs algorithm optimization calculation and network model training based on the foreign fiber information, working information and defect images fed back by the foreign fiber machine, and deploys them on the foreign fiber machine.

7. The foreign fiber sorting system with quality traceability function according to claim 1 is characterized by: If users are not allowed to access the cloud or local server, they can form a local area network through the foreign fiber machine cluster to share raw material information, foreign fiber machine sorting information, and back-end foreign fiber information, forming big data of raw material and foreign fiber information. The foreign fiber machine cluster distributes data, adjusts the sensitivity of the corresponding image feature algorithm and sends it down, and trains and deploys the adaptive sorting network model to the foreign fiber machine processing unit according to the specific situation of the foreign fiber machine.

8. The foreign fiber sorting system with quality traceability function according to claim 1 is characterized by: The foreign fiber detection machine, foreign fiber detection machine cluster or server evaluates the batch foreign fiber content and cotton blending of the front-end cotton raw materials, the back-end roll foreign fiber information, the back-end yarn foreign fiber information, and the back-end cloth foreign fiber information within the corresponding range, combined with the first process route and the second process route, and outputs statistical reports. The data storage and calculation are stored in the foreign fiber detection machine or server in file or database format, and the user is provided with plans and suggestions for the optimal cotton blending and the optimal process route for the corresponding yarn variety.

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