Loom without stopper warp detection full life cycle adaptive calibration control method, system and storage medium

Abstract

This invention discloses a method, system, and storage medium for adaptive calibration control of the entire lifecycle of a warp breakage detection device for looms without warp breaks. The method includes four steps: initial reference calibration, dynamic light decay compensation, environmental linkage calibration, and anomaly self-checking. Different calibration strategies are adopted for three operating modes of the 940nm infrared laser emitter: 2mW multi-level intermittent emission and 5.5~10mW constant continuous emission. This invention achieves automatic calibration of the warp breakage detection device throughout its entire lifecycle, improving calibration accuracy by over 80%, reducing the false detection rate to below 0.1%, and extending the laser tube's lifespan to 8-10 years in default mode, perfectly adapting to the high humidity and high salt spray conditions of coastal textile operations.

Description

Technical Field

[0001] This invention relates to the field of textile machinery testing technology, and in particular to an adaptive calibration control method, system and storage medium for the entire life cycle of non-stop warp segment testing on looms. Same-day application related explanation

[0002] This application is one of a series of invention patents filed by the applicant on the same day, titled "Woven Warp Detection System for Looms with No Stoppages." This series of patents shares the same core inventive concept: using non-contact laser technology to achieve end-to-end reliability assurance for the detection of undisturbed warp pieces on looms. This series of patents includes seven invention patents, each addressing one of the seven interrelated and indispensable technical aspects of the menopause detection system: 1. Dedicated PCB motherboard for detecting warp breaks without stopping on a loom (hardware basics) 2. Adaptive calibration control method, system, and storage medium (calibration algorithm) for the entire lifecycle of warp detection in looms without warp drops. 3. A multi-level anti-interference and error-proofing control method, system, and storage medium (anti-interference technology) for the entire chain of warp-stop detection on looms. 4. Hardware-level safety interlock state machine control system for detecting warp breaks without stopping on the loom (safety control) 5. LoRa Mesh cluster management method, system, and storage media for looms with non-stop warp beam warp breakage detection devices (cluster management) 6. A control system and method for warp breakage detection, spindle synchronization time slot scheduling, and dual-path hardware split-flow control in a warp breakage detection loom without warp stops (lower-level communication). 7. Non-contact intelligent warp breakage detection and end-to-end integrated production management system for all types of shuttleless looms (production integration) There is a clear technical dependency among the various patented technical solutions, which together solve the overall technical problems of the non-stop menstrual fragment detection system, namely "poor real-time performance, low reliability, and weak adaptability", and comply with the patent law's provisions on unity of invention. Background Technology

[0003] Infrared warp breakage detection technology without warp stoppers is one of the core technologies of modern looms, which can effectively improve weaving efficiency and reduce the labor intensity of workers. Traditional warp breakage detection methods require inserting metal warp stoppers onto each warp yarn. This process is not only cumbersome and time-consuming, but the warp stoppers are also prone to rusting and deformation, leading to false detections and missed detections. At the same time, it increases the frictional resistance of the warp yarns, affecting their service life and weaving quality.

[0004] Infrared warp breakage detection technology identifies warp breakage events through non-contact optical signal detection, eliminating the need for warp breakage discs and completely solving many drawbacks of traditional warp breakage disc detection methods. However, in the harsh working conditions of textile workshops, characterized by high temperature and humidity, abundant cotton dust, and numerous fiber lint particles, the infrared laser emitter experiences irreversible light decay over time. Simultaneously, cotton dust, water mist, and fiber lint continuously adhere to the lens surface, leading to decreased optical signal transmission efficiency, gradually reduced detection accuracy, and a continuous increase in false positive and false negative rates.

[0005] Most existing warp breakage detection devices employ fixed threshold detection methods, failing to consider the effects of laser tube decay and environmental factors. These devices require periodic manual calibration, resulting in high maintenance costs. Furthermore, manual calibration suffers from low accuracy and inconsistent performance, failing to guarantee detection stability throughout its entire lifespan. While some patents mention dynamic calibration, they lack differentiated calibration for different laser emission modes and do not achieve automatic calibration throughout the entire lifespan. Moreover, they generally employ high-power continuous emission methods exceeding 5mW, resulting in a laser tube lifespan of only about 10,000 hours, far shorter than the 10-15 year design lifespan of water-jet and air-jet looms. This necessitates frequent laser tube replacements, increasing maintenance costs and disrupting normal loom production. Summary of the Invention

[0006] The technical problem to be solved by this invention is that existing loom non-stop warp detection devices do not achieve automatic calibration throughout the entire life cycle, do not perform differentiated calibration for different laser emission modes, have low calibration accuracy, and have short laser tube lifespan. Technical solution

[0007] To address the aforementioned technical problems, this invention provides a method, system, and storage medium for adaptive calibration control of the entire lifecycle of warp detection for non-stop warp segments in looms. By establishing an initial reference light intensity matrix, the light attenuation compensation coefficient is dynamically calculated according to a preset period, and real-time correction is performed in conjunction with ambient temperature and humidity. This enables self-cleaning in case of abnormalities and automatic recalibration. Simultaneously, a low-power default design of 2mW is adopted, coupled with multi-level synchronous intermittent emission modes for the main shaft. Different calibration strategies are employed for different operating modes, extending the laser tube's lifespan to a level comparable to that of the loom while ensuring detection accuracy. Beneficial effects

[0008] Compared with the prior art, the present invention has the following outstanding and substantial beneficial effects: Full lifecycle automatic calibration: No manual intervention is required. It automatically completes initial calibration, dynamic light decay compensation, environmental linkage calibration, and anomaly self-check, improving calibration accuracy by more than 80% and reducing the false detection rate to below 0.1%. Differentiated calibration strategy: Different calibration cycles and correction ratios are used for three working modes: constant continuous emission, 2mW single-rotation intermittent emission, and 2mW multi-rotation intermittent emission, to further improve calibration accuracy; Ultra-long service life: The default mode is 2mW low power + intermittent emission every 5 revolutions. The theoretical service life of the laser can reach 29.7 years. Taking the conservative value of 8-10 years for industrial applications, it is basically consistent with the design life of water jet looms and air jet looms. Strong environmental adaptability: Real-time environmental correction is performed based on the correlation between temperature, humidity and optical refractive index, and the detection accuracy remains stable within the full operating range of -10℃ to 45℃ and 40% to 95% RH. Self-cleaning function: Removes dust and water mist from the lens surface through full-power pulse emission, avoiding detection failure caused by lens contamination and extending the maintenance cycle to more than 6 months; Three-tier protection: The three-tier claim structure of general features + power range + specific model maximizes the scope of protection while ensuring examination stability. Attached Figure Description

[0009] Figure 1 This is a flowchart illustrating the complete process of the calibration control method described in this embodiment of the invention. In the diagram: 1. Real-time photoelectric signal acquisition step, 2. Dynamic noise filtering step, 3. Dual threshold intelligent judgment step, 4. Abnormal signal marking step, 5. Calibration parameter self-correction step, 6. Parameter solidification and storage step.

[0010] Figure 2 This is a schematic diagram of the interface architecture between the control system and the PCB hardware according to an embodiment of the present invention; In the diagram: 1. Cluster main control unit, 2. Loom node signal acquisition module, 3. LoRa wireless relay module, 4. Network data fusion module, 5. Cloud data upload module, 6. Network status self-check module, 7. Fault linkage processing module, 8. Network parameter configuration module, 9. Loom stop execution module.

[0011] Figure 3 This is a flowchart illustrating the logic of the dual outlier removal method described in this embodiment of the invention. In the diagram: Solid line S (smooth black curve): Standard photoelectric signal baseline of normal warp yarn (stable signal when the yarn is not broken and there is no interference); Dashed line F (sawtooth spike): Interference abnormal signal (false anomalies such as fly waste, jitter, ambient light, etc.); W1, W2, W3, and W4 are sliding detection windows: sliding detection windows (intervals in the algorithm that analyze the signal segment by segment); ①: Ordinary interference anomaly points (initial screening and identification by the algorithm, belonging to false faults, directly eliminated); ②: Real yarn breakage anomaly points (signal drops significantly, is a real fault, triggers alarm and shutdown); ③: Repair waveform after the algorithm eliminates interference (smooths out false anomalies and restores the real signal).

[0012] Figure 4 This is a schematic diagram of the state transition of the full lifecycle calibration closed loop as described in an embodiment of the present invention; In the figure: ① is the original photoelectric detection signal, ② is the first-level soft threshold filter signal, ③ is the second-level hard threshold judgment signal, ④ is the fracture judgment output signal, ⑤ is the interference signal fluctuation range, and ⑥ is the actual fracture signal drop range. Detailed Implementation

[0013] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. This embodiment is based on the actual working conditions of a water jet loom in a textile factory in Nantong, Jiangsu Province, and completes the full-process test and verification.

[0014] This embodiment uses a JAN9410-001 type 940nm infrared laser emitting tube for testing and verification. Those skilled in the art will understand that other 940nm infrared laser emitting tubes with the same nominal power range (2~10mW) can also achieve the technical solution of this invention and achieve the same technical effect.

[0015] The basis for accurate calculation of laser tube lifespan: Basic lifespan: In 5.5mW continuous emission mode, the nominal lifespan of the JAN9410-001 laser tube is 10,000 hours; Power-to-life conversion: The lifespan of a laser tube is approximately inversely proportional to its output power. Therefore, the theoretical lifespan in 2mW continuous emission mode is (5.5 divided by 2) multiplied by 10000, which equals 27500 hours, or approximately 3.14 years. Intermittent emission duty cycle: The loom spindle rotates 360° in one revolution, with the stable warp yarn shedding range being 80°~270°, totaling 190°. This represents approximately 52.78% of a single revolution (190 divided by 360). When using an intermittent mode emitting once every 5 revolutions, the actual working duty cycle of the laser tube is approximately 10.56% (52.78% divided by 5). Final theoretical lifespan: 27,500 hours divided by 0.1056 is approximately 260,400 hours, or approximately 29.7 years. Considering the impact of harsh environmental factors such as high temperature, high humidity, and high dust in textile workshops on the lifespan of laser tubes, a conservative value of 8-10 years is taken for industrial applications.

[0016] Example 1: 2mW intermittent transmission mode every 5 revolutions (default mode) This embodiment represents the system's default operating mode, suitable for most medium- and low-speed looms (speed < 800 rpm), balancing detection accuracy and laser tube lifespan.

[0017] After the loom is powered on, the main control module 4 controls the infrared laser transmitting and receiving module 1 to operate at a power of 2mW, adopting an intermittent mode of transmitting once every 5 revolutions of the main shaft: transmitting once every 5 weaving cycles, the duration of each transmission corresponds exactly to the stable range of warp yarn opening from 80° to 270° of the main shaft, and each transmission lasts for 0.0528 seconds at a speed of 600rpm, and the laser tube is completely turned off during non-detection intervals.

[0018] Those skilled in the art will understand that the above-mentioned number of emission frequencies is not limited to 1, 5, or 10 times, but can be configured to any positive integer number of times according to actual working conditions such as loom speed, yarn material, and production needs, all of which can achieve the technical effects of the present invention.

[0019] The main shaft signal acquisition module 2 acquires the angle signal output by the main shaft encoder of the loom. When the main shaft rotates to the stable range of 80°~270° warp opening, it acquires the idle light intensity data of 16 channels, establishes the initial reference light intensity matrix, and stores it in the storage module 5.

[0020] Because the laser tube's light decay rate in intermittent emission mode is much lower than in constant mode, the system extends the calibration cycle to 168 hours (7 days) and adjusts the light decay correction ratio to 0.1. Simultaneously, in conjunction with a gain-adjustable amplifier, the signal amplification factor is automatically adjusted to 180 times, ensuring a signal-to-noise ratio comparable to the 5.5mW constant-on mode.

[0021] Environmental parameter acquisition module 3 collects real-time temperature and humidity data from the workshop and calculates environmental correction coefficients based on the temperature / humidity-optical path refractive index correlation model. The environmental correction factor K_env equals 1 minus (0.0002 multiplied by (real-time ambient temperature T minus 25) plus 0.0005 multiplied by (real-time ambient relative humidity RH minus 60)). Where K_env is the environmental correction factor, T is the real-time ambient temperature (unit: °C), and RH is the real-time ambient relative humidity (unit: %). The corrected real-time sampled light intensity value is: the corrected real-time sampled light intensity value V_real is equal to the original sampled light intensity value V_sam divided by the environmental correction factor K_env.

[0022] When the light intensity fluctuation of a certain channel exceeds ±20%, a full-power pulse self-cleaning is triggered: the laser tube is driven to emit three times continuously at a power of 10mW, each lasting 100ms. After self-cleaning is completed, the idle light intensity data of that channel is reacquired, and the reference light intensity matrix and the broken beam detection threshold are updated.

[0023] The test results after 1000 hours of continuous operation in this mode show that the detection accuracy remains above 99.87%, the false detection rate is 0.11%, the laser tube light decay rate is only 0.35%, and the expected service life in industrial environment can reach 8-10 years.

[0024] Example 2: 5.5~10mW constant continuous transmission mode (high-speed optional mode) This embodiment is an optional high-speed mode, suitable for high-speed water jet looms with a rotation speed of ≥800rpm, prioritizing the detection response speed.

[0025] After the loom is powered on, the main control module 4 controls the infrared laser transmitting and receiving module 1 to continuously emit infrared laser light at a constant power of 5.5mW. The main shaft signal acquisition module 2 acquires the angle signal output by the loom's main shaft encoder. When the main shaft rotates to the stable warp yarn opening range of 80°~270°, it acquires the idle light intensity data of 16 channels, establishes an initial reference light intensity matrix, and stores it in the storage module 5.

[0026] The system performs dynamic optical attenuation compensation calibration every 24 hours. Current idle light intensity data is collected within the same spindle aperture stabilization range, and the optical attenuation compensation coefficient for each channel is calculated. The optical attenuation compensation coefficient K_comp is equal to the current idle light intensity value V_current divided by the initial reference light intensity value V_initial. The meridian break detection threshold for each channel is updated based on the optical attenuation compensation coefficient: The puncture detection threshold V_th is equal to the initial reference light intensity value V_initial multiplied by the light attenuation compensation coefficient K_comp multiplied by 0.7.

[0027] The test results after 1000 hours of continuous operation in this mode show that the detection accuracy remains above 99.9%, the false detection rate is 0.08%, the laser tube light decay rate is 3.2%, and the expected service life is about 3 years.

[0028] Example 3: 2mW intermittent emission mode every 10 revolutions (ultra-long lifespan mode) This embodiment is an optional ultra-long life mode, suitable for remote factories or unattended workshops with extremely low maintenance requirements.

[0029] The main control module 4 controls the infrared laser transmitting and receiving module 1 to operate at a power of 2mW, using an intermittent mode where the spindle transmits once every 10 revolutions synchronously, reducing the duty cycle to 5.28%. The system further extends the calibration cycle to 336 hours (14 days) and adjusts the optical attenuation correction ratio to 0.05.

[0030] The test results after 1000 hours of continuous operation in this mode show that the detection accuracy remains above 99.8%, the false detection rate is 0.13%, the laser tube light decay rate is only 0.18%, and the expected service life in industrial environment can reach more than 15 years.

[0031] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for adaptive calibration control of the entire lifecycle of a loom with non-stop warp segment detection, characterized in that, The warp breakage detection method employs a horizontally opposed infrared laser emitting unit and a photoelectric receiving unit. It detects warp breakage events by capturing the light obstruction signal generated by the horizontal displacement of the warp yarn caused by warp breakage and entanglement. The method includes the following steps: S1 Initial reference calibration: When the loom is powered on and running without load, collect the no-load light intensity data of the full beam channel within the preset stable range of warp opening, and establish the initial reference light intensity matrix. S2 Dynamic light decay compensation: According to the preset calibration cycle, the current idle light intensity data is collected in the same stable warp opening range, the light decay compensation coefficient of each channel is calculated, and the warp breakage detection threshold is dynamically updated. S3 Environmental Linkage Calibration: Real-time acquisition of ambient temperature and relative humidity data in the weaving workshop; Based on the correlation between temperature, humidity and optical refractive index, an environmental correction coefficient is generated to correct the current light intensity sampling value in real time. S4 Abnormal Self-Check: When the intensity fluctuation of a single channel exceeds the preset threshold, the infrared laser emitter is triggered to perform a full-power pulse self-cleaning. After completion, the reference intensity of the channel is recalibrated.

2. The method according to claim 1, characterized in that, The infrared laser emitting unit uses a 940nm infrared laser emitting tube and supports three selectable working modes: default 2mW spindle synchronous intermittent emission mode, selectable 5.5~10mW constant continuous emission mode, and selectable 2mW low power multi-level intermittent emission mode.

3. The method according to claim 2, characterized in that, The nominal output power of the 940nm infrared laser emitter is 2~10mW.

4. The method according to claim 3, characterized in that, The 940nm infrared laser emitting tube is specifically the JAN9410-001 type.

5. The method according to claim 2, characterized in that, The multi-level intermittent firing mode supports firing once every N revolutions of the loom, where N is a positive integer, and the duration of each firing corresponds exactly to the stable range of the warp yarn opening.

6. The method according to claim 5, characterized in that, The preferred value of N is 1, 5 or 10.

7. The method according to claim 2, characterized in that, In step S2, the calculation period and correction ratio of the optical attenuation compensation coefficient are automatically adjusted according to the current laser emission working mode.

8. The method according to claim 1, characterized in that, In step S4, the full-power pulse self-cleaning specifically involves driving the infrared laser emitting tube to continuously emit a preset number of times at a preset power, with each emission lasting a preset duration, to remove the cotton dust and water mist adhering to the lens surface.

9. A full-lifecycle adaptive calibration control system for detecting warp segments without stopping on a loom, characterized in that, include: A horizontally opposed infrared laser transmitting and receiving module is used to transmit infrared lasers and receive light signals blocked by warp yarns. The spindle signal acquisition module is used to acquire the rotation angle signal of the loom spindle to determine the stable range of warp yarn shedding. The environmental parameter acquisition module is used to collect temperature and humidity data in the weaving workshop; The main control module is electrically connected to the above modules and is used to execute the adaptive calibration control method according to any one of claims 1-7; The storage module is used to store the initial reference light intensity matrix, light attenuation compensation coefficient, and environmental correction coefficient.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium is a non-volatile computer-readable storage medium selected from at least one of Flash chips, hard disks, SD cards, and eMMC; the storage medium stores computer-executable instructions, which, when executed by a processor, implement the method described in any one of claims 1-7.

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