A yarn cake appearance detection device and control method thereof

Abstract

The present invention relates to a device and method for detecting the appearance of a silk cake. The device comprises a conveyor roller and an industrial camera for photographing the appearance of the silk cake. A ball bearing plate is fixed between two side plates in the middle of the conveyor roller. A lifting baffle is provided on the side of the ball bearing plate close to the discharge direction. A pressure sensor for detecting the placement of the silk cake on a disk head is installed on the lifting baffle. Two groups of conveyor belts are symmetrically provided on both sides of the conveyor roller. The conveyor belts are slidably connected to platforms on both sides of the conveyor roller. Electric telescopic rods for driving the movement of the two groups of conveyor belts are respectively installed on opposite sides. The device for detecting the appearance of the silk cake provided by the present invention can realize automatic detection of the appearance of the silk cake and is suitable for large-scale assembly lines. In addition, the device does not need to grab or lift the silk cake during the silk cake appearance detection process, thereby avoiding damage caused by grabbing and falling of the silk cake. The device has strong applicability and is suitable for further promotion and application.

Description

Technical Field

[0001] The invention relates to the technical field of silk cake production, and relates to a silk cake appearance detection device and a control method thereof. Background Art

[0002] In the chemical fiber industry, chemical fiber yarn cakes are prone to appearance defects such as poor molding, bruises, hairiness, lint, and contamination during the production process. Since the appearance of chemical fiber yarn cakes is an important aspect of yarn quality, it is necessary to conduct special appearance inspections on chemical fiber yarn cakes.

[0003] Existing inspections of bobbin appearance are mostly performed manually, visually inspecting each bobbin's top, bottom, and sides. This process is time-consuming and labor-intensive, and due to differences in judgment standards between personnel, the inspection quality can be unstable. Furthermore, it is not suitable for automated production lines. Summary of the Invention

[0004] In view of the above problems, the present invention proposes a yarn cake appearance detection device and a control method thereof.

[0005] The present invention is achieved through the following technical solutions:

[0006] A device for inspecting the appearance of a silk cake comprises a conveyor roller and an industrial camera for photographing the appearance of the silk cake, a ball bearing plate is fixed between two side plates in the middle of the conveyor roller, a lifting baffle is provided on the side of the ball bearing plate close to the discharge direction, a pressure sensor for detecting the placement of the silk cake on the disc head is installed on the lifting baffle, two groups of conveyor belts are symmetrically provided on both sides of the conveyor roller, the conveyor belts are slidably connected to the platforms on both sides of the conveyor roller, and electric telescopic rods for driving the movement of the two groups of conveyor belts are respectively installed on the opposite sides, a first infrared sensor and a second infrared sensor are respectively installed on the feeding side and the discharging side of the conveyor belt, an upper cover is provided above the ball bearing plate, the upper cover is fixed to the conveyor roller, openings are respectively opened on both sides of the upper cover, and an adjustment device for adjusting the position of the industrial camera is installed on the upper cover;

[0007] The adjustment device includes a transverse screw slide, a longitudinal screw slide mounted on a movable slide of the transverse screw slide, a spacing adjustment mechanism, a first telescopic adjustment mechanism, and a second telescopic adjustment mechanism. A connecting block is fixed to the movable slide of the longitudinal screw slide, and the spacing adjustment mechanisms are respectively installed on the upper and lower sides of the connecting block. The first telescopic adjustment mechanism is respectively installed on the telescopic end of the spacing adjustment mechanism through a connecting piece. The second telescopic adjustment mechanism is installed on the side wall of the connecting block facing the ball bearing plate. The telescopic ends of the first telescopic adjustment mechanism and the second telescopic adjustment mechanism are both installed with industrial cameras.

[0008] The lifting baffle is fixedly mounted on the conveying roller through a fixing plate. The lifting baffle includes a baffle and a lifting electric telescopic rod. The lifting electric telescopic rod is mounted on the fixing plate, and the baffle is mounted on the telescopic end of the lifting electric telescopic rod.

[0009] Furthermore, the industrial camera on the first telescopic adjustment mechanism is installed on the telescopic end of the first telescopic adjustment mechanism through a damping hinge; the industrial camera on the second telescopic adjustment mechanism is fixedly installed on its telescopic end through a connecting piece.

[0010] Furthermore, the industrial camera is equipped with a ring-shaped LED light for lighting.

[0011] Furthermore, a lighting lamp is installed in the inner cavity of the upper cover.

[0012] Preferably, a switch door is installed on the side wall of the upper cover.

[0013] The present invention further provides a control method for a yarn cake appearance detection device, comprising the following steps:

[0014] S1: The adjustment device adjusts the position of the industrial camera according to the position and size of the bobbin, so that the three groups of industrial cameras can respectively shoot the top circle, bottom circle and side wall of the bobbin;

[0015] S2: The conveyor roller conveys the bobbin head with the bobbin toward the ball bearing plate. When the first infrared sensor detects the bobbin head, the electric telescopic rods on both sides extend to push the conveyor belt toward the middle to clamp the bobbin head. At the same time, the lifting baffle rises upward.

[0016] S3: The conveyor belt is operated to place the bobbin containing the yarn cake on the disc head and transport it toward the lifting baffle. When the pressure sensor detects a pressure signal, the conveyor belt on one side is reversed by a preset length to rotate the yarn cake. The industrial camera captures the appearance of the rotating yarn cake to obtain the appearance image of the entire circle of yarn cake.

[0017] S4: The conveyor belt runs in the reverse direction for a preset length and then runs forward. At the same time, the lifting baffle drops and resets, the industrial camera stops shooting, and the conveyor belt transports the yarn cake after appearance inspection to the conveyor roller. When the second infrared sensor detects that the yarn cake is placed on the bobbin, the electric telescopic rod contracts and drives the conveyor belt to move to both sides, and the conveyor roller outputs the inspected yarn cake.

[0018] Furthermore, the conveying speed of the reverse-running conveyor belt in S3 is 0.8-0.9 times the conveying speed of the forward-running conveyor belt.

[0019] Furthermore, the appearance image captured by the industrial camera of the appearance inspection equipment is input into the external inspection system for appearance inspection. The specific inspection method is as follows:

[0020] 1) Expand the appearance images of the rotating silk cakes taken by three sets of industrial cameras into a plane;

[0021] 2) Analyze the spacing information between the two adjacent sides of the winding segment in the plane expansion diagram of each part of the silk cake, and determine the maximum and minimum values ​​of the spacing in the plane expansion diagram;

[0022] 3) Compare the maximum and minimum values ​​of the measured spacing in the plane unfolded diagram of each part of the silk cake with the preset spacing range to determine whether they are within the preset range. If so, it is judged as OK; otherwise, it is judged as NG;

[0023] 4) Determine whether the brightness of the brightness area and its corresponding area in the plane unfolding diagram of each part of the silk cake are within the set brightness threshold and area threshold range. If so, it is judged as OK; otherwise, it is judged as NG.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] The silk cake appearance detection device provided by the present invention can realize automatic detection of silk cake appearance and is suitable for large-scale assembly lines. In addition, the device does not need to grab or lift the silk cake during the silk cake appearance detection process, thereby avoiding damage caused by grabbing and dropping the silk cake. The device has strong applicability and is suitable for further promotion and application. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Attachment Figure 1 is a schematic diagram of the present invention;

[0027] Attachment Figure 2 It is a schematic diagram of the silk cake detection state of the present invention;

[0028] Attachment Figure 3 is a side view of the present invention;

[0029] Attachment Figure 4 This is a schematic diagram of the assembly of the damping hinge and the industrial camera;

[0030] Attachment Figure 5 Schematic diagram of the silk cake and the silk cake head.

[0031] The numbers in the figure represent:

[0032] Coil placement disc-1; coil-2; conveyor roller-3; ball bearing plate-4; conveyor belt-5; electric telescopic rod-6; pressure sensor-7; first infrared sensor-8; lifting baffle-9; fixing plate-10; upper cover-11; lighting lamp-12; adjustment device-13; industrial camera-14; damping hinge-15; second infrared sensor-16; door opening / closing device-17; ball bearing-41; baffle-91; lifting electric telescopic rod-92; transverse screw slide-131; longitudinal screw slide-132; spacing adjustment mechanism-133; first telescopic adjustment mechanism-134; second telescopic adjustment mechanism-135; ring-shaped LED light-141. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the invention for which protection is sought, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0034] Refer to the attached Figure 1-4, a yarn cake appearance inspection device, including a conveying roller 3 and an industrial camera 14 for photographing the appearance of the yarn cake 2, wherein the conveying roller 3 is an existing conveying device for conveying yarn cakes; a ball plate 4 is fixed between the two side plates in the middle of the conveying roller 3, and balls 41 are evenly arranged on the top of the rolling main plate 4; a lifting baffle 9 is provided on the side of the ball plate 4 close to the discharge direction, and a pressure sensor 7 for detecting the placement of the yarn cake on the disk head 1 is installed on the lifting baffle 9, wherein the lifting baffle 9 is fixedly installed on the conveying roller 3 through a fixed plate 10, and the lifting baffle 9 includes a baffle 91 and a lifting electric telescopic rod 92, the lifting electric telescopic rod 92 is installed on the fixed plate 10, and the baffle 91 is installed at the telescopic end of the lifting electric telescopic rod 92. The pressure sensor 7 is mounted on the baffle 91. When the baffle 91 rises by adjusting the extension of the electric telescopic rod 92, the pressure sensor 7 can just touch the bottom disc of the bobbin placement disc 1. Two sets of conveyor belts 5 are symmetrically arranged on both sides of the conveyor roller 3. The conveyor belts 5 are similar to existing conveyor belts. The bottom of the conveyor belts 5 is slidably connected to the platforms on both sides of the conveyor roller 3 through a slide rail and a slide groove structure. The two sets of conveyor belts 5 are respectively installed on the opposite sides of the conveyor belts 5 to drive their movement. The electric telescopic rods 6 can move the conveyor belts 5 in the opposite direction. When the conveyor belts 5 at both ends are clamped toward the middle, the conveyor belts 5 on both sides cooperate with the chassis of the bobbin placement disc 1. The bobbin placement disc 1 can be driven to move by the rotation of the conveyor belts 5. The upper end of the bobbin placement disc 1 has a certain cone angle (see attached Figure 5 ) to avoid obstructing the winding section of the silk cake, so that the industrial camera 14 cannot obtain a complete image of the winding section at the lower end of the silk cake.

[0035] A first infrared sensor 8 and a second infrared sensor 16 are mounted on the feed and discharge sides of the conveyor belt 5, respectively. Each of these sensors consists of an infrared transmitter and an infrared receiver. An upper cover 11 is mounted above the ball bearing plate 4. The upper cover 11 is fixed to the conveyor roller 3 and has openings on both sides. An adjustment device 13 for adjusting the position of an industrial camera 14 is mounted on the upper cover 11. A lighting lamp 12 is mounted within the inner cavity of the upper cover 11 for illuminating the interior of the cover. A switch door 17 is mounted on the side wall of the upper cover 11. If an abnormality occurs in the equipment inside the cover, the switch door 17 can be opened to address the internal anomaly, facilitating repair and troubleshooting of the equipment.

[0036] The adjusting device 13 includes a transverse screw slide 131, a longitudinal screw slide 132 mounted on the movable slide of the transverse screw slide 131, a spacing adjustment mechanism 133, a first telescopic adjustment mechanism 134 and a second telescopic adjustment mechanism 135, wherein the spacing adjustment mechanism 133, the first telescopic adjustment mechanism 134 and the second telescopic adjustment mechanism 135 can be selected from mechanisms and devices such as electric telescopic rods and screws that can be adjusted in length; a connecting block is fixed on the movable slide of the longitudinal screw slide 132, and the spacing adjustment mechanism 133 is respectively installed on the upper and lower sides of the connecting block, and the first telescopic adjustment mechanism 134 is respectively installed on the spacing adjustment mechanism through connecting pieces. The telescopic end of the structure 133 and the side wall of the connecting block facing the ball bearing plate 4 are installed with a second telescopic adjustment mechanism 135, and the telescopic ends of the first telescopic adjustment mechanism 134 and the second telescopic adjustment mechanism 135 are both installed with industrial cameras 14; the longitudinal slide moves so that the industrial camera 14 on the second telescopic adjustment mechanism 135 is relative to the position of the silk cake 2, and then the second telescopic adjustment mechanism 135 is used to adjust the distance between the industrial camera 14 and the silk cake 2; the upper and lower sets of spacing adjustment mechanisms 133 can make the positions of the upper and lower industrial cameras 14 adapt to the height of the silk cake 2, and then the first telescopic adjustment mechanism 134 can realize the lateral position adjustment of the upper and lower industrial cameras 14.

[0037] Furthermore, the industrial camera 14 on the first telescopic adjustment mechanism 134 is mounted to the telescopic end of the first telescopic adjustment mechanism 134 via a damping hinge 15; this arrangement facilitates adjustment of the shooting angles of the upper and lower industrial cameras 14. The industrial camera 14 on the second telescopic adjustment mechanism 135 is fixedly mounted to its telescopic end via a connector. A ring-shaped LED light 141 with adjustable brightness is installed on the industrial camera 14 for illumination. This facilitates the capture of images of the bobbin's appearance by the industrial camera 14.

[0038] This embodiment further provides a control method for a yarn cake appearance detection device, comprising the following steps:

[0039] S1: The adjusting device 13 adjusts the position of the industrial cameras 14 according to the position and size of the yarn cake 2, so that the three groups of industrial cameras 14 respectively photograph the top circle, bottom circle and side wall of the yarn cake 2;

[0040] S2: The conveying roller 3 conveys the silk cake placing disc 1 containing the silk cake 2 toward the ball plate 4. When the first infrared sensor 8 detects the silk cake placing disc 1, the electric telescopic rods 6 on both sides extend to push the conveyor belt 5 toward the middle to clamp the silk cake placing disc 1. The clamping also serves as a positioning function for the silk cake 2, which is convenient for the industrial camera 14 to collect images. At the same time, the lifting baffle 9 rises upward.

[0041] S3: The conveyor belt 5 runs to transport the silk cake placing disc 1 containing the silk cake 2 toward the lifting baffle 9. When the pressure sensor 7 detects the pressure signal, one side of the conveyor belt 5 runs in the reverse direction for a preset length to rotate the silk cake 2 (when the conveyor belts 5 on both sides are opposite, the silk cake placing disc 1 will rotate on the ball plate 4, thereby realizing the rotation shooting of the silk cake 2). The number of reverse running circles is usually 1.5 times the circumference of the chassis of the silk cake placing disc 1 to ensure that the silk cake 2 can rotate a full circle. The industrial camera 14 captures the appearance image of the rotating silk cake 2 to obtain the appearance image of the full circle of the silk cake 2; the conveying speed of the reverse running conveyor belt is 0.8-0.9 times the conveying speed of the forward conveyor belt; ensuring that the conveying speed of the forward conveyor belt is greater than the conveying speed of the reverse conveyor belt can ensure that the silk cake placing disc 1 always contacts the baffle 91 on the lifting baffle 9 during rotation, ensuring that its position does not change, so as to facilitate image acquisition by the industrial camera 14.

[0042] S4: The conveyor belt 5 runs in the reverse direction for a preset length and then runs forward. At the same time, the lifting baffle 9 drops and resets, and the industrial camera 14 stops shooting. The conveyor belt 5 conveys the silk cake 2 after the appearance inspection to the conveyor roller 3. When the second infrared sensor 16 detects that the silk cake is placed on the bobbin head 1, the electric telescopic rod 6 contracts and drives the conveyor belt 5 to move to both sides, and the conveyor roller 3 outputs the inspected silk cake 2.

[0043] Furthermore, the appearance image captured by the industrial camera 14 of the appearance inspection device is input into the external inspection system for appearance inspection. The specific inspection method is as follows:

[0044] 1) unfolding the appearance images of the silk cake 2 after rotation, taken by the three sets of industrial cameras 14, in a plane form;

[0045] 2) Analyze the spacing information between the two adjacent sides of the silk-wrapped segment in the plane unfolding diagram of each part of the silk cake, and determine the maximum and minimum spacing values ​​of the plane unfolding diagram; that is, detect the height and thickness dimensions of the upper and lower ends of the silk segment.

[0046] 3) Compare the maximum and minimum spacing values ​​of the measured planar expansion diagram of each part of the silk cake with the preset spacing range to determine whether they are within the preset range. If so, it is judged as OK, otherwise it is judged as NG, which means it is unqualified;

[0047] 4) Determine whether the brightness of the brightness zones and their corresponding areas in the planar unfolded image of each part of the yarn cake are within the set brightness and area thresholds. If so, the result is considered OK; otherwise, it is considered NG. (If the yarn cake's outer surface exhibits appearance defects such as poor forming, bruises, hairiness, lint, or contamination, the reflectivity of the outer surface will vary. This brightness difference in each area is used to determine whether the appearance defect is acceptable.)

[0048] The above-mentioned yarn cake appearance inspection equipment is connected to the yarn cake sorting equipment to sort OK and NG yarn cakes respectively.

[0049] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A control method using a yarn cake appearance detection device, wherein the yarn cake appearance detection device comprises a conveying roller (3) and an industrial camera (14) for photographing the appearance of a yarn cake (2), characterized in that: A ball bearing plate (4) is fixed between the two side plates in the middle of the conveying roller (3), and a lifting baffle (9) is provided on the side of the ball bearing plate (4) close to the discharge direction, and a pressure sensor (7) for detecting the placement of the silk cake disc (1) is installed on the lifting baffle (9), and two groups of conveyor belts (5) are symmetrically provided on both sides of the conveying roller (3), and the conveyor belts (5) are slidably connected to the platforms on both sides of the conveying roller (3), and the two groups of conveyor belts (5) are respectively installed with electric telescopic rods (6) for driving them to move on the opposite sides, and the feeding side and the discharging side of the conveyor belt (5) are respectively installed with a first infrared sensor (8) and a second infrared sensor (16), and an upper cover (11) is provided above the ball bearing plate (4), and the upper cover (11) is fixed on the conveying roller (3), and openings are respectively opened on both sides of the upper cover (11), and an adjusting device (13) for adjusting the position of an industrial camera (14) is installed on the upper cover (11); The adjusting device (13) includes a transverse screw slide (131), a longitudinal screw slide (132) mounted on a movable slide of the transverse screw slide (131), a spacing adjustment mechanism (133), a first telescopic adjustment mechanism (134) and a second telescopic adjustment mechanism (135), a connecting block is fixed on the movable slide of the longitudinal screw slide (132), and the spacing adjustment mechanisms (133) are respectively mounted on the upper and lower sides of the connecting block, the first telescopic adjustment mechanism (134) is respectively mounted on the telescopic end of the spacing adjustment mechanism (133) through a connecting piece, the second telescopic adjustment mechanism (135) is mounted on the side wall of the connecting block facing the ball plate (4), and the telescopic ends of the first telescopic adjustment mechanism (134) and the second telescopic adjustment mechanism (135) are both mounted with an industrial camera (14); The lifting baffle (9) is fixedly mounted on the conveying roller (3) via a fixed plate (10), the lifting baffle (9) comprises a baffle (91) and a lifting electric telescopic rod (92), the lifting electric telescopic rod (92) is mounted on the fixed plate (10), and the baffle (91) is mounted on the telescopic end of the lifting electric telescopic rod (92); The control method comprises the following steps: S1: The adjusting device (13) adjusts the position of the industrial camera (14) according to the position and size of the silk cake (2), so that the three groups of industrial cameras (14) respectively photograph the top circle, bottom circle and side wall of the silk cake (2); S2: The conveying roller (3) conveys the silk cake placing disc (1) containing the silk cake (2) toward the ball plate (4). When the first infrared sensor (8) detects the silk cake placing disc (1), the electric telescopic rods (6) on both sides extend to push the conveyor belt (5) toward the middle to clamp the silk cake placing disc (1) and at the same time the lifting baffle (9) rises upward; S3: The conveyor belt (5) is operated to place the silk cake (2) on the disk head (1) and transport it toward the lifting baffle (9). When the pressure sensor (7) detects a pressure signal, one side of the conveyor belt (5) is reversely operated for a preset length to rotate the silk cake (2). The industrial camera (14) takes an image of the appearance of the rotating silk cake (2) to obtain an appearance image of the entire circle of the silk cake (2). S4: The conveyor belt (5) runs in the reverse direction for a preset length and then runs in the forward direction. At the same time, the lifting baffle (9) descends and resets, and the industrial camera (14) stops shooting. The conveyor belt (5) conveys the silk cake (2) after the appearance inspection to the conveyor roller (3). When the second infrared sensor (16) detects that the silk cake is placed on the disk head (1), the electric telescopic rod (6) contracts and drives the conveyor belt (5) to move to both sides, and the conveyor roller (3) outputs the inspected silk cake (2).

2. The control method using the yarn cake appearance detection device according to claim 1, characterized in that The industrial camera (14) on the first telescopic adjustment mechanism (134) is mounted on the telescopic end of the first telescopic adjustment mechanism (134) via a damping hinge (15); the industrial camera (14) on the second telescopic adjustment mechanism (135) is fixedly mounted on the telescopic end thereof via a connecting member.

3. The control method using the yarn cake appearance detection device according to claim 1, characterized in that The industrial camera (14) is equipped with a ring-shaped LED light (141) for lighting.

4. The control method using the yarn cake appearance detection device according to claim 1, characterized in that The inner cavity of the upper cover (11) is equipped with a lighting lamp (12).

5. The control method using the yarn cake appearance detection device according to claim 4, characterized in that A switch door (17) is installed on the side wall of the upper cover (11).

6. The control method using the yarn cake appearance detection device according to claim 1, characterized in that: The conveying speed of the reverse conveyor belt in S3 is 0.8-0.9 times the conveying speed of the forward conveyor belt.

7. The control method using the yarn cake appearance detection device according to claim 1, characterized in that: The appearance image captured by the industrial camera (14) of the appearance inspection equipment is input into the external inspection system for appearance inspection. The specific inspection method is as follows: 1) unfolding the appearance images of the silk cake (2) after rotation, which are photographed by three sets of industrial cameras (14), in a plane form; 2) Analyze the spacing information between the two adjacent sides of the winding segment in the plane unfolding diagram of each part of the silk cake, and determine the maximum and minimum spacing values ​​of the plane unfolding diagram; 3) Compare the maximum and minimum spacing values ​​of the measured planar expansion diagram of each part of the silk cake with the preset spacing range to determine whether they are within the preset range. If so, it is judged as OK; otherwise, it is judged as NG; 4) Determine whether the brightness of the brightness area and its corresponding area in the plane unfolding diagram of each part of the silk cake are within the set brightness threshold and area threshold range. If so, it is judged as OK; otherwise, it is judged as NG.

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