A method and device for cleaning foam

Abstract

The present invention discloses a method for cleaning foam, belonging to the technical field of foam cleaning, which includes the following steps: driving a dust removal roller matching the width of the foam to rotate and adjusting the gap between the dust removal roller and the foam, and the dust removal roller contacts the foam to perform preliminary dust removal; the control system classifies the defects of the sub-image of the foam after preliminary dust removal through the detection of an industrial camera, and drives the defect treatment component to perform corresponding preliminary defect treatment; the control system classifies the defects of the foam with the defects preliminarily treated again through the detection of a thickness detection instrument, and drives the defect treatment component to perform corresponding defect re-treatment. The application has a small judgment error, prevents defective products from flowing into the next production stage, ensures the molding quality of the product, and the defect treatment component has a high working efficiency, can improve the cleaning efficiency, and further improve the production efficiency. The application also relates to a foam cleaning device for implementing the above foam cleaning method.

Description

Technical Field

[0001] The present invention relates to the technical field of foam cleaning, and particularly to a foam cleaning method and a device implemented by the above foam cleaning method. Background Art

[0002] Foam is a material obtained by foaming plastic particles, abbreviated as foam. Foam is divided into PU foam, anti-static foam, conductive foam, EPE, anti-static EPE, CR, EVA, cross-linked PE, SBR, EPDM, etc. Foam has a series of characteristics such as elasticity, light weight, fast pressure-sensitive fixation, easy use, flexible bending, ultra-thin volume, and reliable performance.

[0003] During the production process of foam rolls, dust will fall on the foam, which will affect the normal use of the foam. Chinese patent document CN 211918072 U provides a dust removal component. By using a sticky dust roller, the cleaning efficiency of the dust removal component is greatly improved. However, this structure cannot detect defects in the dust removal situation, and there may still be problems of dust residue. Chinese patent document CN 113102282 A provides a method and system for automatic detection of defects on the surface of workpieces. However, this method only uses a single image acquisition module for defect detection, without making specific distinctions on the types of defects, and it is easy to have situations of missed judgment and misjudgment, resulting in defective products flowing into the next production stage, affecting the forming quality of the products, unable to meet customer requirements, and unable to perform corresponding processing on defects during the foam production process. It is necessary to suspend the operation, and then continue the operation after the defect treatment is completed, resulting in low cleaning efficiency and low production efficiency. Summary of the Invention

[0004] One of the main purposes of the present invention is to provide a foam cleaning method that can improve the cleaning efficiency in view of the deficiencies in the prior art.

[0005] Another main purpose of the present invention is to provide a foam cleaning device that can improve the cleaning efficiency in view of the deficiencies in the prior art.

[0006] One of the purposes of the present invention is achieved by adopting the following technical solution:

[0007] A foam cleaning method includes the following steps:

[0008] Step (1), measure the width of the foam through sensors on both sides of the foam, and transmit the measurement data to the control system. The control system calculates the number of dust removal rollers that match the width of the foam;

[0009] Step (2): Rotate the dust removal roller that matches the width of the foam, and adjust the gap between the dust removal roller and the foam. The dust removal roller contacts the foam for preliminary dust removal. The dust removal roller is floatingly connected to the foam through an elastic member to prevent indentation.

[0010] Step (3): Use an industrial camera to collect images of the preliminarily dust-removed foam and feed them back to the control system. The image processing module of the control system divides the image into multiple sub-images, and each sub-image is compared one by one with all defect categories stored in the storage module of the control system. The control system can classify the defects of each sub-image according to the detection of the industrial camera as: dust residue, indentation, ink color error. The control system determines the defect category based on the above defect information and gives the defect position information.

[0011] Step (4): The control system drives the defect processing component to preliminarily process the defects of each sub-image. If the defect category is dust residue, the control system drives the first nozzle to blow cold air at the defect area for secondary cleaning. If the defect category is indentation, the control system drives the first nozzle to blow hot air at the defect area to heat it and make it expand. If the defect category is ink color error, the control system drives the second nozzle to spray ink on all the preliminarily dust-removed foam for color overlay processing.

[0012] Step (5): After the defect processing component preliminarily processes the defects of each sub-image, then use multiple thickness detection instruments arranged at intervals along the width direction of the foam to measure the thickness of different parts of all the foam with preliminarily processed defects and transmit the data to the control system. The control system can classify the defects of the foam according to the measurement of the thickness detection instruments as: too thin spraying of foaming agent, too thick spraying of foaming agent.

[0013] Step (6): The defect processing component reprocesses the defects of the foam. If the defect category is too thin spraying of foaming agent, the control system drives the third nozzle to spray foaming agent at the defect area. If the defect category is too thick spraying of foaming agent, the control system drives the scraper to scrape the defect area.

[0014] Further, in step (4), after the second nozzle sprays ink on the foam for color overlay processing, then perform UV curing on the foam.

[0015] Further, in step (6), after the third nozzle sprays foaming agent at the defect area, then perform UV curing on the foam.

[0016] Further, in step (6), after the scraper scrapes the defect area, the control system then drives the first nozzle to blow cold air at the defect area for secondary cleaning.

[0017] Further, the foam cleaning method further includes step (7), and specifically, step (7) is: cutting and removing both sides of the foam by knives installed at both ends of the foam to ensure uniform spraying of the foaming agent on both edges of the foam.

[0018] Further, in step (6), after the scraper scrapes the defective part, the excess foaming agent is collected by the recovery component and can be reused.

[0019] The second object of the present invention is achieved by the following technical solution:

[0020] A foam cleaning device for implementing any of the above foam cleaning methods, including a bracket, a pressure roller assembly, a dust removal assembly, a control system, further including a defect detection component and a defect treatment component. The pressure roller assembly is rotatably installed on the bracket for transporting the foam. The dust removal assembly includes a plurality of dust removal units. The dust removal units are selectively moved up and down by the control system. The dust removal units are spaced apart along their axial directions. The dust removal unit includes a dust removal roller and an elastic member. The dust removal roller is rotatably installed on the bracket. The axial direction of the dust removal roller is parallel to the axial direction of the pressure roller assembly. The outside of the dust removal roller is wound with dust removal paper. The dust removal paper contacts the foam for preliminary dust removal. The elastic member is installed at both ends of the dust removal roller and connected to the bracket. The defect detection component and the defect treatment component are both installed on the bracket. The defect detection component includes an industrial camera and a thickness detection instrument. The thickness detection instruments are arranged at intervals along the width direction of the foam. The defect treatment component includes a plurality of nozzles and a scraper. The defect detection component can move along the direction of the defective part of the foam. The foam after preliminary dust removal is subjected to defect detection by the defect detection component. The defect detection component feeds the defect information back to the control system. The control system determines the defect category according to the defect information and controls the nozzles and the scraper to perform corresponding treatments.

[0021] Further, the bracket includes a first bracket and a second bracket, the pressing roller assembly includes a first pressing roller assembly, a second pressing roller assembly, and a third pressing roller assembly. The first pressing roller assembly is installed on the top of the first bracket, the second pressing roller assembly is installed at the connection of the first bracket and the second bracket, and the third pressing roller assembly is installed at the bottom of the second bracket. The first pressing roller assembly and the second pressing roller assembly are located on the opposite side of the foam, and the first pressing roller assembly and the third pressing roller assembly are located on the same side of the foam. The dust removal assembly is installed on the first bracket and close to the first pressing roller assembly. The foam between the dust removal assembly and the second pressing roller assembly is the preliminarily dust-removed foam. The defect detection assembly is installed at the connection of the first bracket and the second bracket, and the defect treatment assembly is installed on the second bracket. The number of the dust removal assembly, the defect detection assembly, and the defect treatment assembly is 2 each, and they are respectively located on the front and back sides of the foam.

[0022] Further, the foam cleaning device further includes a cutter, the cutter is installed on the second bracket and located on both sides of the preliminarily dust-removed foam, and the cutter is electrically connected to the control system.

[0023] Further, the foam cleaning device further includes a recycling assembly, the recycling assembly is installed on the second bracket and electrically connected to the control system.

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

[0025] (1) The present invention conducts multiple defect detections on the foam through an industrial camera and a thickness detection instrument and classifies the defects specifically. In this way, the judgment error is small, and it is not easy to have missed judgments or misjudgments. There will be no defective products flowing into the next production stage, ensuring the final forming quality of the product and meeting the customer's requirements.

[0026] (2) The present invention processes the foam defects in sequence through the defect treatment assembly. In this way, there will be no interference during the treatment. The present invention can perform corresponding treatments on the defects during the foam production process, without the need to suspend the operation and wait for the defect treatment to be completed before continuing the operation. Moreover, the working efficiency of the defect treatment assembly is high, which can improve the cleaning efficiency and further improve the production efficiency. Description of the Drawings

[0027] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings of the embodiments will be briefly introduced below. Obviously, the drawings described below only relate to some embodiments of the present invention and do not limit the present invention, where:

[0028] Figure 1 is the step flow chart of the foam cleaning method of the present invention;

[0029] Figure 2 This is a schematic structural diagram of the foam cleaning device of the present invention;

[0030] Figure 3 is Figure 2 Another schematic structural diagram of the foam cleaning device.

[0031] In the figure: 10, bracket; 11, first bracket; 12, second bracket; 20, pressure roller assembly; 21, first pressure roller assembly; 22, second pressure roller assembly; 23, third pressure roller assembly; 30, dust removal assembly; 31, dust removal unit; 311, dust removal roller; 312, elastic member; 40, defect detection assembly; 41, industrial camera; 42, thickness detection instrument; 50, defect treatment assembly; 51, first nozzle; 52, second nozzle; 53, third nozzle; 54, scraper; 60, control system; 70, recycling assembly; 80, cutter. Detailed implementation manners

[0032] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0033] In the accompanying drawings, for clarity, the shapes and dimensions may be enlarged, and the same reference numerals will be used throughout all the figures to indicate the same or similar components.

[0034] Unless otherwise defined, the technical terms or scientific terms used herein shall have the ordinary meanings understood by those of ordinary skill in the art to which the present invention pertains. The "first", "second" and similar terms used in the specification and claims of this patent application of the present invention do not denote any order, quantity or importance, but are only used to distinguish different components. Similarly, the terms such as "a", "one" or "the" do not denote a quantity limitation, but mean that there is at least one. The terms such as "comprising" or "including" mean that the elements or objects appearing before "comprising" or "including" cover the elements or objects listed after "comprising" or "including" and their equivalents, and do not exclude other elements or objects. The terms such as "upper", "lower", "left", "right" etc. are only used to represent relative positional relationships, and when the absolute position of the object being described changes, the relative positional relationship may also change accordingly.

[0035] In the following description, terms such as center, thickness, height, length, front, back, rear, left, right, top, bottom, upper, lower, etc. are defined with respect to the configurations shown in the respective drawings. In particular, "height" corresponds to the dimension from the top to the bottom, "width" corresponds to the dimension from the left to the right, and "depth" corresponds to the dimension from the front to the back. These are relative concepts and may accordingly vary depending on their different positions and usage states. Therefore, these or other orientations should not be construed as restrictive terms.

[0036] Terms related to attachment, connection, etc. (e.g., "connect" and "attach") refer to the relationship in which these structures are directly or indirectly fixed or attached to each other through an intermediate structure, as well as the relationship of movable or rigid attachment, unless otherwise explicitly stated.

[0037] In Embodiment 1:

[0038] As Figure 1 shown, a foam cleaning method includes the following steps:

[0039] Step (1), measure the width of the foam through sensors on both sides of the foam, and transmit the measurement data to the control system 60. The control system 60 calculates the number of dust removal rollers 311 that match the width of the foam;

[0040] Step (2), drive the dust removal roller 311 that matches the width of the foam to rotate and adjust the gap between the dust removal roller 311 and the foam. The dust removal roller 311 contacts the foam for preliminary dust removal. The dust removal roller 311 is floatingly connected to the foam through an elastic member 312 to prevent indentation;

[0041] Step (3), collect images of the preliminarily dust-removed foam through an industrial camera 41 and feedback them to the control system 60. The image processing module of the control system 60 divides the image into multiple sub-images. Each sub-image is compared one by one with all the defect categories in the storage module of the control system. The control system 60 can classify the defects of each sub-image according to the detection of the industrial camera 41 as: dust residue, indentation, and ink color error. The control system 60 determines the defect category based on the above defect information and gives the defect position information;

[0042] Step (4), the control system 60 drives the defect processing component 50 to perform preliminary processing on the defects of each sub-image. If the defect category is dust residue, the control system 60 drives the first nozzle 51 to blow cold air at the defect site for secondary cleaning; if the defect category is indentation, the control system 60 drives the first nozzle 51 to blow hot air at the defect site to heat it and make it expand; if the defect category is ink color error, the control system 60 drives the second nozzle 52 to spray ink on all the preliminarily dust-removed foam for color overlay processing;

[0043] Step (5): After the defect handling component 50 preliminarily processes the defects of each sub-image, multiple thickness detection instruments 42 arranged at intervals along the width direction of the foam are used to measure the thickness of different parts of the foam with preliminarily processed defects and transmit the data to the control system 60. The control system 60 can classify the defects of the foam according to the measurements of the thickness detection instruments 42 as: too thin spraying of the foaming agent, too thick spraying of the foaming agent;

[0044] Step (6): The defect handling component 50 reprocesses the defects of the foam. If the defect category is too thin spraying of the foaming agent, the control system 60 drives the third nozzle 53 to spray the foaming agent on the defective part; if the defect category is too thick spraying of the foaming agent, the control system 60 first drives the scraper 54 to scrape the defective part, and then drives the first nozzle 51 to blow cold air on the defective part for secondary cleaning.

[0045] In step (1), the width of the foam is 1 - 1.5 m. In this embodiment, the width of the foam is 1.2 m.

[0046] In step (2), since the length of the dust removal roller 311 is 0.3 m and the number of the dust removal rollers 311 is 5, according to the width of the foam, the control system 60 only needs to drive 4 dust removal rollers 311 to achieve the preliminary dust removal of the foam.

[0047] In step (3), the specific steps for the control system 60 to process the images collected by the industrial camera 41 are as follows:

[0048] a1: Cut the captured image along two centerlines to obtain four sub-images, and perform dual-tree complex wavelet transform on each sub-image to obtain 6 matrices of 256×256;

[0049] a2: Substitute the obtained 6 matrices into the Markov model, obtain the parameters of the Markov model, and perform normalization processing on the obtained parameters;

[0050] a3: Construct vectors for the normalized parameters to obtain the texture feature vectors of the foam in each sub-image;

[0051] a4: Compare each obtained texture feature vector with the texture feature vectors of qualified products respectively. If the Euclidean distances between them are not greater than the preset qualified product threshold, the foam in the image is a qualified product, and the foam flows to the next stage normally, and the defect detection component 40 does not need to perform any processing; if the Euclidean distances between them are greater than the qualified product threshold, then compare the corresponding sub-image texture feature vectors with the foam texture feature vectors of all preselected defect types respectively. If the Euclidean distances between them are not greater than the corresponding defect threshold, the foam in the corresponding sub-image belongs to the corresponding defect type, and the control system 60 records it and gives the defect position information.

[0052] In step (4), after the second nozzle 52 sprays ink on the foam for color overlay processing, the foam can be subjected to UV curing in the next stage. The curing temperature is 50 - 70 °C, and the curing time is 5 - 10 min, so as to enhance the adhesion between the foam substrate and the ink, ensure the forming quality of the foam, and meet the customer requirements. In this embodiment, the customer's required color is green, but the staff mispainted it as yellow. Then, according to the color overlay principle, only blue ink needs to be reapplied.

[0053] In step (6), after the third nozzle 53 sprays the foaming agent on the defective part, the foam can be subjected to UV curing in the next stage. The curing temperature is 50 - 70 °C, and the curing time is 5 - 10 min, so as to enhance the adhesion between the foam substrate and the foaming agent, ensure the forming quality of the foam, and meet the customer requirements; after the scraper 54 scrapes the defective part, the excess foaming agent is collected through the recycling component 70, which can be reused to reduce production costs.

[0054] The foam cleaning method further includes step (7), and step (7) is specifically: cut off the two side edges of the foam through the knives 80 installed at both ends of the foam. Since the left and right side edges of the foam are, on the one hand, cleaning dead corners, and on the other hand, it is easy to not be covered with coatings, etc., so in order to ensure the coating quality and facilitate subsequent processing and use, the two sides of the foam are trimmed, cutting off a certain width of fabric on the left and right sides of the foam. In this way, the remaining foam surface is covered with the coating. In this embodiment, the cutting edge width on one side of the foam is 2 - 6 cm. According to step (1), a 1.2 m wide foam is selected. In this step, the cut foam width is set at 4 cm, and the circular knife 80 is used to cut off the edge material of the foam. The circular knife 80 is driven by a motor to rotate, and the position of the knife 80 can be adjusted to adjust the width of the cut edge material. The cut edge material falls into the collection box and can be recycled.

[0055] In Embodiment 2:

[0056] Such as Figures 2-3As shown in the figure, a foam cleaning device is used to implement any of the above foam cleaning methods, and includes a bracket 10, a pressure roller assembly 20, a dust removal assembly 30, a defect detection assembly 40, a defect treatment assembly 50, a control system 60, a recycling assembly 70, and a cutter 80.

[0057] The bracket 10 includes a first bracket 11 and a second bracket 12, and the first bracket 11 and the second bracket 12 are fixedly connected.

[0058] The pressure roller assembly 20 includes a first pressure roller assembly 21, a second pressure roller assembly 22, and a third pressure roller assembly 23. The pressure roller assembly 20 is rotatably installed on the bracket 10 for transporting the foam. The first pressure roller assembly 21 is installed on the top of the first bracket 11, the second pressure roller assembly 22 is installed at the connection between the first bracket 11 and the second bracket 12, and the third pressure roller assembly 23 is installed at the bottom of the second bracket 12. The first pressure roller assembly 21 and the second pressure roller assembly 22 are located on opposite sides of the foam, and the first pressure roller assembly 21 and the third pressure roller assembly 23 are located on the same side of the foam. In this embodiment, both the first pressure roller assembly 21 and the third pressure roller assembly 23 are located on the front side of the foam, and the second pressure roller assembly 22 is located on the back side of the foam.

[0059] The dust removal assembly 30 is installed on the first bracket 11 and is close to the first pressure roller assembly 21. The dust removal assembly 30 includes a plurality of dust removal units 31. The dust removal units 31 are selectively moved up and down through the control system 60. The dust removal units 31 are distributed at intervals along their axial directions. The dust removal unit 31 includes a dust removal roller 311 and an elastic member 312. The dust removal roller 311 is rotatably installed on the first bracket 11. The axial direction of the dust removal roller 311 is parallel to the axial direction of the pressure roller assembly 20. A dust removal paper is wound around the outside of the dust removal roller 311. The dust removal paper contacts the foam to perform preliminary dust removal. The dust removal paper can be replaced at any time without replacing the dust removal roller 311, reducing the installation time and improving the dust removal efficiency. The foam between the dust removal assembly 30 and the second pressure roller assembly 22 is the foam that has been preliminarily dusted. The elastic member 312 is installed at both ends of the dust removal roller 311 and is connected to the first bracket 11. The extending direction of the elastic member 312 is perpendicular to the axial direction of the dust removal roller 311. The dust removal roller 311 is in floating contact with the foam through the elastic member 312 to avoid causing indentations on the foam. In this embodiment, the number of the dust removal assemblies 30 is 2, which are respectively located on the front and back sides of the foam. The number of the dust removal rollers 311 of each dust removal assembly 30 is 3 to 5. The length of the dust removal roller 311 of each dust removal unit 31 is 0.2 to 0.5 m. The length of the dust removal assembly 30 is greater than or equal to the width of the foam. The closer the dust removal assembly 30 is to the first pressure roller assembly 21, the larger the area of the foam that has been preliminarily dusted, and the larger the range for subsequent defect detection assembly 40 and defect treatment assembly 50 to perform detection and treatment, which can further improve the cleaning efficiency. The cross-section of the dust removal roller 311 is a multi-prism with edges. According to the travel of the foam, when the foam reaches a certain travel, one side of the prism is rotated. In this way, the contacting side can be cleaned by negative pressure for a longer time, and at the same time, it can ensure that the side where the prism contacts the foam maintains contact for a period of time to clean the dust.

[0060] In a preferred embodiment, a servo motor can also be provided at one end of the dust removal roller 311. The rotation angle of the servo motor is controlled to be 60° each time, and the rotation interval time is 2 min. In this way, it can be controlled that after each rotation of the dust removal roller 311, it can turn over one side, and this side has 2 min to fully contact the foam, then absorb the dust on the foam to this side. At the same time, when this side rotates under the negative pressure, there is enough time to use the negative pressure to remove the dust on the dust removal roller 311. After 2 min, the next side continues to perform dust removal on the foam, and the operation is cycled.

[0061] In another preferred embodiment, a dust suction hood can also be provided above the cleaning device. The dust is discharged by negative pressure through the dust suction port of the dust suction hood. The other end of the dust suction port is connected to an air extraction pump. The air extraction pump extracts the air in the dust suction hood. Under the negative pressure state, the dust on the dust removal roller 311 is stripped and extracted.

[0062] The defect detection component 40 includes an industrial camera 41 and a thickness detection instrument 42. The industrial camera 41 is installed at the connection of the first bracket 11 and the second bracket 12, collects images of the preliminarily dust-removed foam and feeds the image information back to the control system 60. A plurality of thickness detection instruments 42 are installed on the first bracket 11 and are arranged at intervals along the width direction of the foam to detect the thickness of different parts of the foam and transmit the data to the control system 60. The control system 60 determines the defect category according to the defect information and controls the defect processing component 50 to perform corresponding processing. In this embodiment, the number of the defect processing components 50 is 2, which are respectively located on the front and back sides of the foam. The thickness detection instrument 42 includes a laser emitter and a photoelectric sensor, and does not need to contact the foam during the detection process, and will not cause indentation to the foam, etc.

[0063] The defect processing component 50 includes a first nozzle 51, a second nozzle 52, a third nozzle 53, and a scraper 54. The defect processing component 50 is installed on the second bracket 12 and can move along the direction of the defect part of the foam. The first nozzle 51 is selectively communicated with the cold air channel and the hot air channel through the control system 60. The second nozzle 52 is communicated with the ink channel. The third nozzle 53 is communicated with the foaming agent channel. Among them, the first nozzle 51 and the second nozzle 52 are used for the preliminary defect processing of the sub-image of the foam; the third nozzle 53 and the scraper 54 are used for the reprocessing of all the foams with preliminarily processed defects. The defect processing component 50 processes the foam defects in sequence, so that there will be no interference during processing and the working efficiency of the defect processing component 50 is relatively high. In this embodiment, the number of the defect processing components 50 is 2, which are respectively located on the front and back sides of the foam. The defect detection component 40 and the defect processing component 50 operate separately, that is, when the preliminarily dust-removed foam is transported between the second pressing roller component 22 and the third pressing roller component 23, the defect processing is carried out again to improve the operating efficiency of each component.

[0064] The recycling component 70 is installed on the second bracket 12 and is electrically connected to the control system 60. The recycling component 70 collects the excess foaming agent scraped by the scraper 54 and can be reused.

[0065] The cutter 80 is installed on the second bracket 12 and is located on both sides of the preliminarily dust-removed foam. The cutter 80 is electrically connected to the control system 60 and is used for trimming the two sides of the foam, cutting off a certain width of fabric on the left and right sides of the foam, so that the remaining foam surface is covered with the coating, ensuring the coating quality and facilitating subsequent processing and use.

[0066] When the present application performs cleaning on the foam, first, the number of dust removal rollers 311 that matches the width of the foam is calculated according to the width of the foam, and then the above-mentioned dust removal rollers 311 are driven to rotate and the gap between the dust removal rollers 311 and the foam is adjusted so that the dust removal paper on the dust removal rollers 311 contacts the foam for preliminary dust removal. Among them, the dust removal rollers 311 are in floating contact with the foam through elastic members 312, which can prevent indentations on the foam while achieving preliminary dust removal. Then, an industrial camera 41 is used to detect defects on the preliminarily dust-removed foam, determine the defect categories of the sub-images, and perform corresponding preliminary defect processing through a defect processing component 50. Then, multiple thickness detection instruments 42 are used to detect defects on the foam that has been preliminarily processed for defects again, and then corresponding defect reprocessing is performed through the defect processing component 50. The present invention performs multiple defect detections on the foam through the industrial camera 41 and the thickness detection instruments 42 and classifies the defects specifically, so the judgment error is small, and it is not easy to have missed judgments or misjudgments. No defective products will flow into the next production stage, ensuring the final forming quality of the product and meeting customer requirements. The present invention processes the foam defects in sequence through the defect processing component, so there will be no interference during processing. The present invention can perform corresponding processing on defects during the foam production process without pausing operations and waiting for the defect processing to be completed before continuing operations, and the working efficiency of the defect processing component is high, which can improve the cleaning efficiency and further improve the production efficiency.

[0067] The equipment quantities and treatment scales described herein are used to simplify the description of the present invention. Applications, modifications, and variations of the present invention will be apparent to those skilled in the art.

[0068] Although the embodiments of the present invention have been disclosed as above, they are not limited to the applications listed in the specification and the embodiments. It can be fully applied to various fields suitable for the present invention. For those familiar with the field, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the equivalent scope, the present invention is not limited to the specific details and the examples shown and described herein.

Claims

1. A method for cleaning foam, characterized in that: The foam cleaning method includes the following steps: Step (1): Measure the width of the foam through sensors on both sides of the foam, and transmit the measurement data to the control system. The control system calculates the number of dust removal rollers that match the width of the foam. Step (2): Drive the dust removal rollers that match the width of the foam to rotate and adjust the gap between the dust removal rollers and the foam. The dust removal rollers contact the foam for preliminary dust removal. The dust removal rollers are floatingly connected to the foam through elastic members to prevent indentation. Step (3): Collect images of the preliminarily dust-removed foam through an industrial camera and feedback them to the control system. The image processing module of the control system divides the image into multiple sub-images. Each sub-image is compared one by one with all defect categories in the storage module of the control system. The control system can classify the defects of each sub-image according to the detection of the industrial camera as: dust residue, indentation, and incorrect ink color. The control system determines the defect category based on the above defect information and gives the defect position information. Step (4): The control system drives the defect processing component to preliminarily process the defects of each sub-image. If the defect category is dust residue, the control system drives the first nozzle to blow cold air at the defect area for secondary cleaning. If the defect category is indentation, the control system drives the first nozzle to blow hot air at the defect area to heat it and make it expand. If the defect category is incorrect ink color, the control system drives the second nozzle to spray ink on all the preliminarily dust-removed foam for color overlay processing. Step (5): After the defect processing component preliminarily processes the defects of each sub-image, measure the thickness of different parts of all the foam with preliminarily processed defects through multiple thickness detection instruments arranged at intervals along the width direction of the foam and transmit the data to the control system. The control system can classify the defects of the foam according to the measurement of the thickness detection instruments as: too thin spraying of foaming agent, too thick spraying of foaming agent. Step (6): The defect processing component reprocesses the defects of the foam. If the defect category is too thin spraying of foaming agent, the control system drives the third nozzle to spray foaming agent at the defect area. If the defect category is too thick spraying of foaming agent, the control system drives the scraper to scrape the defect area.

2. The foam cleaning method according to claim 1, wherein: In step (4), after the second nozzle sprays ink on the foam for color overlay processing, UV curing is performed on the foam.

3. The foam cleaning method according to claim 1, wherein: In step (6), after the third nozzle sprays foaming agent at the defect area, UV curing is performed on the foam.

4. The foam cleaning method according to claim 1, characterized in that: In step (6), after the scraper scrapes the defect area, the control system then drives the first nozzle to blow cold air at the defect area for secondary cleaning.

5. The foam cleaning method according to claim 1, wherein: The foam cleaning method further includes step (7), and specifically, step (7) is: Cut off both sides of the foam through the tools installed at both ends of the foam to ensure uniform spraying of foaming agent on both edges of the foam.

6. The foam cleaning method according to claim 1, characterized in that: In step (6), after the scraper scrapes the defect area, the excess foaming agent is collected through the recovery component and can be reused.

7. A foam cleaning device, characterized in that: The foam cleaning device is used to implement the foam cleaning method according to any one of claims 1-6. The foam cleaning device includes a bracket, a pressure roller assembly, a dust removal assembly, and a control system. It further includes a defect detection assembly and a defect treatment assembly. The pressure roller assembly is rotatably installed on the bracket and is used to convey the foam. The dust removal assembly includes a plurality of dust removal units. The dust removal units are selectively moved up and down through the control system. The dust removal units are distributed at intervals along their axial directions. Each dust removal unit includes a dust removal roller and an elastic member. The dust removal roller is rotatably installed on the bracket. The axial direction of the dust removal roller is parallel to the axial direction of the pressure roller assembly. A dust removal paper is wound around the outside of the dust removal roller. The dust removal paper contacts the foam to perform preliminary dust removal. The elastic member is installed at both ends of the dust removal roller and is connected to the bracket. The defect detection assembly and the defect treatment assembly are both installed on the bracket. The defect detection assembly includes an industrial camera and a thickness detection instrument. The thickness detection instruments are arranged at intervals along the width direction of the foam. The defect treatment assembly includes a plurality of nozzles and a scraper. The defect detection assembly can move along the direction of the defect part of the foam. The foam after preliminary dust removal is subjected to defect detection by the defect detection assembly. The defect detection assembly feeds back the defect information to the control system. The control system determines the defect category according to the defect information and controls the nozzles and the scraper to perform corresponding treatments.

8. The foam cleaning device according to claim 7, wherein: The bracket includes a first bracket and a second bracket. The pressure roller assembly includes a first pressure roller assembly, a second pressure roller assembly, and a third pressure roller assembly. The first pressure roller assembly is installed at the top of the first bracket. The second pressure roller assembly is installed at the connection between the first bracket and the second bracket. The third pressure roller assembly is installed at the bottom of the second bracket. The first pressure roller assembly and the second pressure roller assembly are located on opposite sides of the foam. The first pressure roller assembly and the third pressure roller assembly are located on the same side of the foam. The dust removal assembly is installed on the first bracket and is close to the first pressure roller assembly. The foam between the dust removal assembly and the second pressure roller assembly is the foam that has been preliminarily dusted. The defect detection assembly is installed at the connection between the first bracket and the second bracket. The defect treatment assembly is installed on the second bracket. The number of the dust removal assembly, the defect detection assembly, and the defect treatment assembly is 2 each, and they are respectively located on the front and back sides of the foam.

9. The foam cleaning device according to claim 8, wherein: The foam cleaning device further includes a cutter. The cutter is installed on the second bracket and is located on both sides of the foam that has been preliminarily dusted. The cutter is electrically connected to the control system.

10. The foam cleaning device according to claim 8, characterized in that: The foam cleaning device further includes a recycling assembly. The recycling assembly is installed on the second bracket and is electrically connected to the control system.

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