A system and method for detecting the circulation of fabric in a dyeing machine

Abstract

The application provides a fabric circulation detection system and method in a dyeing machine, comprising a dyeing machine, an imaging detection device arranged along a fabric circulation track outside the dyeing machine, the imaging detection device being connected to a PC terminal through a coaxial shielded cable of an RS-485 communication protocol, a monitoring module arranged along the fabric circulation track outside the dyeing machine 1, the monitoring module being connected to a switch through a network cable of a TCP / IP protocol, the switch being connected to the PC terminal, and the monitoring module at least comprising a temperature sensor, a pump body regulator, a valve regulator and a cloth wheel controller. The dyeing machine is subjected to thermal imaging by infrared rays, the fabric circulation running state is detected, and it is judged whether cloth blocking occurs. The detection is prevented from being affected by the high-temperature dyeing process, the accuracy and timeliness of cloth blocking detection are ensured, cloth blocking problems are automatically eliminated in the first time by intelligent regulation, the complicated operation of traditional cooling and opening of the cylinder for manual removal and modification of the design of the dyeing machine is saved, and the work efficiency and productivity are improved.

Description

Technical Field

[0001] This invention belongs to the field of textile printing and dyeing technology, and relates to a fully automatic monitoring device, particularly a textile circulation detection system and detection method in a dyeing machine. Background Technology

[0002] Currently, the dyeing process of fabrics is still carried out by various dyeing machines. Taking the walking dyeing machine as an example, the movement of the fabric in the dyeing machine is subject to multiple propulsive forces, such as the spraying of dye liquor from the nozzle, the propulsion of the dye liquor flowing in the guide tube, and the lifting of the fabric by the rotation of the lifting wheel. This easily generates multiple variables that can change the speed of the fabric. In addition, the turbulent changes in the flow of water on the fabric cause a certain degree of inconsistency in the overall circulation. It is very easy for the fabric to be blocked at the junction of the guide tube and the end of the storage tank, thus affecting the dyeing effect and production efficiency.

[0003] Because fabrics generally require high temperature and high pressure during the dyeing process to meet the chemical requirements, the fabric circulation within the dyeing machine typically needs to be carried out in a closed environment. This limits real-time monitoring of the fabric's operating status, and often once a blockage occurs, it is a complete blockage, requiring cooling, opening the dyeing tank, and manual removal, severely impacting dyeing quality and production efficiency.

[0004] Therefore, in order to solve the above problems, it is necessary to provide a system and method for detecting the circulation of fabrics inside a dyeing machine at high temperatures, so as to overcome the defects in the prior art. Summary of the Invention

[0005] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing an infrared thermal imaging continuous cyclic monitoring system and method for accurately and promptly detecting and addressing fabric blockages in dyeing machines to ensure normal operation.

[0006] The objective of this invention can be achieved through the following technical solution: a fabric circulation detection system within a dyeing machine, comprising a dyeing machine, wherein an imaging detection device is movable along the fabric circulation trajectory around the outer periphery of the dyeing machine, the imaging detection device is connected to a PC terminal via a coaxial shielded cable using the RS-485 communication protocol, a monitoring module is set along the fabric circulation trajectory around the outer periphery of the dyeing machine, the monitoring module is connected to a switch via a network cable using the TCP / IP protocol, the switch is connected to the PC terminal, and the monitoring module includes at least a temperature sensor, a pump controller, a valve controller, and a fabric wheel controller.

[0007] In the aforementioned fabric circulation detection system within the dyeing machine, an annular slide rail is arranged parallel to the fabric circulation trajectory on the outer periphery of the dyeing machine. The imaging detection device is connected to the annular slide rail via rollers to form a rolling-sliding connection. The rollers are driven by a moving motor. The imaging detection device includes an environmental monitoring module, a data transmission module, a power supply module, an infrared thermal imaging module, a camera module, an image processing module, a movement module, and an alarm module.

[0008] In the fabric circulation detection system inside the dyeing machine described above, the environmental monitoring module has a temperature sensing element and a temperature compensation element; the data transmission module communicates and processes data with the PC terminal; the power supply module monitors the power supply unit and the mobile power supply unit through electromagnetic isolation; the camera module is divided into a photographic imaging unit and a scanning recognition unit; the image processing module transmits the processed image information to the display screen of the PC terminal; and the alarm module is connected to a buzzer and an alarm light through a circuit.

[0009] In the above-mentioned fabric circulation detection system in the dyeing machine, the dyeing machine includes a machine body with a head and a tail. A spray nozzle is provided at the head, and the spray nozzle and the tail are connected by a dye liquor circulation pipeline. A drive pump and several regulating valves are connected in series on the dye liquor circulation pipeline. A fabric lifting wheel is provided at the head, and the fabric lifting wheel is driven by a fabric wheel motor.

[0010] In the fabric circulation detection system inside the dyeing machine described above, the initial point of the imaging detection device is set above the tail of the dyeing machine. A starting sensor is fixed at the initial point. Several detection points are arranged sequentially from the tail to the head of the dyeing machine. A label barcode is affixed to the first detection point located at the tail. A position sensor and a temperature sensor are set at each detection point.

[0011] A detection method for a fabric circulation detection system inside a dyeing machine includes the following steps:

[0012] 1) After the imaging detection device moves to the initial point and contacts the starting sensor, the moving module drives the moving motor to move in the opposite direction, causing the imaging detection device to move towards the first detection point.

[0013] 2) After moving to the first detection point, the camera module of the imaging detection device scans the barcode on the tail of the machine to confirm the dyeing machine number, and the data transmission module of the imaging detection device queries the PC terminal to see if the dyeing machine being inspected is in operation.

[0014] 3) If the dyeing machine under inspection is currently in operation, the imaging inspection device will start to divide the inspection area into monitoring areas and enable the data transmission module to obtain the dyeing process temperature required by the dyeing machine under inspection through the PC terminal, and set the corresponding area temperature threshold according to the required temperature.

[0015] 4) Perform a total of M frames of infrared video thermal imaging on the divided area, and detect the temperature distribution of each area frame by frame. The data transmission module sends the temperature processing data to the PC terminal to determine whether there is a sub-area where the temperature is continuously below the threshold of the corresponding process temperature for N frames due to the blockage of the cloth.

[0016] 5) After the M-frame infrared video thermal imaging ends, if the temperature of a sub-region is below the threshold for N consecutive frames, the alarm module controls the buzzer and alarm light to display an alarm, and the PC terminal displays the words "Dyeing machine X is clogged"; the PC terminal controls the monitoring module through the switch to adjust the speed and power of the drive pump, adjust the opening of several regulating valves, and adjust the power of the cloth wheel motor to eliminate the cloth clogging phenomenon.

[0017] 6) After the blockage phenomenon is eliminated or after the M-frame infrared video thermal imaging ends, if the temperature of the non-sub-region is below the threshold for N consecutive frames, the imaging detection device moves to the next detection point.

[0018] 7) When the imaging detection device moves to the next detection point, it automatically detects whether it is the final detection point. If not, it repeats steps 3) to 6). If it is the final detection point, the imaging detection device returns to the initial point and starts the next full process operation.

[0019] In the above-mentioned detection method of the fabric circulation detection system in the dyeing machine, in step 2), if the dyeing machine being inspected is currently in a stopped or offline state, the imaging detection device will automatically move to the next detection point.

[0020] In the detection method of the fabric circulation detection system in the dyeing machine described above, in step 4), the value of M is greater than the value of N.

[0021] In the detection method of the fabric circulation detection system in the dyeing machine described above, in step 5), if the fabric blockage problem is not resolved after adjusting the drive pump and several regulating valves for a set time, the PC terminal display will show the words "manual removal".

[0022] Compared with existing technologies, the fabric circulation detection system and method in this dyeing machine have the following advantages:

[0023] 1. Infrared thermal imaging is used to examine the interior of the dyeing machine, detecting the fabric's circulation status and determining if fabric blockage has occurred. This avoids the impact of high-temperature dyeing processes on detection, ensuring the accuracy and timeliness of blockage detection. Intelligent control is then used to automatically eliminate blockages in the first instance, reducing the cumbersome manual troubleshooting and modifications to the dyeing machine design required by traditional methods, thus improving work efficiency and production capacity.

[0024] 2. This testing method does not require additional equipment to be installed on the dyeing machine, does not disrupt the high-temperature and high-pressure process environment inside the dyeing machine, reduces testing costs, saves manual labor, and improves the degree of automation. It provides a new approach for the testing of dyed fabrics and is suitable for widespread application. Attached Figure Description

[0025] Figure 1 This is a framework diagram of the fabric circulation detection system inside the dyeing machine.

[0026] Figure 2 This is a diagram showing the module composition of the imaging detection device in the fabric circulation detection system of this dyeing machine.

[0027] Figure 3 This is a flowchart of the actual detection process of the fabric circulation detection system inside the dyeing machine.

[0028] Figure 4 This is a flowchart of the detection method of the fabric circulation detection system inside the dyeing machine.

[0029] Figure 3 In the middle, 1. dyeing machine; 1a. machine head; 1b. machine tail; 2. dye liquor circulation pipeline; 3. drive pump; 4. regulating valve; 5. imaging detection device. Detailed Implementation

[0030] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0031] like Figures 1 to 3 As shown, the fabric circulation detection system inside the dyeing machine includes a dyeing machine 1. An imaging detection device 5 is installed around the outer periphery of the dyeing machine 1 along the fabric circulation trajectory. The imaging detection device 5 is connected to a PC terminal via a coaxial shielded cable with RS-485 communication protocol. A monitoring module is installed around the outer periphery of the dyeing machine 1 along the fabric circulation trajectory. The monitoring module is connected to a switch via a network cable with TCP / IP protocol. The switch is connected to the PC terminal. The monitoring module includes at least a temperature sensor, a pump controller, a valve controller, and a fabric wheel controller.

[0032] A circular slide rail is set parallel to the fabric circulation track on the outer periphery of the dyeing machine 1. The imaging detection device 5 is connected to the circular slide rail by rollers to form a rolling-sliding connection. The rollers are driven by a moving motor. Figure 2 As shown, the imaging detection device 5 is equipped with an environmental monitoring module, a data transmission module, a power supply module, an infrared thermal imaging module, a camera module, an image processing module, a motion module, and an alarm module.

[0033] The environmental monitoring module has a temperature sensing element and a temperature compensation element. The data transmission module communicates and processes data with the PC terminal. The power supply module has an electromagnetically isolated monitoring power supply unit and a mobile power supply unit. The camera module is divided into a photo imaging unit and a scanning and recognition unit. The image processing module transmits the processed image information to the display screen of the PC terminal. The alarm module is connected to a buzzer and an alarm light through a circuit.

[0034] The environmental monitoring module monitors the current ambient temperature and performs corresponding temperature compensation; the data transmission module processes relevant monitoring data and sends it to the PC terminal, and also processes and analyzes signal data from the PC terminal; the power supply module's monitoring power supply unit supplies power to the monitoring components, and the power supply module's mobile power supply unit supplies power to the mobile motor; the infrared thermal imaging module performs infrared thermal imaging of the target; the camera module is used for dividing the imaging area and scanning barcodes; the image processing module uses relevant neural networks to process image data, obtain high-resolution image information, and use it for terminal display; the mobility module is used to move the imaging detection device 5 to different detection points; and the alarm module uses a buzzer and alarm light to display the detection results.

[0035] like Figure 3 As shown, the dyeing machine 1 includes a machine body with a head 1a and a tail 1b. A spray nozzle is installed at the head 1a. The spray nozzle and the tail 1b are connected by a dye liquor circulation pipe 2. A drive pump 3 and several regulating valves 4 are connected in series on the dye liquor circulation pipe 2. A fabric lifting wheel is installed at the head 1a, and the fabric lifting wheel is driven by a fabric wheel motor. The dyeing machine 1 is existing equipment, and its structure and operating principle are all existing technology; therefore, they will not be described in detail here.

[0036] The initial point of the imaging detection device 5 is set above the tail 1b of the dyeing machine 1. A starting sensor is fixed at the initial point. Several detection points are arranged sequentially from the tail 1b to the head 1a of the dyeing machine 1. A label barcode is affixed to the first detection point on the tail 1b. A position sensor and a temperature sensor are installed at each detection point. Several position sensors are installed on annular slide rails at corresponding positions on the dyeing machine 1, thereby sensing the movement of the imaging detection device 5 to reach the corresponding detection point.

[0037] like Figure 4 As shown, a detection method for a fabric circulation detection system inside a dyeing machine includes the following steps:

[0038] 1) After the imaging detection device 5 is activated, moves to the initial point and contacts the starting sensor, the moving module drives the moving motor to move in the opposite direction, causing the imaging detection device 5 to move towards the first detection point.

[0039] 2) After moving to the first detection point, the camera module of the imaging detection device 5 scans the barcode on the tail 1b to confirm the number of the dyeing machine 1, and the data transmission module of the imaging detection device 5 queries the PC terminal to see if the dyeing machine 1 being inspected is in operation.

[0040] If the staining machine 1 being inspected is currently stopped or offline, the imaging detection device 5 will automatically move to the next detection point.

[0041] 3) If the dyeing machine 1 being inspected is currently in operation, the imaging detection device 5 will start to divide the detection area into monitoring areas and enable the data transmission module to obtain the dyeing process temperature required by the dyeing machine 1 being inspected through the PC terminal, and set the corresponding area temperature threshold according to the required temperature.

[0042] 4) Perform a total of M frames of infrared video thermal imaging on the divided area, and detect the temperature distribution of each area frame by frame. The data transmission module sends the temperature processing data to the PC terminal to determine whether there is a sub-area where the temperature is continuously below the threshold of the corresponding process temperature for N frames due to blockage of the cloth; where M is greater than N.

[0043] 5) After the M-frame infrared video thermal imaging ends, if the temperature of a sub-region is below the threshold for N consecutive frames, the alarm module controls the buzzer and alarm light to display an alarm, and the PC terminal displays the words "Dyeing machine 1 No. X has experienced cloth blockage"; the PC terminal controls the monitoring module through the switch to adjust the speed and power of the drive pump 3, adjust the opening of several regulating valves 4, and adjust the power of the cloth wheel motor to eliminate the cloth blockage.

[0044] The aforementioned adjustment methods for the drive pump 3 include, but are not limited to, increasing the speed and power; the adjustment methods for the regulating valve 4 include, but are not limited to, increasing the opening degree; and the adjustment methods for the cloth wheel motor include, but are not limited to, increasing the power. These adjustment methods are prior art in this field and will not be described in detail here.

[0045] If the cloth blockage problem is not resolved after a set time by adjusting the drive pump 3 and several regulating valves 4, the PC terminal display will show the words "Manual removal".

[0046] 6) After the blockage phenomenon is eliminated or after the M-frame infrared video thermal imaging ends, if the temperature of the non-sub-region is below the threshold for N consecutive frames, the imaging detection device 5 moves to the next detection point.

[0047] 7) When the imaging detection device 5 moves to the next detection point, it automatically detects whether it is the final detection point. If not, it repeats steps 3) to 6). If it is the final detection point, the imaging detection device 5 returns to the initial point and starts the next full process operation.

[0048] Compared with existing technologies, the fabric circulation detection system and method in this dyeing machine have the following advantages:

[0049] 1. Infrared thermal imaging is used to examine the interior of the dyeing machine, detecting the fabric's circulation status and determining if fabric blockage has occurred. This avoids the impact of high-temperature dyeing processes on detection, ensuring the accuracy and timeliness of blockage detection. Intelligent control is then used to automatically eliminate blockages in the first instance, reducing the cumbersome manual troubleshooting and modifications to the dyeing machine design required by traditional methods, thus improving work efficiency and production capacity.

[0050] 2. This testing method does not require additional equipment to be installed on the dyeing machine, does not disrupt the high-temperature and high-pressure process environment inside the dyeing machine, reduces testing costs, saves manual labor, and improves the degree of automation. It provides a new approach for the testing of dyed fabrics and is suitable for widespread application.

[0051] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

[0052] Although this document frequently uses terms such as dyeing machine 1; machine head 1a; machine tail 1b; dye liquor circulation pipeline 2; drive pump 3; regulating valve 4; imaging detection device 5, the possibility of using other terms is not excluded. These terms are used merely for the convenience of describing and explaining the essence of the invention; interpreting them as any additional limitation would contradict the spirit of the invention.

[0053] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

Claims

1. A detection method for a fabric circulation detection system within a dyeing machine, the fabric circulation detection system comprising a dyeing machine, an imaging detection device being moved along the fabric circulation trajectory around the outer periphery of the dyeing machine, the imaging detection device being connected to a PC terminal via a coaxial shielded cable using the RS-485 communication protocol, a monitoring module being arranged along the fabric circulation trajectory around the outer periphery of the dyeing machine, the monitoring module being connected to a switch via a network cable using the TCP / IP protocol, the switch being connected to the PC terminal, and the monitoring module comprising at least a temperature sensor, a pump controller, a valve controller, and a fabric wheel controller; The detection method of the fabric circulation detection system inside the dyeing machine is characterized in that... Includes the following steps: 1) After the imaging detection device moves to the initial point and contacts the starting sensor, the moving module drives the moving motor to move in the opposite direction, causing the imaging detection device to move towards the first detection point; 2) After moving to the first detection point, the camera module of the imaging detection device scans the barcode on the tail of the machine to confirm the dyeing machine number, and the data transmission module of the imaging detection device queries the PC terminal to see if the dyeing machine being inspected is in operation. 3) If the dyeing machine under inspection is currently in operation, the imaging inspection device will start to divide the inspection area into monitoring areas and enable the data transmission module to obtain the dyeing process temperature required by the dyeing machine under inspection through the PC terminal, and set the corresponding area temperature threshold according to the required temperature. 4) Perform a total of M frames of infrared video thermal imaging on the divided area, and detect the temperature distribution of each area frame by frame. The data transmission module sends the temperature processing data to the PC terminal to determine whether there is a sub-area where the temperature is continuously below the threshold of the corresponding process temperature for N frames due to the blockage of the cloth. 5) After the M-frame infrared video thermal imaging ends, if the temperature of a sub-region is below the threshold for N consecutive frames, the alarm module controls the buzzer and alarm light to display an alarm, and the PC terminal displays the words "Dyeing machine X is clogged"; the PC terminal controls the monitoring module through the switch to adjust the speed and power of the drive pump, adjust the opening of several regulating valves, and adjust the power of the cloth wheel motor to eliminate the cloth clogging phenomenon. 6) After the blockage phenomenon is eliminated or after the M-frame infrared video thermal imaging ends, if the temperature of the non-sub-region is below the threshold for N consecutive frames, the imaging detection device moves to the next detection point. 7) When the imaging detection device moves to the next detection point, it automatically detects whether it is the final detection point. If not, it repeats steps 3) to 6). If it is the final detection point, the imaging detection device returns to the initial point and starts the next full-process operation.

2. The detection method of the fabric circulation detection system in the dyeing machine as described in claim 1, characterized in that, The dyeing machine has a circular slide rail parallel to the fabric circulation track on its outer periphery. The imaging detection device is connected to the circular slide rail by rollers to form a rolling-sliding connection. The rollers are driven by a moving motor. The imaging detection device is equipped with an environmental monitoring module, a data transmission module, a power supply module, an infrared thermal imaging module, a camera module, an image processing module, a movement module, and an alarm module.

3. The detection method of the fabric circulation detection system in the dyeing machine as described in claim 2, characterized in that, The environmental monitoring module has a temperature sensing element and a temperature compensation element. The data transmission module communicates and processes data with the PC terminal. The power supply module has an electromagnetically isolated monitoring power supply unit and a mobile power supply unit. The camera module is divided into a photographic imaging unit and a scanning recognition unit. The image processing module transmits the processed image information to the display screen of the PC terminal. The alarm module is connected to a buzzer and an alarm light through a circuit.

4. The detection method of the fabric circulation detection system in the dyeing machine as described in claim 1, characterized in that, The dyeing machine includes a machine body with a head and a tail. A spray nozzle is provided at the head. The spray nozzle and the tail are connected by a dye liquor circulation pipeline. A drive pump and several regulating valves are connected in series on the dye liquor circulation pipeline. A fabric lifting wheel is provided at the head. The fabric lifting wheel is driven by a fabric wheel motor.

5. The detection method of the fabric circulation detection system in the dyeing machine as described in claim 4, characterized in that, The initial point of the imaging detection device is set above the tail of the dyeing machine. A starting sensor is fixed at the initial point. Several detection points are arranged sequentially from the tail to the head of the dyeing machine. A label barcode is affixed to the first detection point on the tail. A position sensor and a temperature sensor are set at each detection point.

6. The detection method of the fabric circulation detection system in the dyeing machine as described in claim 1, characterized in that, In step 2), if the staining machine being inspected is currently stopped or offline, the imaging detection device will automatically move to the next detection point.

7. The detection method of the fabric circulation detection system in the dyeing machine as described in claim 1, characterized in that, In step 4), the value of M is greater than the value of N.

8. The detection method of the fabric circulation detection system in the dyeing machine as described in claim 1, characterized in that, In step 5), if the cloth blockage problem is not resolved after a set time by adjusting the drive pump and several regulating valves, the PC terminal display will show the words "Manual removal".

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