A jacquard machine misalignment monitoring system and method

Abstract

The present application relates to the field of textile technology, and in particular to a jacquard machine misalignment monitoring system and method. The method comprises: real-time monitoring of the fabric to obtain monitoring data; extracting a monitoring image of the fabric based on the monitoring data; matching the monitoring image with a preset normal image; if the monitoring image does not match the preset normal image, it is determined that there is a misalignment, and the jacquard machine is controlled to stop working; according to the monitoring data and the monitoring image, the retraction length of the fabric retraction processing is obtained; and the fabric is retracted according to the retraction length. The present application improves the processing efficiency of misalignment problems through automated monitoring and processing; at the same time, based on the image matching method, the misalignment judgment process is simplified, making it more intuitive and easy to implement; in addition, by determining and retracting the fabric to the area before the misalignment position, it can ensure that the wrong position can be accurately located when repairing the misalignment, thereby improving the accuracy of the repair.

Description

Technical Field

[0001] The present application relates to the field of textile technology, and in particular to a jacquard machine misalignment monitoring system and method. Background Art

[0002] In the textile industry, jacquard machines are important production equipment, and their work efficiency and product quality directly affect the economic benefits and market competitiveness of enterprises. However, in the actual operation of jacquard machines, due to the influence of various factors such as equipment wear, operating errors, and raw material quality, wrong stitches often occur, that is, the knitting needles fail to correctly insert or remove the yarn during the weaving process, resulting in the formation of wrong patterns or designs on the fabric. In order to solve this problem, the existing technology has developed high-definition recognition technology to identify the wrong stitch phenomenon on the jacquard machine. By capturing the image of the fabric with a high-definition camera and combining it with an image processing algorithm, the position and type of the wrong stitch on the fabric can be accurately identified. This technology greatly improves the accuracy and efficiency of wrong stitch recognition and provides strong support for subsequent processing.

[0003] However, existing jacquard machine image recognition technology faces significant challenges in identifying and handling misaligned stitch problems, including the expansion of misaligned stitch problems due to delayed response, increased difficulty in repair, and insufficient recognition accuracy due to interference from the shooting environment and camera shooting angle problems. These have had a significant impact on the production and quality control of jacquard machines and need to be improved. Summary of the invention

[0004] The present application provides a jacquard machine misaligned needle monitoring system and method to solve the significant challenges of existing jacquard machine image recognition technology in identifying and processing misaligned needle problems, including the expansion of misaligned needle problems and increased difficulty in repair due to delayed response, as well as insufficient recognition accuracy caused by interference from the shooting environment and camera shooting angle problems.

[0005] In a first aspect, the present application provides a method for monitoring misaligned needles in a jacquard machine, comprising:

[0006] Performing real-time monitoring on the fabric to obtain monitoring data; extracting a monitoring image of the fabric according to the monitoring data; and matching the monitoring image with a preset normal image;

[0007] If the monitoring image does not match the preset normal image, it is determined that there is a wrong needle situation, and the jacquard machine is controlled to stop working;

[0008] The retraction length of the fabric retraction process is obtained according to the monitoring data and the monitoring image; and the fabric is retracted according to the retraction length.

[0009] The above technical solution has the following advantages: through automated monitoring and processing, the tediousness and time-consuming nature of manual operations are greatly reduced, and the efficiency of handling misaligned stitch problems is improved; at the same time, the image matching method is used to simplify the misaligned stitch judgment process, making it more intuitive and easy to implement; and the preset normal image provides a clear reference standard, making the misaligned stitch judgment more accurate and reliable; in addition, by determining and retracting the fabric to the area before the misaligned stitch position, it can be ensured that the error position can be accurately located when repairing the misaligned stitch, thereby improving the accuracy of the repair.

[0010] Optionally, obtaining the retraction length of the fabric retraction process according to the monitoring data and the monitoring image includes:

[0011] Extracting the initial time node when the wrong needle occurs according to the monitoring data and the monitoring image;

[0012] After the jacquard machine stops working, extracting the initial stop time node of the jacquard machine and the stop end time point of the jacquard machine according to the monitoring data;

[0013] Obtaining a first time interval according to the initial time node of the occurrence of the wrong stitch and the initial time node of the stoppage of the jacquard machine;

[0014] Obtaining a second time interval according to an initial time node of the shutdown of the jacquard machine and an end time point of the shutdown of the jacquard machine;

[0015] Obtaining the spinning speed of the jacquard machine in the uniform speed stage;

[0016] Determining the fabric length in the uniform speed stage according to the weaving speed and the first time interval;

[0017] The spinning speed is used as the initial speed of the jacquard machine in the deceleration stage, and the ending speed of the jacquard machine in the deceleration stage is used as the final speed;

[0018] determining the fabric length in the deceleration stage according to the initial speed, the final speed, and the second time interval;

[0019] The retraction length of the fabric retraction process is obtained according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage.

[0020] The above technical solution has the following advantages: by calculating the fabric length in the uniform speed stage and the deceleration stage, the retraction length of the fabric can be accurately controlled to ensure that it retracts to the correct position. The accurate retraction length can reduce unnecessary fabric waste and reduce production costs. Accurate retraction can locate the wrong needle position more quickly and improve the repair efficiency.

[0021] Optionally, determining the fabric length in the uniform speed stage according to the weaving speed and the first time interval includes:

[0022] The fabric length in the uniform speed stage is determined according to the weaving speed and the first time interval, with reference to the following formula:

[0023] ;

[0024] in, represents the fabric length in the uniform speed stage, Indicates the spinning speed, Indicates the first time interval.

[0025] The above technical solution has the following advantages: the fabric length in the uniform speed stage is calculated based on a mathematical formula, which realizes an accurate and repeatable method to estimate the fabric length that needs to be retracted; this method not only improves the accuracy of the calculation, but also enhances reliability and predictability. In addition, the use of standardized formulas also helps to achieve a consistent retraction process between different systems and different operators.

[0026] Optionally, determining the fabric length in the deceleration stage according to the initial speed, the final speed, and the second time interval includes:

[0027] The fabric length in the deceleration stage is determined according to the initial speed, the final speed, and the second time interval, with reference to the following formula:

[0028] ;

[0029] in, represents the fabric length during the deceleration phase, represents the initial speed, 0 represents the final speed, Indicates the second time interval.

[0030] The above technical solution has the following advantages: the fabric length in the deceleration stage is calculated by a specific mathematical formula, which further improves the accuracy and reliability of the calculation; this method not only takes into account the initial and final speeds of the jacquard machine, but also takes into account the time interval experienced during the deceleration process, so that the fabric length that needs to be retracted can be estimated more accurately. In addition, the use of standardized formulas also helps to achieve a consistent retraction process between different systems and different operators, thereby improving production efficiency and product quality.

[0031] Optionally, obtaining the retraction length of the fabric retraction process according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage includes:

[0032] According to the fabric length in the uniform speed stage and the fabric length in the deceleration stage, the retraction length of the fabric retraction process is obtained, specifically referring to the following formula:

[0033] ;

[0034] Indicates the retraction length of the fabric retraction process. represents the fabric length in the uniform speed stage, Indicates the fabric length during the deceleration phase.

[0035] The above technical solution has the following advantages: by combining the fabric lengths in the uniform speed stage and the deceleration stage, the fabric length that needs to be retracted can be accurately calculated, thereby ensuring the accuracy of the retraction. This method not only improves the efficiency of the retraction process, but also helps to reduce unnecessary fabric waste and reduce production costs. In addition, the standardized calculation formula also helps to achieve a consistent retraction process between different systems and different operators, improving the stability and reliability of the production process.

[0036] Optionally, the method further includes:

[0037] After the fabric is returned, a re-inspection image is collected for the fabric to obtain a re-inspection image;

[0038] Matching the re-examination image with a preset normal image;

[0039] If the re-inspected image matches the preset normal image, it is determined that the fabric retraction process is completed.

[0040] The above technical solution has the following advantages: by adding a re-inspection step, the quality of the fabric after the return process can be checked to ensure the correctness and completeness of the return process. This helps to improve product quality and reduce the scrap rate. At the same time, through image matching technology, the quality status of the fabric can be quickly and accurately judged, improving production efficiency and automation level.

[0041] Optionally, the method further includes:

[0042] If the re-inspected image does not match the preset normal image, the process of fabric return processing is checked according to the re-inspected image;

[0043] According to the troubleshooting results, determine the cause of the abnormal fabric return;

[0044] According to the reasons for the abnormal fabric retreat, a new treatment plan is formulated.

[0045] The above technical solution has the following advantages: by adding a processing flow for when the re-inspected image does not match the preset normal image, the problem can be discovered and solved in time, ensuring the correctness and integrity of the fabric return process. This helps to reduce errors and waste in the production process and improve product quality and production efficiency. At the same time, by formulating and executing a new processing plan, it can quickly respond to abnormal situations and ensure the continuity and stability of production.

[0046] In a second aspect, the present application provides a jacquard machine misalignment monitoring system, comprising:

[0047] A monitoring module is used to monitor the fabric in real time and obtain monitoring data; extract a monitoring image of the fabric according to the monitoring data; and match the monitoring image with a preset normal image;

[0048] An analysis module, used for determining that there is a misaligned needle situation if the monitoring image does not match the preset normal image, and controlling the jacquard machine to stop working;

[0049] The program formulation module is used to obtain the retraction length of the fabric retraction processing according to the monitoring data and the monitoring image; and perform retraction processing on the fabric according to the retraction length.

[0050] Optionally, the program formulation module is specifically used to:

[0051] Extracting the initial time node when the wrong needle occurs according to the monitoring data and the monitoring image;

[0052] After the jacquard machine stops working, extracting the initial stop time node of the jacquard machine and the stop end time point of the jacquard machine according to the monitoring data;

[0053] Obtaining a first time interval according to the initial time node of the occurrence of the wrong stitch and the initial time node of the stoppage of the jacquard machine;

[0054] Obtaining a second time interval according to an initial time node of the shutdown of the jacquard machine and an end time point of the shutdown of the jacquard machine;

[0055] Obtaining the spinning speed of the jacquard machine in the uniform speed stage;

[0056] Determining the fabric length in the uniform speed stage according to the weaving speed and the first time interval;

[0057] The spinning speed is used as the initial speed of the jacquard machine in the deceleration stage, and the ending speed of the jacquard machine in the deceleration stage is used as the final speed;

[0058] determining the fabric length in the deceleration stage according to the initial speed, the final speed, and the second time interval;

[0059] The retraction length of the fabric retraction process is obtained according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage.

[0060] Optionally, the program formulation module is specifically used to:

[0061] The fabric length in the uniform speed stage is determined according to the weaving speed and the first time interval, with reference to the following formula:

[0062] ;

[0063] in, represents the fabric length in the uniform speed stage, Indicates the spinning speed, Indicates the first time interval.

[0064] Optionally, the program formulation module is specifically used to:

[0065] The fabric length in the deceleration stage is determined according to the initial speed, the final speed, and the second time interval, with reference to the following formula:

[0066] ;

[0067] in, represents the fabric length during the deceleration phase, represents the initial speed, 0 represents the final speed, Indicates the second time interval.

[0068] Optionally, the program formulation module is specifically used to:

[0069] According to the fabric length in the uniform speed stage and the fabric length in the deceleration stage, the retraction length of the fabric retraction process is obtained, specifically referring to the following formula:

[0070] ;

[0071] Indicates the retraction length of the fabric retraction process. represents the fabric length in the uniform speed stage, Indicates the fabric length during the deceleration phase.

[0072] Optionally, the jacquard machine misalignment monitoring system further includes a re-inspection module, which is used to:

[0073] After the fabric is returned, a re-inspection image is collected for the fabric to obtain a re-inspection image;

[0074] Matching the re-examination image with a preset normal image;

[0075] If the re-inspected image matches the preset normal image, it is determined that the fabric retraction process is completed.

[0076] Optionally, the jacquard machine misalignment monitoring system further includes a troubleshooting module, which is used to:

[0077] If the re-inspected image does not match the preset normal image, the process of fabric return processing is checked according to the re-inspected image;

[0078] According to the troubleshooting results, determine the cause of the abnormal fabric return;

[0079] According to the reasons for the abnormal fabric retreat, a new treatment plan is formulated. BRIEF DESCRIPTION OF THE DRAWINGS

[0080] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, a brief introduction will be given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0081] Figure 1 A schematic diagram of an application scenario provided for an embodiment of the present application;

[0082] Figure 2 A flowchart of a method for monitoring misaligned needles in a jacquard machine provided in one embodiment of the present application;

[0083] Figure 3 A schematic structural diagram of a jacquard machine misalignment monitoring system provided in one embodiment of the present application. DETAILED DESCRIPTION

[0084] In order to make the purpose, technical scheme and advantages of the embodiments of the present application clearer, the technical scheme in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0085] In addition, the term "and / or" in this article is only a description of the association relationship of associated objects, indicating that there can be three relationships. For example, A and / or B can represent: A exists alone, A and B exist at the same time, and B exists alone. In addition, the character " / " in this article, unless otherwise specified, generally means that the associated objects before and after are in an "or" relationship.

[0086] The embodiments of the present application are further described in detail below in conjunction with the drawings in the specification.

[0087] Existing technology has developed high-definition recognition technology to identify the phenomenon of wrong stitches on jacquard machines. By capturing the image of the fabric with a high-definition camera and combining it with an image processing algorithm, the position and type of wrong stitches on the fabric can be accurately identified. This technology greatly improves the accuracy and efficiency of wrong stitch identification and provides strong support for subsequent processing.

[0088] However, existing jacquard machine image recognition technology faces significant challenges in identifying and handling misaligned stitch problems, including the expansion of misaligned stitch problems due to delayed response, increased difficulty in repair, and insufficient recognition accuracy due to interference from the shooting environment and camera shooting angle problems. These have had a significant impact on the production and quality control of jacquard machines and need to be improved.

[0089] Specifically, the existing jacquard machine image recognition technology, after identifying the wrong needle situation, there is a non-negligible time interval between triggering the stop command and the actual stop of the jacquard machine. During this period of time, the jacquard machine will continue to work, resulting in the problem of wrong needles on the fabric not only failing to be corrected in time, but also continuously expanding its scope of influence as the machine runs. This not only increases the workload of subsequent rollback work, but also significantly increases the difficulty of repair work. What is more complicated is that when the jacquard machine is working, many wire harnesses are intertwined and complex, seriously blocking the camera's line of sight, making it difficult for the image recognition system to accurately capture the specific position and characteristics of the wrong needle on the fabric, and because of the problem of the camera shooting angle, the length on the image is inconsistent with the actual length. Therefore, when judging the width and length of the wrong needle, the existing image recognition technology often fails to achieve the expected accuracy, which brings considerable challenges to the production and quality control of the jacquard machine.

[0090] Based on this, the present application provides a jacquard machine misalignment monitoring system and method. Through automated monitoring and processing, the tediousness and time-consumingness of manual operation are greatly reduced, and the processing efficiency of misalignment problems is improved; at the same time, based on the image matching method, the misalignment judgment process is simplified, making it more intuitive and easy to implement; and the preset normal image provides a clear reference standard, making the misalignment judgment more accurate and reliable; in addition, by determining and retracting the fabric to the area before the misalignment position, it can be ensured that the wrong position can be accurately located when repairing the misalignment, thereby improving the accuracy of the repair.

[0091] Figure 1A schematic diagram of an application scenario provided for the present application. During the operation of the jacquard machine, the present application is applied to monitor the misaligned needles. Specifically, the server communicates with the monitoring device, and the server communicates with the terminal device, and sends a real-time monitoring instruction to the monitoring device, and controls the monitoring device to monitor the misaligned needles of the jacquard machine according to the real-time monitoring instruction, and feeds back the monitoring data, analyzes the monitoring data, and formulates a processing plan, such as the retraction length of the fabric retraction processing, and sends the processing plan to the terminal device to adjust the jacquard machine; through automated monitoring and processing, the tediousness and time-consumingness of manual operation are greatly reduced, and the efficiency of processing the misaligned needle problem is improved. The specific implementation method can refer to the following embodiments.

[0092] Figure 2 This is a flowchart of a method for monitoring misaligned needles in a jacquard machine provided in an embodiment of the present application. The method of this embodiment can be applied to the server in the above scenario. Figure 2 As shown, the method includes:

[0093] S201, monitor the fabric in real time to obtain monitoring data; extract a monitoring image of the fabric according to the monitoring data; and match the monitoring image with a preset normal image.

[0094] Specifically, a high-definition camera is installed in the working area of ​​the jacquard machine (for example, in front of the stitches to reduce interference from the harness) to capture the weaving process of the fabric in real time; the video stream data from the camera is received in real time and converted into monitoring data; the monitoring data is stored in the form of image frames and contains information such as the texture, color, and pattern of the fabric.

[0095] A monitoring image of the current fabric is extracted from the received monitoring data; this image is captured in real time and represents the current state of the fabric.

[0096] Next, the extracted surveillance image is matched with a preset normal image; the preset normal image can be a previously captured fabric image representing a normal weaving state, or a simulated image generated based on the fabric design and weaving process; the matching process can be achieved through various image matching algorithms, such as template matching, feature point matching, etc.; these algorithms will calculate the similarity or difference between the surveillance image and the normal image.

[0097] S202: If the monitored image does not match the preset normal image, it is determined that there is a wrong needle situation, and the jacquard machine is controlled to stop working.

[0098] Specifically, if the matching result between the monitoring image and the preset normal image does not meet the preset matching threshold (i.e., the similarity is lower than the threshold or the difference is higher than the threshold), it is determined that there is a wrong needle situation. At this time, the specific location and type of the wrong needle are recorded, and a corresponding wrong needle report is generated.

[0099] Once a wrong needle is detected, a stop command is immediately sent to the control system of the jacquard machine to stop the jacquard machine from working; at the same time, based on the information in the wrong needle report and combined with the preset wrong needle processing rules, a processing plan is automatically formulated; the processing plan includes the precise positioning of the wrong needle position, the method of removing the stitches, the order of rethreading, etc.

[0100] S203, obtaining a retraction length of the fabric retraction process according to the monitoring data and the monitoring image; and performing retraction process on the fabric according to the retraction length.

[0101] Specifically, when it is determined that there is a misaligned needle situation, a stop command is sent to the jacquard machine to stop the jacquard machine. According to the monitoring data and monitoring images, combined with the weaving speed and position information of the fabric, the retraction length of the fabric retraction process is calculated and determined. This retraction length should be long enough to ensure that the fabric segment before the misaligned needle position is retracted to the processable area of ​​the jacquard machine.

[0102] According to the determined retraction length, the jacquard machine is controlled to retract the fabric. This process usually includes steps such as releasing the tension of the fabric and controlling the retraction movement of the fabric to ensure that the fabric can be accurately retracted to the position where it needs to be repaired; after the repair is completed, the jacquard machine is restarted to continue the weaving process of the fabric.

[0103] Through the method provided in this embodiment, through automated monitoring and processing, the tediousness and time-consuming nature of manual operations are greatly reduced, and the efficiency of handling the misaligned stitch problem is improved; at the same time, the method based on image matching simplifies the process of judging the misaligned stitch, making it more intuitive and easy to implement; and the preset normal image provides a clear reference standard, making the judgment of the misaligned stitch more accurate and reliable; in addition, by determining and retracting the fabric to the area before the misaligned stitch position, it can be ensured that the wrong position can be accurately located when repairing the misaligned stitch, thereby improving the accuracy of the repair.

[0104] In some embodiments, the initial time node of the occurrence of misaligned stitches is extracted according to monitoring data and monitoring images; after the jacquard machine stops working, the initial stop time node and the end time point of the jacquard machine are extracted according to the monitoring data; the first time interval is obtained according to the initial time node of the occurrence of misaligned stitches and the initial time node of the stop of the jacquard machine; the second time interval is obtained according to the initial time node of the stop of the jacquard machine and the end time point of the stop of the jacquard machine; the weaving speed of the jacquard machine in the uniform speed stage is obtained; the fabric length in the uniform speed stage is determined according to the weaving speed and the first time interval; the weaving speed is used as the initial speed of the jacquard machine in the deceleration stage, and the end speed of the jacquard machine in the deceleration stage is used as the final speed; the fabric length in the deceleration stage is determined according to the initial speed, the final speed and the second time interval; the retraction length of the fabric retraction processing is obtained according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage.

[0105] The initial time point of the wrong stitch can be considered as the specific time point when the wrong stitch occurs during the weaving process of the fabric is detected by the monitoring device (such as a high-definition camera). This time point marks the occurrence of the wrong stitch event.

[0106] Among them, the initial downtime node can be considered as the time when the jacquard machine needs to stop working immediately after detecting the wrong needle to avoid more errors. This initial downtime node is the specific time point when the jacquard machine switches from the normal operation state to the stop state.

[0107] The stop end time point may be considered as the time point before the jacquard machine is ready to restart work or perform rollback processing after stopping.

[0108] The first time interval may be considered as the time difference between the initial time node of the misaligned needle and the initial downtime time node.

[0109] The second time interval can be considered as the time from the initial downtime time node to the downtime end time node. This time interval is usually used for error checking, calculating the rollback length, adjusting the device status and other preparatory work.

[0110] Among them, the weaving speed can be considered to refer to the weaving speed of the fabric when the jacquard machine is operating normally, which is usually expressed in terms of the length of the fabric per unit time (such as meters per minute).

[0111] The initial speed can be considered as the running speed of the jacquard machine before the deceleration stage begins, that is, the speed of the jacquard machine when the wrong needle event occurs.

[0112] The final speed can be considered to be the speed of the jacquard after the deceleration stage. For the retraction process, this speed is usually zero because the jacquard needs to stop completely when retracting.

[0113] Specifically, the initial time node of the misaligned needle is extracted according to the monitoring data and the monitoring image. After the jacquard machine stops working, the initial stop time node and the end time point of the stop of the jacquard machine are extracted from the monitoring data. According to the initial time node of the misaligned needle and the initial stop time node of the jacquard machine, the first time interval is calculated. According to the initial stop time node and the end time point of the stop of the jacquard machine, the second time interval is calculated. The spinning speed of the jacquard machine in the uniform speed stage is obtained from the equipment parameters of the jacquard machine.

[0114] According to the weaving speed and the first time interval, the length of the fabric weaved in the uniform speed stage is calculated using the formula of speed multiplied by time. Assume that the speed change of the jacquard in the deceleration stage is linear (or according to a known deceleration curve). The weaving speed is taken as the initial speed of the jacquard in the deceleration stage, and the end speed of the jacquard in the deceleration stage (usually zero or close to zero) is taken as the final speed. According to the initial speed, the final speed and the second time interval, the speed formula of uniform deceleration motion or the deceleration curve is used to calculate the length of the fabric weaved in the deceleration stage. The fabric length in the uniform speed stage and the fabric length in the deceleration stage are added to obtain the retraction length of the fabric retraction process. According to the calculated retraction length, the jacquard is controlled to retract the fabric.

[0115] Through the solution provided by this embodiment, by calculating the fabric length in the uniform speed stage and the deceleration stage, the retraction length of the fabric can be accurately controlled to ensure that it is retracted to the correct position. The accurate retraction length can reduce unnecessary fabric waste and reduce production costs. Accurate retraction can locate the wrong needle position more quickly and improve the repair efficiency.

[0116] In some embodiments, the fabric length in the uniform speed stage is determined according to the weaving speed and the first time interval, with specific reference to the following formula (1):

[0117] ;

[0118] in, represents the fabric length in the uniform speed stage, Indicates the spinning speed, Indicates the first time interval.

[0119] Through the solution provided by this embodiment, the fabric length in the uniform speed stage is calculated based on a mathematical formula, thereby realizing an accurate and repeatable method for estimating the fabric length that needs to be retracted; this method not only improves the accuracy of the calculation, but also enhances reliability and predictability. In addition, the use of a standardized formula also helps to achieve a consistent retraction process between different systems and different operators.

[0120] In some embodiments, the fabric length in the deceleration stage is determined according to the initial speed, the final speed, and the second time interval, with reference to the following formula (2):

[0121] ;

[0122] in, represents the fabric length during the deceleration phase, represents the initial speed, 0 represents the final speed, Indicates the second time interval.

[0123] Through the solution provided by this embodiment, the fabric length in the deceleration stage is calculated by a specific mathematical formula, which further improves the accuracy and reliability of the calculation; this method not only takes into account the initial speed and final speed of the jacquard machine, but also takes into account the time interval experienced during the deceleration process, so that the fabric length that needs to be retracted can be estimated more accurately. In addition, the use of standardized formulas also helps to achieve a consistent retraction process between different systems and different operators, thereby improving production efficiency and product quality.

[0124] In some embodiments, the retraction length of the fabric retraction process is obtained according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage, with reference to the following formula (3) for details:

[0125] ;

[0126] Indicates the retraction length of the fabric retraction process. represents the fabric length in the uniform speed stage, Indicates the fabric length during the deceleration phase.

[0127] Through the solution provided by this embodiment, by combining the fabric lengths in the uniform speed stage and the deceleration stage, the fabric length that needs to be retracted can be accurately calculated, thereby ensuring the accuracy of the retraction. This method not only improves the efficiency of the retraction process, but also helps to reduce unnecessary fabric waste and reduce production costs. In addition, the standardized calculation formula also helps to achieve a consistent retraction process between different systems and different operators, thereby improving the stability and reliability of the production process.

[0128] In some embodiments, after the fabric rewinding process, a re-inspection image of the fabric is captured to obtain a re-inspection image; the re-inspection image is matched with a preset normal image; if the re-inspection image matches the preset normal image, it is determined that the fabric rewinding process is completed.

[0129] Specifically, after the fabric is rewound, a high-definition camera or other image acquisition device is used to collect re-inspection images of the fabric to obtain a re-inspection image. This step is to check whether the fabric after the rewinding process meets the quality standard. The re-inspection image is matched with a preset normal image. The preset normal image is set in advance and represents the image that the fabric should present when it is in the correct weaving state.

[0130] If the re-inspected image matches the preset normal image, it means that the fabric after the back-processing has reached the expected quality standard, and it can be determined that the fabric back-processing is completed. At this point, the subsequent weaving work can be continued.

[0131] Through the solution provided by this embodiment, by adding a re-inspection step, the quality of the fabric after the return process can be checked to ensure the correctness and completeness of the return process. This helps to improve product quality and reduce the scrap rate. At the same time, through image matching technology, the quality status of the fabric can be quickly and accurately judged, thereby improving production efficiency and automation level.

[0132] In some embodiments, if the re-inspected image does not match the preset normal image, the fabric rollback process is checked based on the re-inspected image; based on the checking results, the cause of the abnormal fabric rollback is determined; and based on the cause of the abnormal fabric rollback, a new processing plan is formulated.

[0133] Specifically, if the re-inspected image does not match the preset normal image, the troubleshooting process is initiated. The troubleshooting mainly revolves around the fabric retraction process, including checking whether the retraction length is calculated correctly, whether the control instructions of the jacquard machine are accurately executed, and whether there are any faults in the mechanical parts.

[0134] According to the investigation results, determine the specific reasons for the abnormal fabric retraction. Possible reasons include incorrect calculation of the retraction length, inaccurate execution of jacquard machine control instructions, mechanical component failure, etc.

[0135] According to the determined abnormal reasons, a new treatment plan is formulated. For example, if the return length is calculated incorrectly, the return length is recalculated and the return process is performed; if the jacquard machine control command is executed inaccurately, the control command is adjusted and re-executed; if the mechanical parts are faulty, they are repaired or replaced.

[0136] The operation is performed according to the newly formulated processing plan until the re-examination image matches the preset normal image.

[0137] Through the solution provided by this embodiment, by adding a processing flow for when the re-inspected image does not match the preset normal image, the problem can be discovered and solved in time, ensuring the correctness and integrity of the fabric return process. This helps to reduce errors and waste in the production process and improve product quality and production efficiency. At the same time, by formulating and executing a new processing plan, abnormal situations can be quickly responded to, ensuring the continuity and stability of production.

[0138] Figure 3 A schematic diagram of a jacquard machine misalignment monitoring system provided in one embodiment of the present application is shown in FIG. Figure 3 As shown, the jacquard machine misalignment monitoring system 300 of this embodiment includes: a monitoring module 301, an analysis module 302, and a plan formulation module 303.

[0139] The monitoring module 301 is used to monitor the fabric in real time and obtain monitoring data; extract a monitoring image of the fabric according to the monitoring data; and match the monitoring image with a preset normal image;

[0140] The analysis module 302 is used to determine that there is a wrong needle situation if the monitoring image does not match the preset normal image, and control the jacquard machine to stop working;

[0141] The plan formulation module 303 is used to obtain the retraction length of the fabric retraction processing according to the monitoring data and the monitoring image; and perform retraction processing on the fabric according to the retraction length.

[0142] Optionally, the plan formulation module 303 is specifically used to:

[0143] Extracting the initial time node when the wrong needle occurs according to the monitoring data and the monitoring image;

[0144] After the jacquard machine stops working, extracting the initial stop time node of the jacquard machine and the stop end time point of the jacquard machine according to the monitoring data;

[0145] Obtaining a first time interval according to the initial time node of the occurrence of the wrong stitch and the initial time node of the stoppage of the jacquard machine;

[0146] Obtaining a second time interval according to an initial time node of the shutdown of the jacquard machine and an end time point of the shutdown of the jacquard machine;

[0147] Obtaining the spinning speed of the jacquard machine in the uniform speed stage;

[0148] Determining the fabric length in the uniform speed stage according to the weaving speed and the first time interval;

[0149] The spinning speed is used as the initial speed of the jacquard machine in the deceleration stage, and the ending speed of the jacquard machine in the deceleration stage is used as the final speed;

[0150] determining the fabric length in the deceleration stage according to the initial speed, the final speed, and the second time interval;

[0151] The retraction length of the fabric retraction process is obtained according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage.

[0152] Optionally, the plan formulation module 303 is specifically used to:

[0153] The fabric length in the uniform speed stage is determined according to the weaving speed and the first time interval, with reference to the following formula:

[0154] ;

[0155] in, represents the fabric length in the uniform speed stage, Indicates the spinning speed, Indicates the first time interval.

[0156] Optionally, the plan formulation module 303 is specifically used to:

[0157] The fabric length in the deceleration stage is determined according to the initial speed, the final speed, and the second time interval, with reference to the following formula:

[0158] ;

[0159] in, represents the fabric length during the deceleration phase, represents the initial speed, 0 represents the final speed, Indicates the second time interval.

[0160] Optionally, the plan formulation module 303 is specifically used to:

[0161] According to the fabric length in the uniform speed stage and the fabric length in the deceleration stage, the retraction length of the fabric retraction process is obtained, specifically referring to the following formula:

[0162] ;

[0163] Indicates the retraction length of the fabric retraction process. represents the fabric length in the uniform speed stage, Indicates the fabric length during the deceleration phase.

[0164] Optionally, the jacquard machine misalignment monitoring system 300 further includes a recheck module 304, which is used to:

[0165] After the fabric is returned, a re-inspection image is collected for the fabric to obtain a re-inspection image;

[0166] Matching the re-examination image with a preset normal image;

[0167] If the re-inspected image matches the preset normal image, it is determined that the fabric retraction process is completed.

[0168] Optionally, the jacquard machine misalignment monitoring system 300 further includes a troubleshooting module 305, which is used to:

[0169] If the re-inspected image does not match the preset normal image, the process of fabric return processing is checked according to the re-inspected image;

[0170] According to the troubleshooting results, determine the cause of the abnormal fabric return;

[0171] According to the reasons for the abnormal fabric retreat, a new treatment plan is formulated.

[0172] The jacquard machine misalignment monitoring system of this embodiment can be used to execute the method of any of the above embodiments, and its implementation principle and technical effect are similar, which will not be repeated here.

Claims

1. A method for monitoring misaligned needles in a jacquard machine, characterized in that: include: Monitor the fabric in real time and obtain monitoring data; extracting a monitoring image of the fabric according to the monitoring data; Matching the monitored image with a preset normal image; If the monitoring image does not match the preset normal image, it is determined that there is a wrong needle situation, and the jacquard machine is controlled to stop working; According to the monitoring data and the monitoring image, a retraction length of the fabric retraction process is obtained; and the fabric is retracted according to the retraction length; Extracting the initial time node when the wrong needle occurs according to the monitoring data and the monitoring image; After the jacquard machine stops working, extracting the initial stop time node of the jacquard machine and the stop end time point of the jacquard machine according to the monitoring data; Obtaining a first time interval according to the initial time node of the occurrence of the wrong stitch and the initial time node of the stoppage of the jacquard machine; Obtaining a second time interval according to an initial time node of the shutdown of the jacquard machine and an end time point of the shutdown of the jacquard machine; Obtaining the spinning speed of the jacquard machine in the uniform speed stage; Determining the fabric length in the uniform speed stage according to the weaving speed and the first time interval; The spinning speed is used as the initial speed of the jacquard machine in the deceleration stage, and the ending speed of the jacquard machine in the deceleration stage is used as the final speed; determining the fabric length in the deceleration stage according to the initial speed, the final speed, and the second time interval; The retraction length of the fabric retraction process is obtained according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage.

2. The method according to claim 1, characterized in that Determining the fabric length in the uniform speed stage according to the weaving speed and the first time interval comprises: The fabric length in the uniform speed stage is determined according to the weaving speed and the first time interval, with reference to the following formula: L const =V const ×T const ; Among them, L const Indicates the fabric length in the uniform speed stage, V const Indicates the spinning speed, T const Indicates the first time interval.

3. The method according to claim 1, characterized in that The step of determining the fabric length in the deceleration stage according to the initial speed, the final speed, and the second time interval comprises: The fabric length in the deceleration stage is determined according to the initial speed, the final speed, and the second time interval, with reference to the following formula: Among them, L dec Denotes the fabric length during the deceleration phase, V init represents the initial speed, 0 represents the final speed, T dec Indicates the second time interval.

4. The method according to claim 3, characterized in that: The step of obtaining the retraction length of the fabric retraction process according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage comprises: L total =L const +L dec ; L total Indicates the retraction length of the fabric retraction process, L const Indicates the fabric length at the uniform speed stage, L dec Indicates the fabric length during the deceleration phase.

5. The method according to claim 4, characterized in that The method further comprises: After the fabric is returned, a re-inspection image is collected for the fabric to obtain a re-inspection image; Matching the re-examination image with a preset normal image; If the re-inspected image matches the preset normal image, it is determined that the fabric retraction process is completed.

6. The method according to claim 5, characterized in that The method further comprises: If the re-inspected image does not match the preset normal image, the process of fabric return processing is checked according to the re-inspected image; According to the troubleshooting results, determine the cause of the abnormal fabric return; According to the reasons for the abnormal fabric retreat, a new treatment plan is formulated.

7. A jacquard machine misalignment monitoring system, characterized in that: include: A monitoring module is used to monitor the fabric in real time and obtain monitoring data; extracting a monitoring image of the fabric according to the monitoring data; Matching the monitored image with a preset normal image; An analysis module, used for determining that there is a misaligned needle situation if the monitoring image does not match the preset normal image, and controlling the jacquard machine to stop working; A plan formulation module is used to obtain a retraction length of the fabric retraction process according to the monitoring data and the monitoring image; and perform retraction processing on the fabric according to the retraction length; Extracting the initial time node when the wrong needle occurs according to the monitoring data and the monitoring image; After the jacquard machine stops working, extracting the initial stop time node of the jacquard machine and the stop end time point of the jacquard machine according to the monitoring data; Obtaining a first time interval according to the initial time node of the occurrence of the wrong stitch and the initial time node of the stoppage of the jacquard machine; Obtaining a second time interval according to an initial time node of the shutdown of the jacquard machine and an end time point of the shutdown of the jacquard machine; Obtaining the spinning speed of the jacquard machine in the uniform speed stage; Determining the fabric length in the uniform speed stage according to the weaving speed and the first time interval; The spinning speed is used as the initial speed of the jacquard machine in the deceleration stage, and the ending speed of the jacquard machine in the deceleration stage is used as the final speed; determining the fabric length in the deceleration stage according to the initial speed, the final speed, and the second time interval; The retraction length of the fabric retraction process is obtained according to the fabric length in the uniform speed stage and the fabric length in the deceleration stage.

Images