High-strength low-shrinkage differentiated nylon filament production equipment and method

Abstract

The application discloses a high-strength low-shrinkage differentiated nylon filament production equipment and method, relates to the nylon filament production field, and comprises an infrared camera for acquiring an infrared image of a heating roller; a plurality of industrial cameras are respectively used for acquiring a plurality of monitoring images of different monitoring areas of the long filaments to be monitored; and a controller is used for determining whether the temperature of the heating roller is uniform according to the infrared image, and determining the drafting state of the long filaments based on the proportion of long filament pixels in a sliding window of the plurality of monitoring images in the case that it is determined that the temperature of the heating roller is not uniform; otherwise, the drafting state of the long filaments is determined based on the proportion of long filament pixels in a rolling window of the plurality of monitoring images. The application determines whether the temperature of each group of heating rollers is not uniform through the infrared camera and the controller, determines the drafting state of the long filaments at the input and output positions of each group of heating rollers through the industrial camera and the controller, thereby determining whether the long filaments appear the phenomenon of uneven drafting, and further improving the production quality of the nylon long filaments.

Description

Technical Field

[0001] This application relates to the field of nylon filament production, and in particular to a high-strength, low-shrinkage differentiated nylon filament production equipment and method. Background Technology

[0002] Currently, in order to improve the strength and shrinkage differentiation of nylon filaments, nylon filaments are usually produced by multiple drawing processes at different temperatures.

[0003] Specifically, after the nylon filament is extruded, it is stretched multiple times by setting multiple sets of stretching rollers with gradually increasing temperatures. Experiments show that this method of stretching multiple times at different temperatures can effectively improve the strength of the nylon filament.

[0004] During multiple drawing processes, if any heating and stretching roller malfunctions, causing uneven temperature during nylon filament drawing, the resulting nylon filament diameter will be uneven, affecting the production quality. Therefore, it is necessary to monitor the diameter of the nylon filament during the drawing process.

[0005] Although existing computer imaging technology can be used to acquire images of nylon filaments during the drawing process and identify the edges of the nylon filaments through edge detection and edge enhancement techniques, and then further determine the diameter of the nylon filaments based on the identified edges, thereby determining whether the drawing state of the nylon filaments is normal, this method is difficult to meet the needs of production line monitoring. Summary of the Invention

[0006] To improve the speed of determining the drawing state of nylon filaments on the production line, this application provides a high-strength, low-shrinkage differentiated nylon filament production equipment and method.

[0007] The high-strength, low-shrinkage differentiated nylon filament production equipment provided in this application adopts the following technical solution:

[0008] A high-strength, low-shrinkage differentiated nylon filament production equipment includes a background contrast plate, an industrial camera, an infrared camera, and a controller, all positioned below the filament to be monitored.

[0009] The infrared camera is used to acquire infrared images of the heating roller;

[0010] The multiple industrial cameras are used to acquire multiple monitoring images of different monitoring areas of the filament to be monitored;

[0011] The controller is used to determine whether the temperature of the heating roller is uniform based on the infrared image, and if the temperature of the heating roller is determined to be uneven, the controller determines the stretching state of the filament based on the proportion of filament pixels in the sliding window of the multiple monitoring images; otherwise, the controller determines the stretching state of the filament based on the proportion of filament pixels in the scrolling window of the multiple monitoring images.

[0012] By adopting the above technical solution, setting up infrared cameras and controllers, it is possible to determine whether there is uneven temperature at each group of heating rollers. The background contrast board is used to improve the distinction between filament pixels and background pixels in each monitoring image, which facilitates the identification of filaments. The industrial camera and controller are used to determine the stretching state of the filaments at the input and output positions of each group of heating rollers, thereby determining whether there is uneven stretching of nylon filaments and thus improving the production quality of nylon filaments.

[0013] Preferably, the controller is specifically used for:

[0014] Obtain the first grayscale image of the area corresponding to the heating roller in the infrared image;

[0015] The first grayscale image is divided into multiple second grayscale images along the arrangement extension direction of the heating units of the heating roller;

[0016] Based on the predetermined correspondence between grayscale values ​​and temperature, the temperature corresponding to each of the second grayscale images is determined;

[0017] If the difference between the temperature corresponding to any second grayscale image and the operating temperature of the heating roller is greater than a preset threshold, the temperature of the heating roller is determined to be uneven; otherwise, the temperature of the heating roller is determined to be uniform.

[0018] By adopting the above technical solution, the correspondence between grayscale values ​​and temperature in this scenario is determined in advance through multiple experiments. Based on the grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined. The temperature corresponding to each second grayscale image is used to characterize the temperature of different heating areas of the heating roller, so as to determine whether the heating roller has uneven temperature.

[0019] Preferably, the second grayscale image corresponds to the heating unit, and the controller is specifically used for:

[0020] Obtain the average grayscale value of each of the second grayscale images;

[0021] Based on the predetermined correspondence between grayscale values ​​and temperature, and the average grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined.

[0022] By adopting the above technical solution, each second grayscale image can represent the temperature of each heating unit, and in the event of a temperature change due to a malfunction in any heating unit, the temperature change can be accurately reflected based on the second grayscale image corresponding to that heating unit.

[0023] Preferably, the controller is specifically used for:

[0024] The number of first-class pixels and second-class pixels in each scrolling window of the grayscale image of each monitored image is determined, wherein the pixels corresponding to the background contrast panel are regarded as first-class pixels, and the other pixels are regarded as second-class pixels;

[0025] The drawing state of the filament is determined based on the first proportion of the second type of pixels in each scrolling window in the grayscale image of each monitoring image to all pixels in the corresponding scrolling window, and the rate of change of the first proportion corresponding to multiple scrolling windows in the grayscale image of each monitoring image.

[0026] By adopting the above technical solution, the width of the filament in each scrolling window is characterized by the first proportion of the second type of pixels to the total number of pixels in each scrolling window; the uniformity of the filament stretching change state is characterized by the rate of change of the first proportion in multiple scrolling windows of each monitoring image, and the stretching state of the filament is determined by the first proportion and the rate of change of the first proportion.

[0027] Preferably, the controller is specifically used for:

[0028] For each grayscale image of the monitored image, if the deviation between the first ratio of any of its scrolling windows and the preset ratio threshold is greater than the first preset value, then it is confirmed that the filament stretching state is uneven.

[0029] For each grayscale image of the monitored image, if the deviation between the first ratio change rate corresponding to the multiple scrolling windows and the preset change rate threshold is greater than the second preset value, then it is confirmed that the filament stretching state is uneven.

[0030] Otherwise, confirm that the filament stretching is uniform.

[0031] By adopting the above technical solution, for each grayscale image of a monitoring image, if the deviation of the first ratio of any scrolling window from the preset ratio threshold is greater than the first preset value, it indicates that the filament width in that area has changed, which also indicates that the filament stretching state is uneven; for each grayscale image of a monitoring image, if the deviation of the change rate of the first ratio corresponding to multiple scrolling windows from the preset change rate threshold is greater than the second preset value, it is confirmed that the filament stretching state is uneven.

[0032] Preferably, the controller is specifically used for:

[0033] For each grayscale image of the monitored image, obtain the difference in the first ratio between two adjacent scrolling windows;

[0034] The determined differences are fitted to obtain a fitting function for the grayscale image of each monitored image, and the slope of the fitting function is determined as the rate of change of the first proportion.

[0035] By adopting the above technical solution, the rate of change of the first ratio was quickly determined based on the first ratio.

[0036] Preferably, the controller is specifically used for:

[0037] The number of third-class and fourth-class pixels in each sliding window of the grayscale image of each monitored image is determined, wherein the pixels corresponding to the background contrast panel are regarded as third-class pixels, and the other pixels are regarded as fourth-class pixels;

[0038] The drawing state of the filament is determined based on the second proportion of the third type of pixels in each scrolling window in the grayscale image of each monitoring image to all pixels in the corresponding scrolling window, and the rate of change of the second proportion corresponding to multiple sliding windows in the grayscale image of each monitoring image.

[0039] By adopting the above technical solution, a scrolling window is used instead of a sliding window in the processing of each monitoring image, thereby increasing the amount of computation in the processing process, but improving the accuracy of the processing process.

[0040] Secondly, the high-strength, low-shrinkage differentiated nylon filament production method provided in this application adopts the following technical solution:

[0041] Infrared images of the heating roller are acquired using an infrared camera;

[0042] Multiple monitoring images of different monitoring areas of the filament to be monitored are acquired using multiple industrial cameras.

[0043] The controller determines whether the temperature of the heating roller is uniform based on the infrared image. If the temperature of the heating roller is determined to be uneven, the drafting state of the filament is determined based on the proportion of filament pixels in the sliding window of the multiple monitoring images. Otherwise, the drafting state of the filament is determined based on the proportion of filament pixels in the scrolling window of the multiple monitoring images.

[0044] Preferably, the step of determining whether the temperature of the heating roller is uniform based on the infrared image by the controller specifically includes:

[0045] Obtain the first grayscale image of the area corresponding to the heating roller in the infrared image;

[0046] The first grayscale image is divided into multiple second grayscale images along the arrangement extension direction of the heating units of the heating roller;

[0047] Based on the predetermined correspondence between grayscale values ​​and temperature, the temperature corresponding to each of the second grayscale images is determined;

[0048] If the difference between the temperature corresponding to any second grayscale image and the operating temperature of the heating roller is greater than a preset threshold, the temperature of the heating roller is determined to be uneven; otherwise, the temperature of the heating roller is determined to be uniform.

[0049] Preferably, the step of determining the temperature corresponding to each of the second grayscale images based on a predetermined correspondence between grayscale values ​​and temperature specifically includes:

[0050] Obtain the average grayscale value of each of the second grayscale images;

[0051] Based on the predetermined correspondence between grayscale values ​​and temperature, and the average grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined.

[0052] In summary, this application includes at least one of the following beneficial technical effects:

[0053] 1. The width of the filament in each scrolling window is characterized by the first proportion of the second type of pixels to the total number of pixels in each scrolling window; the uniformity of the filament stretching state is characterized by the rate of change of the first proportion in multiple scrolling windows of each monitoring image; and the stretching state of the filament is determined by the first proportion and the rate of change of the first proportion.

[0054] 2. By conducting multiple preliminary experiments, the correspondence between grayscale values ​​and temperature in this scenario is determined. Based on the grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined. The temperature corresponding to each second grayscale image is used to characterize the temperature of different heating areas of the heating roller, so as to determine whether the heating roller has uneven temperature.

[0055] 3. By monitoring the temperature of the heating rollers, the controller determines the stretching state of the nylon filament using a faster detection method when the temperature of the heating rollers is uniform; and determines the stretching state of the nylon filament using a more accurate detection method when the temperature of the heating rollers is uneven. This achieves a balance between detection accuracy and detection speed, making it better suited for the production of nylon filaments. Attached Figure Description

[0056] Figure 1 This is a schematic diagram of the structure of the high-strength, low-shrinkage differentiated nylon filament production equipment of this application;

[0057] Figure 2 This is a schematic diagram of the production method of high-strength, low-shrinkage differentiated nylon filament of this application;

[0058] Reference numerals: 1. Heating roller; 2. Infrared camera; 3. Industrial camera; 4. Background contrast board. Detailed Implementation

[0059] The following is in conjunction with the appendix Figure 1-2 This application will be described in further detail.

[0060] This application discloses a high-strength, low-shrinkage differentiated nylon filament production equipment.

[0061] Reference Figure 1 The high-strength, low-shrinkage differentiated nylon filament production equipment includes a background contrast plate 4 set under the filament to be monitored, an industrial camera 3, an infrared camera 2, and a controller;

[0062] The infrared camera 2 is used to acquire infrared images of the heating roller 1;

[0063] The multiple industrial cameras 3 are used to acquire multiple monitoring images of different monitoring areas of the filament to be monitored;

[0064] The controller is used to determine whether the temperature of the heating roller 1 is uniform based on the infrared image, and if the temperature of the heating roller 1 is determined to be uneven, the controller determines the stretching state of the filament based on the proportion of filament pixels in the sliding window of the multiple monitoring images; otherwise, the controller determines the stretching state of the filament based on the proportion of filament pixels in the scrolling window of the multiple monitoring images.

[0065] Background contrast board 4 is a marking board that contrasts with the color of the produced nylon filament. Its installation method is determined according to the equipment. It can simply be fixed under the nylon filament on the production line.

[0066] The production equipment for nylon filament includes basic hoppers, extrusion, spinning, and suction devices. After the above steps, the nylon filament on the production line passes through multiple sets of heating rollers 1 with progressively increasing temperatures for stretching, thereby improving its strength. In this embodiment, two sets of heating rollers 1 are provided; in other feasible embodiments, the number of heating rollers 1 can be increased according to the production needs of the nylon filament.

[0067] Infrared cameras 2 are positioned above heating rollers 1, corresponding to the two sets of heating rollers 1. There are two cameras, each used to acquire infrared images of the two sets of heating rollers 1.

[0068] The controller is electrically connected to the infrared camera 2, thereby determining whether the temperature at the heating roller 1 is uniform based on the infrared image of the heating roller 1 acquired by the infrared camera 2.

[0069] Furthermore, in this embodiment, the monitoring area corresponds to the heating roller 1, and a monitoring area is defined at the input and output ends of each group of heating rollers 1. Therefore, four industrial cameras 3 are correspondingly provided, such as... Figure 1 As shown, monitoring images of the filaments to be monitored in four monitoring areas are obtained respectively.

[0070] It should be noted that, due to the setting of the background contrast plate 4, the image acquired by each industrial camera 3 only includes a local background contrast plate 4 and the filament to be monitored located in the middle of the background contrast plate 4. As long as the relative position of the equipment remains unchanged, the position of the nylon filament in the image acquired by each industrial camera 3 will not change.

[0071] The industrial camera 3 is electrically connected to the controller and is used to upload the monitoring images it acquires to the controller.

[0072] Understandably, in the process of determining each monitoring image, the pixels corresponding to the filament and the pixels corresponding to the background contrast plate 4 can be identified by setting a window, thereby determining the width of the filament based on the pixels corresponding to the filament, and thus obtaining the stretching state of the filament.

[0073] The detection window can be either a scrolling window or a sliding window. When the window is a sliding window, the amount of data that needs to be processed during detection is much greater than that generated when the window is a scrolling window.

[0074] Therefore, this application uses infrared images to determine whether the temperature at heating roller 1 is uniform. When the controller determines that the temperature at both sets of heating rollers 1 is uniform based on the acquired infrared images, it is considered that the possibility of uneven drawing during filament production is low. Therefore, a rolling window method is used to detect the monitoring images to improve the equipment's detection efficiency of filament drawing status.

[0075] When the controller determines that the temperature of the two sets of heating rollers 1 is uneven based on the acquired infrared image, it considers that the filament production is likely to be unevenly drawn. Therefore, a sliding window method is used to detect the monitoring image to improve the accuracy of the equipment in identifying the filament drawing state. This allows for accurate determination of whether the filament drawing state is affected by the heating rollers 1, leading to filament quality problems.

[0076] This invention uses an infrared camera 2 and a controller to determine whether there is temperature unevenness at each group of heating rollers 1. A background contrast plate 4 is used to improve the distinction between filament pixels and background pixels in each monitoring image, which facilitates the identification of filaments. An industrial camera 3 and a controller are used to determine the stretching state of the filaments at the input and output positions of each group of heating rollers 1, thereby determining whether there is uneven stretching of nylon filaments and thus improving the production quality of nylon filaments.

[0077] In the high-strength, low-shrinkage differentiated nylon filament production equipment of the present invention, the controller is specifically used for:

[0078] Obtain the first grayscale image of the region corresponding to heating roller 1 in the infrared image;

[0079] The first grayscale image is divided into multiple second grayscale images along the arrangement extension direction of the heating units of the heating roller 1;

[0080] Based on the predetermined correspondence between grayscale values ​​and temperature, the temperature corresponding to each of the second grayscale images is determined;

[0081] If the difference between the temperature corresponding to any second grayscale image and the working temperature of the heating roller 1 is greater than a preset threshold, it is determined that the temperature of the heating roller 1 is uneven; otherwise, it is determined that the temperature of the heating roller 1 is uniform.

[0082] Since the relative position and shooting angle of the infrared camera 2 and the heating roller 1 do not change, the relative position of the heating roller 1 in the infrared image will not change either. Therefore, the position of the heating roller 1 in the infrared image can be determined in advance. Then, the infrared image acquired in real time during production can be cropped to obtain the area corresponding to the heating roller 1 in the infrared image. Furthermore, the image of this area can be grayscaled to obtain the first grayscale image.

[0083] Based on this, in order to determine whether the temperature at the heating roller 1 is uniform according to the first grayscale image, the first grayscale image can be divided into multiple second grayscale images along the arrangement extension direction of the heating units of the heating roller 1.

[0084] It can be understood that the heating unit of the heating roller 1 can be a common electric heating wire. The electric heating wire is wound in the roller body, and each turn of the electric heating wire is regarded as a heating unit. The winding direction of the electric heating wire, that is, the length direction of the heating roller 1, is regarded as the arrangement and extension direction of the heating unit.

[0085] Furthermore, the correspondence between grayscale values ​​and temperature in this production scenario is determined in advance through multiple experiments. Based on the grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined. The temperature of different heating areas of the heating roller 1 is characterized by the temperature corresponding to each second grayscale image, so as to determine whether the heating roller 1 has uneven temperature.

[0086] Specifically, each group of heating rollers 1 has its corresponding working temperature. If the absolute value of the difference between the temperature corresponding to any second grayscale image and the working temperature in the second grayscale image of each group of heating rollers 1 is greater than a preset threshold, the temperature of the heating roller 1 is considered to be uneven; otherwise, the temperature of the heating roller 1 is considered to be uniform.

[0087] The preset threshold is determined based on experience, and it is believed that the temperature deviation will only affect the drawing state of the filament if it is greater than the preset threshold.

[0088] In the high-strength, low-shrinkage differentiated nylon filament production equipment of the present invention, the second grayscale image is correspondingly divided with the heating unit, and the controller is specifically used for:

[0089] Obtain the average grayscale value of each of the second grayscale images;

[0090] Based on the predetermined correspondence between grayscale values ​​and temperature, and the average grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined.

[0091] Furthermore, in this application, the second grayscale image corresponds to the division of heating units in the heating roller 1, that is, the number of second grayscale images is the same as the number of heating units, and the position corresponds to the position of each heating unit.

[0092] In this way, each second grayscale image can represent the temperature of each heating unit, and if any heating unit malfunctions and causes a temperature change, the temperature change can be accurately reflected based on the second grayscale image corresponding to that heating unit.

[0093] Based on this, the pixel values ​​of each second grayscale image corresponding to the heating unit are relatively similar. Therefore, in order to improve the recognition speed of the temperature of the heating roller 1, the average grayscale value of each second grayscale image can be directly calculated. According to the predetermined correspondence between grayscale value and temperature, the temperature corresponding to the average grayscale value is found and determined as the temperature corresponding to the second grayscale image.

[0094] In the high-strength, low-shrinkage differentiated nylon filament production equipment of the present invention, the controller is specifically used for:

[0095] The number of first-class pixels and second-class pixels in each scrolling window of the grayscale image of each monitored image is determined, wherein the pixels corresponding to the background contrast panel 4 are regarded as first-class pixels, and the other pixels are regarded as second-class pixels;

[0096] The drawing state of the filament is determined based on the first proportion of the second type of pixels in each scrolling window in the grayscale image of each monitoring image to all pixels in the corresponding scrolling window, and the rate of change of the first proportion corresponding to multiple scrolling windows in the grayscale image of each monitoring image.

[0097] Understandably, the relative positions of the industrial camera 3 and the heating roller 1 in the device remain unchanged. Although the width of the filament itself may vary slightly due to the influence of the stretching state, the approximate position of the filament in each monitoring image will not change.

[0098] Therefore, the approximate position of the filament in each monitoring image can be determined in advance, and a corresponding scrolling window can be designed based on this position. In this embodiment, the scrolling window is a square window, so that each window can completely cover the filament pixels in the corresponding area, and there are also pixels corresponding to the background contrast panel 4 on both sides of the window.

[0099] Since the color of the background contrast panel 4 remains unchanged, and the production environment of the filament, including the light during production, remains unchanged, the grayscale values ​​of the corresponding pixels of the background contrast panel 4 also tend to be the same.

[0100] Therefore, the grayscale value range of the pixels corresponding to the background contrast plate 4 can be determined in advance. For the monitoring image acquired in real time, the pixels that are within the grayscale value range are determined as the first type of pixels corresponding to the background contrast plate 4, and the pixels that are not within the grayscale value range are determined as the second type of pixels corresponding to the filament, and the number of pixels in each type is determined.

[0101] Furthermore, the width of the filament in each scrolling window can be characterized by the first proportion of the second type of pixels to the total number of pixels in each scrolling window; the uniformity of the filament stretching change state can be characterized by the rate of change of the first proportion in multiple scrolling windows of each monitoring image, and the stretching state of the filament can be determined by the first proportion and the rate of change of the first proportion.

[0102] In the high-strength, low-shrinkage differentiated nylon filament production equipment of the present invention, the controller is specifically used for:

[0103] For each grayscale image of the monitored image, if the deviation between the first ratio of any of its scrolling windows and the preset ratio threshold is greater than the first preset value, then it is confirmed that the filament stretching state is uneven.

[0104] For each grayscale image of the monitored image, if the deviation between the first ratio change rate corresponding to the multiple scrolling windows and the preset change rate threshold is greater than the second preset value, then it is confirmed that the filament stretching state is uneven.

[0105] Otherwise, confirm that the filament stretching is uniform.

[0106] The preset ratio threshold is determined based on the proportion of the second type of pixels corresponding to the filament in the total number of pixels in each scrolling window under normal production conditions. The first preset value is an empirical value.

[0107] For each grayscale image of a monitoring image, if the deviation of the first ratio of any scrolling window from the preset ratio threshold is greater than the first preset value, it indicates that the filament width in that area has changed, which also indicates that the filament stretching state is uneven.

[0108] Furthermore, it can generally be assumed that the width change of the filament after drawing is uniform. Therefore, for multiple scrolling windows along the production line direction of each monitoring image, the rate of change of the first proportion should also be approximately uniform.

[0109] Therefore, the drafting state of the filament can be further determined based on the deviation between the rate of change of the first proportion corresponding to multiple scrolling windows and the preset rate of change threshold. The preset rate of change threshold is obtained through prior experimentation, and the second preset value is an empirical value.

[0110] For each grayscale image of a monitoring image, if the deviation between the first ratio change rate corresponding to multiple scrolling windows and the preset change rate threshold is greater than the second preset value, then the uneven filament stretching state is confirmed.

[0111] If the above conditions are not met, the filament drawing state is considered stable, and no factors affecting the filament drawing state appear in the production environment. Therefore, the filament drawing state is considered uniform.

[0112] In the high-strength, low-shrinkage differentiated nylon filament production equipment of the present invention, the controller is specifically used for:

[0113] For each grayscale image of the monitored image, obtain the difference in the first ratio between two adjacent scrolling windows;

[0114] The determined differences are fitted to obtain a fitting function for the grayscale image of each monitored image, and the slope of the fitting function is determined as the rate of change of the first proportion.

[0115] In one specific implementation, for each grayscale image of the monitored image, n scrolling windows are set up along the moving direction of the filament production line.

[0116] Calculate the difference P1 between the first proportion of the second scrolling window and the first proportion of the first scrolling window, the difference P2 between the first proportion of the third scrolling window and the first proportion of the second scrolling window, and so on, until the difference Pn-1 between the first proportion of the nth scrolling window and the (n-1)th scrolling window.

[0117] Fitting is performed on P1, P2 to Pn-1 to obtain its fitting function, and the slope of the fitting function is determined as the rate of change of the first proportion.

[0118] In the high-strength, low-shrinkage differentiated nylon filament production equipment of the present invention, the controller is specifically used for:

[0119] The number of third-class and fourth-class pixels in each sliding window of the grayscale image of each monitored image is determined, wherein the pixels corresponding to the background contrast panel 4 are regarded as third-class pixels, and the other pixels are regarded as fourth-class pixels;

[0120] The drawing state of the filament is determined based on the second proportion of the third type of pixels in each scrolling window in the grayscale image of each monitoring image to all pixels in the corresponding scrolling window, and the rate of change of the second proportion corresponding to multiple sliding windows in the grayscale image of each monitoring image.

[0121] This implementation method is largely the same as the above implementation method, except that a scrolling window is used instead of a sliding window in the processing of each monitoring image, thereby increasing the amount of computation in the processing process, but improving the accuracy of the processing process, so it will not be described again.

[0122] The step size of the scrolling window is determined based on the length of each monitored image and the processing speed of the actual controller used.

[0123] The implementation principle of the high-strength, low-shrinkage differentiated nylon filament production equipment in this application embodiment is as follows: the controller monitors the temperature of the heating roller 1, and when the temperature of the heating roller 1 is determined to be uniform, a faster detection method is used to determine the stretching state of the nylon filament; when the temperature of the heating roller 1 is determined to be uneven, a more accurate detection method is used to determine the stretching state of the nylon filament, thereby achieving a balance between detection accuracy and detection speed, and is better applied to the production of nylon filament.

[0124] Reference Figure 2 This embodiment provides a method for producing high-strength, low-shrinkage differentiated nylon filament, including:

[0125] Step 201: Acquire an infrared image of the heating roller 1 using the infrared camera 2;

[0126] Step 202: Multiple monitoring images of different monitoring areas of the filament to be monitored are acquired by multiple industrial cameras 3;

[0127] Step 203: The controller determines whether the temperature of the heating roller 1 is uniform based on the infrared image. If the temperature of the heating roller 1 is determined to be uneven, the stretching state of the filament is determined based on the proportion of filament pixels in the sliding window of the multiple monitoring images. Otherwise, the stretching state of the filament is determined based on the proportion of filament pixels in the scrolling window of the multiple monitoring images.

[0128] Background contrast board 4 is a marking board that contrasts with the color of the produced nylon filament. Its installation method is determined according to the equipment. It can simply be fixed under the nylon filament on the production line.

[0129] The production equipment for nylon filament includes basic hoppers, extrusion, spinning, and suction devices. After the above steps, the nylon filament on the production line passes through multiple sets of heating rollers 1 with progressively increasing temperatures for stretching, thereby improving its strength. In this embodiment, two sets of heating rollers 1 are provided; in other feasible embodiments, the number of heating rollers 1 can be increased according to the production needs of the nylon filament.

[0130] Infrared cameras 2 are positioned above heating rollers 1, corresponding to the two sets of heating rollers 1. There are two cameras, each used to acquire infrared images of the two sets of heating rollers 1.

[0131] The controller is electrically connected to the infrared camera 2, thereby determining whether the temperature at the heating roller 1 is uniform based on the infrared image of the heating roller 1 acquired by the infrared camera 2.

[0132] Furthermore, in this embodiment, the monitoring area corresponds to the heating roller 1, and a monitoring area is defined at the input and output ends of each group of heating rollers 1. Therefore, four industrial cameras 3 are correspondingly provided, such as... Figure 1 As shown, monitoring images of the filaments to be monitored in four monitoring areas are obtained respectively.

[0133] It should be noted that, due to the setting of the background contrast plate 4, the image acquired by each industrial camera 3 only includes a local background contrast plate 4 and the filament to be monitored located in the middle of the background contrast plate 4. As long as the relative position of the equipment remains unchanged, the position of the nylon filament in the image acquired by each industrial camera 3 will not change.

[0134] The industrial camera 3 is electrically connected to the controller and is used to upload the monitoring images it acquires to the controller.

[0135] Understandably, in the process of determining each monitoring image, the pixels corresponding to the filament and the pixels corresponding to the background contrast plate 4 can be identified by setting a window, thereby determining the width of the filament based on the pixels corresponding to the filament, and thus obtaining the stretching state of the filament.

[0136] The detection window can be either a scrolling window or a sliding window. When the window is a sliding window, the amount of data that needs to be processed during detection is much greater than that generated when the window is a scrolling window.

[0137] Therefore, this application uses infrared images to determine whether the temperature at heating roller 1 is uniform. When the controller determines that the temperature at both sets of heating rollers 1 is uniform based on the acquired infrared images, it is considered that the possibility of uneven drawing during filament production is low. Therefore, a rolling window method is used to detect the monitoring images to improve the equipment's detection efficiency of filament drawing status.

[0138] When the controller determines that the temperature of the two sets of heating rollers 1 is uneven based on the acquired infrared image, it considers that the filament production is likely to be unevenly drawn. Therefore, a sliding window method is used to detect the monitoring image to improve the accuracy of the equipment in identifying the filament drawing state. This allows for accurate determination of whether the filament drawing state is affected by the heating rollers 1, leading to filament quality problems.

[0139] This invention uses an infrared camera 2 and a controller to determine whether there is temperature unevenness at each group of heating rollers 1. A background contrast plate 4 is used to improve the distinction between filament pixels and background pixels in each monitoring image, which facilitates the identification of filaments. An industrial camera 3 and a controller are used to determine the stretching state of the filaments at the input and output positions of each group of heating rollers 1, thereby determining whether there is uneven stretching of nylon filaments and thus improving the production quality of nylon filaments.

[0140] In the method for producing high-strength, low-shrinkage differentiated nylon filaments according to the present invention, the step of determining whether the temperature of the heating roller 1 is uniform based on the infrared image by a controller specifically includes:

[0141] Obtain the first grayscale image of the region corresponding to heating roller 1 in the infrared image;

[0142] The first grayscale image is divided into multiple second grayscale images along the arrangement extension direction of the heating units of the heating roller 1;

[0143] Based on the predetermined correspondence between grayscale values ​​and temperature, the temperature corresponding to each of the second grayscale images is determined;

[0144] If the difference between the temperature corresponding to any second grayscale image and the working temperature of the heating roller 1 is greater than a preset threshold, it is determined that the temperature of the heating roller 1 is uneven; otherwise, it is determined that the temperature of the heating roller 1 is uniform.

[0145] Since the relative position and shooting angle of the infrared camera 2 and the heating roller 1 do not change, the relative position of the heating roller 1 in the infrared image will not change either. Therefore, the position of the heating roller 1 in the infrared image can be determined in advance. Then, the infrared image acquired in real time during production can be cropped to obtain the area corresponding to the heating roller 1 in the infrared image. Furthermore, the image of this area can be grayscaled to obtain the first grayscale image.

[0146] Based on this, in order to determine whether the temperature at the heating roller 1 is uniform according to the first grayscale image, the first grayscale image can be divided into multiple second grayscale images along the arrangement extension direction of the heating units of the heating roller 1.

[0147] It can be understood that the heating unit of the heating roller 1 can be a common electric heating wire. The electric heating wire is wound in the roller body, and each turn of the electric heating wire is regarded as a heating unit. The winding direction of the electric heating wire, that is, the length direction of the heating roller 1, is regarded as the arrangement and extension direction of the heating unit.

[0148] Furthermore, the correspondence between grayscale values ​​and temperature in this production scenario is determined in advance through multiple experiments. Based on the grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined. The temperature of different heating areas of the heating roller 1 is characterized by the temperature corresponding to each second grayscale image, so as to determine whether the heating roller 1 has uneven temperature.

[0149] Specifically, each group of heating rollers 1 has its corresponding working temperature. If the absolute value of the difference between the temperature corresponding to any second grayscale image and the working temperature in the second grayscale image of each group of heating rollers 1 is greater than a preset threshold, the temperature of the heating roller 1 is considered to be uneven; otherwise, the temperature of the heating roller 1 is considered to be uniform.

[0150] The preset threshold is determined based on experience, and it is believed that the temperature deviation will only affect the drawing state of the filament if it is greater than the preset threshold.

[0151] In the method for producing high-strength, low-shrinkage differentiated nylon filaments according to the present invention, the step of determining the temperature corresponding to each second grayscale image based on a predetermined correspondence between grayscale values ​​and temperature specifically includes:

[0152] Obtain the average grayscale value of each of the second grayscale images;

[0153] Based on the predetermined correspondence between grayscale values ​​and temperature, and the average grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined.

[0154] Furthermore, in this application, the second grayscale image corresponds to the division of heating units in the heating roller 1, that is, the number of second grayscale images is the same as the number of heating units, and the position corresponds to the position of each heating unit.

[0155] In this way, each second grayscale image can represent the temperature of each heating unit, and if any heating unit malfunctions and causes a temperature change, the temperature change can be accurately reflected based on the second grayscale image corresponding to that heating unit.

[0156] Based on this, the pixel values ​​of each second grayscale image corresponding to the heating unit are relatively similar. Therefore, in order to improve the recognition speed of the temperature of the heating roller 1, the average grayscale value of each second grayscale image can be directly calculated. According to the predetermined correspondence between grayscale value and temperature, the temperature corresponding to the average grayscale value is found and determined as the temperature corresponding to the second grayscale image.

[0157] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A high-strength, low-shrinkage differentiated nylon filament production equipment, characterized in that: Includes a background contrast panel (4) placed under the filament to be monitored, an industrial camera (3), an infrared camera (2), and a controller; The infrared camera (2) is used to acquire infrared images of the heating roller (1); The multiple industrial cameras (3) are used to acquire multiple monitoring images of different monitoring areas of the filament to be monitored; The controller is used to determine whether the temperature of the heating roller (1) is uniform based on the infrared image, and if the temperature of the heating roller (1) is not uniform, it determines the stretching state of the filament based on the proportion of filament pixels in the sliding window of the multiple monitoring images; otherwise, it determines the stretching state of the filament based on the proportion of filament pixels in the scrolling window of the multiple monitoring images. The controller is specifically used for: Obtain the first grayscale image of the region corresponding to the heating roller (1) in the infrared image; The first grayscale image is divided into multiple second grayscale images along the arrangement extension direction of the heating units of the heating roller (1); Based on the predetermined correspondence between grayscale values ​​and temperature, the temperature corresponding to each of the second grayscale images is determined; If the difference between the temperature corresponding to any second grayscale image and the working temperature of the heating roller (1) is greater than a preset threshold, it is determined that the temperature of the heating roller (1) is uneven; otherwise, it is determined that the temperature of the heating roller (1) is uniform. The second grayscale image is correspondingly divided with the heating unit, and the controller is specifically used for: Obtain the average grayscale value of each of the second grayscale images; Based on the predetermined correspondence between grayscale values ​​and temperature, and the average grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined. When the controller determines the drawing state of the filament based on a scrolling window of the multiple monitoring images, the controller is specifically used to: Determine the number of first-class pixels and second-class pixels in each scrolling window of the grayscale image of each monitored image, wherein the pixels corresponding to the background contrast panel (4) are taken as first-class pixels and the other pixels are taken as second-class pixels; The drawing state of the filament is determined based on the first proportion of the second type of pixels in each scrolling window in the grayscale image of each monitoring image to all pixels in the corresponding scrolling window, and the rate of change of the first proportion corresponding to multiple scrolling windows in the grayscale image of each monitoring image. The controller is specifically used for: For each grayscale image of a monitoring image, if the deviation between the first ratio of any of its scrolling windows and the preset ratio threshold is greater than the first preset value, then it is confirmed that the filament stretching state is uneven. For each grayscale image of a monitoring image, if the deviation between the first ratio change rate corresponding to the multiple scrolling windows and the preset change rate threshold is greater than the second preset value, then it is confirmed that the filament stretching state is uneven. Otherwise, confirm that the filament stretching is uniform; The controller is specifically used for: For each grayscale image of a monitored image, obtain the difference in the first ratio between its two adjacent scrolling windows; The determined multiple differences are fitted to obtain a fitting function for the grayscale image of each monitored image, and the slope of the fitting function is determined as the rate of change of the first proportion. When the controller determines the drawing state of the filament based on a sliding window of the multiple monitoring images, the controller is specifically used to: Determine the number of third-class and fourth-class pixels in each sliding window of the grayscale image of each monitored image, wherein the pixels corresponding to the background contrast plate (4) are taken as third-class pixels, and the other pixels are taken as fourth-class pixels; The drawing state of the filament is determined based on the second proportion of the third type of pixels in each scrolling window in the grayscale image of each monitoring image to all pixels in the corresponding scrolling window, and the rate of change of the second proportion corresponding to multiple sliding windows in the grayscale image of each monitoring image.

2. The production method of a high-strength, low-shrinkage differentiated nylon filament production equipment according to claim 1, characterized in that, include: Infrared images of the heating roller (1) are acquired by infrared camera (2); Multiple monitoring images of different monitoring areas of the filament to be monitored are obtained by multiple industrial cameras (3); The controller determines whether the temperature of the heating roller (1) is uniform based on the infrared image. If the temperature of the heating roller (1) is not uniform, the drawing state of the filament is determined based on the proportion of filament pixels in the sliding window of the multiple monitoring images. Otherwise, the drawing state of the filament is determined based on the proportion of filament pixels in the scrolling window of the multiple monitoring images. The step of determining whether the temperature of the heating roller (1) is uniform based on the infrared image using a controller specifically includes: Obtain the first grayscale image of the region corresponding to the heating roller (1) in the infrared image; The first grayscale image is divided into multiple second grayscale images along the arrangement extension direction of the heating units of the heating roller (1); Based on the predetermined correspondence between grayscale values ​​and temperature, the temperature corresponding to each of the second grayscale images is determined; If the difference between the temperature corresponding to any second grayscale image and the working temperature of the heating roller (1) is greater than a preset threshold, it is determined that the temperature of the heating roller (1) is uneven; otherwise, it is determined that the temperature of the heating roller (1) is uniform. The step of determining the temperature corresponding to each of the second grayscale images based on a predetermined correspondence between grayscale values ​​and temperature specifically includes: Obtain the average grayscale value of each of the second grayscale images; Based on the predetermined correspondence between grayscale values ​​and temperature, and the average grayscale value of each second grayscale image, the temperature corresponding to each second grayscale image is determined. The step of determining the stretching state of the filament by the proportion of filament pixels in the scrolling window of the multiple monitoring images specifically includes: Determine the number of first-class pixels and second-class pixels in each scrolling window of the grayscale image of each monitored image, wherein the pixels corresponding to the background contrast panel (4) are taken as first-class pixels and the other pixels are taken as second-class pixels; The drawing state of the filament is determined based on the first proportion of the second type of pixels in each scrolling window in the grayscale image of each monitoring image to all pixels in the corresponding scrolling window, and the rate of change of the first proportion corresponding to multiple scrolling windows in the grayscale image of each monitoring image. The step of determining whether the temperature of the heating roller is uniform based on the infrared image using a controller specifically includes: For each grayscale image of a monitoring image, if the deviation between the first ratio of any of its scrolling windows and the preset ratio threshold is greater than the first preset value, then it is confirmed that the filament stretching state is uneven. For each grayscale image of a monitoring image, if the deviation between the first ratio change rate corresponding to the multiple scrolling windows and the preset change rate threshold is greater than the second preset value, then it is confirmed that the filament stretching state is uneven. Otherwise, confirm that the filament stretching is uniform; The rate of change of the first proportion is determined in the following manner: For each grayscale image of a monitored image, obtain the difference in the first ratio between its two adjacent scrolling windows; The determined multiple differences are fitted to obtain a fitting function for the grayscale image of each monitored image, and the slope of the fitting function is determined as the rate of change of the first proportion. The step of determining the stretching state of the filament by the proportion of filament pixels in the sliding window of the multiple monitoring images specifically includes: Determine the number of third-class and fourth-class pixels in each sliding window of the grayscale image of each monitored image, wherein the pixels corresponding to the background contrast plate (4) are taken as third-class pixels, and the other pixels are taken as fourth-class pixels; The drawing state of the filament is determined based on the second proportion of the third type of pixels in each scrolling window in the grayscale image of each monitoring image to all pixels in the corresponding scrolling window, and the rate of change of the second proportion corresponding to multiple sliding windows in the grayscale image of each monitoring image.

Images