Leather embossing process

Abstract

The present application discloses a leather embossing process, and relates to the technical field of leather production monitoring, and solves the technical problem that there is no systematic and scientific method to accurately control the embossing process. The present application filters historical data according to parameter requirements, and determines standard embossing parameters by calculating the correlation degree using the Pearson correlation coefficient, instead of relying on experience alone. The surface image of the target object is acquired and recognized using a high-definition camera and machine vision technology, so that abnormal areas can be found in time. After determining the cause of the abnormality, the influence of the abnormality on the embossing effect is analyzed based on historical data, and an influence factor is calculated. The standard embossing parameters are then adjusted and calibrated accordingly. The standard embossing parameters are adjusted and calibrated based on these influence factors, so that deviations in the production process can be corrected.

Description

Technical Field

[0001] This invention relates to the field of leather production monitoring technology, specifically to leather embossing technology. Background Technology

[0002] Printed and embossed leather is widely used in the production of clothing, shoes, bags, handbags, toys, furniture, packaging boxes, handicrafts, decorations and other products.

[0003] According to CN110987954B, a method and system for eliminating blind spots in the detection of surface defects in leather are disclosed, belonging to the field of machine vision surface inspection technology. The method provides a machine vision inspection system that orthogonally combines linear and area arrays, employing a side-entry area array system for auxiliary detection. The final detection result is obtained by comparing the detection results of the two systems. This allows for online monitoring of leather to detect both isotropic defects such as creases, bubbles, and perforations, and anisotropic defects such as uneven gloss / dullness, ink, and embossing along the leather conveying direction. It also detects anisotropic defects such as uneven gloss / dullness, ink, and embossing in directions perpendicular to the leather conveying direction. This results in a 100% recognition rate for defects such as embossing and ink on the leather surface, significantly reducing the product defect rate.

[0004] While the aforementioned patents eliminate blind spots in defect detection and significantly reduce the number of cameras required, thus lowering production costs, some existing leather embossing processes rely on experience to determine embossing parameters. This lack of systematic and scientific methods makes it difficult to precisely control the embossing process for different leather materials, texture requirements, and various complex production conditions, resulting in unstable embossing quality and low production efficiency. Summary of the Invention

[0005] In view of the shortcomings of existing technologies, this invention provides a leather embossing process, which solves the problem of lacking a systematic and scientific method and the difficulty in accurately controlling the embossing process.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a leather embossing process, comprising:

[0007] The embossing parameter acquisition unit is used to acquire parameter requirements and transmit the acquired parameter requirements to the embossing parameter analysis unit.

[0008] The embossing parameter analysis unit is used to analyze the acquired parameter requirements, determine the standard embossing parameters by combining historical data, and perform embossing treatment on the leather according to the standard embossing parameters. At the same time, the quality of the obtained leather is analyzed and analysis results are generated, including normal results and abnormal results. Then, the abnormal results are transmitted to the abnormal processing unit, and the normal results are transmitted to the calibration information output unit.

[0009] The anomaly processing unit is used to process the acquired parameter anomaly analysis signals. It acquires the surface image of the target object, identifies the specific cause of the anomaly in the target object, and transmits the specific cause to the comprehensive calibration analysis unit.

[0010] The integrated calibration analysis unit is used to analyze the specific reasons for the acquisition, adjust and calibrate the standard embossing parameters by analyzing the impact of the specific reasons on the embossing effect, obtain calibration information based on the influence analysis of texture complexity, and transmit the calibration information to the calibration information output unit.

[0011] As a further aspect of the present invention, the parameter requirements include texture, embossing temperature, embossing speed, and pressure.

[0012] As a further aspect of the present invention, the embossing parameter analysis unit determines the standard embossing parameters in the following specific way:

[0013] Obtain parameter requirements and historical data, and filter the historical data according to the parameter requirements to obtain pre-selected historical data. At the same time, filter the standard embossing parameters based on the obtained pre-selected historical data.

[0014] The correlation between the required parameters and the pre-selected historical data is calculated, and the correlation is reflected by the Pearson correlation coefficient. At the same time, the pre-selected historical data with the highest correlation is selected as the standard, and the standard embossing parameters are generated from the embossing parameters in the pre-selected historical data.

[0015] As a further aspect of the present invention, the specific method by which the embossing parameter analysis unit performs quality analysis on the obtained leather and generates analysis results is as follows:

[0016] The embossed leather obtained is recorded as the target object, and the production texture of the target object is recorded as the target texture. Then the target texture is compared with the parameter requirements.

[0017] If the target pattern matches the parameter requirements, it indicates that the standard embossing parameters are normal and do not need adjustment. At the same time, the standard embossing parameters are transmitted to the calibration information output unit. If the target pattern does not match the parameter requirements, it indicates that the standard embossing parameters are abnormal and need adjustment. At the same time, a parameter abnormality analysis signal is generated and transmitted to the abnormality processing unit.

[0018] As a further aspect of the present invention, the specific method by which the anomaly processing unit processes the acquired parameter anomaly analysis signal is as follows:

[0019] The surface image of the target object is acquired, and abnormal areas are identified by identifying the surface image. Then, historical data is acquired, and the abnormal parameters corresponding to different abnormal situations in the historical data are acquired, as well as the abnormal features corresponding to the abnormal areas. Then, the abnormal features are matched with the abnormal parameters to screen the specific causes of the abnormal areas, and the specific causes are transmitted to the integrated calibration analysis unit.

[0020] As a further aspect of the present invention, the specific method by which the comprehensive calibration analysis unit analyzes the specific causes is as follows:

[0021] Obtain the specific reasons and historical data, and analyze the impact of the specific reasons on the embossing effect by combining the historical data. Obtain the data corresponding to the same specific reasons in the historical data, and analyze the impact of specific reasons with different values. Calculate the corresponding impact factors by combining the impact of specific reasons with different values, and analyze the impact factors.

[0022] As a further aspect of the present invention, the specific method by which the comprehensive calibration analysis unit analyzes the influencing factors is as follows:

[0023] Obtain the texture depth L of the target object and the corresponding texture depth in the parameter requirements, denoted as L1. At the same time, evaluate the texture complexity of the target object to obtain the texture complexity value. The texture complexity can be specifically classified into four levels: simple, relatively complex, complex, and very complex. Assign values ​​to the texture complexity of different levels and record the assigned texture complexity value.

[0024] As a further aspect of the present invention, the specific method by which the comprehensive calibration analysis unit obtains calibration information based on the influence analysis of texture complexity is as follows:

[0025] The pressure value in the parameter requirements is denoted as P0, and the depth ratio is calculated and denoted as k, where the depth ratio is determined by the formula... The calculated pressure P is obtained by substituting the acquired parameters into the formula P = [P0 × (1 + k) × α], where α is a preset proportional coefficient.

[0026] Simultaneously, the texture complexity value of the target object is obtained and denoted as Yn, where n = 1, 2, 3, and 4. The weight coefficients corresponding to the texture complexity value Yn are also obtained and denoted as a1, a2, ... Then, the obtained calculation pressure and texture complexity value Yn are substituted into the formula Pz = (P × Y1 × a1) + (P × Y2 × a2) + ... + (P × Yn × an) to calculate the calibration pressure Pz. At the same time, calibration information is generated and transmitted to the calibration information output unit.

[0027] This invention provides a leather embossing process. Compared with existing technologies, it has the following advantages:

[0028] This invention determines standard embossing parameters by filtering historical data based on parameter requirements and using Pearson correlation coefficient to calculate correlation. It no longer relies solely on experience. By using high-definition cameras and machine vision technology to acquire and identify surface images of target objects, abnormal areas can be detected in a timely manner. After determining the cause of the abnormality, the impact on the embossing effect is analyzed in conjunction with historical data, and influencing factors are calculated. Then, the standard embossing parameters are adjusted and calibrated in a targeted manner based on these influencing factors. The calibration and adjustment of the standard embossing parameters based on these influencing factors can correct deviations in the production process. Attached Figure Description

[0029] Figure 1 This is a block diagram illustrating the system principle of the present invention;

[0030] Figure 2 This is a flowchart of the present invention. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Example 1, please refer to Figure 1 and Figure 2 This application provides a leather embossing process, which is controlled and implemented by a corresponding embossing system. The embossing system includes an embossing parameter acquisition unit, an embossing parameter analysis unit, an anomaly handling unit, a comprehensive calibration analysis unit, and a calibration information output unit, and the above functional units are unidirectionally electrically connected to each other.

[0033] The embossing parameter acquisition unit is used to acquire parameter requirements and transmit them to the embossing parameter analysis unit. The parameter requirements are represented as the current production requirements, which specifically include texture, embossing temperature, embossing speed, and pressure.

[0034] Embossing parameter analysis unit: This unit is used to analyze the acquired parameter requirements, determine the standard embossing parameters by combining historical data, and perform embossing treatment on the leather according to the standard embossing parameters. At the same time, the quality of the obtained leather is analyzed and analysis results are generated. The analysis results include normal results and abnormal results. Then, the abnormal results are transmitted to the abnormality processing unit, and the normal results are transmitted to the calibration information output unit.

[0035] Specifically, the parameter requirements and historical data are obtained, and the historical data is filtered based on the parameter requirements to obtain pre-selected historical data. The filtering method is as follows: historical data that meets the parameter requirements are filtered out. For example, if the parameter requirement is that the leather embossing pattern is a complex pattern, the embossing parameters corresponding to the complex pattern in the historical data are further obtained and marked as pre-selected historical data. At the same time, standard embossing parameters are obtained based on the obtained pre-selected historical data. The specific filtering method is as follows: the correlation between the parameter requirements and the pre-selected historical data is calculated, and the correlation is determined by the Pearson correlation coefficient. The pre-selected historical data with the highest correlation is selected as the standard, and the standard embossing parameters are generated from the embossing parameters in the pre-selected historical data.

[0036] Using pattern clarity as the primary focus (the parameter requirements stipulate that the pattern clarity score must be above 4), the Pearson correlation coefficients between parameters such as pressure, temperature, and speed and the pattern clarity and complexity requirements were calculated.

[0037] Suppose that calculations reveal that in a certain set of historical data, the deviation from pattern clarity is small when the pressure is 2 MPa, the temperature is 100℃, and the speed is 4 m / min. Furthermore, the overall correlation with the parameter requirements is highest when calculated using the Pearson correlation coefficient (for example, the correlation for pressure is 0.8, the correlation for temperature is 0.7, and the correlation for speed is 0.6; the overall correlation is obtained by weighted averaging, assuming weights of 0.4, 0.3, and 0.3 respectively, resulting in an overall correlation of 0.74). In this case, the embossing parameters (pressure 2 MPa, temperature 100℃, speed 4 m / min) from this set of data will be used as the standard embossing parameters.

[0038] Next, the leather is embossed according to the obtained standard embossing parameters. The resulting embossed leather is designated as the target object, and the production texture of the target object is recorded as the target texture. The target texture is then compared with the parameter requirements. If the target texture matches the parameter requirements, after careful comparison and analysis, it is found that the target texture is completely consistent with the complex texture specified in the parameter requirements, with clear and delicate lines, and the interweaving method and depth of the pattern meet expectations, presenting a very good three-dimensional effect and texture. This indicates that the standard embossing parameters performed normally in this production, and therefore, the standard embossing parameters are normal and do not require adjustment. Simultaneously, the standard embossing parameters are transmitted to the calibration information output unit. If the target texture does not match the parameter requirements, for example, if during the inspection of the target texture, it is found that some lines of the pattern are not clear enough, some areas of the texture depth are shallow, and the overall texture effect differs from the complex texture specified in the parameter requirements, then the standard embossing parameters are abnormal and require adjustment. Simultaneously, a parameter abnormality analysis signal is generated and transmitted to the abnormality processing unit.

[0039] The calibration information output unit is used to display the acquired standard embossing parameters to the corresponding operators.

[0040] Example 2, as Example 2 of the present invention, is implemented based on Example 1, and differs from Example 1 in the following ways:

[0041] The anomaly processing unit is used to process the acquired parameter anomaly analysis signals. It acquires and identifies the surface image of the target object to determine the specific cause of the anomaly, and transmits the specific cause to the integrated calibration analysis unit.

[0042] High-definition cameras are used to capture comprehensive, high-resolution images of the target object (embossed leather). For example, an industrial-grade high-definition camera with a resolution of [X]×[Y] (e.g., 2048×1536 pixels) is installed in a suitable position to ensure that every detail of the leather surface can be clearly captured. Simultaneously, the camera's shooting parameters need to be adjusted according to the characteristics of the leather and the complexity of the embossing pattern. For example, the exposure time is set to milliseconds (e.g., 50 milliseconds) to adapt to different lighting conditions, ensuring moderate brightness and contrast in the image, making the embossed texture clearly visible. The high-definition camera is used to capture images of the target object. The surface image of the object is acquired and machine vision technology is used to identify it. For example, a median filtering algorithm is used to remove noise from the image, with the filter window size set to [specific value] × [specific value] (e.g., 3×3 pixels) to maintain the clarity of the texture edges. Then, a threshold segmentation algorithm is used to separate the embossed texture from the background. The threshold selection can adopt an adaptive thresholding method, automatically determining the optimal threshold based on the local features of the image to adapt to the differences in light reflection caused by different leather materials and colors. At the same time, surface images with abnormalities are filtered out and recorded as abnormal areas. Then, the abnormal areas are processed. The analysis of the anomalies corresponding to the domains involves: acquiring historical data and extracting the abnormal parameters corresponding to different anomalies in the historical data. For example, cases of blurred patterns due to excessive pressure are grouped together, while cases of insufficient three-dimensionality of patterns due to excessively low temperature are grouped together. For each group of anomalies, the corresponding abnormal parameter features are extracted, such as the average and maximum pressure values ​​and the extent to which the pressure exceeds the normal range in the excessively high pressure group; and the average and minimum temperature values ​​and the difference from the standard temperature in the excessively low temperature group. The abnormal features corresponding to the abnormal areas are then compared with the anomalies. The system matches constant parameters to filter out the specific causes of abnormal areas. These causes may include embossing time, embossing pressure, embossing speed, and embossing temperature. For example, suppose the current abnormal area is characterized by thicker and smaller spacing of the pattern lines, while some patterns become blurred. Through analysis of historical data, it is found that when the pressure is too high (the average pressure in the historical data exceeds the normal range of MPa, such as 2.8 MPa, while the normal range is 2-2.5 MPa), similar thickening and blurring of the pattern lines will occur. The specific causes are then transmitted to the integrated calibration analysis unit.

[0043] The integrated calibration analysis unit is used to analyze the specific reasons for the acquisition, adjust and calibrate the standard embossing parameters by analyzing the impact of the specific reasons on the embossing effect, obtain calibration information based on the influence analysis of texture complexity, and transmit the calibration information to the calibration information output unit.

[0044] The specific cause was determined, and historical data was also collected. The impact of the specific cause on the embossing effect was analyzed in combination with the historical data. The specific analysis method was as follows: the data corresponding to the same situation as the specific cause in the historical data was collected, and the impact of the specific cause under different values ​​was analyzed. The impact factors of the specific cause under different values ​​were calculated. Assuming that the specific cause of the current leather embossing abnormality was determined through the previous detection and analysis process, the embossing temperature was too high. For example, the actual detected embossing temperature was 130℃, while according to the standard process requirements, the appropriate temperature range should be between 100-120℃. At the same time, data from the past 50 embossing productions were collected, and 10 of them had abnormal temperature situations (temperatures exceeding the normal range).

[0045] Assuming the temperatures in these 10 abnormal temperature data points are 125℃, 132℃, 128℃, 135℃, 127℃, 130℃, 131℃, 126℃, 129℃, and 133℃, the corresponding leather materials are cowhide and sheepskin, the thickness is between 2-4 mm, the pressure is between 2-3 MPa, and the speed is between 3-5 m / min, the embossing effect evaluation includes pattern clarity score (out of 10) and three-dimensionality score (out of 10), and for each different temperature value, analyze its specific impact on the embossing effect;

[0046] For example, at a temperature of 125℃, the difference in pattern sharpness score is 8-7=1 point, and the difference in three-dimensionality score is 7-6=1 point. These score differences are normalized to obtain relative score differences. Assuming that after normalization, the relative score difference for pattern sharpness is 0.125 (1÷8), and the relative score difference for three-dimensionality is 0.143 (1÷7), and assuming that calculations show the average relative score difference for pattern sharpness is 0.11 and for three-dimensionality is 0.13 when the temperature is between 125℃ and 130℃; and the average relative score difference for three-dimensionality is 0.25 and for three-dimensionality is 0.32 when the temperature is between 131℃ and 135℃.

[0047] Based on the acquired influence factors, the standard embossing parameters are calibrated and adjusted. Here, the analysis uses the pressure data corresponding to the influence factors as an example. The texture depth L of the target object is obtained, and L represents the texture height obtained from the current embossing. The texture depth corresponding to the parameter requirements is recorded as L1. Simultaneously, the texture complexity of the target object is evaluated to obtain a texture complexity value. Texture complexity can be specifically classified into four levels: simple (e.g., straight-line texture), relatively complex (e.g., simple cross-texture), complex (e.g., irregular interwoven texture), and very complex (e.g., texture containing multiple shapes and directions). Values ​​are assigned to different levels of texture complexity; for example, the complexity coefficient for simple texture is set to 1, for relatively complex texture to 1.3, for complex texture to 1.6, and for very complex texture to 2.0. The assigned texture complexity is recorded as the texture complexity value.

[0048] Next, obtain the pressure value from the parameter requirements, denoted as P0, where P0 represents the initial pressure, and calculate the depth ratio, denoted as k, where the depth ratio is determined by the formula... The calculated pressure P is obtained by substituting the acquired parameters into the formula P = [P0 × (1 + k) × α], where α is a preset proportional coefficient.

[0049] Simultaneously, the texture complexity value of the target object is obtained and denoted as Yn, where n = 1, 2, 3, and 4. Specifically, n here represents the corresponding different level assignments. The weight coefficients corresponding to the texture complexity value Yn are also obtained and denoted as a1, a2, ... Then, the obtained calculation pressure and texture complexity value Yn are used to calculate the calibration pressure, and the specific calculation formula is Pz = (P × Y1 × a1) + (P × Y2 × a2) + ... + (P × Yn × an). The calibration pressure Pz is calculated according to the formula, and calibration information is generated and transmitted to the calibration information output unit.

[0050] The calibration information output unit is used to display the acquired calibration information to the corresponding operator.

[0051] Example 3, as Example 3 of the present invention, focuses on combining the implementation processes of Example 1 and Example 2.

[0052] Some of the data in the above formulas are numerical calculations with dimensions removed, and the contents not described in detail in this specification are all prior art known to those skilled in the art.

[0053] The above embodiments are only used to illustrate the technical methods of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of the present invention without departing from the spirit and scope of the technical methods of the present invention.

Claims

1. A leather embossing process, characterized in that, Includes the following steps: Step 1: This leather embossing process analyzes the required parameters through an embossing control system, which includes: The parameter acquisition unit is used to collect the parameter requirements during the embossing process and transmit the acquired parameter requirements to the embossing parameter analysis unit. The embossing parameter analysis unit is used to analyze the acquired parameter requirements, determine the standard embossing parameters by combining historical data, and perform embossing treatment on the leather according to the standard embossing parameters. At the same time, the quality of the obtained leather is analyzed and analysis results are generated, including normal results and abnormal results. Then, the abnormal results are transmitted to the abnormal processing unit, and the normal results are transmitted to the calibration information output unit. The anomaly processing unit is used to process the acquired parameter anomaly analysis signals. It acquires the surface image of the target object, identifies the specific cause of the anomaly in the target object, and transmits the specific cause to the comprehensive calibration analysis unit. The integrated calibration and analysis unit is used to analyze the specific reasons for the acquisition, and to adjust and calibrate the standard embossing parameters by analyzing the impact of the specific reasons on the embossing effect. The specific processing procedure is as follows: Obtain the specific reasons and historical data, and analyze the impact of the specific reasons on the embossing effect by combining the historical data. Obtain the data corresponding to the same situation as the specific reasons in the historical data, and analyze the impact of specific reasons with different values. Calculate the corresponding impact factor by combining the impact of specific reasons with different values, and analyze the impact factor. Obtain the texture depth L of the target object, and obtain the corresponding texture depth in the parameter requirements, denoted as L1. At the same time, evaluate the texture complexity of the target object to obtain the texture complexity value. Calibration information is obtained based on the impact analysis of texture complexity, and the calibration information is transmitted to the calibration information output unit. The specific processing procedure is as follows: The pressure value in the parameter requirements is denoted as P0, and the depth ratio is calculated and denoted as k, where the depth ratio is determined by the formula... The calculations are obtained, and the acquired parameters are substituted into the formula. The calculated pressure P is obtained, where This is a preset proportional coefficient; Simultaneously, obtain the texture complexity value of the target object, denoted as Yn, where n = 1, 2, 3, and 4. Also obtain the weight coefficients corresponding to the texture complexity value Yn, denoted as a1, a2, ... Then, substitute the obtained computational pressure and texture complexity value Yn into the formula. The calibration pressure Pz is calculated, calibration information is generated, and the calibration information is transmitted to the calibration information output unit. Step 2: Display the obtained calibration information to the corresponding operator through the calibration information output unit.

2. The leather embossing process according to claim 1, characterized in that, The required parameters include texture, embossing temperature, embossing speed, and pressure.

3. The leather embossing process according to claim 1, characterized in that, The specific method by which the embossing parameter analysis unit determines the standard embossing parameters is as follows: Obtain parameter requirements and historical data, and filter the historical data according to the parameter requirements to obtain pre-selected historical data. At the same time, filter the standard embossing parameters based on the obtained pre-selected historical data. The correlation between the required parameters and the pre-selected historical data is calculated, and the correlation is reflected by the Pearson correlation coefficient. At the same time, the pre-selected historical data with the highest correlation is selected as the standard, and the standard embossing parameters are generated from the embossing parameters in the pre-selected historical data.

4. The leather embossing process according to claim 1, characterized in that, The specific method by which the embossing parameter analysis unit performs quality analysis on the obtained leather and generates analysis results is as follows: The embossed leather obtained is recorded as the target object, and the production texture of the target object is recorded as the target texture. Then the target texture is compared with the parameter requirements. If the target pattern matches the parameter requirements, it indicates that the standard embossing parameters are normal and do not need adjustment. At the same time, the standard embossing parameters are transmitted to the calibration information output unit. If the target pattern does not match the parameter requirements, it indicates that the standard embossing parameters are abnormal and need adjustment. At the same time, a parameter abnormality analysis signal is generated and transmitted to the abnormality processing unit.

5. The leather embossing process according to claim 1, characterized in that, The complexity of the texture is specifically classified into four levels: simple, relatively complex, complex, and very complex. At the same time, different levels of texture complexity are assigned values, and the assigned texture complexity is recorded as the texture complexity value.

6. The leather embossing process according to claim 1, characterized in that, The specific process for processing the acquired parameter anomaly analysis signal is as follows: The surface image of the target object is acquired, and abnormal areas are identified by identifying the surface image. Then, historical data is acquired, and the abnormal parameters corresponding to different abnormal situations in the historical data are acquired. The abnormal features corresponding to the abnormal areas are also acquired. Then, the abnormal features are matched with the abnormal parameters to screen the specific causes of the abnormal areas, and the specific causes are transmitted to the integrated calibration analysis unit.

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