Device and method for detecting number of monofilaments

Abstract

The invention belongs to the technical field of yarn detection, and particularly relates to a monofilament number detection device and method. The device comprises a tow clamp, a workbench, an operation display device, a high-speed camera shooting assembly, an electrostatic adsorption device, a pneumatic device and a master control device. The electrostatic adsorption device is arranged and mounted on the workbench; the pneumatic equipment is electrically connected with the general control device; the high-speed camera shooting assembly is installed on the workbench and electrically connected with the master control device. The master control device is installed on the workbench and used for processing and analyzing the tow images uploaded by the high-speed camera shooting assembly. The operation display device is installed on the workbench and electrically connected with the master control device. According to the technical scheme, the number of monofilaments can be accurately detected in the radial direction of tows, and accuracy is improved. Multiple components cooperate to adapt to various tow types and production environments. The device is simple in structure, convenient to operate and high in function expansibility, has a reinspection process, effectively ensures that the detection result is reliable, and assists spinning quality control and production management optimization.

Description

Technical Field

[0001] The invention belongs to the technical field of yarn detection, and in particular relates to a monofilament quantity detection device and method. Background Art

[0002] It is of vital importance to count the single filaments in the spinning machine. In terms of quality control: this is a key link to ensure product quality. The spinneret is the core component of spinning. It has many small holes, each of which corresponds to a single filament. Once the spinneret is blocked, the number of single filaments will change. Through single filament counting, this abnormality can be quickly detected, and the spinneret can be maintained or replaced in time to ensure the stability of the quality of the tow. Moreover, the consistency of the number of single filaments has a great influence on the uniformity of the tow. If the number of single filaments is uneven, the performance indicators such as the thickness and strength of the tow will be uneven, which will cause fabric defects, insufficient strength and other quality problems in the subsequent weaving process. Single filament counting can effectively control the uniformity of the tow. In the field of production management: single filament counting is indispensable for accurate output calculation. The number of single filaments in tows of different specifications is different. Accurate single filament counting combined with factors such as production time can accurately calculate the output of each spindle and the entire spinning machine, which is of great significance for production planning, cost accounting and production efficiency evaluation. At the same time, in large-scale production, managers can grasp the production status of each spinning machine and each spindle in real time. If the single-filament count of a spindle is abnormal, the parameters can be adjusted or the equipment can be maintained in time to ensure smooth production. From the perspective of process optimization: single-filament counting provides key data for research and development and improvement. In the process of research and development and improvement of spinning processes, a large amount of experimental data is required. Single-filament counting can reflect information such as the number of single filaments and the structure of the tow, and help R&D personnel understand the impact of process parameters on the quality and performance of the tow. For example, when adjusting parameters such as spinning speed, temperature, and pressure, the best combination of process parameters can be found through single-filament counting and changes in tow quality. In addition, different textiles have different requirements for the number of single filaments in the tow. Single-filament counting can meet the specific needs of customers, produce products that meet different specifications, and enhance the competitiveness of enterprises in the market.

[0003] Traditional single-filament counting requires manual counting of multiple (180) spindle positions of each spinning machine, that is, it is mainly manual operation, which has the disadvantages of high labor intensity, low efficiency, inability to work for a long time, and inability to meet the needs of large-scale detection. In this regard, a single-filament number detection device is designed in the prior art to replace manual single-filament detection. For example, the invention patent document with publication number CN112381203A discloses a single-filament number detection device, including an electrostatic device, a pressing device, a visual system, a conveying device and a control device; wherein the control device controls the electrostatic device, the pressing device, the conveying device and the visual system respectively. It uses the principle of electrostatic separation to detect the number of single-filament fibers, which can effectively automatically detect the fiber single fibers in the yarn. The defects of this prior art are:

[0004] 1. Detection accuracy

[0005] 1) Limitations of axial images: It collects axial images of the tow and detects the number of monofilaments based on the axial images of the tow. There may be limitations in only collecting axial images of the tow to detect the number of monofilaments. In the actual production process of the tow, the arrangement of the monofilaments may be more complicated, and it may not be possible to fully and accurately capture the state of each monofilament from an axial perspective. For example, the monofilaments may be entangled or overlapped with each other. Relying solely on axial images may cause some monofilaments to be blocked and not accurately identified and counted, thereby affecting the accuracy of monofilament number detection.

[0006] 2) Potential impact of electrostatic separation: Although the principle of electrostatic separation can achieve a certain degree of single-filament separation for detection, the electrostatic effect may not be able to achieve the ideal separation state for all single-filaments. Some single-filaments may not be completely and evenly separated under the action of electrostatics due to their own characteristics (such as surface roughness, electrostatic adsorption differences, etc.), which will also make it difficult to accurately count the single-filaments, resulting in deviations in the counting results.

[0007] 2. Adaptability

[0008] 1) Limited adaptability to different types of tows: Different spinning processes and tows of different materials have different characteristics, such as the thickness of the tow, the flexibility and elasticity of the single filaments, etc. The detection device may work well for certain types of tows, but for tows of other special materials or specifications, its electrostatic separation effect and the detection method based on axial images may not be well adapted, thus affecting the effective detection of the number of single filaments in different tows.

[0009] 2) Insufficient adaptability to changes in the production environment: There may be many changing factors in the spinning production environment, such as temperature, humidity, dust, etc. For example, in an environment with high humidity, the effect of electrostatic separation may be greatly reduced, because moisture will affect the generation and effect of static electricity; when there is a lot of dust, it may adhere to the surface of the tow, interfering with the visual system's collection and analysis of the axial image of the tow, thereby reducing the device's ability to adapt to different production environments and affecting the stability of single-filament quantity detection. Summary of the invention

[0010] In view of the problems existing in the above-mentioned prior art, the present technical solution proposes a monofilament number detection device and method, which can realize efficient and accurate detection of the number of monofilaments from the radial direction of the yarn bundle, reduce the intensity of manual labor and the number of people employed.

[0011] The above objectives are achieved specifically through the following technical solutions:

[0012] A device for detecting the number of single fibers, characterized in that it includes a fiber bundle clamp, a workbench, an operation display device, a high-speed camera assembly, an electrostatic adsorption device, a pneumatic device, and a master control device. The electrostatic adsorption device is arranged and installed on the workbench, and is used to electrostatically adsorb the fiber bundle to be tested clamped by the fiber bundle clamp. The pneumatic device is electrically connected to the master control device, and is used to blow away the single fibers in the fiber bundle to be tested by blowing air under the control of the master control device. The high-speed camera assembly is installed on the workbench and is electrically connected to the master control device, and is used to capture images from the radial direction of the fiber bundle to be tested, and send the captured images to the master control device. The master control device is installed on the workbench and is used to process and analyze the fiber bundle images uploaded by the high-speed camera assembly. The operation display device is installed on the workbench and is electrically connected to the master control device, and is used to display the fiber bundle image processed and analyzed by the master control device, and cooperate with the master control device to calculate the number of single fibers in the fiber bundle to be tested in the current fiber bundle image.

[0013] Preferably, the master control device includes a Da Vinci series DSP+ARM module, a display control unit, an acquisition control unit and a pneumatic control unit; the operation display device is connected to the Da Vinci series DSP+ARM module through the display control unit; the high-speed camera assembly is connected to the Da Vinci series DSP+ARM module through the acquisition control unit; and the pneumatic device is connected to the Da Vinci series DSP+ARM module through the pneumatic control unit.

[0014] Preferably, the operation display device is a touch screen, and the touch screen is connected to the master control device via a USB interface.

[0015] Preferably, the operation display device comprises a computer host, a display, a keyboard and a mouse, the master control device is installed inside the computer host, and the display, keyboard and mouse are respectively connected to the computer host.

[0016] Preferably, the high-speed camera assembly includes a high-speed camera and a camera bracket, and the high-speed camera is mounted on a workbench through the camera bracket with an adjustable posture angle.

[0017] Preferably, the pneumatic equipment includes an air duct, an air nozzle and a compressed air source device, the air nozzle is connected to the compressed air source device through the air duct, and a solenoid valve is installed in the air duct, and the solenoid valve is electrically connected to the master control device.

[0018] Preferably, the electrostatic adsorption device comprises an electrostatic generator and an electrostatic adsorption plate; the electrostatic adsorption plate is placed flat on a workbench and is electrically connected to the electrostatic generator.

[0019] Preferably, an air jet hole is vertically opened on the electrostatic adsorption plate, and the air nozzle of the pneumatic device is installed in the air jet hole with its opening facing upward.

[0020] A method for detecting the number of monofilaments, using a monofilament number detection device of the technical solution, comprises the following steps:

[0021] S1, sampling the tow from each single spindle position of the spinning machine to obtain the tow to be tested, and washing and drying the tow to be tested;

[0022] S2, clamping the to-be-tested yarn bundle into a yarn bundle fixture, and then cutting the to-be-tested yarn bundle to a preset length, and placing the yarn bundle fixture clamped with the to-be-tested yarn bundle on an electrostatic adsorption device;

[0023] S3, start the electrostatic adsorption device and the pneumatic device; start the electrostatic adsorption device to perform high-voltage electric shock separation on the to-be-tested filament bundle, and at the same time, the pneumatic device sprays high-speed air to perform pneumatic separation on the to-be-tested filament bundle;

[0024] S4, in the process of synchronously performing high-voltage electric shock separation and pneumatic separation on the to-be-tested tow, collecting tow images from the radial direction of the to-be-tested tow by means of a high-speed camera assembly, and transmitting the collected tow images to the master control device;

[0025] S5, the master control device pre-processes the tow image and transmits it to the operation display device for display;

[0026] S6, using the operation display device to perform analysis and detection based on the current yarn bundle image to measure the number of single yarns in the current yarn bundle to be tested;

[0027] S7, judging whether the number of monofilaments meets the production requirements; if so, the test ends and is judged as qualified; if not, proceeding to step S8;

[0028] S8, repeat steps S1 to S6 for re-inspection, and after the re-inspection, determine whether the number of monofilaments meets the production requirements; if yes, the test is completed and it is determined to be qualified; if not, it is determined to be unqualified.

[0029] Preferably, in step S1, cleaning and drying the to-be-tested yarn bundle comprises the following steps:

[0030] S11, rinse the to-be-tested tow with clean water at 24-27°C for 10-12 seconds;

[0031] S12, squeezing out water on the yarn bundle to be tested, and ensuring that no hair is formed on the yarn bundle to be tested;

[0032] S13, using an infrared drying box to dry the to-be-tested yarn bundle; the drying temperature is controlled at 43-51° C., and the drying time is 1-3 minutes.

[0033] Preferably, in step S4, when the high-speed camera assembly collects the tow image, the camera distance of the high-speed camera is 110 mm and the magnification is 0.5X-1.5X.

[0034] Preferably, in step S5, the master control device preprocesses the tow image including:

[0035] Grayscale processing: convert the color tow image into a grayscale image;

[0036] Filtering and noise reduction: Use median filtering or Gaussian filtering algorithm to remove noise in the tow image;

[0037] Image enhancement: According to the characteristics of the tow image, image processing methods including contrast enhancement and histogram equalization are used to improve the clarity and contrast of the tow image, making the details of the tow to be tested in the tow image more obvious.

[0038] Preferably, in step S6, measuring the number of monofilaments in the current to-be-measured tow includes the following steps:

[0039] S61, threshold segmentation: using a preset threshold selection method to determine the segmentation threshold, and dividing the tow image into two parts: a tow target and an image background;

[0040] S62, grayscale enhancement: performing a grayscale enhancement operation on the fiber bundle image after the threshold segmentation, so as to improve the contrast between the fiber bundle to be tested and the background in the fiber bundle image;

[0041] S63, connected domain processing: marking the connected domains of the enhanced tow image to divide the tow to be tested in the tow image into single independent connected regions; during this period, by setting an area threshold, the misidentified regions caused by noise and / or image defects are removed, and the connected domains that truly represent the single fibers are retained;

[0042] S64, performing feature analysis on the retained connected domains, and screening and confirming the connected domains corresponding to the single-filament region according to the geometric features of the single-filament;

[0043] S65, count the number of connected domains corresponding to the single-filament area, which is the number of single-filament roots.

[0044] Preferably, in step S61, dividing the tow image into two parts, namely, the tow target and the image background, comprises the following steps:

[0045] S611, assuming that the pixel gray value of the tow image is i, the total number of pixels is N, and the number of pixels with gray value i is ni, then the probability is pi = ni / N;

[0046] S612, assuming the threshold is t, divide the image into two categories, C0 and C1; where the grayscale value range of C0 is 0~t, the probability is w0, and the mean is μ0; the grayscale value range of C1 is (t+1)~(L-1), the probability is w1, the mean is μ1, and L represents the total number of gray levels; therefore, the inter-class variance is g(t)=w0*w1*(μ0-μ1) 2 ;

[0047] S613, traverse all relevant thresholds t, and find the t value that maximizes the inter-class variance g(t) as the segmentation threshold;

[0048] S614, setting pixels with grayscale values ​​less than or equal to t in the tow image as target pixels, and pixels with grayscale values ​​greater than t as background pixels, thereby preliminarily separating the tow target from the image background.

[0049] Beneficial effects of the present invention:

[0050] 1. Advantages in detection accuracy

[0051] Advantages of radial images: The present invention uses images collected from the radial direction of the tow to detect the number of monofilaments. Compared with the prior art method of only collecting axial images of the tow, it can capture the state of the monofilaments more comprehensively and accurately. Because the arrangement of the monofilaments in the tow is complex in actual production, the monofilaments are easily entangled and overlapped and blocked during axial observation, resulting in the inability to accurately identify and count some monofilaments. Shooting from a radial angle can avoid the problem of monofilament blockage in the axial direction, and can better present the distribution of each monofilament, thereby improving the accuracy of monofilament number detection.

[0052] Multiple means work together to ensure the effect of monofilament separation: The present invention not only utilizes an electrostatic adsorption device, but also combines pneumatic equipment to separate the monofilaments. On the basis of the preliminary separation of the monofilaments by electrostatic adsorption, the pneumatic equipment ejects high-speed air to further disperse the monofilaments. The synergistic effect of the two can make the monofilaments reach a more ideal separation state. Compared with the existing technology that only relies on electrostatic separation, for those monofilaments that are difficult to separate completely and evenly under the action of electrostatics due to their own characteristics (such as surface roughness, electrostatic adsorption differences, etc.), pneumatic blowing can better solve this problem, reduce the counting deviation caused by insufficient separation of the monofilaments, and further improve the detection accuracy.

[0053] 2. Advantages in adaptability

[0054] Enhanced adaptability to different types of tows: The detection device and method of the present invention can better adapt to different spinning processes and tows of different materials and specifications through the reasonable configuration and coordinated work of various components. For example, the high-speed camera in the high-speed camera assembly is installed on the workbench through a camera bracket with an adjustable posture angle. The shooting angle can be flexibly adjusted according to the thickness, placement, etc. of different tows to ensure that images can be collected from the appropriate radial direction; the air pressure and other parameters of the pneumatic equipment can be adjusted by the master control device, and different intensities of airflow can be used for blowing and separation of tows with different flexibility and elasticity; the electrostatic generator of the electrostatic adsorption device can also be controlled by the master control device. Related parameters to adapt to the different responses of tows of different materials to electrostatic effects, thereby overcoming the defect of the limited adaptability of the prior art to different types of tows, and can effectively detect the number of single filaments in a variety of tows.

[0055] Improved adaptability to changes in the production environment: When faced with changing factors such as temperature, humidity, and dust in the spinning production environment, the present invention has better coping capabilities. For example, when the humidity is high and affects the electrostatic filament separation effect, the pneumatic equipment can still play an effective role, and the weakening of the electrostatic filament separation effect can be compensated by appropriately increasing the airflow blowing force to ensure the separation of the monofilaments; for situations where there is a lot of dust that may interfere with image acquisition and analysis, the pre-processing operations (such as filtering and noise reduction, image enhancement, etc.) performed by the master control device on the image can reduce the influence of interference factors such as dust on the tow image to a certain extent, so that the subsequent monofilament quantity measurement can still be carried out more accurately, improving the adaptability of the device to different production environments, ensuring the stability of monofilament quantity detection, and compared with the existing technology, there is a significant improvement in this regard.

[0056] 3. Advantages in operation and functional expansion

[0057] Convenient and user-friendly operation: In terms of operation and display equipment, a touch screen is used and connected to the master control device through a USB interface, or a computer host, monitor, keyboard and mouse are configured. Users can easily perform various parameter settings, command issuance and other operations through intuitive touch operations or conventional computer input devices. For example, the voltage of the electrostatic adsorption device, the air pressure of the pneumatic equipment and other parameters can be easily adjusted through the touch screen, and the test results can be viewed. The operation is simpler and more intuitive. Compared with traditional manual counting and the operation methods of some existing detection devices, it greatly reduces the difficulty of the operator's work and improves work efficiency.

[0058] Moreover, the master control device is composed of Da Vinci series DSP+ARM modules, and is subdivided into display control unit, acquisition control unit and pneumatic control unit. Each unit has a clear division of labor, which facilitates the refined management and control of the entire detection process, making the collaborative work between various devices smoother and more stable, and also convenient for subsequent functional expansion and optimization upgrades according to actual needs.

[0059] Strong functional expandability: In the method of calculating the number of single fibers, the present invention has detailed and systematic steps, from threshold segmentation, grayscale enhancement, connected domain processing to feature analysis, quantity statistics and other multi-step operations. It can not only accurately separate and identify the single fibers from the image for counting, but also flexibly adjust relevant parameters (such as threshold selection, area threshold setting, etc.) according to actual conditions to adapt to the characteristics of different yarn bundle images and further improve the accuracy of the measurement. At the same time, these steps also provide a good foundation for the subsequent optimization of the detection algorithm, the integration of new image processing technology and other functional expansions, so that the entire detection device and method have stronger scalability and can better meet the evolving needs of spinning production quality inspection. 4. Advantages in the rationality and reliability of the detection process

[0060] Tow pretreatment guarantees the basis for testing: Before the testing process begins, there are detailed and scientifically reasonable cleaning and drying steps for the tow to be tested. Rinsing with clean water in a specific temperature range (24-27°C) and drying in an infrared drying oven at a suitable temperature (43-51°C) and time (1-3min) can effectively remove impurities and moisture on the surface of the tow, while avoiding damage to the tow or affecting its performance due to improper treatment, providing a good initial state of the tow for subsequent accurate separation of monofilaments, image acquisition, and quantity detection, ensuring the reliability of the entire testing process.

[0061] The re-inspection mechanism ensures accurate results: The present invention sets up a re-inspection process. When the first test determines that the number of monofilaments does not meet the production requirements, the entire testing steps will be repeated for re-inspection. Multiple tests can eliminate misjudgments that may be caused by accidental factors (such as momentary environmental interference, slight fluctuations in equipment parameters, etc.) in a single test process, further improve the accuracy and reliability of the test results, and make the final test judgment more truly reflect whether the number of monofilaments in the yarn bundle meets the requirements. Compared with some existing technologies, it has obvious advantages in the rigor of result judgment. BRIEF DESCRIPTION OF THE DRAWINGS

[0062] Figure 1 It is a schematic diagram of the basic structure of a single-filament number detection device;

[0063] Figure 2 It is a principle block diagram of a single-filament quantity detection device;

[0064] Figure 3 The figure is a basic implementation flow chart of a method for detecting the number of single fibers.

[0065] In the figure:

[0066] 1. Wire bundle clamp; 2. Workbench; 3. Operation display device; 4. Master control device; 5. High-speed camera; 6. Camera bracket; 7. Air duct; 8. Air nozzle; 9. Compressed air source device; 10. Electrostatic generator; 11. Electrostatic adsorption plate; 12. Jet hole; 13. Solenoid valve. DETAILED DESCRIPTION

[0067] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution of the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings of the embodiments of the present invention. It should not be understood that the present invention is limited to the following examples. Without departing from the concept of the present invention, the deformation and improvement of the present invention in this field should be included in the protection scope of the claims of the present invention.

[0068] Unless otherwise defined, the technical terms or scientific terms used in the present disclosure should be understood by people with ordinary skills in the field to which the present disclosure belongs. The words "or", "comprising" and the like used in the present disclosure mean that the elements or objects appearing before the word include the elements or objects listed after the word and their equivalents, without excluding other elements or objects.

[0069] Example 1

[0070] This embodiment discloses a monofilament number detection device, as a preferred embodiment of the present invention, such as Figure 1 As shown, it includes a tow clamp, a workbench, an operation display device, a high-speed camera component, an electrostatic adsorption device, a pneumatic device and a master control device.

[0071] The material of the tow fixture should have a certain hardness and wear resistance to ensure that it will not be deformed or damaged during long-term use. The tow fixture is used to constrain the tow to be tested to prevent it from being disrupted when it is separated. Based on the gravity of the tow fixture, the tow to be tested will not be blown away or moved.

[0072] The electrostatic adsorption device is installed on the workbench and is used to perform high-voltage electric shock separation and electrostatic adsorption on the to-be-tested tow clamped by the tow fixture. The working parameters of the electrostatic adsorption device need to be set beforehand, including the high-voltage electric shock voltage, current and duration. Too high a voltage may damage the tow, and too low a voltage may not effectively separate the adhered monofilaments. The specific setting can be based on experience. For example, for some common synthetic fiber tows, the voltage can be set between 5 and 10 kV, the current is at the microampere level, and the duration ranges from tens of milliseconds to hundreds of milliseconds.

[0073] The pneumatic equipment is electrically connected to the master control device and is used to separate the single filaments in the to-be-tested tow by blowing air under the control of the master control device. The air source of the pneumatic equipment should be stable and reliable, and the air pressure can be adjusted. Generally, an air compressor is used as the air source, and the air pressure of the blowing is controlled by a pressure regulating valve. For thinner and lighter tows, the air pressure can be set between 0.1 and 0.3 MPa; for thicker and heavier tows, the air pressure can be appropriately increased to 0.3 to 0.5 MPa.

[0074] The high-speed camera assembly is installed on the workbench and electrically connected to the master control device. It is used to capture images from the radial direction of the tow to be tested and send the captured images to the master control device. Camera parameters: Parameters such as the frame rate, resolution and sensitivity of the high-speed camera assembly have an important influence on the image quality. In order to clearly capture the shape of the single wire, the frame rate should be high enough, such as 100 to 1000fps. The resolution can be set between 1 million and 10 million pixels according to the detection accuracy requirements. The sensitivity should be adjusted according to the lighting conditions of the shooting environment to ensure the brightness and clarity of the image. The focal length and aperture of the lens also need to be selected according to the size of the tow to be tested and the working distance. For smaller tows, a macro lens can be used to obtain a larger magnification; the aperture is adjusted according to the depth of field requirements, generally between f / 2 and f / 8.

[0075] The master control device is installed on the workbench and is used to process and analyze the tow images uploaded by the high-speed camera component. The image processing algorithm in the master control device is the core part. The image processing algorithm includes image preprocessing algorithm and single-filament extraction algorithm. Image preprocessing algorithms include graying, filtering, etc. to remove noise and interference in the image. Single-filament extraction algorithms such as edge detection algorithms (such as Canny edge detection) or threshold segmentation algorithms are used to accurately identify the outline of single filaments. According to the extracted single-filament outline features, morphological analysis or connected domain analysis methods are used to calculate the number of single filaments. The master control device should also have a data storage function that can store the captured image data and processing results for subsequent query and analysis. At the same time, to ensure stable and reliable data transmission between other components, high-speed data transmission interfaces such as USB3.0 and Ethernet can be used.

[0076] The operation display device is installed on the workbench and electrically connected to the master control device. It is used to display the image of the tow after processing and analysis by the master control device, and to cooperate with the master control device to calculate the number of single fibers in the tow to be measured in the current tow image. The human-computer interaction interface of the operation display device should be simple and intuitive, so that operators can operate and view the results conveniently. The interface can display information such as the real-time image of the tow, the statistical results of the number of single fibers, and the operating status of the equipment. The operator sets the equipment parameters, controls the image viewing, and other operations through the touch screen or buttons. In order to better display the tow image, the display device should have good color reproduction, contrast, and brightness adjustment functions. A high-resolution LCD or OLED display can be used to ensure that the image details are clearly visible.

[0077] Based on the structure of the above-mentioned single-filament number detection device, its use principle is as follows: first, place the tow to be tested in the tow clamp, which not only plays the role of fixing the tow, but also ensures that the tow will not leave the workbench and transition displacement in subsequent operations through its own gravity. The electrostatic adsorption device implements high-voltage electric shock separation on the clamped tow to be tested, so that the single filaments that may be stuck together are initially separated, and then the tow is relatively fixed on the workbench by electrostatic adsorption for subsequent processing. The pneumatic equipment works under the command of the master control device, and further blows away and separates the single filaments in the tow to be tested by blowing air, so that the single filaments present a state that is more conducive to detection. The high-speed camera component captures images from the radial direction of the tow to be tested and transmits the images to the master control device in real time. After receiving the image, the master control device uses a specific image processing algorithm to process and analyze the image, such as reducing noise, enhancing contrast, extracting single-filament contours, etc. The operation display device receives the image data processed by the master control device and displays it. At the same time, it works in coordination with the master control device to calculate the number of single fibers in the tow to be measured in the current tow image according to the image features and a preset calculation model, and displays the result intuitively on the screen.

[0078] Therefore, the advantages of this technical solution are:

[0079] Non-contact detection: The device uses electrostatic adsorption and pneumatic blowing combined with high-speed camera, without direct contact with the yarn bundle, avoiding mechanical damage to the yarn bundle. It is especially suitable for fine yarn bundle detection with high requirements on yarn bundle quality.

[0080] High-precision detection: Through high-speed camera components and advanced image processing algorithms in the master control device, the number of single fibers can be accurately identified and counted, with high detection accuracy, which can meet the strict requirements of tow quality control in industrial production.

[0081] High degree of automation: The entire testing process is completed automatically under the control of the master control device, reducing manual intervention and improving testing efficiency and reliability. The operation display device also facilitates operators to monitor and manage, reducing labor intensity.

[0082] Example 2

[0083] This embodiment discloses a single-filament number detection device, as a preferred implementation scheme of the present invention, that is, based on Example 1, its master control device includes a Da Vinci series DSP+ARM module. The high-speed camera component is generally directly connected to a specific interface of the Da Vinci series DSP+ARM module through a data transmission line, such as a USB interface. This is a relatively simple and direct connection that can realize data transmission between the high-speed camera component and the master control device. Therefore, after the high-speed camera component captures the image of the tow, it will send the image data to the Da Vinci series DSP+ARM module through the USB interface in the form of a digital signal. For example, the high-speed camera component may be connected to the master control device using a USB2.0 or USB3.0 standard interface. The transmission speed of USB3.0 is faster and can meet the needs of fast transmission of higher-resolution images.

[0084] In order to enable the master control device to adapt to more image acquisition devices, preferably, the master control device also includes an acquisition control unit, and the high-speed camera assembly is connected to the Da Vinci series DSP+ARM module through the acquisition control unit. More specifically, the acquisition control unit includes an image sensor interface circuit, a video codec module, a data cache module, and a signal conditioning module.

[0085] 1. Image sensor interface circuit

[0086] If the image sensor used in the high-speed camera component is not directly compatible with the interface of the Da Vinci series DSP+ARM module, an image sensor interface circuit is required for signal conversion and adaptation. For example, some high-speed camera components use image sensors with the MIPICSI (Mobile Industry Processor Interface-Camera Serial Interface) protocol, and the Da Vinci series DSP+ARM module may not have an interface that directly supports this protocol. In this case, a MIPICSI to USB or other conversion circuit module compatible with the master control device is required to convert the signal output by the image sensor into a format that the master control device can receive and process.

[0087] Physical connection: The image sensor interface circuit is connected to the Da Vinci series DSP+ARM module through a specific interface. For example, taking DM365 and DM6437 as examples, they have an image sensor interface (ISIF) and a CMOS imager interface that can be used to connect the image sensor interface circuit, and the output end of the image sensor interface circuit can be directly connected to these corresponding pins.

[0088] Signal transmission: The image data collected by the high-speed camera component is format converted and adapted through the interface circuit, and then transmitted in a signal form that can be recognized and processed by the Da Vinci series DSP+ARM module. For example, the original image data output by the high-speed camera component is converted into a format supported by the DSP+ARM module, such as BT.601 / BT.656 / BT.1120 digital YCbCr4:2:2, and then the data is transmitted to the internal cache or designated storage area of ​​the Da Vinci series DSP+ARM module through the data bus.

[0089] Control signal: The Da Vinci series DSP+ARM module sends control signals to the image sensor interface circuit to configure the working parameters of the high-speed camera assembly, such as exposure time, gain, resolution, etc. These control signals are transmitted from the Da Vinci series DSP+ARM module to the image sensor interface circuit through the corresponding control lines, and then forwarded to the high-speed camera assembly by the image sensor interface circuit.

[0090] 2. For the video codec module

[0091] It is used to compress or decompress the image data collected by the high-speed camera component to reduce the amount of data transmission or to store and process it more efficiently in the master control device. If the amount of image data collected by the high-speed camera component is large, in order to avoid occupying too much bandwidth during the transmission process, the video codec module can compress the image data according to H.264 or other video coding standards, and then transmit it to the Da Vinci series DSP+ARM module. At the master control device end, the decompression operation is then performed to restore the image data for subsequent processing and analysis.

[0092] Software interface connection: With the help of the codec engine and related application program interface provided by the Da Vinci series DSP+ARM module, such as the codec function module in the video processing subsystem of DM6437, the ARM-side program can use the functions of the codec module by calling the API interface provided by the codec engine, such as the VISA (Video, Imaging, Speech and Audio) interface.

[0093] Data transmission channel: The image data to be encoded or decoded is transmitted between the Da Vinci series DSP+ARM module and the video codec module through the internal data bus. For example, the original image data is obtained from the DSP end and passed to the codec module for encoding, or the encoded data is transmitted back to the DSP end for further processing or storage.

[0094] Hardware collaboration: The codec module works in collaboration with other hardware resources of the Da Vinci series DSP+ARM modules, such as using the EDMA (enhanced DMA) controller to achieve fast data transfer, reduce CPU intervention, and improve codec efficiency.

[0095] 3. For data cache module

[0096] Since the high-speed camera component may collect images at a fast speed, while the Da Vinci series DSP+ARM module has a limited data processing speed, the data cache module can be used to temporarily store image data and play a buffering role to prevent data loss or untimely processing. Specifically, a high-speed SRAM or DRAM can be used as a data cache. When the high-speed camera component collects image data, the data is first stored in the cache module, and the Da Vinci series DSP+ARM module then reads the data from the cache for processing, which can improve the overall performance and stability of the system.

[0097] Directly connected to the bus: The data cache module is generally directly connected to the internal data bus of the Da Vinci series DSP+ARM module. For example, the DDR2 / mDDR interface in the DM365 can be connected to an external cache chip as a data cache module. In this way, the image data can be directly stored in the cache module when it is transmitted on the bus.

[0098] Managed by controller: The relevant controllers in the Da Vinci series DSP+ARM modules, such as the memory controller, are responsible for managing the read and write operations of the data cache module. The controller decides when to read or write data from the cache according to the needs of the system to ensure efficient use of data and smooth operation of the system.

[0099] Collaboration with other modules: The data cache module works in collaboration with the image sensor interface circuit, video codec module, etc., to play the role of data buffering and temporary storage. For example, the data collected by the image sensor interface circuit is first stored in the cache module, and then the video codec module reads the data from the cache for encoding and decoding processing.

[0100] 4. For signal conditioning module

[0101] The signal output by the high-speed camera component is amplified, filtered and other conditioning operations are performed to improve the signal quality and ensure the accuracy and stability of the image data. If the image signal output by the high-speed camera component is weak or there is noise interference, the signal conditioning module can amplify and filter the signal to remove noise, enhance the strength and clarity of the signal, and enable the Da Vinci series DSP+ARM module to receive better quality image data.

[0102] The front end is connected to the image sensor: the input end of the signal conditioning module is connected to the image sensor of the high-speed camera component to receive the original image signal output by it.

[0103] The back-end is connected to the Da Vinci series DSP+ARM module: the image signal after amplification, filtering and other conditioning is transmitted from the output end of the signal conditioning module to the corresponding interface of the Da Vinci series DSP+ARM module, such as the analog front-end interface (AFE). Taking DM365 as an example, it has a 16-bit parallel AFE interface with a maximum frequency of 120MHz, and the signal after signal conditioning can enter the DSP+ARM module through this interface.

[0104] Example 3

[0105] This embodiment discloses a single-filament quantity detection device, as a preferred implementation scheme of the present invention, that is, based on Example 1 or 2, its master control device includes a Da Vinci series DSP+ARM module. In some simple architectures, the operation display device can be directly connected to the Da Vinci series DSP+ARM module. The connection is usually made through a USB interface or an HDMI interface. For example, if the operation display device supports the USB display function, it can be directly connected to the USB interface of the Da Vinci series DSP+ARM module. This connection method is relatively direct, and data can be directly transmitted from the Da Vinci series DSP+ARM module to the operation display device for display. Taking HDMI connection as an example, the HDMI interface of the Da Vinci series DSP+ARM module can send the processed image signal to the operation display device in accordance with the HDMI protocol standard.

[0106] In order to enable the master control device to adapt to more operation display devices, preferably, the master control device also includes a display control unit, and the operation display device is connected to the Da Vinci series DSP+ARM module through the display control unit. More specifically, the display control unit includes a display controller, an image cache module and a protocol conversion module.

[0107] 1. For display controller

[0108] The display controller is mainly used to manage and optimize image display. It can further process the image signal transmitted from the Da Vinci series DSP+ARM module, such as adjusting the image resolution, color correction, contrast enhancement and other operations to ensure that the image can be displayed with the best effect on the operation display device. The display controller is located between the Da Vinci series DSP+ARM module and the operation display device, usually connected through a high-speed data interface. It receives the image signal from the Da Vinci series DSP+ARM module, and after processing, transmits the image signal to the operation display device through an interface suitable for the operation display device (such as LVDS-Low Voltage Differential Signal Interface for LCD). For example, when the image resolution sent by the Da Vinci series DSP+ARM module does not match the optimal resolution of the operation display device, the display controller will perform resolution conversion so that the image can be displayed completely and clearly on the operation display device.

[0109] Data transmission connection: Da Vinci series DSP+ARM modules are usually connected to the display controller through an internal high-speed data bus, such as AMBA bus (including AHB, APB, etc.). Da Vinci series DSP+ARM modules transmit the processed image data to the display controller through the data bus according to the pre-defined format and protocol. For example, in some Da Vinci series chips, image data is sent to the display controller through the AXI bus.

[0110] Control signal connection: The Da Vinci series DSP+ARM module also sends various control signals to the display controller to configure the display controller's operating mode, parameters, etc. These control signals include display resolution settings, color mode selection, refresh frequency settings, etc. The control signals are transmitted from the Da Vinci series DSP+ARM module to the display controller through a dedicated control line, allowing the display controller to process and display images according to the requirements of the Da Vinci series DSP+ARM module.

[0111] 2. For the image cache module

[0112] The image cache module is used to temporarily store the image data to be displayed. Since the speed at which the Da Vinci series DSP+ARM module processes images and the refresh speed of the operating display device may not completely match, the image cache module can act as a buffer. It can store one or more frames of images to ensure that image data can be provided in a timely manner when the operating display device is refreshed, avoiding screen flickering or freezing. It is generally connected to both the Da Vinci series DSP+ARM module and the operating display device. It receives image data from the Da Vinci series DSP+ARM module and stores it, and then transmits the stored image data to the operating display device according to the refresh frequency and data requirements of the operating display device. For example, in an LCD display, the image cache module can be connected to the control panel of the LCD display to provide corresponding image data according to the vertical synchronization and horizontal synchronization signals of the LCD display.

[0113] Data write connection: After receiving the image data from the Da Vinci series DSP+ARM module, the display controller will write the image data to the image cache module if the data transmission speed does not match the refresh speed of the operation display device, or if the image data needs to be further processed and optimized. The data is written to the corresponding storage unit of the image cache module through the output port of the operation display device according to a certain timing and protocol.

[0114] Data reading connection: When the operation display device needs to refresh the display, the display controller will read the image data from the image cache module. The reading operation is also performed according to the refresh timing and display requirements of the operation display device to ensure that the operation display device can display the image stably and smoothly. The display controller obtains the image data from the image cache module through a specific reading control line and data bus, and after necessary format conversion and processing, transmits it to the operation display device or the next level module.

[0115] 3. Protocol conversion module

[0116] If the image signal format output by the Da Vinci series DSP+ARM module is inconsistent with the format supported by the operation display device, a protocol conversion module is required. For example, the Da Vinci series DSP+ARM module may output signals in a custom digital image format, while the operation display device only supports standard VGA or HDMI formats. The protocol conversion module can convert the signal format to meet the reception requirements of the operation display device. One end of the protocol conversion module is connected to the output interface of the Da Vinci series DSP+ARM module to receive the original image signal. After format conversion, it is connected to the input interface of the operation display device through the other end to send the converted signal to the operation display device. For example, a digital image signal based on a specific encoding method is converted into a signal format that complies with the HDMI 1.4 or 2.0 standard, and then sent to the operation display device that supports the standard through the HDMI interface.

[0117] Front-end connection: In order to support the access of different types of operation display devices, the display controller is connected to the protocol conversion module, considering that different operation display devices support different display protocols. The display controller will output image data and related control signals to the input end of the protocol conversion module according to its own output format.

[0118] Back-end connection: The protocol conversion module converts the received image data and control signals to conform to the protocol format supported by the operation display device. The converted signal is transmitted from the output end of the protocol conversion module to the operation display device, thereby achieving compatible display of operation display devices with different protocols.

[0119] Signal transmission connection: The output end of the protocol conversion module is directly connected to the input end of the operation display device through the corresponding interface. For example, if the operation display device has a VGA interface, the protocol conversion module will connect the converted analog VGA signal to the VGA interface of the operation display device through a VGA cable; if it is an operation display device with an HDMI interface, the protocol conversion module will output a digital signal that complies with the HDMI protocol and connect it to the HDMI interface of the operation display device through an HDMI cable.

[0120] Example 4

[0121] This embodiment discloses a single-filament quantity detection device as a preferred implementation scheme of the present invention, that is, based on Example 1, 2 or 3, its pneumatic equipment includes an air duct, an air nozzle and a compressed air source device, the air nozzle is connected to the compressed air source device through the air duct, and an electromagnetic valve is installed in the air duct, and the electromagnetic valve is electrically connected to the main control device.

[0122] The compressed air source device is the power source of the entire pneumatic system and can provide compressed air with a specific pressure. Its pressure output needs to be stable and adjustable to meet the requirements of different tow separation. For example, for thicker and tighter tows, higher air pressure may be required to achieve effective blowing, while for thinner and looser tows, the air pressure can be reduced to avoid excessive blowing of single filaments and affect the detection accuracy. Common compressed air source devices include air compressors, which compress and store air through motor drive, and then output compressed air as needed.

[0123] The main function of the air guide tube is to transmit the compressed air generated by the compressed air source device to the air nozzle. The material of the air guide tube needs to have a certain pressure resistance, flexibility and sealing to ensure that there will be no leakage or rupture during the air pressure transmission process. The diameter of the tube will affect the transmission speed and flow of the air flow. It is generally selected according to the overall design requirements of the pneumatic system to ensure that it can meet the air flow supply required by the air nozzle.

[0124] The solenoid valve is controlled by the master control device to open and close the state, thereby realizing the control of the compressed air flow. When the master control device sends a signal to open the solenoid valve, the compressed air generated by the compressed air source device can flow to the air nozzle through the air guide pipe, and then blow the wire bundle to be tested; when the solenoid valve is closed, the air flow stops, realizing the precise control of the working state of the pneumatic equipment. The response speed and reliability of the solenoid valve have an important impact on the operating efficiency and accuracy of the entire detection device. It needs to be able to switch states quickly and accurately according to the instructions of the master control device, and maintain stable performance during long-term operation.

[0125] Example 5

[0126] This embodiment discloses a single-filament quantity detection device as a preferred implementation scheme of the present invention, that is, based on Example 4, its master control device includes not only the Da Vinci series DSP+ARM module but also a pneumatic control unit, and a solenoid valve control drive circuit is provided in the pneumatic control unit.

[0127] Hardware connection: The Da Vinci series DSP+ARM module of the master control device selects a suitable digital output pin (such as a GPIO pin) to connect to the solenoid valve control drive circuit of the pneumatic control unit. Since the solenoid valve usually requires a large drive current, and the GPIO pin of the Da Vinci series DSP+ARM module has a limited output current, the solenoid valve control drive circuit is required to amplify the current. Common solenoid valve control drive circuits can be built using transistors or MOSFETs. Taking the NPN transistor as an example, the base of the transistor is connected to the GPIO pin of the Da Vinci series DSP+ARM module, the emitter is grounded, and the collector is connected to the control end of the solenoid valve through a current limiting resistor. When the GPIO pin outputs a high level, the transistor is turned on, and the control end of the solenoid valve obtains enough current to open; when the GPIO pin outputs a low level, the transistor is turned off and the solenoid valve is closed. In order to protect the circuit and ensure the stable operation of the solenoid valve, a freewheeling diode is connected in parallel at both ends of the solenoid valve. When the solenoid valve is closed, the self-inductance electromotive force generated by its coil can form a loop through the freewheeling diode to avoid damage to the drive circuit.

[0128] Software control: In the software system of the master control device, the GPIO pin connected to the solenoid valve must first be initialized and configured to set it to output mode. When the solenoid valve needs to be opened for blowing operation, the software system writes a specific value (such as 1) to the corresponding GPIO register to make the pin output a high level, thereby triggering the transistor to turn on and turn on the solenoid valve. At the same time, a timer can be set to determine the length of the blowing time according to actual needs. For example, the timer is set to 5 seconds. During these 5 seconds, the solenoid valve remains open, and the pneumatic equipment blows to blow away the single filaments in the filament bundle body. When the timer time is reached, the software system writes the opposite value (such as 0) to the GPIO register again, causing the pin to output a low level, the transistor to be cut off, and the solenoid valve to be closed, completing a blowing operation.

[0129] Example 6

[0130] This embodiment discloses a single-filament quantity detection device as a preferred implementation scheme of the present invention, that is, based on Example 1, its operation display device is a touch display screen, and the touch display screen is connected to the master control device via a USB interface.

[0131] The USB interface is a widely used and standardized interface type, which is equipped in many electronic devices. The use of the USB interface to connect the touch screen and the master control device means that the compatibility between the devices is good. Whether it is replacing a touch screen of different models or a master control device, as long as they have a standard USB interface, they can be connected relatively conveniently, without the need to customize special interface lines, reducing the cost and difficulty of equipment maintenance, upgrading and replacement. The USB interface supports multiple data transmission modes and can meet the needs of two-way data interaction between the operation display device and the master control device. For example, the master control device can transmit the processed and analyzed tow image data to the touch screen through the USB interface for display. At the same time, the instructions input by the user through the touch operation on the touch screen (such as start detection, parameter adjustment, etc.) can also be accurately and quickly transmitted to the master control device via the USB interface, ensuring the real-time and smoothness of the entire system operation. In addition, the data transmission rate of the USB interface can meet the timeliness requirements of the detection device for image display and command response, ensuring that the user can see the tow image and detection results and other information in time. Some USB interfaces have power supply capabilities, which provides a convenient way to power the touch screen. If the power consumption of the touch screen is within the power supply capacity of the USB interface, it is possible to obtain power directly from the master control device or the power supply connected to it through the USB cable, reducing the trouble of additional independent power supply, simplifying the overall wiring and power management of the equipment, and making the structure of the entire detection device more compact and simple.

[0132] Since it is a touch screen and connected to the master control device via a USB interface, users can call various functions and set parameters directly on the screen through touch operations. For example, the single-filament quantity detection process can be started by tapping the corresponding icon on the screen, or the voltage of the electrostatic adsorption device, the air pressure of the pneumatic device and other parameters can be conveniently adjusted through touch interactive elements such as sliders and input boxes. This intuitive and convenient operation method is efficiently realized with the help of the stable data transmission of the USB interface, allowing users to complete the control of the entire detection device without the help of complex external control devices (such as keyboards, mice, etc.).

[0133] Through the connection of the USB interface, the touch screen can receive and display the latest information from the master control device in real time. It can not only display the image of the tow processed and analyzed by the master control device, allowing users to clearly observe the distribution of the monofilaments, but also dynamically display the progress of the current detection, the statistical results of the number of monofilaments, and possible abnormal prompt information (such as excessive overlap of monofilaments affecting the counting accuracy, etc.). At the same time, based on the information feedback seen on the touch screen, the user can send corresponding instructions to the master control device in a timely manner through touch operation, forming a good human-computer interaction cycle and further optimizing the detection process and results.

[0134] The master control device can push system update information to the touch display screen through the USB interface, such as updating the layout of the display interface, optimizing the algorithm for image display, etc., so that the functions and display effects of the touch display screen are continuously improved. And if the function of the operation display device is to be expanded in the future, such as adding new test data display panels or integrating more quick operation buttons, etc., the convenience of the USB interface can be used to relatively easily implement software-level upgrades without making large-scale changes to the hardware connection lines, ensuring the flexibility and sustainability of the entire detection device in terms of functional upgrades.

[0135] Example 7

[0136] This embodiment discloses a single-filament quantity detection device as a preferred implementation scheme of the present invention, that is, based on Example 1, its operation display device includes a computer host, a display, a keyboard and a mouse, the master control device is installed inside the computer host, and the display, keyboard and mouse are respectively connected to the computer host.

[0137] The computer host is the core control hub of the entire operation display device and even the entire single-filament number detection device, and undertakes many important tasks. The master control device is installed inside it, which can be responsible for coordinating and directing the relevant components to work in an orderly manner. For example, it receives the image data of the tow taken by the high-speed camera component, and uses the built-in master control device related software and algorithms to process and analyze these images, such as using image recognition algorithms to distinguish single fibers from the background, identify the outline of single fibers, etc., and then complete the measurement of the number of single fibers.

[0138] The computer host is equipped with a storage device (such as a hard disk, etc.) to store various data during the testing process. These data include the tow image obtained in each test, the corresponding single-filament number result, the test time, and the relevant equipment parameter settings (such as the voltage value of the electrostatic adsorption device, the air pressure value of the pneumatic equipment, etc.), which facilitates subsequent query, statistics, and data analysis, and provides a basis for further optimizing the testing process and tracing the testing history.

[0139] The computer host has a variety of interfaces for connecting to the monitor, keyboard, mouse and other external devices connected to the master control device (such as high-speed camera components, etc.). Data transmission and command interaction are achieved through these interfaces to ensure smooth information flow between the various parts of the entire system. For example, the USB interface receives operation instructions from the keyboard and mouse, and then transmits the processed image data to the monitor for display through the corresponding video interface.

[0140] The main function of the display is to intuitively display the image of the tow and related test information processed and analyzed by the computer host to the user. The user can clearly observe the distribution and morphological characteristics of the single filaments in the tow to be tested through the display, so as to make an intuitive judgment on the test results. At the same time, the display will also show specific values ​​such as the number of single filaments, the working status of the equipment (such as whether the pneumatic equipment is blowing, whether the electrostatic adsorption device is turned on, etc.) and various operation prompts, so that the user can understand the operation of the entire detection device and perform corresponding operations.

[0141] The display presents a visual human-computer interaction interface. Based on the operating system and related detection software running on the computer host, its interface layout will reasonably arrange various functional modules and display areas. For example, there is an image display window for displaying tow images, and a parameter setting area for adjusting equipment parameters by mouse clicks, keyboard input, etc., building a convenient communication bridge between users and detection devices.

[0142] As a commonly used input device, the keyboard provides users with a way to send various precise instructions to the computer host. Users can complete operations such as setting detection parameters (such as entering the expected air pressure value of pneumatic equipment, the voltage gear of electrostatic adsorption device, etc.), changing system configuration (such as adjusting the resolution and contrast of image display parameters), and performing file management (such as saving detection data, opening historical detection record files, etc.) by tapping the corresponding keys on the keyboard. It greatly enriches the flexibility and accuracy of users' control over the detection device. When it is necessary to make text notes on the detection situation, record special detection phenomena, or add explanations to the detection results, the text input function of the keyboard is particularly important. Users can easily enter text content in the corresponding text box or document, which is convenient for subsequent detection report generation and data collation.

[0143] The mouse is mainly used for intuitive operations on the graphical interface presented on the display. By moving the mouse pointer, the user can locate different function buttons, menu options, image areas and other positions on the interface, and then click the left or right mouse button or scroll the wheel to achieve various operations such as starting the detection process (clicking the "Start Detection" button), selecting different detection modes (selecting from the drop-down menu), zooming in or out of the tow image (using the wheel zoom function), etc., making the operation of complex detection software interfaces more convenient and efficient, and enhancing the friendliness of human-computer interaction. When it is necessary to quickly adjust equipment parameters or select specific detection items, the mouse's quick pointing and clicking functions allow users to quickly complete the operation, which can save a lot of time and improve the overall efficiency of the detection operation compared to using only keyboard input. For example, when it is necessary to quickly switch the working state of pneumatic equipment, just click the corresponding switch icon with the mouse, without having to enter complex command codes through the keyboard.

[0144] In the whole process of single-filament number detection, each component plays an indispensable role in collaboration. First, the user sets the equipment parameters on the operation interface of the computer host through the keyboard and mouse, such as setting the air pressure of the pneumatic equipment and the shooting parameters of the high-speed camera component. These instructions are transmitted to the corresponding external equipment through the computer host to prepare for the detection. Then, the detection device starts to run, the high-speed camera component takes the image of the tow and transmits the data to the master control device inside the computer host. The computer host processes and analyzes the image to obtain information such as the single-filament number result. Finally, the display displays these processed images and related test results. The user can further adjust the parameters or perform the next round of detection operations according to the displayed content through the keyboard and mouse. This cycle is repeated to achieve accurate, efficient and convenient detection of the number of single filaments, and ensure that the user can easily control the entire detection device and understand various situations during the detection process.

[0145] Example 8

[0146] This embodiment discloses a single-filament quantity detection device as a preferred implementation scheme of the present invention, that is, based on any one of embodiments 1 to 7, its high-speed camera assembly includes a high-speed camera and a camera bracket, and the high-speed camera is installed on a workbench through the camera bracket with an adjustable posture angle.

[0147] High-speed cameras can use industrial-specific high-speed and high-resolution cameras, which are the core components of the entire high-speed camera assembly. They have the ability to shoot at high speed and can capture multiple frames of images continuously in a short time. In the single-filament number detection device, since the state of the single filaments in the to-be-tested tow may change rapidly after electrostatic adsorption and pneumatic blowing, such as the fluttering and dispersion of the single filaments, the high-speed camera can shoot at a high frame rate to ensure that no key instantaneous images are missed, thereby providing clear and complete image materials for subsequent accurate analysis of the tow image and counting of the number of single filaments. In addition, high-speed cameras have a high resolution and can clearly present the detailed features of the single filaments, such as the thickness of the single filaments, the contour edges, etc., which can be accurately displayed in the captured images. This is very critical for distinguishing different single filaments and avoiding misjudging two or more close-together single filaments as one, which helps to improve the accuracy of single-filament number detection.

[0148] The primary function of the camera bracket is to provide a stable support structure for the high-speed camera so that it can be stably installed on the workbench. During the inspection process, due to factors such as the vibration of the equipment itself and slight interference from the external environment, if there is no reliable bracket to fix the high-speed camera, the captured image is prone to blurring, shaking and other quality problems. A stable bracket can effectively avoid these situations and ensure the clarity and stability of the captured image. The most prominent feature of the camera bracket is that it can achieve adjustable installation of the attitude angle of the high-speed camera. Through the various adjustment mechanisms equipped on the bracket (such as rotating joints, pitch adjustment mechanisms and lifting mechanisms, etc.), the position, angle and other parameters of the high-speed camera relative to the tow to be tested can be flexibly changed.

[0149] In the process of detecting the number of monofilaments, the high-speed camera assembly plays a key role in image acquisition. First, with the adjustable characteristics of the camera bracket, the operator can accurately adjust the posture angle of the high-speed camera according to the specific position, shape and detection requirements of the tow to be tested on the workbench, so as to ensure that it can capture the image of the tow from the most suitable radial direction. Then, with its advantages of high-speed shooting and high resolution, the high-speed camera can quickly and clearly capture the instantaneous shape and distribution of the monofilament when the monofilament is in a relatively dispersed state after the separation operation, and output these image data to the master control device in real time. In this way, the high-speed camera assembly provides a high-quality original image data basis for the subsequent master control device to perform accurate image processing and analysis and accurately calculate the number of monofilaments, which is one of the important links to ensure that the entire monofilament number detection device can operate reliably and efficiently. Moreover, the design of adjustable posture angle also gives the entire detection device a certain flexibility and adaptability, so that it can cope with the detection needs of different types and specifications of tows to be tested, and broadens the application range of the detection device.

[0150] Example 9

[0151] This embodiment discloses a single-filament quantity detection device as a preferred implementation scheme of the present invention, that is, based on any one of embodiments 1 to 8, its electrostatic adsorption device includes an electrostatic generator and an electrostatic adsorption plate; the electrostatic adsorption plate is placed flat on a workbench and is electrically connected to the electrostatic generator.

[0152] The electrostatic generator is the core power source of the electrostatic adsorption device, which can generate high-voltage static electricity. In the process of detecting the number of single fibers, the high-voltage static electricity generated can apply a specific electric field force to the fiber bundle in the case of tightly entangled or adhered single fibers in the fiber bundle. Fiber bundles of different materials respond differently to the electric field. By adjusting parameters such as the output voltage, the electrostatic generator can accurately provide an electric field of appropriate intensity for various fiber bundles to be tested, causing the charge distribution between the single fibers to change, thereby achieving the separation effect of the single fibers. For example, for some fiber bundle materials with good insulation, a higher voltage may be required to overcome the internal charge binding force so that the single fibers can be effectively separated.

[0153] The electrostatic generator has electrical control capabilities and can exchange signals with the master control device and receive control instructions. The master control device calculates and sets the output voltage, current and other parameters required by the electrostatic generator based on the initial state and material of the tow. The electrostatic generator can accurately respond to these instructions and adjust its own working state. At the same time, it can also feedback its own working state information (such as whether it is working normally, the current output voltage value, etc.) to the master control device so that the master control device can monitor and diagnose faults in real time throughout the detection process to ensure the stability and safety of the electrostatic adsorption operation.

[0154] The electrostatic adsorption plate is placed flat on the workbench. Its main function is to serve as a conductive medium for the electric field, evenly distributing the electric field generated by the electrostatic generator in the working area where the tow is located. Since the tow usually has a certain width and length, only by ensuring that the electric field is evenly distributed throughout the tow can each single wire be subjected to a relatively uniform electric field force, thus avoiding the situation where the separation effect of local single wires is poor or excessive separation. The material of the electrostatic adsorption plate is usually a metal material with good conductivity and a uniform and flat surface (such as aluminum plate, etc.), which can effectively reduce the loss and distortion of the electric field during the conduction process, and ensure that the electric field can act on the tow in the expected manner.

[0155] After the single-filament separation operation is completed, the electrostatic adsorption plate uses the electrostatic charge on its surface to generate adsorption force on the single-filament in a dispersed state, so that the single-filament can be relatively stably fixed on the workbench to prevent it from being displaced or entangled again due to factors such as airflow disturbance and equipment vibration during the subsequent detection process (such as when the high-speed camera component takes images). The size of this adsorption force needs to be moderate, ensuring that the single-filament will not float around and affect the detection, but it should not be too large to cause the single-filament to be overly pressed on the adsorption plate and difficult to distinguish or cause adverse consequences such as deformation of the single-filament. By working in coordination with the electrostatic generator and setting reasonable electrical parameters, the charge density and electric field strength on the surface of the electrostatic adsorption plate can be accurately controlled, thereby achieving effective regulation of the single-filament adsorption force.

[0156] In the process of detecting the number of single fibers, the electrostatic adsorption device plays an important role. First, when the to-be-tested tow is placed on the workbench and located above the electrostatic adsorption plate, the master control device starts the electrostatic generator, sets appropriate electrostatic parameters according to the characteristics of the tow, and the electrostatic generator generates high-voltage static electricity and transmits it to the electrostatic adsorption plate, so that the tow is in an electric field environment. Under the action of the electric field force, the tightly bound monofilaments inside the tow begin to separate, achieving a preliminary monofilament untangling effect. Then, in the subsequent detection process, the electrostatic adsorption plate continues to maintain a certain electrostatic adsorption force, stably adsorbing the separated monofilaments on the workbench, providing a clear and stable shooting object for the high-speed camera assembly. This working mode of separation first and adsorption later makes full use of the physical properties of static electricity, effectively solves the problem of unstable position during monofilament winding and detection, and greatly improves the accuracy and reliability of monofilament number detection. At the same time, compared with other mechanical separation and fixing methods, the electrostatic adsorption device has the advantages of no contact and less damage to the monofilaments. It is especially suitable for some detection scenarios with high requirements for tow quality and relatively fragile monofilament materials, further broadening the application field of the monofilament number detection device.

[0157] Example 10

[0158] This embodiment discloses a single-filament quantity detection device as a preferred implementation scheme of the present invention, that is, based on Example 9, an air jet hole is vertically opened on the electrostatic adsorption plate, the air nozzle of the pneumatic device is installed in the air jet hole with the opening facing upward, and a wire bundle clamp clamping the wire bundle to be tested is placed above the air jet hole.

[0159] The air nozzle of the pneumatic equipment is installed in the air jet hole of the electrostatic adsorption plate to achieve effective spatial integration. This compact layout design reduces the space occupied by the entire detection device on the workbench, making the device structure more compact and reasonable. Compared with setting the air nozzle separately in other positions, it avoids the problems of large equipment size and complex pipelines caused by the loose layout of each component, improves the space utilization of the workbench, and facilitates unified management and maintenance of various components. From the perspective of the air flow transmission path, this design enables the airflow to act directly from the air jet hole upward to the wire bundle fixture with the wire bundle to be tested placed above it, reducing the energy loss and direction change of the airflow during the transmission process, and can more efficiently transfer the energy of the compressed air to the wire bundle, thereby enhancing the effect of pneumatic blowing of the monofilaments.

[0160] In the process of separating single filaments, the electrostatic adsorption device and the pneumatic equipment need to work together. When the electrostatic adsorption plate initially separates the single filaments in the filament bundle through electrostatic action, the pneumatic equipment starts immediately, and the air nozzle sprays air upward from the air jet hole. Since the air nozzle and the electrostatic adsorption plate are tightly combined in structure, the airflow can act on the filament bundle accurately. Under the dual effects of the electrostatic field and the airflow field, the single filaments can be more fully separated and dispersed. For example, for some filament bundles with high viscosity or tightly entangled, relying solely on the electrostatic adsorption device may not be able to completely separate the single filaments. At this time, the impact of the airflow can further overcome the adhesion between the single filaments, complement each other with the electrostatic effect, and improve the effect and efficiency of single filament separation.

[0161] Since this installation method of the air nozzle can make the airflow act on the filament bundle more evenly and stably, the state of the monofilaments during the separation process is more consistent and predictable. When taking images of the filament bundle, the high-speed camera assembly can obtain clearer images that better reflect the actual distribution of the monofilaments. For example, some monofilaments will not be over-blown and difficult to identify due to uneven airflow, or some monofilaments will not be misjudged because they are still in a sticky state, thereby improving the accuracy of the master control device calculating the number of monofilaments through the image processing algorithm. Moreover, during the entire detection process, the position of the filament bundle above the electrostatic adsorption plate is relatively fixed, and will not undergo large displacement or shaking due to the impact of the airflow. This also helps the high-speed camera assembly to have better consistency and comparability between images taken at different time points, reducing the detection error introduced by changes in the position of the filament bundle, and further improving the accuracy of monofilament number detection.

[0162] From the perspective of equipment operation, this structural design reduces the impact of external factors (such as airflow interference, component vibration, etc.) on the detection process. Since the air nozzle is closely combined with the electrostatic adsorption plate, the mechanical structure of the entire device is more stable, and the relative positions and working conditions between the components can remain relatively stable during long-term operation. For example, there will be no problems such as changes in airflow direction and unstable air pressure caused by loose or offset air nozzles, which ensures the consistency of single-filament separation and detection conditions during each test, thereby enhancing the overall stability of the detection device and making the test results more repeatable and reliable.

[0163] Embodiment 11

[0164] This embodiment discloses a method for detecting the number of monofilaments. As a preferred embodiment of the present invention, a monofilament number detection device described in any one of Embodiments 1 to 10 is used, and the method includes the following steps:

[0165] S1, sample the tows for each spindle position of the spinning machine to obtain the tows to be tested. Sampling the tows for each spindle position of the spinning machine can accurately detect the quality of the tows produced by each independent production unit, which helps to timely discover possible production problems in a single spindle position, such as spinning nozzle failure, abnormal raw material supply, etc., which lead to deviations in the number of single fibers. By individually testing the tows of each spindle position, the entire spinning production process can be finely managed and quality controlled to avoid the spread of local problems affecting the overall product quality.

[0166] The wire bundle to be tested is cleaned and dried. More specifically, the cleaning and drying of the wire bundle to be tested includes the following steps:

[0167] S11, rinse the to-be-tested tow with clean water at 24-27°C for 10-12 seconds. This temperature range is close to room temperature and the rinsing time is short, which can effectively remove impurities, dust, and spinning agent residues that may be attached to the surface of the tow without causing excessive impact on the physical properties of the tow (such as single-filament strength, flexibility, etc.). For example, water at too high a temperature may cause some thermoplastic tow materials to deform or deteriorate in performance, and rinsing for too long may cause excessive loss of some water-soluble components in the tow, affecting the overall quality of the tow and the accuracy of subsequent test results.

[0168] S12, squeeze out the water on the tow to be tested and ensure that no lint is formed on the tow to be tested. This step is crucial to ensure the integrity and stability of the tow during the subsequent clamping, handling and testing process. If there is too much water left on the tow, it may cause the tow to slip or shift when clamped into the tow fixture, affecting the accuracy of the test; and the formation of lint will interfere with the detection of the number of single fibers, causing blurred filaments to appear in the image taken by the high-speed camera component, making it difficult to accurately distinguish the boundaries and number of single fibers, increasing the detection error.

[0169] S13, use an infrared drying box to dry the tow to be tested; the drying temperature is controlled at 43-51°C, and the drying time is 1-3 minutes. Infrared drying has the characteristics of fast heating speed, high thermal efficiency and relative uniformity. Selecting this temperature range and drying time can remove moisture from the tow in a short time, restore the tow to a stable dry state, and facilitate subsequent clamping and testing operations. At the same time, the appropriate drying temperature can avoid problems such as aging, discoloration or adhesion of the tow material due to excessive temperature, ensuring that the tow can maintain its original physical and chemical properties during the test process, thereby improving the reliability of the test results.

[0170] S2, clamp the tow to be tested into the tow fixture, then cut the tow to be tested to a preset length, and place the tow fixture with the tow to be tested on the electrostatic adsorption device. The clamping operation can fix the position of the tow, so that it remains relatively stable during the subsequent high-voltage electric shock separation and pneumatic separation process, avoiding the shaking of the tow from affecting the single-filament separation effect and the accuracy of image acquisition. Cutting to a preset length is to make the tow have a suitable length range within the detection area, so that the high-speed camera assembly can fully capture the radial image of the tow, and it is also beneficial for the electrostatic adsorption device and the pneumatic equipment to act uniformly and effectively on the tow in a limited space. For example, if the tow is too long, part of the tow may exceed the detection area and cannot be accurately detected; if the tow is too short, the overall characteristics of the tow may not be fully reflected, affecting the representativeness of the single-filament quantity statistics.

[0171] S3, start the electrostatic adsorption device and the pneumatic equipment; start the electrostatic adsorption device to perform high-voltage electric shock separation on the to-be-tested filament bundle, and at the same time, the pneumatic equipment sprays high-speed air to perform pneumatic separation on the to-be-tested filament bundle.

[0172] The electrostatic adsorption device uses high-voltage electric shock to separate the tow to be tested, and uses the electrostatic field to generate force on the single filaments in the tow, so that the charge distribution between the single filaments changes, thereby breaking the original adhesion or entanglement state. For some single filaments that are tightly bound due to electrostatic effects, van der Waals forces and other factors, high-voltage static electricity can provide enough energy to overcome these binding forces and achieve preliminary separation of the single filaments. Tows of different materials respond differently to electrostatic fields. By adjusting the voltage and other parameters of the electrostatic adsorption device, it can meet the separation needs of various types of tows.

[0173] The pneumatic equipment sprays high-speed air to perform pneumatic separation on the to-be-tested filament bundles. The impact force of the high-speed airflow further acts on the filaments in the filament bundles, making the filaments more dispersed in space. Pneumatic separation and electrostatic separation work together to enhance the effect of filament separation. For example, for some thicker or more viscous filament bundles, electrostatic separation alone may not be able to completely disperse the filaments, while the addition of pneumatic separation can provide additional external force to separate the filaments more thoroughly, and can adjust the direction, intensity and other parameters of the airflow to optimize the separation effect, ensuring that the filaments are in a more ideal dispersed state during the subsequent image acquisition process.

[0174] S4, in the process of high-voltage electric shock separation and pneumatic separation of the to-be-tested tow, the tow image is collected from the radial direction of the to-be-tested tow by the high-speed camera assembly, and the collected tow image is transmitted to the master control device. Furthermore, when the high-speed camera assembly collects the tow image, the camera distance of the high-speed camera is 110mm and the magnification is 0.5X-1.5X. It is necessary to ensure appropriate lighting conditions, shooting angles and resolutions to obtain clear, complete images that reflect the characteristics of the tow. For example, a ring light source is used to evenly illuminate the tow so that the outline of the tow and the details of the single filament can be clearly presented, and the shooting resolution is set to the minimum width that can accurately distinguish the single filament.

[0175] Selecting a camera distance of 110mm and a magnification range of 0.5X-1.5X can ensure that the entire tow is captured while keeping the size of the monofilaments moderate in the image. It will not be too magnified to show only part of the tow area in the image, nor will it be too small to make the details of the monofilaments difficult to distinguish. Using a ring light source to evenly illuminate the tow can avoid shadows caused by uneven lighting, so that the outline of the tow and the details of the monofilaments can be clearly presented. The appropriate shooting resolution is set to the minimum width that can accurately distinguish the monofilaments, which is crucial for subsequent image processing and monofilament quantity statistics. Only by clearly distinguishing each monofilament can accurate counting and analysis be performed.

[0176] S5, the master control device pre-processes the tow image and transmits it to the operation display device for display. More specifically, the master control device pre-processes the tow image including:

[0177] Grayscale processing: Convert the color tow image into a grayscale image. This step can reduce the amount of data, and the grayscale image is more convenient for analyzing the edge and shape of the single thread in subsequent processing. For example, using the weighted average method, according to the sensitivity of the human eye to different colors, different weights are assigned to the three color channels of red, green, and blue to calculate the corresponding grayscale value.

[0178] Filtering and noise reduction: Gaussian filtering algorithm is used to remove noise in the tow image. Gaussian filtering smoothes the image by performing weighted average calculation on each pixel in the image and its neighboring pixels, reducing the interference of noise on subsequent processing while retaining important information such as the edge of the tow.

[0179] Image enhancement: According to the characteristics of the tow image, image processing methods including contrast enhancement and histogram equalization are used to improve the clarity and contrast of the tow image, making the details of the tow to be tested more obvious. For example, histogram equalization redistributes the grayscale of the image to make the grayscale distribution of the image more uniform, thereby enhancing the contrast of the image and highlighting the difference between the tow and the background.

[0180] S6, using the operation display device to analyze and detect based on the current tow image to measure the number of single fibers in the current tow to be measured. Specifically, the following steps are included:

[0181] S61-1, edge detection: Use edge detection operators (such as the Canny edge detection algorithm) to detect the edge of each single filament in the tow. The algorithm first smoothes the image through a Gaussian filter to reduce the influence of noise; then calculates the gradient amplitude and direction of the image, and determines the edge pixels through non-maximum suppression; finally, uses dual threshold detection and connection edges to obtain a more accurate single filament edge contour.

[0182] S61-2, Morphological processing: Perform morphological operations on the image after edge detection, such as erosion and dilation. The erosion operation can remove small burrs and isolated noise points on the edge, and the dilation operation can fill the tiny holes inside the monofilament, making the shape of the monofilament more complete and continuous, which is convenient for subsequent counting and analysis.

[0183] S61-3, Contour extraction and segmentation: Based on the results of edge detection and morphological processing, the contour of the monofilament is extracted. Specifically, a contour tracking method is used, starting from a certain starting point in the image, and tracking along the contour pixels according to the set rules, to separate the contour of each monofilament and achieve monofilament segmentation.

[0184] S61-4, single-filament number counting: Count the segmented single-filament contours to obtain the number of single-filaments in the tow, by traversing all contours and using a counter to record the number of contours, which is the number of single-filaments.

[0185] S7, judging whether the number of monofilaments meets the production requirements; if so, the test is completed and judged as qualified; if not, proceeding to step S8.

[0186] S8, repeat steps S1 to S6 for re-inspection. After the re-inspection, determine whether the number of monofilaments meets the production requirements; if it does, the test is completed and it is judged as qualified; if it does not, it is judged as unqualified. The purpose of re-inspection is to eliminate misjudgment caused by accidental errors that may occur during a single test (such as interference at the moment of image acquisition, fluctuations in equipment parameters, etc.). Through re-inspection, if the number of monofilaments meets the requirements, it is judged as qualified; if it still does not meet the requirements, it is judged as unqualified. This re-inspection mechanism can improve the accuracy and reliability of the test results, ensuring that only tows that truly meet the quality requirements can enter the next process or leave the factory as qualified products, thereby effectively ensuring the quality stability and consistency of the products.

[0187] Example 12

[0188] This embodiment discloses a method for detecting the number of monofilaments. As a preferred embodiment of the present invention, a monofilament number detection device described in any one of Embodiments 1 to 10 is used, and the method includes the following steps:

[0189] S1, sampling a tow from each single spindle position of the spinning machine to obtain a tow to be tested, and washing and drying the tow to be tested. More specifically, washing and drying the tow to be tested includes the following steps:

[0190] S11, rinse the tested yarn bundle with clean water at 24-27°C for 10-12s.

[0191] S12, squeeze out the water on the yarn bundle to be tested, and ensure that no lint is formed on the yarn bundle to be tested.

[0192] S13, using an infrared drying box to dry the to-be-tested yarn bundle; the drying temperature is controlled at 43-51° C., and the drying time is 1-3 minutes.

[0193] S2, clamping the tow to be tested into the tow fixture 1, and then cutting the tow to be tested to a preset length, and placing the tow fixture 1 clamped with the tow to be tested on the electrostatic adsorption device.

[0194] S3, start the electrostatic adsorption device and the pneumatic equipment; start the electrostatic adsorption device to perform high-voltage electric shock separation on the to-be-tested filament bundle, and at the same time, the pneumatic equipment sprays high-speed air to perform pneumatic separation on the to-be-tested filament bundle.

[0195] S4, in the process of synchronously performing high-voltage electric shock separation and pneumatic separation on the to-be-tested tow, the tow image is collected from the radial direction of the to-be-tested tow by the high-speed camera assembly, and the collected tow image is transmitted to the master control device 4. Further, when the high-speed camera assembly collects the tow image, the camera distance of its high-speed camera 5 is 110mm and the magnification is 0.5X-1.5X. It is necessary to ensure that the shooting environment is stable, the light is uniform and there is no obvious interference, so that the image can clearly reflect the detailed characteristics of the tow. For example, a high-resolution, high-speed camera is used, and a suitable frame rate and exposure time are set to capture the image of the tow in different states, providing basic data for subsequent precise processing.

[0196] S5, the master control device 4 pre-processes the tow image and transmits it to the operation display device 3 for display. More specifically, the master control device 4 converts the color image into a grayscale image to reduce the data dimension and the amount of calculation. Common grayscale conversion formulas such as the weighted average method: Gray = 0.299 × R + 0.587 × G + 0.114 × B; where Gray represents the grayscale value, and R, G, and B represent the red, green, and blue channel pixel values ​​of the color image, respectively. This can highlight the contrast between the tow and the background, which is convenient for subsequent processing.

[0197] Filtering and noise reduction: Use median filtering or Gaussian filtering to remove noise from the image. Median filtering has a good effect on removing salt and pepper noise. It smoothes the image by sorting the grayscale values ​​in the pixel neighborhood and taking the middle value as the new grayscale value of the pixel; Gaussian filtering is suitable for removing Gaussian noise. It uses the Gaussian function to perform convolution operations on the image to make the image smoother while retaining the edge information of the tow.

[0198] Image enhancement: According to the characteristics of the tow image, image processing methods including contrast enhancement and histogram equalization are used to improve the clarity and contrast of the tow image, making the details of the tow to be tested more obvious. For example, histogram equalization redistributes the grayscale of the image to make the grayscale distribution of the image more uniform, thereby enhancing the contrast of the image and highlighting the difference between the tow and the background.

[0199] S6, using the operation display device 3 to analyze and detect based on the current tow image to measure the number of single fibers in the current tow to be measured. Specifically, the following steps are included:

[0200] S62-1, threshold segmentation: Use a suitable threshold selection method to determine the segmentation threshold. For example, the Otsu's method can be used to automatically calculate the threshold. The Otsu's method is based on the grayscale histogram of the image. It determines the optimal threshold by maximizing the inter-class variance and divides the image into two parts: the target (tow) and the background. Specifically: Let the pixel grayscale value of the tow image be i, the total number of pixels be N, and the number of pixels with grayscale value i be ni, then the probability is pi = ni / N. Assuming the threshold is t, the image is divided into two categories, C0 and C1; where the grayscale value range of C0 is 0~t, the probability is w0, and the mean is μ0; the grayscale value range of C1 is (t+1)~(L-1), the probability is w1, the mean is μ1, and L represents the total number of grayscale levels; therefore, the inter-class variance is g(t) = w0*w1*(μ0-μ1) 2 Traverse all relevant thresholds t and find the t value that maximizes the inter-class variance g(t) as the segmentation threshold. Set the pixels with grayscale values ​​less than or equal to t in the tow image as target pixels (such as white), and the pixels greater than t as background pixels (such as black), so as to preliminarily separate the tow target from the image background.

[0201] S62-2, Grayscale enhancement: Perform grayscale enhancement on the image after threshold segmentation to further improve the contrast between the tow and the background. Linear stretching or histogram equalization can be used. Linear stretching sets a new grayscale range and maps the grayscale value of the original image to the new range in proportion to enhance the overall contrast of the image; histogram equalization transforms the histogram of the image to make the grayscale distribution of the image more uniform, thereby increasing the local contrast of the image and making the details of the tow more clearly discernible.

[0202] S62-3, connected domain processing: mark the connected domains of the enhanced image. Scan each pixel in the image, and when encountering an unlabeled target pixel, assign it a new label, and recursively label the target pixels adjacent to it until all connected target pixels are labeled. In this way, the fiber bundles in the image can be divided into independent connected regions, which is convenient for subsequent analysis and counting. Remove small connected domains. Since noise or image defects may cause some small areas of misidentification, by setting an area threshold, the connected domains with an area smaller than the threshold are removed, and the larger connected domains that truly represent the fiber bundles are retained to improve the accuracy of recognition.

[0203] S62-4, feature analysis is performed on the processed connected domain, and the fiber bundle area is further screened and confirmed according to the geometric features of the fiber bundle, such as shape, length, width, etc. For example, a reasonable range of length and width is set to exclude the connected domain that does not meet the fiber bundle characteristics.

[0204] S62-5, counting the number of remaining connected domains, that is, the number of tows, and storing and transmitting the counting result to the master control device 4 for subsequent data processing and display operations.

[0205] S7, judging whether the number of monofilaments meets the production requirements; if so, the test is completed and judged as qualified; if not, proceeding to step S8.

[0206] S8, repeat steps S1 to S6 for re-inspection, and after the re-inspection, determine whether the number of monofilaments meets the production requirements; if yes, the test is completed and it is determined to be qualified; if not, it is determined to be unqualified.

Claims

1. A monofilament number detection device, characterized in that: It comprises a tow clamp (1), a workbench (2), an operation display device (3), a high-speed camera assembly, an electrostatic adsorption device, a pneumatic device and a master control device (4); The electrostatic adsorption device is arranged and installed on a workbench (2) and is used to electrostatically adsorb the tow to be tested clamped by the tow clamp (1); The pneumatic device is electrically connected to the master control device (4) and is used to disperse the single filaments in the to-be-tested filament bundle by blowing air under the control of the master control device (4); The high-speed camera assembly is installed on the workbench (2) and is electrically connected to the master control device (4), and is used to capture images from the radial direction of the tow to be measured, and to send the captured images to the master control device (4); The master control device (4) is installed on the workbench (2) and is used to process and analyze the tow image uploaded by the high-speed camera assembly; The operation display device (3) is installed on the workbench (2) and is electrically connected to the master control device (4) for displaying the image of the yarn bundle processed and analyzed by the master control device (4) and for cooperating with the master control device (4) to calculate the number of single yarns in the yarn bundle to be measured in the current yarn bundle image.

2. A single-filament number detection device as claimed in claim 1, characterized in that: The master control device (4) comprises a Da Vinci series DSP+ARM module, a display control unit, an acquisition control unit and a pneumatic control unit; the operation display device (3) is connected to the Da Vinci series DSP+ARM module via the display control unit; the high-speed camera assembly is connected to the Da Vinci series DSP+ARM module via the acquisition control unit; and the pneumatic device is connected to the Da Vinci series DSP+ARM module via the pneumatic control unit.

3. A monofilament number detection device as claimed in claim 1, characterized in that: The operation display device (3) is a touch display screen, and the touch display screen is connected to the master control device (4) via a USB interface.

4. A monofilament number detection device as claimed in claim 1, characterized in that: The operation display device (3) comprises a computer host, a display, a keyboard and a mouse. The master control device (4) is installed inside the computer host. The display, keyboard and mouse are respectively connected to the computer host.

5. A monofilament number detection device as claimed in claim 1, characterized in that: The high-speed camera assembly comprises a high-speed camera (5) and a camera bracket (6); the high-speed camera (5) is mounted on the workbench (2) via the camera bracket (6) in an adjustable posture angle.

6. A monofilament number detection device as claimed in claim 1, characterized in that: The pneumatic device comprises an air guide pipe (7), an air nozzle (8) and a compressed air source device (9); the air nozzle (8) is connected to the compressed air source device (9) through the air guide pipe (7); an electromagnetic valve (13) is installed in the air guide pipe (7); and the electromagnetic valve (13) is electrically connected to the master control device (4).

7. A monofilament number detection device as claimed in claim 6, characterized in that: The electrostatic adsorption device comprises an electrostatic generator (10) and an electrostatic adsorption plate (11); the electrostatic adsorption plate (11) is placed flat on a workbench (2) and is electrically connected to the electrostatic generator (10).

8. A monofilament number detection device as claimed in claim 7, characterized in that: The electrostatic adsorption plate (11) is vertically provided with an air jet hole (12), and the air nozzle (8) of the pneumatic device is installed in the air jet hole (12) with its opening facing upward.

9. A method for detecting the number of monofilaments, characterized in that: A monofilament quantity detection device as claimed in any one of claims 1 to 8 is used, comprising the following steps: S1, sampling the tow from each single spindle position of the spinning machine to obtain the tow to be tested, and washing and drying the tow to be tested; S2, clamping the to-be-tested yarn bundle into a yarn bundle fixture (1), then cutting the to-be-tested yarn bundle to a preset length, and placing the yarn bundle fixture (1) clamped with the to-be-tested yarn bundle on an electrostatic adsorption device; S3, start the electrostatic adsorption device and the pneumatic device; start the electrostatic adsorption device to perform high-voltage electric shock separation on the to-be-tested filament bundle, and at the same time, the pneumatic device sprays high-speed air to perform pneumatic separation on the to-be-tested filament bundle; S4, in the process of synchronously performing high-voltage electric shock separation and pneumatic separation on the to-be-tested tow, collecting tow images from the radial direction of the to-be-tested tow by means of a high-speed camera assembly, and transmitting the collected tow images to the master control device (4); S5, the master control device (4) pre-processes the tow image and transmits it to the operation display device (3) for display; S6, using the operation display device (3) to perform analysis and detection based on the current yarn bundle image to measure the number of single yarns in the current yarn bundle to be tested; S7, judging whether the number of monofilaments meets the production requirements; if so, the test ends and is judged as qualified; if not, proceeding to step S8; S8, repeat steps S1 to S6 for re-inspection, and after the re-inspection, determine whether the number of monofilaments meets the production requirements; if yes, the test is completed and it is determined to be qualified; if not, it is determined to be unqualified.

10. A method for detecting the number of monofilaments as claimed in claim 9, characterized in that: In step S1, the cleaning and drying of the to-be-tested yarn bundle includes the following steps: S11, rinse the to-be-tested tow with clean water at 24-27°C for 10-12 seconds; S12, squeezing out water on the yarn bundle to be tested, and ensuring that no hair is formed on the yarn bundle to be tested; S13, using an infrared drying box to dry the to-be-tested yarn bundle; the drying temperature is controlled at 43-51° C., and the drying time is 1-3 minutes.

11. A method for detecting the number of monofilaments as claimed in claim 9, characterized in that: In the step S4, when the high-speed camera assembly collects the image of the tow, the camera distance of the high-speed camera (5) is 110 mm and the magnification is 0.5X-1.5X.

12. A method for detecting the number of monofilaments as claimed in claim 9, characterized in that: In the step S5, the master control device (4) pre-processes the tow image, including: Grayscale processing: convert the color tow image into a grayscale image; Filtering and noise reduction: Use median filtering or Gaussian filtering algorithm to remove noise in the tow image; Image enhancement: According to the characteristics of the tow image, image processing methods including contrast enhancement and histogram equalization are used to improve the clarity and contrast of the tow image, making the details of the tow to be tested in the tow image more obvious.

13. A method for detecting the number of monofilaments as claimed in claim 9, characterized in that: In step S6, measuring the number of monofilaments in the current to-be-measured tow includes the following steps: S61, threshold segmentation: using a preset threshold selection method to determine the segmentation threshold, and dividing the tow image into two parts: a tow target and an image background; S62, grayscale enhancement: performing a grayscale enhancement operation on the fiber bundle image after the threshold segmentation, so as to improve the contrast between the fiber bundle to be tested and the background in the fiber bundle image; S63, connected domain processing: marking the connected domains of the enhanced tow image to divide the tow to be measured in the tow image into single independent connected regions; during this period, by setting an area threshold, the misidentified regions caused by noise and / or image defects are removed, and the connected domains that truly represent the single filaments are retained; S64, performing feature analysis on the retained connected domains, and screening and confirming the connected domains corresponding to the single-filament region according to the geometric features of the single-filament; S65, counting the number of connected domains corresponding to the single-filament region, that is, the number of single-filament roots.

14. A method for detecting the number of monofilaments as claimed in claim 13, characterized in that: In step S61, dividing the tow image into two parts, a tow target and an image background, comprises the following steps: S611, assuming that the pixel grayscale value of the tow image is i, the total number of pixels is N, and the number of pixels with grayscale value i is ni, then the probability is pi = n l / N; S612, assuming the threshold is t, divide the image into two categories c0 and c1; where the grayscale value range of C0 is 0~t, the probability is w0, and the mean is μ0; the grayscale value range of C1 is (t+1)~(L-1), the probability is w1, the mean is μ1, and L represents the total number of gray levels; therefore, the inter-class variance is g(t)=w0*w1*(μ0-μ1) 2 ; S613, traverse all relevant thresholds t, and find the t value that maximizes the inter-class variance g(t) as the segmentation threshold; S614, setting pixels with grayscale values ​​less than or equal to t in the tow image as target pixels, and setting pixels with grayscale values ​​greater than t as background pixels, thereby preliminarily separating the tow target from the image background.

Images