Automatic paper tube detection system and method for chemical fiber industry

Abstract

The invention relates to the technical field of chemical fiber industrial product detection, in particular to an automatic paper tube detection system and method for the chemical fiber industry. The system comprises a paper tube length detection module, a paper tube end face and inner side wall detection module, a paper tube righting module, a paper tube outer side wall three-dimensional detection module and a paper tube outer side wall surface flaw detection module which are arranged on the basis of an assembly line, the paper tube end face and inner side wall detection module adopts two sets of camera devices to respectively photograph two end faces of a paper tube and performs identification detection on images based on a deep learning algorithm; the paper tube outer side wall three-dimensional detection module and the paper tube outer side wall surface flaw detection module use a jacking rotating mechanism to cooperate with a 3D depth camera and an area array color camera to detect the outer side wall of the paper tube. According to the invention, all-around defect detection can be carried out on the product, and the detection efficiency is effectively improved.

Description

Technical Field

[0001] The present invention relates to the technical field of chemical fiber industry product detection, and in particular to an automatic detection system and method for paper tubes used in the chemical fiber industry. Background Art

[0002] In the chemical fiber industry, synthetic fiber threads on spindles, such as polyester fibers and nylon fibers, are usually wound on paper tubes, which not only provide support and stability for the spindles, but also facilitate transportation and storage. Therefore, paper tubes must undergo strict quality inspections before use to ensure that they meet quality requirements during production and use and can effectively play their role.

[0003] Common chemical fiber paper tube inspection items include appearance inspection, size measurement, pressure resistance, surface hardness, tensile strength, etc. The pressure resistance, surface hardness, and tensile strength of the paper tube are determined by the paper tube structure, production materials and production process. The performance is relatively stable and does not require secondary inspection before use. The paper tube appearance (whether there are cracks, deformation, etc.) and size (length, diameter, etc.) are easily affected by factors such as bumps and extrusion during transportation and change, so secondary inspection is required before use.

[0004] At present, the chemical fiber industry generally uses manual inspection to ensure that the appearance and size of the paper tubes used meet the quality requirements. However, the manual inspection method has some obvious disadvantages: Inefficiency: Manual inspection is usually slower than automated inspection, especially in the case of large-scale production or long inspection time, which may lead to slow production progress.

[0005] Affected by fatigue: Manual inspection requires long-term concentration and is easily affected by factors such as fatigue and distraction, which may lead to missed detections or misjudgments.

[0006] Poor consistency: Different manual inspectors may make different judgments on the same product. The lack of standardization leads to inconsistent results and may even cause quality disputes.

[0007] Strong subjectivity: Manual inspection relies heavily on the inspector’s experience and subjective opinions, so there may be errors in subjective judgment, especially when detecting some defects that are difficult to quantify, which can easily lead to deviations.

[0008] High cost: Manual inspection requires a lot of manpower costs, especially when frequent inspections or complex inspections are required, the cost is more significant.

[0009] Affected by the environment: Environmental factors such as light, temperature, and humidity may also affect the accuracy of manual appearance inspection.

[0010] Difficulty in handling complex defects: Some minor or complex appearance defects may be difficult to detect through manual inspection, while automated inspection systems can identify these problems more accurately. Summary of the invention

[0011] In order to solve the above technical problems existing in the prior art, the present invention proposes an automatic detection system and method for paper tubes for chemical fiber industry, and its specific technical scheme is as follows: A paper tube automatic detection system for chemical fiber industry is provided with a paper tube length detection module, a paper tube end face and inner wall detection module, a paper tube straightening module, a paper tube outer wall three-dimensional detection module and a paper tube outer wall surface defect detection module based on an assembly line. The paper tube length detection module uses a distance sensor to obtain parameters to detect the length of the paper tube, the paper tube end face and inner wall detection module uses two sets of camera devices to take pictures of the two end faces of the paper tube respectively and recognizes and detects the images based on a deep learning algorithm, and the paper tube outer wall three-dimensional detection module and the paper tube outer wall surface defect detection module use a lifting and rotating mechanism to cooperate with a 3D depth camera and an area array color camera to detect the outer wall of the paper tube.

[0012] Furthermore, the paper tube length detection module also includes a driving cylinder, a fixed plate, and a movable plate. The fixed plate and the movable plate are used to clamp the paper tube. The movable plate is driven by the cylinder to extend and retract to adjust the distance between it and the fixed plate, thereby realizing clamping and loosening at both ends of the paper tube. The distance sensor detects the displacement distance when the movable plate is extended and retracted, and compares the displacement distance value with the calibrated standard length value.

[0013] Furthermore, an annular light source is provided between the camera device and the end surface of the paper tube, and the annular light source is used to provide sufficient lighting.

[0014] Furthermore, the lifting and rotating mechanism rotates the paper tube at a constant speed, and the 3D depth camera and the area array color camera take pictures of the surface of the paper tube rotating at a constant speed, and detect it through an image processing algorithm.

[0015] Furthermore, the paper tube outer wall three-dimensional detection module and the paper tube outer wall surface defect detection module are both set to a double-station mode.

[0016] A method for automatically detecting paper tubes for chemical fiber industry, comprising: Step 1. The product rolls into the system assembly line. When it passes the fixed plate, the driving cylinder drives the connected movable plate to clamp the movable plate and the fixed plate. At the same time, the distance sensor obtains the displacement parameters of the movable plate, and detects whether the paper tube length meets the requirements through the displacement parameters. Step 2: Use two sets of camera devices to take pictures of the two end surfaces of the paper tube respectively and recognize and detect the images based on the deep learning algorithm; Step 3, the rolling paper tube detected in step 2 is grabbed by the robotic arm and placed vertically; Step 4: Place the vertically placed paper tube on the lifting and rotating mechanism and rotate it at a constant speed. At the same time, the 3D depth camera and the area array color camera located on the side of the lifting and rotating mechanism take pictures of the surface and detect it through the image processing algorithm.

[0017] The system and method of the present invention are applied to the appearance and size detection of paper tubes before they are wound with wire. Specifically, the system and method can realize the detection of defects such as surface scribing of the paper tube, bottom paper cornering, end face burrs, end face cracks, no knife grooves, few points or no points on the point knife, paper tube overlap width, overall height of the paper tube, surface oil stains, surface unevenness, surface damage, surface wrinkles, surface glue stains, knife groove wire guide groove gaps, knife groove main knife displacement, and point knife damage, thereby effectively improving the detection efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of a working assembly line of an automatic detection system for paper tubes used in chemical fiber industry according to an embodiment of the present invention; Figure 2 2 is a schematic diagram of the structure of the hardware configuration of the paper roll length detection module according to an embodiment of the present invention; Figure 3 2 is a schematic structural diagram of the hardware configuration of the three-dimensional detection module for the outer wall of a paper tube according to an embodiment of the present invention; Figure 4 It is a schematic diagram of a process flow of an automatic detection method for paper tubes for chemical fiber industry implemented by the present invention; In the figure, 1-length detection station, 2-left and right end faces and inner wall defect detection station, 3-paper tube straightening station, 4-outer wall three-dimensional scale measurement station, 5-outer wall surface defect detection station, 6-paper tube, 11-driving cylinder, 12-fixed plate, 13 moving plate, 14-distance sensor, 21-lifting and rotating mechanism, 22-3D depth camera. DETAILED DESCRIPTION

[0019] In order to make the purpose, technical scheme and technical effect of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0020] The paper tube automatic detection system for chemical fiber industry in this embodiment includes a paper tube length detection module, a paper tube end surface and inner wall detection module, a paper tube straightening module and a paper tube outer wall three-dimensional detection module. Figure 1 As shown, a length detection station 1, a left and right end face and inner wall surface defect detection station 2, a paper tube straightening station 3, an outer wall three-dimensional dimension measurement station 4 and an outer wall surface defect detection station 5 are arranged on the system assembly line. Each module is arranged at a corresponding station, and the paper tube 6 is conveyed through the above-mentioned stations in sequence through the assembly line to complete a full range of inspections.

[0021] Figure 1In the embodiment, the paper tube 6 flowing into the inlet of the system assembly line is detected at the length detection station 1. Specifically, Figure 2 As shown, the paper tube length detection module includes a driving cylinder 11, a fixed plate 12, a movable plate 13 and a distance sensor 14. The fixed plate 12 and the movable plate 13 are used to clamp the paper tube 6. The movable plate 13 is driven by the cylinder to extend and retract to adjust the distance between it and the fixed plate 12, thereby realizing clamping and loosening at both ends of the paper tube 6. An industrial high-precision distance sensor 14 is used to detect the displacement distance of the movable plate 13 when it is extended and retracted, and the displacement distance value is compared with the calibrated standard length value to output whether the current paper tube 6 height data meets the standard.

[0022] At the left and right end faces and inner wall defect detection station 2, two sets of camera devices are used to respectively take pictures of the flatness, burrs, cracks, and end face roundness of the two end faces of the paper tube 6, and the images are recognized and detected using a deep learning algorithm. An annular shadow light source is arranged between the camera device and the paper tube 6 to ensure uniform lighting. The two end faces of the paper tube 6 are photographed separately, and the two end faces and the inner side of the paper tube 6 can be completely inspected.

[0023] At the paper tube straightening station 7, the horizontally placed paper tube 6 can be straightened by a robot and placed perpendicular to the work surface to facilitate subsequent inspection process processing.

[0024] like Figure 3 As shown, at the outer wall three-dimensional scale measurement station 4, the lifting and rotating mechanism 21 is used in conjunction with the 3D depth camera 22 to rotate the paper tube at a constant speed and perform surface 3D detection, which can detect surface unevenness defects and ensure that the defect value is ≥ 0.4mm detection accuracy. Figure 1 In order to keep pace with the front-end workstation, this workstation uses two sets of devices to simultaneously perform 3D inspection on the appearance of two paper tubes. Similarly, in the outer wall surface defect inspection workstation 5, the lifting and rotating mechanism 21 is used in conjunction with a high-precision area array color camera to take surface photos of the outer side of the paper tube rotating at a uniform speed, and the image processing algorithm is used to detect defects such as oil stains, damage, wrinkles, and glue stains of particles adhering to the outer surface. In this workstation, the dual-station method is used to improve the timing delay caused by rotating photography, improve the working efficiency of the entire system, and meet actual production needs.

[0025] like Figure 4 As shown, the detection method using this system includes: Step 1: The product rolls into the system assembly line. When it passes between the fixed plate 12 and the movable plate 13, the driving cylinder 11 drives the movable plate 13 to clamp it. At the same time, the distance sensor 14 obtains the displacement parameters of the movable plate 13, and detects whether the paper tube length meets the requirements through the displacement parameters; Step 2: Use two sets of camera devices to take pictures of the two end surfaces of the paper tube 6 respectively and recognize and detect the images based on the deep learning algorithm; Step 3, the rolling paper tube detected in step 2 is grabbed by the robotic arm and placed vertically; Step 4: Place the vertically placed paper tube 6 on the lifting and rotating mechanism and rotate it at a constant speed. At the same time, the 3D depth camera 22 and the area array color camera located on the side of the lifting and rotating mechanism 21 take surface photos and detect them through image processing algorithms.

[0026] In summary, the defect range detected by this system includes product areas: the left and right end faces of the paper tube, and the inner and outer sides of the paper tube. This system is applied to the appearance and size detection of the paper tube before winding, which can realize the surface scribing of the paper tube, the corner of the bottom paper, the end face burr, the end face crack, no knife groove, few points of the point knife, no points, the width of the paper tube overlap, the overall height of the paper tube, surface oil stains, surface unevenness, surface damage, surface wrinkles, surface glue stains (particle adhesion), the gap between the knife groove and the wire guide groove, the displacement of the main knife of the knife groove, and the damage of the point knife.

[0027] The above is only a preferred implementation case of the present invention and does not limit the present invention in any form. Although the implementation process of the present invention is described in detail above, for those familiar with the art, they can still modify the technical solutions recorded in the above examples, or replace some of the technical features therein with equivalents. All modifications, equivalent replacements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. An automatic detection system for paper tubes for chemical fiber industry, characterized in that: A paper tube length detection module, a paper tube end face and inner wall detection module, a paper tube straightening module, a paper tube outer wall three-dimensional detection module and a paper tube outer wall surface defect detection module are arranged based on the production line. The paper tube length detection module uses a distance sensor (14) to obtain parameters to detect the length of the paper tube (6). The paper tube end face and inner wall detection module uses two sets of camera devices to take pictures of the two end faces of the paper tube (6) respectively and recognize and detect the images based on a deep learning algorithm. The paper tube outer wall three-dimensional detection module and the paper tube outer wall surface defect detection module use a lifting and rotating mechanism (21) in conjunction with a 3D depth camera (22) and a surface array color camera to detect the outer wall of the paper tube (6).

2. The automatic detection system for paper tubes for chemical fiber industry as claimed in claim 1, characterized in that: The paper tube length detection module further comprises a driving cylinder (11), a fixed plate (12), and a movable plate (13). The fixed plate (12) and the movable plate (13) are used to clamp the paper tube (6). The movable plate (13) is driven by the cylinder to extend and retract to adjust the distance between the movable plate (13) and the fixed plate (12), thereby achieving clamping and loosening at both ends of the paper tube (6). The distance sensor (14) detects the displacement distance when the movable plate (13) is extended and retracted, and compares the displacement distance value with the calibrated standard length value.

3. The automatic detection system for paper tubes for chemical fiber industry as claimed in claim 1, characterized in that: An annular light source is provided between the camera device and the end surface of the paper tube (6).

4. The automatic detection system for paper tubes for chemical fiber industry as claimed in claim 1, characterized in that: The lifting and rotating mechanism (21) rotates the paper tube (6) at a constant speed, and the 3D depth camera (22) and the area array color camera take photos of the surface of the paper tube (6) rotating at a constant speed, and perform detection through an image processing algorithm.

5. The automatic detection system for paper tubes for chemical fiber industry as claimed in claim 1, characterized in that: The paper tube outer wall three-dimensional detection module and the paper tube outer wall surface defect detection module are both set to a double-station mode.

6. A detection method using the paper tube automatic detection system according to any one of claims 1 to 5, characterized in that: include: Step 1, the product rolls into the system assembly line, and when passing through the fixed plate (12), the driving cylinder (11) drives the movable plate (13) connected thereto, so that the movable plate (13) and the fixed plate (12) are clamped, and at the same time, the distance sensor (14) obtains the displacement parameter of the movable plate (13), and detects whether the length of the paper tube (6) meets the requirements through the displacement parameter; Step 2: using two sets of camera devices to take pictures of the two end faces of the paper tube (6) respectively and perform recognition and detection on the images based on a deep learning algorithm; Step 3, the rolling paper tube (6) detected in step 2 is grabbed by a robotic arm and placed vertically; Step 4: Place the vertically placed paper tube (6) on the lifting and rotating mechanism and rotate it at a constant speed. At the same time, the 3D depth camera (22) and the area array color camera located on the side of the lifting and rotating mechanism (21) take surface photos and perform detection through image processing algorithms.

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