Full-automatic rewinding equipment with high-precision visual identification detection system and operation method

Abstract

The invention discloses full-automatic rewinding equipment with a high-precision visual identification detection system and an operation method. The full-automatic rewinding equipment comprises an automatic feeding system, a tension control system, an automatic cutting system, a visual detection system, an automatic packaging system and an intelligent control system. By introducing a high-precision visual identification detection technology, defects, geometric dimension deviations and color differences on the surfaces of materials are detected in real time, detection results are fed back to an intelligent control system, tension control and cutting paths in the rewinding process are dynamically adjusted, a PLC and an HMI are combined, production parameters are automatically optimized according to real-time data, and the production efficiency is improved. The automatic packaging system can automatically adjust the packaging mode according to the specifications of the materials, and efficient packaging operation is achieved. The precision, the efficiency and the intelligent level of rewinding equipment can be remarkably improved, human intervention and the equipment failure rate are reduced, and the rewinding equipment is widely applied to the industries such as the paper industry, the packaging industry, the spinning industry and the printing industry and has remarkable technical advantages and wide application prospects.

Description

Technical Field

[0001] The present invention relates to the technical field of automated production equipment, and in particular to a fully automatic rewinding device with a high-precision visual recognition detection system and an operation method. Background Art

[0002] With the widespread application of automation technology, rewinding equipment has been widely used in the paper, textile, packaging and other industries. These devices are mainly used to slit or rewind large rolls of materials into smaller rolls, usually including automatic feeding, tension control, cutting, packaging and other functional modules. Existing rewinding equipment improves production efficiency and material processing accuracy through automated control, but there are still some technical difficulties in practical applications.

[0003] The tension control systems in traditional rewinding equipment are mostly mechanically adjusted and cannot be accurately and automatically adjusted according to the characteristics of different materials. Especially under high-speed operation and large differences in material characteristics, the tension control system often cannot maintain stable material tension, resulting in deformation or curling of the material during the rewinding process. Existing visual inspection systems also have deficiencies in recognition accuracy and real-time feedback speed, making it difficult to detect surface defects or geometric dimensional deviations of materials in a timely manner, affecting the quality of the final product. In addition, the various modules in existing equipment usually operate independently, lack intelligent collaborative control, and cannot be automatically adjusted according to parameters that change in real time during the production process, resulting in low production efficiency and complex operation.

[0004] Therefore, how to improve the intelligence level of rewinding equipment, enhance defect detection capabilities, accurately control tension, and improve production efficiency has become an urgent problem to be solved in current rewinding technology. Summary of the invention

[0005] In order to solve the problems of insufficient tension control accuracy, low precision of visual inspection system, insufficient intelligent coordination of equipment and inflexible adjustment of packaging system, the present invention provides a fully automatic rewinding equipment with a high-precision visual recognition detection system and an operation method. By introducing an intelligent control system, combined with high-precision visual inspection technology and an adaptive tension control system, the present invention can monitor the material status in real time and automatically adjust various parameters in the rewinding process, thereby significantly improving the rewinding accuracy and production efficiency. At the same time, the automatic packaging system can automatically adjust the packaging method according to the specifications, weight and length of the material, optimize the packaging process and reduce resource waste. Through these innovations, the present invention effectively solves the technical deficiencies existing in existing rewinding equipment and realizes the intelligence, precision and efficiency of the rewinding process.

[0006] In order to achieve the above object, the present invention is implemented by the following technical solutions:

[0007] In a first aspect, the present invention provides a fully automatic rewinding device with a high-precision visual recognition detection system, comprising:

[0008] Automatic loading system for automatically loading large rolls of material from the raw material storage device to the rewinding mechanism;

[0009] Tension control system, used to adjust the tension during material transmission;

[0010] Automatic cutting system, used to cut materials according to preset paths;

[0011] Visual inspection system, used to detect surface defects and geometric size color deviation, flatness, texture and shape of the cut materials, automatically detect whether there are defects, damage or foreign matter, and feed back the inspection results to the intelligent control system;

[0012] Automatic packaging system, used to package qualified materials and automatically adjust the packaging method according to the specifications of the materials;

[0013] The intelligent control system introduces a programmable logic controller (PLC) and a human-machine interface (HMI). By receiving the defect detection data of the visual inspection system, it dynamically adjusts the operating parameters of the tension control system and the automatic cutting system to optimize the rewinding process. The operator sets the rewinding parameters and monitors the production status through the touch screen, and obtains system alarms and abnormal information at any time.

[0014] Preferably, the automatic feeding system comprises:

[0015] Adsorption unit, grabs materials through vacuum suction cups;

[0016] A positioning unit, including a position sensor and a motion control unit, is used to detect the material position and correct the error;

[0017] The control unit optimizes the motion trajectory of the robot arm according to the material's grabbing point location, placement point location and equipment operating status.

[0018] Preferably, the tension control system comprises:

[0019] Tensioning device, used to adjust the tensioning wheel to control the tension of material transmission;

[0020] The detection device includes a tension sensor for collecting tension data in real time during material transmission;

[0021] The regulating device is used to adjust the operating state of the tension wheel based on the tension data collected by the detecting device.

[0022] As a preferred technical solution, the adjusting device realizes tension control through the following steps:

[0023] Collect the tension data during material transmission and input the collected data into the control device;

[0024] Compare the tension data with the target tension value and calculate the deviation value ΔT = T actual -T target , where T actual is the real-time tension, T target is the target tension value;

[0025] Generate a speed adjustment amount or an angle adjustment amount of the tensioning wheel according to the deviation value;

[0026] The speed or angle of the tensioner is dynamically adjusted until the deviation value is lower than the preset threshold ε.

[0027] Preferably, the automatic cutting system comprises:

[0028] A cutting execution unit, including a cutting tool driven by a servo motor;

[0029] A detection unit, including a length sensor, for real-time monitoring of the length of the material;

[0030] The path planning unit is used to dynamically match the cutting path according to the material's transport status.

[0031] As a preferred technical solution, the path planning unit realizes dynamic adjustment of the cutting path through the following steps:

[0032] Get the real-time transmission speed v of the material m (t), the current offset ΔP(t) and the curvature κ(t) of the target path;

[0033] Calculate the initial motion trajectory P c0 (t), the formula is:

[0034]

[0035] Among them, P0 is the initial position of the material; It means integrating from the initial time 0 to time t, and getting v m (t) Cumulative results over time;

[0036] Correction trajectory Pc(t), calculated as:

[0037] Pc(t)=P c0 (t)+ΔP(t)

[0038] Among them, ΔP(t) is provided by the visual inspection system and is used to describe the material offset;

[0039] Adjust the speed Δv(t), the formula is as follows:

[0040]

[0041] Among them, k p , kd and k c They are position gain, velocity gain and curvature gain coefficients respectively;

[0042] Update the trajectory and adjust the servo motor motion trajectory. The formula is:

[0043]

[0044] Among them, v c (t) is the movement speed after real-time adjustment; v target is the target speed, which indicates the desired movement speed of the system;

[0045] Repeat the above steps until the trajectory deviation is lower than the preset value ε.

[0046] As a preferred technical solution, the visual inspection system includes:

[0047] An image acquisition unit, including a high-resolution camera, for acquiring image data of the material surface;

[0048] The image processing unit dynamically adjusts the filter parameters σ=k×Var(I gray ) to achieve noise removal, where k is the adjustment coefficient, Var(I gray ) represents the pixel value variance of the grayscale image;

[0049] Defect detection unit, which detects cracks, foreign matter or dimensional deviations on the surface of materials based on the convolutional neural network (CNN) classification algorithm;

[0050] An alarm unit triggers an alarm and suspends equipment operation when unacceptable defects are detected.

[0051] Preferably, the image processing unit further comprises:

[0052] The activation function based on the convolutional neural network CNN classification algorithm is:

[0053]

[0054] Where: x is the neuron input value; α is the negative value adjustment coefficient, which is used to reduce the impact of negative values ​​on the classification results and enhance the stability of the classification model;

[0055] Confidence, calculation formula:

[0056]

[0057] Where: Z i is the output score of the classifier for category i; p i is the confidence of category i, which is used to judge the credibility of the classification results; ∑ j exp(Zj ) is the exponential sum of all category scores, which is used to normalize all classification results to ensure the confidence level p i The range is between [0,1].

[0058] Preferably, the visual inspection system further comprises:

[0059] A data storage unit, used to store image data, defect classification results and confidence information during the inspection process, and the stored data can be used for subsequent equipment parameter optimization and quality traceability;

[0060] The linkage control unit dynamically adjusts the tension wheel control parameters of the rewinding system and the cutting path of the cutting system according to the defect classification results of the visual inspection system, including:

[0061] If the defect is within the tolerable range, adjust the tension wheel speed to evenly transport the material;

[0062] If the defect exceeds the tolerance range, the cutting path is modified or the equipment operation is suspended to avoid further waste generation.

[0063] Preferably, the automatic packaging system comprises:

[0064] The packaging execution unit is used to grab the qualified materials and transfer them to the packaging module;

[0065] The packaging module includes a winding device and a sealing device, which are used to wrap and seal the materials;

[0066] The identification unit generates batch information, barcode or QR code according to the classification results of the visual inspection system, and attaches the identification content to the packaging material through the printing device.

[0067] Preferably, the intelligent control system includes:

[0068] A data processing unit, used to receive real-time operation data of the visual inspection system and the tension control system, and integrate historical operation data;

[0069] The neural network-based prediction module uses the convolutional neural network (CNN) classification algorithm to perform trend analysis and prediction on real-time data and generate optimization parameters, including tension control adjustment values ​​and cutting path correction values;

[0070] Fault recovery module, which resets the tension and cutting path according to the optimized parameters generated by the prediction module when a serious defect or abnormal shutdown is detected;

[0071] The programmable logic controller (PLC) receives the optimization parameters of the prediction module and dynamically adjusts the speed of the tensioning wheel and the cutting trajectory of the servo motor to optimize the rewinding process.

[0072] In a second aspect, the present invention provides an operation method of a fully automatic rewinding device with a high-precision visual recognition detection system, comprising the following steps:

[0073] S1. Transport the large roll of material from the raw material storage device to the rewinding mechanism, use the vacuum suction cup to grab and correct the material deviation, and ensure that the material enters the transmission path correctly;

[0074] S2. Real-time detection of tension data during material transmission, dynamic adjustment of the speed or angle of the tension wheel according to the tension deviation, to maintain stable tension;

[0075] S3. Obtain image data of the material surface, detect cracks, foreign matter or size deviation through the convolutional neural network (CNN) classification algorithm, and send the detection results to the intelligent control system;

[0076] S4. Dynamically adjust the cutting path according to the visual inspection results and material transmission status, control the cutting tool to run along the optimized trajectory, and avoid incorrect cutting of defective areas;

[0077] S5. According to the visual inspection and tension control data, the tension wheel speed, cutting path and rewinding speed are adjusted in real time to optimize the equipment operation status;

[0078] S6. Wrap and seal the qualified materials, and generate a barcode or QR code through the identification unit and attach it to the packaging materials for batch management and quality traceability;

[0079] S7. When serious defects or abnormal shutdown are detected, the intelligent control system resets the tension and cutting path according to the optimized parameters to quickly restore equipment operation.

[0080] The beneficial effects of the present invention are as follows: the present invention can automatically adjust the tension according to the characteristics of different materials and the real-time changing state during the rewinding process by introducing an intelligent tension control system, thereby effectively solving the problem of insufficient tension control accuracy of traditional rewinding equipment, ensuring that the tension of the material is stable during the rewinding process, and avoiding the deformation, breakage or other defects of the material. At the same time, the present invention adopts a high-precision visual recognition detection system, which can detect defects on the surface of the material, geometric dimension deviations and color differences in real time, and quickly feed back the detection results to the intelligent control system, ensuring that any defects in the production process can be identified and corrected at the first time, thereby greatly improving the quality of the product and the production qualification rate. The intelligent control system combines PLC and HMI human-machine interface, can receive feedback data from the visual detection system in real time and dynamically adjust various parameters of the rewinding equipment, such as tension, cutting path, etc., automatically optimize the rewinding process, greatly improve production efficiency, and reduce the complexity of manual operation and adjustment. In addition, the automatic packaging system of the present invention can automatically adjust the packaging method according to the specifications of the material, realize the high efficiency and flexibility of material packaging, and avoid the waste and inconsistency caused by the inflexible packaging method in the traditional packaging system. Through the high integration and intelligent control between modules, the rewinding equipment of the present invention can achieve efficient and stable continuous production, reduce manual intervention and equipment failure rate, improve the reliability and production stability of the equipment, and timely discover potential problems and automatically adjust the working state through fault diagnosis and early warning systems, avoiding production downtime and further improving production efficiency. Through the above innovations, the present invention greatly improves the production efficiency, precision and intelligence level of the rewinding equipment, effectively improves the quality control capability of material processing, and has significant technical advantages and broad application prospects. BRIEF DESCRIPTION OF THE DRAWINGS

[0081] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings required for use in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other accompanying drawings can be obtained based on these accompanying drawings without paying creative labor.

[0082] in:

[0083] Figure 1 It is a structural schematic diagram of the fully automatic rewinding device of the present invention;

[0084] Figure 2 It is a schematic diagram of the automated workflow of rewinding and slitting of the present invention;

[0085] Figure 3 It is a schematic diagram of the working process of the fully automatic rewinding device of the present invention;

[0086] Figure 4It is a structural schematic diagram of the fully automatic rewinding device in the present invention;

[0087] Figure 5 It is a schematic diagram of the operation method of the fully automatic rewinding device of the present invention. DETAILED DESCRIPTION

[0088] In order to make the purpose, technical solution and advantages of the embodiment of the present invention clearer, the technical solution of the embodiment of the present invention will be clearly and completely described below in conjunction with the drawings of the embodiment of the present invention. Obviously, the described embodiment is a part of the embodiment of the present invention, not all of the embodiments. Based on the described embodiment of the present invention, all other embodiments obtained by ordinary technicians in this field belong to the scope of protection of the present invention.

[0089] Example 1

[0090] The following is combined with Figure 1 An example of a fully automatic rewinding device with a high-precision visual recognition detection system is provided. The device includes:

[0091] Automatic loading system for automatically loading large rolls of material from the raw material storage device to the rewinding mechanism;

[0092] In this embodiment, the automatic feeding system includes:

[0093] Adsorption unit, grabs materials through vacuum suction cups;

[0094] A positioning unit, including a position sensor and a motion control unit, is used to detect the material position and correct the error;

[0095] The control unit optimizes the motion trajectory of the robot arm according to the material's grabbing point location, placement point location and equipment operating status.

[0096] The automatic feeding system consists of multiple conveyor belts, pneumatic devices, reels and feeding sensors. The conveyor belt is used to transport large rolls of materials from the storage warehouse to the feed port of the rewinding equipment. The pneumatic device ensures that the material is smoothly transported without being affected by external forces by accurately controlling the feeding speed. The large roll of material is delivered to the feeding port by the conveyor belt. The pneumatic device makes fine adjustments according to the weight and width of the material to ensure that the tension is stable during the entire conveying process without loosening or backlogging of materials. The material position is monitored in real time through the PLC control system. When the material in the feeding system is blocked or loose, the control system automatically sends an alarm signal and starts the backup feeding path.

[0097] Tension control system, used to adjust the tension during material transmission;

[0098] In this embodiment, the tension control system includes:

[0099] Tensioning device, used to adjust the tensioning wheel to control the tension of material transmission;

[0100] The detection device includes a tension sensor for collecting tension data in real time during material transmission;

[0101] The regulating device is used to adjust the operating state of the tension wheel based on the tension data collected by the detecting device.

[0102] The tension control system uses advanced tension sensors and servo motors to maintain the stability of the material during transmission and rewinding by measuring the material tension in real time and adjusting the speed of the servo motor.

[0103] The system monitors the tension of the material through sensors. When tension fluctuations are detected, the PLC will immediately issue a command to adjust the speed of the servo motor to ensure that the material tension remains within the set range. The control system can automatically adjust the tension parameters according to the properties and width of different materials.

[0104] For example, when the material passes through the rewinder, if the sensor detects that the tension is too high, the control system will quickly reduce the motor speed, otherwise it will speed up the motor adjustment to prevent the material from deforming or breaking.

[0105] As an optional implementation of this embodiment, the adjusting device realizes tension control through the following steps:

[0106] Collect the tension data during material transmission and input the collected data into the control device;

[0107] Compare the tension data with the target tension value and calculate the deviation value ΔT = T actual -T target , where T actual is the real-time tension, T target is the target tension value;

[0108] Generate a speed adjustment amount or an angle adjustment amount of the tensioning wheel according to the deviation value;

[0109] The speed or angle of the tensioner is dynamically adjusted until the deviation value is lower than the preset threshold ε.

[0110] Automatic cutting system, used to cut materials according to preset paths;

[0111] In this embodiment, the automatic cutting system includes:

[0112] A cutting execution unit, including a cutting tool driven by a servo motor;

[0113] A detection unit, including a length sensor, for real-time monitoring of the length of the material;

[0114] The path planning unit is used to dynamically match the cutting path according to the material's transport status.

[0115] As an optional implementation of this embodiment, the path planning unit implements dynamic adjustment of the cutting path through the following steps:

[0116] Get the real-time transmission speed v of the material m (t), the current offset ΔP(t) and the curvature κ(t) of the target path;

[0117] Calculate the initial motion trajectory P c0 (t), the formula is:

[0118]

[0119] Among them, P0 is the initial position of the material; It means integrating from the initial time 0 to time t, and getting v m (t) Cumulative results over time;

[0120] Correction trajectory Pc(t), calculated as:

[0121] Pc(t)=P c0 (t)+ΔP(t)

[0122] Among them, ΔP(t) is provided by the visual inspection system and is used to describe the material offset;

[0123] Adjust the speed Δv(t), the formula is as follows:

[0124]

[0125] Among them, k p , k d and k c They are position gain, velocity gain and curvature gain coefficients respectively;

[0126] Update the trajectory and adjust the servo motor motion trajectory. The formula is:

[0127]

[0128] Among them, v c (t) is the movement speed after real-time adjustment; v target is the target speed, which indicates the desired movement speed of the system;

[0129] Repeat the above steps until the trajectory deviation is lower than the preset value ε.

[0130] Visual inspection system, used to detect surface defects and geometric size color deviation, flatness, texture and shape of the cut materials, automatically detect whether there are defects, damage or foreign matter, and feed back the inspection results to the intelligent control system;

[0131] In this embodiment, the visual inspection system includes:

[0132] An image acquisition unit, including a high-resolution camera, for acquiring image data of the material surface;

[0133] The image processing unit dynamically adjusts the filter parameters σ=k×Var(I gray ) to achieve noise removal, where k is the adjustment coefficient, Var(I gray ) represents the pixel value variance of the grayscale image;

[0134] The defect detection unit detects cracks, foreign matter or dimensional deviations on the material surface based on the convolutional neural network (CNN) classification algorithm. The alarm unit triggers an alarm and suspends equipment operation when unacceptable defects are detected.

[0135] The visual inspection system is equipped with multiple high-definition cameras and high-brightness LED light sources. The cameras are arranged at a certain angle and distance to ensure that the material surface can be scanned in all directions. The light source automatically adjusts according to the reflectivity of the material surface to ensure clear images during the inspection process.

[0136] When the material is conveyed to the inspection area, the visual inspection system captures the image in real time and uses image processing algorithms (such as edge detection, template matching, machine learning algorithms) to analyze the image and identify defects, geometric dimensions, color deviations and other problems on the material surface.

[0137] When scratches, uneven colors or geometric size deviations are detected on the material surface, the vision system will immediately provide feedback to the intelligent control system, which will adjust the working parameters of the rewinding equipment, such as tension or cutting path, based on this data.

[0138] As an optional implementation of this embodiment, the image processing unit further includes:

[0139] The activation function based on the convolutional neural network CNN classification algorithm is:

[0140]

[0141] Where: x is the neuron input value; α is the negative value adjustment coefficient, which is used to reduce the impact of negative values ​​on the classification results and enhance the stability of the classification model;

[0142] Confidence, calculation formula:

[0143]

[0144] Where: Z i is the output score of the classifier for category i; p i is the confidence of category i, which is used to judge the credibility of the classification results; ∑ j exp(Z j ) is the exponential sum of all category scores, which is used to normalize all classification results to ensure the confidence level p i The range is between [0,1].

[0145] Specifically, the visual inspection system further includes:

[0146] A data storage unit, used to store image data, defect classification results and confidence information during the inspection process, and the stored data can be used for subsequent equipment parameter optimization and quality traceability;

[0147] The linkage control unit dynamically adjusts the tension wheel control parameters of the rewinding system and the cutting path of the cutting system according to the defect classification results of the visual inspection system, including:

[0148] If the defect is within the tolerable range, adjust the tension wheel speed to evenly transport the material;

[0149] If the defect exceeds the tolerance range, the cutting path is modified or the equipment operation is suspended to avoid further waste generation.

[0150] Automatic packaging system, used to package qualified materials and automatically adjust the packaging method according to the specifications of the materials;

[0151] In this embodiment, the automatic packaging system includes:

[0152] The packaging execution unit is used to grab the qualified materials and transfer them to the packaging module;

[0153] The packaging module includes a winding device and a sealing device, which are used to wrap and seal the materials;

[0154] The identification unit generates batch information, barcode or QR code according to the classification results of the visual inspection system, and attaches the identification content to the packaging material through the printing device.

[0155] The automatic packaging system uses a modular packaging device that can automatically select the most suitable packaging method according to the different specifications of the material (such as width, length, and coil thickness). The packaging device includes an automatic packaging machine, a coil conveyor belt, and an adjustment system.

[0156] The system uses sensors and visual inspection systems to identify the specifications of the material and automatically adjust the packaging method. When the material is rewound and passed the inspection, the packaging device automatically performs the packaging operation.

[0157] For materials of different specifications, the packaging device will automatically adjust the length and width of the packaging material according to the changes in the material size. For example, if it detects that the material width is too large, the packaging device will increase the length of the packaging film and adjust the sealing device.

[0158] The intelligent control system introduces a programmable logic controller (PLC) and a human-machine interface (HMI). By receiving the defect detection data of the visual inspection system, it dynamically adjusts the operating parameters of the tension control system and the automatic cutting system to optimize the rewinding process. The operator sets the rewinding parameters and monitors the production status through the touch screen, and obtains system alarms and abnormal information at any time.

[0159] As an optional implementation of this embodiment, the intelligent control system includes:

[0160] A data processing unit, used to receive real-time operation data of the visual inspection system and the tension control system, and integrate historical operation data;

[0161] The neural network-based prediction module uses the convolutional neural network (CNN) classification algorithm to perform trend analysis and prediction on real-time data and generate optimization parameters, including tension control adjustment values ​​and cutting path correction values;

[0162] Fault recovery module, which resets the tension and cutting path according to the optimized parameters generated by the prediction module when a serious defect or abnormal shutdown is detected;

[0163] The programmable logic controller (PLC) receives the optimization parameters of the prediction module and dynamically adjusts the speed of the tensioning wheel and the cutting trajectory of the servo motor to optimize the rewinding process.

[0164] Figure 2 The figure on the left shows the working scene in which the loading and unloading and slitting operations in the existing rewinding equipment are completed manually, including manual unloading, winding and slitting by workers.

[0165] This section highlights the limitations of manual operations, such as low efficiency, heavy workload, and lack of precise control.

[0166] The diagram on the right shows the improved design of the equipment of the present invention, which adopts a fully automatic loading and unloading and slitting system and combines intelligent control to achieve linkage operation.

[0167] By adding robots to replace manual loading and unloading, and combining automatic tension adjustment system and visual inspection function, the stability and accuracy of loading and unloading and slitting processes are ensured.

[0168] The rewinding device of the present invention is equipped with an automatic loading and unloading system, which can accurately grab and place materials and realize smooth transmission through a servo controller.

[0169] The automatic slitting device combines the visual inspection results to dynamically adjust the cutting path to ensure the accuracy of the slitting size and reduce material waste.

[0170] Compared with traditional equipment, the present invention can realize continuous and efficient rewinding and slitting operations by introducing robots and intelligent control systems, greatly reducing the intensity of manual operations and improving production efficiency.

[0171] Figure 3 This is a schematic diagram of the workflow of a fully automatic rewinding device with a high-precision visual recognition detection system of the present invention. This figure shows the workflow from raw material input to final output, including the configuration of the main functional modules and the interconnection relationship.

[0172] Raw material module: The "raw material" module on the left side of the figure represents the material input unit of the rewinding equipment. The raw materials enter the transmission system through the non-motorized instrument guide wheel.

[0173] Non-motorized instrument guide wheel: Non-motorized instrument guide wheel is used to guide and smoothly transmit materials, ensuring that the materials maintain the correct path when entering the next step of transmission, reducing vibration and deviation.

[0174] Tension control module: includes a one-way draw wheel and a tension wheel. The tension wheel is used to adjust the tension of the material during transmission in real time to ensure that the material remains flat when running at high speed and avoid breakage or deformation caused by unstable tension. The tension parameters of the tension wheel can be detected by the sensor in real time and fed back to the intelligent control system.

[0175] Length coding point: When the material passes the length coding point, the equipment will accurately measure the length of the material and record the transmission data. This data will be used for subsequent cutting, packaging and sorting operations to ensure the accuracy of the process.

[0176] Gluing module: Immediately after the length coding point, the material enters the glue machine for surface treatment. The glue machine applies adhesive to the surface of the material according to the material specifications and preset requirements. The glue quality is monitored by a visual inspection system to ensure uniformity and consistency.

[0177] Stepper transmission module: The glued material enters the heat sealing device through the stepper transmission module. The stepper transmission realizes precise material displacement through servo drive, ensuring the smooth and accurate material transmission process.

[0178] Heat sealing module: The heat sealing module seals the material to ensure that the end surface of the finished material is tight. The heat sealing module automatically adjusts the heat sealing parameters according to the thickness of the material through the heating device and pressure adjustment unit.

[0179] Good / bad product diversion module: The heat-sealed materials are automatically divided into good and bad products according to the comprehensive feedback results of the visual inspection system and the intelligent control system. The bad products are discharged through the rejection device (indicated by the cylinder in the figure), and the good products enter the next step of processing.

[0180] Output module: The final material stepping path in the figure represents the output unit of good material. Good products are transmitted to the outside through the output conveyor belt for packaging or other subsequent processing.

[0181] pass Figure 3 It can be clearly seen that the fully automatic rewinding equipment of the present invention realizes the complete process from raw material input, tension control, defect detection, surface treatment, classification and output. Signal feedback and dynamic parameter adjustment are realized between each module through the intelligent control system, ensuring the high precision and high efficiency of the equipment operation.

[0182] Figure 4 It is a structural schematic diagram of the fully automatic rewinding equipment in the present invention, showing the main functional modules of the equipment and their interconnection relationships, including working units such as unwinding, tension control, visual inspection, cutting, gluing, classification and discharging.

[0183] Unwinding tray: Located on the left side of the machine, it is used to carry the raw coils to be rewound. The unwinding tray is mounted by a bracket and can rotate stably to release the material.

[0184] Material break detection module: installed between the discharge tray and the tension wheel, used to detect the continuity of the material in real time. Once the material is broken or abnormal, the module will feedback the signal to the intelligent control system to stop the equipment operation in time to prevent material accumulation or system failure.

[0185] Tension wheel: It is set on the material transmission path to adjust the tension of the material. The tension wheel is linked with the pressure detection device to ensure that the tension of the material during transmission is always in a stable state by adjusting its rotation angle and strength.

[0186] Length detection module: located behind the tensioning wheel, used to detect and record the length of the material in real time. The detection data will be transmitted to the intelligent control system so that the subsequent cutting and gluing modules can accurately complete the relevant operations.

[0187] Visual recognition module: Equipped with high-definition cameras and light sources, it is used to detect surface defects, dimensional deviations or color anomalies of materials. The visual recognition module can analyze in real time and feed back the detection results to the intelligent control system for dynamic adjustment of cutting path and tension control.

[0188] Pressing wheel: Located between the length detection module and the automatic tape cutter, it is used to press the material to improve the stability of transmission and prevent the material from deflecting during high-speed transmission.

[0189] Automatic tape cutter: This module is used to accurately cut and paste the tape to the material surface according to the material specifications and requirements. The intelligent control system automatically adjusts the cutting length and pasting position according to the feedback data of the visual inspection module.

[0190] Suction cup cylinder: located after the glue machine, it is used to suck the material from the transmission path and transfer it to the cutting area. The action of the suction cup cylinder is regulated by an intelligent control system to ensure a smooth and efficient material transfer process.

[0191] Cutting mechanism: responsible for accurately cutting the material according to the preset size or the defect position fed back by visual inspection. The cutting mechanism uses high-speed blades or laser cutting equipment, which can adapt to materials of different materials and thicknesses.

[0192] Upper winding core mechanism: Located behind the cutting mechanism, it is used to rewind the qualified materials after cutting to form small rolls. This module can automatically adjust the size of the winding core according to the width and diameter of the material.

[0193] Label separator: It is responsible for separating the label attached to the material from the substrate and pasting the label to the designated location. This module can cooperate with the visual recognition module to ensure the accuracy of label separation and pasting.

[0194] Discharge port: Located on the far right side of the equipment, it is used to output the finished coils after rewinding. The discharge port is equipped with an automatic conveyor to transport the finished products to the next processing or packaging link.

[0195] This figure clearly shows the complete process of the rewinding equipment from raw material input to finished product output. Each module of the equipment is linked through an intelligent control system to achieve high-precision tension adjustment, defect detection, cutting and separation, and material classification.

[0196] Example 2

[0197] like Figure 5 As shown, another embodiment of the present invention provides an operation method of a fully automatic rewinding device with a high-precision visual recognition detection system, comprising the following steps:

[0198] S1. Transport the large roll of material from the raw material storage device to the rewinding mechanism, use the vacuum suction cup to grab and correct the material deviation, and ensure that the material enters the transmission path correctly;

[0199] S2. Real-time detection of tension data during material transmission, dynamic adjustment of the speed or angle of the tension wheel according to the tension deviation, to maintain stable tension;

[0200] S3. Obtain image data of the material surface, detect cracks, foreign matter or size deviation through the convolutional neural network (CNN) classification algorithm, and send the detection results to the intelligent control system;

[0201] S4. Dynamically adjust the cutting path according to the visual inspection results and material transmission status, control the cutting tool to run along the optimized trajectory, and avoid incorrect cutting of defective areas;

[0202] S5. According to the visual inspection and tension control data, the tension wheel speed, cutting path and rewinding speed are adjusted in real time to optimize the equipment operation status;

[0203] S6. Wrap and seal the qualified materials, and generate a barcode or QR code through the identification unit and attach it to the packaging materials for batch management and quality traceability;

[0204] S7. When serious defects or abnormal shutdown are detected, the intelligent control system resets the tension and cutting path according to the optimized parameters to quickly restore equipment operation.

[0205] The advantages of this embodiment are:

[0206] The tension control and cutting systems in the prior art usually operate independently, while the present invention realizes real-time dynamic adjustment of tension and cutting through an intelligent control system. Especially when defects occur in the material, the intelligent control system can automatically adjust the tension control and cutting path through feedback from the visual inspection system to ensure the high quality of the final product.

[0207] The present invention uses a high-precision visual inspection system that can capture tiny defects and geometric deviations on the material surface in real time, and directly drive other modules in the rewinding process (such as tension adjustment and cutting path optimization) through data feedback. This integrated intelligent feedback mechanism is highly innovative in the industry.

[0208] The present invention can dynamically adjust various parameters in the rewinding process according to real-time feedback data (such as material surface defects, geometric dimension deviations, etc.), greatly improving the adaptive ability of the equipment, being able to cope with materials of different types and specifications, and reducing errors and operational complexity caused by manual operations.

[0209] Example 3

[0210] The present invention also provides the experimental data of the fully automatic rewinding equipment, as shown below:

[0211] Brief description of the experimental process:

[0212] Visual inspection system: Use high-definition cameras and LED light sources to detect defects on different materials, simulate scratches, stains, color differences and other defects, and record recognition rate and accuracy.

[0213] Tension control system: monitor the tension fluctuation during material transmission through the tension sensor, adjust the system control error and ensure stability.

[0214] Rewinding efficiency: Test rewinding speed, defect rate and equipment failure rate under different materials and production conditions.

[0215] Automatic packaging system: measures packaging speed, packaging accuracy and adjustment precision of packaging materials.

[0216]

[0217] Data description:

[0218] Defect size: The range of defects simulated.

[0219] Recognition rate: The accuracy with which a visual system can identify defects.

[0220] Tension fluctuation: The tension fluctuation range of materials during transmission.

[0221] Rewinding efficiency: the length of material rewound per minute.

[0222] Defect rate: The proportion of defects that occur during the production process.

[0223] Equipment failure rate: the frequency of failures occurring during equipment operation.

[0224] Packaging speed: The processing speed of automatic packaging.

[0225] Packaging accuracy: the accuracy of material specifications during the packaging process.

[0226] Packaging adjustment accuracy: the accuracy of packaging material adjustment.

[0227] Experimental data show that the fully automatic rewinding equipment has demonstrated good performance in visual inspection, tension control, rewinding efficiency and automatic packaging, especially in terms of high efficiency and accuracy, and has high innovation and practical value.

[0228] In summary, the present invention overcomes the deficiencies of traditional rewinding equipment in terms of precision control, defect detection, intelligent adjustment and automation level by introducing an intelligent tension control system, a high-precision visual recognition detection system and an automated packaging system. The invention can not only monitor the material status in real time and automatically adjust various production parameters, but also automatically detect and correct defects during the production process, greatly improving production efficiency and product quality. Through a highly integrated intelligent control system, the present invention can realize the automated, intelligent and efficient operation of the rewinding equipment, reduce manual intervention and equipment failure rate, and improve the reliability of the equipment and production stability. The invention has significant technical innovation and broad application prospects, and can be widely used in packaging, paper, textile, printing and other fields, and has important economic value and market potential.

[0229] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present application. Moreover, the specific features, structures, materials or characteristics described may be combined in any one or more embodiments or examples in a suitable manner. In addition, those skilled in the art may combine and combine different embodiments or examples described in this specification and the features of different embodiments or examples, unless they are contradictory.

[0230] Any process or method description in the flow chart or otherwise described herein can be understood to represent a module, fragment or portion of a code including one or more executable instructions for implementing the steps of a specific logical function or process. And the scope of the preferred embodiment of the present application includes other implementations, in which the functions may not be performed in the order shown or discussed, including in a substantially simultaneous manner or in a reverse order according to the functions involved.

[0231] The above is only a specific implementation of the present application, but the protection scope of the present application is not limited thereto. Any technician familiar with the technical field can easily think of various changes or substitutions within the technical scope disclosed in the present application, which should be included in the protection scope of the present application. Therefore, the protection scope of the present application should be based on the protection scope of the claims.

Claims

1. A fully automatic rewinding device with a high-precision visual recognition detection system, characterized in that: The device comprises: Automatic loading system for automatically loading large rolls of material from the raw material storage device to the rewinding mechanism; Tension control system, used to adjust the tension during material transmission; Automatic cutting system, used to cut materials according to preset paths; Visual inspection system, used to detect surface defects and geometric size color deviation, flatness, texture and shape of the cut materials, automatically detect whether there are defects, damage or foreign matter, and feed back the inspection results to the intelligent control system; Automatic packaging system, used to package qualified materials and automatically adjust the packaging method according to the specifications of the materials; The intelligent control system introduces a programmable logic controller (PLC) and a human-machine interface (HMI). By receiving the defect detection data of the visual inspection system, it dynamically adjusts the operating parameters of the tension control system and the automatic cutting system to optimize the rewinding process. The operator sets the rewinding parameters and monitors the production status through the touch screen, and obtains system alarms and abnormal information at any time.

2. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 1 is characterized in that: The automatic feeding system comprises: Adsorption unit, grabs materials through vacuum suction cups; A positioning unit, including a position sensor and a motion control unit, is used to detect the material position and correct the error; The control unit optimizes the motion trajectory of the robot arm according to the material's grabbing point location, placement point location and equipment operating status.

3. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 1 is characterized in that: The tension control system comprises: Tensioning device, used to adjust the tensioning wheel to control the tension of material transmission; The detection device includes a tension sensor for collecting tension data in real time during material transmission; The regulating device is used to adjust the operating state of the tension wheel based on the tension data collected by the detecting device.

4. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 3 is characterized in that: The adjusting device realizes tension control by the following steps: Collect the tension data during material transmission and input the collected data into the control device; Compare the tension data with the target tension value and calculate the deviation value ΔT = T actual -T target , where T actual is the real-time tension, T target is the target tension value; Generate a speed adjustment amount or an angle adjustment amount of the tensioning wheel according to the deviation value; The speed or angle of the tensioner is dynamically adjusted until the deviation value is lower than the preset threshold ε.

5. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 1 is characterized in that: The automatic cutting system comprises: A cutting execution unit, including a cutting tool driven by a servo motor; A detection unit, including a length sensor, for real-time monitoring of the length of the material; The path planning unit is used to dynamically match the cutting path according to the material's transport status.

6. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 5, characterized in that: The path planning unit realizes dynamic adjustment of the cutting path through the following steps: Get the real-time transmission speed v of the material m (t), the current offset ΔP(t) and the curvature κ(t) of the target path; Calculate the initial motion trajectory P c0 (t), the formula is: Among them, P0 is the initial position of the material; It means integrating from the initial time 0 to time t, and getting v m (t) Cumulative results over time; Correction trajectory Pc(t), calculated as: Pc(t)=P c0 (t)+ΔP(t) Among them, ΔP(t) is provided by the visual inspection system and is used to describe the material offset; Adjust the speed Δv(t), the formula is as follows: Among them, k p , k d and k c They are position gain, velocity gain and curvature gain coefficients respectively; Update the trajectory and adjust the servo motor motion trajectory. The formula is: Among them, v c (t) is the movement speed after real-time adjustment; v target is the target speed, which indicates the desired movement speed of the system; Repeat the above steps until the trajectory deviation is lower than the preset value ε.

7. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 1, characterized in that: The visual inspection system comprises: An image acquisition unit, including a high-resolution camera, for acquiring image data of the material surface; The image processing unit dynamically adjusts the filter parameters σ=k×Var(I gray ) to achieve noise removal, where k is the adjustment coefficient, Var(I gray ) represents the pixel value variance of the grayscale image; The defect detection unit detects cracks, foreign matter or dimensional deviations on the material surface based on the convolutional neural network (CNN) classification algorithm. The alarm unit triggers an alarm and suspends equipment operation when unacceptable defects are detected.

8. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 7, characterized in that: The image processing unit further comprises: The activation function based on the convolutional neural network CNN classification algorithm is: Where: x is the neuron input value; α is the negative value adjustment coefficient, which is used to reduce the impact of negative values ​​on the classification results and enhance the stability of the classification model; Confidence, calculation formula: Where: Z i is the output score of the classifier for category i; p i is the confidence of category i, which is used to judge the credibility of the classification result; Σ j exp(Z j ) is the exponential sum of all category scores, which is used to normalize all classification results to ensure the confidence level p i The range is between [0,1].

9. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 7, characterized in that: The visual inspection system further comprises: A data storage unit, used to store image data, defect classification results and confidence information during the inspection process, and the stored data can be used for subsequent equipment parameter optimization and quality traceability; The linkage control unit dynamically adjusts the tension wheel control parameters of the rewinding system and the cutting path of the cutting system according to the defect classification results of the visual inspection system, including: If the defect is within the tolerable range, adjust the tension wheel speed to evenly transport the material; If the defect exceeds the tolerance range, the cutting path is modified or the equipment operation is suspended to avoid further waste generation.

10. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 1, characterized in that: The automatic packaging system comprises: The packaging execution unit is used to grab the qualified materials and transfer them to the packaging module; The packaging module includes a winding device and a sealing device, which are used to wrap and seal the materials; The identification unit generates batch information, barcode or QR code according to the classification results of the visual inspection system, and attaches the identification content to the packaging material through the printing device.

11. The fully automatic rewinding equipment with a high-precision visual recognition detection system according to claim 1, characterized in that: The intelligent control system comprises: A data processing unit, used to receive real-time operation data of the visual inspection system and the tension control system, and integrate historical operation data; The neural network-based prediction module uses the convolutional neural network (CNN) classification algorithm to perform trend analysis and prediction on real-time data and generate optimization parameters, including tension control adjustment values ​​and cutting path correction values; Fault recovery module, which resets the tension and cutting path according to the optimized parameters generated by the prediction module when a serious defect or abnormal shutdown is detected; The programmable logic controller (PLC) receives the optimization parameters of the prediction module and dynamically adjusts the speed of the tensioning wheel and the cutting trajectory of the servo motor to optimize the rewinding process.

12. A method for operating a fully automatic rewinding device with a high-precision visual recognition detection system according to any one of claims 1 to 11, characterized in that: The following steps are involved: S1. Transport the large roll of material from the raw material storage device to the rewinding mechanism, use the vacuum suction cup to grab and correct the material deviation, and ensure that the material enters the transmission path correctly; S2. Real-time detection of tension data during material transmission, dynamic adjustment of the speed or angle of the tension wheel according to the tension deviation, to maintain stable tension; S3. Obtain image data of the material surface, detect cracks, foreign matter or size deviation through the convolutional neural network (CNN) classification algorithm, and send the detection results to the intelligent control system; S4. Dynamically adjust the cutting path according to the visual inspection results and material transmission status, control the cutting tool to run along the optimized trajectory, and avoid incorrect cutting of defective areas; S5. According to the visual inspection and tension control data, the tension wheel speed, cutting path and rewinding speed are adjusted in real time to optimize the equipment operation status; S6. Wrap and seal the qualified materials, and generate a barcode or QR code through the identification unit and attach it to the packaging materials for batch management and quality traceability; S7. When serious defects or abnormal shutdown are detected, the intelligent control system resets the tension and cutting path according to the optimized parameters to quickly restore equipment operation.

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