A detection system and detection method for large circular knitting machine needle cylinder

Abstract

The present invention relates to the technical field of circular knitting machine needle cylinder detection technology, and discloses a detection system and method for circular knitting machine needle cylinders. The system comprises: an acquisition module for collecting needle groove images of the circular knitting machine needle cylinder, resistance data from resistance detection, and operating temperature and vibration data; a processing module for processing the needle groove images to determine the size and wear of the needle groove; and selecting corresponding inserts for resistance detection; and adjusting the wear degree according to the resistance data to obtain a final wear degree; a resistance detection module for performing resistance detection on the needle groove according to the inserts selected by the processing module; and a determination module for determining whether each needle groove in the circular knitting machine needle cylinder is qualified based on the final wear degree, temperature data, and vibration data. The present invention performs multi-faceted detection on the circular knitting machine needle cylinder, improves detection efficiency and accuracy, and provides a scientific basis for preventive maintenance of the equipment.

Description

Technical Field

[0001] The present invention relates to the technical field of circular knitting machine needle cylinder detection, and in particular to a detection system and a detection method for a circular knitting machine needle cylinder. Background Art

[0002] Circular knitting machine needle cylinders are a crucial component of knitting equipment, and their quality directly impacts knitwear production efficiency and product quality. However, traditional methods often rely on manual inspections, such as using a vernier caliper to measure the width and depth of the needle grooves or using a clockwise motion to gauge the smoothness of the grooves. These inspection methods often suffer from low efficiency and accuracy, failing to meet the high-efficiency and high-quality demands of modern production. Therefore, developing an efficient and accurate circular knitting machine needle cylinder inspection system and method is of great practical significance. Summary of the Invention

[0003] The purpose of the present invention is to provide a detection system and detection method for the needle cylinder of a large circular knitting machine, so as to solve the problems that traditional detection methods often have problems such as low detection efficiency and insufficient accuracy, and cannot meet the requirements of modern production for high efficiency and high quality.

[0004] The present invention provides a detection system for a needle cylinder of a large circular knitting machine, the system comprising:

[0005] An acquisition module is used to acquire the needle groove image of the circular knitting machine needle cylinder and the resistance data when performing needle groove resistance detection. The acquisition module is also used to acquire the temperature data and vibration data of the circular knitting machine needle cylinder during operation;

[0006] a processing module connected to the acquisition module, the processing module being configured to process the needle groove image to determine the size and wear of each needle groove in the needle cylinder of the large circular knitting machine; select a corresponding insert according to the size of each needle groove to perform resistance detection; and adjust the wear according to the resistance data to obtain a final wear degree;

[0007] a resistance detection module connected to the acquisition module and the processing module, and configured to control the insertion of the insert into the needle groove of the needle cylinder of the circular knitting machine according to the insert selected by the processing module, so as to perform resistance detection on the needle groove;

[0008] A determination module is connected to the processing module, and is used to determine whether each needle groove in the needle cylinder of the large circular knitting machine is qualified according to the final wear degree, temperature data and vibration data.

[0009] Preferably, the processing module is used to process the needle groove image to determine the size of each needle groove in the needle cylinder of the circular knitting machine, including:

[0010] performing grayscale processing on the needle groove image to convert the needle groove image into a grayscale image;

[0011] Performing binarization processing on the grayscale image to convert the grayscale image into a binary image;

[0012] Detecting the binary image to determine the boundary of the needle groove in the binary image;

[0013] The size of the needle groove is obtained according to the determined needle groove boundary.

[0014] Preferably, the processing module is used to process the needle groove image to determine the wear degree of each needle groove in the needle cylinder of the circular knitting machine, including:

[0015] Acquire a standard needle slot image, where the standard needle slot image is an image of a needle slot that is not in use;

[0016] comparing the needle groove image with the standard needle groove image to determine a difference image, wherein the difference image is determined based on the RGB value of each pixel in the needle groove image and the RGB value of the standard needle groove image;

[0017] determining the wear degree of each needle groove in the needle cylinder of the circular knitting machine according to the difference image;

[0018] The wear degree is calculated according to the following formula:

[0019] ,

[0020] M represents the degree of wear, m represents the length of the difference image in pixels, and n represents the width of the difference image in pixels. 、 、 represents the red, green, and blue values of the m-th pixel in the x-th row of the difference image, and C represents the influencing factor of wear.

[0021] Preferably, the processing module is configured to adjust the wear degree according to the resistance data to obtain a final wear degree, including:

[0022] A number of resistance value ranges are set, each of which corresponds to a unique adjustment coefficient. The corresponding adjustment coefficient is determined according to the resistance value range in which the resistance data is located, and the wear degree is adjusted according to the adjustment coefficient to obtain a final wear degree.

[0023] Preferably, the determination module is used to determine whether each needle groove in the needle cylinder of the circular knitting machine is qualified according to the final wear degree, temperature data and vibration data, including:

[0024] Pre-set wear threshold;

[0025] Comparing the final wear degree with the wear degree threshold, and determining whether the needle groove of the circular knitting machine needle cylinder is qualified according to the comparison result;

[0026] If the needle groove of the needle cylinder of the large circular knitting machine is unqualified, the needle groove will be marked as a needle groove to be repaired.

[0027] Preferably, the determination module is used to determine whether each needle groove in the needle cylinder of the circular knitting machine is qualified according to the final wear degree, temperature data and vibration data, and further includes:

[0028] The vibration data includes vibration frequency and vibration amplitude;

[0029] Pre-set temperature threshold, vibration frequency threshold and vibration amplitude threshold;

[0030] The temperature data is compared with the temperature threshold, the vibration frequency is compared with the vibration frequency threshold, and the vibration amplitude is compared with the vibration amplitude threshold. Whether the needle slot is qualified is determined based on the comparison results.

[0031] Preferably, the determination module is used to determine whether each needle groove in the needle cylinder of the circular knitting machine is qualified according to the final wear degree, temperature data and vibration data, and further includes:

[0032] Determine the temperature change rate, vibration frequency change rate, and vibration amplitude change rate of the temperature data at time t relative to time t-1;

[0033] Presetting the temperature change rate threshold, vibration frequency change rate threshold and vibration amplitude change rate threshold;

[0034] The temperature change rate is compared with the temperature change rate threshold, the vibration frequency change rate is compared with the vibration frequency change rate threshold, and the vibration amplitude change rate is compared with the vibration amplitude change rate threshold, and whether the needle slot secondary determination is qualified is determined based on the comparison results.

[0035] Preferably, after the determination module calibrates the needle slot as a needle slot to be repaired, the method further includes:

[0036] Determining the position information of the needle slot to be repaired;

[0037] The maintenance information of the needle slot is sent to the management machine of the needle cylinder of the large circular knitting machine, and the maintenance information includes the position information of the needle slot to be repaired.

[0038] The present invention also discloses a detection method for a large circular knitting machine needle cylinder, which is applied to the above-mentioned detection system for a large circular knitting machine needle cylinder. The method comprises:

[0039] Collect the needle groove image of the circular knitting machine needle cylinder and the temperature and vibration data of the circular knitting machine needle cylinder during operation;

[0040] Processing the needle groove image to determine the size and wear of each needle groove in the needle cylinder of the large circular knitting machine, and selecting a corresponding insert according to the size of each needle groove to perform resistance detection;

[0041] collecting resistance data when performing resistance detection on the needle groove of the needle cylinder of the circular knitting machine, and adjusting the wear degree according to the resistance data to obtain a final wear degree;

[0042] Whether each needle groove in the needle cylinder of the circular knitting machine is qualified is determined based on the final wear degree, temperature data and vibration data.

[0043] Compared with the prior art, the beneficial effect of the present invention is that, by collecting needle groove images, temperature data and vibration data, the present invention can detect the needle cylinder of the large circular knitting machine from multiple aspects, ensuring a comprehensive understanding of its condition. It not only improves the efficiency and accuracy of detection, but also provides a scientific basis for preventive maintenance of equipment, greatly reduces production losses due to equipment problems, and has high practical value. The present invention can more accurately evaluate the condition of the needle groove and improve the reliability of the detection results by processing the needle groove image and detecting the resistance, combined with the comprehensive judgment of temperature and vibration data. The present invention also provides a resistance detection module, which can select the corresponding insert for resistance detection according to the size of each needle groove, making the detection more targeted and able to more accurately evaluate the wear of each needle groove. Through strict testing and secondary judgment, the present invention ensures that each needle groove in the needle cylinder of the large circular knitting machine meets the quality requirements, thereby improving the overall quality and stability of the product. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without any creative work.

[0045] Figure 1 This is a functional block diagram of a detection system for a circular knitting machine needle cylinder according to the present invention;

[0046] Figure 2 The present invention is a flow chart of a method for detecting a needle cylinder of a large circular knitting machine. DETAILED DESCRIPTION

[0047] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0048] like Figure 1 As shown, the present invention provides a detection system for a needle cylinder of a large circular knitting machine, the system comprising:

[0049] The acquisition module is used to collect the needle groove image of the large circular knitting machine needle cylinder and the resistance data when performing needle groove resistance detection. The acquisition module is also used to collect the temperature data and vibration data of the large circular knitting machine needle cylinder during operation.

[0050] A processing module is connected to the acquisition module, and is used to process the needle groove image to determine the size and wear of each needle groove in the needle cylinder of the large circular knitting machine; select a corresponding insert according to the size of each needle groove to perform resistance detection; and adjust the wear according to the resistance data to obtain a final wear degree.

[0051] The resistance detection module is connected to the acquisition module and the processing module. The resistance detection module is used to control the insertion of the insert into the needle groove of the needle cylinder of the large circular knitting machine according to the insert selected by the processing module, and perform resistance detection on the needle groove.

[0052] A determination module is connected to the processing module, and is used to determine whether each needle groove in the needle cylinder of the large circular knitting machine is qualified according to the final wear degree, temperature data and vibration data.

[0053] In this embodiment, the present invention mainly provides a detection system for large circular knitting machine needle cylinders. The system has a high level of intelligence and automation and can comprehensively detect and evaluate various performance indicators of large circular knitting machine needle cylinders. The system mainly includes the following parts:

[0054] The acquisition module primarily collects various data about the circular knitting machine's needle cylinders. First, it uses image acquisition technology to capture images of the needle grooves, providing the system with a direct understanding of the groove's condition. Second, it collects resistance data during resistance testing, which is crucial for assessing needle groove wear. Furthermore, it collects real-time temperature and vibration data during needle operation, providing the system with a better understanding of the needle's operating status.

[0055] The processing module processes the collected data to determine the size and wear of each needle groove in the circular knitting machine's needle cylinder. First, it processes the needle groove image to obtain more accurate dimensional information. Then, based on the size of each needle groove, it intelligently selects the corresponding insert for resistance testing. Finally, based on the resistance data, it adjusts the wear degree to obtain the final wear value.

[0056] The resistance detection module's main function is to control the insertion of an insert into the needle slot of the circular knitting machine's needle cylinder, based on the insert selected by the processing module, and to perform resistance detection on the needle slot. In this application, using an insert for resistance detection is an existing method. A force sensor is provided on the resistance detection module to determine the resistance of the needle slot in the circular knitting machine's needle cylinder by detecting the force applied when the insert is inserted into the slot. (When using an insert for resistance detection, the insert is connected to a force sensor, and the force applied during insertion can be detected by the force sensor to determine the resistance.) This allows for more accurate resistance data to be obtained through actual operation, which can be further analyzed and processed by the processing module.

[0057] The judgment module determines whether each needle groove in the circular knitting machine's needle cylinder is qualified based on the final wear degree. If the needle groove is determined to be qualified, a secondary judgment is performed based on temperature and vibration data. If the secondary judgment also passes, the needle groove inspection is confirmed to be qualified.

[0058] In general, the detection system provided by the present invention can comprehensively, accurately and efficiently detect the needle cylinder of the large circular knitting machine, improve production efficiency, reduce production costs, and has high practical value and promotion value.

[0059] Preferably, the processing module is used to process the needle groove image and determine the size of each needle groove in the needle cylinder of the large circular knitting machine, including: grayscale processing of the needle groove image to convert the needle groove image into a grayscale image; binarization processing of the grayscale image to convert the grayscale image into a binary image; detecting the binary image to determine the boundary of the needle groove in the binary image; and obtaining the size of the needle groove based on the determined needle groove boundary.

[0060] In this embodiment, the processing module determines the specific dimensions of each needle groove within a circular knitting machine's needle cylinder. This involves grayscaling the original needle groove image, converting the image from color to grayscale. This reduces the complexity of the image data while preserving the most critical light and dark information, facilitating subsequent processing steps. Next, the grayscaled image is binarized, setting the grayscale value of each pixel in the image to either 0 or 255, thereby converting the image to black and white. This step is intended to better highlight the needle grooves in the image, making them easier to identify in subsequent detection steps. Next, boundary detection is performed on the binarized image to determine the specific location of the needle grooves within the image. This step uses a series of algorithmic operations to identify and mark the outline of the needle grooves, thereby determining their boundaries. Finally, based on the detected groove boundaries, the specific dimensions of the grooves, such as length and width, can be calculated. Overall, this series of image processing operations effectively determines the dimensions of each needle groove within a circular knitting machine's needle cylinder, thereby improving production efficiency and product quality.

[0061] Preferably, the processing module is used to process the needle groove image to determine the wear degree of each needle groove in the needle cylinder of the circular knitting machine, including: obtaining a standard needle groove image; comparing the needle groove image with the standard needle groove image to determine a difference image, wherein the difference image is determined according to the RGB value of each pixel in the needle groove image and the RGB value of the standard needle groove image; and determining the wear degree of each needle groove in the needle cylinder of the circular knitting machine according to the difference image;

[0062] The wear degree is calculated according to the following formula:

[0063] ,

[0064] M represents the degree of wear, m represents the length of the difference image in pixels, and n represents the width of the difference image in pixels. 、 、 represents the red, green, and blue values of the m-th pixel in the x-th row of the difference image, and C represents the influencing factor of wear.

[0065] Preferably, the standard needle slot image is an image of a needle slot that is not in use.

[0066] In this embodiment, the processing module mainly performs a series of processing operations on the needle groove image in order to accurately determine the degree of wear of each needle groove in the needle cylinder of the large circular knitting machine. First, a standard needle groove image is obtained. This image refers to the needle groove images that have not been used as a reference. Next, the needle groove image to be processed is compared with the standard needle groove image. Through this comparison, a difference image can be determined. The generation of this difference image is based on the comparison of the RGB value of each pixel in the needle groove image and the RGB value of the corresponding pixel of the standard needle groove image. Finally, the degree of wear of each needle groove in the needle cylinder of the large circular knitting machine is judged based on this difference image. In this way, the wear of the needle groove can be quantitatively analyzed, thereby providing a basis for the maintenance and replacement of the equipment.

[0067] It is understandable that each pixel in the difference image is determined according to the following formula:

[0068] ;

[0069] ;

[0070] ;

[0071] in, 、 、 Indicates the red, green, and blue values of the m-th pixel in the x-th row of the needle slot image. 、 、 Represents the red, green, and blue values of the m-th pixel in the x-th row of the standard needle slot image.

[0072] Preferably, the processing module is used to adjust the wear degree according to the resistance data to obtain the final wear degree, including: setting several resistance value ranges, each resistance value range corresponds to a unique adjustment coefficient, determining the corresponding adjustment coefficient according to the resistance value range in which the resistance data is located, and adjusting the wear degree according to the adjustment coefficient to obtain the final wear degree.

[0073] It is understandable that when the wear degree is adjusted according to the resistance data to obtain the final wear degree, the method includes: presetting a first resistance value, a second resistance value, and a third resistance value, wherein the first resistance value, the second resistance value, and the third resistance value increase in sequence; selecting a corresponding adjustment coefficient according to the relationship between the resistance data and the first resistance value, the second resistance value, and the third resistance value, and adjusting the wear degree M to obtain the final wear degree; if the resistance data is less than the first resistance value, selecting the first adjustment coefficient a1 to adjust the wear degree M, and obtaining a final wear degree of M×a1; if the resistance data is greater than or equal to the first resistance value, first resistance value, and the resistance data is less than the second resistance value, the second adjustment coefficient a2 is selected to adjust the wear degree M, and the final wear degree is M×a2; if the resistance data is greater than or equal to the second resistance value, and the resistance data is less than the third resistance value, the third adjustment coefficient a3 is selected to adjust the wear degree M, and the final wear degree is M×a3; if the resistance data is greater than or equal to the third resistance value, the fourth adjustment coefficient a4 is selected to adjust the wear degree M, and the final wear degree is M×a4; wherein, 1.0<a1<a2<a3<a4<1.2.

[0074] In this embodiment, during the operation of the circular knitting machine, the needle groove of the needle cylinder is constantly subjected to the up and down impact of the knitting needles and the friction between the yarn and the fabric. These long-term mechanical effects will cause the originally smooth surface to gradually become rough, and may cause wear or bumps. This wear not only affects the smoothness of the needle groove, but may also lead to a decrease in fabric quality and production efficiency. At this time, when the insert is used for detection, the resistance encountered will increase. When the needle groove is not worn, the insert can fit the smooth surface inside the needle groove, so the resistance felt is small. When the needle groove is worn due to long-term use and mechanical wear, its internal surface will become rough and uneven, which will increase the friction force encountered by the insert when inserted, thereby increasing the resistance. Therefore, the present application adjusts the wear degree by determining the relationship between the resistance data and the first resistance value, the second resistance value and the third resistance value, and then determining the corresponding adjustment coefficient.

[0075] It is understandable that, assuming there is a needle groove of a large circular knitting machine needle cylinder with an initial wear degree M=0.5. The collected resistance data is 0.8, which is less than the first resistance value 1. Then the first adjustment coefficient a1=1.1 is selected, and the final wear degree after adjustment is 0.5×1.1=0.55. Suppose there is another needle groove with a wear degree M=0.6 and a resistance data of 1.5, which is greater than or equal to the first resistance value 1 and less than the second resistance value 2. Then the second adjustment coefficient a2=1.05 is selected, and the final wear degree after adjustment is 0.6×1.05=0.63.

[0076] Preferably, the determination module is used to determine whether each needle groove in the needle cylinder of the large circular knitting machine is qualified based on the final wear degree, including: pre-setting a wear degree threshold; comparing the final wear degree with the wear degree threshold, and determining whether the needle groove of the needle cylinder of the large circular knitting machine is qualified based on the comparison result; if the final wear degree is less than the wear degree threshold, the needle groove of the needle cylinder of the large circular knitting machine is determined to be qualified; if the final wear degree is greater than or equal to the wear degree threshold, the needle groove of the needle cylinder of the large circular knitting machine is determined to be unqualified, and the needle groove is marked as a needle groove to be repaired.

[0077] It's understood that the judgment module is designed to evaluate the quality of each needle groove within the circular knitting machine's needle cylinder. It operates based on a pre-set wear threshold. During operation, the module compares the final wear of each needle groove against the set wear threshold. Based on this comparison, the judgment module determines whether the quality of each groove meets the specified standards. Specifically, if the final wear of a groove falls below the wear threshold, the judgment module determines that the groove is acceptable. Conversely, if the final wear of a groove equals or exceeds the wear threshold, the judgment module determines that the groove fails to meet the quality standards. In this case, the judgment module further operates to designate the unqualified groove as a groove for repair, facilitating subsequent maintenance and repair. This mechanism ensures the efficient and stable use of the circular knitting machine's needle cylinder. Timely maintenance and repair prevent equipment failures caused by excessive wear, thereby ensuring the continuity of the production process and the stability of product quality.

[0078] It can be seen that automated wear detection and assessment significantly improves the efficiency and accuracy of needle groove quality assessment. Compared to traditional manual inspection methods, the automated assessment module can complete large-scale needle groove wear assessments in a short period of time while eliminating the influence of human factors on the test results, making the assessment results more objective and reliable. It also enables real-time monitoring and early warning of needle groove wear. When the wear of the needle groove approaches or exceeds the threshold, the assessment module immediately calibrates the wear, allowing staff to promptly identify and repair the problem. This timely maintenance and care effectively prevents equipment failures caused by excessive needle groove wear, thereby ensuring production continuity and stable product quality. It also extends the equipment's service life and reduces maintenance costs. Through timely maintenance and care, needle groove wear is effectively controlled, thereby extending the equipment's service life. Furthermore, by promptly identifying and addressing problems, downtime and product quality issues caused by equipment failures are avoided, thereby reducing maintenance and production costs.

[0079] Preferably, the judgment module is used to perform a secondary judgment on the needle slot based on the temperature data and vibration data when the needle slot is judged to be qualified, including: the vibration data includes vibration frequency and vibration amplitude; pre-setting a temperature threshold, a vibration frequency threshold and a vibration amplitude threshold; comparing the temperature data with the temperature threshold, comparing the vibration frequency with the vibration frequency threshold, and comparing the vibration amplitude with the vibration amplitude threshold, and determining whether the needle slot is qualified in the secondary judgment based on the comparison result; if the temperature data is less than the temperature threshold, and the vibration frequency is less than the vibration frequency threshold, and the vibration amplitude is less than the vibration amplitude threshold, then determining that the needle slot is initially qualified in the secondary judgment.

[0080] If the temperature data is greater than the temperature threshold, it is determined that the needle slot secondary judgment is unqualified; if the vibration frequency is greater than the vibration frequency threshold, it is determined that the needle slot secondary judgment is unqualified; if the vibration amplitude is greater than the vibration amplitude threshold, it is determined that the needle slot secondary judgment is unqualified.

[0081] In this embodiment, the determination module's primary function is to, after determining whether the needle slot meets the qualification criteria, further evaluate the needle slot using the temperature and vibration data. This evaluation process includes comprehensive consideration of the vibration data (including vibration frequency and amplitude). This evaluation requires pre-setting a series of thresholds, including temperature, frequency, and amplitude. Specifically, the temperature data is compared with the preset temperature thresholds, the vibration frequency is compared with the frequency threshold, and the vibration amplitude is compared with the amplitude threshold. These comparison results determine whether the needle slot meets the secondary evaluation qualification criteria. If any temperature data item exceeds the set temperature threshold, the needle slot is deemed unqualified in the secondary evaluation. Similarly, if the vibration frequency exceeds the frequency threshold or the vibration amplitude exceeds the amplitude threshold, the needle slot is also deemed unqualified in the secondary evaluation. Conversely, if all temperature data, vibration frequency, and vibration amplitude are within the corresponding threshold ranges, the needle slot is deemed qualified in the secondary evaluation. After these determinations are completed, if the needle slot is deemed qualified in the secondary evaluation, it will remain in its original evaluation status. However, if the needle slot is deemed unqualified during the secondary assessment, it will be designated as a needle slot for repair so that appropriate repair measures can be taken to ensure that it can meet the specified operating standards. Overall, this process is intended to ensure the safety and reliability of the needle slot, thereby improving the performance of the overall equipment.

[0082] Preferably, after determining that the needle slot secondary judgment is initially qualified, the judgment module further includes: determining the temperature change rate, vibration frequency change rate, and vibration amplitude change rate of the temperature data at time t relative to time t-1; presetting a temperature change rate threshold, a vibration frequency change rate threshold, and a vibration amplitude change rate threshold; comparing the temperature change rate with the temperature change rate threshold, comparing the vibration frequency change rate with the vibration frequency change rate threshold, and comparing the vibration amplitude change rate with the vibration amplitude change rate threshold, and determining whether the needle slot secondary judgment is qualified based on the comparison results. If the temperature change rate is less than the temperature change rate threshold, the vibration frequency change rate is less than the vibration frequency change rate threshold, and the vibration amplitude change rate is less than the vibration amplitude change rate threshold, then the needle slot secondary judgment is determined to be qualified.

[0083] In this embodiment, the determination module, based on confirming the initial qualification of the needle slot secondary determination, further includes a series of activities. First, the module determines the temperature change rate, vibration frequency change rate, and vibration amplitude change rate of the needle slot temperature data between time t and the previous time t-1. The changes in these three indicators are important criteria for determining the needle slot's condition. Next, the determination module pre-sets a series of thresholds: temperature change rate threshold, vibration frequency change rate threshold, and vibration amplitude change rate threshold. These thresholds are based on an understanding of the normal operation of the needle slot and accumulated empirical data, and serve as a benchmark for determining whether the needle slot is qualified. The determination module then compares the measured temperature change rate, vibration frequency change rate, and vibration amplitude change rate with the corresponding thresholds. This step determines whether the changes in these three indicators exceed the normal range, thereby assessing whether there are potential problems with the needle slot. Finally, if the temperature change rate is less than the preset temperature change rate threshold, the vibration frequency change rate is also less than the preset vibration frequency change rate threshold, and the vibration amplitude change rate is also less than the preset vibration amplitude change rate threshold, the determination module concludes that the needle slot secondary determination is qualified. This means that the needle slot has maintained stability and reliability during operation, with no abnormalities. This determination is of great significance for ensuring the normal operation of the needle slot and preventing potential failures.

[0084] Preferably, after the determination module calibrates the needle slot as a needle slot to be repaired, it also includes: determining the location information of the needle slot to be repaired; sending the maintenance information of the needle slot to the management machine of the large circular knitting machine needle cylinder, and the maintenance information includes the location information of the needle slot to be repaired.

[0085] The present invention also discloses a method for detecting the needle cylinder of a large circular knitting machine, such as Figure 2 As shown, the method applied to the above-mentioned detection system for the needle cylinder of the large circular knitting machine includes:

[0086] S1, collects the needle groove image of the circular knitting machine needle cylinder and the temperature data and vibration data of the circular knitting machine needle cylinder during operation.

[0087] S2, processing the needle groove image, determining the size and wear of each needle groove in the needle cylinder of the large circular knitting machine, and selecting a corresponding insert according to the size of each needle groove to perform resistance detection.

[0088] S3, collecting resistance data when performing resistance detection on the needle groove of the needle cylinder of the large circular knitting machine, adjusting the wear degree according to the resistance data, and obtaining a final wear degree.

[0089] S4, judging whether each needle groove in the needle cylinder of the circular knitting machine is qualified based on the final wear degree, temperature data and vibration data.

[0090] It can be seen that by collecting the needle groove image of the large circular knitting machine needle cylinder as well as the temperature data and vibration data during operation, the working status of the needle cylinder can be comprehensively and accurately evaluated. In particular, in step S2, the size and wear of the needle groove are determined by image processing technology, and the corresponding insert is selected for resistance detection. This innovative method not only improves the accuracy of the detection, but also improves the detection efficiency. In step S3, the wear is adjusted using resistance data to further ensure the accuracy of the wear assessment. This feedback adjustment mechanism based on actual operating data makes the test results closer to the actual working conditions and improves the reliability of the test. In step S4, the needle groove is further evaluated through the final wear, temperature and vibration data to ensure the comprehensiveness and accuracy of the test results. This judgment method effectively avoids the misjudgment caused by single data and further improves the accuracy of the test.

[0091] The detection method of the present invention has a high level of automation and intelligence, can realize fast and accurate detection of large circular knitting machine needle cylinders, and greatly improves production efficiency. Secondly, this detection method realizes a comprehensive evaluation of the working status of the needle cylinder by collecting a variety of data, and provides strong data support for subsequent maintenance and care. Finally, this detection method is also scalable and customizable, and can be adjusted and optimized accordingly according to different detection requirements to meet the different needs of different users. In summary, the detection method for large circular knitting machine needle cylinders of the present invention not only has a high degree of accuracy and reliability, but also has a high level of automation and intelligence, and provides strong technical support for the production of the textile industry.

[0092] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit the same. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that they can still modify or replace the technical solutions of the present invention with equivalents, and these modifications or equivalent replacements cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

[0093] The system provided in the above embodiment is only illustrated by the division of the above functional modules. In actual applications, the above functions can be assigned to different functional modules as needed, that is, the modules or steps in the embodiments of the present invention can be further decomposed or combined. For example, the modules in the above embodiment can be combined into one module or further divided into multiple sub-modules to complete all or part of the functions described above. The names of the modules and steps involved in the embodiments of the present invention are only for distinguishing the modules or steps and are not to be regarded as improper limitations of the present invention.

[0094] Those skilled in the art should be able to appreciate that, in conjunction with the modules and method steps of each example described in the embodiments disclosed herein, it is possible to implement them with electronic hardware, computer software, or a combination of the two, and the programs corresponding to the software modules and method steps can be placed in random access memory (RAM), internal memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disks, removable disks, CD-ROMs, or any other form of storage medium known in the art. In order to clearly illustrate the interchangeability of electronic hardware and software, the composition and steps of each example have been generally described in terms of function in the above description. Whether these functions are performed in electronic hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered to exceed the scope of the present invention.

Claims

1. A detection system for a large circular knitting machine needle cylinder, characterized in that: include: An acquisition module is used to acquire the needle groove image of the circular knitting machine needle cylinder and the resistance data when performing needle groove resistance detection. The acquisition module is also used to acquire the temperature data and vibration data of the circular knitting machine needle cylinder during operation; a processing module connected to the acquisition module, the processing module being configured to process the needle groove image to determine the size and wear of each needle groove in the needle cylinder of the large circular knitting machine; select a corresponding insert according to the size of each needle groove to perform resistance detection; and adjust the wear according to the resistance data to obtain a final wear degree; a resistance detection module connected to the acquisition module and the processing module, and configured to control the insertion of the insert into the needle groove of the needle cylinder of the circular knitting machine according to the insert selected by the processing module, so as to perform resistance detection on the needle groove; a determination module connected to the processing module, configured to determine whether each needle groove in the needle cylinder of the circular knitting machine is qualified based on the final wear degree, temperature data, and vibration data; The processing module is used to process the needle groove image to determine the wear degree of each needle groove in the needle cylinder of the circular knitting machine, including: Acquire standard needle groove images; Comparing the needle groove image with the standard needle groove image to determine a difference image, wherein the difference image is determined based on the RGB value of each pixel in the needle groove image and the RGB value of the standard needle groove image; determining the wear degree of each needle groove in the needle cylinder of the circular knitting machine according to the difference image; The processing module is used to process the needle groove image to determine the size of each needle groove in the needle cylinder of the circular knitting machine, including: performing grayscale processing on the needle groove image to convert the needle groove image into a grayscale image; performing a binarization process on the grayscale image to convert the grayscale image into a binary image; Detecting the binary image to determine the boundary of the needle groove in the binary image; The size of the needle groove is obtained according to the determined needle groove boundary; The processing module is configured to adjust the wear degree according to the resistance data to obtain a final wear degree, including: A number of resistance value ranges are set, each of which corresponds to a unique adjustment coefficient. The corresponding adjustment coefficient is determined according to the resistance value range in which the resistance data is located, and the wear degree is adjusted according to the adjustment coefficient to obtain a final wear degree.

2. The detection system for the needle cylinder of a circular knitting machine according to claim 1, characterized in that: The standard needle slot image is an image of a needle slot that is not in use.

3. The detection system for the needle cylinder of a circular knitting machine according to claim 1, characterized in that: The determination module is used to determine whether each needle groove in the needle cylinder of the circular knitting machine is qualified according to the final wear degree, temperature data and vibration data, including: Pre-set wear threshold; Comparing the final wear degree with the wear degree threshold, and determining whether the needle groove of the circular knitting machine needle cylinder is qualified according to the comparison result; If the needle groove of the needle cylinder of the large circular knitting machine is unqualified, the needle groove will be marked as a needle groove to be repaired.

4. The detection system for the needle cylinder of a circular knitting machine according to claim 3, characterized in that: The determination module is used to determine whether each needle groove in the needle cylinder of the circular knitting machine is qualified according to the final wear degree, temperature data and vibration data, and also includes: The vibration data includes vibration frequency and vibration amplitude; Pre-set temperature threshold, vibration frequency threshold and vibration amplitude threshold; The temperature data is compared with the temperature threshold, the vibration frequency is compared with the vibration frequency threshold, and the vibration amplitude is compared with the vibration amplitude threshold. Whether the needle slot is qualified is determined based on the comparison results.

5. The detection system for the needle cylinder of a circular knitting machine according to claim 4, characterized in that: The determination module is used to determine whether each needle groove in the needle cylinder of the circular knitting machine is qualified according to the final wear degree, temperature data and vibration data, and also includes: Determine the temperature change rate, vibration frequency change rate, and vibration amplitude change rate of the temperature data at time t relative to time t-1; Presetting the temperature change rate threshold, vibration frequency change rate threshold, and vibration amplitude change rate threshold; The temperature change rate is compared with the temperature change rate threshold, the vibration frequency change rate is compared with the vibration frequency change rate threshold, and the vibration amplitude change rate is compared with the vibration amplitude change rate threshold, and whether the needle slot secondary determination is qualified is determined based on the comparison results.

6. The detection system for the needle cylinder of a circular knitting machine according to claim 3, characterized in that: When the determination module determines that the needle slot is a needle slot to be repaired, the method further includes: Determining the position information of the needle slot to be repaired; The maintenance information of the needle slot is sent to the management machine of the needle cylinder of the large circular knitting machine, and the maintenance information includes the position information of the needle slot to be repaired.

7. A method for detecting a needle cylinder of a circular knitting machine, applied to a detection system for a needle cylinder of a circular knitting machine according to any one of claims 1 to 6, characterized in that: The method comprises: Collect the needle groove image of the circular knitting machine needle cylinder and the temperature and vibration data of the circular knitting machine needle cylinder during operation; Processing the needle groove image to determine the size and wear of each needle groove in the needle cylinder of the circular knitting machine, and selecting a corresponding insert according to the size of each needle groove to perform resistance detection; collecting resistance data when performing resistance detection on the needle groove of the needle cylinder of the circular knitting machine, and adjusting the wear degree according to the resistance data to obtain a final wear degree; Whether each needle groove in the needle cylinder of the circular knitting machine is qualified is determined based on the final wear degree, temperature data and vibration data.

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