Intelligent sewing thread quality detection system

Abstract

The invention relates to the technical field of intelligent detection, in particular to an intelligent detection system for sewing thread quality. Comprising an image acquisition module, an appearance defect detection module, a physical performance detection module and a feedback early warning module, the image acquisition module acquires and preprocesses image data of sewing threads; the appearance defect detection module detects the appearance quality problem of the sewing thread in the production process; the physical property detection module comprehensively evaluates the mechanical property of the sewing thread in the actual use process; the feedback early warning module adjusts the production process through an automatic feedback and early warning strategy; the tensile strength, the elastic property and the wear resistance of the sewing thread are accurately detected, a production line and a quality control department are helped to identify unqualified products, and the unqualified products are fed back in real time for processing; the production efficiency of enterprises is greatly improved, the product quality is ensured, the quality risk is reduced, and powerful support is provided for production of sewing thread products.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent detection, and particularly relates to an intelligent detection system for the quality of sewing threads. Background Art

[0002] As a basic industrial material, sewing threads play a crucial role. Their materials, structures, specifications, functions, etc. determine their applications in different fields; by selecting appropriate sewing threads, the smooth progress of the sewing process can be ensured, and the overall quality and durability of the products can be improved; the quality inspection of sewing threads plays a crucial role in the entire production chain. It is directly related to the product quality, production efficiency, enterprise cost control, and consumer satisfaction. Through strict quality inspection, the stability and reliability of sewing threads can be effectively ensured, potential production risks can be avoided, and a guarantee can be provided for the enterprise to establish a good brand image in the market;

[0003] At present, although automated detection technologies are gradually developing, in some production environments with a small scale or more manual operations, manual inspection still dominates. Manual inspection is easily affected by subjective factors and may miss some subtle defects; many existing detection methods only focus on the appearance defects of sewing threads, such as wire diameter, surface defects, etc., while ignoring the detection of the internal quality or specific properties of the wire materials. For example, detecting insufficient strength or insufficient ductility of sewing threads that lead to sewing problems, and these defects may not be easily found during the sewing process. Summary of the Invention

[0004] Therefore, the present invention provides an intelligent detection system for the quality of sewing threads to overcome the problems mentioned in the above background art.

[0005] To achieve the above object, the present invention provides an intelligent detection system for the quality of sewing threads, including: an appearance defect detection module, a physical property detection module, and a feedback warning module;

[0006] The appearance defect detection module identifies the color difference, uneven wire diameter, breakage, and dirt of the sewing thread, and detects the appearance quality problems of the sewing thread during the production process; the specific steps are as follows:

[0007] Convert the collected RGB image to the Lab color space, which is a color space containing luminance (L) and chrominance (a, b); input the standard Lab color values (L standard, a standard, b standard); arbitrarily select a section of sewing thread as the sewing thread segment to be detected, and obtain the color values (Ln, an, bn) of the sewing thread segment to be detected, where n = 1, 2, 3... N, N is a positive integer, N represents the total number of segments of the sewing thread, and n represents the serial number of any one segment of the sewing thread; substitute the numerical values of the standard color Lab color values (L standard, A standard, B standard) and the color values (Ln, An, Bn) of the sewing thread to be detected into the formula Calculate the color difference ΔE of the sewing thread segment;

[0008] Set a color difference threshold, and compare and analyze the obtained color difference of the sewing thread segment with the set color difference threshold. When the color difference is less than the set threshold, the detection result is qualified; when the color difference is greater than or equal to the set threshold, the detection result is unqualified and needs further processing, and this sewing thread segment to be detected is sent to the feedback warning module;

[0009] Mark the voids or irregular faults in the image as sewing thread breaks, perform fracture detection on the image and mark the image of the fracture part; mark the prominent bright spots or irregular texture areas in the image as sewing thread impurities, perform impurity detection on the image and mark the image of the impurity part; mark the local intertwined areas or abnormal shapes and textures in the image as sewing thread kinks, perform kink detection on the image and mark the image of the kink part; send the marked images of sewing thread breaks, sewing thread impurities and sewing thread kinks to the feedback warning module;

[0010] The physical property detection module comprehensively evaluates the mechanical properties of the sewing thread during actual use by measuring the tensile strength, elastic modulus, recovery rate and wear resistance of the sewing thread;

[0011] The feedback warning module timely discovers unqualified sewing thread segments by real-time monitoring and evaluating the physical properties of the sewing thread, and adjusts the production process through an automated feedback and warning mechanism.

[0012] As a preferred embodiment of the present invention, the specific analysis of the uneven thread diameter of the sewing thread is as follows:

[0013] Extract the edge contour of the sewing thread using the Canny edge detection algorithm, perform horizontal cutting on the sewing thread segment to be detected, measure the transverse diameter of the sewing thread segment, and label it as Dn; set a qualified standard range for the thread diameter (Dmin, Dmax); compare and analyze the transverse diameter of the sewing thread segment with the set qualified standard range for the thread diameter. When the transverse diameter of the sewing thread segment is greater than the maximum value of the set qualified standard range for the thread diameter, then the sewing thread segment is an over-thick segment; when the transverse diameter of the sewing thread segment is less than the minimum value of the set qualified standard range for the thread diameter, then the sewing thread segment is an under-thin segment; when the transverse diameter of the sewing thread segment is within the set qualified standard range for the thread diameter, then the sewing thread segment is a qualified segment; mark the over-thick segments and under-thin segments and send them to the feedback warning module; obtain the transverse diameters of five consecutive sewing thread segments, where the five consecutive sewing thread segments are Dn-2, Dn-1, Dn, Dn+1, and Dn+2 respectively; calculate the average wire diameter by calculating the average value of the transverse diameters of the sewing thread segments Dn-2, Dn-1, Dn, Dn+1, and Dn+2, and obtain the maximum wire diameter and the minimum wire diameter among the transverse diameters of the five consecutive sewing thread segments; substitute the average wire diameter, the maximum wire diameter, and the minimum wire diameter among the transverse diameters of the five consecutive sewing thread segments into the formula Calculate the wire diameter change rate of the sewing thread segment to be detected; set a change rate threshold, and compare and analyze the obtained wire diameter change rate of the sewing thread segment to be detected with the set change rate threshold; when the wire diameter change rate of the sewing thread segment to be detected is less than the set threshold, the detection result is qualified; when the wire diameter change rate of the sewing thread segment to be detected is greater than or equal to the set threshold, mark the uneven sewing thread in this section of the image and send it to the feedback warning module.

[0014] As a preferred embodiment of the present invention, it further includes an image acquisition module, specifically:[

[0015] The image acquisition module acquires the image data of the sewing thread through a high-resolution camera and preprocesses the acquired image; automatically takes pictures of the sewing thread through the high-resolution camera to ensure that the images of each section of the sewing thread are completely acquired; the preprocessing of the image includes Gaussian filtering for noise reduction, contrast enhancement, and brightness adjustment processing.

[0016] As a preferred embodiment of the present invention, the tensile strength of the sewing thread is specifically analyzed as:[

[0017] Install the sewing thread segment to be detected into a tensile testing machine and set a fixed tensile rate; calculate the tensile strength Fmax of the sewing thread segment to be detected using the formula Fmax = max(T), where T is the tensile force at different tensile stages and max(T) is the maximum tensile force before the sewing thread segment breaks; set a standard tensile strength threshold. Compare and analyze the tensile strength of the sewing thread segment to be detected with the set standard tensile strength threshold. When the tensile strength of the sewing thread segment to be detected is greater than or equal to the set standard tensile strength threshold, the quality is qualified; when the tensile strength of the sewing thread segment to be detected is less than the set standard tensile strength threshold, the quality is unqualified. Mark this section of the sewing thread and send it to the feedback warning module.

[0018] As a preferred embodiment of the present invention, the specific analysis of the elastic modulus and recovery rate of the sewing thread is as follows:

[0019] Install the sewing thread segment to be detected into the clamping device of a tensile testing machine, obtain the stress-strain data of the sewing thread segment to be detected, and mark the stress-strain data as Yn and Xn respectively; substitute the values of the stress Yn and strain Xn of the sewing thread segment to be detected into the formula Calculate the elastic modulus Qn of the sewing thread segment to be detected; obtain the initial length of the sewing thread segment to be detected and mark it as Cinitial; obtain the stretched length and the recovered length after compression of the sewing thread segment to be detected, and mark them as C 拉 stretch and Crecovery respectively; substitute the values of the initial length Cinitial, the stretched length C 拉 stretch and the recovered length Crecovery after compression of the sewing thread segment to be detected into the formula Calculate the recovery rate Rn of the sewing thread segment to be detected; set an elastic modulus standard threshold. Compare and analyze the elastic modulus of the sewing thread segment to be detected with the set elastic modulus standard threshold; when the elastic modulus of the sewing thread segment to be detected is greater than or equal to the set elastic modulus standard threshold, it indicates that the elastic performance of the sewing thread segment to be detected is qualified; when the elastic modulus of the sewing thread segment to be detected is less than the set elastic modulus standard threshold, it indicates that the elastic performance of the sewing thread segment to be detected is insufficient and the quality is unqualified. Mark the unqualified sewing thread segment to be detected and send it to the feedback warning module; set a recovery standard threshold. Compare and analyze the recovery rate of the sewing thread segment to be detected with the set recovery standard threshold; when the recovery rate of the sewing thread segment to be detected is greater than or equal to the set recovery standard threshold, the quality is qualified; when the recovery rate of the sewing thread segment to be detected is less than the set recovery standard threshold, the quality is unqualified. Mark the unqualified sewing thread segment to be detected and send it to the feedback warning module.

[0020] As a preferred embodiment of the present invention, the abrasion resistance of the sewing thread is specifically analyzed as follows:

[0021] Place the sewing line segment to be detected in a friction and wear testing machine, and conduct wear testing through friction for a certain period of time; obtain the length of the sewing line segment to be detected before the test, and mark it as C before test; obtain the length of the sewing line segment to be detected after the test, and mark it as C after test; the length C of the sewing line segment to be detected before the test 测试前 and the length C after the test 测试后 Substitute the numerical values into the formula Calculate the wear degree Wn of the sewing line segment to be detected; set a wear degree standard threshold, and compare and analyze the wear degree of the sewing line segment to be detected with the set wear degree standard threshold; when the wear degree of the sewing line segment to be detected is less than or equal to the set wear degree standard threshold, it indicates that the wear resistance of the sewing line segment to be detected is qualified; when the wear degree of the sewing line segment to be detected is greater than the set wear degree standard threshold, it indicates that the wear resistance of the sewing line segment to be detected is unqualified, mark the sewing line segment to be detected with unqualified wear resistance, and send it to the feedback warning module.

[0022] As a preferred implementation manner of the present invention, the feedback and warning are specifically as follows:

[0023] Mark the unqualified data, and generate a real-time feedback record, which includes unqualified items, production batches, serial numbers of sewing line segments, and defect types; for unqualified sewing line segments, generate warning information and send the warning information to operators, production responsible persons, and quality control personnel; operators adjust the production process in a timely manner according to the warning information, mark or isolate unqualified sewing threads to prevent them from entering the next stage or flowing into the market; update the feedback information to the quality management system in a timely manner for management personnel to track and review; set different warning levels, and decide whether emergency treatment is required according to the degree of unqualifiedness.

[0024] Advantages of the present invention:

[0025] 1. Through precise image processing technology and color difference calculation, edge detection, fracture, impurity, and kink identification, the detection of quality problems such as color difference, wire diameter, fracture, impurity, and kink of sewing threads is realized; effectively helps the production line to timely detect unqualified sewing threads, improves the detection efficiency and accuracy, reduces manual errors, and provides data support for subsequent production optimization.

[0026] 2. Through detection means such as tensile strength, elastic modulus, recovery rate, and wear resistance, the mechanical properties of sewing threads in actual applications are comprehensively evaluated; accurately detects the tensile strength, elastic properties, and wear resistance of sewing threads, helps the production line and quality control department to identify unqualified products, and gives real-time feedback for processing; greatly improves the production efficiency of enterprises, ensures product quality, reduces quality risks, and provides strong support for the production of sewing thread products.

[0027] 3. By monitoring in real time and generating alerts, ensure that quality problems can be promptly identified and addressed during the production process, prevent quality problems from persisting into the next stage or entering the market, and safeguard the quality of end products; take corresponding measures according to the severity of defects, reasonably allocate production resources, avoid excessive intervention and ensure the continuous operation of the production line; through the update of feedback information and the accumulation of historical data, provide traceable quality data for production managers, thereby providing data support for subsequent quality improvement, technology optimization, and process adjustment, and promoting the long-term optimization of overall quality management. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 is a schematic diagram of the connection of the system modules of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0029] In order to make the objectives and advantages of the present invention clearer and more understandable, the present invention will be further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0030] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are only used to explain the technical principles of the present invention and do not limit the protection scope of the present invention.

[0031] It should be noted that in the description of the present invention, the terms indicating directions or positional relationships such as "upper", "lower", "left", "right", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings. This is only for convenience of description and does not indicate or imply that the device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be construed as a limitation of the present invention.

[0032] In addition, it should be noted that in the description of the present invention, unless otherwise clearly specified and limited, the terms "installation", "connection", and "connection" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements. For those skilled in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0033] Please refer to Figure 1 as shown, the present invention is an intelligent sewing thread quality detection system, including: an image acquisition module, an appearance defect detection module, a physical property detection module, and a feedback and warning module;

[0034] The image acquisition module collects the image data of the sewing thread through a high-resolution camera and preprocesses the collected images; automatically takes pictures of the sewing thread through the high-resolution camera to ensure that the images of each section of the sewing thread are completely collected; the preprocessing of the images includes Gaussian filtering for noise reduction, contrast enhancement, and brightness adjustment.

[0035] The appearance defect detection module identifies color differences, uneven thread diameters, breaks, impurities, and kinks in the sewing thread to detect appearance quality problems during the production process of the sewing thread; the specific steps are as follows:

[0036] Convert the collected RGB image to the Lab color space, which is a color space containing luminance (L) and chrominance (a, b); according to the product quality requirements or the standard color provided by the standard color card, input the standard Lab color values (L standard, a standard, b standard); arbitrarily select a section of the sewing thread as the sewing thread segment to be detected, and obtain the color values (Ln, an, bn) of the sewing thread segment to be detected, where n = 1, 2, 3... N, N takes positive integer values, N represents the total number of sections of the sewing thread, and n represents the serial number of any one section of the sewing thread; substitute the numerical values of the standard color Lab color values (L standard, A standard, B standard) and the color values (Ln, An, Bn) of the sewing thread to be detected into the set formula Calculate the color difference value ΔE of the sewing thread segment; according to industry standards or quality requirements, set a color difference threshold, and compare and analyze the obtained color difference value of the sewing thread segment with the set color difference threshold. When the color difference value is less than the set threshold, it means that the color meets the standard and the detection result is qualified; when the color difference value is greater than or equal to the set threshold, it means that the color deviation is large, the detection result is unqualified, and further processing is required, and this sewing thread segment to be detected is sent to the feedback warning module.

[0037] The edge contour of the sewing thread is extracted using the Canny edge detection algorithm. The sewing thread segment to be detected is horizontally cut, and the transverse diameter of the sewing thread segment is measured and marked as Dn. A qualified standard range of the segment diameter (Dmin, Dmax) is set. The transverse diameter of the sewing thread segment is compared and analyzed with the set qualified standard range of the segment diameter. When the transverse diameter Dn of the sewing thread segment is greater than the maximum value of the set qualified standard range of the segment diameter, the sewing thread segment is a too-thick segment. When the transverse diameter of the sewing thread segment is less than the minimum value of the set qualified standard range of the segment diameter, the sewing thread segment is a too-thin segment. When the transverse diameter Dn of the sewing thread segment is within the set qualified standard range of the segment diameter, the sewing thread segment is a qualified segment. The too-thick segments and too-thin segments are marked and sent to the feedback warning module. The transverse diameters of five consecutive sewing thread segments are obtained, and the five consecutive sewing thread segments are Dn-2, Dn-1, Dn, Dn+1, and Dn+2 respectively. The average wire diameter is calculated by taking the average of the transverse diameters of the sewing thread segments Dn-2, Dn-1, Dn, Dn+1, and Dn+2, and the maximum wire diameter and the minimum wire diameter among the transverse diameters of the five consecutive sewing thread segments are obtained. The average wire diameter, the maximum wire diameter, and the minimum wire diameter among the transverse diameters of the five consecutive sewing thread segments are substituted into the set formula The wire diameter change rate of the sewing thread segment to be detected is calculated. A change rate threshold is set, and the obtained wire diameter change rate of the sewing thread segment to be detected is compared and analyzed with the set change rate threshold. When the wire diameter change rate of the sewing thread segment to be detected is less than the set threshold, it indicates that the wire diameter meets the standard and the detection result is qualified. When the wire diameter change rate of the sewing thread segment to be detected is greater than or equal to the set threshold, it indicates that the wire diameter is uneven, and the uneven sewing thread in this section of the image is marked and sent to the feedback warning module;

[0038] The voids or irregular faults in the image are marked as sewing thread breaks, and the break detection of the image and the image of the broken part are marked. The prominent bright spots or irregular texture areas in the image are marked as sewing thread impurities, and the impurity detection of the image and the image of the impurity part are marked. The local interlaced areas or abnormal shapes and textures in the image are marked as sewing thread kinks, and the kink detection of the image and the image of the kink part are marked. The images of the marked sewing thread breaks, sewing thread impurities, and sewing thread kinks are sent to the feedback warning module;

[0039] Through precise image processing techniques and color difference calculation, edge detection, break, impurity, and kink recognition, the detection of quality problems such as sewing thread color difference, wire diameter, break, impurity, and kink is achieved; effectively helps the production line to timely discover unqualified sewing threads, improves the detection efficiency and accuracy, reduces manual errors, and provides data support for subsequent production optimization;

[0040] The physical properties testing module comprehensively evaluates the mechanical properties of sewing threads during actual use by measuring the tensile strength, elastic modulus, recovery rate and abrasion resistance of sewing threads. The specific steps are as follows:

[0041] Install the sewing thread segment to be tested into the tensile testing machine, and set a fixed tension rate; it should be noted that the tension rate is set by professional and technical personnel in the field according to needs, generally 5 mm / min; use the formula Fmax=max(T) to calculate the tensile strength Fmax of the sewing thread segment to be tested, where T is the tension at different stretching stages, and max(T) is the maximum tension before the sewing thread segment breaks; set a standard tensile strength threshold, compare and analyze the tensile strength of the sewing thread segment to be tested with the set standard tensile strength threshold, when the tensile strength of the sewing thread segment to be tested is greater than or equal to the set standard tensile strength threshold, it means that the sewing thread segment to be tested meets the strength standard and is of qualified quality; when the tensile strength of the sewing thread segment to be tested is less than the set standard tensile strength threshold, it means that the sewing thread segment to be tested does not meet the strength requirements and is of unqualified quality, and the sewing thread segment is marked and sent to the feedback warning module;

[0042] Install the sewing thread segment to be tested into the clamping device of the tensile testing machine, obtain the stress and strain data of the sewing thread segment to be tested, and mark the stress and strain data as Yn and Xn respectively; substitute the values ​​of stress Yn and strain Xn of the sewing thread segment to be tested into the set formula Calculate the elastic modulus Qn of the sewing line segment to be tested; obtain the initial length of the sewing line segment to be tested and mark it as Cinitial; obtain the stretched length and the recovered length after compression of the sewing line segment to be tested and mark them as C 拉 Stretch and C recovery; the initial length of the sewing line segment to be tested is C initial, and the length after stretching is C 拉 Substitute the value of the recovery length C after extension and compression into the set formula Calculate the recovery rate Rn of the sewing line segment to be detected; assume there is a standard threshold for the elastic modulus, and compare and analyze the elastic modulus Qn of the sewing line segment to be detected with the set standard threshold for the elastic modulus; when the elastic modulus of the sewing line segment to be detected is greater than or equal to the set standard threshold for the elastic modulus, it indicates that the elastic performance of the sewing line segment to be detected is qualified; when the elastic modulus of the sewing line segment to be detected is less than the set standard threshold for the elastic modulus, it indicates that the elastic performance of the sewing line segment to be detected is insufficient and the quality is unqualified, mark the unqualified sewing line segment to be detected, and send it to the feedback warning module; assume there is a standard threshold for recovery, and compare and analyze the recovery rate Rn of the sewing line segment to be detected with the set standard threshold for recovery; when the recovery rate of the sewing line segment to be detected is greater than or equal to the set standard threshold for recovery, it indicates that the elastic performance of the sewing line segment to be detected is qualified; when the recovery rate of the sewing line segment to be detected is less than the set standard threshold for recovery, it indicates that the elastic performance of the sewing line segment to be detected is poor and the quality is unqualified, mark the unqualified sewing line segment to be detected, and send it to the feedback warning module;

[0043] Place the sewing line segment to be detected in a friction and wear testing machine, and conduct wear testing through friction for a certain period of time; obtain the length of the sewing line segment to be detected before the test, and mark it as C 测试 Before; obtain the length of the sewing line segment to be detected after the test, and mark it as C 测试后 ; Substitute the values of the length C before the test and the length C after the test of the sewing line segment to be detected into the set formula Calculate the wear degree Wn of the sewing line segment to be detected; assume there is a standard threshold for the wear degree, and compare and analyze the wear degree of the sewing line segment to be detected with the set standard threshold for the wear degree; when the wear degree of the sewing line segment to be detected is less than or equal to the set standard threshold for the wear degree, it indicates that the wear resistance of the sewing line segment to be detected is qualified; when the wear degree of the sewing line segment to be detected is greater than the set standard threshold for the wear degree, it indicates that the wear resistance of the sewing line segment to be detected is unqualified, mark the sewing line segment to be detected with unqualified wear resistance, and send it to the feedback warning module;

[0044] Through the detection means of tensile strength, elastic modulus, recovery rate and wear resistance, the mechanical properties of the sewing thread in actual application are comprehensively evaluated; accurately detect the tensile strength, elastic performance and wear resistance of the sewing thread, help the production line and quality control department identify unqualified products, and give real-time feedback for processing; greatly improve the production efficiency of the enterprise, ensure the product quality, reduce the quality risk, and provide strong support for the production of sewing thread products;

[0045] The feedback warning module monitors and evaluates the physical properties of sewing threads in real time, promptly detects unqualified sewing thread segments, and adjusts the production process through automated feedback and warning strategies; the specific steps are as follows:

[0046] Mark the unqualified data and generate real-time feedback records, including information on unqualified items, production batches, serial numbers of sewing segments and defect types; generate warning information for unqualified sewing segments and send it to operators, production managers and quality control personnel; operators adjust the production process in a timely manner based on the warning information, mark or isolate unqualified sewing threads to prevent them from entering the next stage or flowing into the market; feedback information is updated to the quality management system in a timely manner for management personnel to track and review; set different warning levels to determine whether emergency processing is required based on the degree of unqualifiedness, and the warning levels are level one, level two and level three respectively;

[0047] When the color difference value of the sewing thread segment is greater than 2, it means that the color difference is large and exceeds the acceptable range, and a first-level warning is triggered; when the wire diameter of the sewing thread segment exceeds the standard range of ±5%, it means that the wire diameter difference is extremely large, resulting in a significant decrease in the strength and stability of the sewing thread, and a first-level warning is triggered; when the tensile strength of the sewing thread segment is less than 30% or more of the set standard value, it means that the sewing thread segment cannot withstand the normal use load, there is a great quality risk, and a first-level warning is triggered; when the elastic modulus of the sewing thread segment is less than 25% or more of the set standard value, it indicates that the elastic performance of the sewing thread segment is seriously insufficient and cannot meet the use requirements, and a first-level warning is triggered. When the recovery rate of a sewing thread segment is less than 30% or more of the set recovery standard threshold, it indicates that the sewing thread has poor recovery, which will cause repeated deformation or breakage in actual application, and trigger a first-level warning; when the wear of a sewing thread segment exceeds the standard wear threshold by 30% or more, it indicates that the sewing thread is not wear-resistant and will break or have other serious problems after long-term use, and trigger a first-level warning; the specific measures for the first-level warning are: immediately suspend the production line, conduct a detailed investigation and troubleshooting, start the emergency repair procedure, check the quality of production equipment or raw materials, and suspend batch production if necessary; notify relevant quality management personnel to carry out comprehensive rectification and optimization;

[0048] When the color difference value of a sewing thread segment is greater than 1 and less than or equal to 2, it indicates that the color difference is acceptable, but further inspection may be required in some products. It is a lighter color difference problem and a secondary warning is triggered. When the wire diameter of a sewing thread segment exceeds the standard range of ±3% to 4%, it indicates that there is a significant unevenness in the wire diameter, which affects the quality of the product and triggers a secondary warning. When the tensile strength of a sewing thread segment is less than 15% to 29% of the set standard value, it indicates that the strength of the sewing thread is insufficient, which affects its use under high loads and triggers a secondary warning. When the elastic modulus of a sewing thread segment is less than 15% to 24% of the set standard value, it indicates that the elastic performance is reduced, which affects the long-term durability of the sewing thread and triggers a secondary warning. When the recovery rate of a sewing thread segment is less than 15% to 24% of the set standard value, it indicates that the elastic performance is reduced, which affects the long-term durability of the sewing thread and triggers a secondary warning. If the wear of the sewing thread segment exceeds the standard wear threshold of 15% to 29%, it means that the elastic recovery ability of the sewing thread is weak, which will affect its performance after long-term stretching and trigger the second-level warning. When the wear of the sewing thread segment exceeds the standard wear threshold of 15% to 29%, it means that the sewing thread has certain wear resistance problems, but it will not cause immediate failure and trigger the second-level warning. The specific measures for the second-level warning are: conduct a detailed investigation to determine the root cause of the problem, check the status of the production process, raw materials and equipment; optimize and adjust the production line to avoid the continued outflow of unqualified products; the production line can continue to operate, but the batch of products needs to be specially inspected and unqualified products need to be handled in time; breakage, impurities and kinks directly trigger the second-level warning.

[0049] When the color difference value of the sewing thread segment is less than or equal to 1, the color difference is within the acceptable range and a third-level warning is triggered; when the wire diameter of the sewing thread segment exceeds the standard range of ±1% to 2%, it means that the wire diameter difference is small, but it still affects the appearance and durability of the product, and a third-level warning is triggered; when the tensile strength of the sewing thread segment is less than 5% to 14% of the set standard value, it means that the tensile strength has decreased slightly, but it is still within the acceptable range, and a third-level warning is triggered; when the elastic modulus of the sewing thread segment is less than 5% to 14% of the set standard value, it means that the elastic modulus has decreased, but it will not immediately affect the product. Normal use, and triggering the third-level warning; when the recovery rate of the sewing thread segment is less than 5% to 14% of the set recovery standard threshold, it indicates that the recovery ability is slightly poor, affecting the long-term use of the product, and triggering the second-level warning; when the wear of the sewing thread segment exceeds the standard wear threshold of 5% to 14%, it indicates that the wear resistance is slightly poor, but it will not seriously affect the product performance, and triggering the third-level warning; the specific measures for the third-level warning are: conduct inspections, record the products of the batch, and improve or optimize the relevant issues; determine whether there are systemic problems or links that can be improved in the production process;

[0050] All warning and feedback information is recorded in the log, including the triggering time of each alarm, responding personnel, solutions, etc., for easy traceability; and quality reports are generated regularly to summarize non-conforming problems in the production process to help with long-term quality control and process optimization;

[0051] By means of real-time monitoring and generating alerts, it is ensured that quality problems can be promptly identified and addressed during the production process, preventing quality issues from persisting into the next stage or entering the market, and guaranteeing the quality of end products; corresponding measures are taken according to the severity of defects, rationally scheduling production resources, avoiding excessive interference and ensuring the continuous operation of the production line; through the update of feedback information and the accumulation of historical data, traceable quality data is provided for production management personnel, thereby providing data support for subsequent quality improvement, technology optimization, and process adjustment, and promoting the long-term optimization of overall quality management;

[0052] So far, the technical solution of the present invention has been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it is easily understood by those skilled in the art that the protection scope of the present invention is obviously not limited to these specific embodiments. Without departing from the principle of the present invention, those skilled in the art can make equivalent changes or substitutions to relevant technical features, and the technical solutions after these changes or substitutions will all fall within the protection scope of the present invention.

[0053] The above are only the preferred embodiments of the present invention and are not used to limit the present invention; for those skilled in the art, the present invention can have various changes and modifications. Any modification, equivalent substitution, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. An intelligent sewing thread quality detection system, comprising an appearance defect detection module, a physical property detection module and a feedback warning module; characterized in that: The appearance defect detection module identifies the color difference, uneven wire diameter, breakage and dirt of the sewing thread, and detects the appearance quality problems of the sewing thread during the production process; the specific steps are as follows: Convert the collected RGB image into Lab color space; input the standard Lab color value according to the product quality requirements or the standard color provided by the standard color card; arbitrarily select a section of sewing thread as the sewing thread segment to be detected, and obtain the color value of the sewing thread segment to be detected; normalize the values ​​of the standard color Lab color value and the color value of the sewing thread to be detected to obtain the color difference value of the sewing thread segment; A color difference threshold is set, and the color difference value of the obtained sewing thread segment is compared and analyzed with the set color difference threshold. When the color difference value is less than the set threshold, the detection result is qualified; when the color difference value is greater than or equal to the set threshold, the detection result is unqualified and needs further processing, and the sewing thread segment to be detected is sent to the feedback warning module; Mark the gaps or irregular faults in the image as sewing thread breaks, perform image break detection and mark the image of the broken part; mark the prominent bright spots or irregular texture areas in the image as sewing thread impurities, perform image impurity detection and mark the image of the impurity part; mark the local interweaving areas or abnormal shapes and textures in the image as sewing thread kinks, perform image kink detection and mark the image of the kinked part; send the marked images of sewing thread breaks, sewing thread impurities and sewing thread kinks to the feedback warning module; The physical properties testing module comprehensively evaluates the mechanical properties of sewing threads during actual use by measuring the tensile strength, elastic modulus, recovery rate and abrasion resistance of sewing threads. The feedback and early warning module monitors and evaluates the physical properties of sewing threads in real time, promptly detects unqualified sewing thread segments, and adjusts the production process through automated feedback and early warning strategies.

2. The intelligent sewing thread quality detection system according to claim 1, characterized in that: The specific analysis of uneven diameter of sewing thread is as follows: The Canny edge detection algorithm is used to extract the edge contour of the sewing line, and the sewing line segment to be detected is horizontally cut to measure the transverse diameter of the sewing line segment; a segment diameter qualified standard range is set; the transverse diameter of the sewing line segment is compared with the set segment diameter qualified standard range. When the transverse diameter of the sewing line segment is greater than the maximum value of the set segment diameter qualified standard range, the sewing line segment is too thick; when the transverse diameter of the sewing line segment is less than the minimum value of the set segment diameter qualified standard range, the sewing line segment is too thin; when the transverse diameter of the sewing line segment is within the set segment diameter qualified standard range, the sewing line segment is qualified; the over-thick segment and the over-thin segment are marked and sent to the feedback warning module; the continuous The transverse diameters of five consecutive sewing line segments are calculated, and the average of the transverse diameters of five consecutive sewing line segments is calculated to obtain the average wire diameter, and the maximum wire diameter and the minimum wire diameter among the transverse diameters of five consecutive sewing line segments are obtained; the values ​​of the average wire diameter, the maximum wire diameter and the minimum wire diameter among the transverse diameters of five consecutive sewing line segments are normalized to obtain the wire diameter change rate of the sewing line segment to be detected; a change rate threshold is set, and the obtained wire diameter change rate of the sewing line segment to be detected is compared and analyzed with the set change rate threshold; when the wire diameter change rate of the sewing line segment to be detected is less than the set threshold, the detection result is qualified; when the wire diameter change rate of the sewing line segment to be detected is greater than or equal to the set threshold, the uneven sewing line in the image is marked and sent to the feedback warning module.

3. The intelligent sewing thread quality detection system according to claim 1, characterized in that: It also includes an image acquisition module, specifically: The image acquisition module collects the image data of the sewing thread through a high-resolution camera and pre-processes the collected images; the image of the sewing thread is automatically captured by the high-resolution camera to ensure that the image of each section of the sewing thread is completely captured; the image pre-processing includes Gaussian filtering denoising, contrast enhancement and brightness adjustment.

4. The intelligent sewing thread quality detection system according to claim 1, characterized in that: The specific analysis of the tensile strength of sewing thread is: The sewing thread segment to be tested is installed in a tensile testing machine, and a fixed tension rate is set; the tensile strength of the sewing thread segment to be tested is calculated based on the maximum tension before the sewing thread segment breaks; a standard tensile strength threshold is set, and the tensile strength of the sewing thread segment to be tested is compared and analyzed with the set standard tensile strength threshold. When the tensile strength of the sewing thread segment to be tested is greater than or equal to the set standard tensile strength threshold, the quality is qualified; when the tensile strength of the sewing thread segment to be tested is less than the set standard tensile strength threshold, the quality is unqualified, the sewing thread segment is marked, and sent to the feedback warning module.

5. The intelligent sewing thread quality detection system according to claim 1, characterized in that: The specific analysis of the elastic modulus and recovery rate of sewing thread is: Install the sewing thread segment to be tested into the clamping device of the tensile testing machine to obtain stress and strain data of the sewing thread segment to be tested; normalize the stress and strain values ​​of the sewing thread segment to be tested to obtain the elastic modulus of the sewing thread segment to be tested; and obtain the initial length of the sewing thread segment to be tested; Obtain the length after stretching and the recovery length after compression of the sewing line segment to be detected; normalize the values ​​of the initial length, the length after stretching and the recovery length after compression of the sewing line segment to be detected to obtain the recovery rate of the sewing line segment to be detected; set an elastic modulus standard threshold, and compare and analyze the elastic modulus of the sewing line segment to be detected with the set elastic modulus standard threshold; when the elastic modulus of the sewing line segment to be detected is greater than or equal to the set elastic modulus standard threshold, it means that the elastic performance of the sewing line segment to be detected is qualified; when the elastic modulus of the sewing line segment to be detected is less than the set elastic modulus standard threshold, it means that the elastic performance of the sewing line segment to be detected is insufficient and the quality is unqualified, and the unqualified sewing line segment to be detected is marked and sent to the feedback warning module; A recovery standard threshold is set, and the recovery rate of the sewing line segment to be detected is compared and analyzed with the set recovery standard threshold; when the recovery rate of the sewing line segment to be detected is greater than or equal to the set recovery standard threshold, the quality is qualified; when the recovery rate of the sewing line segment to be detected is less than the set recovery standard threshold, the quality is unqualified, and the unqualified sewing line segment to be detected is marked and sent to the feedback warning module.

6. The intelligent sewing thread quality detection system according to claim 1, characterized in that: The specific analysis of the wear resistance of sewing thread is: The sewing thread segment to be tested is placed in a friction and wear testing machine, and a wear test is performed by friction for a certain period of time; the length of the sewing thread segment to be tested before the test and the length after the test are obtained; the values ​​of the length of the sewing thread segment to be tested before the test and the length after the test are normalized to obtain the wear degree of the sewing thread segment to be tested; a wear degree standard threshold is set, and the wear degree of the sewing thread segment to be tested is compared and analyzed with the set wear degree standard threshold; when the wear degree of the sewing thread segment to be tested is less than or equal to the set wear degree standard threshold, it indicates that the wear resistance of the sewing thread segment to be tested is qualified; when the wear degree of the sewing thread segment to be tested is greater than the set wear degree standard threshold, it indicates that the wear resistance of the sewing thread segment to be tested is unqualified, and the sewing thread segment to be tested with unqualified wear resistance is marked and sent to the feedback warning module.

7. The intelligent sewing thread quality detection system according to claim 1, characterized in that: Feedback and warning are as follows: Mark the unqualified data and generate real-time feedback records, including the unqualified items, production batches, serial numbers of sewing thread segments and defect types; generate warning information for unqualified sewing thread segments and send it to operators, production managers and quality control personnel; operators adjust the production process in a timely manner based on the warning information, mark or isolate unqualified sewing threads to prevent them from entering the next stage or flowing into the market; Feedback information is updated to the quality management system in a timely manner for management personnel to track and review; different warning levels are set to determine whether emergency processing is required based on the degree of non-conformity.

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