Garment fabric production printing and dyeing process monitoring control system

Abstract

The invention discloses a garment fabric production printing and dyeing process monitoring and control system, and relates to the technical field of printing and dyeing monitoring, the garment fabric production printing and dyeing process monitoring and control system comprises a data acquisition module, a processing module and an execution module, the data acquisition module comprises a plurality of monitoring units, and the monitoring units are distributed in a working area of printing and dyeing equipment and are arranged at positions of different heights; a plurality of monitoring units are configured on each height level of the working area; each monitoring unit divides the working area into a plurality of monitoring areas. Multi-layer and multi-point monitoring units are arranged in the printing and dyeing equipment, dye temperature, flow velocity and concentration data are collected in real time, the data consistency and the anti-jamming capability are improved in cooperation with the preprocessing and normalization technology, the processing module can call historical calibration data based on the process conditions, and the accuracy of calibration is improved. And performing difference comparison and trend analysis on the data of each monitoring area.

Description

Technical Field

[0001] The present invention relates to the technical field of printing and dyeing monitoring, and particularly to a monitoring and control system for the printing and dyeing process of clothing fabric production. Background Art

[0002] In current clothing fabric production, the printing and dyeing process often requires continuous or alternating processing of multiple batches of fabric, and there are differences in the models, process parameters, working area structures, etc. of the printing and dyeing equipment used. The differences between different batches and different equipment make it difficult to uniformly control key process parameters such as dye temperature, flow rate, and concentration, resulting in difficulties in ensuring the dyeing uniformity, color consistency, and quality stability of each batch of fabric. Especially under mass production conditions, the consistency of fabric processing quality directly affects the overall shipping efficiency and finished product yield.

[0003] Existing technologies usually only perform local data monitoring and passive adjustment for single-machine and single-batch fabric, lacking a mechanism for unified standardized management of different printing and dyeing equipment under multi-batch processing processes. In practical applications, the height distributions of the processing areas of different equipment are different, and there are also slight differences in the physical properties such as dye flow, heating, and replenishment.

[0004] After retrieval, Chinese Patent (Publication No.: CN118655940B) discloses an on-line monitoring and control system for printing and dyeing process parameters. The patent includes a time control unit, a dye solution control unit, a temperature control unit, a raw material judgment unit, a product judgment unit, and an on-line supervision and control platform; during the printing and dyeing process, by identifying and classifying the products to be printed and dyed, the printing and dyeing process is automatically obtained according to the database. After the printing and dyeing is completed, quality inspection and confirmation are performed on the printed and dyed products, and the printing and dyeing control parameters are traced and analyzed according to the results of the quality inspection and confirmation.

[0005] In the existing technology, the current quality inspection methods for fabric after dyeing mainly focus on single sampling or large-scale fixed detection, and fail to combine the process characteristics of different height intervals during the processing of multiple equipment for dynamic detection and quality feedback control. Therefore, standardizing the printing and dyeing parameters at the unified processing height for multiple batches of fabric and multiple equipment, and having the ability of full-process dynamic monitoring and control compensation is one of the research and development directions. Furthermore, the present application proposes a monitoring and control system for the printing and dyeing process of clothing fabric production. Summary of the Invention

[0006] The purpose of the present invention is to provide a monitoring and control system for the printing and dyeing process of clothing fabric production to solve the problems mentioned in the above background art.

[0007] The present invention can be realized through the following technical solutions: A monitoring and control system for the printing and dyeing process of clothing fabric production includes a data acquisition module, a processing module, and an execution module;

[0008] The execution module includes a plurality of dye heating units, a plurality of dye acceleration units, and a dye addition unit;

[0009] Each dye heating unit and each acceleration unit are evenly distributed in the working area of the printing and dyeing equipment, and the dye addition unit can adjust its height in the working area as needed;

[0010] The data acquisition module includes a plurality of monitoring units. Each monitoring unit is distributed in the working area of the printing and dyeing equipment and is set at different heights. And at each height level in the working area, a plurality of monitoring units are configured, so as to divide the working area in the printing and dyeing equipment into a plurality of monitoring areas. And the corresponding monitoring units at different height levels are located on the same axis, that is, a plurality of monitoring units are finally arranged in a plurality of vertical and horizontal settings;

[0011] Each monitoring unit is set with corresponding coordinate information and is used to obtain the printing and dyeing parameters of the dye at the corresponding position. Specifically, the printing and dyeing parameters include dye temperature data, dye flow rate data, and dye concentration data;

[0012] And after each monitoring unit obtains the dye temperature data, dye flow rate data, and dye concentration data of the dye at the corresponding position;

[0013] After the processing module collects the dye temperature data, dye flow rate data, and dye concentration data of each monitoring area, it preprocesses them;

[0014] And the processing module retrieves the corresponding calibration data from the historical database based on printing and dyeing conditions such as the model of the printing and dyeing equipment, the printing and dyeing process, and the printing and dyeing fabric. The calibration data specifically includes historical dye temperature data, historical dye flow rate data, and historical dye concentration data that meet the requirements for the final fabric dyeing based on the corresponding printing and dyeing conditions;

[0015] The processing module calculates the dye temperature data, dye flow rate data, and dye concentration data at the same height after preprocessing respectively, and judges whether the differences between the dye temperature data, dye flow rate data, and dye concentration data in different monitoring areas at the same height are within the preset corresponding parameter difference thresholds. The corresponding parameter difference thresholds include the dye temperature data difference threshold, the dye flow rate data difference threshold, and the dye concentration data difference threshold. When comparing, each item of data is compared with the corresponding difference threshold respectively;

[0016] When any one of the dye temperature data, dye flow rate data, or dye concentration data in the monitoring area exceeds its corresponding parameter difference threshold, the processing module marks the monitoring area as a suspicious area. At the same time, the processing module calculates the average value of the temperature data, dye flow rate data, or dye concentration data that do not exceed the corresponding difference threshold, and uses it as the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at the corresponding height.

[0017] Subsequently, the processing module compares the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at the corresponding height with their corresponding calibration data respectively to determine whether the dye temperature, dye flow rate, and dye concentration in the working area at this height are normal, that is, whether the difference between the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data and the corresponding historical dye temperature data, historical dye flow rate data, and historical dye concentration data in the calibration data exceeds the preset fluctuation threshold.

[0018] When one or more of the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas except the abnormal area at this height are abnormal, the execution module performs a correction operation on the working area at the corresponding height of the working area.

[0019] When the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas except the abnormal area at this height are all normal, the processing module calculates the working areas at the remaining heights, and the logic is the same as that of the working area at this height, to determine whether there is an abnormal area and whether the dye temperature, dye flow rate, and dye concentration in the working area are normal.

[0020] The processing module marks each monitoring area marked as a suspicious area (that is, the monitoring area where the dye temperature, flow rate, or concentration exceeds the corresponding parameter difference threshold) as a marginal point, and generates a corresponding detection area based on the coordinate information of the monitoring unit corresponding to the monitoring area. Subsequently, the processing module calculates the proportion of the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas in the detection area that are lower than the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at their corresponding heights respectively. If the proportion of a certain item is lower than its preset proportion threshold, the processing module determines that the dye temperature, dye flow rate, or dye concentration in the detection area is abnormal, and then the dye heating unit, dye acceleration unit, or dye addition unit corresponding to the detection area is started to correct the dye temperature, dye flow rate, or dye concentration in the detection area.

[0021] A further technical improvement of the present invention lies in: the method for generating the detection area includes:

[0022] S1. The processing module checks the coordinate information of each monitoring point and records the coordinates of the monitoring unit marked as a suspicious area ;

[0023] S2. Select the two farthest marginal points to determine the detection area. The specific steps include:

[0024] Calculate the angular difference of all marginal points. For any two marginal points and , calculate their angular difference , . If the angular difference is greater than π, then select the shortest angular difference, that is, select the counterclockwise or clockwise path: ;

[0025] Use the Euclidean distance formula to calculate the distance between marginal points and :

[0026] ; where and are the radii of the two marginal points respectively, and are the angles of the two marginal points respectively;

[0027] Select the two farthest marginal points, that is, and with the largest distance between them. The two marginal points represent the focus points of the detection area respectively;

[0028] S3. Based on the coordinates and of the two farthest marginal points, generate the boundary of the detection area, including:

[0029] Height calculation: For the two selected marginal points and , calculate the vertical height difference between them to determine the Y-axis range of the detection area , where , ; and are the heights of the two marginal points respectively;

[0030] Angle range calculation: According to the angular difference of the two marginal points, determine the angular range of the detection area (i.e., the horizontal range when the working area is circular);

[0031] S4. According to the boundary of the detection area, generate the coordinate range of the detection area.

[0032] A further technical improvement of the present invention is that when the execution module performs a correction operation, the processing module records the following working information:

[0033] Power data (data of the equipment in the execution module that specifically adjusts the dye temperature, dye flow rate, or dye concentration during operation);

[0034] Adjusted dye temperature, dye flow rate, and dye concentration;

[0035] Corresponding working height: Record the working height of the execution module in the printing and dyeing equipment;

[0036] First timestamp: Record the timestamp when the execution module starts the adjustment operation, which is the reference time required for subsequent calculation of delay;

[0037] Subsequently, the processing module records the time when the monitoring unit in the corresponding area monitors that the corresponding items reach the normal data, that is, the difference values between the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data and the corresponding historical dye temperature data, historical dye flow rate data, and historical dye concentration data in the calibration data are within the preset fluctuation threshold, and records this time as the second timestamp;

[0038] The processing module obtains the working delay time of the execution module under this working information based on the difference between the second timestamp and the first timestamp;

[0039] And the processing module classifies this working delay time as normal delay or abnormal delay based on the detection result of fabric dyeing;

[0040] If it is a normal delay, record the working information of this execution module as available data and record it in the database as reference data for subsequent same working tasks;

[0041] If it is an abnormal delay, use the working information of this execution module to correct the available data in the database.

[0042] A further technical improvement of the present invention lies in that the monitoring and control system includes an inspection module for detecting the quality of the fabric after dyeing to obtain the detection result of the corresponding fabric dyeing. The specific steps include:

[0043] Y1. Divide the surface of the fabric to be detected into multiple recognition ranges according to its height during processing in the printing and dyeing equipment, that is, the height of each recognition range corresponds to each height level of the working area in the printing and dyeing equipment, ensuring that subsequent detection can be analyzed in combination with processing conditions;

[0044] Y2. Randomly select k detection parts in each recognition range, and its set is , and when selecting, the detection parts are evenly distributed within the recognition range to ensure coverage of different positions;

[0045] Y3. Subsequently, the inspection module first performs flatness detection on each detection part;

[0046] Y4. For the detected part that passes the flatness detection, detect the color difference between it and the preset reference color , ; where L, a, and b are the color parameters of the detected part; , , are the color parameters of the preset reference color; L is the brightness, a is the red - green axis value; b is the yellow - blue axis value;

[0047] When the color difference is not greater than the preset color difference allowable threshold, the inspection module determines that the color difference of the detected part is qualified.

[0048] A further technical improvement of the present invention is that: in step Y2, if more than a preset proportion of the randomly selected k detected parts fail the flatness, the detection module divides the initial range into small ranges equally on the basis of, that is ;

[0049] If there are still unqualified items exceeding the preset proportion in the reduced detection, the detection range is reduced again.

[0050] A further technical improvement of the present invention is that: for the continuously collected monitoring dye temperature data, monitoring dye flow rate data, and monitoring dye concentration data, according to their time series, the processing module calculates the change rate of each printing and dyeing parameter , for example, for any printing and dyeing parameter X (including dye temperature, dye flow rate, and dye concentration), the formula used is ; where is the monitored value of the printing and dyeing parameter corresponding to the current moment; is the monitored value of the corresponding printing and dyeing parameter at the previous moment;

[0051] And the processing module determines whether the change rate of the corresponding printing and dyeing parameter continuously changes in a single direction (continuously rising or continuously falling) exceeding the set continuity period threshold V, that is:

[0052] , if the change direction is the same for V consecutive times, it is determined as a continuous change;

[0053] Subsequently, the processing module reads the historical working delay time D under this working information, and calculates the current moment t, and estimates the abnormal arrival time , and starts the execution module D time in advance;

[0054] Specifically, the calculation method of the abnormal arrival time is to use the change rate Based on this, through the formula Calculate the time required for an anomaly to arrive Then the anomaly arrival time is ; In the formula is the preset anomaly threshold for the corresponding printing and dyeing parameter; is the monitored value of the corresponding printing and dyeing parameter at the current moment;

[0055] When the continuous change of the corresponding printing and dyeing parameter holds, and the predicted anomaly time of this printing and dyeing parameter minus the delay time is less than the current moment (i.e., immediate compensation is required), then:

[0056] Start the dye heating unit to increase the dye temperature;

[0057] Start the dye acceleration unit to increase the dye flow rate;

[0058] Start the dye addition unit to supplement the dye concentration.

[0059] Compared with the prior art, the present invention has the following beneficial effects:

[0060] By arranging multi-level and multi-point monitoring units inside the printing and dyeing equipment, the present invention can collect data on dye temperature, flow rate, and concentration in real time. Combining with pretreatment and normalization techniques, it improves data consistency and anti-interference ability. The processing module can call historical calibration data based on process conditions, conduct difference comparison and trend analysis on the data in each monitoring area, accurately identify potential abnormal areas, and automatically start the heating, acceleration, and addition units for local correction according to the degree of anomaly, significantly improving the uniformity and stability of dye distribution;

[0061] And the present invention introduces a working delay time compensation mechanism. Based on the extrapolation prediction of the continuous change trend, it activates the execution module in advance for compensation control, avoiding the problem of reduced dyeing quality caused by response lag in the traditional method. At the same time, by dynamically recording the working information of the execution module and classifying abnormal delays, the present invention can perform boundary correction and quality optimization on historical available data, establishing a self-learning and self-correcting data management system, providing a higher-reliability data reference for subsequent printing and dyeing tasks;

[0062] On the other hand, the present invention is also provided with an inspection module, which combines the process height during production to sample and detect the flatness and color difference indicators of the fabric in different areas, and has an automatic scaling detection range mechanism based on the detection failure ratio, so as to realize the refined and dynamic detection of the fabric dyeing quality. Through the linkage analysis of the fabric detection results and the printing and dyeing process monitoring data, the present invention constructs a complete production-detection-correction closed loop, greatly improving the consistency of printing and dyeing products and the overall production efficiency. Description of the Drawings

[0063] For the convenience of those skilled in the art to understand, the present invention will be further described below in conjunction with the accompanying drawings.

[0064] Figure 1 is the system block diagram of the present invention;

[0065] Figure 2 is the system schematic diagram of the present invention;

[0066] Figure 3 is the schematic diagram of the processing module in the present invention. Specific Embodiments

[0067] To further elaborate on the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the following will describe in detail the specific embodiments, structures, features and their effects of the present invention in conjunction with the accompanying drawings and preferred embodiments.

[0068] Embodiment 1

[0069] Inside the dyeing equipment, the dye liquid is not in a homogeneous static state, but shows certain fluidity, temperature gradient and concentration difference. Especially in continuous dyeing or vertically arranged equipment, due to different heat source positions, liquid circulation directions or dye addition points at different height levels, there are local parameter fluctuations in the dye, which in turn leads to inconsistent dyeing effects of the fabric in the vertical direction;

[0070] Therefore, please refer to Figure 1-2 As shown, the present invention provides a monitoring and control system for the dyeing process of clothing fabrics, including a data acquisition module, a processing module and an execution module, which are used for the fabric dyeing process using common continuous or intermittent dyeing methods in industry. After the fabric enters the dyeing equipment, it is unfolded through a tensioning device and kept in a flat or vertically suspended state, and passes through a padding, spraying or padding structure in the "working area" inside the equipment in turn, fully contacting with the dye liquid, and then completing the dyeing process through processes such as steaming, washing and drying. The "working area" is the physical area where the dye contacts and acts on the fabric and completes the dyeing reaction. The monitoring and regulation structure in the present invention is arranged in this working area;

[0071] The execution module includes a plurality of dye heating units, a plurality of dye accelerating units and a dye adding unit;

[0072] Each dye heating unit and each accelerating unit are evenly distributed in the working area of the dyeing equipment, and the dye adding unit can adjust the height according to needs;

[0073] The data acquisition module includes multiple monitoring units. Each monitoring unit is distributed in the working area of the printing and dyeing equipment and is set at different heights. Moreover, at each height level in the working area, multiple monitoring units are configured, thereby dividing the working area inside the printing and dyeing equipment into multiple monitoring areas. And multiple corresponding monitoring units at different height levels are located on the same axis, that is, multiple monitoring units are finally arranged in multiple vertical and horizontal settings;

[0074] In the printing and dyeing process, especially in continuous vertical printing and dyeing equipment or vertical fabric printing and dyeing equipment, the fabric passes through the working area of the printing and dyeing equipment in a vertically suspended or tensioned state. Since the dye is in a dynamic circulation, spraying or overflow state inside the equipment, affected by the equipment structure, heating source distribution, dye inlet and liquid power direction, there are spatial differences in the temperature, flow rate and concentration of the dye at different height positions. If this difference is not monitored and adjusted, it is very easy to cause deviations in the dyeing depth, color difference and reaction adequacy of the upper and lower parts of the fabric, affecting the consistency of the finished product quality;

[0075] Therefore, the present invention sets multiple detection units at different heights in the working area of the printing and dyeing equipment to collect the dye temperature, dye flow rate and dye concentration data of each height level in real time. These data can form a printing and dyeing parameter matrix divided by height levels, and the processing module judges whether there are:

[0076] Parameter consistency problems between different heights;

[0077] Local anomalies between different positions at the same height;

[0078] Overall trend changes (such as concentration decrease, flow rate lag, etc.);

[0079] Each monitoring unit is set with corresponding coordinate information and is used to obtain the dye temperature data, dye flow rate data and dye concentration data of the dye at the corresponding position;

[0080] And after each monitoring unit obtains the dye temperature data, dye flow rate data and dye concentration data of the dye at the corresponding position, it uploads them to the processing module;

[0081] After the processing module collects the dye temperature data, dye flow rate data and dye concentration data of each monitoring area, it preprocesses them, including data cleaning, denoising and normalization, to ensure the consistency of each data and eliminate data fluctuations caused by sensor errors or environmental changes;

[0082] And the processing module retrieves the corresponding calibration data from the historical database based on printing and dyeing conditions such as the model of the printing and dyeing equipment, printing and dyeing process and printing and dyeing fabric. The calibration data specifically includes the historical dye temperature data, historical dye flow rate data and historical dye concentration data that meet the requirements for the final fabric dyeing based on the corresponding printing and dyeing conditions;

[0083] The processing module calculates the dye temperature data, dye flow rate data, and dye concentration data at the same height after preprocessing respectively, and determines whether the differences between the dye temperature data, dye flow rate data, and dye concentration data in different monitoring areas at the same height are within the preset corresponding parameter difference thresholds. The corresponding parameter difference thresholds include the dye temperature data difference threshold, the dye flow rate data difference threshold, and the dye concentration data difference threshold. When comparing, each item of data is compared with the corresponding difference threshold respectively;

[0084] When any one of the dye temperature data, dye flow rate data, or dye concentration data in the intermediate material monitoring area exceeds its corresponding parameter difference threshold, the processing module marks this monitoring area as a suspicious area. At the same time, the processing module calculates the average value of the remaining temperature data, dye flow rate data, or dye concentration data that do not exceed the corresponding difference threshold as the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at the corresponding height;

[0085] Subsequently, the processing module compares the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at the corresponding height with their corresponding calibration data respectively to determine whether the dye temperature, dye flow rate, and dye concentration in the working area at this height are normal, that is, whether the differences between the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data and the corresponding historical dye temperature data, historical dye flow rate data, and historical dye concentration data in the calibration data exceed the preset fluctuation threshold;

[0086] When one or more of the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas except the abnormal area at this height are abnormal, the execution module performs a correction operation on the working area corresponding to this height of the working area;

[0087] For example, when the dye temperature at the corresponding height of the working area is too low, start the dye heating unit, and adjust the power of the heating unit according to the feedback dye temperature data to raise the temperature of this area to the predetermined standard;

[0088] If the dye temperature at the corresponding height of the working area is too low, then reduce the power of the heating unit;

[0089] For the area where the dye flow rate is too slow, start the dye acceleration unit (such as increasing the pump speed or adjusting the liquid flow path) to increase the dye flow rate in this area; for the area where the dye flow rate is too fast, adjust the pump speed, reduce the output power of the acceleration unit, or use a flow rate regulating valve to reduce the dye flow rate to ensure uniform liquid flow rate;

[0090] If the dye concentration at the height corresponding to the working area is low, the dye addition unit is activated. According to the concentration difference in this area, the working height of the dye addition unit is adjusted, and the dye solution is added to this area until the concentration reaches the set standard; for areas with too high concentration, the system adjusts the concentration of the dye solution to the normal range through an automatic dilution mechanism, and the system can add an appropriate amount of solvent to this area to dilute the dye solution to ensure uniform concentration;

[0091] When the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas except the abnormal areas at this height are all normal, the processing module calculates the working areas at the remaining heights, and the logic is the same as that of the working area at this height, to determine whether there are abnormal areas and whether the dye temperature, dye flow rate, and dye concentration in the working area are normal;

[0092] The processing module marks the monitoring areas marked as suspicious areas (i.e., the monitoring areas where the dye temperature, flow rate, or concentration exceeds the corresponding parameter difference threshold) as marginal points, and based on the coordinate information of the monitoring units corresponding to the monitoring areas, generates corresponding detection areas. Subsequently, the processing module calculates the ratios of the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas in the detection area that are lower than the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at their corresponding heights respectively. If the ratio of a certain item is lower than its preset ratio threshold, the processing module determines that the dye temperature, dye flow rate, or dye concentration in the detection area is abnormal, and then the dye heating unit, dye acceleration unit, or dye addition unit corresponding to the detection area is activated to correct the dye temperature, dye flow rate, or dye concentration in the detection area;

[0093] The method for generating a detection area includes:

[0094] S1. The processing module checks the coordinate information of each monitoring point and records the coordinates of the monitoring units marked as suspicious areas ;

[0095] S2. Select the two farthest marginal points to determine the detection area. The specific steps include:

[0096] Calculate the angular differences of all marginal points. For any two marginal points and , calculate their angular difference , , if the angular difference is greater than π, then select the shortest angular difference, that is, select the counterclockwise or clockwise path: ;

[0097] Use the Euclidean distance formula to calculate the distance between the marginal points and :

[0098] ; wherein, and are respectively the radii of two marginal points, and are respectively the angles of two marginal points;

[0099] Select the two farthest marginal points, that is, and the two marginal points with the largest distance between them, and the two marginal points respectively represent the focal points of the detection area;

[0100] S3. Based on the coordinates and of the two farthest marginal points, generate the boundary of the detection area, including:

[0101] Height calculation: For the two selected marginal points and [[ID=(30)]] calculate the vertical height difference between them to determine the Y-axis range of the detection area, where , ; and are respectively the heights of the two marginal points;

[0102] Angle range calculation: According to the angle difference of the two marginal points, determine the angle range of the detection area (i.e., the horizontal range when the working area is circular);

[0103] S4. According to the boundary of the detection area, generate the coordinate range of the detection area.

[0104] When the execution module performs the correction operation, the processing module records the following working information:

[0105] Power data (data of the equipment in the execution module that specifically adjusts the dye temperature, dye flow rate, or dye concentration during operation);

[0106] Adjusted dye temperature, dye flow rate, and dye concentration;

[0107] Corresponding working height: Record the working height of the execution module in the printing and dyeing equipment;

[0108] First timestamp: Record the timestamp when the execution module starts to perform the adjustment operation, and this timestamp is the reference time required for subsequent calculation of the delay;

[0109] Subsequent processing module records the time when the monitoring unit in the corresponding area monitors that the corresponding item reaches the normal data, that is, the difference values between the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data and the corresponding historical dye temperature data, historical dye flow rate data, and historical dye concentration data in the calibration data are within the preset fluctuation threshold, and records this time as the second timestamp;

[0110] Based on the difference between the second timestamp and the first timestamp, the processing module obtains the working delay time of the execution module under this working information;

[0111] And the processing module classifies this working delay time as normal delay or abnormal delay based on the detection result of fabric dyeing;

[0112] If it is a normal delay, record the working information of this execution module as available data and record it in the database as reference data for subsequent same work tasks;

[0113] If it is an abnormal delay, use the working information of this execution module to correct the available data in the database;

[0114] Specifically, correcting the available data in the database includes but is not limited to:

[0115] Obtain normal available data from the database. These data are the working data of the equipment verified in historical tasks, including but not limited to: power data, heating time, adjustment rate, etc.;

[0116] Set the maximum and minimum boundaries of the power data through the working information of this execution module (such as power adjustment). If the power data in the database exceeds the adjustment range of this time, perform constraint correction;

[0117] Similarly, constrain the historical heating time in the database to ensure that it does not exceed the heating time range adjusted this time;

[0118] If the historical data in the database (such as power, heating time, adjustment rate) exceeds the maximum and minimum boundaries adjusted by this equipment, perform correction to ensure that the historical data is within the adjustment range of the equipment.

[0119] The monitoring and control system includes an inspection module for detecting the quality of the fabric after dyeing to obtain the detection result of the corresponding fabric dyeing. The specific steps include:

[0120] Y1. Divide the surface of the fabric to be detected into multiple identification ranges according to its height during processing in the printing and dyeing equipment, that is, the height of each identification range corresponds to each height level of the working area in the printing and dyeing equipment, ensuring that subsequent detection can be analyzed in combination with processing conditions;

[0121] For example, the total height of the working area is H, and the fabric is divided into n segments along the height direction, and the height range of each segment is as follows:

[0122] , and i = 1, 2,..., n; where H is the height of the fabric, which usually corresponds to the height of the working area of the printing and dyeing equipment; n is the number of divided segments; i is the number of the current recognition range; represents the upper and lower height intervals of the i-th recognition range; for example, if the total height is 100 cm and n = 5, the height range of the third segment is [40, 60] cm;

[0123] Y2. In each recognition range, randomly select k detection parts, and the set is , and when selecting, the detection parts are evenly distributed within the recognition range to ensure coverage of different positions;

[0124] Y3. Subsequently, the inspection module first performs flatness detection on each detection part. In this embodiment, the detection module performs detection based on structured light, and it passes the formula ; where: is the flatness deviation of the j-th detection part; is the height at the detection point u; is the average height of the j-th detection part;

[0125] When is not greater than the preset flatness threshold, the inspection module determines that the detection part is flat and proceeds to the next color difference detection;

[0126] Y4. For the detection parts that pass the flatness detection, detect the color difference between them and the preset reference color , ; where L, a, and b are the color parameters of the detection part; , , are the color parameters of the preset reference color; L is the brightness, a is the red-green axis value; b is the yellow-blue axis value;

[0127] When the color difference is not greater than the preset allowable color difference threshold, the inspection module determines that the color difference of the detection part is qualified.

[0128] In step Y2, if more than the preset proportion of the randomly selected k detection parts do not pass the flatness, the detection module divides the initial range into small ranges equally, that is , for example, in this embodiment, it is divided into 2 times finer on the basis of the initial range;

[0129] If there are still non-conforming items exceeding the preset ratio in the reduced inspection, the inspection range is reduced again;

[0130] If there are still a large number of non-conforming items after n times of reduction, it can be determined that there are obvious dyeing quality problems in this area, and a warning or non-conforming flag is output.

[0131] Embodiment 2

[0132] A monitoring and control system for the printing and dyeing process of clothing fabrics includes a data acquisition module, a processing module, and an execution module;

[0133] The execution module includes multiple dye heating units, multiple dye acceleration units, and a dye addition unit;

[0134] Each dye heating unit and each acceleration unit are evenly distributed in the working area of the printing and dyeing equipment, and the height of the dye addition unit can be adjusted as needed;

[0135] The data acquisition module includes multiple monitoring units, which are distributed in the working area of the printing and dyeing equipment and are set at different heights. And at each height level in the working area, multiple monitoring units are configured, so as to divide the working area in the printing and dyeing equipment into multiple monitoring areas. And the multiple corresponding monitoring units at different height levels are on the same axis, that is, multiple monitoring units are finally arranged in multiple vertical and horizontal settings;

[0136] Each monitoring unit is set with corresponding coordinate information and is used to obtain the dye temperature data, dye flow rate data, and dye concentration data of the dye at the corresponding position;

[0137] And after each monitoring unit obtains the dye temperature data, dye flow rate data, and dye concentration data of the dye at the corresponding position, it adds a time stamp to them and uploads them to the processing module;

[0138] After the processing module collects the dye temperature data, dye flow rate data, and dye concentration data of each monitoring area, it preprocesses them;

[0139] And the processing module retrieves the corresponding calibration data from the historical database based on the printing and dyeing conditions such as the model of the printing and dyeing equipment, the printing and dyeing process, and the printing and dyeing fabric. The calibration data specifically includes the historical dye temperature data, historical dye flow rate data, and historical dye concentration data for which the final fabric dyeing meets the requirements based on the corresponding printing and dyeing conditions;

[0140] The processing module calculates the dye temperature data, dye flow rate data, and dye concentration data at the same height after preprocessing respectively, and judges whether the differences between the dye temperature data, dye flow rate data, and dye concentration data in different monitoring areas at the same height are within the preset corresponding parameter difference threshold range;

[0141] When any one of the dye temperature data, dye flow rate data, or dye concentration data in the SINOMA monitoring area exceeds its corresponding parameter difference threshold, the processing module marks the monitoring area as a suspicious area. At the same time, the processing module calculates the average value of the temperature data, dye flow rate data, or dye concentration data that do not exceed the corresponding difference threshold, and uses it as the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at the corresponding height.

[0142] Subsequently, the processing module compares the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at the corresponding height with their corresponding calibration data respectively to determine whether the dye temperature, dye flow rate, and dye concentration in the working area at this height are normal, that is, whether the difference between the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data and the corresponding historical dye temperature data, historical dye flow rate data, and historical dye concentration data in the calibration data exceeds the preset fluctuation threshold.

[0143] When one or more of the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas except the abnormal area at this height are abnormal, the execution module performs a correction operation on the working area corresponding to this height of the working area.

[0144] When the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas except the abnormal area at this height are all normal, the processing module calculates the working area of the remaining heights, and the logic is the same as that of the working area at this height, and determines whether there is an abnormal area and whether the dye temperature, dye flow rate, and dye concentration in the working area are normal.

[0145] The processing module marks each monitoring area marked as a suspicious area (that is, the monitoring area where the dye temperature, flow rate, or concentration exceeds the corresponding parameter difference threshold) as a marginal point, and generates a corresponding detection area based on the coordinate information of the monitoring unit corresponding to the monitoring area. Subsequently, the processing module calculates the ratio of the dye temperature, dye flow rate, and dye concentration in the remaining monitoring areas in the detection area that are lower than the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data at their corresponding heights respectively. If the ratio of a certain item is lower than its preset ratio threshold, the processing module determines that the dye temperature, dye flow rate, or dye concentration in the detection area is abnormal, and then the dye heating unit, dye acceleration unit, or dye addition unit corresponding to the detection area is started to correct the dye temperature, dye flow rate, or dye concentration in the detection area.

[0146] When the execution module performs a correction operation, the processing module records the following working information:

[0147] Power data (data of the equipment in the execution module that specifically adjusts the dye temperature, dye flow rate, or dye concentration during operation);

[0148] Adjusted dye temperature, dye flow rate, and dye concentration;

[0149] Corresponding working height: Record the working height of the execution module in the printing and dyeing equipment;

[0150] First timestamp: Record the timestamp when the execution module starts the adjustment operation. This timestamp is the reference time required for subsequent calculation of the delay;

[0151] Subsequently, the processing module records the time when the monitoring unit in the corresponding area monitors that the corresponding item reaches the normal data, that is, the difference values between the monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data and the corresponding historical dye temperature data, historical dye flow rate data, and historical dye concentration data in the calibration data are within the preset fluctuation threshold, and records this time as the second timestamp;

[0152] The processing module obtains the working delay time of the execution module under this working information based on the difference between the second timestamp and the first timestamp;

[0153] And the processing module classifies this working delay time as normal delay or abnormal delay based on the detection result of fabric dyeing;

[0154] If it is a normal delay, record the working information of this time of the execution module as available data and record it in the database as reference data for subsequent same working tasks;

[0155] If it is an abnormal delay, use the working information of this execution module to correct the available data in the database;

[0156] For the continuously collected monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data, according to their time series, the processing module calculates the change rate of each printing and dyeing parameter , for example, for any printing and dyeing parameter X (including dye temperature, dye flow rate, and dye concentration), the formula used is ; where is the monitored value of the corresponding printing and dyeing parameter at the current moment; is the monitored value of the corresponding printing and dyeing parameter at the previous moment;

[0157] And the processing module determines whether the change rate of the corresponding printing and dyeing parameter continuously changes in a single direction (continuously rising or continuously falling) exceeding the set continuity period threshold V, that is:

[0158] , if the change direction is the same for consecutive V times, it is considered a continuous change;

[0159] Subsequently, the processing module reads the historical working delay time D under this working information and calculates the expected abnormal arrival time at the current moment t , start the execution module D time in advance;

[0160] Specifically, the abnormal arrival time The calculation method is based on the change rate recognized as continuous change On the basis, through the formula Calculate the time required for the abnormality to reach , then the abnormal arrival time is ; In the formula is the preset abnormal threshold value of the corresponding printing and dyeing parameter; is the monitored value of the corresponding printing and dyeing parameter at the current moment;

[0161] Subsequently, the processing module calculates the start compensation time ;

[0162] When the continuous change of the corresponding printing and dyeing parameter is established, and the predicted abnormal time of the printing and dyeing parameter minus the delay time is less than the current moment (that is, immediate compensation is required), then:

[0163] Start the dye heating unit to increase the dye temperature;

[0164] Start the dye acceleration unit to increase the dye flow rate;

[0165] Start the dye addition unit to supplement the dye concentration.

[0166] The above is only a preferred embodiment of the present invention, and it is not intended to limit the present invention in any form. Although the present invention has been disclosed above with a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art can make some changes or modifications to the above-disclosed technical content within the scope of the technical solution of the present invention to make equivalent embodiments of equivalent changes. However, as long as it does not depart from the content of the technical solution of the present invention, any simple modification, equivalent change and modification made to the above embodiments based on the technical essence of the present invention still fall within the scope of the technical solution of the present invention.

Claims

1. A monitoring and control system for the printing and dyeing process of a clothing fabric, comprising a data acquisition module, a processing module, and an execution module, characterized in that: The data acquisition module includes multiple monitoring units, each monitoring unit is distributed at different heights in the working area of the printing and dyeing equipment, and multiple monitoring units are configured at each height level in the working area; Each monitoring unit divides the working area into multiple monitoring areas; Each monitoring unit is provided with corresponding coordinate information and is used to obtain the printing and dyeing parameters of the dye at the corresponding position. The parameter items of the printing and dyeing parameters include dye temperature data, dye flow rate data, and dye concentration data; After the processing module collects the printing and dyeing parameters of each monitoring area, it retrieves the calibration data of the corresponding printing and dyeing parameters from the historical database based on the printing and dyeing conditions; At the same time, the processing module calculates the printing and dyeing parameters at the same height respectively, and judges whether the difference between the printing and dyeing parameters in different monitoring areas at the same height is within the preset corresponding parameter difference threshold; When any parameter item in the printing and dyeing parameters exceeds its corresponding parameter difference threshold, the processing module marks the monitoring area as a suspicious area, and the processing module calculates the average value of the remaining printing and dyeing parameters as the monitoring printing and dyeing parameters at the corresponding height; Subsequently, the processing module compares the monitoring printing and dyeing parameters at the corresponding height with their corresponding calibration data respectively to judge whether the monitoring printing and dyeing parameters are normal; When any one or more parameter items of the printing and dyeing parameters in the remaining monitoring areas except the abnormal area at this height are abnormal, the execution module performs a correction operation on the working area at the corresponding height of the working area; When the printing and dyeing parameters in the remaining monitoring areas except the abnormal area at this height are all normal, the processing module calculates the working areas at the remaining heights; The processing module judges whether it is a marginal point according to the border relationship between the suspicious areas or its edge position in the coordinate system, and marks each eligible suspicious area as a marginal point; The processing module generates a closed detection area containing the marginal points based on the coordinate information of the marginal points and a preset spatial distribution template; The execution module calls the corresponding preset regulation strategy according to the position and abnormal type of the detection area, and performs a differential adjustment operation on the regulation nodes in the detection area for the printing and dyeing parameters.

2. The monitoring and control system for the production and printing and dyeing process of a clothing fabric according to claim 1, wherein, The execution module includes multiple dye heating units, multiple dye acceleration units, and a dye addition unit; Each dye heating unit and each acceleration unit are evenly distributed in the working area of the printing and dyeing equipment; The dye addition unit adjusts its height in the working area as needed.

3. The monitoring and control system for the production and printing and dyeing process of a clothing fabric according to claim 2, characterized in that, The calibration data includes historical dye temperature data, historical dye flow rate data, and historical dye concentration data that meet the requirements for the final fabric dyeing based on the corresponding printing and dyeing conditions; The monitoring printing and dyeing parameters include monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data; The judgment condition for whether the monitoring printing and dyeing parameters are normal is: Whether the difference between the monitored dye temperature data, monitored dye flow rate data, or monitored dye concentration data and the corresponding historical dye temperature data, historical dye flow rate data, or historical dye concentration data exceeds the preset fluctuation threshold; If it exceeds the preset fluctuation threshold, the corresponding parameter item is judged to be abnormal, otherwise it is judged to be normal.

4. A monitoring and control system for the production and printing and dyeing process of a clothing fabric according to claim 3, characterized in that, The processing module calculates the proportion of each monitoring area within the detection area where its printing and dyeing parameters are lower than its monitored printing and dyeing parameters; If the proportion of any one parameter item in the printing and dyeing parameters is lower than its preset proportion threshold, the processing module determines that the corresponding parameter item in the detection area is abnormal, and then the dye heating unit, dye acceleration unit, or dye addition unit in the corresponding area of the detection area is activated to correct the dye temperature, dye flow rate, or dye concentration in the detection area.

5. A monitoring and control system for the production and printing and dyeing process of a clothing fabric according to claim 4, characterized in that, Method for generating a detection area, including: S1. The processing module checks the coordinate information of each monitoring point and records the coordinates of the monitoring units marked as suspicious areas. ; S2. Select the two farthest marginal points to determine the detection area. The specific steps include: Calculate the angular difference for all marginal points. For any two marginal points and , calculate their angular difference , . If the angular difference is greater than π, then select the shortest angular difference; Use the Euclidean distance formula to calculate the marginal points and calculate the distance between them, and select the two farthest marginal points; S3. Based on the coordinates of the two farthest marginal points and , generate the boundary of the detection area, including: Height calculation: For the two selected marginal points and , calculate the vertical height difference between them to determine the Y-axis range of the detection area , where , ; and are the heights of the two marginal points respectively; Angle range calculation: Determine the angle range of the detection area based on the angle difference between two marginal points , and determine the angle range of the detection area ; S4. Generate the coordinate range of the detection area according to the boundary of the detection area .

6. The monitoring and control system for the printing and dyeing process of a clothing fabric production according to claim 4, wherein, When the execution module performs a correction operation, the processing module records the working information of the printing and dyeing equipment. The working information includes: Power data; Adjusted dye temperature, dye flow rate, and dye concentration; Corresponding working height: the working height of the execution module in the printing and dyeing equipment; First timestamp: the timestamp when the execution module starts to perform the adjustment operation; Second timestamp: the time point when the difference between the corresponding parameter item in the monitored printing and dyeing parameters and the calibration data monitored by the monitoring unit reaches within the preset fluctuation threshold; The processing module obtains the working delay time of the execution module under this working information based on the difference between the second timestamp and the first timestamp; And the processing module classifies this working delay time as normal delay or abnormal delay based on the detection result of the fabric dyeing; If it is a normal delay, the working information of the execution module for this time is recorded as available data and recorded in the database as reference data for subsequent same working tasks; If it is an abnormal delay, the working information of the execution module for this time is used to correct the available data in the database.

7. A monitoring and control system for the production and printing and dyeing process of a clothing fabric according to claim 5, characterized in that, The monitoring and control system includes an inspection module for detecting the quality of the fabric after dyeing to obtain the detection result of the corresponding fabric dyeing. The specific steps include: Y1. The surface of the fabric to be detected is correspondingly divided into multiple recognition ranges according to its height during processing in the printing and dyeing equipment; Y2. In each recognition range, randomly select k detection parts, and their set is ; Y3. Subsequently, the inspection module first performs a flatness detection on each detection part; Y4. For the detection parts that pass the flatness detection, detect the color difference between them and the preset reference color; When the color difference is not greater than the preset color difference allowable threshold, the inspection module determines that the color difference of this detection part is qualified.

8. A monitoring and control system for the production and printing and dyeing process of a clothing fabric according to claim 7, characterized in that, In step Y2, if more than a preset proportion of the randomly selected k detection parts fail to pass the flatness test, the detection module divides the initial range into equal small ranges , and .

9. A monitoring and control system for the production and printing and dyeing process of a clothing fabric according to claim 5, characterized in that, For the continuously collected monitored dye temperature data, monitored dye flow rate data, and monitored dye concentration data, according to their time series, the processing module calculates the change rate of each printing and dyeing parameter ; The processing module determines whether the change rate of the corresponding printing and dyeing parameters continuously changes in a single direction and exceeds the set continuity period threshold V; Subsequently, the subsequent processing module reads the historical work delay time D under this work information, and calculates the current time t and the expected abnormal arrival time , and starts the execution module D time in advance; When the continuity change of the corresponding printing and dyeing parameter holds, and the predicted abnormal time of the printing and dyeing parameter minus the historical working delay time D is less than the current time t, the execution module is started to perform a compensation operation.

10. The monitoring and control system for the production and printing and dyeing process of a clothing fabric according to claim 9, characterized in that, Abnormal arrival time The calculation method is as follows: Based on the change rate recognized as continuous change and through the formula calculate the time required for abnormal arrival ; Abnormal arrival time is ; where is the preset abnormal threshold corresponding to the printing and dyeing parameters; is the monitored value of the printing and dyeing parameters corresponding to the current moment.

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