Nondestructive testing system and method for ring spinning over 300 extra-high count yarns

Abstract

The invention relates to the field of yarn nondestructive testing, and provides a nondestructive testing system and method for ring spinning 300 or more extra-high count yarns, and the system comprises infrared photoelectric sensing modules which are used for transmitting infrared rays with a preset wavelength to the surface of a steel collar ring at a preset elevation angle by using each gated infrared photoelectric module, receiving infrared light reflected by the steel collar ring when the steel wire ring rotates along the steel collar ring, and converting the light intensity of the infrared light into an electric signal; the multi-channel parallel capture module is used for carrying out spindle speed parallel estimation by combining ADC sampling through a multi-channel capture strategy and a low-power-consumption optimization strategy, and judging the current yarn state; the comparator threshold value self-adaption module is used for dynamically adjusting the threshold value of the comparator through a self-adaption threshold value strategy; and the light intensity self-adaptive regulation and control module is used for adjusting the emission light intensity of the infrared photoelectric module through a light intensity self-adaptive regulation and control strategy in combination with PWM output. According to the invention, real-time accurate identification and early warning of yarn abnormity can be realized.

Description

Technical Field

[0001] This disclosure relates to the field of non-destructive testing technology for yarns, and in particular to a non-destructive testing system and method for ring-spun yarns of 300 count and above. Background Technology

[0002] Ring spinning is a classic mechanical spinning method that plays an important role in the textile industry. Its key process steps include: First, the fiber sliver is drafted using a roller device. By precisely controlling the speed and pressure of the rollers, the fibers in the fiber sliver are fully stretched and arranged in an orderly manner. Then, a high-speed rotating spindle drives the traveler to rotate continuously along the collar. Under the combined action of the friction between the traveler and the collar and the centrifugal force generated by the high-speed rotation of the spindle, twist is applied to the drafted fiber sliver, thereby achieving twisting into yarn and ultimately forming a yarn with stable structure and excellent performance.

[0003] Currently, the textile industry is accelerating its transformation towards high-count yarns and high-value-added products. The production of extra-high-count yarns (300 count and above) (these yarns have extremely fine diameters, low strength, and are prone to breakage) poses a severe challenge to yarn testing technology. However, traditional yarn testing methods, due to insufficient accuracy and mechanical contact damage, are unable to meet the non-destructive and highly reliable testing requirements for these yarns. Furthermore, existing single-spindle testing systems generally suffer from insufficient sensitivity, high false alarm rates, and complex operation in extra-high-count yarn applications, severely restricting the improvement of production efficiency and product quality.

[0004] In engineering applications, during the spinning process, differences in the winding shape of the yarn bobbin (such as variations in taper and diameter) and changes in yarn color (such as changes in yarn variety) can affect the absorption rate and scattering characteristics of the yarn for infrared radiation. These changes cause irregular fluctuations in the effective reflected light intensity, disrupting the stability of the photoelectric conversion in the receiving tube. This results in pulse signal waveform distortion and a decrease in the signal-to-noise ratio, reducing not only the accuracy of calculating the traveler and spindle speeds but also weakening the detection system's adaptability to various yarn varieties. This problem is particularly prominent in scenarios involving ultra-high count yarns of 300 count and above.

[0005] Furthermore, during the spinning process, the running attitude angle of the traveler on the ring ring is dynamically changing, mainly affected by centrifugal force, yarn tension, friction between the ring and the traveler, as well as the geometry and weight of the traveler itself. This change affects the reflection path of infrared light on the surface of the ring ring, causing irregular fluctuations in the effective reflected light intensity received by the receiver tube. This results in pulse signal waveform distortion and a decrease in the signal-to-noise ratio, ultimately reducing the measurement accuracy and detection stability of the traveler and spindle speeds.

[0006] For extra-high count yarns (300 count and above), due to their extremely fine diameter, very small traveler sizes are required, and the spindle speed is relatively low. The small traveler size results in a smaller reflective cross-sectional area, and the lower spindle speed reduces the traveler's attitude angle. These factors reduce the amount of infrared light reflected by the traveler, leading to a significant attenuation of the pulse signal generated by the traveler's reflection. This signal is easily overwhelmed by background signals such as reflected light from the collar and ambient light, causing a sharp deterioration in the signal-to-noise ratio and greatly increasing the difficulty of calculating the traveler and spindle speeds.

[0007] Due to the influence of multiple factors such as differences in material properties and fluctuations in production processes, infrared optoelectronic devices exhibit poor consistency, which inevitably affects the stability and reliability of the detection system. Summary of the Invention

[0008] This disclosure aims to address at least one of the problems existing in the prior art by providing a non-destructive testing system and method for ring-spun extra-high count yarns of 300 count and above.

[0009] One aspect of this disclosure provides a non-destructive testing system for ring-spun ultra-high count yarns of 300 count and above, the system comprising: An infrared photoelectric sensing module is used to emit infrared light of a preset wavelength onto the surface of a steel collar at a preset elevation angle using selected infrared photoelectric modules, and to receive the infrared light reflected back by the steel collar as the steel wire loop rotates along the steel collar, and to convert the intensity of the infrared light into an electrical signal. A multi-channel parallel acquisition module is used to select the currently operating infrared photoelectric module, perform ADC sampling on the electrical signal output by the infrared photoelectric sensing module to obtain the corresponding valid signal; use a comparator to compare and shape the valid signal to obtain the corresponding periodic pulse signal; and determine the current yarn state based on the periodic pulse signal. A comparator threshold adaptive module is used to dynamically adjust the threshold of the comparator based on the valid signal; The light intensity adaptive control module is used to gradually adjust the duty cycle of the PWM generator based on the average ADC sampling value of the effective signal within the sampling window, so as to gradually adjust the emitted light intensity of the infrared photoelectric module.

[0010] Optionally, the infrared optoelectronic module includes an infrared emitting tube, a photosensitive receiving tube, and a guide block; The guide block is used to fix the position and angle of the infrared emitting tube and the photosensitive receiving tube, and at the same time physically isolate the infrared emitting tube and the photosensitive receiving tube for optical path optimization. The infrared emitting tube is used to emit infrared rays of the preset wavelength onto the surface of the steel collar at the preset elevation angle when the selection is made. The photosensitive receiving tube is used to receive the infrared light reflected back by the steel collar during the rotation of the steel wire ring when the selection is performed, and to convert the intensity of the infrared light into the electrical signal.

[0011] Optionally, the guide block is also used to partially and physically block the infrared emitting tube and the photosensitive receiving tube.

[0012] Optionally, the multi-channel parallel capture module includes an analog multiplexer, dual operational amplifiers, and a shift register; The analog multiplexer is used to select the currently operating infrared optoelectronic module and add a delay after switching channels; The dual operational amplifier is used to construct a voltage-controlled constant current source circuit, and adopts a shared drive strategy to drive the selected infrared optoelectronic module using the voltage-controlled constant current source circuit; The shift register is used to control the channel switching of the infrared photoelectric module and the switching of the voltage-controlled constant current source circuit. After sending all the shift register data that needs to be updated, the latch pin is pulled high to update all outputs at once.

[0013] Optionally, the multi-channel parallel acquisition module is used to select the currently operating infrared photoelectric module and perform ADC sampling on the electrical signal output by the infrared photoelectric sensing module, including: The multi-channel parallel acquisition module is used to alternately sample each of the infrared optoelectronic modules using a polling method, specifically including: Step 1: Turn off all the infrared emitters and open the target channel. ; Step 2: Select the target channel The corresponding infrared optoelectronic module; Step 3: Open the target channel The corresponding infrared emitting tube; Step 4: Set the preset delay duration; Step 5: Execute the target channel ADC sampling and timer capture to obtain the target channel The corresponding electrical signal output by the photosensitive receiving tube and the corresponding signal time interval; Step 6: Close the target channel The corresponding infrared emitting tube; Step 7: Let ,exist When the number of infrared photoelectric modules is greater than the total number of infrared photoelectric sensing modules in the infrared photoelectric sensing module, let Repeat steps 2 through 6.

[0014] Optionally, the multi-channel parallel capture module is further configured to activate early warning control logic based on the current yarn state; The early warning control logic includes: When the current yarn status is a broken yarn, the red light is turned on. When the current yarn state is characterized by continuous yarn breakage within a preset duration, the red light is controlled to flash. When the current yarn state is a weak twist yarn, control the blue light to illuminate; When the current yarn state is high-twist yarn, control the blue light to flash; When the current yarn state is that the infrared photoelectric module is blocked by an obstruction or wrapped by a foreign object, control the red light and blue light to light up simultaneously; When the current yarn state is other than the specified state, both the red and blue lights will turn off simultaneously.

[0015] Optionally, the comparator threshold adaptive module is specifically used for: The threshold of the comparator is dynamically adjusted according to the following formula: ; in, Indicates the first The adjusted comparator threshold voltage corresponding to each channel of the infrared optoelectronic module; Indicates the range of values ​​as The saturation processing function, Indicates the lower limit of the threshold voltage. Indicates the upper limit of the threshold voltage; Indicates the first The peak voltage of the effective signal corresponding to each channel of the infrared optoelectronic module; Indicates the first The voltage offset corresponding to each channel of the infrared optoelectronic module; Indicates the first The adaptive adjustment coefficients corresponding to the infrared optoelectronic modules of each channel and , Indicates the first The design value of the adjustment coefficient corresponding to each channel of the infrared optoelectronic module. Represents the effective signal distribution factor. Indicates the first The average voltage of the effective signal corresponding to each channel of the infrared optoelectronic module and , Indicates the first The standard deviation of the effective signal voltage corresponding to each channel of the infrared optoelectronic module and , Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each sampled voltage and , Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each ADC sample value, This indicates the operating voltage of the ADC module. Indicates the maximum range of the ADC module. Indicates the number of sampling points.

[0016] Optionally, the comparator threshold adaptive module is further configured to: Using the sliding window processing mechanism, the following formula is used to process the first... The adaptive adjustment coefficients corresponding to the infrared photoelectric modules of each channel are dynamically adjusted: ; in, Indicates the first The adaptive adjustment coefficients corresponding to the infrared photoelectric modules of each channel after the sliding window processing. Indicates the first The adaptive adjustment coefficients corresponding to the infrared photoelectric modules of each channel after the previous sliding window processing. Indicates design parameters.

[0017] Optionally, the light intensity adaptive control module is specifically used for: Based on on-site modulation experience, the first step is set... The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module for , Indicates the initial duty cycle; Set the ADC sampling frequency and sampling window size, and initialize the buffer or array used to store the ADC sampled values; Based on the set ADC sampling frequency and sampling window size, the ADC module processes the data for the first... The electrical signal output from the infrared photoelectric module of each channel is sampled, and the obtained ADC sampled value is stored in the buffer or array. The value of the first channel is calculated according to the following formula. The average ADC sampled value within the sampling window corresponding to each channel of the infrared optoelectronic module : ; in, Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each ADC sample value, This indicates the number of sampling points within the sampling window; If calculated Below the minimum boundary value Then the first The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module is set to the initial duty cycle. Conversely: If calculated Higher than the highest expected value Then, the step size is gradually increased for the first step. The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module; If calculated Below the minimum expected value Then, by setting a step size, the number of steps will be gradually reduced. The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module; If calculated Within the expected range Inside, then maintain the first The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module remains unchanged.

[0018] Another aspect of this disclosure provides a non-destructive testing method for ring-spun yarns of 300 count and above, wherein the non-destructive testing method for ring-spun yarns of 300 count and above is implemented using the non-destructive testing system for ring-spun yarns of 300 count and above described above, and the non-destructive testing method for ring-spun yarns of 300 count and above includes: The selected infrared photoelectric modules emit infrared light of a preset wavelength onto the surface of the steel collar ring, and receive the infrared light reflected back by the steel collar ring as the steel wire ring rotates along the steel collar ring, and convert the intensity of the infrared light into an electrical signal. The currently operating infrared photoelectric module is selected, and the electrical signal output by the infrared photoelectric sensing module is sampled by an ADC to obtain the corresponding valid signal; the valid signal is compared and shaped by a comparator to obtain the corresponding periodic pulse signal; the current yarn state is determined based on the periodic pulse signal. The threshold of the comparator is dynamically adjusted based on the valid signal; Based on the average ADC sampling value of the valid signal within the sampling window, the duty cycle of the PWM generator is gradually adjusted to gradually adjust the emitted light intensity of the infrared photoelectric module.

[0019] Compared with existing technologies, this disclosure has advantages such as non-contact measurement, high accuracy, fast response, and strong anti-interference capabilities. It can completely replace the manual patrol inspection mode, realize real-time and accurate identification and early warning of abnormalities such as yarn breakage and weak twist, help manufacturing enterprises to carry out intelligent equipment maintenance, improve the production efficiency of extra-high count yarns of 300 count and above, and reduce operation and maintenance costs. It has great theoretical research significance and engineering application value. Attached Figure Description

[0020] One or more embodiments are illustrated by way of example with the corresponding pictures in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Elements with the same reference numerals in the drawings are denoted as similar elements. Unless otherwise stated, the figures in the drawings are not to be limited by scale.

[0021] Figure 1 A schematic diagram illustrating the working principle of a non-destructive testing system for ring-spun yarns of 300 count or higher, provided in one embodiment of this disclosure; Figure 2 A schematic diagram of the structure of a guide block provided in another embodiment of this disclosure; Figure 3 A schematic diagram of an improved design for a guide block provided in another embodiment of this disclosure; Figure 4 A schematic diagram of 8-channel parallel capture provided for another embodiment of this disclosure; Figure 5 A schematic diagram of controlling a dual-color dual-control LED light using cascaded 74HC595s, as provided in another embodiment of this disclosure. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the various embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details have been provided in the various embodiments of this disclosure to facilitate a better understanding of the disclosure. However, the technical solutions claimed in this disclosure can be implemented even without these technical details and with various variations and modifications based on the following embodiments. The division of the various embodiments below is for ease of description and should not constitute any limitation on the specific implementation of this disclosure. The various embodiments can be combined with and referenced by each other without contradiction.

[0023] One embodiment of this disclosure relates to a non-destructive testing system for ring-spun ultra-high count yarns of 300 count and above, including an infrared photoelectric sensing module, a multi-channel parallel capture module, a comparator threshold adaptive module, and a light intensity adaptive control module.

[0024] The infrared photoelectric sensing module is used to emit infrared light of a preset wavelength onto the surface of the steel collar at a preset elevation angle using selected infrared photoelectric modules, and to receive the infrared light reflected back by the steel collar as the steel wire ring rotates along the steel collar, converting the intensity of the infrared light into an electrical signal.

[0025] The multi-channel parallel acquisition module is used to select the currently working infrared photoelectric module, perform ADC sampling on the electrical signal output by the infrared photoelectric sensing module to obtain the corresponding valid signal; a comparator is used to compare and shape the valid signal to obtain the corresponding periodic pulse signal; and the current yarn state is determined based on the periodic pulse signal.

[0026] The comparator threshold adaptive module is used to dynamically adjust the comparator threshold based on the valid signal.

[0027] The light intensity adaptive control module is used to gradually adjust the duty cycle of the PWM generator based on the average ADC sampling value of the effective signal within the sampling window, so as to gradually adjust the emitted light intensity of the infrared photoelectric module.

[0028] Combined Figure 1 The infrared photoelectric sensing module can include multiple infrared photoelectric modules, each equipped with an infrared sensor. A multi-channel parallel acquisition module, a comparator threshold adaptive module, and a light intensity adaptive control module can form an edge intelligent decision-making unit. The multi-channel parallel acquisition module determines the current yarn state by combining a multi-channel acquisition strategy and a low-power optimization strategy with ADC sampling and parallel spindle speed estimation. The comparator threshold adaptive module dynamically adjusts the comparator threshold using an adaptive threshold strategy to optimize the parallel spindle speed estimation of the multi-channel parallel acquisition module. The light intensity adaptive control module adjusts the emitted light intensity of the infrared sensor in the infrared photoelectric module using a light intensity adaptive control strategy combined with PWM output.

[0029] The detection principle of the above-mentioned non-destructive testing system for ring-spun yarns of 300 count and above includes: (1) Using the infrared sensors in each selected infrared photoelectric module, infrared rays of a preset wavelength are emitted to the surface of the steel collar at a preset elevation angle. Considering factors such as detection range, installation height, and on-site operation convenience, the preset elevation angle can be set to 5 to 10 degrees to optimize the detection coverage, improve detection accuracy and stability, adapt to different installation heights, simplify on-site installation and debugging, and enhance the robustness and environmental adaptability of the system. Based on fully considering the complex optical environment of the spinning workshop and interference factors such as dust and flying flowers, the preset wavelength is set to 940nm after strict screening to better balance penetration and reflection characteristics. (2) When the steel wire ring rotates along the steel collar and enters the infrared beam action area, the surface of the steel wire ring will reflect some of the infrared rays, causing the infrared light intensity received by the infrared sensor to decrease periodically. (3) The infrared sensor converts the received light intensity change into an electrical signal. After signal processing circuits such as preamplification and filtering, a periodic pulse signal is formed. The frequency of this periodic pulse signal is the rotation frequency of the wire traveler. Then, based on the proportional relationship between the wire traveler speed and the spindle speed, the actual speed of the spindle can be calculated using existing calculation methods. (4) Based on the measured wire traveler speed, existing technology can be used to estimate key states in spinning production such as yarn breakage, repeated yarn breakage, idleness, successful yarn splicing, weak twist yarn, and strong twist yarn at the single spindle level, thereby achieving non-destructive testing of ring-spun yarns of 300 count and above. For example, an infrared optoelectronic module includes an infrared emitting diode, a photosensitive receiving diode, and a guide block. The infrared emitting diode and the photosensitive receiving diode together constitute an infrared sensor.

[0030] An infrared emitting diode is used to emit infrared light of a preset wavelength onto the surface of a steel collar at a preset elevation angle during selection. When the preset wavelength is set to 940nm, the infrared emitting diode can be directly selected with a wavelength of 940nm.

[0031] A photosensitive receiver tube is used to receive infrared light reflected back by the steel collar as the steel wire ring rotates along the steel collar during the selection process, and to convert the intensity of the infrared light into an electrical signal.

[0032] The guide block is used to fix the position and angle of the infrared emitter and the photosensitive receiver, and to physically isolate the infrared emitter and the photosensitive receiver for optical path optimization.

[0033] Figure 2The structure of the guide block is shown. By using the guide block to fix the position and angle of the infrared emitting tube and the photosensitive receiving tube, it is possible to use the selected infrared emitting tube to emit infrared light of a preset wavelength at a preset elevation angle onto the surface of the steel collar at a preset elevation angle during engineering implementation, without adjusting the position and angle of the infrared emitting tube and the photosensitive receiving tube, and use the selected photosensitive receiving tube to receive the infrared light reflected back by the steel collar as the steel wire ring rotates along the steel collar, converting the light intensity of the infrared light into an electrical signal.

[0034] For example, the guide block is also used to partially block the infrared emitting tube and the photosensitive receiving tube with a non-transparent physical shield.

[0035] Specifically, combined Figure 3 This embodiment employs an optical isolation mechanism with a physical light-shielding structure to... Figure 2 The guide block shown is further improved by using it to physically shield the upper portion (preferably the upper 1 / 4 to 1 / 3) of the infrared emitter and photosensitive receiver with a non-transparent layer. This reduces measurement interference caused by variations in the yarn's winding shape and color. For example, black plastic can be used as the material for partially shielding the infrared emitter and photosensitive receiver.

[0036] For example, a multi-channel parallel capture module includes an analog multiplexer, dual operational amplifiers, and a shift register.

[0037] An analog multiplexer is used to select the currently operating infrared optoelectronic module, especially the currently operating infrared sensor, and adds a delay after channel switching to avoid detection errors caused by glitches during switching or insufficient analog signal settling time. For example, it is combined with... Figure 4 The analog multiplexer can be an 8-channel analog multiplexer CD4051 to switch channels for each infrared sensor when the infrared photoelectric sensing module includes 8 infrared sensors.

[0038] Dual operational amplifiers are used to construct voltage-controlled constant current source circuits, employing a shared drive strategy to drive the selected infrared optoelectronic module, thus achieving a balance between low cost and low power consumption. For example, the dual operational amplifier LM358 can be selected. (This is combined with...) Figure 4 When using a shared drive strategy, each pair of infrared emitting diodes can share a voltage-controlled constant current source circuit built with a dual operational amplifier LM358 for driving.

[0039] The shift register is used to control the channel switching of the infrared photoelectric module and the switching of the voltage-controlled constant current source circuit. After sending all the shift register data that needs to be updated, the latch pin is pulled high to update all outputs at once. For example, it is combined with... Figure 4The shift register can be an 8-bit serial input, parallel output shift register 74HC595 to control the 8-channel analog multiplexer CD4051 for channel switching and the switching of the voltage-controlled constant current source circuit built with dual operational amplifiers LM358. After sending all the shift register data that needs to be updated, the latch pin is pulled high to update all outputs at once to ensure the synchronicity of the control signal changes.

[0040] For example, a multi-channel parallel acquisition module is used to select the currently operating infrared photoelectric module and perform ADC sampling on the electrical signal output by the infrared photoelectric sensing module. This includes: a multi-channel parallel acquisition module used to alternately sample each infrared photoelectric module using a polling method, specifically including: Step 1: Turn off all infrared emitters and open the target channel. ; Step 2: Select the target channel The corresponding infrared optoelectronic module; Step 3: Open the target channel The corresponding infrared emitter; Step 4: Delay for a preset duration to ensure stable infrared light intensity and stable circuit setup at the receiving end; Step 5: Execute the target channel ADC sampling and timer capture to obtain the target channel The corresponding electrical signal output by the photosensitive receiver and the corresponding signal time interval; Step 6: Close the target channel The corresponding infrared emitter; Step 7: Let ,exist When the number of infrared photoelectric modules is greater than the total number of infrared photoelectric sensing modules in the infrared photoelectric sensing module, let Repeat steps 2 through 6.

[0041] For example, taking 8-channel capture as an example, combined with... Figure 4 The polling method is used to alternately sample each infrared optoelectronic module, specifically including: Step 1: Initialization: Turn off all infrared emitters and enable the target channel. ; Step 2: Select the target channel The corresponding infrared sensor; Step 3: Open the target channel The corresponding infrared emitter in the infrared sensor; Step 4: Delay for a preset duration to ensure stable infrared light intensity and stable circuit setup at the receiving end; Step 5: Execute the target channel ADC sampling is used to obtain the signal strength of the photosensitive receiver tube to obtain the target channel. The corresponding electrical signal output by the photosensitive receiving tube is captured by a timer to obtain the corresponding signal time interval for calculating the rotational speed of the wire coil; Step 6: Close the target channel The corresponding infrared emitter; Step 7: Let ,exist At 8 o'clock, the order Repeat steps 2 through 6.

[0042] For example, after the multi-channel parallel acquisition module samples the electrical signal output by the infrared photoelectric sensing module using an ADC, it can obtain the corresponding valid signal by processing the ADC sampled signal through a multi-stage method circuit. Then, a comparator is used to compare and shape the valid signal to obtain the corresponding periodic pulse signal. The frequency of this periodic pulse signal is the rotation frequency of the wire traveler. Therefore, the multi-channel parallel acquisition module can first calculate the wire traveler speed based on the periodic pulse signal, then calculate the actual speed of the spindle based on the relationship between the wire traveler speed and the spindle speed, and determine the current yarn state based on the actual speed of the spindle, thereby realizing the determination of the current yarn state based on the periodic pulse signal.

[0043] For example, suppose the system clock frequency corresponding to the timer is Perform system clock operation The frequency is divided once and used as the clock source for the timer, with a signal time interval of . Then the rotation speed of the wire coil Through formula The calculation yields a result in revolutions per minute (RPM), with [·] indicating rounding. Furthermore, the actual rotational speed of the spindle... Through formula The calculation yielded a result in revolutions per minute (RPM). This indicates the linear speed of the rollers, and its unit is inches per minute. This indicates the diameter of the yarn bobbin winding, and its unit is millimeters.

[0044] For example, determining whether the current yarn state is broken based on the actual spindle rotation speed can be done by using a single-spindle yarn breakage model. The constraint condition for this model is: if the actual spindle rotation speed is continuous... The second time is less than the design threshold. If so, the current yarn state is determined to be a broken yarn.

[0045] Based on the actual spindle rotation speed, the method to determine whether the current yarn state is a continuous yarn breakage within a preset time period can be as follows: A single-spindle repeated yarn breakage model is used to determine whether the current yarn state is a continuous yarn breakage within a preset time period. The constraint condition of the single-spindle repeated yarn breakage model is: if a single spindle experiences a continuous yarn breakage within a preset time period... If a yarn breakage event occurs, the current yarn state is determined to be a continuous yarn breakage within a preset time period.

[0046] The method to determine whether the current yarn state is a high-twist yarn based on the actual spindle speed can be as follows: A high-twist model is used to determine whether the current yarn state is a high-twist yarn. The constraint condition for the high-twist model is: if the actual speed of a single spindle exceeds the reference spindle speed... And the duration exceeds the design threshold. If so, the current yarn state is determined to be a high-twist yarn, where, To design the threshold.

[0047] The method to determine whether the current yarn state is a weakly twisted yarn based on the actual spindle speed can be as follows: A weak twist model can be used to determine whether the current yarn state is a weakly twisted yarn. The constraint condition of the weak twist model is: assuming the yarn has not broken, if the actual speed of a single spindle is lower than the reference spindle speed... ×100%, and the duration exceeds the design threshold. If so, the current yarn state is determined to be a weak twist yarn, where, To design the threshold.

[0048] Based on the actual spindle speed, it can also be determined whether the current yarn status is that the spindle is idle or the spindle splicing is successful. Specifically, determining whether the current yarn status is idle based on the actual spindle speed can be as follows: if the actual spindle speed indicates a yarn breakage and the breakage duration exceeds a designed threshold... If the spindle is idle, it is determined that the spindle is not in use. The method to determine whether the current yarn state is a successful spindle splice based on the actual spindle speed can be: if the actual speed of a single spindle is continuous... This is higher than the design threshold. If the spindle joint is successful, then the spindle connection is considered successful.

[0049] Of course, the multi-channel parallel capture module can also determine the current yarn status based on the actual rotation speed of the spindle, whether it is a broken yarn, a continuous broken yarn within a preset time, a strong twist yarn, a weak twist yarn, an idle spindle, or a successful spindle splice, according to actual needs. This implementation does not limit the specific determination method.

[0050] For example, the multi-channel parallel capture module can also determine whether the current yarn state is due to foreign objects obstructing the infrared photoelectric module based on the ADC sampling value corresponding to the periodic pulse signal. For instance, when the infrared photoelectric module is obstructed by flying lint or other obstructions, the received infrared light intensity signal will be too strong, resulting in a low corresponding ADC sampling value. Alternatively, when foreign objects such as dust or lint cover the infrared sensor beads of the infrared photoelectric module, the received infrared light intensity signal will be too weak, resulting in a high corresponding ADC sampling value. Therefore, the multi-channel parallel capture module can determine that the current yarn state is due to an obstruction obstructing the infrared photoelectric module when the ADC sampling value corresponding to the periodic pulse signal is consistently below the normal operating lower limit. Alternatively, the multi-channel parallel capture module can also determine that the current yarn state is due to a foreign object covering the infrared photoelectric module when the ADC sampling value corresponding to the periodic pulse signal is consistently above the normal operating upper limit.

[0051] For example, the multi-channel parallel capture module is also used to initiate early warning control logic based on the current yarn status. Combined with... Figure 5 The early warning control logic can be implemented by controlling red and blue dual-color dual-control LED lights through cascaded 74HC595.

[0052] For example, the early warning control logic includes: When the current yarn status is a broken yarn, control the red light to illuminate; When the yarn breaks continuously for a preset duration, control the red light to flash. When the current yarn is a low-twist yarn, control the blue light to illuminate; When the current yarn is a high-twist yarn, control the blue light to flash; When the current yarn is blocked by an obstruction or wrapped by a foreign object, control the red and blue lights to light up simultaneously; When the current yarn status is other than other states, control the red and blue lights to turn off simultaneously.

[0053] For example, the comparator threshold adaptive module is specifically used to: dynamically adjust the comparator threshold according to the following formula: ; in, Indicates the first The adjusted comparator threshold voltage corresponding to each channel of the infrared optoelectronic module can be adjusted online via DAC output. Indicates the range of values ​​as The saturation processing function, Indicates the lower limit of the threshold voltage. Indicates the upper limit of the threshold voltage; Indicates the first The voltage peak value of the effective signal corresponding to each channel of the infrared optoelectronic module can be obtained in real time through ADC sampling and processing. Indicates the first The voltage offset corresponding to each channel of the infrared optoelectronic module; Indicates the first The adaptive adjustment coefficients corresponding to the infrared optoelectronic modules of each channel and , Indicates the first The design value of the adjustment coefficient corresponding to each channel of the infrared optoelectronic module. This represents the effective signal distribution factor (which can be configured online via DAC output). Indicates the first The average voltage of the effective signal corresponding to each channel of the infrared optoelectronic module and , Indicates the first The standard deviation of the effective signal voltage corresponding to each channel of the infrared optoelectronic module and , Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each sampled voltage and , Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each ADC sample value, This indicates the operating voltage of the ADC module. Indicates the maximum range of the ADC module. This indicates the number of sampling points. It should be noted that... This is an empirical value determined based on the characteristics and signal features of infrared photoelectric modules, especially infrared sensors. It can be determined through calibration experiments of a non-destructive testing system for ring-spun high-count yarns of 300 count and above. For example, considering the consistency of each infrared photoelectric module, especially the infrared sensor, within the infrared photoelectric sensing module and the actual environmental conditions, The recommended value range is [0.5, 2.0], where, The preferred value is 1.0.

[0054] Specifically, under the multi-channel acquisition strategy, the effective signal fed into the comparator is dynamic; therefore, the corresponding comparator threshold should also be dynamic. To this end, this embodiment designs a dynamic threshold model for the comparator to adjust the comparator threshold voltage.

[0055] Through the triple anti-interference design of "optical path optimization + beam spatial offset + comparator threshold adaptive strategy", the interference of yarn winding shape and yarn color changes on the light intensity received by the receiving tube can be effectively eliminated when performing parallel estimation of spindle speed.

[0056] For example, the comparator threshold adaptive module is further configured to: utilize a sliding window processing mechanism to apply the following formula to the first... The adaptive adjustment coefficients corresponding to the infrared photoelectric modules of each channel are dynamically adjusted: ; in, Indicates the first The adaptive adjustment coefficients corresponding to the infrared optoelectronic modules of each channel after the sliding window processing; Indicates the first The adaptive adjustment coefficients corresponding to the infrared optoelectronic modules of each channel after the previous sliding window processing; This represents the design parameter, a smoothing factor for the sliding window, used to balance the weights of historical and current values ​​of the adaptive adjustment coefficient to avoid sudden threshold changes. It should be noted that... The range of values ​​can be determined based on signal stability and response speed requirements, for example, The value range can be set to [0, 1]. During the operation of the non-destructive testing system for ring-spun high-count yarns (300 count and above),... The specific value can be optimized based on its range by observing the stability of the comparator threshold adjustment and its response speed to signal changes. For example, The initial value can be set to 0.7. During the operation of the non-destructive testing system for ring-spun high-count yarns (300 count and above), if the comparator threshold fluctuates significantly, the value should be increased. The possible values, for example, The value can be set to 0.8 or higher, or, if the response to signal changes is lagging, it can be reduced. The possible values, for example, The value can be set to 0.6 or higher.

[0057] By using a sliding window processing mechanism to dynamically adjust the adaptive adjustment coefficient, the anti-interference effect can be further improved, and the interference of changes in the yarn winding shape and yarn color on the light intensity received by the receiving tube can be eliminated.

[0058] For example, in response to the problems of poor consistency of infrared optoelectronic devices and disturbances in the industrial environment, this embodiment proposes an adaptive control strategy for the light intensity of infrared emitting diodes. Based on the average ADC sampling value of the effective signal within the sampling window, the duty cycle of the PWM generator is gradually adjusted, which then acts on the voltage-controlled constant current source to achieve fine adaptive control of the light intensity of the infrared emitting diode. This can effectively ensure the stability and consistency of infrared optoelectronic devices under different working conditions, thereby improving the performance and reliability of the overall detection system.

[0059] When implementing the infrared emitting diode light intensity adaptive control strategy, the light intensity adaptive control module is specifically used for: Initialization: Based on field modulation experience, set the first... The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module for , Indicates the initial duty cycle; Set the ADC sampling frequency and sampling window size, and initialize the buffer or array used to store the ADC sampled values; ADC Sampling: Based on the set ADC sampling frequency and sampling window size, the ADC module samples the first... The electrical signal output from the infrared photoelectric module of each channel is sampled, and the obtained ADC sampled value is stored in a value buffer or array. The value of the first channel is then calculated according to the following formula. The average ADC sampled value within the sampling window corresponding to each channel of the infrared optoelectronic module : ; in, Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each ADC sample value, This indicates the number of sampling points within the sampling window; Duty cycle control: If the calculated Below the minimum boundary value Then the first The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module is set to the initial duty cycle. Conversely: If calculated Higher than the highest expected value Then, the step size is gradually increased for the first step. The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module; If calculated Below the minimum expected value Then, by setting a step size, the number of steps will be gradually reduced. The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module; If calculated Within the expected range Inside, then maintain the first The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module remains unchanged.

[0060] Feedback and iteration: By repeating the initialization, ADC sampling, and duty cycle adjustment steps described above, continuous adaptive control of light intensity can be achieved.

[0061] Specifically, the expected range for The expected range, which is related to factors such as yarn type and industrial environment. Minimum boundary value. for The minimum boundary value is used to identify the saturation state of the photosensitive receiver. For example, when an infrared sensor is severely obscured by dust, its photosensitive receiver is prone to saturation once cleaned.

[0062] For example, a non-destructive testing system for ring-spun yarns of 300 count and above can adopt a master-slave printed circuit board (PCB) design to integrate a multi-channel parallel capture module, a comparator threshold adaptive module, and a light intensity adaptive control module. For instance, a long, rectangular master-slave PCB layout can be used, which may include one main board (integrated MCU) and two slave boards (without MCU), thus significantly reducing hardware costs. The non-destructive testing system for ring-spun yarns of 300 count and above adopts a separate design. That is, the infrared sensors in the infrared photoelectric sensing module are connected to the circuit boards containing the multi-channel parallel capture module, the comparator threshold adaptive module, and the light intensity adaptive control module via wiring harnesses, achieving a modular and detachable design. This effectively adapts to various spinning machine spindle pitches (such as 60mm to 80mm).

[0063] For example, a non-destructive testing system for ring-spun yarns of 300 count and above can use a dedicated track bracket to integrate a main board, slave board, and infrared photoelectric sensor module to form a testing device. This testing device can be installed on the edge of the ring band, thereby using a modified guide block to position the infrared emitting tube and photosensitive receiving tube, so that the infrared emitting tube can emit infrared rays onto the surface of the ring band at a specific tilt angle, i.e., a preset elevation angle. By adjusting the testing device laterally along the edge of the ring band, the infrared emitting tube beam space can also be deviated from the center of the ring band, thereby further suppressing the influence of reflection signal fluctuations and yarn color changes.

[0064] The non-destructive testing system for ring-spun yarns of 300 count and above provided in this disclosure offers advantages over existing technologies, including non-contact measurement, high precision, rapid response, and strong anti-interference capabilities. It can completely replace manual, roving inspection methods, enabling real-time and accurate identification and early warning of abnormalities such as yarn breakage and weak twist. This facilitates intelligent equipment maintenance for manufacturing enterprises, improves the production efficiency of 300 count and above yarns, and reduces maintenance costs, demonstrating significant theoretical research value and engineering application value. Currently, this non-destructive testing system for ring-spun yarns of 300 count and above has been successfully industrialized and has demonstrated excellent testing results in actual production in textile enterprises, resulting in a significant increase in production efficiency and economic benefits, and powerfully promoting the intelligent upgrading and high-quality development of the textile industry.

[0065] Another embodiment of this disclosure relates to a non-destructive testing method for ring-spun yarns of 300 count and above. This method is implemented using the non-destructive testing system for ring-spun yarns of 300 count and above described in the above embodiment. The method includes: The selected infrared photoelectric modules emit infrared light of a preset wavelength onto the surface of the steel collar ring, and receive the infrared light reflected back by the steel collar ring as the steel wire ring rotates along the steel collar ring, converting the intensity of the infrared light into an electrical signal. Select the currently operating infrared photoelectric module, perform ADC sampling on the electrical signal output by the infrared photoelectric sensing module to obtain the corresponding valid signal; use a comparator to compare and shape the valid signal to obtain the corresponding periodic pulse signal; determine the current yarn state based on the periodic pulse signal; The threshold of the comparator is dynamically adjusted based on the valid signal; Based on the average ADC sampling value of the valid signal within the sampling window, the duty cycle of the PWM generator is gradually adjusted to gradually adjust the emitted light intensity of the infrared photoelectric module.

[0066] The non-destructive testing method for ring-spun high-count yarns of 300 count and above provided in this disclosure has advantages over existing technologies, including non-contact measurement, high accuracy, rapid response, and strong anti-interference capabilities. It can completely replace the manual patrol inspection mode, enabling real-time and accurate identification and early warning of abnormalities such as yarn breakage and weak twist. This method helps manufacturing enterprises to perform intelligent equipment maintenance, improve the production efficiency of high-count yarns of 300 count and above, and reduce operation and maintenance costs. It has great theoretical research significance and engineering application value.

[0067] Those skilled in the art will understand that the above embodiments are specific implementations of this disclosure, and in practical applications, various changes can be made to them in form and detail without departing from the spirit and scope of this disclosure.

Claims

1. A non-destructive testing system for ring-spun extra-high count yarns of 300 count and above, characterized in that, The non-destructive testing system for ring-spun extra-high count yarns of 300 count and above includes: An infrared photoelectric sensing module is used to emit infrared light of a preset wavelength onto the surface of a steel collar at a preset elevation angle using selected infrared photoelectric modules, and to receive the infrared light reflected back by the steel collar as the steel wire loop rotates along the steel collar, and to convert the intensity of the infrared light into an electrical signal. A multi-channel parallel acquisition module is used to select the currently operating infrared photoelectric module, perform ADC sampling on the electrical signal output by the infrared photoelectric sensing module to obtain the corresponding valid signal; use a comparator to compare and shape the valid signal to obtain the corresponding periodic pulse signal; and determine the current yarn state based on the periodic pulse signal. A comparator threshold adaptive module is used to dynamically adjust the threshold of the comparator based on the valid signal; The light intensity adaptive control module is used to gradually adjust the duty cycle of the PWM generator based on the average ADC sampling value of the effective signal within the sampling window, so as to gradually adjust the emitted light intensity of the infrared photoelectric module.

2. The non-destructive testing system for ring-spun extra-high count yarns of 300 count and above according to claim 1, characterized in that, The infrared optoelectronic module includes an infrared emitting tube, a photosensitive receiving tube, and a guide block; The guide block is used to fix the position and angle of the infrared emitting tube and the photosensitive receiving tube, and at the same time physically isolate the infrared emitting tube and the photosensitive receiving tube for optical path optimization. The infrared emitting tube is used to emit infrared rays of the preset wavelength onto the surface of the steel collar at the preset elevation angle when the selection is made. The photosensitive receiving tube is used to receive the infrared light reflected back by the steel collar during the rotation of the steel wire ring when the selection is performed, and to convert the intensity of the infrared light into the electrical signal.

3. The non-destructive testing system for ring-spun extra-high count yarns of 300 count and above according to claim 2, characterized in that, The guide block is also used to partially and physically shield the infrared emitting tube and the photosensitive receiving tube.

4. The non-destructive testing system for ring-spun extra-high count yarns of 300 count and above according to claim 1, characterized in that, The multi-channel parallel capture module includes an analog multiplexer, dual operational amplifiers, and a shift register; The analog multiplexer is used to select the currently operating infrared optoelectronic module and add a delay after switching channels; The dual operational amplifier is used to construct a voltage-controlled constant current source circuit, and adopts a shared drive strategy to drive the selected infrared optoelectronic module using the voltage-controlled constant current source circuit; The shift register is used to control the channel switching of the infrared photoelectric module and the switching of the voltage-controlled constant current source circuit. After sending all the shift register data that needs to be updated, the latch pin is pulled high to update all outputs at once.

5. The non-destructive testing system for ring-spun high-count yarns (300 count and above) according to claim 2, characterized in that, The multi-channel parallel acquisition module is used to select the currently operating infrared photoelectric module and perform ADC sampling on the electrical signal output by the infrared photoelectric sensing module, including: The multi-channel parallel acquisition module is used to alternately sample each of the infrared optoelectronic modules using a polling method, specifically including: Step 1: Turn off all the infrared emitters and open the target channel. ; Step 2: Select the target channel The corresponding infrared optoelectronic module; Step 3: Open the target channel The corresponding infrared emitting tube; Step 4: Set the preset delay duration; Step 5: Execute the target channel ADC sampling and timer capture to obtain the target channel The corresponding electrical signal output by the photosensitive receiving tube and the corresponding signal time interval; Step 6: Close the target channel The corresponding infrared emitting tube; Step 7: Let ,exist When the number of infrared photoelectric modules is greater than the total number of infrared photoelectric sensing modules in the infrared photoelectric sensing module, let Repeat steps 2 through 6.

6. The non-destructive testing system for ring-spun extra-high count yarns of 300 count and above according to claim 1, characterized in that, The multi-channel parallel capture module is also used to activate early warning control logic based on the current yarn state; The early warning control logic includes: When the current yarn status is a broken yarn, the red light is turned on. When the current yarn state is characterized by continuous yarn breakage within a preset duration, the red light is controlled to flash. When the current yarn state is a weak twist yarn, control the blue light to illuminate; When the current yarn state is high-twist yarn, control the blue light to flash; When the current yarn state is that the infrared photoelectric module is blocked by an obstruction or wrapped by a foreign object, control the red light and blue light to light up simultaneously; When the current yarn state is other than the specified state, both the red and blue lights will turn off simultaneously.

7. The non-destructive testing system for ring-spun extra-high count yarns of 300 count and above according to claim 1, characterized in that, The comparator threshold adaptive module is specifically used for: The threshold of the comparator is dynamically adjusted according to the following formula: ； in, Indicates the first The adjusted comparator threshold voltage corresponding to each channel of the infrared optoelectronic module; Indicates the range of values ​​as The saturation processing function, Indicates the lower limit of the threshold voltage. Indicates the upper limit of the threshold voltage; Indicates the first The peak voltage of the effective signal corresponding to each channel of the infrared optoelectronic module; Indicates the first The voltage offset corresponding to each channel of the infrared optoelectronic module; Indicates the first The adaptive adjustment coefficients corresponding to the infrared optoelectronic modules of each channel and , Indicates the first The design value of the adjustment coefficient corresponding to each channel of the infrared optoelectronic module. Represents the effective signal distribution factor. Indicates the first The average voltage of the effective signal corresponding to each channel of the infrared optoelectronic module and , Indicates the first The standard deviation of the effective signal voltage corresponding to each channel of the infrared optoelectronic module and , Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each sampled voltage and , Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each ADC sample value, This indicates the operating voltage of the ADC module. Indicates the maximum range of the ADC module. Indicates the number of sampling points.

8. The non-destructive testing system for ring-spun extra-high count yarns of 300 count and above according to claim 7, characterized in that, The comparator threshold adaptive module is further configured to: Using the sliding window processing mechanism, the following formula is used to process the first... The adaptive adjustment coefficients corresponding to the infrared photoelectric modules of each channel are dynamically adjusted: ； in, Indicates the first The adaptive adjustment coefficients corresponding to the infrared photoelectric modules of each channel after the sliding window processing. Indicates the first The adaptive adjustment coefficients corresponding to the infrared photoelectric modules of each channel after the previous sliding window processing. Indicates design parameters.

9. The non-destructive testing system for ring-spun extra-high count yarns of 300 count and above according to claim 1, characterized in that, The light intensity adaptive control module is specifically used for: Based on on-site modulation experience, the first step is set... The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module for , Indicates the initial duty cycle; Set the ADC sampling frequency and sampling window size, and initialize the buffer or array used to store the ADC sampled values; Based on the set ADC sampling frequency and sampling window size, the ADC module processes the data for the first... The electrical signal output from the infrared photoelectric module of each channel is sampled, and the obtained ADC sampled value is stored in the buffer or array. The value of the first channel is calculated according to the following formula. The average ADC sampled value within the sampling window corresponding to each channel of the infrared optoelectronic module : ； in, Indicates the first The effective signal corresponding to the infrared photoelectric module of the first channel Each ADC sample value, Indicates the number of sampling points within the sampling window; If calculated Below the minimum boundary value Then the first The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module is set to the initial duty cycle. Conversely: If calculated Higher than the highest expected value Then, the step size is gradually increased to the set step size. The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module; If calculated Below the minimum expected value Then, by setting a step size, the number of steps will be gradually reduced. The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module; If calculated Within the expected range Inside, then maintain the first The duty cycle of the PWM generator corresponding to each channel of the infrared photoelectric module remains unchanged.

10. A non-destructive testing method for ring-spun extra-high count yarns of 300 count and above, characterized in that, The non-destructive testing method for ring-spun yarns of 300 count and above is implemented using the non-destructive testing system for ring-spun yarns of 300 count and above as described in any one of claims 1 to 9. The non-destructive testing method for ring-spun yarns of 300 count and above includes: The selected infrared photoelectric modules emit infrared light of a preset wavelength onto the surface of the steel collar ring, and receive the infrared light reflected back by the steel collar ring as the steel wire ring rotates along the steel collar ring, and convert the intensity of the infrared light into an electrical signal. The currently operating infrared photoelectric module is selected, and the electrical signal output by the infrared photoelectric sensing module is sampled by an ADC to obtain the corresponding valid signal; the valid signal is compared and shaped by a comparator to obtain the corresponding periodic pulse signal; the current yarn state is determined based on the periodic pulse signal. The threshold of the comparator is dynamically adjusted based on the valid signal; Based on the average ADC sampling value of the valid signal within the sampling window, the duty cycle of the PWM generator is gradually adjusted to gradually adjust the emitted light intensity of the infrared photoelectric module.

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