Carpet surface flaw detection device and detection method

Abstract

The invention relates to the technical field of flaw detection, in particular to a carpet surface flaw detection device and method. According to the technical scheme, a power applying mechanism and a coloring mechanism are arranged between an unwinding roller and a winding roller, the power applying mechanism comprises a shell and a detection shell, an electric roller is rotationally installed in the shell, a high-voltage electrostatic generator is arranged on the side of the shell, and a plurality of first needle-shaped electrodes are distributed on the electric roller at equal intervals; the coloring mechanism comprises a plurality of operation shells which are located above the moving chamber and fixedly installed in the coloring shell. According to the invention, through the power applying mechanism and the coloring mechanism, the power applying mechanism applies static electricity to the carpet during operation, so that a thread residue, needing to be detected, of the carpet is upright, and the upright thread residue is colored in a space in cooperation with an atomized mixed solution with static electricity generated by the coloring mechanism, so that the thread residue can be quickly positioned; and the subsequent repairing efficiency is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of defect detection, in particular to a carpet surface defect detection device and method. BACKGROUND

[0002] In the carpet production process, excess yarn ends are one of the key defects affecting product quality. Such yarn ends not only affect the flatness and aesthetics of the carpet surface, but also may cause problems such as falling off and entanglement during subsequent use, reducing user experience. Therefore, accurately identifying and removing the excess yarn ends is a core requirement in the carpet quality detection process.

[0003] Currently, the industry mainly relies on two types of technologies for detecting carpet excess yarn ends: one is manual visual inspection, in which the detection personnel observes the carpet surface in sections under standard light and identifies the upright or loose excess yarn ends with the naked eye. This method is simple to operate and low in cost, but has significant drawbacks: on the one hand, it is affected by factors such as subjective judgment differences and long-term detection fatigue, resulting in high miss rate and low efficiency; the second is machine vision detection technology, which captures carpet surface images through an industrial camera and identifies excess yarn ends using algorithms. However, this technology is limited by the low visual contrast between excess yarn ends and the main body of the carpet: the carpet surface pile is in a fluffy state, and the shape and color difference between the excess yarn ends and the normal pile is small, especially on dark or patterned carpet surfaces, the algorithm is prone to misjudgment of the excess yarn ends as normal pile, or miss detection due to the attachment of the yarn ends to the carpet surface. And this kind of detection method, after the equipment takes a photo and locks the defect, the carpet needs to continue to move and be conveyed to the manual repair station, so that the position of the detected defect will also be displaced due to the movement of the carpet, and the repair personnel cannot directly lock the repair position. SUMMARY

[0004] The purpose of the present application is to solve the problems in the background art and provide a carpet surface defect detection device and method.

[0005] The technical solution of the present application is a carpet surface defect detection device, which comprises a unwinding roller, a winding roller and a guide roller, and a power supply mechanism and a coloring mechanism are arranged between the unwinding roller and the winding roller. The power supply mechanism comprises a shell and a detection shell, an electric roller is rotatably installed in the shell, a high-voltage static electricity generator is arranged on the side of the shell, a plurality of first needle-shaped electrodes are equidistantly distributed on the electric roller, a static electricity detection sensor and a second needle-shaped electrode are installed in the detection shell, and the second needle-shaped electrode and the first needle-shaped electrode are electrically connected with the high-voltage static electricity generator. The coloring mechanism comprises a coloring shell, a shell, a detection shell and a moving chamber formed between the shell and the coloring shell, and a plurality of working shells fixedly installed above the moving chamber and in the coloring shell, the working shells are fixedly connected between adjacent working shells, the working shell comprises a surface cavity and an isolation cavity, a suction fan is installed on the top of the coloring shell, a plurality of suction shells are communicated with the suction fan, the suction shells are located above the working shells and have a distance between the working shells, a liquid tank is installed on the side of the coloring shell, a plurality of atomizers are installed in the liquid tank, an electrode ring is arranged at the gas outlet of the atomizer, the electrode ring and the first needle electrode have opposite polarities of electric charge, the atomizer is further provided with a spray head, and the liquid tank is filled with a mixed liquid of colored pigments and volatile solvents.

[0006] Preferably, the electricity applying mechanism further comprises a hot air machine installed outside the shell, the hot air machine is communicated with a wind pipe located in the shell, the wind pipe is provided with a plurality of gas outlets, the wind pipe is located beside the electric roller, and the gas outlets of the wind pipe are obliquely arranged.

[0007] Preferably, a plurality of friction rods are equidistantly distributed on the electric roller, a roller sleeve is arranged on the surface of the electric roller, a jacking roller is rotatably installed at the bottom of the shell, and the jacking roller is located below the electric roller.

[0008] Preferably, two symmetrical hair removal shells are installed on the top of the shell, the hair removal shells are hinged to the shell, and the hair removal shells are provided with sticky heads.

[0009] Preferably, rubber curtains are arranged on both sides of the moving chamber, one rubber curtain is fixed to the shell, the other rubber curtain is fixed to the coloring shell, an electrically conductive coating is arranged on the inner wall of the coloring shell and connected with the grounding system of the workshop.

[0010] Preferably, the shell, the detection shell, the coloring shell, the suction shell and the working shell are all made of insulating materials, and rubber partitions are hinged to the top of the isolation cavity on both sides.

[0011] A carpet surface defect detection method comprises the following steps: S1: winding the carpet to be detected on a winding roller, passing one end of the carpet through a guide roller, and then winding the carpet on a winding roller through a moving chamber; S2: starting the electric roller, the high-voltage electrostatic generator and the suction fan, and injecting the mixed liquid into the liquid tank, the first needle electrode and the carpet are in contact with each other as the moving chamber moves, so that the carpet has static electricity; S3: moving the carpet with static electricity into the coloring shell, passing the carpet thread through the isolation cavity into the coloring shell, atomizing the mixed liquid by the atomizer, applying static electricity by the electrode ring, and then contacting the atomized mixed liquid with the thread and coloring the thread.

[0012] Compared with the prior art, the beneficial effects of the present application are that: the present application can make the thread ends of the carpet that need to be detected stand up by the electrostatic mechanism applying static electricity to the carpet during operation, and the straight thread ends can be colored in a space by the atomized mixed solution with static electricity generated by the coloring mechanism, so that the thread ends can be quickly located, and the efficiency of subsequent repair is improved. BRIEF DESCRIPTION OF DRAWINGS

[0013] Figure 1 The structure schematic diagram in the embodiment of the present application is shown in the figure; Figure 2 The structure schematic diagram of the electrostatic mechanism and the coloring mechanism in the embodiment of the present application is shown in the figure; Figure 3 The structure schematic diagram of the electrostatic mechanism and the coloring mechanism in the embodiment of the present application is shown in the figure; Figure 4 The structure schematic diagram of the electrostatic mechanism and the coloring mechanism in the embodiment of the present application is shown in the figure; Figure 5 The structure schematic diagram of the electrostatic mechanism and the coloring mechanism in the embodiment of the present application is shown in the figure; Figure 6 The structure schematic diagram of the electrostatic mechanism and the coloring mechanism in the embodiment of the present application is shown in the figure.

[0014] The structure schematic diagram of the electrostatic mechanism and the coloring mechanism in the embodiment of the present application is shown in the figure. DETAILED DESCRIPTION

[0015] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments.

[0016] Embodiment one Refer to the attached Figures 1-6 A carpet surface defect detection device, comprising a pay-off roller 100, a take-up roller 200 and a guide roller 300, and an electrostatic mechanism 1 and a coloring mechanism 2 are arranged between the pay-off roller 100 and the take-up roller 200. The electricity applying mechanism 1 comprises a shell 11 and a detection shell 12, the electric roller 3 is rotatably installed in the shell 11, a high-voltage electrostatic generator 4 is arranged on the side of the shell 11, a plurality of first needle electrodes 5 are equidistantly distributed on the electric roller 3, and a static electricity detection sensor 6 and a second needle electrode 7 are installed in the detection shell 12; the second needle electrode 7 and the first needle electrode 5 are electrically connected with the high-voltage electrostatic generator 4; The coloring mechanism 2 comprises a coloring shell 21, a moving chamber 500 is formed between the shell 11, the detection shell 12 and the coloring shell 21, the coloring mechanism 2 further comprises a plurality of working shells 24 which are fixedly installed above the moving chamber 500 and in the coloring shell 21, the adjacent working shells 24 are fixedly connected, the working shell 24 comprises a surface cavity 241 and an isolation cavity 242, a suction fan 22 is installed at the top of the coloring shell 21, a plurality of suction shells 23 are communicated with the suction fan 22, the suction shells 23 are located above the working shells 24 and there is a distance between the suction shells 23 and the working shells 24, a liquid tank 25 is installed on the side of the coloring shell 21, a plurality of atomizers 26 are installed in the liquid tank 25, an electrode ring 27 is arranged at the air outlet of the atomizer 26, the electrode ring 27 and the first needle electrode 5 generate opposite charges, the atomizer 26 is further provided with a spray head 28, and a mixed solution of colored pigment and volatile solvent is injected into the liquid tank 25.

[0017] The existing detection through machine vision detection technology, the carpet needs to continue to move and convey to the artificial repair table, so that the carpet moves, and the detected defective position will also be displaced, the maintenance personnel cannot directly lock the repair position, thereby affecting the repair efficiency.

[0018] The present application applies electricity to the carpet, so that the excess yarn ends form static electricity. When detecting, the carpet moves between the unwinding roller 100, the winding roller 200 and the guide roller 300, and enters the moving chamber 500. After the high-voltage electrostatic generator 4 is connected to the workshop industrial power supply, low-voltage alternating current is converted into high-voltage direct current through the internal high-frequency transformer and the voltage doubling rectifier circuit. Then the high-voltage direct current is transmitted to the first needle electrode 5. At this time, if the high-voltage electrostatic generator 4 is connected to the positive electrode of the first needle electrode 5, the tip will repel positive ions and attract negative ions. Finally, the positive ions move to the yarn ends on the surface of the carpet under the action of the electric field force. At this time, the carpet slowly moves in the moving chamber 500, and the rotation of the electric roller 3 will make the first needle electrode 5 continuously contact the carpet. The positive ions released by the electrode tip of the first needle electrode 5 will be attached to the surface of the yarn ends by the contact transfer method. Therefore, for loose and upright ends, the positive ions directly contact the ends and transfer the charge, so that the ends are quickly positively charged. For the ends attached to the main body of the carpet, the positive ions first attach to the surface of the main body of the carpet, and then the surface of the ends is induced to have a negative charge through charge induction. At the same time, the positive charge inside the ends moves away from the main body. Finally, under the action of the electric field force, the ends gradually separate from the main body and absorb positive ions, completing the charging.

[0019] Subsequently, the positively charged yarn will be subjected to two repulsive forces: one is the repulsive force between the carpet body and the yarn, and the other is the repulsive force between adjacent yarns. The two forces work together to overcome the weight of the yarn and the adhesion between the fibers, making the originally attached and loose yarn gradually stand up and expand its difference with the carpet body, preparing for subsequent coloring.

[0020] As the carpet continues to move into the detection shell 12, the static electricity of the yarn can be monitored in real time by the electrostatic detection sensor 6. If the static electricity is insufficient, the second needle electrode 7 will be in contact with the carpet again to supplement the electricity, avoiding the subsequent adsorption failure caused by weak static electricity.

[0021] When the carpet moves in the detection shell 12, the carpet surface that should be upright and the yarn will be squeezed. When it stops moving in the coloring shell 21, the surface of the carpet will enter the surface cavity 241, and the excess yarn will pass through the isolation cavity 242 into the coloring shell 21. The yarn is located between the air suction shell 23 and the working shell 24. At this time, the air suction machine 22 works to generate suction force. The air suction shell 23 aligned with the isolation cavity 242 can have a certain upward adsorption force. This further ensures that the yarn enters the coloring shell 21. Subsequently, the atomizer 26 atomizes the mixed liquid and applies a negative charge to it through the electrode ring 27 when it is discharged. Subsequently, the mixed liquid is discharged between the working shell 24 and the air suction shell 23 through the nozzle 28. The atomized mixed liquid is forced to adsorb a negative charge, thereby forming negatively charged colored particles. Subsequently, between the working shell 24 and the air suction shell 23, the negatively charged mixed liquid particles will be adsorbed with the positively charged yarn, and the yarn will complete the dyeing. Subsequently, the carpet is moved, and then the dyed yarn can be quickly found by the operator when it is moved to the repair workbench.

[0022] And it needs to be explained that in this embodiment, the colored pigment can be selected as azo red solid particles, and the volatile solvent can be selected as ethanol or isopropyl alcohol. The surface tension of the volatile solvent is low, 20-30 mN / m, which is much lower than that of water, 72 mN / m. Under the action of the atomizer, it is easy to be broken into uniform droplets of 5-10 μm. This size can overcome its own gravity to avoid rapid falling and can be stably suspended in the electrostatic field to avoid escaping with the airflow, which exactly matches the adsorption requirement of the yarn diameter of 0.1-1 mm, ensuring that each atomized particle can effectively contact the yarn.

[0023] In addition, during the specific operation, the atomized mixed liquid will also be adsorbed by the air suction shell 23 when coloring the yarn, avoiding deposition in the coloring shell 21. In addition, the nozzle 28 is directly opposite the isolation cavity 242, so that the atomized mixed liquid can be colored on the yarn first and then be sucked away.

[0024] In addition, in the embodiment, the detection device is provided with a detection camera 400, which can be arranged at the guide roller 300 to perform machine vision detection in the prior art, and can also be arranged at the winding roller 200 to perform re-inspection after dyeing.

[0025] In addition, specifically, the two sides of the moving chamber 500 are provided with rubber curtains 600, one of which is fixed on the shell 11, and the other is fixed on the dyeing shell 21, so that the carpet can continuously pass through but prevent gas from overflowing, avoiding static electricity leakage. The inner wall of the dyeing shell 21 is provided with a conductive coating and is connected with the grounding system of the workshop, so that the conductive coating on the inner wall of the cavity is grounded, and finally forms a complete path with the ground, so that the charge on the conductive coating can be quickly introduced into the ground, avoiding the accumulation of charge.

[0026] The shell 11, the detection shell 12, the dyeing shell 21, the air suction shell 23 and the operation shell 24 are all made of insulating materials, and the top of the isolation cavity 242 is hinged with rubber partitions 243. When working, the thread will first pass through the isolation cavity 242 due to its light weight, and then the rubber partition 243 will be sucked up under the action of the continuous air suction shell 23, so as to cover the isolation cavity 242, preventing the atomized mixture from entering the operation shell 24.

[0027] Embodiment two Referring to the accompanying drawings Figure 2 , Figure 3 and Figure 4 , based on the basis of embodiment one, the electric power supply mechanism 1 further comprises a hot air blower 15 installed outside the shell 11, the hot air blower 15 is communicated with an air pipe 16 located in the shell 11, the air pipe 16 is provided with a plurality of air outlets, the air pipe 16 is located beside the electric roller 3, and the air outlets of the air pipe 16 are inclinedly arranged.

[0028] In the embodiment, a plurality of friction rods 32 are equidistantly distributed on the electric roller 3, the surface of the electric roller 3 is provided with a roller sleeve 31, the bottom of the shell 11 is rotatably installed with a jacking roller 17, the jacking roller 17 is located below the electric roller 3, and the top of the shell 11 is installed with two symmetrical dehairing shells 13, the dehairing shells 13 are hinged to the shell 11, and the dehairing shells 13 are provided with sticky heads 14.

[0029] In the embodiment, in order to improve the effect of enhancing static electricity of the carpet, the roller sleeve 31 and the friction rod 32 are used to generate static electricity by friction, specifically, the static electricity is generated by friction between different materials, such as the friction between the carpet fiber and the insulating material, which generates additional static electricity. After superposition with high-voltage static electricity, the surface potential of the thread can be increased, the standing is more obvious, and the static electricity retention time is longer. Specifically, if the surface of the carpet is polyester / polyamide, the roller sleeve 31 and the friction rod 32 are made of silica gel material, and if the carpet is wool, the roller sleeve 31 and the friction rod 32 are made of nylon material, so as to ensure that the static electricity of the same polarity of the high-voltage electrode is avoided to be offset by the charge after friction. The hot air blower 15 is started to input hot air into the shell 11 through the air pipe 16, and the hot air can blow the loose yarn ends on the surface of the carpet, especially in a humid environment, the fibers are easy to stick together, the hot air can make the yarn ends more fluffy, and at the same time, the humidity of the fibers is reduced, and the dry fibers are easier to store static electricity than the humid fibers, and the leakage of static electricity caused by water vapor is reduced.

[0030] It should be noted that in the present embodiment, the temperature of the hot air is strictly controlled between 30-45℃ to avoid fire, and a temperature sensor is arranged in the shell 11 to monitor the temperature in real time.

[0031] The friction rod 32 can also adhere to the excess hair-like bodies on the carpet, which are similar to the dropped fluff on a sweater, and the hair-like bodies are adhered by the friction rod 32, and when the friction rod 32 rotates to the dehairing shell 13, the excess hair-like bodies are adhered and discharged by the adhering head 14.

[0032] The present application also discloses a carpet surface defect detection method, comprising the following steps: S1: winding the carpet to be detected on the unwinding roller 100, one end of the carpet passing through the guide roller 300, and then winding on the winding roller 200 through the moving chamber 500; S2: starting the electric roller 3, the high-voltage static generator 4, and the air blower 22, and injecting the mixed liquid into the liquid tank 25, and the first needle electrode 5 contacts the carpet to make the carpet have static electricity as the moving chamber 500 moves; S3: the carpet with static electricity moves into the coloring shell 21, the yarn ends of the carpet pass through the isolation cavity 242 into the coloring shell 21, the mixed liquid is atomized by the atomizer 26, and static electricity is applied by the electrode ring 27, and then the atomized mixed liquid contacts the yarn ends and colors them.

[0033] In the description of the present application, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0034] In addition, the terms "first", "second", etc. are used only for the purpose of description, and should not be understood as indicating or implying relative importance or implying the number of the technical features indicated. Therefore, the features defined as "first", "second" can explicitly or implicitly include one or more of the features. In the description of the present application, the meaning of "a plurality of" is two or more, unless otherwise specifically limited.

[0035] The above description is only the preferred embodiment of the present application, but the protection scope of the present application is not limited thereto, any person skilled in the art can make equivalent replacements or changes within the technical range disclosed by the present application according to the technical solution and the inventive concept of the present application, which should be covered within the protection scope of the present application.

Claims

1. A carpet surface defect detection device, comprising an unwinding roller, a winding roller, and a guide roller, characterized in that, An electric shock mechanism and a coloring mechanism are provided between the unwinding roll and the take-up roll; The electric application mechanism includes an outer shell and a detection shell. An electric roller is rotatably installed inside the outer shell, and a high-voltage electrostatic generator is provided on the side of the outer shell. Several first needle-shaped electrodes are evenly distributed on the electric roller. An electrostatic detection sensor and a second needle-shaped electrode are installed inside the detection shell. Both the second needle-shaped electrode and the first needle-shaped electrode are electrically connected to the high-voltage electrostatic generator. The coloring mechanism includes a coloring shell, and a moving chamber is formed between the outer shell, the detection shell, and the coloring shell. The coloring mechanism also includes several working shells, which are fixedly connected to each other. A suction fan is installed on the top of the coloring shell, and the suction fan is connected to several suction shells. The suction shells are located above the working shells and there is a distance between them. A liquid tank is installed on the side of the coloring shell, and several atomizers are installed in the liquid tank. The outlet of the atomizer is equipped with an electrode ring. The electrode ring and the first needle electrode generate charges with opposite polarities. The atomizer is also equipped with a nozzle. A mixture of colored pigment and volatile solvent is injected into the liquid tank.

2. The carpet surface defect detection device according to claim 1, characterized in that, The working shell is located above the moving chamber and is fixedly installed inside the coloring shell. The working shell includes a surface cavity and an isolation cavity.

3. The carpet surface defect detection device according to claim 1, characterized in that, The power supply mechanism also includes a hot air blower installed outside the enclosure, which is connected to a duct located inside the enclosure.

4. The carpet surface defect detection device according to claim 3, characterized in that, The air duct has several air outlets, and the air duct is located next to the electric roller. The air outlets of the air duct are set at an angle.

5. The carpet surface defect detection device according to claim 3, characterized in that, The electric roller has several friction rods evenly distributed on its surface, and a roller sleeve is provided on the surface of the electric roller. A lifting roller is rotatably installed at the bottom of the outer shell and is located below the electric roller.

6. The carpet surface defect detection device according to claim 5, characterized in that, Two symmetrically arranged de-hair shells are installed on the top of the outer shell. The de-hair shells are hinged to the outer shell and have adhesive heads inside.

7. The carpet surface defect detection device according to claim 1, characterized in that, Rubber curtains are installed on both sides of the mobile compartment. One rubber curtain is fixed to the outer shell, and the other rubber curtain is fixed to the upper shell.

8. The carpet surface defect detection device according to claim 1, characterized in that, The outer shell, detection shell, coloring shell, suction shell, and working shell are all made of insulating materials, and rubber partitions are hinged to the top of both sides of the isolation chamber.

9. A carpet surface defect detection device according to claim 6, characterized in that, The inner wall of the colored shell is coated with a conductive coating, which is connected to the workshop's grounding system.

10. A method for detecting surface defects in carpets, based on the carpet surface defect detection device according to claim 1, characterized in that, Includes the following steps: S1: The carpet to be tested is wound onto the unwinding roller. One end of the carpet passes through the guide roller and then passes through the moving chamber to be wound onto the winding roller. S2: Start the electric roller, high-voltage electrostatic generator, and suction fan, and inject the mixture into the liquid tank. As the moving chamber moves, the first needle electrode comes into contact with the carpet, causing the carpet to become statically charged. S3: The carpet with static electricity moves into the coloring shell. The carpet thread ends pass through the isolation chamber into the coloring shell, where the mixture is atomized by the atomizer and static electricity is applied through the electrode ring. Then, the atomized mixture comes into contact with the thread ends and is colored.

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