Small-size image sensor used in limited space and application thereof

Abstract

The invention relates to a small-size image sensor used in a limited space. The small-size image sensor comprises an upper-layer PCB, a lower-layer PCB, a plurality of supporting columns and an FPC flexible circuit board. A main control chip is integrated on the upper-layer PCB to form a front-end control transmission module; a CMOS image sensor is integrated on the lower PCB, and a lens is assembled on the CMOS image sensor to form a rear-end imaging module; the plurality of supporting columns are connected between the upper-layer PCB and the lower-layer PCB, so that a preset distance is kept between the two layers of PCBs, and a double-layer three-dimensional stacked structure is formed; and two ends of the FPC are respectively connected with the upper layer PCB and the lower layer PCB. The module is simplified, a double-layer three-dimensional stacking structure is adopted, the front-end control transmission module and the rear-end imaging module are integrated on the upper PCB and the lower PCB respectively, and the distance between the boards is controlled accurately through the supporting columns, so that the total size is greatly reduced, and meanwhile, a protection shell and an additional heat dissipation component which are conventionally used are omitted; the total volume is further reduced.

Description

Technical Field

[0001] This invention belongs to the field of textile machinery and equipment technology, and in particular relates to a small-volume image sensor for use in confined spaces and its application. Background Technology

[0002] The quality of cotton slivers produced by carding machines is a key indicator for evaluating their core performance. Accurate detection of the number of neps within the sliver is an indispensable quality control step in the entire textile production process. Neps, a typical defect in cotton processing, are mainly formed by the entanglement and knotting of cotton fibers. The characteristics of currently predominantly machine-harvested cotton raw materials further exacerbate the difficulty of nep control.

[0003] Machine-harvested cotton, limited by its harvesting method, inherently exhibits significant differences in fiber maturity and a higher proportion of short fibers. Furthermore, during mechanical harvesting, the fibers are crushed and beaten by the harvesting equipment, and the friction and tumbling during subsequent pipeline transport easily lead to a substantial increase in the number of neps. Excessive neps have a dual negative impact: firstly, they significantly increase the load on the carding machine's impurity removal system, potentially causing equipment blockages and shutdowns, directly affecting production continuity; secondly, the small neps remaining after carding are easily absorbed by the yarn in subsequent processes, becoming persistent defects throughout the entire textile and dyeing process, ultimately affecting the quality of the finished yarn and fabric. Therefore, accurate nep detection before cotton is spun into yarn or woven into fabric is of significant practical importance for ensuring product quality and improving production efficiency.

[0004] The current mainstream nip detection solution in the industry adopts an independent structure that separates the detection system from the carding machine. The detection system acquires images of the cotton web and identifies nipples during the operation of the carding machine. However, this solution has a clear technical bottleneck: the cover module of the nip detection system is designed to fit the overall structure of the carding machine, and its internal installation space is fixed. Existing image sensors on the market are limited by traditional design concepts and have obvious volume redundancy issues: on the one hand, they integrate multiple functional modules and are equipped with a heavy protective shell and complex heat dissipation structure to ensure operational stability; on the other hand, their integration methods mostly adopt planar arrangement or simple multi-layer stacked design, resulting in a large overall size and shape, which cannot fit into the narrow installation space of the cover module.

[0005] To resolve the aforementioned mismatch between installation space and sensor size, targeted improvements to the image sensor structure without altering the fixed cover module structure have become a key research and development direction for overcoming existing technological bottlenecks. Summary of the Invention

[0006] The main objective of this invention is to propose a small-volume image sensor for use in confined spaces and its application, which can effectively solve the problems in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] A small-volume image sensor for use in confined spaces, comprising:

[0009] The upper PCB board integrates the main control chip, which forms the front-end control and transmission module.

[0010] The lower PCB board integrates a CMOS image sensor, and the CMOS image sensor is equipped with a lens to form a back-end imaging module.

[0011] Multiple support columns are connected between the upper PCB board and the lower PCB board, so that the two PCB boards maintain a predetermined distance and form a double-layer three-dimensional stacked structure.

[0012] The FPC flexible circuit board is connected to the upper PCB board and the lower PCB board at both ends, respectively.

[0013] Preferably, the total envelope size of the double-layer three-dimensional stacked structure does not exceed 30mm×30mm×20mm.

[0014] Preferably, the support column is a copper column and is fixed to the upper PCB board and the lower PCB board by screwing or welding.

[0015] Preferably, a vertical slot is provided on one side of the upper PCB board, one end of the FPC flexible circuit board is inserted into and fixed in the vertical slot, and the other end is connected to the CMOS image sensor.

[0016] Preferably, the vertical slot is provided with at least one limiting protrusion, and the corresponding position of the FPC flexible circuit board is provided with a matching limiting groove, and the limiting protrusion and the limiting groove cooperate to form a mechanical limit.

[0017] An application of a small-volume image sensor for use in confined spaces, wherein the small-volume image sensor for use in confined spaces is installed in a fixed cover module of a carding machine, and the lens images the cotton web through a glass window of the cover module.

[0018] This invention provides a small-volume image sensor for use in confined spaces and its application, which has the following beneficial effects.

[0019] This invention simplifies the module by adopting a double-layer three-dimensional stacked structure, integrating the front-end control and transmission module and the back-end imaging module on the upper and lower PCB boards respectively, and precisely controlling the board spacing through support columns, thereby achieving a significant reduction in overall volume. At the same time, it also eliminates the conventionally used protective shell and additional heat dissipation components, further reducing the overall volume. This ensures that the overall envelope size of the image sensor is strictly controlled within 30mm×30mm×20mm, perfectly fitting the limited installation space within the carding machine's fixed cover module, ensuring that the lens maintains the optimal imaging distance with the cotton web, avoiding spatial interference with other components, and achieving a blind spot-free field of view for capturing cotton knots. Attached Figure Description

[0020] Figure 1 This is a schematic diagram showing the installation location of the detection components on a carding machine.

[0021] Figure 2 This is a schematic diagram of the cover module.

[0022] Figure 3 This is a schematic diagram of the structure of a small-volume image sensor for use in a confined space according to the present invention.

[0023] Figure 4 This is a schematic diagram of the module distribution on the upper and lower PCB boards of the present invention.

[0024] In the diagram: 1. Cotton box; 2. Spike roller; 3. Cylinder; 4. Doffer; 5. Outer shell; 6. Cover module; 7. Fixing shell; 8. Glass window; 9. Side cover; 10. Base; 11. Upper PCB board; 12. Lower PCB board; 13. Supporting copper pillar; 14. Domestic main control chip; 15. FPC flexible connector body; 16. CMOS image sensor; 17. Lens; 18. Vertical slot. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0026] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," and "counterclockwise," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0027] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a mechanical connection or an electrical connection; they may refer to a direct connection or an indirect connection through an intermediate medium; and they may refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0028] like Figure 1 As shown, the main structure of the carding machine includes a cotton box 1, a licker-in roller 2, a cylinder 3 and a doffer 4 connected in sequence. The outer shell 5 covers the core components to form a closed monitoring space.

[0029] The carding machine is equipped with a cotton knot detection and fixing cover module 6, which is installed on the plate of the carding machine housing 5, specifically located next to the gap between the cylinder 3 and the doffer 4; an image sensor is built into the cover module 6, with its lens facing the gap between the cylinder 3 and the doffer 4, which can penetrate the gap to photograph the passing cotton web, thereby realizing the dynamic capture of cotton knots in the cotton web.

[0030] like Figure 2As shown, the cover module 6 consists of a fixed shell 7, a glass window 8, a side cover 9, and a base 10. These components work together to achieve installation, fixation, and sealing protection. The fixed shell 7 has a rectangular shell structure, with a rectangular glass window 8 embedded on its side facing the gap between the cylinder and the doffer. This window is aligned with the lens of the image sensor, ensuring the lens can clearly capture images of the cotton web through the window. A glass plate is pasted on the inner side of the glass window 8, forming a double-layer protective structure to enhance sealing performance. Screw holes are provided on the remaining outer surfaces of the fixed shell 7, corresponding one-to-one with the round holes on the side cover 9, allowing for a secure connection using screws. The side cover 9 has a flat plate structure. During installation, a sealing gasket is added between the mating surfaces of the fixed shell 7 and the side cover 9 to further improve overall sealing and prevent cotton lint, dust, and other debris generated during the carding machine's operation from entering the detection mechanism, thus avoiding affecting detection accuracy. The base 10 serves as the connection base between the cover module and the carding machine, achieving stable installation through its adaptation structure with the outer shell 5.

[0031] In this embodiment, the small-volume image sensor of the present invention for use in confined spaces is used in the above-mentioned cotton knot detection scenario of a carding machine. The structure of the small-volume image sensor for use in confined spaces will be described in detail below.

[0032] Reference Figure 3-4 The present invention provides a small-volume image sensor for use in confined spaces, comprising:

[0033] The upper PCB board 11 integrates the main control chip 14, which constitutes the front-end control and transmission module.

[0034] The lower PCB board 12 integrates a CMOS image sensor 16, and a lens 17 is mounted on the CMOS image sensor 16 to form a back-end imaging module.

[0035] Multiple support columns 13 are connected between the upper PCB board 11 and the lower PCB board 12, so that the two PCB boards maintain a predetermined distance and form a double-layer three-dimensional stacked structure.

[0036] The FPC flexible circuit board 15 is connected to the upper PCB board 11 and the lower PCB board 12 at both ends, respectively.

[0037] The total envelope size of the double-layer three-dimensional stacked structure does not exceed 30mm×30mm×20mm.

[0038] Specifically, the front-end control and transmission module uses the main control chip 14 as its core functional component, which is integrated on the upper PCB board 11 (size 28mm×28mm×1mm). It includes a main control module, a power supply module, an interface module, and a communication connection module. The control program embedded in the chip realizes the timing scheduling of the entire camera system, including exposure control of the CMOS image sensor, data reading triggering, etc., and completes high-speed acquisition and external transmission of image data to ensure the real-time performance of the detection data.

[0039] The back-end imaging module uses a CMOS image sensor 16 as its core, is equipped with a zoom lens 17, and is fitted with high-precision resistive and capacitive components (tolerance ±5%). It is integrated on the lower PCB board 12 (size 28mm×28mm×1mm) to form a complete imaging functional unit. This module, through the progressive scan mode of the CMOS sensor and the clear imaging range of the lens 17, can accurately capture cotton knot features larger than 0.2mm on the surface of the cotton web.

[0040] The upper PCB board 11 and the lower PCB board 12 form a double-layer three-dimensional stacked structure connected by four support columns 13, so that the distance between the two PCB boards is stably controlled at 5mm±0.2mm, ensuring the consistency of the internal space layout.

[0041] Signal transmission between the upper PCB board 11 and the lower PCB board 12 is achieved through an 8-pin FPC flexible circuit board 15. The FPC flexible circuit board 15 is made of 0.1mm thick polyimide substrate (temperature resistance -40℃~125℃) and 5mm wide. Within a 28mm×28mm×18mm three-dimensional integrated space, the FPC flexible circuit 15 is planned with a U-shaped wiring path according to the shortest path principle, with a bending radius ≤1mm, to avoid line breakage caused by stress concentration and achieve low-loss transmission of cross-board signals.

[0042] This invention simplifies the module by adopting a double-layer three-dimensional stacked structure, integrating the front-end control and transmission module and the back-end imaging module on the upper and lower PCB boards respectively, and precisely controlling the board spacing through support columns, thereby achieving a significant reduction in overall volume. At the same time, it also eliminates the conventionally used protective shell and additional heat dissipation components, further reducing the overall volume. This ensures that the overall envelope size of the image sensor is strictly controlled within 30mm×30mm×20mm, perfectly fitting the limited installation space within the carding machine's fixed cover module, ensuring that the lens maintains the optimal imaging distance with the cotton web, avoiding spatial interference with other components, and achieving a blind spot-free field of view for capturing cotton knots.

[0043] Signal transmission between the upper PCB board 11 and the lower PCB board 12 is achieved through the FPC flexible circuit board 15, which reduces intermediate connecting parts, shortens the signal transmission path, ensures signal connectivity and structural flexibility, and adapts to the overall small volume layout requirements.

[0044] As a preferred embodiment, the support column 13 is a metal copper column, which is fixed to the upper PCB board 11 and the lower PCB board 12 by screwing or welding. This not only forms a stable support frame mechanically, but also helps to dissipate heat by utilizing the good thermal conductivity of metal.

[0045] In this embodiment, the support column 13 is made of H62 brass with a diameter of 3mm. Both ends are machined with M3 external threads, and the length is precisely calculated and controlled to be 6mm (including the threaded section). It is fixedly connected to the M3 threaded holes at the corresponding positions of the upper and lower PCB boards to form a rigid support frame. The end of the support column located on the upper PCB board has a protruding section, which serves as a bottom support and facilitates installation into the cover module 6.

[0046] As a preferred embodiment, a vertical slot 18 is provided on one side of the upper PCB board 11, one end of the FPC flexible circuit board 15 is inserted into and fixed in the vertical slot 18, and the other end is connected to the CMOS image sensor 16.

[0047] Furthermore, the vertical slot 18 is provided with at least one limiting protrusion, and the corresponding position of the FPC flexible circuit board 15 is provided with a matching limiting groove. The limiting protrusion and the limiting groove cooperate to form a mechanical limit.

[0048] The vertical slot 18 and the FPC flexible circuit board 15 are tightly fitted by limiting protrusions and limiting grooves, which effectively constrains the insertion and removal direction and position of the FPC flexible circuit board 15, prevents loosening and displacement of the connection, improves the connection reliability under vibration environment, and ensures the electrical connection stability in small volume structure.

[0049] It should be noted that although this invention is mainly used for cotton nip detection in carding machines, its miniaturization, high integration, and high adaptability make it applicable to other fields such as industrial visual inspection, medical imaging, and even special environment monitoring, and it has broad application prospects.

[0050] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A small-volume image sensor for use in confined spaces, characterized in that, include: The upper PCB board integrates the main control chip, which forms the front-end control and transmission module. The lower PCB board integrates a CMOS image sensor, and the CMOS image sensor is equipped with a lens to form a back-end imaging module. Multiple support columns are connected between the upper PCB board and the lower PCB board, so that the two PCB boards maintain a predetermined distance and form a double-layer three-dimensional stacked structure. The FPC flexible circuit board is connected to the upper PCB board and the lower PCB board at both ends, respectively.

2. A small-volume image sensor for use in confined spaces according to claim 1, characterized in that, The total envelope size of the double-layer three-dimensional stacked structure does not exceed 30mm×30mm×20mm.

3. A small-volume image sensor for use in confined spaces according to claim 1, characterized in that, The support column is a metal copper column, which is fixed to the upper PCB board and the lower PCB board by screwing or welding.

4. A small-volume image sensor for use in confined spaces according to claim 1, characterized in that, A vertical slot is provided on one side of the upper PCB board. One end of the FPC flexible circuit board is inserted into and fixed in the vertical slot, and the other end is connected to the CMOS image sensor.

5. A small-volume image sensor for use in confined spaces according to claim 4, characterized in that, The vertical slot is provided with at least one limiting protrusion, and the corresponding position of the FPC flexible circuit board is provided with a matching limiting groove. The limiting protrusion and the limiting groove cooperate to form a mechanical limit.

6. An application of the small-volume image sensor according to any one of claims 1-5 in a confined space, characterized in that, The small-volume image sensor for use in confined spaces is installed in the fixed cover module of the carding machine, and the lens images the cotton web through the glass window of the cover module.

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