Flame-retardant test control system and method for chemical flame-retardant fabric production

Abstract

The invention discloses a flame-retardant test control system and a flame-retardant test control method for chemical flame-retardant fabric production, and relates to the technical field of flame-retardant test.The flame-retardant test control system and the flame-retardant test control method are characterized in that fabric image data are collected and analyzed in real time after first-time ignition through an automatic process, an extinguishment coefficient in a quantitative extinguishment state is calculated, and whether fabric is extinguished or not is accurately judged according to the extinguishment coefficient; and if the flame retardant is extinguished, immediately executing second ignition to simulate a reignition risk, otherwise, returning to retry or ending, so that the whole process realizes objective and rapid evaluation of the flame retardant property. According to the invention, human eye judgment is replaced by image acquisition and intelligent analysis, so that automation and standardization of flame extinguishing identification are realized; the extinguishing state or the smoldering state is accurately distinguished by combining a double analysis mechanism of area and position change; the system immediately triggers secondary ignition after judging that the material is extinguished, so that the material is ensured to be in a standard thermal state, and the reignition risk is truly simulated; the whole closed-loop process improves the test efficiency and reliability, and provides a quantitative evaluation basis for the flame retardant property.

Description

Technical Field

[0001] This invention relates to the field of flame retardant testing technology, specifically to a flame retardant testing control system and method for the production of chemical flame retardant fabrics. Background Technology

[0002] In flame retardant testing, a second ignition is required immediately after the initial flame is extinguished. This is intended to simulate the extreme risk of material reignition under high-temperature damage in a real fire. However, the effectiveness of this test is fundamentally contradictory: the determination of complete flame extinguishment relies entirely on human vision, which makes it impossible for the operator to accurately grasp the timing. This subjective judgment inevitably introduces a time delay, causing the thermal state of the material to change uncontrollably during the second ignition, ultimately compromising the accuracy of the test. Summary of the Invention

[0003] Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a flame-retardant testing and control system and method for the production of chemical flame-retardant fabrics. It solves the problem that in vertical burning tests, the stringent intent to simulate the risk of reignition is contradictory due to the subjective time delay caused by relying on human judgment of flame extinguishing, leading to the loss of control over the thermal state of the material during secondary ignition and thus weakening the accuracy of the test.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a flame retardant testing and control method for the production of chemical flame retardant fabrics, comprising the following specific steps: Step 1: igniting the flame retardant fabric for the first time; Step 2: acquiring fabric image data in real time and preprocessing it; Step 3: calculating and analyzing the preprocessed fabric image data to obtain the extinguishing coefficient; Step 4: analyzing the extinguishing status of the flame retardant fabric based on the extinguishing coefficient; Step 5: if the flame retardant fabric is extinguished, proceed to Step 6; otherwise, return to Step 1 or terminate directly; Step 6: igniting the flame retardant fabric for the second time, and returning to Step 1 or terminating directly.

[0005] Furthermore, the specific method for obtaining the extinction coefficient is as follows: the fabric image data is calculated using an image contour segmentation algorithm and an image contour tracking algorithm to obtain an image contour; the image contour is matched with a preset reference template to obtain a hot spot contour; the area change anomaly value and the position change anomaly value are calculated based on the area change and temperature change of the hot spot contour respectively; the area change anomaly value and the position change anomaly value are comprehensively calculated and normalized to obtain the extinction coefficient.

[0006] Furthermore, the specific method for obtaining the area change anomaly is as follows: the fabric image data includes the number of pixels and the coordinates of the pixels. Therefore, in the time series, the number of pixels in the hot spot outline at each moment is counted to obtain the hot spot outline area at each moment, which is recorded as the hot spot area. The increase of the hot spot area at the next moment and the hot spot area at the previous moment is analyzed. If an increase is found, the increase area of ​​the hot spot area is calculated to obtain the area change anomaly.

[0007] Furthermore, the method for analyzing the increase of the hot spot area at the next moment compared with the hot spot area at the previous moment is as follows: the hot spot area at the next moment is compared with the hot spot area at the previous moment. If the hot spot area at the next moment is greater than the hot spot area at the previous moment, it indicates an increase. If the hot spot area at the next moment is less than or equal to the hot spot area at the previous moment, it indicates a decrease or no change.

[0008] Furthermore, the specific calculation method for the increase in the hot spot area is as follows: the difference between the hot spot area at the next moment and the hot spot area at the previous moment is calculated sequentially to obtain each increase area, and then the increase areas are summed.

[0009] Furthermore, the specific method for obtaining the position change anomaly value is as follows: if the hot spot area at the next moment is less than or equal to the hot spot area at the previous moment, then the change of each pixel point within the hot spot outline is calculated to obtain the position change anomaly value.

[0010] Furthermore, the specific method for calculating the changes of each pixel within the hot spot contour is as follows: The magnitude of each pixel coordinate in the hot spot contour at the next moment is calculated by combining the magnitudes of each pixel coordinate in the hot spot contour at the previous moment. Then, the magnitudes are summed.

[0011] Furthermore, the specific method for analyzing the extinguishing status of flame-retardant fabric based on the extinguishing coefficient is as follows: a preset extinguishing threshold and a detection period are set, and the extinguishing coefficient is compared with the extinguishing threshold. If the extinguishing coefficient is greater than the extinguishing threshold within the detection period, it indicates that the flame-retardant fabric has not been extinguished. If the extinguishing coefficient is always less than or equal to the extinguishing threshold within the detection period, it indicates that the flame-retardant fabric has been extinguished.

[0012] Furthermore, the specific method for obtaining the extinction threshold is as follows: the historical values ​​of the extinction coefficient are averaged to obtain the extinction threshold.

[0013] A flame-retardant testing and control system for the production of chemical flame-retardant fabrics includes the following specific modules: a data acquisition module, a material extinguishing analysis module, and an ignition module. The data acquisition module is used to acquire fabric image data in real time and perform preprocessing. The material extinguishing analysis module is used to calculate and analyze the preprocessed fabric image data to obtain an extinguishing coefficient. Based on the extinguishing coefficient, the extinguishing status of the flame-retardant fabric is analyzed. If the flame-retardant fabric is extinguished, the ignition module is executed; otherwise, the process returns to the data acquisition module or terminates directly. The ignition module is used to perform the first and second ignitions on the flame-retardant fabric. After ignition, the process returns directly to the data acquisition module or terminates directly.

[0014] Beneficial effects Compared with the prior art, the embodiments of the present invention have at least the following advantages or beneficial effects: 1. By using high-resolution image acquisition and real-time processing algorithms, the traditional subjective judgment relying on human eyes is replaced, eliminating time errors caused by differences in operator experience or reaction delays. This makes the judgment standard for the moment of extinguishing uniform and repeatable, providing a reliable basis for subsequent accurate secondary ignition.

[0015] 2. This invention not only monitors the growth of hot spot area, but also innovatively captures its stability by quantifying the positional changes of pixels inside the hot spot when the area does not grow. This dual analysis mechanism of area change and position change can more finely distinguish between states such as extinguishing, stable smoldering, and imminent reignition, significantly improving the accuracy of judgment and early warning capability.

[0016] 3. The system can trigger secondary ignition immediately at the moment the flame is truly extinguished. This minimizes the uncontrollable cooling interval between the first extinguishing and the secondary ignition, ensuring that the material is still in the high-temperature thermal damage state expected by the standard during secondary ignition. This realistically simulates the risk of reignition in actual fires, making the test results more scientific.

[0017] 4. By integrating image acquisition, intelligent analysis, and ignition control into an automated, cyclical process, this system operates stably, reduces human intervention and operational errors, significantly improves testing efficiency, is suitable for rapid batch testing on production lines, and provides quantitative data support for the evaluation and grading of fabric flame retardancy through data-driven extinguishing coefficients.

[0018] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0019] Figure 1 This is a flowchart of the flame retardant testing and control method of the present invention.

[0020] Figure 2This is a structural diagram of the flame retardant test and control system of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus.

[0023] Example 1: like Figure 1 As shown in the figure, this invention provides a flame retardant testing and control method for the production of chemical flame retardant fabrics, including the following specific steps: Step 1: The flame-retardant fabric is ignited for the first time using a methane igniter. The flame length, output heat flow, distance and angle of the methane igniter from the sample are precisely controlled according to international standards to ensure the consistency of ignition conditions for each test and to provide a repeatable and comparable heat source. Flame-retardant fabric samples are typically suspended vertically in a specially designed metal clamp to ensure they are wrinkle-free. A non-combustible dark background is placed behind them to enhance image contrast. A methane igniter is fixed on a precisely movable bracket so that its nozzle is aligned with the designated center position of the lower edge of the sample and maintained at a preset distance and angle. This arrangement simulates the vertical fire state of the fabric, ensuring a standardized contact between the flame and the fabric, while providing a clear field of view for image acquisition.

[0024] Step 2: Real-time acquisition of fabric image data using a thermal imager, followed by noise reduction processing. This involves smoothing random noise using Gaussian filtering, removing inherent noise from the image sensor in the thermal imager, while preserving key details of the flame and fabric edges, thereby increasing the accuracy of the assessment of the fabric's flame retardant performance.

[0025] Step 3: Calculate and analyze the noise-reduced fabric image data to obtain the extinguishing coefficient; Step 4: Analyze the extinguishing performance of the flame-retardant fabric based on the extinguishing coefficient; Step 5: If the flame-retardant fabric extinguishes, proceed to Step 6; otherwise, return to Step 1 or end the process directly. Step Six: Ignite the flame-retardant fabric a second time using a methane igniter, and then return to Step One or end the process directly.

[0026] Example 2 differs from Example 1 in that: The specific method for obtaining the extinction coefficient is as follows: Image contour segmentation and image contour tracking algorithms are used to calculate fabric image data. For example, the Sobel algorithm first converts the image data to grayscale to simplify calculations. Then, it convolves the data with 3×3 kernels in the horizontal and vertical directions to obtain the horizontal and vertical gradient matrices. Next, it calculates the gradient magnitude and direction; the former determines the edge, and the latter determines the edge extension direction. Finally, it performs threshold binarization, marking pixels above the threshold as contours, thus obtaining the image contour. Image contour tracking algorithms, such as the Lucas-Kanade optical flow method, establish optical flow constraint equations based on the assumption of constant brightness between adjacent frames. It calculates spatial and temporal gradients using the Sobel algorithm and frame differences, constructs an overdetermined system of equations assuming consistent neighborhood motion, and solves for the optical flow velocity using the least squares method. Finally, it performs tracking and position updates to track the image contour. The image contour is matched with a preset reference template. Hot spots are identified based on the significant characteristics of flames and high-temperature areas in specific color channels, such as extremely high red channel values ​​and extremely low blue channel values ​​in RGB images. Therefore, a color threshold template based on historical data is preset. If the color values ​​of most pixels in the image contour fall within the range of this template, it is determined to be a hot spot contour. The hot spot contour is then obtained. The area change and temperature change of the hot spot contour are calculated to obtain area change anomalies and position change anomalies. The area change anomalies and position change anomalies are combined and normalized to eliminate the difference in dimensions and transform the values ​​of different orders of magnitude into a unified numerical range to obtain the extinguishing coefficient. ; in, This indicates the extinguishing coefficient, reflecting the extinguishing performance of the flame-retardant fabric. This indicates anomalies in area variation, reflecting changes in the area of ​​the hot spot. This indicates anomalies in location changes, reflecting abnormalities in the movement of hot spot positions. or Represents a positive real number to avoid the extinguishing coefficient being meaningless when the area change or position change is an anomaly.

[0027] The specific methods for obtaining outlier values ​​in area variation are as follows: Fabric image data includes the number of pixels and pixel coordinates. Therefore, in the time series, the number of pixels within the hot spot outline at each moment is counted to obtain the hot spot outline area at each moment, which is recorded as the hot spot area. The increase of the hot spot area at the next moment compared with the hot spot area at the previous moment is analyzed. That is, flame-retardant fabrics are designed to prevent the spread of fire. If the hot spot area continues to increase, it indicates that the flame-retardant performance is insufficient. Therefore, by accurately capturing this growth trend, the flame-retardant ability of the fabric is assessed to determine whether it meets the standards. If an increase is found, the increase area of ​​the hot spot area is calculated to obtain the area change anomaly value.

[0028] The method for analyzing the increase in hotspot area between the next and previous time steps is as follows: The area of ​​the hot spot at the next moment is compared with the area of ​​the hot spot at the previous moment. If the area of ​​the hot spot at the next moment is greater than the area of ​​the hot spot at the previous moment, it indicates an increase. If the area of ​​the hot spot at the next moment is less than or equal to the area of ​​the hot spot at the previous moment, it indicates a decrease or no change.

[0029] The specific calculation method for the increase in hot spot area is as follows: The difference between the hotspot area at the next moment and the hotspot area at the previous moment is calculated sequentially to obtain the growth area, and then the growth areas are summed.

[0030] The specific methods for obtaining location change outliers are as follows: If the area of ​​the hot spot at the next moment is less than or equal to the area of ​​the hot spot at the previous moment, the changes of each pixel within the hot spot outline are calculated to obtain the position change anomaly value.

[0031] The specific method for calculating the changes of each pixel within the hot spot outline is as follows: The magnitude of the vectors of the coordinates of each pixel within the hotspot contour at the next moment and the coordinates of each pixel within the hotspot contour at the previous moment are calculated. The magnitudes are then summed. That is, when the hotspot area does not increase, its stability is evaluated by quantifying the positional changes of pixels within the contour. If the hotspot is extinguishing, the contour shrinks and the internal pixel positions are stable, and the sum of the magnitudes is small. If the hotspot is not extinguishing but undergoes regional movement or deformation, the pixel coordinates change significantly, and the sum of the magnitudes is large. Thus, the magnitude of the sum of the magnitudes distinguishes between the state of gradual extinguishing and the state of continuous burning without expansion, so that the abnormal values ​​of positional changes directly reflect the continuous tendency of the hotspot.

[0032] The specific method for analyzing the extinguishing performance of flame-retardant fabrics based on the extinguishing coefficient is as follows: The system presets an extinction threshold and a detection period. For example, if the detection period is 3 seconds, the extinction coefficient is compared with the extinction threshold. If the extinction coefficient is greater than the extinction threshold within the detection period, it means that the flame-retardant fabric is not extinguished. If the extinction coefficient is always less than or equal to the extinction threshold within the detection period, it means that the flame-retardant fabric is extinguished.

[0033] The specific method for obtaining the extinction threshold is as follows: The extinction threshold is obtained by averaging the historical values ​​of the extinction coefficient.

[0034] Example 3: like Figure 2 As shown: A flame retardant testing and control system for the production of chemical flame retardant fabrics includes the following specific modules: Data acquisition module: used to acquire fabric image data in real time and perform noise reduction processing; Material Extinguishing Analysis Module: This module calculates and analyzes the noise-reduced fabric image data to obtain the extinguishing coefficient. Based on the extinguishing coefficient, it analyzes the extinguishing status of the flame-retardant fabric. If the flame-retardant fabric is extinguished, the ignition module is executed; otherwise, it returns to the data acquisition module or terminates directly. Ignition module: Used for the first and second ignition of flame-retardant fabric. After ignition, it returns directly to the data acquisition module or ends directly.

[0035] The preferred embodiments of the present invention disclosed above are merely illustrative examples to help those skilled in the art understand the technical solutions and implementation methods of the present invention, and are not intended to limit the scope of protection of the present invention. These embodiments do not exhaustively list all possible implementation details, nor do they constitute a limitation on the uniqueness of the technical solutions of the present invention. Based on the principles and concepts disclosed in this specification, those skilled in the art can make appropriate adjustments, substitutions, or combinations to the method steps, module structures, algorithm parameters, or hardware configurations without creative effort. For example, different image filtering algorithms can be used, hot spot recognition thresholds can be adjusted, and equivalent ignition control devices can be replaced. These modifications and changes should still be considered to fall within the scope of protection defined by the claims of the present invention. Therefore, any equivalent substitutions, structural modifications, or logical improvements made based on the content of this specification and drawings, as long as they do not depart from the technical spirit disclosed in the present invention, should be included within the scope of protection of this patent. The scope of protection of the present invention is defined only by the appended claims and their legal equivalents.

Claims

1. A flame retardant testing and control method for the production of chemical flame retardant fabrics, characterized in that: The specific steps include the following: Step 1: Ignite the flame-retardant fabric for the first time; Step 2: Acquire fabric image data in real time and perform preprocessing; Step 3: Calculate and analyze the preprocessed fabric image data to obtain the extinguishing coefficient; Step 4: Analyze the extinguishing performance of the flame-retardant fabric based on the extinguishing coefficient; Step 5: If the flame-retardant fabric extinguishes, proceed to Step 6; otherwise, return to Step 1 or end the process directly. Step Six: Ignite the flame-retardant fabric a second time, and then return to Step One or end the process directly.

2. The flame retardant testing and control method for the production of chemical flame retardant fabrics according to claim 1, characterized in that: The specific method for obtaining the extinction coefficient is as follows: The fabric image data is calculated using image contour segmentation and image contour tracking algorithms to obtain the image contour. The image contour is then matched with a preset reference template to obtain the hot spot contour. Based on the area change and temperature change of the hot spot contour, outliers in area change and position change are calculated. The outliers in area change and position change are then combined and normalized to obtain the extinguishing coefficient.

3. The flame retardant testing and control method for the production of chemical flame retardant fabrics according to claim 2, characterized in that: The specific method for obtaining the abnormal values ​​of area change is as follows: Fabric image data includes the number of pixels and pixel coordinates. Therefore, in the time series, the number of pixels in the hot spot outline at each moment is counted to obtain the hot spot outline area at each moment, which is recorded as the hot spot area. The increase of the hot spot area at the next moment and the hot spot area at the previous moment is analyzed. If an increase is found, the increase area of ​​the hot spot area is calculated to obtain the area change anomaly value.

4. The flame retardant testing and control method for the production of chemical flame retardant fabrics according to claim 3, characterized in that: The method for analyzing the increase of the hotspot area at the next moment compared to the previous moment is as follows: The area of ​​the hot spot at the next moment is compared with the area of ​​the hot spot at the previous moment. If the area of ​​the hot spot at the next moment is greater than the area of ​​the hot spot at the previous moment, it indicates an increase. If the area of ​​the hot spot at the next moment is less than or equal to the area of ​​the hot spot at the previous moment, it indicates a decrease or no change.

5. The flame retardant testing and control method for the production of chemical flame retardant fabrics according to claim 4, characterized in that: The specific method for calculating the increase in the area of ​​the hot spot is as follows: The difference between the hotspot area at the next moment and the hotspot area at the previous moment is calculated sequentially to obtain the growth area, and then the growth areas are summed.

6. The flame retardant testing and control method for the production of chemical flame retardant fabrics according to claim 5, characterized in that: The specific method for obtaining the abnormal value of the location change is as follows: If the area of ​​the hot spot at the next moment is less than or equal to the area of ​​the hot spot at the previous moment, the changes of each pixel within the hot spot outline are calculated to obtain the position change anomaly value.

7. The flame retardant testing and control method for the production of chemical flame retardant fabrics according to claim 6, characterized in that: The specific method for calculating the changes of each pixel within the hot spot contour is as follows: The magnitude of each pixel coordinate in the hot spot contour at the next moment is calculated by combining the magnitudes of each pixel coordinate in the hot spot contour at the previous moment. Then, the magnitudes are summed.

8. The flame retardant testing and control method for the production of chemical flame retardant fabrics according to claim 7, characterized in that: The specific method for analyzing the extinguishing status of flame-retardant fabrics based on the extinguishing coefficient is as follows: The system presets an extinction threshold and a detection period. It compares the extinction coefficient with the extinction threshold. If the extinction coefficient is greater than the extinction threshold within the detection period, it means that the flame-retardant fabric is not extinguished. If the extinction coefficient is always less than or equal to the extinction threshold within the detection period, it means that the flame-retardant fabric is extinguished.

9. The flame retardant testing and control method for the production of chemical flame retardant fabrics according to claim 8, characterized in that: The specific method for obtaining the extinction threshold is as follows: The extinction threshold is obtained by averaging the historical values ​​of the extinction coefficient.

10. A flame retardant testing and control system for the production of chemical flame retardant fabrics, used to implement the flame retardant testing and control method for the production of chemical flame retardant fabrics as described in any one of claims 1-9, characterized in that, The flame retardant test and control system for the production of chemical flame retardant fabrics includes: a data acquisition module, a material extinguishing analysis module, and an ignition module. Data acquisition module: used to acquire fabric image data in real time and perform preprocessing; Material Extinguishing Analysis Module: This module calculates and analyzes the pre-processed fabric image data to obtain the extinguishing coefficient. Based on the extinguishing coefficient, it analyzes the extinguishing status of the flame-retardant fabric. If the flame-retardant fabric is extinguished, the ignition module is executed; otherwise, it returns to the data acquisition module or terminates directly. Ignition module: Used for the first and second ignition of flame-retardant fabric. After ignition, it returns directly to the data acquisition module or ends directly.

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