Online indigo dye concentration detection equipment based on spectral change

Abstract

The invention discloses online indigo dye concentration detection equipment based on spectral change, relates to the technical field of dye concentration detection, and solves the problems of lagging, large manual error, no closed-loop control and the like of the existing offline detection. The equipment comprises a box body, a sampling assembly, a filtering assembly, a spectrum detection assembly, a display control assembly, a cleaning mechanism and a dye flow adjusting assembly, the inside of the box body is divided into a detection area and a control area, the sampling mechanism collects dye liquor from a sizing and dyeing combination machine, the dye liquor enters the detection pool after secondary filtration, the spectrum detection mechanism combines multiple sensors to collect spectrum signals, the controller calculates the real-time concentration through an algorithm, the flow adjusting assembly can be linked to achieve automatic supply of dye, and the dye liquor can flow back and be reused after detection. The cleaning mechanism can automatically clean the detection pool. The equipment is high in detection precision and strong in interference resistance, realizes online continuous detection and closed-loop control of indigo dye concentration, is adaptive to continuous production of a sizing and dyeing combination machine, reduces labor cost and dye waste, and improves the quality of printed and dyed products.

Description

Technical Field

[0001] This invention relates to the field of dye concentration detection technology, and more specifically, to an online indigo dye concentration detection device based on spectral changes. Background Technology

[0002] Indigo dye is a widely used natural or synthetic dye. Its unique blue color makes it crucial in the textile dyeing industry (especially denim dyeing), and it is also used in coloring processes in the chemical, food, and pharmaceutical fields. Indigo dye itself is insoluble in water. In textile dyeing and printing processes, it must be reduced to a water-soluble leuco form using a reducing agent (such as sodium dithionite) before dyeing can proceed. The concentration of the leuco form directly determines the color depth, uniformity, and colorfastness of the dyed fabric, while the content of oxidized indigo affects dyeing stability and wastewater treatment efficiency. Therefore, real-time and accurate detection of the concentrations of oxidized and reduced indigo dye solutions is of great significance for ensuring production quality, reducing production costs, and minimizing wastewater discharge.

[0003] In the denim dyeing and finishing industry, the sizing and dyeing combined machine is the core equipment for continuous dyeing and sizing of denim yarn. It adopts a continuous long-carriage production mode, characterized by high production efficiency and large capacity, making it a key piece of equipment for large-scale denim production. Indigo dye, as the core raw material for denim dyeing, directly determines the dyeing uniformity and color consistency of denim yarn and subsequent fabrics through its concentration stability. Fluctuations in dye concentration can lead to quality defects in denim products, such as color differences and uneven coloring, affecting not only the product qualification rate but also causing dye waste and increased production costs.

[0004] Currently, indigo dye concentration is primarily monitored offline during the production process of a combined sizing and dyeing machine. Operators periodically sample the dye liquor circulation system, perform laboratory testing using spectrophotometers or similar equipment, and then manually adjust the dye supply flow rate based on the results. This method has significant drawbacks: First, there is a lag in detection. The offline sampling, testing, and analysis process takes time, while combined sizing and dyeing machines operate continuously for extended periods. During this time, the dye liquor concentration may have changed considerably, leading to untimely adjustments and batch quality issues. Second, human error is significant. The representativeness of the samples, the standardization of the testing process, and the accuracy of manual flow adjustments all rely on the operator's experience, making human error prone to occur. Third, the labor intensity is high. Frequent sampling, testing, and adjustments during continuous production increase labor costs and make 24-hour uninterrupted monitoring difficult. Fourth, the existing offline detection method cannot match the continuous production rhythm of the combined sizing and dyeing machine, failing to achieve closed-loop control of dye concentration and thus failing to meet the refined requirements of high-quality denim production. Summary of the Invention

[0005] The purpose of this invention is to provide an online indigo dye concentration detection device based on spectral changes. This device is suitable for continuous long-run production in sizing and dyeing combined machines, has high detection accuracy, strong anti-interference ability, and can adjust the dye flow rate in conjunction with the machine, thus solving the key pain points of the current denim printing and dyeing industry.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: an online detection device for indigo dye concentration based on spectral changes, comprising a housing, a sampling mechanism, a filtering mechanism, a spectral detection mechanism, and a display and control component; the back of the housing is provided with a detachable heat dissipation plate, and the interior is provided with a vertically arranged partition that divides the interior of the housing into a detection area and a control area, and the filtering mechanism and the spectral detection mechanism are installed in the detection area;

[0007] The sampling mechanism includes a sampling pump and a sampling tube; the sampling pump is located on the top of the housing, one end of the sampling tube is connected to the input end of the sampling pump, and the other end is connected to the dye liquor circulation pipeline of the pulp and dyeing combined machine; the output end of the sampling pump is provided with a connecting pipe connected to the filtration mechanism.

[0008] The spectral detection mechanism includes a spectral detector, a light source generator, a detection cell, and a signal conditioning module; the filtration mechanism is connected to the inside of the detection cell via a connecting pipe; the spectral detector and the light source generator are located on opposite sides of the detection cell; the detection cell has a drain outlet with a drain pipe penetrating the side of the housing, and an electrically controlled valve is located at the drain outlet; the light source generator emits detection light of a specific wavelength, the spectral detector captures the absorption spectral signal of the dye solution to the detection light, and the signal conditioning module processes the electrical signal output by the spectral detector;

[0009] The display and control components include a controller, a data storage module, a signal transmission module, a display screen, and a button control area. The display screen and button control area are located on the front of the housing, and the button control area has several multi-function buttons. The controller has a built-in concentration calculation algorithm for analyzing and processing spectral signals and calculating the real-time concentration of indigo dye. The data storage module is used to store detection data and equipment parameters, and the signal transmission module is used to realize data transmission.

[0010] By adopting the above technical solution, real-time online sampling, filtration, and spectral detection of indigo dye liquor are achieved, abandoning the traditional offline detection method. Dye concentration is accurately calculated using spectral changes, and the detection data is displayed, stored, and transmitted in real time, replacing the traditional offline detection method and solving the problems of detection lag and large human error. By dividing the internal chamber into a detection area and a control area, dry and wet separation is achieved, improving the safety and stability of equipment operation. The display screen and button control area enable real-time display of detection data and convenient operation of the equipment. The data storage module enables data retention and traceability, and the signal transmission module enables remote data transmission, adapting to the intelligent management needs of industrial production. Overall, online, real-time, and automated detection of indigo dye concentration is achieved, adapting to the continuous production rhythm of the sizing and dyeing combined machine. The sampling mechanism is directly connected to the dye liquor circulation pipeline of the sizing and dyeing combined machine, enabling continuous and uninterrupted sampling, adapting to continuous long-run production modes, and reducing manual labor intensity.

[0011] The present invention is further configured such that: the filtering mechanism includes a filter one, the filter one including a cover, an upper shell and a lower shell; the cover is threadedly sealed to the top of the upper shell, and the bottom of the upper shell is threadedly sealed to the top of the lower shell; the inner walls of the upper shell and the lower shell are provided with limiting rings, and the limiting rings are provided with a plurality of limiting holes; the upper shell and the lower shell are respectively provided with filter screen one and filter screen two, and the bottom edges of filter screen one and filter screen two are provided with limiting posts; filter screen one and filter screen two are inserted into the limiting holes of the adjacent limiting rings through the limiting posts; the top of the cover is provided with a liquid inlet one, and the bottom of the lower shell is provided with a liquid outlet one; one end of the connecting pipe one is connected to the liquid inlet one, and the liquid outlet one is provided with a connecting pipe two and a connecting pipe three for connection; the outer surface of the upper shell is provided with a limiting protruding ring.

[0012] By adopting the above technical solutions, filter one uses a split structure with threaded sealing connection, which enables quick disassembly and assembly, facilitating the cleaning, replacement, and maintenance of the internal filter screen. The cooperation of the limiting post and limiting hole ensures precise positioning and fixation of filter screen one and filter screen two, preventing filter screen displacement due to dye liquor impact and ensuring the stability of the filtration effect. The double-layer filter screen allows for step-by-step coarse filtration of the dye liquor, effectively removing large particulate impurities and flocculent matter, preventing impurities from entering the detection cell and affecting the accuracy of spectral detection. The limiting protruding ring facilitates hand-held disassembly, assembly, and placement of filter one, improving the convenience of equipment maintenance.

[0013] The present invention is further configured such that: the filtration mechanism further includes a second filter, the second filter being a ceramic filter element; the second filter is provided with a second inlet and a second outlet; one end of the second connecting pipe is connected to the first outlet and the other end is connected to the second inlet; one end of the third connecting pipe is connected to the second outlet and the other end is connected to the detection pool; a fixing clamp is provided on the inner side wall of the box, the fixing clamp being used to fix the first filter and the second filter.

[0014] By adopting the above technical solution, a fine filtration stage with a ceramic filter element is added to the coarse filtration, realizing secondary filtration of the dye liquor. This further removes tiny suspended impurities in the dye liquor, minimizing the interference of impurities on spectral detection and improving detection accuracy. The ceramic filter element is characterized by corrosion resistance, high filtration accuracy, and long service life, making it suitable for the highly corrosive environment of indigo dye liquor. Fixing clamps are used to secure filter one and filter two, preventing filter shaking during equipment operation that could lead to loosening of pipe connections and leakage, ensuring the operational stability of the filtration mechanism. At the same time, it makes the filter installation layout more regular and saves space inside the housing.

[0015] The present invention is further configured such that: the first filter screen and the second filter screen are stainless steel filter screens, the first filter screen has a pore size of 50-100 mesh, and the second filter screen has a pore size of 20-60 mesh; the second filter screen has a filtration accuracy of 1-5μm.

[0016] By adopting the above technical solution, the stainless steel filter screen possesses the characteristics of corrosion resistance, high strength, and easy cleaning, making it suitable for the corrosive environment of indigo dyeing liquor and extending the service life of the filter screen. Setting filter screen one to 50-100 mesh and filter screen two to 20-60 mesh achieves step-by-step coarse filtration from fine to coarse, first removing smaller large-particle impurities, and then intercepting larger flocculent matter and impurities, avoiding rapid clogging of a single filter screen and improving the efficiency and continuity of coarse filtration. The fine filtration accuracy of filter two (1-5μm) can effectively remove tiny suspended impurities invisible to the naked eye in the dyeing liquor, ensuring that the dyeing liquor entering the detection pool is free from impurity interference, guaranteeing the penetration of spectral detection light, and improving the accuracy of concentration detection from the source.

[0017] The invention is further configured such that: the detection pool includes a body and a cover; the body is hollow inside and open at the top; the cover is detachably mounted on the top of the body; each of the opposite sides of the detection pool has a detection window, each detection window contains transparent glass, and a sealing gasket is provided at the connection between the transparent glass and the detection window; the spectral detector and the light source generator are respectively disposed on opposite sides of the detection pool and are close to and correspond to the detection windows; the cover has a through pipe interface three, which is connected to a connecting pipe three; a temperature sensor, a liquid level sensor, and a pressure sensor are disposed inside the body.

[0018] By adopting the above technical solutions, the detection pool uses a detachable body and cover structure, which facilitates manual deep cleaning and component maintenance of the detection pool interior. The high-transmittance glass in the detection window ensures smooth penetration of the detection light, and the sealing gasket improves the sealing performance of the detection window to prevent dye leakage. The spectral detector and light source generator are positioned corresponding to the detection window to ensure that the detection light passes perpendicularly through the dye in the detection pool, reducing optical path deviation and improving the accuracy of spectral detection. The setting of temperature, liquid level, and air pressure sensors can monitor the environmental parameters of the dye in real time. The liquid level sensor ensures that the dye is within the effective detection range during the detection process, and the air pressure sensor prevents abnormal air pressure from causing poor dye flow or air bubbles to form in the detection window, further improving the accuracy of the detection results and reducing interference from environmental factors.

[0019] The invention is further configured as follows: a cleaning mechanism is provided, the cleaning mechanism including a cleaning liquid tank, a cleaning pump, and an annular pipe; the annular pipe is installed at the bottom of the cover, and a plurality of rinsing nozzles are spaced apart at the bottom of the annular pipe; the cover is provided with a second pipe interface, the bottom end of the second pipe interface is connected to the annular pipe, and the top end of the second pipe interface is provided with a purified water pipe; the side of the box is provided with a first pipe interface, one end of the first pipe interface inside the box is connected to one end of the purified water pipe, and the other end of the first pipe interface outside the box is provided with a cleaning liquid pipe, which is connected to the cleaning pump, the cleaning pump being installed inside the cleaning liquid tank; an electrically controlled valve is provided on the purified water pipe.

[0020] By adopting the above technical solutions and adding an automatic cleaning mechanism, the detection pool can be automatically cleaned on a timed or on-demand basis through the controller, replacing manual cleaning and significantly reducing the labor intensity of equipment maintenance. The annular pipe, combined with multiple sets of flushing nozzles, can achieve all-round, no-dead-angle flushing of the inner wall of the detection pool and the light-transmitting glass, effectively removing residual dye and attached impurities in the detection pool, preventing dye scaling from affecting the accuracy of subsequent spectral detection, and ensuring the long-term stable operation of the detection equipment. The electrically controlled valve can realize the automatic control of the cleaning fluid passage, and together with the controller, it can realize the automatic start and stop of the cleaning program, improving the automation level of the equipment.

[0021] The invention is further configured such that: the drain pipe passes through the box body and is provided with a three-way valve; the other two ports of the three-way valve are respectively provided with a return pipe and a sewage pipe; and the other end of the return pipe is connected to the dye liquor circulation pipeline of the pulp and dyeing combined machine.

[0022] By adopting the above technical solution and using a three-way valve to divert dye liquor after testing, qualified dye liquor after testing can be returned to the dye liquor circulation pipeline of the sizing and dyeing combined machine through a return pipe, realizing the recycling and reuse of dye liquor, reducing dye waste, and lowering production costs; only the wastewater after washing or dye liquor with more impurities is discharged through the sewage pipe, reducing the total amount of dyeing and printing wastewater discharged, which is more in line with environmental protection production requirements; at the same time, it avoids the resource loss caused by direct discharge of dye liquor, making the online testing process more economical and environmentally friendly.

[0023] The present invention is further configured to include a dye flow rate regulating component, which includes a dye storage tank, a dye supply pipeline, a flow regulating valve, a flow sensor, and a supply pump. One end of the dye supply pipeline is connected to the dye storage tank, and the other end is connected to the dye liquor circulation pipeline of the pulp and dyeing combined machine. The flow regulating valve, the flow sensor, and the supply pump are all installed on the dye supply pipeline. The flow regulating valve, the flow sensor, and the supply pump are all electrically connected to the controller.

[0024] By adopting the above technical solution, the dye flow regulation component is electrically connected to the controller to realize the linkage control of dye concentration detection and dye replenishment, forming a closed-loop control system for indigo dye concentration. When the controller detects that the dye liquor concentration is lower than the set threshold, it can automatically control the replenishment pump to start and the flow regulation valve to open, replenishing dye to the dye liquor circulation pipeline. The flow sensor detects the replenishment flow in real time and feeds it back to the controller. The controller accurately adjusts the opening of the flow regulation valve according to the concentration difference to achieve quantitative dye replenishment. When the concentration returns to the set range, the replenishment automatically stops. No manual intervention is required throughout the process, completely solving the error problem of traditional manual flow adjustment, ensuring the continuous stability of the dye liquor concentration in the sizing and dyeing combined machine, and improving the dyeing quality of denim products.

[0025] The invention is further configured such that: the light source generator is a xenon lamp or an LED light source; the controller is a PLC controller; the data storage module is an SD card or a solid-state drive; the flow sensor is an electromagnetic flow meter; the housing is made of stainless steel with anti-corrosion treatment on the surface; the signal transmission module supports RS485, Ethernet, or WiFi transmission; the sampling pump is a corrosion-resistant peristaltic pump, and the replenishment pump is a corrosion-resistant centrifugal pump, both with adjustable speed.

[0026] By adopting the above technical solutions, the light source generator offers two options: xenon lamps and LED light sources. Xenon lamps have a wide spectral range and stable light intensity, while LED light sources have low energy consumption and long service life, allowing for flexible selection based on actual production needs. The PLC controller features strong anti-interference capabilities, stable operation, and flexible programming, making it suitable for the industrial environment of textile printing and dyeing workshops and ensuring stable equipment operation. SD cards or solid-state drives offer advantages such as large storage capacity, fast read / write speeds, and good shock resistance, enabling long-term stable storage of detection data and equipment parameters. The electromagnetic flowmeter boasts high measurement accuracy and no mechanical wear, making it suitable for the corrosive environment of dye liquor and ensuring accurate flow detection. The stainless steel anti-corrosion housing enhances the equipment's corrosion resistance and wear resistance, making it suitable for the harsh environment of printing and dyeing workshops. The multi-mode signal transmission module can flexibly adapt to the communication networking needs of different workshops, enabling local display and remote transmission of detection data. The corrosion-resistant sampling pump and replenishment pump are suitable for the use environment of indigo dye liquor, extending the pump's service life. The adjustable speed function allows for adjustment of sampling and replenishment flow rates according to production needs, improving the equipment's adaptability and flexibility.

[0027] The present invention is further configured such that: the heat dissipation back plate is provided with a dustproof net on one side inside the box.

[0028] By adopting the above technical solutions, the dustproof net can effectively prevent dust, lint, and fiber impurities from the dyeing and printing workshop from entering the inside of the housing, avoiding impurities from adhering to the surface of the electrical control components and spectral detection components, which would affect the heat dissipation effect and detection accuracy of the equipment. At the same time, it reduces the accumulation of dirt and corrosion on the components and extends the service life of the equipment. The detachable heat dissipation back plate facilitates the cleaning and replacement of the dustproof net, ensuring the continuity of the dustproof and heat dissipation effects and reducing the difficulty of equipment maintenance.

[0029] In summary, the present invention has the following beneficial effects:

[0030] 1. It solves the problem of lag in traditional offline detection. By connecting the sampling mechanism with the dye liquor circulation pipeline of the sizing and dyeing combined machine, continuous online sampling of the dye liquor can be achieved. Combined with the real-time detection of the spectral detection mechanism, the concentration of indigo dye can be monitored 24 hours a day. It is suitable for continuous long-run production mode and avoids batch quality problems caused by concentration fluctuations.

[0031] 2. It solves the problems of large errors and high labor intensity in manual operation. By automating spectral detection, concentration calculation and dye replenishment control, it replaces the entire process of manual sampling, detection and adjustment, reduces the impact of human factors on detection and replenishment, and significantly reduces the workload of operators and lowers labor costs.

[0032] 3. It solves the problems of low detection accuracy and weak anti-interference ability. Impurities in the dye solution are removed step by step through a two-stage filtration mechanism, avoiding interference from the source. The detection area and control area are separated to reduce electromagnetic interference, which improves the accuracy and precision of concentration detection in many ways.

[0033] 4. Closed-loop control of dye concentration is achieved. Through the linkage between the detection mechanism and the flow regulation component, the controller can automatically and accurately adjust the dye supply amount according to the real-time detected concentration, ensuring the continuous stability of the dye liquor concentration, improving the dyeing uniformity and color consistency of denim products, and reducing the product defect rate.

[0034] 5. It solves the problems of dye waste and environmental pollution. The three-way valve enables the return and reuse of dye liquor after testing, reducing dye loss. Only wastewater and impurity dye liquor are discharged, reducing the discharge of printing and dyeing wastewater and meeting the requirements of environmentally friendly production.

[0035] 6. Reduced equipment maintenance costs; the addition of an automatic cleaning mechanism enables all-round automatic cleaning of the testing pool, preventing scale buildup in the dye solution from affecting testing accuracy; all components are designed to be corrosion-resistant and easy to disassemble, facilitating cleaning, replacement and maintenance, extending equipment lifespan and improving operational stability.

[0036] 7. Adapting to the needs of intelligent industrial production, the equipment has the functions of real-time display, historical storage, and remote transmission of detection data. It can be networked with the workshop central control system to realize intelligent management of indigo dye concentration detection. At the same time, various components of the equipment can be flexibly selected to adapt to the production needs of different printing and dyeing workshops, making it highly practical. Attached Figure Description

[0037] Figure 1 This is a schematic diagram of the online indigo dye concentration detection device in an embodiment of the present invention;

[0038] Figure 2 This is a rear view of the online indigo dye concentration detection device in an embodiment of the present invention;

[0039] Figure 3 This is a schematic diagram of the internal structure of the online indigo dye concentration detection device in an embodiment of the present invention;

[0040] Figure 4 This is a schematic diagram of the internal structure of the online indigo dye concentration detection device in an embodiment of the present invention;

[0041] Figure 5 This is a structural diagram of a filter in an embodiment of the present invention;

[0042] Figure 6 This is a structural diagram of the detection cell in an embodiment of the present invention;

[0043] Figure 7 This is a structural diagram of the detection cell in an embodiment of the present invention;

[0044] Figure 8 This is a schematic diagram of the heat dissipation backplate and dustproof mesh in an embodiment of the present invention.

[0045] In the diagram: 1. Housing; 2. Sampling pump; 3. Display screen; 4. Button control area; 5. Three-way valve; 6. Sampling tube; 7. Cleaning fluid tube; 8. Return tube; 9. Drain tube; 10. Power plug; 11. Pipe interface one; 12. Heat dissipation backplate; 13. Partition; 14. Controller; 15. Filter one; 16. Filter two; 17. Electrically controlled valve one; 18. Detection cell; 19. Electrically controlled valve two; 20. Drain outlet; 21. Light source generator; 22. Drain tube; 23. Clean water tube; 24. Connecting tube one; 25. Connecting tube two; 26. Connecting tube 3; 27. Data storage module; 28. Spectrometer detector; 29. ​​Fixing clamp; 30. Dustproof net; 151. Upper shell; 152. Lower shell; 153. Cover; 154. Filter screen one; 155. Filter screen two; 156. Limiting ring; 157. Limiting hole; 158. Limiting post; 159. Limiting convex ring; 1510. Liquid inlet one; 181. Body; 182. Cover; 183. Detection window; 184. Transparent glass; 185. Pipe interface two; 186. Pipe interface three; 187. Annular pipe; 188. Flushing nozzle. Detailed Implementation

[0046] The following is in conjunction with the appendix Figure 1-8 The present invention will be described in further detail below.

[0047] Example: An online detection device for indigo dye concentration based on spectral changes, such as... Figures 1-8 As shown, it includes a housing 1, a sampling mechanism, a filtering mechanism, a spectral detection mechanism, and a display and control component; the back of the housing 1 is provided with a removable heat dissipation plate, and the interior of the housing 1 is provided with a vertically arranged partition 13 that divides the interior of the housing 1 into a detection area and a control area, and the filtering mechanism and the spectral detection mechanism are installed in the detection area;

[0048] The sampling mechanism includes a sampling pump 2 and a sampling tube 6. The sampling pump 2 is located on the top of the housing 1. One end of the sampling tube 6 is connected to the input end of the sampling pump 2, and the other end is connected to the dye liquor circulation pipeline of the pulp and dyeing combined machine. The output end of the sampling pump 2 is provided with a connecting pipe 24 to connect to the filtration mechanism.

[0049] The spectral detection mechanism includes a spectral detector 28, a light source generator 21, a detection cell 18, and a signal conditioning module; the filtration mechanism is connected to the inside of the detection cell 18 via a connecting pipe 26; the spectral detector 28 and the light source generator 21 are located on opposite sides of the detection cell 18; the detection cell 18 has a drain outlet 20 with a drain pipe 22 penetrating the side of the housing 1, and an electrically controlled valve 19 is located at the drain outlet 20; the light source generator 21 is used to emit detection light of a specific wavelength, the spectral detector 28 is used to capture the absorption spectral signal of the dye solution to the detection light, and the signal conditioning module is used to process the electrical signal output by the spectral detector 28;

[0050] The display and control components include a controller 14, a data storage module 27, a signal transmission module, a display screen 3, and a button control area 4. The display screen 3 and the button control area 4 are located on the front of the housing 1. The button control area 4 is equipped with several multi-function buttons. The controller 14 has a built-in concentration calculation algorithm for analyzing and processing spectral signals and calculating the real-time concentration of indigo dye. The data storage module 27 is used to store detection data and equipment parameters. The signal transmission module is used to realize data transmission.

[0051] Filter 15 includes a cover 153, an upper housing 151, and a lower housing 152; the cover 153 is threadedly sealed to the top of the upper housing 151, and the bottom of the upper housing 151 is threadedly sealed to the top of the lower housing 152; both the upper housing 151 and the lower housing 152 have limiting rings 156 on their inner walls, and the limiting rings 156 have several limiting holes 157; the upper housing 151 and the lower housing 152 are respectively provided with filter screen 154 and filter screen 154. 155. Filter screen 154 and filter screen 2 155 have limiting posts 158 at their bottom edges. Filter screen 154 and filter screen 2 155 are inserted into the limiting holes 157 of the adjacent limiting ring 156 through the limiting posts 158. The top of the cover 153 has an inlet 1510, and the bottom of the lower housing 152 has an outlet 1. One end of the connecting pipe 24 is connected to the inlet 1510. The outer surface of the upper housing 151 has a limiting protruding ring 159. Filter 2 16 uses a ceramic filter element. Filter 2 16 has an inlet 2 and an outlet 2. One end of the connecting pipe 25 is connected to the outlet 1, and the other end is connected to the inlet 2. One end of the connecting pipe 3 26 is connected to the outlet 2, and the other end is connected to the detection pool 18. The inner wall of the housing 1 has a fixing clamp 29, which is used to fix and place filter 1 15 and filter 2 16. Filter screen 154 and filter screen 255 are made of stainless steel. Filter screen 154 has a mesh size of 50-100 mesh, and filter screen 255 has a mesh size of 20-60 mesh. Filter screen 216 has a filtration accuracy of 1-5μm.

[0052] The detection pool 18 includes a body 181 and a cover 182. The body 181 is hollow inside and open at the top. The cover 182 is detachably mounted on the top of the body 181. Detection windows 183 are provided on opposite sides of the detection pool 183. Transparent glass 184 is provided inside each detection window 183. A sealing gasket is provided at the connection between the transparent glass 184 and the detection window 183. A spectrometer 28 and a light source generator 21 are respectively located on opposite sides of the detection pool 18 and are close to and correspond to the detection windows 183. The cover 182 has a through pipe interface 3 186, which is connected to a connecting pipe 3 26. A temperature sensor, a liquid level sensor, and a pressure sensor are provided inside the body 181.

[0053] The cleaning mechanism includes a cleaning fluid tank, a cleaning pump, and an annular pipe 187. The annular pipe 187 is installed at the bottom of the cover 182, and several rinsing nozzles 188 are spaced apart at the bottom of the annular pipe 187. The cover 182 is provided with a second pipe interface 185, the bottom end of which is connected to the annular pipe 187, and the top end of which is provided with a clean water pipe 23. The side of the box 1 is provided with a first pipe interface 11, one end of which is connected to one end of the clean water pipe 23 inside the box 1, and the other end of which is provided with a cleaning fluid pipe 7 outside the box 1. The cleaning fluid pipe 7 is connected to the cleaning pump, which is located inside the cleaning fluid tank. The clean water pipe 23 is provided with an electrically controlled valve 17.

[0054] The drain pipe 22 passes through the box body 1 and is equipped with a three-way valve 5. The other two ports of the three-way valve 5 are respectively equipped with a return pipe 8 and a sewage pipe 9. The other end of the return pipe 8 is connected to the dye liquor circulation pipeline of the pulp and dyeing combined machine.

[0055] The dye flow regulation assembly (not shown in the attached figure) includes a dye storage tank, a dye supply pipeline, a flow regulation valve, a flow sensor, and a supply pump. One end of the dye supply pipeline is connected to the dye storage tank, and the other end is connected to the dye liquor circulation pipeline of the sizing and dyeing combined machine. The flow regulation valve, flow sensor, and supply pump are all installed on the dye supply pipeline. The flow regulation valve, flow sensor, and supply pump are all electrically connected to the controller 14.

[0056] The light source generator 21 uses a xenon lamp or LED light source; the controller 14 uses a PLC controller 14; the data storage module 27 uses an SD card or solid-state drive; the flow sensor uses an electromagnetic flow meter; the housing 1 is made of stainless steel with anti-corrosion treatment; the signal transmission module supports RS485, Ethernet, or WiFi transmission; the sampling pump 2 uses a corrosion-resistant peristaltic pump, and the replenishment pump uses a corrosion-resistant centrifugal pump, both with adjustable speed. The heat dissipation backplate 12 is located inside the housing 1 and has a dustproof screen 30 on one side.

[0057] An online indigo dye concentration detection device based on spectral changes includes a housing 1, a sampling mechanism, a filtering mechanism, a spectral detection mechanism, a display and control component, a cleaning mechanism, and a dye flow regulation component. The housing 1 is made of 304 stainless steel. A power cord and power plug 10 are provided on one side of the housing 1. The surface of the housing 1 is treated with powder coating for corrosion protection. A detachable heat dissipation backplate 12 is bolted to its back. A dustproof net 30 is fixed to one side of the heat dissipation backplate 12 inside the housing 1 through a slot. Vertically arranged partitions 13 are welded inside the housing 1, dividing the interior of the housing 1 into independent detection and control areas. The core components of the filtering mechanism, spectral detection mechanism, and cleaning mechanism are installed in the detection area, and the core electronic control components of the display and control component are installed in the control area.

[0058] The sampling mechanism includes a sampling pump 2 and a sampling tube 6. The sampling pump 2 is a corrosion-resistant peristaltic pump, which is fixed to the top of the housing 1 by a bracket. Its speed can be adjusted by the controller 14. One end of the sampling tube 6 is sealed to the input end of the sampling pump 2, and the other end extends into the dye liquor circulation pipeline of the pulp and dyeing combined machine. The output end of the sampling pump 2 is sealed to a connecting pipe 24, and the other end of the connecting pipe 24 is connected to the filtration mechanism.

[0059] The filtration mechanism includes filter one 15 and filter two 16. A fixing clamp 29 is welded to the inner wall of the detection area of ​​housing 1, and both filter one 15 and filter two 16 are fixed by clamping onto the fixing clamp 29. Filter one 15 consists of a cover 153, an upper housing 151, and a lower housing 152. The cover 153 is threaded to the top of the upper housing 151, and the bottom of the upper housing 151 is threaded to the top of the lower housing 152. The inner walls of the upper housing 151 and the lower housing 152 are integrally formed with limiting rings 156. Several evenly distributed limiting holes 157 are provided on the limiting rings 156. Filter one 154 is placed inside the upper housing 151, and filter two 155 is placed inside the lower housing 152. The bottom edges of filter one 154 and filter two 155 are welded with... A limiting post 158 ​​is inserted into the limiting hole 157 of the adjacent limiting ring 156 to fix the filter screen. A limiting protruding ring 159 is integrally formed on the outer surface of the upper housing 151. The top of the cover 153 has a liquid inlet 1510, and the connecting pipe 24 is sealed to the liquid inlet 1510. The bottom of the lower housing 152 has a liquid outlet 1, and the liquid outlet 1 is sealed to the connecting pipe 25. The filter 2 16 uses a ceramic filter element, with a liquid inlet 2 at the top and a liquid outlet 2 at the bottom. The connecting pipe 25 is sealed to the liquid inlet 2, and the liquid outlet 2 is sealed to the connecting pipe 3 26. Among them, the filter screen 154 uses an 80-mesh stainless steel filter screen, the filter screen 2 155 uses a 40-mesh stainless steel filter screen, and the filtration accuracy of the filter 2 16 is 3μm.

[0060] The spectral detection mechanism includes a spectral detector 28, a light source generator 21, a detection cell 18, and a signal conditioning module. The light source generator 21 is an LED light source, the spectral detector 28 is a fiber optic spectrometer, and the signal conditioning module is integrated inside the controller 14. The detection cell 18 includes a body 181 and a cover 182. The body 181 is hollow inside and open at the top. The cover 182 is detachably connected to the top of the body 181 by flange bolts. Detection windows 183 are provided on opposite sides of the body 181. Transparent glass 184 made of high-transmittance optical glass is embedded in the detection windows 183. A fluororubber sealing gasket is provided at the connection between the transparent glass 184 and the detection window 183. The spectrum detector 28 and the light source generator 21 are fixedly installed on opposite sides of the detection pool 18, and their detection ends and emission ends are precisely aligned with the light-transmitting glass 184. A through pipe interface 3 186 is provided on the cover 182, and the connecting pipe 3 26 is sealed to the pipe interface 3 186. A temperature sensor, a liquid level sensor and a pressure sensor are fixed inside the body 181, and the signal output ends of the three are electrically connected to the controller 14. A drain outlet 20 is provided at the bottom of the body 181, and an electrically controlled valve 2 19 is installed at the drain outlet 20. The drain outlet 20 is sealed to a drain pipe 22, which passes through the side of the box 1 and is sealed to a three-way valve 5.

[0061] The display and control components include a PLC controller 14, a data storage module 27, an RS485+WiFi dual-mode signal transmission module, an LCD screen 3, and a button control area 4. The screen 3 and the button control area 4 are both embedded in the front of the housing 1. The button control area 4 has several multi-function buttons such as power on, parameter setting, cleaning start, and mode switching. The controller 14, data storage module 27, and signal transmission module are all fixed in the control area of ​​the housing 1. The controller 14 has a built-in concentration calculation algorithm based on the spectral characteristics of indigo dye. Its signal input terminal is electrically connected to the spectral detector 28, temperature sensor, liquid level sensor, and air pressure sensor. Its signal output terminal is electrically connected to the screen 3, electrically controlled valve 17, electrically controlled valve 29, and light source generator 21.

[0062] The cleaning mechanism includes a cleaning fluid tank, a cleaning pump, and an annular pipe 187. The annular pipe 187 is fixed to the bottom of the cover 182 of the test pool 18 by a bracket. Eight fan-shaped flushing nozzles 188 are evenly spaced at the bottom of the annular pipe 187. A through pipe interface 185 is opened on the cover 182. The bottom end of the pipe interface 185 is sealed to the annular pipe 187, and the top end is sealed to a clean water pipe 23. An electrically controlled valve 17 is installed on the clean water pipe 23. A pipe interface 11 is opened on the side of the box 1. One end of the pipe interface 11 inside the box 1 is sealed to the clean water pipe 23, and the other end outside the box 1 is sealed to a cleaning fluid pipe 7. The other end of the cleaning fluid pipe 7 is sealed to the output end of the cleaning pump. The cleaning pump is a corrosion-resistant centrifugal pump and is fixedly placed inside the cleaning fluid tank. The cleaning pump is electrically connected to the controller 14.

[0063] The other two ports of the three-way valve 5 are respectively sealed and connected to the return pipe 8 and the drain pipe 9. The other end of the return pipe 8 is sealed and connected to the dye liquor circulation pipeline of the pulp and dyeing combined machine to realize the return of dye liquor. The drain pipe 9 is used to discharge the wastewater after cleaning.

[0064] The dye flow regulation assembly includes a dye storage tank, a dye supply pipeline, an electric flow regulating valve, an electromagnetic flow sensor, and a corrosion-resistant centrifugal pump supply pump. One end of the dye supply pipeline is connected to the dye storage tank, and the other end is connected to the dye liquor circulation pipeline of the sizing and dyeing combined machine. The flow regulating valve, the flow sensor, and the supply pump are all installed sequentially on the dye supply pipeline, and all three are electrically connected to the controller 14. The signal output terminal of the flow sensor is connected to the controller 14, and the signal output terminal of the controller 14 is connected to the flow regulating valve and the supply pump.

[0065] Among them, sampling pump 2 and replenishment pump are both equipped with adjustable speed function, signal transmission module can be networked with workshop central control system to realize remote transmission of detection data, and data storage module 27 can store at least 12 months of detection data and equipment operating parameters.

[0066] Working Principle: This equipment starts synchronously when the dyeing and sizing machine starts production. The operator first presets the equipment operating parameters such as the concentration threshold of indigo dye, the sampling flow rate of sampling pump 2, the cleaning interval time of the cleaning mechanism, and the flow range of dye replenishment in the PLC controller 14 through the button control area 4 on the front of the housing 1. After the parameters are set, the controller 14 controls the sampling pump 2 to start at the set speed. The sampling pump 2 quantitatively extracts indigo dye liquor from the dye liquor circulation pipeline of the dyeing and sizing machine through the sampling tube 6. The dye liquor enters the inlet 1510 of filter 15 through the connecting pipe 24, and passes through the filter screen 154 and filter screen 155 in sequence to complete coarse filtration, removing large particulate impurities and flocculent matter in the dye liquor. The coarsely filtered dye liquor enters the filter 16 through the outlet 1 and the connecting pipe 25, and completes fine filtration of 1-5μm through the ceramic filter element to remove tiny suspended impurities and ensure the purity of the dye liquor.

[0067] After fine filtration, the dye liquor enters the main body 181 of the detection pool 18 through connecting pipe 3 26 and pipe interface 3 186. The liquid level sensor in the main body 181 detects the liquid level of the dye liquor in real time. When the liquid level reaches the preset effective detection range, the controller 14 controls the light source generator 21 to start, emitting detection light with the characteristic absorption wavelength of indigo dye. The detection light passes vertically through the dye liquor and the light-transmitting glass 184 in the detection pool 18 and is captured by the spectrum detector 28 on the other side. The spectrum detector 28 converts the light signal into an electrical signal and transmits it to the signal conditioning module in the controller 14. After the electrical signal is amplified, filtered, and converted from analog to digital, the controller 14 analyzes it through the built-in concentration calculation algorithm. At the same time, it combines the parameters detected by the temperature sensor and the air pressure sensor for compensation and correction, and accurately calculates the real-time concentration of indigo dye.

[0068] The controller 14 transmits the calculated real-time concentration data to the display screen 3 for real-time display, and simultaneously stores it through the data storage module 27. The concentration data and equipment operating status are then transmitted to the workshop central control system via the signal transmission module for remote monitoring. When the controller 14 detects that the real-time concentration is below the preset lower threshold, it immediately controls the replenishment pump to start and the flow regulating valve to open, replenishing indigo dye to the dye liquor circulation pipeline of the pulp and dyeing combined machine through the dye replenishment pipeline. The flow sensor detects the replenished dye flow rate in real time and feeds the signal back to the controller 14. The controller 14 precisely adjusts the opening of the flow regulating valve based on the difference between the actual concentration and the preset threshold to achieve quantitative dye replenishment. When the detected concentration returns to the preset normal threshold range, the controller 14 automatically controls the replenishment pump to stop and the flow regulating valve to close, completing the dye replenishment and achieving closed-loop control of the dye liquor concentration.

[0069] After the test is completed, the controller 14 controls the electric control valve 19 to open. The dye liquor in the test tank 18 enters the three-way valve 5 through the drain outlet 20 and the drain pipe 22. At this time, the return flow path of the three-way valve 5 is opened and the sewage discharge path is closed. The dye liquor flows back to the dye liquor circulation pipeline of the pulp and dyeing combined machine through the return pipe 8, realizing the recycling and reuse of the dye liquor. When the equipment reaches the preset cleaning interval, or when the controller 14 detects abnormal liquid level or air pressure causing signal distortion, the cleaning program is automatically started: First, the sampling pump 2 and the replenishment pump are stopped, the return flow path of the three-way valve 5 is closed, the sewage discharge path is opened, and the second electrical control valve 19 is opened to empty the residual dye in the detection pool 18; then, the first electrical control valve 17 and the cleaning pump are started, and the cleaning liquid in the cleaning liquid tank enters the annular pipe 187 through the cleaning liquid pipe 7, the pipe interface 11, the clean water pipe 23, and the second pipe interface 185, and is sprayed out in a fan shape through the flushing nozzle 188 to thoroughly and completely flush the inner wall of the detection pool 18 and the light-transmitting glass 184, removing the attached residual dye and impurities; the wastewater after cleaning is discharged through the drain outlet 20, the drain pipe 22, and the sewage discharge pipe 9. After cleaning is completed, the controller 14 controls the cleaning pump and the first electrical control valve 17 to close, opens the return flow path of the three-way valve 5, and controls the sampling pump 2 to restart, and the equipment resumes the normal online detection process.

[0070] During equipment operation, the heat generated by the electrical control components in the control area is dissipated through the heat dissipation backplate 12. The dustproof net 30 effectively blocks dust, fiber impurities, etc. in the air from entering the interior of the housing 1, preventing the accumulation of dirt on the components from affecting operation and detection accuracy. When the equipment needs maintenance, the operator can disassemble the heat dissipation backplate 12 to clean or replace the dustproof net 30. The threaded connection of filter 15 can be unscrewed to clean or replace filter 154 and filter 2 155. The cover 182 of the detection pool 18 can be disassembled to perform manual deep cleaning of the inside of the detection pool. The various detachable structural designs greatly improve the convenience of equipment maintenance.

[0071] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. An online detection device for indigo dye concentration based on spectral changes, characterized in that, It includes a housing (1), a sampling mechanism, a filtering mechanism, a spectral detection mechanism, and a display and control component; the back of the housing (1) is provided with a detachable heat dissipation plate, and the interior of the housing (1) is provided with a vertically arranged partition (13) that divides the interior of the housing (1) into a detection area and a control area, and the filtering mechanism and the spectral detection mechanism are installed in the detection area; The sampling mechanism includes a sampling pump (2) and a sampling tube (6); the sampling pump (2) is located on the top of the box (1), one end of the sampling tube (6) is connected to the input end of the sampling pump (2), and the other end is connected to the dye liquor circulation pipeline of the pulp and dyeing combined machine; the output end of the sampling pump (2) is provided with a connecting pipe (24) connected to the filter mechanism. The spectral detection mechanism includes a spectral detector (28), a light source generator (21), a detection pool (18), and a signal conditioning module; the filtration mechanism is provided with a connecting pipe three (26) communicating with the inside of the detection pool (18); the spectral detector (28) and the light source generator (21) are located on opposite sides of the detection pool (18); the detection pool (18) is provided with a drain outlet (20) and a drain pipe (22) penetrating the side of the box body (1) is provided at the drain outlet (20); an electrically controlled valve two (19) is provided at the drain outlet (20); the light source generator (21) is used to emit detection light of a specific wavelength, the spectral detector (28) is used to capture the absorption spectral signal of the dye liquid to the detection light, and the signal conditioning module is used to process the electrical signal output by the spectral detector (28); The display and control components include a controller (14), a data storage module (27), a signal transmission module, a display screen (3), and a button control area (4); the display screen (3) and the button control area (4) are located on the front of the housing (1), and the button control area (4) is provided with several multi-functional buttons; the controller (14) has a built-in concentration calculation algorithm for analyzing and processing spectral signals and calculating the real-time concentration of indigo dye; the data storage module (27) is used to store detection data and equipment parameters; and the signal transmission module is used to realize data transmission.

2. The online indigo dye concentration detection device based on spectral changes according to claim 1, characterized in that, The filtration mechanism includes a filter one (15), which includes a cover (153), an upper housing (151), and a lower housing (152). The cover (153) is threadedly sealed to the top of the upper housing (151), and the bottom of the upper housing (151) is threadedly sealed to the top of the lower housing (152). The inner walls of the upper housing (151) and the lower housing (152) are provided with limiting rings (156), and the limiting rings (156) are provided with a plurality of limiting holes (157). The upper housing (151) and the lower housing (152) are respectively provided with filter screen one (154) and filter screen two (155). The bottom edge of filter screen one (154) and filter screen two (155) is provided with limiting post (158); filter screen one (154) and filter screen two (155) are inserted into the limiting hole (157) of the adjacent limiting ring body (156) through the limiting post (158); the top of the cover (153) is provided with liquid inlet one (1510), and the bottom of the lower shell (152) is provided with liquid outlet one; one end of the connecting pipe one (24) is connected to the liquid inlet one (1510), and the liquid outlet one is provided with connecting pipe two (25) and connecting pipe three (26) for connection; the outer surface of the upper shell (151) is provided with limiting protruding ring body (159).

3. The online indigo dye concentration detection device based on spectral changes according to claim 2, characterized in that, The filtration mechanism also includes a second filter (16), which uses a ceramic filter element; the second filter (16) is provided with an inlet and an outlet, one end of the connecting pipe (25) is connected to the outlet and the other end is connected to the inlet; one end of the connecting pipe (26) is connected to the outlet and the other end is connected to the detection pool (18); a fixing clamp (29) is provided on the inner wall of the box (1), which is used to fix the first filter (15) and the second filter (16).

4. The online indigo dye concentration detection device based on spectral changes according to claim 3, characterized in that, The filter screen one (154) and filter screen two (155) are made of stainless steel. The filter screen one (154) has a mesh size of 50-100 mesh, and the filter screen two (155) has a mesh size of 20-60 mesh. The filter screen two (16) has a filtration accuracy of 1-5μm.

5. The online indigo dye concentration detection device based on spectral changes according to claim 1, characterized in that, The detection pool (18) includes a body (181) and a cover (182). The body (181) is hollow inside and open at the top. The cover (182) is detachably installed on the top of the body (181). Detection windows (183) are provided on opposite sides of the detection pool (18). Transparent glass (184) is provided inside each detection window (183). A sealing gasket is provided at the connection between the transparent glass (184) and the detection window (183). The spectral detector (28) and the light source generator (21) are respectively installed on opposite sides of the detection pool (18) and are close to and correspond to the detection window (183). The cover (182) is provided with a through pipe interface three (186), which is connected to the connecting pipe three (26). A temperature sensor, a liquid level sensor, and a pressure sensor are provided inside the body (181).

6. The online indigo dye concentration detection device based on spectral changes according to claim 5, characterized in that, A cleaning mechanism is also provided, which includes a cleaning liquid tank, a cleaning pump, and an annular pipe (187); the annular pipe (187) is installed at the bottom of the cover (182), and a number of rinsing nozzles (188) are spaced apart at the bottom of the annular pipe (187); the cover (182) is provided with a second pipe interface (185), the bottom end of the second pipe interface (185) is connected to the annular pipe (187), and the top end of the second pipe interface (185) is provided with a clean water pipe (23); the side of the box (1) is provided with a first pipe interface (11), one end of the first pipe interface (11) inside the box (1) is connected to one end of the clean water pipe (23), and the other end of the first pipe interface (11) outside the box (1) is provided with a cleaning liquid pipe (7), which is connected to the cleaning pump, and the cleaning pump is set inside the cleaning liquid tank; an electrically controlled valve (17) is provided on the clean water pipe (23).

7. The online indigo dye concentration detection device based on spectral changes according to claim 6, characterized in that, The drain pipe (22) passes through the box body (1) and is equipped with a three-way valve (5). The other two ports of the three-way valve (5) are respectively equipped with a return pipe (8) and a sewage pipe (9). The other end of the return pipe (8) is connected to the dye liquor circulation pipe of the pulp and dyeing combined machine.

8. The online indigo dye concentration detection device based on spectral changes according to claim 1, characterized in that, It also includes a dye flow regulation component, which includes a dye storage tank, a dye supply pipeline, a flow regulation valve, a flow sensor and a supply pump. One end of the dye supply pipeline is connected to the dye storage tank, and the other end is connected to the dye liquor circulation pipeline of the pulp and dyeing combined machine. The flow regulation valve, the flow sensor and the supply pump are all installed on the dye supply pipeline. The flow regulation valve, the flow sensor and the supply pump are all electrically connected to the controller (14).

9. An online indigo dye concentration detection device based on spectral changes according to claims 1-8, characterized in that, The light source generator (21) uses a xenon lamp or an LED light source; the controller (14) uses a PLC controller (14); the data storage module (27) uses an SD card or a solid-state drive; the flow sensor uses an electromagnetic flow meter; the housing (1) is made of stainless steel and the surface is treated with anti-corrosion; the signal transmission module supports RS485, Ethernet or WiFi transmission; the sampling pump (2) uses a corrosion-resistant peristaltic pump and the replenishment pump uses a corrosion-resistant centrifugal pump, both of which have adjustable speed.

10. The online indigo dye concentration detection device based on spectral changes according to claim 1, characterized in that, The heat dissipation backplate (12) is provided with a dustproof net (30) on one side inside the box (1).

Images