A method and apparatus for register control for sheet web quality control

Abstract

The application provides a method and device for alignment control of sheet width quality control, comprising: establishing an initial position relationship mapping table, which includes the mapping relationship between the identification of each width quality control mechanism in the control area and the coordinate of each initial detection point in the measurement area; positioning the initial position of the measured sheet to determine the initial position information; controlling the measured sheet to move along a preset movement direction, and in the movement process, performing the following operations according to the preset frequency: obtaining the image information of the measured sheet through a visual detection device, calculating the comprehensive offset and width change of the measured sheet according to the image information and the initial position information, judging the abnormal type of the measured sheet, correcting the coordinate of the detection point in the position relationship mapping table according to the abnormal type, the comprehensive offset and the width change of the measured sheet, and updating the position relationship mapping table. The method can solve the problem of control error caused by the offset of the sheet.

Description

Technical Field

[0001] This invention relates to the field of industrial process control technology, and in particular to a method and apparatus for alignment control of sheet width profile quality control. Background Technology

[0002] Existing banner quality control systems typically include a high-precision quality inspection device, a zone control mechanism, and an intelligent control system. The high-precision quality inspection device scans back and forth along the banner direction of the sheet, collecting quality data for each zone in real time. The zone control mechanism is used to apply local control to the material. The intelligent control system intelligently controls the system based on a preset control strategy. When the high-precision quality inspection device detects that the quality of a certain position of the sheet deviates from the set target, the intelligent control system controls the corresponding control mechanism to adjust it, thereby achieving the purpose of controlling the quality of that inspection point.

[0003] Existing high-precision quality inspection devices and zone control mechanisms are spaced a certain distance apart. The zone control mechanism is generally located upstream of the production line, while the high-precision quality inspection device is typically located downstream. During the sheet's movement, factors such as serpentine movement, thermal expansion and contraction, equipment thermal deformation, or production line speed fluctuations can cause mechanical phase drift, leading to a misalignment between the detection position and the original control mechanism, resulting in a "misaligned" detection that exacerbates uneven width. Once drift occurs during operation, it is difficult to detect and correct in time, causing control deviations to accumulate undetected over a long period. Most systems lack effective lateral measurement / control position alignment calibration functions, and even minute lateral deviations (typically only 1–2 mm) can affect the control effect of the entire area, resulting in defective products. For example, in the paper industry, large specialty paper / cabinet production lines can reach hundreds of meters in length. Because the paper web undergoes multiple processes at high speeds (up to 1500 m / min), minute lateral deviations are amplified at each stage, leading to problems such as uneven edge tightness, wrinkling, delamination, and even paper breaks in the entire roll.

[0004] Patent text CN113870217A proposes a machine vision-based edge offset visual measurement method and image detector, which can detect the offset of the stamping sheet edge. However, its main function is to identify the alarm after the offset, and it cannot solve the offset problem in real time. Summary of the Invention

[0005] This invention provides a method and apparatus for alignment control of sheet banner quality control, to solve the problem that the quality of the banner is difficult to guarantee due to adjustment errors caused by sheet misalignment.

[0006] A alignment control method for quality control of sheet banners, comprising: Establish an initial positional relationship mapping table, which includes the mapping relationship between the identifiers of each banner quality control mechanism in the control area and the coordinates of each initial detection point in the measurement area. The initial position of the sheet being tested is determined to establish the initial position information. The sheet under test is controlled to move along a preset direction, and the following operations are performed at a preset frequency during the movement: image information of the sheet under test is acquired through a visual detection device set in the measurement area; the comprehensive offset and width change of the sheet under test are calculated based on the image information and the initial position information, and the abnormality type of the sheet under test is determined; the coordinates of the detection points in the position relationship mapping table are corrected based on the abnormality type of the sheet under test, the comprehensive offset and width change, and the position relationship mapping table is updated.

[0007] Furthermore, an initial positional relationship mapping table is established, including: Multiple banner quality control mechanisms are distributed and set in the control area of ​​the sheet being tested, and the number or physical coordinates of each banner quality control mechanism are used as the identifier of the corresponding banner quality control mechanism. Adjust the output of each banner quality control mechanism to obtain the effective response area of ​​each banner quality control mechanism; Within the measurement area, the detection location area corresponding to each effective response area is determined, and the coordinates in each detection location area are obtained as the initial detection point coordinates. The initial detection point coordinates are then mapped to the identifier of the banner quality control mechanism to obtain the initial positional relationship mapping table.

[0008] Furthermore, the control area and the measurement area correspond in the horizontal direction; determining the detection position area corresponding to each effective response area includes: Obtain the width of each valid response area in the banner direction; In the measurement area, the detection position area corresponding to the width of each effective response area in the horizontal direction is determined.

[0009] Furthermore, the initial position of the sheet being tested is determined, including: An initial image of the sheet under test in its initial state is obtained through a visual inspection device. Based on the initial image, edge recognition of the sheet under test is performed to obtain the first initial edge and the second initial edge on both sides of the sheet under test in the horizontal direction. The midpoint is calculated based on the first and second initial edges, and a coordinate system is established using the midpoint as the zero point coordinate. In the coordinate system, the coordinates of the first initial edge and the coordinates of the second initial edge are used as the initial position information.

[0010] Further, based on the image information and the initial position information, the comprehensive offset and width change of the tested sheet are calculated, and the anomaly type of the tested sheet is determined, including: Based on the image information, the first real-time edge and the second real-time edge on both sides of the horizontal direction of the sheet being tested are identified. Obtain the coordinates of the first real-time edge and the second real-time edge in the coordinate system. A first deviation value is calculated based on the coordinates of the first initial edge and the corresponding coordinates of the first real-time edge; a second deviation value is calculated based on the coordinates of the second initial edge and the corresponding coordinates of the second real-time edge. Calculate the combined offset and width change based on the first and second deviation values; The abnormality type of the tested sheet is determined based on the first deviation value and the second deviation value. The abnormality type includes at least one of offset, shrinkage, and expansion.

[0011] Furthermore, the overall offset is half of the sum of the first deviation value and the second deviation value; the width change is the difference between the second deviation value and the first deviation value.

[0012] The type of abnormality of the tested sheet is determined based on the first deviation value and the second deviation value, including: Compare the first deviation value and the second deviation value to determine whether the tested sheet has shifted. Based on whether the positive and negative signs of the first deviation value and the second deviation value are the same, and whether the absolute values ​​of the first deviation value and the second deviation value are equal, it can be determined whether the tested sheet has expanded or contracted. Based on the magnitude and sign of the first and second deviation values, determine whether the tested sheet material is simultaneously shifting and expanding, or simultaneously shifting and shrinking.

[0013] Furthermore, the coordinates of the detection points in the current positional mapping table are corrected based on the anomaly type of the tested sheet, the comprehensive offset, and the width change, including: The combined offset and width variation are converted to the same coordinate system as the detection point coordinates; For the sheet material under test that has shifted, add the coordinates of the detection point in the current position relationship mapping table to the comprehensive offset after coordinate transformation to obtain the corrected coordinates of the detection point. For the sheet material under test that shrinks or expands, or shifts and expands simultaneously, or shifts and shrinks simultaneously, the current positional relationship mapping table is divided into regions according to the coordinate system. The correction amount for each region is calculated based on the comprehensive offset after coordinate transformation and the width change. The coordinates of the detection points in the corresponding regions are then corrected based on the correction amount.

[0014] Furthermore, based on the positive and negative directions of the coordinate axes of the coordinate system, the current positional relationship mapping table is divided into a first sub-table and a second sub-table, wherein the first sub-table corresponds to the negative direction of the coordinate axes and the second sub-table corresponds to the positive direction of the coordinate axes; Calculate the first correction amount corresponding to the first sub-table and the second correction amount corresponding to the second sub-table based on the comprehensive offset after coordinate transformation and the width change; Add the detection point coordinates in the first sub-table to the first correction amount, and add the detection point coordinates in the second sub-table to the second correction amount. The detection point coordinates corresponding to the zero point coordinates remain unchanged, and the corrected detection point coordinates are obtained.

[0015] Furthermore, the first correction amount is the difference between the overall offset and half of the width change; the second correction amount is the sum of the overall offset and half of the width change.

[0016] A alignment control device for banner quality control, comprising: The initial module is used to establish an initial positional relationship mapping table, which includes the mapping relationship between the identifiers of each banner quality control mechanism in the control area and the coordinates of each initial detection point in the measurement area. The baseline calculation module is used to locate the initial position of the sheet being tested and determine the initial position information; The table update module is used to perform the following operations at a preset frequency during the movement of the sheet under test: acquire image information of the sheet under test through a visual detection device set in the measurement area; calculate the comprehensive offset and width change of the sheet under test based on the image information and the initial position information, and determine the abnormality type of the sheet under test; correct the detection point coordinates in the current position relationship mapping table based on the abnormality type of the sheet under test, the comprehensive offset and width change, and update the position relationship mapping table.

[0017] Furthermore, the initial module establishes an initial positional relationship mapping table, including: Multiple banner quality control mechanisms are distributed and set in the control area of ​​the sheet being tested, and the number or physical coordinates of each banner quality control mechanism are used as the identifier of the corresponding banner quality control mechanism. Adjust the output of each banner quality control mechanism to obtain the effective response area of ​​each banner quality control mechanism; Within the measurement area, the detection location area corresponding to each effective response area is determined, and the coordinates in each detection location area are obtained as the initial detection point coordinates. The initial detection point coordinates are then mapped to the identifier of the banner quality control mechanism to obtain the initial positional relationship mapping table.

[0018] Furthermore, the control area and the measurement area correspond in the horizontal direction; the initial module determines the detection position area corresponding to each effective response area, including: Obtain the width of each valid response area in the banner direction; In the measurement area, the detection position area corresponding to the width of each effective response area in the horizontal direction is determined.

[0019] Furthermore, the reference calculation module locates the initial position of the sheet under test and determines the initial position information, including: An initial image of the sheet under test in its initial state is obtained through a visual inspection device. Based on the initial image, edge recognition of the sheet under test is performed to obtain the first initial edge and the second initial edge on both sides of the sheet under test in the horizontal direction. The midpoint is calculated based on the first and second initial edges, and a coordinate system is established using the midpoint as the zero point coordinate. In the coordinate system, the coordinates of the first initial edge and the coordinates of the second initial edge are used as the initial position information.

[0020] Furthermore, the table update module calculates the comprehensive offset and width change of the tested sheet based on the image information and the initial position information, and determines the anomaly type of the tested sheet, including: Based on the image information, the first real-time edge and the second real-time edge on both sides of the horizontal direction of the sheet being tested are identified. Obtain the coordinates of the first real-time edge and the second real-time edge in the coordinate system. A first deviation value is calculated based on the coordinates of the first initial edge and the corresponding coordinates of the first real-time edge; a second deviation value is calculated based on the coordinates of the second initial edge and the corresponding coordinates of the second real-time edge. Calculate the combined offset and width change based on the first and second deviation values; The abnormality type of the tested sheet is determined based on the first deviation value and the second deviation value. The abnormality type includes at least one of offset, shrinkage, and expansion.

[0021] Furthermore, the overall offset is half of the sum of the first deviation value and the second deviation value; the width change is the difference between the second deviation value and the first deviation value. The table update module determines the anomaly type of the tested sheet based on the first deviation value and the second deviation value, including: Compare the first deviation value and the second deviation value to determine whether the tested sheet has shifted. Based on whether the positive and negative signs of the first deviation value and the second deviation value are the same, and whether the absolute values ​​of the first deviation value and the second deviation value are equal, it can be determined whether the tested sheet has expanded or contracted. Based on the magnitude and sign of the first and second deviation values, determine whether the tested sheet material is simultaneously shifting and expanding, or simultaneously shifting and shrinking.

[0022] Furthermore, the table update module corrects the coordinates of the detection points in the current positional relationship mapping table based on the anomaly type of the tested sheet, the comprehensive offset, and the width change, including: The overall offset is converted to the same coordinate system as the detection point coordinates; For the sheet material under test that has shifted, add the coordinates of the detection point in the current position relationship mapping table to the comprehensive offset after coordinate transformation to obtain the corrected coordinates of the detection point. For the sheet material under test that shrinks or expands, or shifts and expands simultaneously, or shifts and shrinks simultaneously, the current positional relationship mapping table is divided into regions according to the coordinate system. The correction amount for each region is calculated based on the comprehensive offset after coordinate transformation and the width change. The coordinates of the detection points in the corresponding regions are then corrected based on the correction amount.

[0023] Furthermore, based on the positive and negative directions of the coordinate system, the current positional relationship mapping table is divided into a first sub-table and a second sub-table, wherein the first sub-table corresponds to the negative direction of the coordinate axis and the second sub-table corresponds to the positive direction of the coordinate axis; Calculate the first correction amount corresponding to the first sub-table and the second correction amount corresponding to the second sub-table based on the comprehensive offset after coordinate transformation and the width change; Add the detection point coordinates in the first sub-table to the first correction amount, and add the detection point coordinates in the second sub-table to the second correction amount. The detection point coordinates corresponding to the zero point coordinates remain unchanged, and the corrected detection point coordinates are obtained.

[0024] Furthermore, the first correction amount is the difference between the overall offset and half of the width change; the second correction amount is the sum of the overall offset and half of the width change.

[0025] A alignment control system for banner quality control includes a processor and a memory, and also includes a visual inspection device disposed in a measurement area; the memory stores multiple instructions, and the processor is used to read the instructions and execute the method described above.

[0026] The alignment control method and apparatus for quality control of sheet banners provided by the present invention have at least the following beneficial effects: (1) By constructing a dynamic mapping mechanism between the coordinates of the detection point and the control mechanism, and integrating the machine vision system on this basis, the real-time dynamic perception of the material's lateral offset, shrinkage, and expansion, as well as the alignment calibration between the coordinates of the detection point and the control mechanism, can achieve the purpose of precise and efficient control of the quality of the roll / sheet material, and significantly improve the ability to ensure the uniformity of materials in the high-end manufacturing process. (2) Effectively solves the problem of "misalignment control" caused by factors such as material offset, material shrinkage deformation, and equipment drift; (3) Edge recognition technology based on machine vision effectively improves the perception accuracy and precision of offset, thereby improving the accuracy of alignment and control, and greatly reducing the need for manual intervention. (4) It enables continuous production lines of rolls or sheets to perform dynamic alignment calibration between the coordinates of the detection points and the control mechanism in real time, without the need to stop production or shut down the machine, which significantly improves production continuity and overall efficiency. Attached Figure Description

[0027] Figure 1 This is a flowchart of one embodiment of the alignment control method for quality control of sheet banners provided by the present invention.

[0028] Figure 2 This is a coordinate diagram illustrating an application scenario of the alignment control method for quality control of sheet banners provided by the present invention.

[0029] Figure 3 This is a schematic diagram of one embodiment of the alignment control device for quality control of sheet banners provided by the present invention.

[0030] Figure 4 This is a schematic diagram of one embodiment of the alignment control system for quality control of sheet banners provided by the present invention. Detailed Implementation

[0031] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0032] refer to Figure 1 In some embodiments, a alignment control method for quality control of sheet banners is provided, comprising: S1. Establish an initial positional relationship mapping table, which includes the mapping relationship between the identifiers of each banner quality control mechanism in the control area and the coordinates of each initial detection point in the measurement area. S2. Locate the initial position of the sheet being tested and determine the initial position information; S3. Control the sheet under test to move along a preset motion direction, and perform the following operations at a preset frequency during the motion: acquire image information of the sheet under test through a visual detection device set in the measurement area, calculate the comprehensive offset and width change of the sheet under test based on the image information and the initial position information, determine the abnormality type of the sheet under test, correct the detection point coordinates in the current position relationship mapping table based on the abnormality type of the sheet under test, the comprehensive offset and width change, and update the position relationship mapping table.

[0033] Specifically, the method provided in this embodiment is applied to a sheet production line, such as papermaking. In a papermaking production line where the propeller box is of the dilution water type, multiple dilution water valves are set in the horizontal direction to adjust the pulp concentration in the corresponding area. The pulp concentration determines the basis weight of the subsequent paper. Multiple basis weight values ​​in the horizontal direction of the paper can be obtained through a downstream basis weight detection device. Based on these basis weight values, the opening of the dilution water valves is adjusted to regulate the pulp concentration, thereby controlling the basis weight of the paper. The method provided in this embodiment is applied to a papermaking production line. The horizontal quality control mechanism can be a dilution water valve. A basis weight detection device is set in the measurement area to scan the horizontal direction of the paper and obtain the basis weight value of the detection point.

[0034] In addition, visual inspection devices can be installed in different sections of the production line according to actual needs.

[0035] In step S1, an initial positional relationship mapping table is established, including: S11. Multiple banner quality control mechanisms are distributed and set in the control area of ​​the sheet being tested, and the number or physical coordinates of each banner quality control mechanism are used as the identifier of the corresponding banner quality control mechanism. S12. Adjust the output of each banner quality control mechanism to obtain the effective response area of ​​each banner quality control mechanism; S13. In the measurement area, determine the detection position area corresponding to each effective response area, obtain the coordinates in each detection position area as the initial detection point coordinates, and match the initial detection point coordinates with the logo of the banner quality control mechanism to obtain the initial position relationship mapping table.

[0036] Specifically, in step S11, the control area is located upstream of the production line, and multiple banner quality control mechanisms are set along the banner direction of the sheet. Each banner quality control mechanism is numbered or its physical coordinates are marked and written into the initial position relationship mapping table as the identifier of the corresponding banner quality control mechanism. In the paper production line, the banner quality control mechanism is a dilution water valve.

[0037] Further, in step S12, the output of each banner quality control mechanism is adjusted to obtain the effective response area of ​​each banner quality control mechanism. The output of the banner quality control mechanism acts on the banner direction of the sheet, and the effective response area is the range of action of the banner quality control mechanism in the banner direction of the sheet. In papermaking, the effective response area of ​​each dilution water valve is the effective range of pulp dilution in the banner direction.

[0038] Further, in step S13, the measurement area is located downstream of the production line and is equipped with a banner quality inspection mechanism. In some embodiments, the banner quality inspection mechanism can be located on a gantry frame to scan the measurement area back and forth, thereby obtaining quality inspection data and corresponding real-time inspection point coordinates in the banner direction of the sheet. Within the measurement area, the inspection position area corresponding to each effective response area is determined. Specifically, the control area and the measurement area correspond in the banner direction. The width of each effective response area in the banner direction is obtained. Based on the width of each effective response area in the banner direction, the corresponding inspection position area is determined within the measurement area. The two are then associated, meaning each inspection position area has a corresponding control range. The coordinates in each inspection position area are obtained as initial inspection point coordinates. These initial inspection point coordinates are written into a position relationship mapping table and matched with the identifier of the corresponding banner quality control mechanism to obtain the initial position relationship mapping table.

[0039] After obtaining the initial positional mapping table, sheet production can begin. Downstream, the banner quality inspection mechanism scans back and forth along the banner direction of the sheet at a preset frequency, acquiring quality information and corresponding real-time coordinates of each inspection point. If a quality issue arises at a particular inspection point, the corresponding banner quality control mechanism can be located in the positional mapping table based on its real-time coordinates. Adjusting this mechanism will then adjust the quality at the corresponding location. For example, on a paper production line with a dilution water-based paddle box, if the basis weight at a certain inspection point does not meet production requirements, the corresponding dilution water valve can be located in the positional mapping table based on its real-time coordinates. Adjusting the opening of this valve changes the pulp concentration within the corresponding effective control zone, thereby altering the basis weight at the corresponding location.

[0040] However, during the sheet production process, the control area and the measurement area may be far apart. The sheet is prone to drifting and deviating from its initial position during its movement, or it may shrink due to thermal expansion and contraction. If the initial positional mapping table is still used at this time, the position may be misadjusted, which will exacerbate the unevenness of the sheet width quality.

[0041] Therefore, in the method provided in this embodiment, after obtaining the initial positional mapping table, it further includes locating the initial position of the sheet being tested and determining the initial position information, specifically as follows: S21. Obtain an initial image of the sheet under test in its initial state using a visual inspection device, and perform edge recognition of the sheet under test based on the initial image to obtain the first initial edge and the second initial edge on both sides of the sheet under test in the horizontal direction. S22. Calculate the midpoint based on the first initial edge and the second initial edge, take the midpoint as the zero point coordinate, take the horizontal direction of the sheet being tested as the abscissa, and the direction perpendicular to the horizontal direction of the sheet being tested as the ordinate, and establish a coordinate system. S23. In the coordinate system, the coordinates of the first initial edge and the coordinates of the second initial edge are used as the initial position information.

[0042] Specifically, in step S21, the visual inspection device can be set on the gantry of the measurement area to obtain an initial image of the sheet under test in its initial state, and perform edge recognition of the sheet under test based on the initial image to obtain two initial edges of the banner in the initial state of the sheet under test: the first initial edge and the second initial edge.

[0043] Specifically, after identifying the two initial edges of the banner in the initial state of the sheet being tested, the midpoint is calculated based on the first initial edge and the second initial edge. For example, two reference points are taken on the first initial edge and the second initial edge respectively. The line connecting the two reference points is parallel to the direction of the banner. The midpoint of the line connecting the two reference points is determined as the midpoint of the first initial edge and the second initial edge. The midpoint is used as the zero point coordinate to establish a coordinate system.

[0044] refer to Figure 2 In some embodiments, a Cartesian coordinate system is established with the operator facing the winding direction of the sheet being tested as the viewing reference: the horizontal direction of the sheet being tested is set as the horizontal axis, and the horizontal quality control mechanism is numbered sequentially from left to right (1-N) along the horizontal axis, with the numbering from small to large corresponding to the negative to positive direction of the horizontal axis; the direction perpendicular to the horizontal direction of the sheet is set as the vertical axis, and the direction of movement of the sheet being tested is the positive direction of the vertical axis.

[0045] In the aforementioned coordinate system, the coordinates of the first initial edge and the coordinates of the second initial edge are used as the initial position information. Specifically, the coordinates of reference points of the two initial edges can be used as this initial position information.

[0046] Furthermore, after obtaining the initial position information, the sheet under test is controlled to move along a preset direction, and during the movement, the visual inspection device is controlled to acquire image information of the sheet under test at a preset frequency. Based on the image information and the initial position information, the comprehensive offset and width change of the sheet under test are calculated, and the abnormality type of the sheet under test is determined. Specifically, this includes: S31. Based on the image information, identify the first real-time edge and the second real-time edge on both sides of the horizontal direction of the sheet being tested; S32. Obtain the coordinates of the first real-time edge and the second real-time edge in the coordinate system. S33. Calculate the first deviation value based on the coordinates of the first initial edge and the corresponding coordinates of the first real-time edge, and calculate the second deviation value based on the coordinates of the second initial edge and the corresponding coordinates of the second real-time edge. S34. Calculate the combined offset and width change based on the first deviation value and the second deviation value; S35. Determine the abnormality type of the tested sheet based on the first deviation value and the second deviation value, wherein the abnormality type includes at least one of offset and shrinkage.

[0047] Further, in step S32, the coordinates of the first real-time edge and the second real-time edge are obtained in the coordinate system. In some embodiments, the zero point of the coordinate system is the midpoint of the line connecting the reference point on the first initial edge and the reference point on the second initial edge. In this coordinate system, the reference point on the first initial edge and the reference point on the second initial edge are located on the horizontal axis, and their vertical coordinates are 0. The coordinates of the first real-time edge can be the coordinates of the intersection of the first real-time edge and the horizontal axis of the coordinate system, and the coordinates of the second real-time edge can be the coordinates of the intersection of the second real-time edge and the horizontal axis of the coordinate system. Similarly, their vertical coordinates are 0.

[0048] In step S33, a first deviation value is calculated based on the coordinates of the first initial edge and the corresponding coordinates of the first real-time edge. As described above, in some embodiments, the reference point on the first initial edge is located on the horizontal axis of the coordinate system, and the first deviation value is the difference between the horizontal coordinate of the reference point on the first initial edge and the horizontal coordinate of the intersection of the first real-time edge and the horizontal axis of the coordinate system. Similarly, the second deviation value is the difference between the horizontal coordinate of the reference point on the second initial edge and the horizontal coordinate of the intersection of the second real-time edge and the horizontal axis of the coordinate system.

[0049] In some embodiments, in step S34, a combined offset and a width change are calculated based on the first deviation value and the second deviation value, wherein the combined offset is half the sum of the first deviation value and the second deviation value, and the width change is the difference between the second deviation value and the first deviation value, i.e.: ΔX=(ΔX1+ΔX2) / 2; (1) ΔW = ΔX2 - ΔX1; (2) Where ΔX represents the overall offset, ΔX1 represents the first deviation value, ΔX2 represents the second deviation value, and ΔW represents the width change.

[0050] In step S35, the abnormality type of the tested sheet is determined based on the first deviation value and the second deviation value, including: Compare the first deviation value and the second deviation value to determine whether the tested sheet has shifted. Based on whether the positive and negative signs of the first deviation value and the second deviation value are the same, and whether the absolute values ​​of the first deviation value and the second deviation value are equal, it can be determined whether the tested sheet has expanded or contracted. Based on the magnitude and sign of the first and second deviation values, determine whether the tested sheet material is simultaneously shifting and expanding, or simultaneously shifting and shrinking.

[0051] Specifically, taking the above coordinate system as an example, if the first deviation value and the second deviation value are equal and both are less than 0, the width change is 0 and the overall offset is less than 0, so the sheet being measured can be determined to be offset to the left.

[0052] If the first deviation value and the second deviation value are equal and both are greater than 0, then the width change is 0 and the overall offset is greater than 0, which means the sheet being tested is offset to the right.

[0053] If the first deviation value is greater than 0, the second deviation value is less than 0, and the absolute values ​​of the first and second deviation values ​​are equal, then the overall offset is 0, the width change is less than 0, and it is determined that the tested sheet has only shrunk.

[0054] If the first deviation value is less than 0, the second deviation value is greater than 0, and the absolute values ​​of the first and second deviation values ​​are equal, then the overall offset is 0, the width change is greater than 0, and it is determined that the tested sheet has only expanded.

[0055] If the first deviation value is less than the second deviation value and both are less than 0, then the overall offset is less than 0 and the width change is greater than 0. This indicates that the sheet being tested has shifted to the left and expanded.

[0056] If the second deviation value is less than the first deviation value and both are less than 0, then the overall offset is less than 0 and the width change is less than 0. This indicates that the sheet being tested has shifted to the left and has shrunk.

[0057] If the second deviation value is greater than the first deviation value and both are greater than 0, then the overall offset is greater than 0 and the width change is greater than 0, which indicates that the sheet being tested has shifted to the right and expanded.

[0058] If the first deviation value is greater than the second deviation value and both are greater than 0, then the overall offset is greater than 0 and the width change is less than 0. This indicates that the sheet being tested has shifted to the right and has shrunk.

[0059] Furthermore, the coordinates of the detection points in the positional relationship mapping table are corrected based on the anomaly type of the tested sheet, the comprehensive offset, and the width change, including: S36. Convert the comprehensive offset to the same coordinate system as the detection point coordinates; S37. For the sheet material under test that has shifted, add the coordinates of the detection point in the current position relationship mapping table to the comprehensive offset after coordinate transformation to obtain the corrected coordinates of the detection point. For the sheet material under test that shrinks or expands, or shifts and expands simultaneously, or shifts and shrinks simultaneously, the current positional relationship mapping table is divided into regions according to the coordinate system. The correction amount for each region is calculated based on the comprehensive offset after coordinate transformation and the width change. The coordinates of the detection points in the corresponding regions are then corrected based on the correction amount.

[0060] Specifically, in step S36, with Figure 2 Taking the established coordinate system as an example, if the sheet being measured shifts to the left, the overall offset is less than 0; conversely, if the sheet being measured shifts to the right, the overall offset is greater than 0. The coordinates of the detection point in the current position relationship mapping table are added together with the overall offset after coordinate transformation.

[0061] Further, in step S37, the current position relationship mapping table is divided into a first sub-table and a second sub-table according to the positive and negative directions of the coordinate system, wherein the first sub-table corresponds to the negative direction of the coordinate axis and the second sub-table corresponds to the positive direction of the coordinate axis. Calculate the first correction amount corresponding to the first sub-table and the second correction amount corresponding to the second sub-table based on the comprehensive offset after coordinate transformation and the width change; Add the detection point coordinates in the first sub-table to the first correction amount, and add the detection point coordinates in the second sub-table to the second correction amount. The detection point coordinates corresponding to the zero point coordinates remain unchanged, and the corrected detection point coordinates are obtained.

[0062] Furthermore, the first correction amount is the difference between the overall offset and half of the width change; the second correction amount is the sum of the overall offset and half of the width change, that is: ΔX 修正1 =ΔX-ΔW / 2; (3) ΔX 修正2 =ΔX+ΔW / 2;(4) Where, ΔX 修正1 Denotes the first correction amount, ΔX 修正2 This indicates the second correction amount.

[0063] by Figure 2Taking the established coordinate system as an example, the negative direction of the horizontal axis corresponds to the first sub-table, and the positive direction of the horizontal axis corresponds to the second sub-table. For the sheet material that only shrinks, the comprehensive offset ΔX is equal to 0, and the width change ΔW is less than 0. That is, the first correction is -ΔW / 2, and the second correction is ΔW / 2. The coordinates of the detection points in the first sub-table are added to the first correction, and the coordinates of the detection points in the second sub-table are added to the second correction.

[0064] For the sheet material that only expands, the overall offset ΔX is equal to 0, and the width change ΔW is greater than 0. That is, the first correction is -ΔW / 2, and the second correction is ΔW / 2. The coordinates of the detection points in the first sub-table are added to the first correction, and the coordinates of the detection points in the second sub-table are added to the second correction.

[0065] For a sheet material that simultaneously experiences leftward offset and expansion, the combined offset ΔX is less than 0 and the width change ΔW is greater than 0. The coordinates of the detection points in the first sub-table are added to the first correction amount, and the coordinates of the detection points in the second sub-table are added to the second correction amount.

[0066] For a sheet material that simultaneously experiences leftward offset and shrinkage, the combined offset ΔX is less than 0 and the width change ΔW is less than 0. The coordinates of the detection points in the first sub-table are added to the first correction amount, and the coordinates of the detection points in the second sub-table are added to the second correction amount.

[0067] For a sheet material that simultaneously experiences rightward offset and expansion, the combined offset ΔX is greater than 0 and the width change ΔW is greater than 0. The coordinates of the detection points in the first sub-table are added to the first correction amount, and the coordinates of the detection points in the second sub-table are added to the second correction amount.

[0068] For a sheet material that simultaneously experiences rightward offset and shrinkage, the overall offset ΔX is greater than 0 and the width change ΔW is less than 0. The coordinates of the detection points in the first sub-table are added to the first correction amount, and the coordinates of the detection points in the second sub-table are added to the second correction amount.

[0069] The positional mapping table is updated according to a preset frequency. During production, the banner quality inspection mechanism scans back and forth along the banner direction of the sheet at a preset frequency, acquiring quality information and corresponding real-time coordinates of each inspection point. If a quality issue arises at a particular inspection point, the corresponding banner quality control mechanism can be located in the latest positional mapping table based on its real-time coordinates. By adjusting this mechanism, the quality at the corresponding position can be corrected. This resolves the issue of "misalignment" caused by sheet drift or shrinkage.

[0070] refer to Figure 3 In some embodiments, an alignment control device for banner quality control is provided, comprising: The initial module 201 is used to establish an initial positional relationship mapping table, which includes the mapping relationship between the identifiers of each banner quality control mechanism in the control area and the coordinates of each initial detection point in the measurement area. The reference calculation module 202 is used to locate the initial position of the sheet being tested and determine the initial position information; The table update module 203 is used to perform the following operations at a preset frequency during the movement of the sheet under test: acquire image information of the sheet under test through a visual detection device set in the measurement area; calculate the comprehensive offset and width change of the sheet under test based on the image information and the initial position information and determine the abnormality type of the sheet under test; correct the detection point coordinates in the current position relationship mapping table based on the abnormality type of the sheet under test, the comprehensive offset and width change, and update the position relationship mapping table.

[0071] Furthermore, the initial module 201 establishes an initial positional relationship mapping table, including: Multiple banner quality control mechanisms are distributed and set in the control area of ​​the sheet being tested, and the number or physical coordinates of each banner quality control mechanism are used as the identifier of the corresponding banner quality control mechanism. Adjust the output of each banner quality control mechanism to obtain the effective response area of ​​each banner quality control mechanism; Within the measurement area, the detection location area corresponding to each effective response area is determined, and the coordinates in each detection location area are obtained as the initial detection point coordinates. The initial detection point coordinates are then mapped to the identifier of the banner quality control mechanism to obtain the initial positional relationship mapping table.

[0072] Furthermore, the control area and the measurement area correspond in the horizontal direction; the initial module 201 determines the detection position area corresponding to each effective response area, including: Obtain the width of each valid response area in the banner direction; In the measurement area, the detection position area corresponding to the width of each effective response area in the horizontal direction is determined.

[0073] Furthermore, the reference calculation module 202 locates the initial position of the sheet under test and determines the initial position information, including: An initial image of the sheet under test in its initial state is obtained through a visual inspection device. Based on the initial image, edge recognition of the sheet under test is performed to obtain the first initial edge and the second initial edge on both sides of the sheet under test in the horizontal direction. The midpoint is calculated based on the first and second initial edges, and a coordinate system is established using the midpoint as the zero point coordinate. In the coordinate system, the coordinates of the first initial edge and the coordinates of the second initial edge are used as the initial position information.

[0074] Further, the table update module 203 calculates the comprehensive offset and width change of the tested sheet based on the image information and the initial position information, and determines the anomaly type of the tested sheet, including: Based on the image information, the first real-time edge and the second real-time edge on both sides of the horizontal direction of the sheet being tested are identified. Obtain the coordinates of the first real-time edge and the second real-time edge in the coordinate system. A first deviation value is calculated based on the coordinates of the first initial edge and the corresponding coordinates of the first real-time edge; a second deviation value is calculated based on the coordinates of the second initial edge and the corresponding coordinates of the second real-time edge. Calculate the combined offset and width change based on the first and second deviation values; The abnormality type of the tested sheet is determined based on the first deviation value and the second deviation value. The abnormality type includes at least one of offset, shrinkage, and expansion.

[0075] Furthermore, the overall offset is half of the sum of the first deviation value and the second deviation value; the width change is the difference between the second deviation value and the first deviation value. The table update module 203 determines the anomaly type of the tested sheet based on the first deviation value and the second deviation value, including: Compare the first deviation value and the second deviation value to determine whether the tested sheet has shifted. Based on whether the positive and negative signs of the first deviation value and the second deviation value are the same, and whether the absolute values ​​of the first deviation value and the second deviation value are equal, it can be determined whether the tested sheet has expanded or contracted. Based on the magnitude and sign of the first and second deviation values, determine whether the tested sheet material is simultaneously shifting and expanding, or simultaneously shifting and shrinking.

[0076] Furthermore, the table update module 203 corrects the coordinates of the detection points in the current positional relationship mapping table based on the anomaly type of the tested sheet, the comprehensive offset, and the width change, including: The overall offset is converted to the same coordinate system as the detection point coordinates; For the sheet material under test that has shifted, add the coordinates of the detection point in the current position relationship mapping table to the comprehensive offset after coordinate transformation to obtain the corrected coordinates of the detection point. For the sheet material under test that shrinks or expands, or shifts and expands simultaneously, or shifts and shrinks simultaneously, the current positional relationship mapping table is divided into regions according to the coordinate system. The correction amount for each region is calculated based on the comprehensive offset after coordinate transformation and the width change. The coordinates of the detection points in the corresponding regions are then corrected based on the correction amount.

[0077] Furthermore, based on the positive and negative directions of the coordinate system, the current positional relationship mapping table is divided into a first sub-table and a second sub-table, wherein the first sub-table corresponds to the negative direction of the coordinate axis and the second sub-table corresponds to the positive direction of the coordinate axis; Calculate the first correction amount corresponding to the first sub-table and the second correction amount corresponding to the second sub-table based on the comprehensive offset after coordinate transformation and the width change; Add the detection point coordinates in the first sub-table to the first correction amount, and add the detection point coordinates in the second sub-table to the second correction amount to obtain the corrected detection point coordinates.

[0078] Furthermore, the first correction amount is the difference between the overall offset and half of the width change; the second correction amount is the sum of the overall offset and half of the width change.

[0079] In some embodiments, an alignment control system for banner quality control is also provided, including a processor and a memory, and a visual inspection device disposed in the measurement area; the memory stores multiple instructions, and the processor is used to read the instructions and execute the method described above.

[0080] Specifically, refer to Figure 4 The system also includes multiple banner quality control mechanisms 101 set in the control area. The multiple banner quality control mechanisms 101 are set along the banner direction of the sheet 100 being tested. In the measurement area B corresponding to the control area A, a gantry is set up. A visual inspection device 102 is set on the gantry, and its shooting range covers the two edges of the sheet being tested. A banner quality inspection mechanism 103 is also set on the gantry, which is used to scan back and forth in the banner direction within the measurement area B to obtain the quality information of each inspection point in the banner direction of the sheet being tested.

[0081] The visual inspection device collects real-time image information of the sheet 100 under test at a preset frequency. The system updates the positional relationship mapping table in real time based on the width change and comprehensive offset calculated from the real-time image information. During the quality inspection of the sheet under test, the banner quality inspection mechanism 103 obtains the quality information of each inspection point in the banner direction of the sheet under test. If the quality of a certain inspection point does not meet the production requirements, the corresponding banner quality control mechanism 101 is found according to the latest positional relationship mapping table, and it is controlled to perform quality control.

[0082] The alignment control method, apparatus, and system for quality control of sheet banners provided in the above embodiments have at least the following beneficial effects: (1) By constructing a dynamic mapping mechanism between the coordinates of the detection point and the control mechanism, and integrating the machine vision system on this basis, the real-time dynamic perception of the material's lateral offset, shrinkage, and expansion, as well as the alignment calibration between the coordinates of the detection point and the control mechanism, is realized, thereby achieving the purpose of precise and efficient control of the quality of the roll / sheet material and significantly improving the ability to ensure the uniformity of materials in the high-end manufacturing process. (2) Effectively solves the problem of "misalignment control" caused by factors such as material offset, material shrinkage deformation, and equipment drift; (3) Edge recognition technology based on machine vision effectively improves the perception accuracy and precision of offset, thereby improving the accuracy of alignment and control, and greatly reducing the need for manual intervention. (4) It enables continuous production lines of rolls or sheets to perform dynamic alignment calibration between the coordinates of the detection points and the control mechanism in real time, without the need to stop production or shut down the machine, which significantly improves production continuity and overall efficiency.

[0083] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention. Clearly, those skilled in the art can make various alterations and modifications to the invention without departing from its spirit and scope. Thus, if these modifications and modifications of the invention fall within the scope of the claims and their equivalents, the invention is also intended to include these modifications and modifications.

Claims

1. A method for alignment control in quality control of sheet banners, characterized in that, include: Establish an initial positional relationship mapping table, which includes the mapping relationship between the identifiers of each banner quality control mechanism in the control area and the coordinates of each initial detection point in the measurement area. The initial position of the sheet being tested is determined to establish the initial position information. The sheet under test is controlled to move along a preset direction, and the following operations are performed at a preset frequency during the movement: image information of the sheet under test is acquired through a visual detection device set in the measurement area; the comprehensive offset and width change of the sheet under test are calculated based on the image information and the initial position information, and the abnormality type of the sheet under test is determined; the detection point coordinates in the current position relationship mapping table are corrected based on the abnormality type of the sheet under test, the comprehensive offset and width change, and the position relationship mapping table is updated.

2. The method according to claim 1, characterized in that, Establish an initial positional mapping table, including: Multiple banner quality control mechanisms are distributed and set in the control area of ​​the sheet being tested, and the number or physical coordinates of each banner quality control mechanism are used as the identifier of the corresponding banner quality control mechanism. Adjust the output of each banner quality control mechanism to obtain the effective response area of ​​each banner quality control mechanism; Within the measurement area, the detection location area corresponding to each effective response area is determined, and the coordinates in each detection location area are obtained as the initial detection point coordinates. The initial detection point coordinates are then mapped to the identifier of the banner quality control mechanism to obtain the initial positional relationship mapping table.

3. The method according to claim 2, characterized in that, The control area and the measurement area correspond to each other in the horizontal direction; Determine the detection location regions corresponding to each valid response region, including: Obtain the width of each valid response area in the banner direction; In the measurement area, the detection position area corresponding to the width of each effective response area in the horizontal direction is determined.

4. The method according to claim 1, characterized in that, The initial position of the sheet being tested is determined, including: An initial image of the sheet under test in its initial state is obtained through a visual inspection device. Based on the initial image, edge recognition of the sheet under test is performed to obtain the first initial edge and the second initial edge on both sides of the sheet under test in the horizontal direction. The midpoint is calculated based on the first and second initial edges, and a coordinate system is established using the midpoint as the zero point coordinate. In the coordinate system, the coordinates of the first initial edge and the coordinates of the second initial edge are used as the initial position information.

5. The method according to claim 4, characterized in that, Based on the image information and the initial position information, calculate the comprehensive offset and width change of the sheet under test, and determine the anomaly type of the sheet under test, including: Based on the image information, the first real-time edge and the second real-time edge on both sides of the horizontal direction of the sheet being tested are identified. Obtain the coordinates of the first real-time edge and the second real-time edge in the coordinate system. A first deviation value is calculated based on the coordinates of the first initial edge and the corresponding coordinates of the first real-time edge; a second deviation value is calculated based on the coordinates of the second initial edge and the corresponding coordinates of the second real-time edge. Calculate the combined offset and width change based on the first and second deviation values; The abnormality type of the tested sheet is determined based on the first deviation value and the second deviation value. The abnormality type includes at least one of offset, shrinkage, and expansion.

6. The method according to claim 5, characterized in that, The overall offset is half the sum of the first deviation value and the second deviation value; the width change is the difference between the second deviation value and the first deviation value. The type of abnormality of the tested sheet is determined based on the first deviation value and the second deviation value, including: Compare the first deviation value and the second deviation value to determine whether the tested sheet has shifted. Based on whether the positive and negative signs of the first deviation value and the second deviation value are the same, and whether the absolute values ​​of the first deviation value and the second deviation value are equal, it can be determined whether the tested sheet has expanded or contracted. Based on the magnitude and sign of the first and second deviation values, determine whether the tested sheet material is simultaneously shifting and expanding, or simultaneously shifting and shrinking.

7. The method according to claim 6, characterized in that, The coordinates of the detection points in the current positional mapping table are corrected based on the anomaly type of the tested sheet, the comprehensive offset, and the width change, including: The combined offset and width variation are converted to the same coordinate system as the detection point coordinates; For the sheet material under test that has shifted, add the coordinates of the detection point in the current position relationship mapping table to the comprehensive offset after coordinate transformation to obtain the corrected coordinates of the detection point. For the sheet material under test that shrinks or expands, or shifts and expands simultaneously, or shifts and shrinks simultaneously, the current positional relationship mapping table is divided into regions according to the coordinate system. The correction amount for each region is calculated based on the comprehensive offset after coordinate transformation and the width change. The coordinates of the detection points in the corresponding regions are then corrected based on the correction amount.

8. The method according to claim 7, characterized in that, Based on the positive and negative directions of the coordinate axes of the coordinate system, the current positional relationship mapping table is divided into a first sub-table and a second sub-table, where the first sub-table corresponds to the negative direction of the coordinate axes and the second sub-table corresponds to the positive direction of the coordinate axes. Calculate the first correction amount corresponding to the first sub-table and the second correction amount corresponding to the second sub-table based on the comprehensive offset after coordinate transformation and the width change; Add the detection point coordinates in the first sub-table to the first correction amount, and add the detection point coordinates in the second sub-table to the second correction amount. The detection point coordinates corresponding to the zero point coordinates remain unchanged, and the corrected detection point coordinates are obtained.

9. The method according to claim 8, characterized in that, The first correction is the difference between the overall offset and half of the width change; the second correction is the sum of the overall offset and half of the width change.

10. A positioning control device for quality control of sheet horizontal banners, characterized in that, include: The initial module is used to establish an initial positional relationship mapping table, which includes the mapping relationship between the identifiers of each banner quality control mechanism in the control area and the coordinates of each initial detection point in the measurement area. The baseline calculation module is used to locate the initial position of the sheet being tested and determine the initial position information; The table update module is used to perform the following operations at a preset frequency during the movement of the sheet under test: acquire image information of the sheet under test through a visual detection device set in the measurement area; calculate the comprehensive offset and width change of the sheet under test based on the image information and the initial position information, and determine the abnormality type of the sheet under test; correct the detection point coordinates in the current position relationship mapping table based on the abnormality type of the sheet under test, the comprehensive offset and width change, and update the position relationship mapping table.

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