A textile fabric roughness on-line detection system

Abstract

This invention discloses an online detection system for textile fabric roughness, belonging to the field of textile fabric detection technology. The invention includes a base, a guide roller, a ceramic support platform, a light-guiding chamber, a camera, a light-emitting element, a light-shielding plate, an electromagnet, a reflective lens, and a heat dissipation assembly. The textile fabric is laid flat and moved on the ceramic support platform. Light from both sides alternately illuminates the fabric surface at an angle of 5° relative to the platform surface. The camera takes pictures at two positions on the light-shielding plate. By comparing the shadow positions in the two images, the surface of the fabric can be determined to be raised or recessed. Continuous shadow areas are magnified through image stacking, and roughness is determined or classified based on the number of shadow areas and the number of pixels.

Description

Technical Field

[0001] This invention relates to the field of textile fabric testing technology, specifically to an online textile fabric roughness testing system. Background Technology

[0002] In the weaving, dyeing, calendering, laminating, coating, and finishing processes of textile fabrics, the smoothness and roughness of the surface directly affect the appearance quality, the stability of subsequent processing, and the consistency of the final product. For fabrics with localized bumps, depressions, indentations, yarn floaters, uneven weave, or slight pits, if these defects are not identified in a timely manner during continuous transport, it can easily cause fluctuations in the quality of the entire roll of fabric. Furthermore, it can force subsequent processes such as setting, coating, laminating, and cutting to continue on a defective basis, thereby increasing rework and scrap rates. Therefore, online roughness detection of textile fabrics in continuously moving conditions has always required a detection method that can provide stable imaging and accurately identify subtle differences in surface morphology.

[0003] In practical applications, existing fabric surface inspection methods tend to focus more on identifying macroscopic defects such as color abnormalities, holes, stains, and obvious stripes. However, ordinary forward-facing photographic inspection methods cannot address the subtle surface undulations related to roughness, especially in scenarios where it is necessary to distinguish between convex and concave surfaces. Summary of the Invention

[0004] To overcome the shortcomings of the prior art, the present invention provides the following technical solution: an online detection system for the roughness of textile fabrics, comprising two guide rollers, a ceramic support platform disposed between the two guide rollers, and a fixed positional relationship between the ceramic support platform and the two guide rollers; light guide chambers are disposed on both sides of the upper surface of the ceramic support platform, the two light guide chambers being used to guide light along an angle of 5° with the upper surface of the ceramic support platform to illuminate the upper surface of the ceramic support platform; a camera is also disposed between the two light guide chambers, the camera being located directly above the ceramic support platform; it also includes two light-emitting elements, the two light-emitting elements being respectively disposed directly above the two light guide chambers, for providing light sources to the light guide chambers; a light-shielding plate is also disposed between the light-emitting elements and the light guide chambers for intermittently blocking the light source of the light-emitting elements from entering the light source inside the light guide chambers; the light-shielding plate blocks the two light guide chambers at a first position and a second position respectively, the time when the light-shielding plate is at the first position and the second position is the time when the camera takes a picture and records the image.

[0005] Preferably, the ceramic support platform is fixedly installed on the base, and the two guide flattening rollers are rotatably installed on the base through corresponding flattening roller brackets. The horizontal height of the two guide flattening rollers is lower than the horizontal height of the upper surface of the ceramic support platform; the camera is fixedly installed on the camera bracket, and the camera bracket is fixedly installed on the base.

[0006] Preferably, the ceramic support platform, guide roller, camera, and light guide chamber are all located inside the housing. The housing is fixedly mounted on the base, and a platform plate is also fixedly mounted on the inner wall of the housing. Two light guide chambers are fixedly mounted on the platform plate, and a sliding frame is fixedly mounted on the upper surface of the platform plate. A light shield is slidably mounted on the inner side of the sliding frame, and one end of the light shield is elastically connected to the sliding frame by multiple elastic ropes. A light-passing hole that can be aligned with one of the light guide chambers is opened on the side of the upper surface of the light shield away from the elastic ropes.

[0007] Preferably, a clearance groove is provided in the middle of the sliding frame, an electromagnet is provided on the inner side of the clearance groove, the electromagnet is fixed on the platform plate, and a passive magnetic block is provided on the side of the electromagnet facing the elastic pull rope, and the passive magnetic block is fixed on the light shield.

[0008] Preferably, heat dissipation fins are also fixedly installed on the inner wall of the housing, wherein two light-emitting elements are fixedly installed on the lower surface of the heat dissipation fins, and an electromagnet is fixedly installed on the lower surface of the heat dissipation fins. The heat dissipation fins are used to dissipate heat from the light-emitting elements and the electromagnet.

[0009] Preferably, a fan is rotatably mounted in the middle of the heat dissipation fins, an air intake hole aligned with the fan is provided in the middle of the upper surface of the housing, and heat dissipation holes aligned with the heat dissipation fins are provided on the top of both sides of the housing.

[0010] Preferably, an inclined reflector is fixedly installed at the bottom of the inner wall of each light guide cavity. The reflector is used to reflect the light emitted by the light-emitting element onto the textile fabric on the ceramic support platform at an angle of 5° to the upper surface of the inclined ceramic support platform. A dustproof and light-transmitting glass plate is also fixedly installed at the bottom of the light guide cavity through a beam shaping baffle. The beam shaping baffle blocks the excess light reflected by the reflector from the light-emitting element and is used to control the area of ​​light reflected by the reflector onto the textile fabric.

[0011] Preferably, the bottom of the outer casing is also provided with a slot, and a snap-on cover is magnetically installed in the slot for the installation of textile fabric; textile fabric perforations are provided at the junction of the outer casing, the snap-on cover and the textile fabric to allow the textile fabric to pass through.

[0012] Compared with the prior art, the present invention has the following advantages: (1) The present invention sets up light guide chambers on both sides of the ceramic support platform and uses a light shield to switch between the first position and the second position, so that the oblique light from the left and right sides illuminates the same detection area at two different times, so that the camera can obtain the shadow difference formed by the same rough defect under opposite illumination directions in two photos. Since the shadow relative position change law of the protrusion and the depression under the reverse oblique light condition is different, it can not only determine whether there is roughness on the fabric surface, but also further determine whether the unevenness is an upward protrusion or a downward depression. It can improve the roughness detection from whether it is abnormal to the abnormal type can be judged, so as to provide a more targeted basis for subsequent process adjustment, equipment pressure roller correction and weaving parameter optimization; (2) The present invention does not simply compare the results of the two photos, but stacks the images obtained at the first position time and the second position time, so that the shadow area corresponding to the rough defect is superimposed and magnified. In this way, the shadow information that was originally weak in boundary, small in area or difficult to be extracted stably in a single image will appear as a more obvious continuous shadow area after stacking. Based on this processing method, roughness level can be further determined according to the number of pixels in continuous shadow areas, the total number of continuous shadow areas, or a combination of the two. This improves the identifiability of minute roughness features and reduces the system's absolute dependence on ultra-high pixel cameras, while enhancing defect representation through dual-image overlay. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the outer shell structure of the present invention.

[0014] Figure 2 This is a schematic diagram of the internal structure of the outer shell of the present invention.

[0015] Figure 3 This is a front view of the overall structural layout of the present invention.

[0016] Figure 4 This is a schematic diagram of the structure of the light-shielding plate of the present invention.

[0017] Figure 5 This is a schematic diagram of the structure of the reflective lens in this invention.

[0018] In the diagram: 101-Base; 102-Guide flattening roller; 103-Flattening roller bracket; 104-Ceramic support platform; 105-Textile fabric; 201-Platform plate; 202-Sliding frame; 203-Light shield; 204-Elastic pull rope; 205-Passive magnetic block; 206-Electromagnet; 207-Light-emitting element; 208-Heat dissipation fins; 209-Allowing groove; 210-Light-passing hole; 211-Camera bracket; 212-Camera; 213-Light guide chamber; 214-Reflector; 215-Beam shaping baffle; 216-Dustproof and light-transmitting glass sheet; 217-Fan; 301-Outer shell; 302-Heat dissipation hole; 303-Air inlet; 304-Clip plate cover; 305-Textile fabric perforation. Detailed Implementation

[0019] The following is in conjunction with the appendix Figures 1-5 The technical solution of the present invention will be further illustrated through specific embodiments.

[0020] This invention provides an online detection system for the roughness of textile fabrics, comprising two guide rollers 102, a ceramic support platform 104 disposed between the two guide rollers 102, and a fixed positional relationship between the ceramic support platform 104 and the two guide rollers 102; light guide chambers 213 are disposed on both sides of the upper surface of the ceramic support platform 104, and the two light guide chambers 213 are used to guide light to illuminate the upper surface of the ceramic support platform 104 at an angle of 5° to the upper surface of the ceramic support platform 104; a camera 212 is also disposed between the two light guide chambers 213. 12 is located directly above the ceramic support platform 104; it also includes two light-emitting elements 207, which are respectively positioned directly above the two light-guiding chambers 213 to provide light sources to the light-guiding chambers 213; a light-shielding plate 203 is also provided between the light-emitting elements 207 and the light-guiding chambers 213 to intermittently block the light source of the light-emitting elements 207 from entering the light-guiding chambers 213; the light-shielding plate 203 blocks the two light-guiding chambers 213 at a first position and a second position respectively, and the moment when the light-shielding plate 203 is at the first position and the second position is the moment when the camera 212 takes pictures and records.

[0021] The ceramic support platform 104 is fixedly installed on the base 101. Two guide flattening rollers 102 are rotatably installed on the base 101 through corresponding flattening roller brackets 103. The horizontal height of the two guide flattening rollers 102 is lower than the horizontal height of the upper surface of the ceramic support platform 104. The camera 212 is fixedly installed on the camera bracket 211, and the camera bracket 211 is fixedly installed on the base 101. The ceramic support platform 104, guide flattening roller 102, camera 212, and light guide chamber 213 are all located inside the housing 301. The housing 301 is fixedly mounted on the base 101. The inner wall of the housing 301 is also fixedly mounted on the platform plate 201. Two light guide chambers 213 are fixedly mounted on the platform plate 201. A sliding frame 202 is fixedly mounted on the upper surface of the platform plate 201. A light shield 203 is slidably mounted on the inner side of the sliding frame 202. One end of the light shield 203 is elastically connected to the sliding frame 202 by multiple elastic ropes 204. A light-passing hole 210 is opened on the side of the upper surface of the light shield 203 away from the elastic ropes 204, which can be aligned with one of the light guide chambers 213. A clearance groove 209 is provided in the middle of the sliding frame 202. An electromagnet 206 is provided on the inner side of the clearance groove 209. The electromagnet 206 is fixed on the platform plate 201. A passive magnetic block 205 is provided on the side of the electromagnet 206 facing the elastic pull rope 204. The passive magnetic block 205 is fixed on the light shield 203.

[0022] A heat dissipation fin 208 is fixedly installed on the inner wall of the outer casing 301. Two light-emitting elements 207 are fixedly installed on the lower surface of the heat dissipation fin 208, and an electromagnet 206 is fixedly installed on the lower surface of the heat dissipation fin 208. The heat dissipation fin 208 is used to dissipate heat from the light-emitting elements 207 and the electromagnet 206. A fan 217 is rotatably mounted in the middle of the heat dissipation fin 208. An air inlet 303 aligned with the fan 217 is opened in the middle of the upper surface of the outer casing 301. Heat dissipation holes 302 aligned with the heat dissipation fin 208 are opened on the top of both sides of the outer casing 301. Each light guide chamber 213 has a tilted reflector 214 fixedly installed at the bottom of its inner wall. The reflector 214 is used to reflect the light emitted by the light-emitting element 207 onto the textile fabric 105 on the ceramic support platform 104 at an angle of 5° to the upper surface of the tilted ceramic support platform 104. At the bottom of the light guide chamber 213, a dustproof and light-transmitting glass plate 216 is also fixedly installed through a beam shaping baffle 215. The beam shaping baffle 215 blocks the excess light reflected by the reflector 214 from the light-emitting element 207 and is used to control the area of ​​light reflected by the reflector 214 onto the textile fabric 105.

[0023] The bottom of the outer casing 301 is also provided with a slot, in which a snap-on cover 304 is magnetically installed for the installation of the textile fabric 105; at the junction of the outer casing 301, the snap-on cover 304 and the textile fabric 105, textile fabric perforations 305 are provided to allow the textile fabric 105 to pass through.

[0024] Open the cover 304 and pass the textile fabric 105 through the guide roller 102, the upper surface of the ceramic support platform 104, and the guide roller 102, ensuring that the textile fabric 105 is laid flat on the upper surface of the ceramic support platform 104. The textile fabric 105 should be horizontal when entering and exiting the housing 301. During testing, the textile fabric 105 needs to be moved while the cover 304 is reset and closed, and one end of the textile fabric 105 is connected to the traction structure. The textile fabric 105 moves on the upper surface of the ceramic support platform 104. The specific testing process is as follows: the two light-emitting elements 207 are in a constantly lit state (to prevent damage caused by frequent start-stop). When the light-shielding plate 203 is in the first position, the light-passing hole 210 is aligned with one of the light-guiding chambers 213. At this time, the shutter of the camera 212 is activated (the camera 212 has optical image stabilization), and the camera 212 takes a picture of the textile fabric 105 on the upper surface of the ceramic support platform 104. The light for taking the picture comes from the light-emitting element 207, which passes through the light-transmitting hole 210 and shines onto the reflective lens 214. The reflective lens 214 reflects the light onto the textile fabric 105. If there are pits or bumps on the surface of the textile fabric 105, shadows will be generated on the pits and bumps because the light shines on the textile fabric 105 at an angle. Then, the electromagnet 206 is activated, and the electromagnet 206 generates a magnetic force that attracts the passive magnetic block 205. The passive magnetic block 205 will move towards the electromagnet 206, and the passive magnetic block 205 will drive the light-shielding plate 203 to move synchronously (to the second position). The light-shielding plate 203 overcomes the elastic pull rope 204. During the pulling motion, the position of the light-passing aperture 210 shifts, no longer aligned with the previously corresponding light-guiding cavity 213, but instead offset. At this point, the light-shielding plate 203 blocks it. Then, the light-shielding plate 203 above another light-guiding cavity 213 moves away, allowing light from the light-emitting element 207 to enter the light-guiding cavity 213. This light is then reflected by the corresponding reflector 214 onto the textile fabric 105. If the surface of the textile fabric 105 has pits or protrusions, these will create shadows. At this moment, the shutter of the camera 212 is activated, and the camera 212 takes a picture of the textile fabric 105 on the upper surface of the ceramic support platform 104. (Refer to...) Figure 5If the pattern received by camera 212 is: the shadow generated at the first position is to the left of the shadow generated at the second position, it indicates that there is a protrusion on the textile fabric 105; otherwise, it is a depression (this can determine whether there is a protrusion or depression on the surface of the textile fabric 105, providing a reference for subsequent process adjustments). The two images captured by camera 212 at the first and second positions are stacked to form a new image (actually, the area occupied by the shadow region is enlarged to improve detection accuracy and reduce the dependence of camera 212 on the number of pixels). The number of pixels occupied by each continuous shadow region is determined according to the total number of pixels of camera 212. The higher the number of pixels of camera 212, the higher the detection accuracy. For example, if the number of pixels occupied by any continuous shadow region is greater than 10,000, the surface roughness of textile fabric 105 is judged to be unqualified, or the roughness level is classified according to the number of pixels occupied by continuous shadow regions. If the number of continuous shadow regions is greater than 200, the surface roughness of textile fabric 105 is judged to be unqualified, or the roughness level is classified according to the number of continuous shadow regions. Alternatively, a comprehensive judgment can be made based on the number of consecutive shadow regions and the number of pixels occupied by each consecutive shadow region.

[0025] It should be noted that the above process needs to be adjusted according to the traction speed of the textile fabric 105, such as the shutter speed of the camera 212, the magnetic force of the electromagnet 206 (i.e., the movement speed of the light-shielding plate 203), and the coordination between the instant of the camera 212's shutter and the two position moments of the light-shielding plate 203's movement. The movement speed of the light-shielding plate 203 in a single direction and the shutter speed of the camera 212 are <1 / 3000s, so the movement speed of the textile fabric 105 has a very small impact on the imaging of the camera 212. If there is motion blur (i.e., the number of pixels in the shadow area of ​​the textile fabric 105 in a stationary state is less than the number of pixels in the shadow area in motion), it can be fine-tuned by increasing the shutter speed of the camera 212 and the movement speed of the light-shielding plate 203 until the motion blur meets the requirements (i.e., the number of pixels in the shadow area of ​​the textile fabric 105 in a stationary state is approximately equal to the number of pixels in the shadow area in motion, but there will be a difference, and this difference is the detection error).

[0026] At the same time, the fan 217 is started. The fan 217 drives the outside air through the air inlet 303 into the heat sink 208, and then dissipates the heat from the heat sink 208. Finally, the hot gas is discharged through the heat dissipation hole 302. The heat sink 208 absorbs the heat from the light-emitting element 207 and the electromagnet 206, which are in operation for a long time, to ensure that they are at the normal operating temperature.

Claims

1. A system for on-line detection of textile fabric roughness, characterized by: It includes two guide flattening rollers (102), and a ceramic support platform (104) is arranged between the two guide flattening rollers (102). The positional relationship between the ceramic support platform (104) and the two guide flattening rollers (102) is fixed. Light guide chambers (213) are arranged on both sides of the upper surface of the ceramic support platform (104). The two light guide chambers (213) are used to guide light along an angle of 5° with the upper surface of the ceramic support platform (104) to irradiate the upper surface of the ceramic support platform (104). A camera (212) is also installed between the two light guide chambers (213), and the camera (212) is located directly above the ceramic support platform (104); It also includes two light-emitting elements (207), which are respectively positioned directly above the two light-guiding cavities (213) to provide light sources to the light-guiding cavities (213); a light-shielding plate (203) is also provided between the light-emitting elements (207) and the light-guiding cavities (213) to intermittently block the light-emitting elements (207) from entering the light source inside the light-guiding cavities (213). The light shield (203) blocks the two light guide chambers (213) at the first position and the second position respectively. The moment when the light shield (203) is at the first position and the second position is the moment when the camera (212) takes a picture.

2. The system according to claim 1, wherein: The ceramic support platform (104) is fixedly installed on the base (101). Two guide flat rollers (102) are rotatably installed on the base (101) through corresponding flat roller brackets (103). The horizontal height of the two guide flat rollers (102) is lower than the horizontal height of the upper surface of the ceramic support platform (104). The camera (212) is fixedly installed on the camera bracket (211), and the camera bracket (211) is fixedly installed on the base (101).

3. The system according to claim 2, wherein: The ceramic support platform (104), guide flat roller (102), camera (212) and light guide chamber (213) are all located inside the housing (301). The housing (301) is fixedly installed on the base (101). The inner wall of the housing (301) is also fixedly installed with a platform plate (201). Two light guide chambers (213) are fixedly installed on the platform plate (201). A sliding frame (202) is fixedly installed on the upper surface of the platform plate (201). A light shield (203) is slidably installed on the inner side of the sliding frame (202). One end of the light shield (203) is elastically connected to the sliding frame (202) by multiple elastic ropes (204). A light-passing hole (210) that can be aligned with one of the light guide chambers (213) is opened on the side of the upper surface of the light shield (203) away from the elastic ropes (204).

4. The system according to claim 3, wherein: A clearance groove (209) is provided in the middle of the sliding frame (202). An electromagnet (206) is provided on the inner side of the clearance groove (209). The electromagnet (206) is fixed on the platform plate (201). A passive magnetic block (205) is provided on the side of the electromagnet (206) facing the elastic pull rope (204). The passive magnetic block (205) is fixed on the light shield (203).

5. The system according to claim 4, wherein: The inner wall of the outer casing (301) is also fixedly installed with heat dissipation fins (208), of which two light-emitting elements (207) are fixedly installed on the lower surface of the heat dissipation fins (208), and an electromagnet (206) is fixedly installed on the lower surface of the heat dissipation fins (208). The heat dissipation fins (208) are used to dissipate heat from the light-emitting elements (207) and the electromagnet (206).

6. The system according to claim 5, wherein: A fan (217) is rotatably mounted in the middle of the heat dissipation fins (208). An air inlet (303) aligned with the fan (217) is provided in the middle of the upper surface of the housing (301). Heat dissipation holes (302) aligned with the heat dissipation fins (208) are provided on the top of both sides of the housing (301).

7. The system according to claim 1, wherein: Each light guide chamber (213) has a tilted reflector (214) fixedly installed at the bottom of its inner wall. The reflector (214) is used to reflect the light emitted by the light-emitting element (207) onto the textile fabric (105) on the ceramic support platform (104) at an angle of 5° to the upper surface of the tilted ceramic support platform (104). At the bottom of the light guide chamber (213), a dustproof and light-transmitting glass plate (216) is also fixedly installed through a beam shaping baffle (215). The beam shaping baffle (215) blocks the reflector (214) from reflecting excess light from the light-emitting element (207). The beam shaping baffle (215) is used to control the area of ​​light reflected by the reflector (214) onto the textile fabric (105).

8. The system according to claim 3, wherein: The bottom of the outer shell (301) is also provided with a slot, and a snap-on cover (304) is magnetically installed in the slot for the installation of the textile fabric (105); textile fabric perforations (305) are provided at the junction of the outer shell (301) and the snap-on cover (304) with the textile fabric (105) so that the textile fabric (105) can pass through.

Images