Textile machine yarn spraying defect detection process

Abstract

This invention provides a process for detecting defects in yarn spraying on textile machines. The invention relates to the field of detection technology and includes the following steps: S1, controlling the sprayer to spray weft yarn, causing the warp and weft yarns to automatically interweave and form fabric; S2, continuously detecting the interwoven fabric using a second detection component. When the second detection component detects an abnormal defect on the fabric surface, it drives a first detection component to move to one side of the abnormal defect area to confirm the defect; S3, when the first detection component confirms that the abnormal defect detection result is a misjudgment, it removes the abnormal defect marker and controls the first detection component to reset to its initial position; after the first detection component further confirms the abnormal defect detection result, it controls a first image detection device to move to the point where the warp and weft yarns automatically interweave to finally confirm the cause of the abnormal defect. This invention can achieve omnidirectional detection of fabrics with a large width span, resulting in a wider detection range, better detection effect, and faster detection efficiency.

Description

Technical Field

[0001] This invention relates to the field of detection technology, and in particular to a process for detecting defects in yarn spraying on textile machines. Background Technology

[0002] In the textile production field, textile machines use a yarn sprayer to spray weft yarns and interweave them with warp yarns to form fabric. To ensure the quality of the finished fabric, image inspection equipment is usually used during the weaving process to perform online defect detection on the yarn-blown fabric. The inspection equipment is usually arranged outside the fabric conveying path and uses an industrial camera to collect fabric images in real time to identify common yarn-blown defects such as broken yarns, skipped yarns, sparse or dense lines, and holes.

[0003] Existing testing processes mostly use a single fixed testing unit for full-area scanning, or a single mobile testing unit for fixed-point testing. Some equipment is equipped with a simple cleaning structure to cope with the working environment of textile workshops with a lot of fly ash, cotton dust, and short fibers.

[0004] Existing methods for detecting defects in textile machine spinning have significant shortcomings. Single detection units are prone to high false positive rates due to distance and dust interference, making it impossible to simultaneously achieve rapid screening across the entire area and precise verification at specific points. After a defect is confirmed, it is difficult to quickly trace its origin back to the spinning source, such as the spinning machine or warp traction, which hinders timely equipment adjustments. This is especially true for fabrics with large spans, where traditional single detection structures are insufficient for comprehensive and efficient detection. As a result, significant defects in textile products are only discovered after they have been present for some time, leading to substantial losses. Summary of the Invention

[0005] To address the aforementioned issues, this invention provides a process for detecting defects in yarn spraying on textile machines. This invention enables comprehensive detection of fabrics with a wide width range, resulting in a larger detection range, better detection effects, and faster detection efficiency.

[0006] To solve the above problems, the technical solution adopted by the present invention is as follows:

[0007] A textile machine yarn spraying defect detection process utilizes a textile machine yarn spraying defect detection device. This device includes a first image detection device located outside the automatic warp and weft yarn interlacing and a second detection device located outside the fabric movement path. The second detection device comprises a relatively movable first detection component and a relatively fixed second detection component. The process includes the following steps: S1, controlling the yarn sprayer to spray weft yarn, causing the warp and weft yarns to automatically interlac and form fabric; S2, continuously detecting the interlaced fabric using the second detection component. When the second detection component detects an abnormal defect on the fabric surface, it drives the first detection component to move to the abnormal defect area to confirm the defect; S3, when the first detection component confirms that the abnormal defect detection result is a misjudgment, it removes the abnormal defect marker and controls the first detection component to reset to its initial position; when the first detection component further confirms the abnormal defect detection result, it controls the first image detection device to move to the automatic warp and weft yarn interlacing point to finally confirm the cause of the abnormal defect and sends the final confirmation result to the processing terminal to notify the operator to adjust the yarn sprayer.

[0008] Preferably, both the first image detection device and the first detection component include a guide rail perpendicular to the warp movement path, a positioning platform is provided on the surface of the guide rail, and the image detection element is located below the positioning platform.

[0009] Preferably, a gas cleaning channel is provided between each of the two positioning platforms and the guide rail, and the two gas cleaning channels are connected by a gas conveying device.

[0010] Preferably, the gas cleaning channel corresponding to the first image detection device is controlled to continuously draw in negative pressure to continuously suck up impurities on the surface of the corresponding guide track; the gas cleaning channel corresponding to the first detection component is controlled to continuously spray out pressurized gas to remove impurities on the surface of the corresponding guide track, and the gas delivery device has a built-in pump to realize unidirectional pumping of airflow.

[0011] Preferably, the positioning platform of the first image detection device is provided with a negative pressure connector at the top, a filter screen is provided at the bottom of the negative pressure connector, and a concentrating device is provided inside the positioning platform below the negative pressure connector, so as to directionally concentrate the impurities attached to the surface of the filter screen to the outside through the concentrating device.

[0012] Preferably, the concentrating device is a spiral cleaning blade, the filter screen is arc-shaped, and the edge of the spiral cleaning blade is in contact with the surface of the filter screen. During the continuous rotation of the spiral cleaning blade, the impurities attached to the surface of the filter screen are directionally concentrated to the outside.

[0013] Preferably, the spiral cleaning blade is hollow inside, and the central device further includes a control rod located inside the hollow spiral cleaning blade. The control rod is normally in an extended state and has a reset elasticity. A control protrusion is provided on the outside of the control rod. An arc-shaped groove adapted to the control protrusion is opened inside the hollow spiral cleaning blade. After the positioning platform of the first image detection device moves to the limit position, the control rod is compressed and drives the spiral cleaning blade to rotate.

[0014] Preferably, the spiral cleaning blade has an internal blade body and a control sleeve located inside the blade body, with a one-way bearing provided between the control sleeve and the blade body, and the arc-shaped groove located on the inner wall of the control sleeve.

[0015] The beneficial effects of this invention are as follows:

[0016] Compared with existing technologies, this process can form a closed-loop control of discovery, confirmation, traceability, and alarm. It can achieve all-round detection of fabrics with a large width range through three detection units, with a larger detection range, better detection effect, and faster detection efficiency. Attached Figure Description

[0017] Figure 1 This is a process flow diagram of the present invention.

[0018] Figure 2 This is a three-dimensional structural diagram of the textile machine yarn spraying defect detection equipment of the present invention.

[0019] Figure 3 For the present invention Figure 2 A side view structural diagram.

[0020] Figure 4 For the present invention Figure 2 A top-view structural diagram.

[0021] Figure 5 This is a schematic diagram of the positioning platform and centralized device structure of the present invention.

[0022] Figure 6 For the present invention Figure 5 A schematic diagram of the internal structure.

[0023] In the diagram: 100, textile mounting frame; 110, first guide roller; 120, second guide roller; 200, yarn sprayer; 300, first image detection device; 310, positioning platform; 311, gas cleaning channel; 320, guide rail; 330, concentrating device; 331, control rod; 332, spiral cleaning blade; 340, negative pressure connector; 400, second detection device; 410, first detection component; 420, second detection component; 500, warp traction device; 600, gas conveying device. Detailed Implementation

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0025] To address the problems mentioned in the background art, see Appendix Figure 1 -Appendix Figure 6 The textile machine yarn spraying defect detection process uses a textile machine yarn spraying defect detection device, which includes a first image detection device 300 located outside the automatic interlacing of warp and weft yarns and a second detection device 400 located outside the fabric movement path. The second detection device 400 includes a relatively movable first detection component 410 and a relatively fixed second detection component 420. By positioning the first image detection device 300, the first detection component 410, and the second detection component 420 at different locations, targeted detection is performed on different areas.

[0026] This process includes the following steps:

[0027] S1. Control the sprayer 200 to spray out the weft yarn, and the warp and weft yarns automatically interweave to form the fabric; the sprayer 200 intermittently sprays pressurized liquid to spray out the weft yarn, and the warp yarn traction device 500 controls the warp yarn to lock the weft yarn alternately up and down, and the sprayed weft yarn is concentrated and cut by the swing structure and the cutting structure, and the warp and weft yarns interweave to form the fabric.

[0028] S2. The second detection component 420 continuously detects the interwoven fabric. When the second detection component 420 detects an abnormal defect on the fabric surface, it drives the first detection component 410 to move to the side of the abnormal defect area to confirm the abnormal defect. The second detection component 420 is located at a position relatively far away from the fabric and can perform wide-area detection on the fabric, realizing real-time and efficient detection of the entire area. However, due to the distance, the detection accuracy is limited.

[0029] S3. When the first detection component 410 confirms that the abnormal defect detection result is a misjudgment, it removes the abnormal defect mark and controls the first detection component 410 to reset to the initial position; at this time, the second detection component 420 is a misjudgment, indicating that the fabric weaving quality meets the requirements and the front and rear sides of the textile machine are in normal operation.

[0030] Once the first detection component 410 further confirms the abnormal defect detection results, it is officially determined to be an actual defect. The first image detection device 300 is then moved to the automatic warp and weft interlacing point to confirm the cause of the abnormal defect. The final confirmation result is then sent to the processing terminal to notify the staff to debug the yarn sprayer 200. The staff then debugs and repairs the yarn sprayer 200, warp traction device 500, and other equipment based on the defects reported by the first image detection device 300, ensuring the normal operation of the subsequent textile machine.

[0031] This process employs a graded detection logic of two-level defect screening and one-level root cause localization, specifically designed for online quality monitoring of the yarn spinning process on high-speed textile machines. It is particularly suitable for comprehensive and rapid detection of fabrics with a wide width range.

[0032] The second detection component 420 is a fixed coarse inspection unit responsible for rapidly scanning the entire fabric area to identify suspected defects such as broken yarn, skipped yarn, knots, sparse or dense yarns, and holes. The first detection component 410 is a mobile fine inspection unit that performs high-resolution verification of suspicious areas, significantly reducing the false judgment rate caused by fly waste, lint, and dust. The first image detection device 300 is a traceability and positioning unit that directly images the warp and weft yarn interlacing points to determine whether the defects are caused by factors such as blockage of the yarn sprayer 200, unstable air pressure, or abnormal weft yarn tension.

[0033] In summary, this process enables a closed-loop control system of discovery, confirmation, traceability, and alarm. With just three detection units, it can perform comprehensive detection of fabrics with a wide width range, resulting in a larger detection range, better detection effect, and faster detection efficiency.

[0034] It should be noted that, considering the different inspection requirements and scenarios, the first inspection component uses a linear array industrial camera, which can achieve continuous full-area scanning of the fabric without blind spots, and is suitable for rough inspection of large-area defects under high-speed production; the second inspection component uses an area array industrial camera, which can focus on the defect area for high-definition imaging, meeting the accuracy requirements for defect review and detail confirmation; the first image inspection device uses a macro high-resolution area array industrial camera, which can capture the details of yarn interlacing and nozzle status clearly at close range, and complete the accurate location and identification of the root cause of defects.

[0035] The first image detection device 300 and the first detection component 410 mentioned above both include a guide rail 320 perpendicular to the warp movement path, a positioning platform 310 is provided on the surface of the guide rail 320, and the image detection element is located below the positioning platform 310.

[0036] The orientation of the first image detection device 300, the first detection component 410, and the second detection component 420 is ultimately determined based on the direction of the fabric to ensure that the image detection element can accurately detect the fabric. The first guide roller 110 and the second guide roller 120 of the textile mounting frame 100 can set the fabric to a horizontal state or an inclined state as shown in the attached figure, which is determined according to the on-site installation environment and detection requirements, to ensure that the image detection element is located above or to the side above the fabric, avoiding the impact of water spray and related impurities on the continuous image detection.

[0037] The guide rail 320 is a high-precision linear guide rail, arranged perpendicular to the yarn travel direction, ensuring that the positioning platform 310 can move along the entire width of the fabric, covering the entire width for inspection. The positioning platform 310 is a servo-driven slide table with a positioning repeatability of ≤±0.1mm, and can quickly stop at the corresponding defect position. The image detection element can be an area array industrial camera, equipped with coaxial and diffuse light sources, capable of clearly capturing the yarn interlacing structure and surface defects.

[0038] Furthermore, in order to adapt to the multi-impurity environment of the textile machine, a gas cleaning channel 311 is provided between the two positioning platforms 310 and the guide rail 320. The two gas cleaning channels 311 are connected by a gas conveying device 600. The gas cleaning channel 311 can continuously clean the impurities attached to the surface of the guide rail 320, so as to ensure that the guide rail 320 and the positioning platform 310 can move smoothly and continuously, meeting the requirements of continuous high-speed drive control and high-precision detection.

[0039] The gas cleaning channel 311 is arranged in a ring along the length of the guide rail 320 and is in close contact with the sliding surface of the guide rail. It is used to remove fly shavings, cotton dust, and short fibers from the surface of the guide rail, preventing impurities from entering the slider and causing jamming or displacement deviation, and ensuring smooth movement of the positioning platform 310. The two gas cleaning channels 311 form a linked gas path through the gas delivery device 600, sharing a single gas source. The structure is simple and the energy consumption is low.

[0040] Specifically, the gas cleaning channel 311 corresponding to the first image detection device 300 is continuously subjected to negative pressure to continuously suck up impurities on the surface of the corresponding guide rail 320; the gas cleaning channel 311 corresponding to the first detection component 410 is continuously ejected with pressurized gas to remove impurities from the surface of the corresponding guide rail 320; and the gas delivery device 600 has a built-in pump to realize unidirectional pumping of airflow.

[0041] The first image detection device 300 uses negative pressure suction to directly suck up dust from the guide rail surface, preventing dust from contaminating the lens; the first detection component 410 uses positive pressure blowing to blow away stubborn lint from the guide rail surface. Suction and blowing form complementary cleaning, and the gas delivery device 600 has a built-in vortex air pump to provide stable negative and positive pressure, with unidirectional airflow circulation, preventing secondary pollution.

[0042] Positive pressure air jet structures are installed in the lens detection of the first detection component 410, the second detection component 420, and the first image detection device 300. These structures are located in front of the lens and are under positive pressure to prevent impurities blown out from adhering to the lens surface and causing problems. The first image detection device 300 is located on the textile side, where there are more impurities adhering to the surface of the guide rail 320. To prevent excessive impurities from entering the fabric and causing defects, and to avoid affecting the image detection lens of the first image detection device 300, a negative pressure suction method is used on one side of the first image detection device 300 for impurity removal. In contrast, the first detection component 410 is far from the warp and weft yarn interlacing area, where there are fewer impurities. Furthermore, the fabric at this location is already woven, so there is no need to worry about a small amount of impurities entering the fabric and affecting the finished product. Through the negative and positive pressure structures, only one system is needed to meet the cleaning requirements of both sides, simplifying the layout and improving cleaning efficiency and effectiveness.

[0043] The gas delivery device 600 described above is a flexible hose with a suspension structure at the top. The gas delivery device 600 is located between the first detection component 410 and the first image detection device 300, so as to achieve real-time and efficient cleaning of impurities on both sides.

[0044] Specifically, the positioning platform 310 of the first image detection device 300 is provided with a negative pressure connector 340 at the top, a filter screen is provided at the bottom of the negative pressure connector 340, and a concentrating device 330 is provided inside the positioning platform 310 below the negative pressure connector 340. The concentrating device 330 directs the impurities attached to the surface of the filter screen to the outside. A collection screen is provided on the outside of the positioning platform 310. The impurities collected in the collection screen are cleaned regularly to avoid long-term accumulation that affects the use.

[0045] The negative pressure connector 340 connects to the gas cleaning channel 311, forming a dust suction inlet; the filter screen is used to intercept short fibers and fly dander, preventing them from entering the air passage and causing blockage. The concentrator 330 automatically pushes impurities on the filter screen to the edge, preventing impurities from accumulating and covering the filter screen, ensuring long-term stable dust suction.

[0046] Specifically, the concentrating device 330 consists of a spiral cleaning blade 332 and an arc-shaped filter screen. The edge of the spiral cleaning blade 332 is in contact with the surface of the filter screen. During the continuous rotation of the spiral cleaning blade 332, impurities attached to the surface of the filter screen are directed and concentrated to the outside. The arc-shaped filter screen can increase the filtration area and also increase the contact area with the spiral cleaning blade 332, thereby improving the cleaning effect. The filter screen is located with its concave side facing down and opposite to the spiral cleaning blade 332, which can achieve efficient cleaning of impurities under the combined action of the spiral cleaning blade 332 and gravity.

[0047] The spiral cleaning blades 332 are made of flexible and wear-resistant material, which fits tightly with the arc-shaped filter screen. When rotating, they create a spiral pushing effect, transporting impurities from the center to the outside, and finally collecting them in the dust collection groove at the edge of the positioning platform 310, thus achieving self-cleaning of the filter screen without the need for frequent manual disassembly and cleaning.

[0048] Furthermore, the spiral cleaning blade 332 is hollow inside, and the central device 330 also includes a control rod 331 located inside the hollow spiral cleaning blade 332. The control rod 331 is normally in the extended state and has a reset elasticity. A reset spring can be provided between the control rod 331 and the hollow interior of the spiral cleaning blade 332 to control the control rod 331 to be normally in the extended state. A control protrusion is provided on the outside of the control rod 331. An arc-shaped groove adapted to the control protrusion is opened in the hollow interior of the spiral cleaning blade 332. After the positioning platform 310 of the first image detection device 300 moves to the limit position, the control rod 331 is compressed, which drives the spiral cleaning blade 332 to rotate.

[0049] The control rod 331 is an elastic push rod. When the positioning platform 310 moves to the extreme position at the end of the guide rail 320, the control rod 331 is compressed by the end limit block, causing the control protrusion to slide along the arc-shaped groove, forcibly driving the spiral cleaning blades 332 to rotate at a certain angle, completing one filter cleaning cycle. Cleaning is triggered by the extreme position of the platform movement, eliminating the need for motors and sensors. The structure is simple and reliable, and it automatically cleans once per round trip.

[0050] The spiral cleaning blade 332 has an internal blade body and a control sleeve located inside the blade body. A one-way bearing is provided between the control sleeve and the blade body, and an arc-shaped groove is located on the inner wall of the control sleeve.

[0051] The one-way bearing ensures that the spiral cleaning blades 332 can only rotate in one direction to deliver dust, preventing reverse rotation that could cause impurities to flow back. This ensures unidirectional concentration of impurities, requiring only one collection screen and reducing the difficulty of subsequent replacement and cleaning of the collection screen. The control lever 331 pushes the control sleeve to rotate, and the one-way bearing drives the blade body to rotate synchronously. When the control lever 331 returns to its original position, the sleeve rotates freely while the blade body remains stationary, ensuring that impurities are always directionally conveyed outwards.

[0052] The above structural design can replace the separate power supply for driving and controlling the spiral cleaning blades 332, making it suitable for working environments with high humidity around textile machines. It achieves automatic control during the movement of the positioning platform 310, which is simple, convenient, efficient and stable.

[0053] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A process for detecting defects in yarn spraying on a textile machine, comprising a yarn spraying defect detection device, characterized in that, The textile machine yarn spraying defect detection equipment includes a first image detection device (300) located outside the automatic interlacing of warp and weft yarns and a second detection device (400) located outside the fabric movement path. The second detection device (400) includes a relatively movable first detection component (410) and a relatively fixed second detection component (420), and includes the following steps: S1. Control the sprayer (200) to spray out the weft yarn, and the warp and weft yarns automatically interweave to form the fabric; S2. The fabric formed by interlacing is continuously detected by the second detection component (420). When the second detection component (420) detects abnormal defects on the surface of the fabric, the first detection component (410) is driven to move to the side of the abnormal defect area to confirm the abnormal defect. S3. When the first detection component (410) confirms that the abnormal defect detection result is a misjudgment, it removes the abnormal defect mark and controls the first detection component (410) to reset to the initial position. When the first detection component (410) further confirms the abnormal defect detection result, it controls the first image detection device (300) to move to the warp and weft yarn automatic interlacing point to make a final confirmation of the cause of the abnormal defect, and sends the final confirmation result to the processing end to notify the staff to debug the yarn sprayer (200).

2. The textile machine yarn spraying defect detection process according to claim 1, characterized in that, Both the first image detection device (300) and the first detection component (410) include a guide rail (320) perpendicular to the warp movement path. A positioning platform (310) is provided on the surface of the guide rail (320), and the image detection element is located below the positioning platform (310).

3. The textile machine yarn spraying defect detection process according to claim 2, characterized in that, A gas cleaning channel (311) is provided between each of the two positioning platforms (310) and the guide rail (320), and the two gas cleaning channels (311) are connected by a gas conveying device (600).

4. The textile machine yarn spraying defect detection process according to claim 3, characterized in that, The gas cleaning channel (311) corresponding to the first image detection device (300) is controlled to continuously draw in negative pressure to continuously suck up impurities on the surface of the corresponding guide rail (320); the gas cleaning channel (311) corresponding to the first detection component (410) is controlled to continuously spray out pressurized gas to remove impurities on the surface of the corresponding guide rail (320); the gas delivery device (600) has a built-in pump to realize unidirectional pumping of airflow.

5. The textile machine yarn spraying defect detection process according to claim 1, characterized in that, The first image detection device (300) has a negative pressure connector (340) on the top of its positioning platform (310), a filter screen at the bottom of the negative pressure connector (340), and a concentrating device (330) located below the negative pressure connector (340) inside the positioning platform (310). The concentrating device (330) directs the impurities attached to the surface of the filter screen to the outside.

6. The textile machine yarn spraying defect detection process according to claim 6, characterized in that, The concentrating device (330) is a spiral cleaning blade (332), the filter screen is arc-shaped, and the edge of the spiral cleaning blade (332) is in contact with the surface of the filter screen. During the continuous rotation of the spiral cleaning blade (332), the impurities attached to the surface of the filter screen are oriented and concentrated to the outside.

7. The textile machine yarn spraying defect detection process according to claim 6, characterized in that, The spiral cleaning blade (332) is hollow inside. The central device (330) also includes a control rod (331) located inside the hollow spiral cleaning blade (332). The control rod (331) is normally in an extended state and has a reset elasticity. A control protrusion is provided on the outside of the control rod (331). An arc-shaped groove adapted to the control protrusion is opened inside the hollow spiral cleaning blade (332). After the positioning platform (310) of the first image detection device (300) moves to the limit position, the control rod (331) is compressed and drives the spiral cleaning blade (332) to rotate.

8. The textile machine yarn spraying defect detection process according to claim 7, characterized in that, The spiral cleaning blade (332) has an internal blade body and a control sleeve located inside the blade body. A one-way bearing is provided between the control sleeve and the blade body, and the arc groove is located on the inner wall of the control sleeve.

Images