A bale wrap detection device for a cotton harvester

Abstract

This invention discloses a cotton harvester baling film detection device, belonging to the field of material testing technology. The device includes a mounting frame with a detection platform on its upper part. A guide roller assembly is rotatably connected to the feed end of the detection platform, with tension sensors embedded between the guide rollers. A tension adjustment component is connected to one side of the guide roller assembly. A pressure roller is rotatably connected to the discharge end of the detection platform, with a correction component on one side of the pressure roller. The detection platform also includes a photoelectric sensor, an industrial camera, a controller, an alarm, and a display screen. A buffer and shock-absorbing pad is provided at the bottom of the mounting frame. This device overcomes high-frequency vibration interference during cotton harvester operation, solves the technical problem of "tension drift," improves the repeatability and reliability of the detection data, and provides a correction margin, avoiding secondary damage to the baling film caused by hard contact, thus reducing the risk of false detections and machine downtime.

Description

Technical Field

[0001] This invention relates to the field of materials testing technology, and more specifically, to a testing device for packing film used in cotton harvesters. Background Technology

[0002] Packing film for cotton harvesters is a key consumable for bundling cotton into round bales after mechanized harvesting. It is mainly used to wrap cotton bales to prevent them from scattering, getting damp, and being contaminated with impurities during transportation and storage. The core testing items include physical properties (tensile strength, elongation at break, puncture resistance), weather resistance (UV resistance, high and low temperature stability), thickness uniformity, and adhesion and sealing performance.

[0003] Common testing methods include using a tensile testing machine to measure mechanical properties, an accelerated aging chamber to simulate outdoor conditions, and a thickness gauge to check thickness deviations. These tests ensure that the breakage rate of the packing film is below 0.5% during operation, guaranteeing the quality of cotton bale formation, reducing cotton contamination and loss, and meeting the continuous and efficient operation requirements of cotton harvesters.

[0004] Currently, during the testing process of packing film used in cotton harvesters: ① The high-frequency vibration during cotton harvester operation can easily lead to loosening of the mechanical structure, causing "tension drift" phenomenon, resulting in decreased repeatability and insufficient reliability of test data, and in severe cases, even affecting the quality of subsequent packaging.

[0005] ② Existing packaging film defect detection is often equipped with a correction structure. Traditional correction devices are usually designed with a stroke of 1.2 to 1.5 times the maximum deviation. When there is extreme deviation, it is easy to exceed the correction range. Moreover, the correction brackets mostly adopt a metal hard contact structure, which can easily cause scratches or damage to the film material, resulting in an increased false detection rate.

[0006] On the other hand, in view of this, we have studied and improved the existing structure to provide a cotton harvester packing film detection device, in order to achieve a more practical purpose. Summary of the Invention

[0007] 1. Technical problems to be solved To address the problems existing in the prior art, the present invention aims to provide a cotton harvester baling film detection device. It can effectively overcome the high-frequency vibration interference during cotton harvester operation, solve the technical problem of "tension drift" caused by vibration in traditional mechanical tensioning devices, significantly improve the repeatability and reliability of detection data, and at the same time, still have a correction margin under extreme deviation conditions, avoiding secondary damage to the baling film caused by hard contact, and greatly reducing the risk of false detection and machine downtime caused by film deviation or damage.

[0008] 2. Technical Solution To solve the above problems, the present invention adopts the following technical solution.

[0009] A cotton harvester packaging film detection device includes a mounting frame, a detection platform on the upper part of the mounting frame, a guide roller assembly rotatably connected to the feed end of the detection platform, a tension sensor embedded between the guide roller assemblies, a tension adjustment component connected to one side of the guide roller assembly, and a pressure roller rotatably connected to the discharge end of the detection platform, with a deviation correction component on one side of the pressure roller. A photoelectric sensor is fixed on the detection platform, facing the surface of the packaging film. An industrial camera is installed above the detection platform. A controller is installed on the side of the mounting frame. The controller is electrically connected to the photoelectric sensor, the industrial camera, and the tension sensor. An alarm is connected to the controller. A display screen is fixed on the outside of the mounting frame. The alarm and the display screen are both connected to the controller via signal lines. A buffer shock-absorbing pad is provided at the bottom of the mounting frame.

[0010] Furthermore, the guide roller assembly includes two guide rollers arranged parallel to each other, and the surface of each guide roller is coated with an anti-slip layer.

[0011] Furthermore, the tension adjustment assembly includes a vertical support, which is fixed to the side of the mounting frame. An adjustment control motor is fixed to the top of the vertical support. A screw is movably connected between the upper and lower ends of the vertical support through a bearing. The output end of the adjustment control motor is connected to the screw through a coupling. One end of the guide roller above the guide roller group is equipped with a slider through a bearing. The other end of the guide roller above the guide roller group slides up and down along a sliding rod. The screw is threadedly connected to the slider, and the slider slides up and down along the vertical support.

[0012] Furthermore, the adjustment control motor is a servo motor with an angle locking function, used to lock the rotation angle of the screw after it stops.

[0013] Furthermore, the photoelectric sensors are arranged in an array along the width of the packaging film.

[0014] Furthermore, the industrial camera is equipped with a zoom lens, and an LED light source is provided on the side of the industrial camera.

[0015] Furthermore, the LED light source is a strip LED light source, which is arranged on both sides of the packaging film.

[0016] Furthermore, the correction component includes a lower slide rail, which is fixed on the mounting frame and has an integrated guide bracket slidably connected to it. A pneumatic push rod is fixed to the side of the mounting frame, and the output end of the pneumatic push rod is fixed to the side of the integrated guide bracket.

[0017] Furthermore, both ends of the integrated guide bracket are U-shaped, and the inner surface of the integrated guide bracket is covered with a wear-resistant rubber layer.

[0018] 3. Beneficial Effects Compared with the prior art, the advantages of this invention are: ① This solution, through a servo motor-driven screw-slider mechanism, achieves micron-level precision adjustment of the guide roller spacing, providing the most suitable tension for packing films of different thicknesses and materials. Combined with the motor's angle locking function, it effectively overcomes high-frequency vibration interference during cotton harvester operation, completely solving the technical problem of "tension drift" caused by vibration in traditional mechanical tensioning devices, and significantly improving the repeatability and reliability of the detection data.

[0019] ② This solution combines a photoelectric sensor array with an adjustable-focus industrial camera, balancing the efficiency of high-speed scanning with the ability to identify microscopic defects, thus eliminating blind spots in single-point detection. Simultaneously, the correction stroke is designed to be twice the maximum deviation amount, and combined with a U-shaped guide bracket with a wear-resistant rubber layer. This not only ensures correction margins even under extreme deviations but also avoids secondary damage to the packaging film caused by rigid contact, significantly reducing the risk of false detections and downtime due to film deviation or damage. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural schematic diagram of the cotton harvester baling film detection device of the present invention; Figure 2 This is a top view schematic diagram of the cotton harvester baling film detection device of the present invention; Figure 3 This is a front view schematic diagram of the cotton harvester baling film detection device of the present invention; Figure 4 This is a schematic diagram of the tension adjustment component in this invention; Figure 5 This is a schematic diagram of the correction component in this invention.

[0021] Explanation of the labels in the diagram: 1. Install the rack; 2. Detection platform; 201. Photoelectric sensor; 202. Industrial camera; 2021. LED light source; 203. Controller; 204. Alarm; 205. Display screen; 3. Guide roller assembly; 4. Tension adjustment assembly; 401. Vertical support; 402. Adjustment control motor; 403. Screw; 404. Slider; 5. Pressure roller; 6. Correction assembly; 601. Lower slide rail; 602. Integrated guide bracket; 603. Pneumatic push rod; 7. Buffer and shock-absorbing pads. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0023] Example 1: Please see Figure 1 - Figure 5 A cotton harvester packaging film detection device includes a mounting frame 1, and a detection platform 2 is provided on the upper part of the mounting frame 1 for carrying the packaging film roll; The feed end of the detection platform 2 is rotatably connected to the guide roller group 3. Tension sensors are embedded between the guide roller groups 3. A tension adjustment component 4 is connected to one side of the guide roller group 3 for detecting and adjusting the tension of the packaging film. The discharge end of the testing platform 2 is rotatably connected to a pressure roller 5, and a correction component 6 is provided on one side of the pressure roller 5 for correcting the lateral position of the packaging film. A photoelectric sensor 201 is fixed on the detection platform 2, and the photoelectric sensor 201 is set facing the surface of the packaging film. An industrial camera 202 is installed above the detection platform 2 to acquire image information of the packaging film. A controller 203 is mounted on the side of the mounting frame 1. The controller 203 is electrically connected to the photoelectric sensor 201, the industrial camera 202, and the tension sensor. An alarm 204 is connected to the controller 203 for abnormal status indication. A display screen 205 is fixed on the outside of the mounting frame 1. The alarm 204 and the display screen 205 are both connected to the controller 203 through signal lines. The bottom of the mounting frame 1 is provided with a buffer shock-absorbing pad 7.

[0024] The cotton harvester baling film detection device automates and integrates the entire process of baling film conveying, tensioning, correction, optical detection, and data feedback. It significantly improves the quality monitoring level of baling film during cotton harvester operation, reduces the risk of film breakage, missed detection, and machine downtime, and enhances the continuity and reliability of cotton harvesting operations.

[0025] Example 2: Based on the above embodiment 1, further description is provided.

[0026] See Figure 1 , Figure 2 , Figure 3 , Figure 4Specifically, the guide roller group 3 includes two guide rollers arranged parallel to each other, and the surface of each guide roller is coated with an anti-slip layer.

[0027] The combination of two guide rollers and an anti-slip layer improves the stability of the packaging film during transport and prevents slippage and deviation.

[0028] Specifically, the tension adjustment assembly 4 includes a vertical support 401, which is fixed to the side of the mounting frame 1. An adjustment control motor 402 is fixed to the top of the vertical support 401. A screw 403 is movably connected between the upper and lower ends of the vertical support 401 through a bearing. The output end of the adjustment control motor 402 is connected to the screw 403 through a coupling. One end of the guide roller above the guide roller group 3 is equipped with a slider 404 through a bearing. The other end of the guide roller above the guide roller group 3 slides up and down along the provided sliding rod. The screw 403 is threadedly connected to the slider 404, and the slider 404 slides up and down along the vertical support 401.

[0029] When the control motor 402 rotates, the screw 403 can be rotated, which in turn controls the slider 404 and the guide rollers above the guide roller group 3 to slide up and down. By adjusting the distance between the two guide rollers of the guide roller group 3, the tension can be continuously adjusted to meet the testing requirements of packaging films of different thicknesses and materials.

[0030] Specifically, the adjustment control motor 402 is a servo motor with an angle locking function, used to lock the rotation angle of the screw 403 after it stops.

[0031] [Effect] After the adjustment control motor 402 stops, the angle of the adjustment control motor 402 shaft can be locked to ensure that after the adjustment is completed, the tension adjustment component 4 can stably maintain the spacing of the guide roller group 3, preventing the tension force from drifting due to equipment vibration, and improving the stability and reliability of tension control during the detection process.

[0032] See Figure 1 , Figure 2 , Figure 3 Specifically, the photoelectric sensors 201 are arranged in an array along the width of the packaging film.

[0033] This enables simultaneous multi-point detection across a wide area of ​​the packaging film, improving the comprehensiveness of defect identification.

[0034] Specifically, the industrial camera 202 is equipped with a zoom lens, and the side of the industrial camera 202 is provided with an LED light source 2021.

[0035] Specifically, the LED light source 2021 uses strip LEDs as its light source, which are arranged on both sides of the packaging film.

[0036] The LED light source 2021 is used to provide uniform illumination, and the industrial camera 202 can adjust the shooting focal length according to the detection accuracy requirements, balancing detection efficiency and detail recognition capabilities.

[0037] See Figure 1 , Figure 2 , Figure 3 , Figure 5 Specifically, the correction component 6 includes a lower slide rail 601, which is fixed on the mounting frame 1. An integrated guide bracket 602 is slidably connected to the lower slide rail 601. A pneumatic push rod 603 is fixed to the side of the mounting frame 1, and the output end of the pneumatic push rod 603 is fixed to the side of the integrated guide bracket 602.

[0038] The lower rail 601 restricts the movement direction of the integrated guide bracket 602, which guides the packaging film. The position of the integrated guide bracket 602 is controlled by the pneumatic push rod 603 to achieve automatic correction of the edge position of the packaging film and prevent deviation from affecting the test results.

[0039] Specifically, both ends of the integrated guide bracket 602 are U-shaped, and the inner surface of the integrated guide bracket 602 is covered with a wear-resistant rubber layer.

[0040] The U-shaped structure, combined with the wear-resistant rubber layer on the inside, effectively clamps and guides the packaging film while reducing wear on the packaging film by the support. The extension stroke of the pneumatic push rod 603 can cover twice the maximum allowable deviation of the packing film. Setting the stroke of the pneumatic push rod 603 to cover the maximum deviation ensures that the device can cope with the most extreme deviation situations, guaranteeing the redundancy and reliability of the correction action.

[0041] Working principle: When the cotton harvester uses the packing film detection device, the packing film to be detected is first introduced by the guide roller group 3. The anti-slip layer on the surface of the guide roller group 3 ensures that the film material is conveyed without slipping.

[0042] The tension sensor monitors the membrane tension in real time and transmits the data to the controller 203. If the tension deviates from the set value, the controller 203 drives the adjustment control motor 402 to rotate the screw 403, and precisely adjusts the height of the upper guide roller through the slider 404 to change the distance between the two rollers to achieve dynamic balance of tension.

[0043] The locking function of the control motor 402 can lock the position after adjustment to prevent tension drift caused by vibration. Subsequently, the packaging film passes through the correction component 6, and the pneumatic push rod 603 pushes the integrated guide bracket 602 to move along the lower rail 601 according to the edge position signal. The U-shaped structure and wear-resistant rubber layer are used to perform non-destructive centering correction of the film material.

[0044] In the inspection area, photoelectric sensors 201 arranged in a width array scan the membrane surface at multiple points, while an industrial camera 202 equipped with a zoom lens and dual-sided LED light sources 2021 acquires high-definition images. All inspection data is aggregated to the controller 203. Once damage, wrinkles, or abnormal thickness are detected, an alarm 204 is immediately triggered and feedback is provided through the display screen 205, thereby achieving closed-loop control of the entire process from conveying, tensioning, and correction to optical inspection.

[0045] The above description is merely a preferred embodiment of the present invention; however, the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and its improved concepts, should be covered within the scope of protection of the present invention.

Claims

1. A cotton harvester baling film detection device, comprising a mounting frame (1), characterized in that: The mounting frame (1) is equipped with a detection platform (2) on the upper part. The feed end of the detection platform (2) is rotatably connected to a guide roller group (3). Tension sensors are embedded between the guide roller groups (3). A tension adjustment component (4) is connected to one side of the guide roller group (3). A pressure roller (5) is rotatably connected to the discharge end of the detection platform (2). A correction component (6) is provided on one side of the pressure roller (5). A photoelectric sensor (201) is fixed on the detection platform (2), and the photoelectric sensor (201) is set facing the surface of the packaging film. An industrial camera (202) is installed above the detection platform (2). A controller (203) is installed on the side of the mounting frame (1). The controller (203) is electrically connected to the photoelectric sensor (201), the industrial camera (202), and the tension sensor. An alarm (204) is connected to the controller (203). A display screen (205) is fixed on the outside of the mounting frame (1). The alarm (204) and the display screen (205) are both connected to the controller (203) through signal lines. A buffer shock-absorbing pad (7) is provided at the bottom of the mounting frame (1).

2. The cotton harvester baling film detection device according to claim 1, characterized in that: The guide roller group (3) includes two guide rollers arranged in parallel, and the surface of any guide roller is coated with an anti-slip layer.

3. The cotton harvester baling film detection device according to claim 2, characterized in that: The tension adjustment assembly (4) includes a vertical support (401), which is fixed to the side of the mounting frame (1). An adjustment control motor (402) is fixed to the top of the vertical support (401). A screw (403) is movably connected between the upper and lower ends of the vertical support (401) through a bearing. The output end of the adjustment control motor (402) is connected to the screw (403) through a coupling. One end of the guide roller above the guide roller group (3) is equipped with a slider (404) through a bearing. The other end of the guide roller above the guide roller group (3) slides up and down along the provided sliding rod. The screw (403) is threadedly connected to the slider (404), and the slider (404) slides up and down along the vertical support (401).

4. The cotton harvester baling film detection device according to claim 3, characterized in that: The regulating control motor (402) is a servo motor with angle locking function, used to lock the rotation angle of the screw (403) after it stops rotating.

5. The cotton harvester baling film detection device according to claim 1, characterized in that: The photoelectric sensor (201) is arranged in an array along the width of the packaging film.

6. The cotton harvester baling film detection device according to claim 1, characterized in that: The industrial camera (202) is equipped with a zoom lens, and the side of the industrial camera (202) is provided with an LED light source (2021).

7. The cotton harvester baling film detection device according to claim 6, characterized in that: The LED light source (2021) is a strip LED light source, which is arranged on both sides of the packaging film.

8. The cotton harvester baling film detection device according to claim 1, characterized in that: The correction component (6) includes a lower slide rail (601), which is fixed on the mounting frame (1) and an integrated guide bracket (602) is slidably connected on the lower slide rail (601). A pneumatic push rod (603) is fixed on the side of the mounting frame (1), and the output end of the pneumatic push rod (603) is fixed to the side of the integrated guide bracket (602).

9. A cotton harvester baling film detection device according to claim 8, characterized in that: Both ends of the integrated guide bracket (602) are U-shaped, and the inner surface of the integrated guide bracket (602) is covered with a wear-resistant rubber layer.

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