A photoelectric method and device for detecting broken threads in the textile industry

Abstract

This application relates to the field of yarn breakage detection technology in the textile industry, and in particular to a photoelectric method and apparatus for yarn breakage detection in the textile industry. The method includes: forming a stripe-shaped light spot using an emitted light source and projecting the stripe-shaped light spot onto the yarn; during the mechanical movement of the yarn, acquiring multiple sets of light intensity change data when the stripe-shaped light spot is blocked by the yarn using a photosensitive array; wherein the photosensitive array contains multiple pixel units with pixel labels, and the size of the pixel unit is smaller than the diameter of the yarn; obtaining the pixel label at the lowest light intensity point in each set of light intensity change data, the lowest pixel light intensity point corresponding to the lowest voltage point output by the photosensitive array; for each set of light intensity change data, calculating the ratio of the minimum to the maximum value among the acquired pixel labels to obtain the rate of change of the yarn at multiple positions; and determining whether the yarn is broken based on the comparison results of multiple rates of change with a preset threshold. This application can accurately and efficiently detect the yarn condition.

Description

Technical Field

[0001] This application relates to the field of textile thread breakage detection technology, and in particular to a photoelectric textile thread breakage detection method and device. Background Technology

[0002] The textile industry, as a crucial sector of traditional manufacturing, has long held a key position in the global economy. With continuous technological advancements, the textile industry's production efficiency and quality have significantly improved, and automated production has gradually become the mainstream trend. In the textile production process, the continuity of yarn is paramount to product quality and production efficiency. If yarn breaks and are not detected and addressed promptly, it can lead to product defects, reduced production efficiency, equipment damage, and increased production costs. Therefore, accurately and efficiently detecting yarn breaks has become a critical issue that urgently needs to be addressed in the development of the textile industry. In recent years, although yarn breakage detection technology has made some progress, many shortcomings still exist, hindering the further development of the textile industry.

[0003] In existing technologies, the following methods are mainly used for yarn breakage detection in the textile industry: Piezoelectric detection utilizes piezoelectric ceramics to detect the frictional vibrations generated when the yarn moves and converts them into electrical signals. When the yarn breaks, the vibration signal disappears, triggering an alarm. Electromagnetic induction detection uses a yarn sensor to detect changes in the electromagnetic field caused by the presence of yarn, outputting different signal levels when yarn is present or absent. Mechanical lever detection relies on yarn tension transmitted through a mechanical lever; when the yarn breaks, the lever position changes, triggering a switch. Photoelectric detection utilizes the light-blocking or reflective properties of the yarn, converting changes in light energy into electrical signals to detect the presence or movement of the yarn.

[0004] However, existing detection methods all have significant drawbacks. Piezoelectric detection is insensitive to weak twist and abnormal tension, easily leading to false alarms and disrupting normal production. Electromagnetic induction can only detect the presence or absence of yarn, unable to determine its movement, and cannot effectively distinguish between "broken yarn" and "stationary yarn," resulting in inaccurate results. Mechanical lever-type detection has low accuracy, and its complex structure makes the transmission parts prone to contamination and jamming, leading to response delays, a high failure rate, and increased maintenance costs and downtime. While photoelectric detection uses a non-contact method and has relatively high sensitivity, it currently generally uses a single receiving surface, detecting through or by reflection, which limits its ability to recognize changes in yarn movement. It cannot accurately determine if the yarn is broken and still resting on the receiving surface. Summary of the Invention

[0005] The purpose of this application is to overcome the above-mentioned technical problems and provide a photoelectric method and device for detecting yarn breakage in the textile industry, which can accurately and efficiently detect whether the yarn is in a broken state.

[0006] Firstly, one embodiment of this application discloses a photoelectric method for detecting broken threads in the textile industry, which employs the following scheme: A photoelectric method for detecting yarn breakage in the textile industry, comprising: S1: A strip-shaped light spot is formed using an emitted light source, and the strip-shaped light spot is projected onto the yarn; S2: During the mechanical movement of the yarn, multiple sets of photosensitivity change data are collected by a photosensitive array when the strip-shaped light spot is blocked by the yarn; wherein, the photosensitive array contains multiple pixel units with pixel labels, and the size of the pixel unit is smaller than the diameter of the yarn; S3: Obtain the pixel number at the lowest point of light intensity in each group of light intensity change data, where the lowest point of light intensity corresponds to the lowest point of voltage output by the photosensitive array; S4: For each set of photosensitivity intensity change data, calculate the ratio of the minimum to the maximum value in the obtained pixel labels to obtain the rate of change of the yarn at multiple positions; S5: Based on the comparison results of multiple rates of change with preset thresholds, determine whether the yarn is in a broken state.

[0007] By adopting the above technical solution, compared with traditional piezoelectric, electromagnetic induction, mechanical lever, and existing photoelectric yarn breakage detection methods, this method uses an emitting light source to form a stripe of light and project it onto the yarn. This avoids the problems of traditional methods, such as piezoelectric methods being insensitive to weak twist and abnormal tension and prone to false alarms, electromagnetic induction methods being unable to determine the yarn's movement state, mechanical lever methods having low detection accuracy, complex structure, and being prone to contamination and jamming leading to response delays and high failure rates, as well as existing photoelectric methods having limited ability to identify changes in yarn movement. During the yarn's mechanical movement, multiple sets of light intensity change data are collected by the photosensitive array when the stripe of light is blocked by the yarn, which can more accurately reflect the yarn's movement state. By obtaining the pixel label at the lowest light intensity point in each set of light intensity change data and calculating the ratio of the minimum to the maximum value of the pixel label to obtain the rate of change of the yarn at multiple positions, the detection accuracy of the yarn's movement state can be improved. Based on the comparison results of multiple rates of change with preset thresholds, it is determined whether the yarn is broken, which can effectively reduce the false judgment rate and more accurately detect the yarn breakage.

[0008] Optionally, step S5 includes: when multiple rates of change are all greater than the preset threshold, the yarn is determined to be in a broken state.

[0009] By adopting the above technical solution, when multiple rates of change are greater than preset thresholds, the yarn is determined to be in a broken state. This can accurately identify the yarn breakage situation, effectively avoid misjudgment, improve the accuracy and reliability of yarn breakage detection, provide more reliable protection for the production process of the textile industry, and reduce production interruptions and resource waste caused by misjudgment.

[0010] Optionally, step S5 further includes: when multiple rates of change are all close to 1, the yarn is determined to be in a broken state.

[0011] By adopting the above technical solution, when multiple rates of change approach 1, the yarn is determined to be in a broken state. This can more accurately identify yarn breakage, improve the accuracy and reliability of yarn breakage detection, and avoid the situation where yarn breakage is not detected in time due to small yarn swing or cessation of movement. It provides a more effective judgment basis for yarn condition monitoring in the textile production process, helps to detect yarn breakage problems in time and take corresponding measures to ensure the normal operation of textile production.

[0012] Optionally, in step S1, forming a strip-shaped light spot using the emitting light source includes: passing the light emitted by the emitting light source through an emitting narrow slit aperture to form the strip-shaped light spot.

[0013] By adopting the above technical solution, the light emitted by the light source is converted into a strip-shaped light spot by using the emitting narrow slit aperture. This provides a suitable light pattern for subsequent detection of yarn status by using the yarn to block the strip-shaped light spot, which is beneficial to improving the accuracy and sensitivity of yarn breakage and motion status detection.

[0014] Optionally, it also includes: providing an emission lens on the optical path exit side of the emission slit aperture to convert the strip-shaped light spot formed by the emission slit aperture into parallel light.

[0015] By adopting the above technical solution, the strip-shaped light spot formed by the transmitting lens through the transmitting narrow slit aperture is converted into parallel light, which can enable the transmitted light to meet the signal strength requirements of the receiving end when the detection distance is relatively short.

[0016] Optionally, before step S2, the method further includes: setting a receiving slit aperture on the incident side of the light path of the photosensitive array to reshape the strip-shaped light spot so that only light within a preset range is allowed to enter the photosensitive array.

[0017] By adopting the above technical solution, a receiving narrow slit aperture is set on the incident side of the optical path of the photosensitive array to reshape the strip light spot. This allows only light within a preset range to enter the photosensitive array, thereby reshaping the received strip light, lengthening the narrow slit channel, and allowing only the strip light perpendicular to the receiving surface to enter. This further suppresses the entry of ambient light and improves the anti-interference light capability of the detection device.

[0018] Optionally, it also includes: providing a receiving filter on the incident side of the receiving slit aperture.

[0019] By adopting the above technical solution, a receiving filter is set on the incident side of the optical path of the receiving narrow slit aperture, which can protect the receiving window and prevent dust and fibers from the field environment from entering the device, making it easy to clean; at the same time, it can also reduce the interference of ambient light on the receiving and improve the anti-interference light capability of the detection device.

[0020] Optionally, the receiving slit aperture and the transmitting slit aperture are coaxially arranged, and the optical axis direction is perpendicular to the linear arrangement direction of the photosensitive array.

[0021] By adopting the above technical solution, the receiving slit aperture and the transmitting slit aperture are set coaxially, which allows the emitted strip-shaped light spot to pass precisely through the receiving slit aperture, reducing light scattering and deviation, and improving the effective utilization rate of light energy. The optical axis direction is perpendicular to the linear arrangement direction of the photosensitive array, which allows the strip-shaped light spot to uniformly cover the photosensitive array, enabling the photosensitive array to receive the light signal blocked by the yarn more comprehensively and accurately, thereby improving the accuracy and reliability of the acquisition of data on changes in photosensitive intensity, and thus improving the accuracy of judging the yarn breakage state.

[0022] Optionally, the photosensitive array is a linear CMOS sensor or a one-dimensional PSD sensor.

[0023] By adopting the above technical solution and using a linear CMOS sensor or a one-dimensional PSD sensor as a photosensitive array, a corresponding analog voltage signal can be output according to the photosensitive intensity of the pixel. By utilizing the light-blocking effect of the yarn diameter being larger than the pixel, yarn breakage and motion state detection can be performed by changing the photosensitive intensity of the pixel, thus achieving high-sensitivity and high-reliability yarn breakage detection.

[0024] Secondly, another embodiment of this application discloses a photoelectric textile thread breakage detection device, which adopts the following scheme: A photoelectric textile yarn breakage detection device, used to perform the method described in any one of the above claims, includes: a light source assembly for generating a stripe-shaped light spot to irradiate the yarn; a photosensitive array, disposed opposite to the light source assembly, for acquiring multiple sets of light intensity change data when the stripe-shaped light spot is blocked by the yarn during a mechanical change time; and a signal processing unit, electrically connected to the photosensitive array, for performing the following processing: acquiring the pixel label at the lowest light intensity point in each set of light intensity change data; calculating the ratio of the minimum to the maximum value of the pixel label in each set of data to obtain the rate of change of the yarn at multiple positions; and determining whether the yarn is in a broken state based on the comparison results of multiple rates of change with a preset threshold.

[0025] By adopting the above technical solution, the light source component generates a strip-shaped light spot to illuminate the yarn. The photosensitive array collects multiple sets of light intensity change data when the strip-shaped light spot is blocked by the yarn. The signal processing unit obtains the pixel label of the point with the lowest light intensity, calculates the ratio of the minimum to the maximum value of the pixel label to obtain the yarn position change rate, and determines whether the yarn is broken based on the comparison result of the change rate and a preset threshold. This can achieve high sensitivity and high reliability in yarn breakage and motion state detection, avoiding the defects of existing piezoelectric, electromagnetic induction, mechanical lever, and traditional photoelectric breakage detection methods. It can accurately determine the yarn state, reduce false alarms, and improve detection accuracy and reliability.

[0026] Thirdly, another embodiment of this application discloses an electronic device that adopts the following solution: An electronic device, comprising: A processor, a memory, and a computer program stored in the memory and capable of running on the processor, the processor being configured to load and execute the computer program stored in the memory to cause the electronic device to perform the method as described in any of the foregoing.

[0027] Fourthly, another embodiment of this application discloses an electronic device that adopts the following solution: A computer-readable storage medium storing a computer program that, when loaded and executed by a processor, implements the method as described in any of the preceding claims.

[0028] In summary, this application includes at least one of the following beneficial technical effects: 1. During the mechanical movement of the yarn, multiple sets of photosensitivity intensity change data are collected by a photosensitive array when the striped light spot is blocked by the yarn, which can more accurately reflect the movement state of the yarn. The pixel number at the lowest photosensitive intensity point in each set of photosensitivity intensity change data is obtained, and the ratio of the minimum to the maximum value of the pixel number is calculated to obtain the rate of change of the yarn at multiple positions, which can improve the detection accuracy of the yarn movement state. Based on the comparison results of multiple rates of change with preset thresholds, it can determine whether the yarn is broken, which can effectively reduce the false judgment rate and more accurately detect the yarn breakage. 2. When multiple rates of change are greater than preset thresholds, the yarn is determined to be in a broken state. This can accurately identify the yarn breakage situation, effectively avoid misjudgment, improve the accuracy and reliability of yarn breakage detection, provide more reliable protection for the production process of the textile industry, and reduce production interruptions and resource waste caused by misjudgment. 3. When multiple rates of change approach 1, the yarn is determined to be in a broken state. This can more accurately identify yarn breakage, improve the accuracy and reliability of yarn breakage detection, and avoid the failure to detect yarn breakage in time due to small yarn swing or cessation of movement. It provides a more effective basis for monitoring yarn condition in the textile production process, helps to detect yarn breakage problems in time and take corresponding measures to ensure the normal operation of textile production. 4. By using a narrow slit aperture to convert the light emitted from the light source into a stripe-shaped light spot, a suitable light pattern can be provided for subsequent detection of yarn status by using the yarn to block the stripe-shaped light spot, which is beneficial to improving the accuracy and sensitivity of yarn breakage and motion status detection. Attached Figure Description

[0029] Figure 1 This is a schematic flowchart of a photoelectric textile thread breakage detection method disclosed in an embodiment of this application; Figure 2 This is a schematic diagram of the structure of a photoelectric textile thread breakage detection device disclosed in another embodiment of this application; Figure 3 This is a schematic diagram of the output voltage amplitude when the linear CMOS is not blocked. Figure 4 This is a schematic diagram of the output voltage amplitude when a linear CMOS sensor is blocked. Detailed Implementation

[0030] The present application will be further described in detail below with reference to the accompanying drawings.

[0031] Embodiments of this application will now be described in more detail with reference to the accompanying drawings. While embodiments of this application are shown in the drawings, it should be understood that this application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to make this application more thorough and complete, and to fully convey the scope of this application to those skilled in the art.

[0032] The terminology used in this application is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. The singular forms “a” and “the” as used in this application and the appended claims are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and includes any or all possible combinations of one or more of the associated listed items.

[0033] It should be understood that although the terms "first," "second," etc., may be used in this application to describe various information, such information should not be limited to these terms. These terms are only used to distinguish information of the same type from one another. For example, without departing from the scope of this application, first information may also be referred to as second information, and similarly, second information may also be referred to as first information. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0034] The technical solutions of the embodiments of this application are described in detail below with reference to the accompanying drawings.

[0035] [First Embodiment] See Figure 1 This application discloses a photoelectric method for detecting yarn breakage in the textile industry, which utilizes changes in the light intensity of a photosensitive array (such as linear CMOS pixels) to determine whether the yarn has broken. Specifically, it includes the following steps: S1: Use an emitting light source to form a stripe-shaped light spot and project the stripe-shaped light spot onto the yarn; S2: During the mechanical movement of the yarn, multiple sets of photosensitivity intensity change data are collected by a photosensitive array when the strip-shaped light spot is blocked by the yarn; wherein, the photosensitive array contains multiple pixel units with pixel labels, and the size of the pixel unit is smaller than the diameter of the yarn. S3: Obtain the pixel number at the lowest point of light intensity in each set of light intensity change data. The lowest point of light intensity corresponds to the lowest point of voltage output by the photosensitive array. S4: For each set of photosensitivity intensity change data, calculate the ratio of the minimum to the maximum value in the obtained pixel labels to obtain the rate of change of the yarn at multiple positions; S5: Based on the comparison results of multiple rates of change with preset thresholds, determine whether the yarn is in a broken state.

[0036] Through the coordinated steps described above, it is possible to accurately determine whether the yarn is in a broken state, avoiding the problem in existing technologies that cannot accurately determine the yarn movement state and breakage status, thus improving the accuracy and reliability of the detection.

[0037] Specifically, in step S1, the emitting light source can be controlled by the emitting unit, such as using a laser or a common LED light source. (See [link to relevant documentation]). Figure 2 Among them, laser light sources have the characteristics of high brightness and good directionality, and can provide stable and high-intensity light, making them suitable for scenarios with high detection accuracy requirements. Ordinary LED light sources are less expensive and have a certain luminous intensity, making them more suitable for some cost-sensitive applications.

[0038] See Figure 2 A narrow slit aperture (emission aperture) is placed in front of the emitting light source. This aperture, which can be made of metal or plastic, has a narrow, elongated slit inside. Its function is to convert the circular light spot of the emitting light source into a stripe-shaped light spot, thus allowing the light to be more concentrated on the yarn. For example, when using a circular light spot to illuminate the yarn, the light is relatively dispersed and may be affected by the surrounding environment, while the stripe-shaped light spot can more accurately illuminate the yarn, improving the accuracy of the detection.

[0039] A transmitting lens is positioned at the end of the transmitting slit aperture furthest from the transmitting light source (i.e., the exit side of the transmitting slit aperture's optical path). The function of the transmitting lens is to convert the point light source of the strip-shaped light spot into parallel light. In line break detection, when the detection distance is relatively short (a few millimeters), if an LED light source with a large emission angle is used, the transmitting lens may not be necessary, and the signal strength requirements of the receiving end can still be met (i.e., the use of a transmitting lens can be selected based on the light intensity and beam quality).

[0040] A receiving slit aperture is installed on the incident side of the optical path of the photosensitive array. Besides shaping the received stripe light, the receiving slit aperture lengthens the narrow slit channel, allowing only stripe light perpendicular to the receiving surface to enter, further suppressing ambient light and improving the detection device's anti-interference light capability. The receiving slit aperture is also made of metal or plastic, and has a narrow slit inside. The width and length of the slit are designed according to actual requirements.

[0041] A receiving filter is installed on the incident side of the optical path of the receiving slit aperture (receiving aperture). This receiving filter can be an optical filter, and its main function is to reduce interference from ambient light, thereby reducing fluctuations in the photosensitive data caused by ambient light interference. This ensures the accuracy of identifying the "lowest photosensitive point," thus improving the reliability of the final line breakage judgment. It also protects the receiving window from dust and fibers in the environment, preventing them from entering the device and facilitating cleaning. Alternatively, a regular glass plate can be used as the receiving filter, providing some protection.

[0042] The receiving slit aperture and the transmitting slit aperture are set coaxially, and the optical axis is perpendicular to the linear arrangement direction of the photosensitive array. This setting can ensure that the strip light spot is accurately projected onto the photosensitive array, thereby improving the detection accuracy.

[0043] The photosensitive array (receiving lamp array) is a linear CMOS sensor. A linear CMOS is a pixel-level photoelectric conversion device consisting of tens to thousands of pixels arranged linearly. Based on the light intensity of each pixel, it outputs a corresponding analog voltage signal. Its pixel pitch ranges from several micrometers to tens of micrometers. Since most yarn diameters are on the order of hundreds of micrometers or larger, the yarn diameter, being larger than the CMOS pixel, provides excellent light-blocking effect. By detecting changes in the light intensity of the linear CMOS pixels, yarn breakage and motion status can be detected, making it a highly sensitive and reliable method. In another embodiment, the photosensitive array can also use a one-dimensional PSD (Position Sensitive Detector), which functions similarly to a linear CMOS, only differing in output signal and calculation method. These differences will not be elaborated upon here; the goal is to achieve the same technical effect.

[0044] It is worth mentioning here that, see Figure 3 In order to make the linear CMOS more sensitive to signal fluctuations, the power of the emitting light source is adjusted to an appropriate value according to the amplitude of the CMOS output voltage, so that the CMOS output level is at the specified value (if the emitted signal is too strong, the CMOS output signal will be saturated, and some weak signal changes will be masked, reducing the system resolution).

[0045] In step S2, the photosensitive array contains multiple pixel units with pixel labels, and the size of the pixel unit is smaller than the diameter of the yarn. When a yarn is within the detection range, since the diameter of the yarn is larger than the size of the pixel unit, it will inevitably block the light-sensing of some pixels. The blocked parts will not output voltage or the output voltage will be reduced.

[0046] In step S3, the pixel index at the lowest photosensitive intensity point in each group of photosensitive intensity change data is obtained. The lowest photosensitive intensity point corresponds to the lowest voltage point output by the photosensitive array, such as... Figure 4 As shown, when the yarn moves, the photosensitive array (linear CMOS pixels) is blocked by the moving yarn. The position where the voltage level drops will appear at the corresponding position on the yarn along the pixel axis. The change and amplitude of the output are calculated from the position of the blocked pixel. Specifically, how the change and amplitude of the output are calculated from the position of the blocked pixel is as follows: For a 512-pixel CMOS sensor, the pixel pitch is 12.5 micrometers, resulting in 512 linearly arranged photosensitive dots. The diameter of a yarn is at least 200 micrometers. Assuming that at a certain moment the yarn is located at the lower end of the CMOS sensor, blocking approximately 10 pixels, the lowest point of the photosensitive intensity signal is identified by sampling the signal and its corresponding pixel number. In the next sampling cycle, the second lowest point is identified and its corresponding pixel number is also determined. By observing the changes in pixel numbers at different times, the changes and amplitude of the yarn signal can be determined.

[0047] When the yarn breaks, either the yarn detaches from the illuminated area, the linear CMOS is no longer blocked from light, and the output waveform of the linear CMOS returns to normal. Figure 3 The waveform shown; Alternatively, the shaded area may remain fixed near a certain pixel and show no change for a certain period of time (this time is related to the machine's operating speed and is mainly designed based on the machine's response speed), or the amplitude may drop sharply, exhibiting characteristics completely different from those of normal yarn movement. The waveform state is identified by sampling the signal.

[0048] Just like the previous example. If the voltage of all 512 sampled pixels is the same and matches the set voltage, it means that none of the pixels are blocked. If some pixels are blocked, a lower voltage level will appear in the sampled data. By finding the corresponding pixel number, we can determine the current position of the yarn within the photosensitive window.

[0049] In step S4, for each set of photosensitivity intensity change data, the ratio of the minimum to the maximum value among the acquired pixel labels is calculated to obtain the rate of change of the yarn at multiple positions. For example, taking a machine operating speed of 5000 rpm as an example, the frequency is converted to 83.3 Hz. The mechanical oscillation frequency of the yarn is also 83.3 Hz, so the time for one mechanical change of the yarn is 1 / 83.3 = 0.012 seconds = 12 milliseconds. If the sampling period is set to 1 microsecond, collecting 512 data points is approximately 0.5 milliseconds. Therefore, at least 20 samples can be collected within one mechanical change time of the yarn to obtain 20 pixel labels of the lowest voltage points. Then, the maximum and minimum values ​​of these 20 pixel labels are found, and the minimum value divided by the maximum value gives the rate of change of the yarn within one mechanical change time. The smaller the rate of change, the greater the oscillation of the yarn, proving that the yarn is moving.

[0050] If the device requires a response time of 1 second, then 20 pixels can be numbered as a group, and multiple groups of data can be used to calculate the rate of change, thereby increasing the reliability of the judgment result.

[0051] In step S5, if several consecutive sets of data indicate that the yarn position change rate is greater than or close to a certain set threshold (preset threshold), it means that the yarn swing is very small or has stopped moving. Then the output unit can output a yarn breakage alarm signal.

[0052] The implementation principle of this embodiment is as follows: This embodiment employs a photoelectric detection method, utilizing an emitted light source to form a stripe of light, combined with a photosensitive array to collect data on changes in light intensity, and determines the yarn breakage state by calculating the rate of change of pixel labels. This method avoids the shortcomings of existing detection methods such as piezoelectric, electromagnetic induction, and mechanical lever methods. For example, piezoelectric methods are not sensitive to weak twist and abnormal tension and are prone to false alarms; electromagnetic induction methods cannot determine the yarn movement state; and mechanical lever methods have low detection accuracy and a high failure rate. Furthermore, this method, through the analysis and processing of light intensity change data, can accurately determine the yarn movement state and breakage condition, improving the accuracy and reliability of detection, reducing the false alarm rate, and is suitable for the actual needs of yarn breakage detection in the textile industry, representing a significant improvement and contribution to existing technologies.

[0053] [Second Embodiment] See Figure 2 The second embodiment of this application discloses a photoelectric textile yarn breakage detection device, which includes a light source component, a photosensitive array, and a signal processing unit. The light source component and the photosensitive array are arranged opposite to each other, and the signal processing unit is electrically connected to the photosensitive array. The three work together to achieve accurate detection of yarn breakage status, avoiding the problem that existing detection devices cannot accurately determine the yarn movement status and breakage status, and improving the accuracy and reliability of detection.

[0054] Specifically, the light source assembly is used to generate a stripe-shaped light spot to illuminate the yarn. The light source assembly includes an emitting light source, an emitting slit aperture, and an emitting lens. The emitting light source can be a laser or a regular LED light source. The light emitted by the emitting light source passes through the emitting slit aperture, which converts the circular light spot into a stripe-shaped light spot. The emitting slit aperture typically has a narrow slit, through which the light forms a stripe-shaped light spot. The emitting lens is positioned on the exit side of the light path of the emitting slit aperture to convert the stripe-shaped light spot formed by the emitting slit aperture into parallel light. When the detection distance is very close (a few millimeters), if a large emission angle LED light source is used, the emitting lens may not be necessary to meet the signal strength requirements at the receiving end (i.e., the use of an emitting lens can be selected based on the light intensity and beam quality).

[0055] A photosensitive array is positioned opposite the light source assembly to collect multiple sets of light intensity change data when a strip of light is blocked by yarn during mechanical movement. The photosensitive array is a linear CMOS sensor or a one-dimensional PSD sensor, serving as the receiving unit in the detection device. A linear CMOS is a pixel-level photoelectric conversion device consisting of tens to thousands of linearly arranged pixels. Based on the light intensity of each pixel, it outputs a corresponding analog voltage signal. Its pixel pitch ranges from several micrometers to tens of micrometers. Since most yarn diameters are on the order of hundreds of micrometers or larger, the yarn diameter, being larger than the CMOS pixel, provides a good light-blocking effect. Detecting yarn breakage and motion status by measuring changes in the light intensity of linear CMOS pixels is a highly sensitive and reliable method. The PSD plays a similar role to the linear CMOS here, but the output signal and calculation method differ.

[0056] A receiving slit aperture is installed on the incident side of the optical path of the photosensitive array. Besides shaping the received stripe light, the receiving slit aperture lengthens the narrow slit channel, allowing only stripe light perpendicular to the receiving surface to enter, further suppressing ambient light and improving the detection device's anti-interference light capability. The width and length of the receiving slit aperture are designed according to actual requirements.

[0057] A receiving filter is also provided on the incident side of the optical path of the receiving slit aperture. This receiving filter can be an optical filter, and its main function is to reduce interference from ambient light during reception. It also protects the receiving window from dust and fibers in the environment, preventing them from entering the device and facilitating cleaning. Alternatively, a regular glass plate can be used to provide some protection.

[0058] The receiving slit aperture and the transmitting slit aperture are set coaxially, and the optical axis is perpendicular to the linear arrangement direction of the photosensitive array. This setting can ensure that the strip light spot is accurately projected onto the photosensitive array, thereby improving the detection accuracy.

[0059] The signal processing unit is electrically connected to the photosensitive array and is used to perform the following processing: Obtain the pixel number at the lowest point of light intensity in each set of light intensity change data. The lowest point of light intensity corresponds to the lowest point of voltage output by the photosensitive array. Calculate the ratio of the minimum to the maximum pixel number in each data set to obtain the rate of change of the yarn at multiple positions; And based on the comparison results of multiple rates of change with preset thresholds, it is determined whether the yarn is in a broken state.

[0060] For example, let's take a machine operating at 5000 revolutions per minute. Converted to a frequency of 83.3 Hz, the mechanical oscillation frequency of the yarn is also 83.3 Hz. Therefore, the time for one mechanical change of the yarn is 1 / 83.3 = 0.012 seconds = 12 milliseconds. If the sampling period is set to 1 microsecond, collecting 512 data points takes approximately 0.5 milliseconds. Therefore, at least 20 data points can be collected within one mechanical change of the yarn, obtaining the pixel numbers of the 20 lowest voltage points. Then, the maximum and minimum values ​​of these 20 pixel numbers are found. Dividing the minimum value by the maximum value gives the rate of change of the yarn within one mechanical change.

[0061] If the device requires a response time of 1 second, then 20 pixels can be numbered as a group, and multiple groups of data can be used to calculate the rate of change, which increases the reliability of the judgment result. If several consecutive groups of data indicate that the yarn position change rate is greater than or close to a certain set threshold, it means that the yarn has oscillated very little or has stopped moving, and a yarn breakage alarm signal is issued.

[0062] The implementation principle of this embodiment is as follows: The photoelectric textile yarn breakage detection device of this embodiment generates a striped light spot to irradiate the yarn through a light source component. The photosensitive array collects data on changes in photosensitive intensity, and the signal processing unit analyzes and processes the data to determine the yarn breakage status. This device avoids the shortcomings of existing detection devices, such as piezoelectric detection devices being insensitive to weak twist and abnormal tension and prone to false alarms, electromagnetic induction detection devices being unable to determine the yarn movement status, and mechanical lever detection devices having low detection accuracy and high failure rate. This device, through accurate acquisition and processing of photosensitive intensity change data, can accurately determine the yarn movement status and breakage status, improving the accuracy and reliability of detection, reducing the false judgment rate, and is suitable for the actual needs of yarn breakage detection in the textile industry, making a significant improvement and contribution to existing technologies.

[0063] It should be noted that the photoelectric textile thread breakage detection system disclosed in this embodiment implements the same photoelectric textile thread breakage detection method as described in the above embodiment, and therefore will not be described in detail here. Optionally, the various modules and other operations or functions in this embodiment are respectively for implementing the methods in the aforementioned embodiments.

[0064] [Third Embodiment] The third embodiment of this application discloses an electronic device, which includes a memory and a processor. The memory is used to store a computer program; the processor is used to execute the computer program to implement the steps of the photoelectric textile thread breakage detection method described in the first embodiment above. For details, please refer to the above description and will not be elaborated here.

[0065] The technical effect of the electronic device provided in this embodiment in practical application is the same as that of the photoelectric textile thread breakage detection method in the first embodiment.

[0066] [Fourth Embodiment] A computer-readable storage medium is disclosed in the fourth embodiment of this application. The computer-readable storage medium is, for example, a non-volatile memory, such as magnetic media (e.g., hard disks, floppy disks, and magnetic tapes), optical media (e.g., CD-ROMs and DVDs), magneto-optical media (e.g., optical discs), and hardware devices specifically configured to store and execute computer-executable instructions (e.g., read-only memory (ROM), random access memory (RAM), flash memory, etc.). A computer program is stored on the computer-readable storage medium. The computer-readable storage medium can be executed by one or more processors or processing devices to implement a photoelectric textile yarn breakage detection method according to the foregoing embodiments.

[0067] Furthermore, it is understood that the foregoing embodiments are merely illustrative examples of the present invention. Provided that the technical features do not conflict, the structure is not contradictory, and the purpose of the invention is not violated, the technical solutions of the various embodiments can be arbitrarily combined and used.

[0068] In the embodiments provided by this invention, it should be understood that the disclosed methods, systems, and measuring devices can be implemented in other ways. For example, the modules included in the systems described above are merely illustrative, and the division of modules is only a logical functional division. In actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be indirect coupling or communication connection through some interfaces, devices, or units, and may be electrical, mechanical, or other forms.

[0069] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0070] Furthermore, in the various embodiments of the present invention, the functional units / modules can be integrated into one processing unit / module, or each unit / module can exist physically separately, or two or more units / modules can be integrated into one unit / module. The integrated unit / module described above can be implemented in hardware or in the form of hardware plus software functional units / modules.

[0071] The integrated units / modules implemented as software functional units / modules described above can be stored in a computer-readable storage medium. These software functional units, stored in a storage medium, include several instructions to cause one or more processors of a computer measurement device (which may be a personal computer, server, or network measurement device, etc.) to execute some steps of the methods described in the various embodiments of this application. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0072] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A photoelectric method for detecting broken threads in the textile industry, characterized in that, include: S1: A strip-shaped light spot is formed using an emitted light source, and the strip-shaped light spot is projected onto the yarn; S2: During the mechanical movement of the yarn, multiple sets of photosensitivity change data are collected by a photosensitive array when the strip-shaped light spot is blocked by the yarn; wherein, the photosensitive array contains multiple pixel units with pixel labels, and the size of the pixel unit is smaller than the diameter of the yarn; S3: Obtain the pixel number at the lowest point of light intensity in each group of light intensity change data, where the lowest point of light intensity corresponds to the lowest point of voltage output by the photosensitive array; S4: For each set of photosensitivity intensity change data, calculate the ratio of the minimum to the maximum value in the obtained pixel labels to obtain the rate of change of the yarn at multiple positions; S5: Based on the comparison results of multiple rates of change with preset thresholds, determine whether the yarn is in a broken state.

2. The photoelectric textile thread breakage detection method according to claim 1, characterized in that, Step S5 includes: If multiple rates of change are greater than the preset threshold, the yarn is determined to be in a broken state.

3. The photoelectric textile thread breakage detection method according to claim 2, characterized in that, Step S5 further includes: When multiple rates of change are close to 1, the yarn is determined to be in a broken state.

4. The photoelectric textile thread breakage detection method according to claim 1, characterized in that, In step S1, forming a strip-shaped light spot using an emitting light source includes: The light emitted by the light source is passed through the narrow slit aperture to form the strip-shaped light spot.

5. The photoelectric textile thread breakage detection method according to claim 4, characterized in that, Also includes: An emission lens is provided on the optical path exit side of the emission slit aperture to convert the strip-shaped light spot formed by the emission slit aperture into parallel light.

6. The photoelectric textile thread breakage detection method according to claim 1 or 4, characterized in that, Prior to step S2, the method further includes: A receiving slit aperture is provided on the incident side of the optical path of the photosensitive array to reshape the strip-shaped light spot so that only light within a preset range is allowed to enter the photosensitive array.

7. The photoelectric textile thread breakage detection method according to claim 6, characterized in that, Also includes: A receiving filter is provided on the incident side of the optical path of the receiving narrow slit aperture.

8. The photoelectric textile thread breakage detection method according to claim 6, characterized in that, The receiving slit aperture and the transmitting slit aperture are coaxially arranged, and the optical axis direction is perpendicular to the linear arrangement direction of the photosensitive array.

9. The photoelectric textile thread breakage detection method according to claim 1, characterized in that, The photosensitive array is a linear CMOS sensor or a one-dimensional PSD sensor.

10. A photoelectric textile thread breakage detection device, characterized in that, For performing the method according to any one of claims 1 to 9, comprising: A light source assembly for generating stripe-shaped light spots to illuminate the yarn; A photosensitive array, arranged opposite to the light source component, is used to collect multiple sets of photosensitivity change data when the strip-shaped light spot is blocked by the yarn during the mechanical change time. A signal processing unit, electrically connected to the photosensitive array, is used to perform the following processing: acquiring the pixel label at the lowest photosensitive intensity point in each group of photosensitive intensity change data; calculating the ratio of the minimum to the maximum value of the pixel label in each group of data to obtain the rate of change of the yarn at multiple positions; and determining whether the yarn is in a broken state based on the comparison results of multiple rates of change with a preset threshold.

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