Dual-wavelength impurity detection photoelectric sensor and cotton carding machine impurity falling system

Abstract

The application relates to a dual-wavelength impurity detection photoelectric sensor and a cotton carding machine impurity dropping system. The photoelectric sensor comprises a transmitting module for transmitting first-wavelength light and second-wavelength light for irradiating a measured cotton ball; a receiving module for receiving the first-wavelength light and the second-wavelength light reflected by the measured cotton ball and converting the first-wavelength light and the second-wavelength light into first voltage signals and second voltage signals respectively; and a signal processing module connected to the output end of the receiving module and used for calculating the impurity content of the measured cotton ball according to the first voltage signals and the second voltage signals and combining a preset impurity content mathematical model. The application can realize real-time and high-precision impurity content detection.

Description

Technical Field

[0001] This invention relates to the field of textile equipment monitoring technology, and in particular to a dual-wavelength photoelectric sensor for detecting foreign matter. Background Technology

[0002] In the textile industry, the carding machine is one of the core pieces of equipment, its function being to separate impurities (such as cotton husks and leaf debris) from cotton fibers. In traditional technology, the test of the impurity rate of the carding machine is mostly done offline. The blocking effect of the dust removal knife and the adjustment of the length of the impurity zone rely on manual operation, which is not only complex and inefficient, but also often requires stopping the machine for adjustments, seriously restricting production efficiency.

[0003] Meanwhile, due to the lack of effective real-time detection methods, the measurement of impurity content cannot be performed online. Fibers and impurities are small in size and move at high speeds (up to 30 m / s), making it difficult for traditional methods to achieve efficient and accurate identification and separation at the air intake. This results in low fiber recycling rates, ultimately affecting the quality and consistency of yarn. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a dual-wavelength impurity detection photoelectric sensor that can detect impurity content in real time and with high precision.

[0005] The technical solution adopted by this invention to solve its technical problem is: to provide a dual-wavelength impurity detection photoelectric sensor, comprising:

[0006] The transmitting module is used to emit first-wavelength light and second-wavelength light to irradiate the cotton ball being tested.

[0007] The receiving module is used to receive a first wavelength light and a second wavelength light reflected by the cotton ball being tested, and to convert the first wavelength light and the second wavelength light into a first voltage signal and a second voltage signal, respectively.

[0008] The signal processing module is connected to the output of the receiving module and is used to calculate the impurity content of the cotton ball under test based on the first voltage signal and the second voltage signal, combined with a preset impurity content mathematical model.

[0009] The first wavelength light is visible light at 660nm.

[0010] The second wavelength light is infrared light at 940nm.

[0011] The dual-wavelength impurity detection photoelectric sensor further includes a lens disposed between the receiving module and the cotton ball under test, for collimating the first wavelength light and the second wavelength light reflected by the cotton ball under test.

[0012] The signal processing module includes:

[0013] The feature value calculation unit is used to calculate the ratio of the first voltage signal to the second voltage signal and use the obtained ratio as the feature value;

[0014] The impurity content calculation unit is used to input the feature value into the impurity content mathematical model to obtain the impurity content of the cotton ball being tested.

[0015] The mathematical model for impurity content is expressed as follows: ,in, The impurity content of the cotton ball being tested. and These are the quantum efficiencies of the first and second wavelengths of light, respectively. and These are the frequencies of the first wavelength light and the second wavelength light, respectively. The reflectance of pure cotton fibers with dual-band wavelengths. For impurity density, cotton fiber density, The reflectance of the impurities for the first wavelength of light. The reflectivity of the impurities for the second wavelength of light. These are the eigenvalues.

[0016] The impurity rate mathematical model is obtained through calibration, specifically including:

[0017] Prepare multiple standard samples with different known impurity contents;

[0018] The dual-wavelength impurity detection photoelectric sensor is used to detect each standard sample, obtain the corresponding first voltage signal and second voltage signal, and calculate the corresponding characteristic value.

[0019] By fitting the known impurity rate with the calculated feature values, a mathematical model of the impurity rate is obtained.

[0020] When preparing multiple standard samples with different known impurity contents, referring to the GB / T 6499-2022 standard, the impurity contents were in the range of 0% to 100%, increasing by 5% in increments, for a total of 21 standard samples, each with a total mass of 1 g.

[0021] The technical solution adopted by this invention to solve its technical problem is: to provide a carding machine impurity removal system, comprising:

[0022] Carding machine;

[0023] The aforementioned dual-wavelength impurity detection photoelectric sensor is used to detect the impurity content of multiple cotton clumps generated by the carding machine.

[0024] The control processor is used to generate control instructions for the dust removal knife based on the impurity detection results of multiple cotton clumps.

[0025] The control processor includes:

[0026] The statistical calculation module is used to calculate the impurity content of the multiple cotton balls within a preset time period and calculate the average value to obtain the average impurity content.

[0027] The comparison execution module is used to compare the average impurity content with a threshold and a target value respectively. When the average impurity content exceeds the threshold, a control command is generated to strengthen dust removal by the dust removal blade; when the average impurity content is less than the target value, a control command is generated to weaken dust removal by the dust removal blade.

[0028] Beneficial effects

[0029] Due to the adoption of the above-mentioned technical solutions, this invention has the following advantages and positive effects compared with the prior art: This invention employs a dual-wavelength light source emission and reception structure, relying on the characteristic values ​​calculated from two voltage signals and a preset mathematical model to calculate the impurity content. It boasts strong real-time detection capabilities, enabling online detection of cotton clumps moving at high speeds in a carding machine without requiring offline operation, thus adapting to high-speed textile production scenarios. This invention utilizes the difference in reflection characteristics of cotton and impurities towards dual-wavelength light, using two voltage signals to eliminate interference from light source fluctuations and ambient light, ensuring stable and accurate detection. The signal processing module of this invention can directly output the impurity content result, and can be linked with the dust removal knife actuator to form a closed-loop control, eliminating manual adjustment processes and improving production efficiency. Simultaneously, it can accurately match the impurity intensity, avoiding excessive impurity induction and fiber waste, effectively improving fiber utilization and yarn quality, and meeting the high-efficiency, high-quality production needs of the textile industry. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the dual-wavelength impurity detection photoelectric sensor according to the first embodiment of the present invention;

[0031] Figure 2 This is a flowchart of the calibration mathematical model for impurity content in the first embodiment of the present invention;

[0032] Figure 3 This is a calibration curve of impurity content in the first embodiment of the present invention. Detailed Implementation

[0033] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the teachings of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0034] The first embodiment of the present invention relates to a dual-wavelength impurity detection photoelectric sensor, such as... Figure 1 As shown, it includes:

[0035] The transmitting module is used to emit first-wavelength light and second-wavelength light to irradiate the cotton ball being tested.

[0036] The receiving module is used to receive a first wavelength light and a second wavelength light reflected by the cotton ball being tested, and to convert the first wavelength light and the second wavelength light into a first voltage signal and a second voltage signal, respectively.

[0037] The signal processing module is connected to the output of the receiving module and is used to calculate the impurity content of the cotton ball under test based on the first voltage signal and the second voltage signal, combined with a preset impurity content mathematical model.

[0038] In this embodiment, the first wavelength light is visible light at 660 nm. The second wavelength light is infrared light at 940 nm.

[0039] In order to enable the receiving module to better receive the first wavelength light and the second wavelength light reflected by the cotton ball under test, this embodiment also provides a lens between the receiving module and the cotton ball under test. The lens is used to collimate the first wavelength light and the second wavelength light reflected by the cotton ball under test.

[0040] The signal processing module in this embodiment includes:

[0041] The feature value calculation unit is used to calculate the ratio of the first voltage signal to the second voltage signal and use the obtained ratio as the feature value;

[0042] The impurity content calculation unit is used to input the feature value into the impurity content mathematical model to obtain the impurity content of the cotton ball being tested.

[0043] The impurity rate mathematical model in this embodiment can be based on the relationship function between the output voltage of 660 nm wavelength light and the impurity rate. The relationship between the output voltage and impurity content of 940 nm wavelength light. The output voltage and impurity content of the 660 nm and 940 nm wavelength light are obtained as follows:

[0044] ;

[0045] ;

[0046] in, The impurity content of the cotton ball being tested. and The quantum efficiencies for light at wavelengths of 660 nm and 940 nm are respectively. and The frequencies of light with a wavelength of 660 nm and 940 nm are respectively. The reflectance of pure cotton fibers with dual-band wavelengths. For impurity density, cotton fiber density, The reflectance of impurities for light at a wavelength of 660 nm. The reflectance of impurities for light at a wavelength of 940 nm.

[0047] Eigenvalues Let be the ratio of the first voltage signal to the second voltage signal. Based on the above formula, the characteristic value can be obtained. With impurity content The relationship is:

[0048] ;

[0049] By rearranging the above formula, we can obtain the mathematical model for impurity rate, namely:

[0050] .

[0051] The impurity rate mathematical model in this embodiment can also be obtained through calibration, such as... Figure 2 As shown, the specific method is as follows:

[0052] First, 21 standard samples were prepared according to GB / T 6499-2022 standard. The impurity content of each standard sample was 0%, 5%, 10%, ..., 100%, and the total mass of each sample was 1 g.

[0053] Then, the dual-wavelength impurity detection photoelectric sensor of this embodiment is used to sequentially detect these 21 standard samples. During each detection, the transmitting module illuminates the standard sample, and the receiving module records the voltage signal converted from the reflected 660 nm wavelength light. The voltage signal converted from the reflection of light with a wavelength of 940 nm Experiments revealed that impurities (such as cotton husks) strongly absorb 660 nm visible light but strongly reflect 940 nm infrared light; therefore, a characteristic value was defined. .

[0054] Finally, based on impurity content The ordinate is the eigenvalue. Plot 21 data points as the x-axis (see...) Figure 3 ), and through physical model derivation and curve fitting, a mathematical model is obtained: .in, The constant obtained from the fitting is called the impurity rate mathematical model.

[0055] The second embodiment of the present invention relates to a carding machine waste removal system, comprising:

[0056] Carding machine;

[0057] The dual-wavelength impurity detection photoelectric sensor of the first embodiment is used to detect the impurity content of multiple cotton clumps generated by the carding machine.

[0058] The control processor is used to generate control instructions for the dust removal knife based on the impurity detection results of multiple cotton clumps.

[0059] When the carding machine is operating normally, a high-speed airflow carries cotton clumps through the detection area of ​​the dual-wavelength impurity detection photoelectric sensor. The emitting module in the dual-wavelength impurity detection photoelectric sensor continuously emits light of two wavelengths. When a cotton clump passes through the detection area, the receiving module receives the reflected light in real time and outputs two voltage signals. and The signal processing module then processes the two voltage signals. and Sampling is performed, and for the current cotton ball, its corresponding feature value is calculated. and the obtained eigenvalues Substituting into the preset impurity content mathematical model, the impurity content of the current cotton ball is obtained. If the cotton ball is large and the fibers are pure, then the voltage signal... and Both are relatively strong, but the voltage signal The attenuation is small, and the eigenvalues Moderate, calculated impurity content The voltage signal is lower. If there are many impurities in the cotton ball, the voltage signal will be lower. Significantly weakened, leading to eigenvalues Increase, and the calculated impurity content Increase.

[0060] In this embodiment, the statistical calculation module in the control processor will statistically analyze the impurity content of multiple cotton clumps detected by the dual-wavelength impurity detection photoelectric sensor within a preset time period (e.g., 1 minute), and calculate the average value to obtain the average impurity content. Then, through the comparison execution module in the control processor, the average impurity content is... Respectively with threshold and target value When comparing, when the average impurity content Exceeding the threshold When the current impurity removal effect is poor, a control command is generated to strengthen dust removal by driving the stepper motor of the dust removal blade, appropriately shortening the length of the impurity removal zone or adjusting the angle of the dust removal blade to enhance the impurity removal capacity; when the average impurity content is... Less than the target value If excessive impurities are detected, a control command is generated to reduce dust removal by the dust removal blade to minimize fiber loss. Through the closed-loop control of the carding machine impurity removal system in this embodiment, the carding machine can automatically adjust process parameters according to the actual impurity content of the raw material, always maintaining optimal operating conditions.

[0061] It is easy to see that this invention employs a dual-wavelength light source emission and reception structure, relying on the characteristic values ​​calculated from two voltage signals and a preset mathematical model to calculate the impurity content. Its detection is highly real-time, enabling online detection of cotton clumps moving at high speeds in a carding machine without requiring offline operation, making it suitable for high-speed textile production scenarios. This invention utilizes the difference in reflection characteristics of cotton and impurities to dual-wavelength light, using two voltage signals to eliminate interference from light source fluctuations and ambient light, ensuring stable and accurate detection. The signal processing module of this invention can directly output the impurity content result, and can be linked with the dust removal knife actuator to form a closed-loop control, eliminating manual adjustment processes and improving production efficiency. Simultaneously, it can accurately match the impurity removal intensity, avoiding excessive impurity removal and fiber waste, effectively improving fiber utilization and yarn quality, and meeting the high-efficiency, high-quality production needs of the textile industry.

Claims

1. A dual-wavelength impurity detection photoelectric sensor, characterized in that, include: The transmitting module is used to emit first-wavelength light and second-wavelength light to irradiate the cotton ball being tested. The receiving module is used to receive a first wavelength light and a second wavelength light reflected by the cotton ball being tested, and to convert the first wavelength light and the second wavelength light into a first voltage signal and a second voltage signal, respectively. The signal processing module is connected to the output of the receiving module and is used to calculate the impurity content of the cotton ball under test based on the first voltage signal and the second voltage signal, combined with a preset impurity content mathematical model.

2. The dual-wavelength impurity detection photoelectric sensor according to claim 1, characterized in that, The first wavelength light is visible light at 660nm.

3. The dual-wavelength impurity detection photoelectric sensor according to claim 1, characterized in that, The second wavelength light is infrared light at 940nm.

4. The dual-wavelength impurity detection photoelectric sensor according to claim 1, characterized in that, Also includes: A lens is disposed between the receiving module and the cotton ball being tested, for collimating the first wavelength light and the second wavelength light reflected by the cotton ball being tested.

5. The dual-wavelength impurity detection photoelectric sensor according to claim 1, characterized in that, The signal processing module includes: The feature value calculation unit is used to calculate the ratio of the first voltage signal to the second voltage signal and use the obtained ratio as the feature value; The impurity content calculation unit is used to input the feature value into the impurity content mathematical model to obtain the impurity content of the cotton ball being tested.

6. The dual-wavelength impurity detection photoelectric sensor according to claim 5, characterized in that, The mathematical model for impurity content is expressed as follows: ,in, The impurity content of the cotton ball being tested. and These are the quantum efficiencies of the first and second wavelengths of light, respectively. and These are the frequencies of the first wavelength light and the second wavelength light, respectively. The reflectance of pure cotton fibers with dual-band wavelengths. For impurity density, cotton fiber density, The reflectance of the impurities for the first wavelength of light. The reflectivity of the impurities for the second wavelength of light. These are the eigenvalues.

7. The dual-wavelength impurity detection photoelectric sensor according to claim 5, characterized in that, The impurity rate mathematical model is obtained through calibration, specifically including: Prepare multiple standard samples with different known impurity contents; The dual-wavelength impurity detection photoelectric sensor is used to detect each standard sample, obtain the corresponding first voltage signal and second voltage signal, and calculate the corresponding characteristic value. By fitting the known impurity rate with the calculated feature values, a mathematical model of the impurity rate is obtained.

8. The dual-wavelength impurity detection photoelectric sensor according to claim 7, characterized in that, When preparing multiple standard samples with different known impurity contents, referring to the GB / T 6499-2022 standard, the impurity contents were in the range of 0% to 100%, increasing by 5% in increments, for a total of 21 standard samples, each with a total mass of 1 g.

9. A carding machine waste removal system, characterized in that, include: Carding machine; The dual-wavelength impurity detection photoelectric sensor as described in any one of claims 1-7 is used to detect the impurity content of multiple cotton clumps generated by the carding machine; The control processor is used to generate control instructions for the dust removal knife based on the impurity detection results of multiple cotton clumps.

10. The carding machine waste removal system according to claim 9, characterized in that, The control processor includes: The statistical calculation module is used to calculate the impurity content of the multiple cotton balls within a preset time period and calculate the average value to obtain the average impurity content. The comparison execution module is used to compare the average impurity content with a threshold and a target value respectively. When the average impurity content exceeds the threshold, a control command is generated to strengthen dust removal by the dust removal blade; when the average impurity content is less than the target value, a control command is generated to weaken dust removal by the dust removal blade.

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