Nonwoven fabric visual inspection apparatus
By combining high-resolution cameras, optical sensors, and AI algorithms with multi-angle light sources and roller assembly design, the problem of low efficiency in manual inspection of nonwoven fabrics has been solved, achieving high-precision and high-speed defect detection and improving the automation level of nonwoven fabric production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- DONGGUAN INNOWAY VISION TECH CO LTD
- Filing Date
- 2025-04-27
- Publication Date
- 2026-08-04
AI Technical Summary
In the production process of nonwoven fabrics, manual inspection is inefficient, prone to errors, and costly, and it is difficult to detect minute defects such as holes, stains, and uneven fibers.
By employing high-resolution cameras, optical sensors, and AI algorithms, combined with multi-angle light sources and roller assembly design, high-precision visual inspection of nonwoven fabrics is achieved, eliminating human error.
It achieves defect detection with micron-level precision, improves production efficiency, ensures the consistency and reliability of detection results, adapts to the needs of high-speed production lines, reduces reliance on skilled workers, and improves product qualification rate.
Smart Images
Figure CN224594499U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of mechanical device technology, and more specifically to a visual inspection device for nonwoven fabrics. Background Technology
[0002] Currently, the nonwoven fabric / cleanroom paper / cleanroom cloth industry suffers from numerous defects during production, including dirt, insect holes, and fraying. These defects are entirely identified and selected manually by visual inspection. Since the material is pure white, prolonged visual inspection can cause eye strain and serious vision damage over time. Nonwoven fabrics may also exhibit defects such as holes, stains, uneven thickness, or uneven fiber distribution. Traditional manual inspection is inefficient, prone to errors, and costly.
[0003] Therefore, how to provide a nonwoven fabric visual inspection device that uses a high-resolution camera and optical sensors to detect minute defects (such as holes, stains, uneven fibers, etc.) that are difficult to detect with the naked eye and eliminate human error is a problem that urgently needs to be solved by those skilled in the art. Utility Model Content
[0004] In view of this, the present invention provides a visual inspection device for nonwoven fabrics.
[0005] To achieve the above objectives, this utility model provides the following technical solution:
[0006] A nonwoven fabric visual inspection device includes: a main frame and feet and rollers fixedly installed at the bottom of the main frame; roller assemblies are arranged sequentially above the main frame for tightening and unwinding the nonwoven fabric; a light source mechanism is fixedly installed above the roller assemblies; a support frame is fixedly installed above the main frame; a set of camera lenses is respectively provided at the bottom of the main frame and the top of the support frame; a set of camera height adjustment modules is fixedly connected to the camera lenses; a connecting frame is fixedly installed on the right side of the support frame; and a labeling machine assembly is fixedly installed on the connecting frame.
[0007] Preferably, the camera height adjustment module includes: a slider connected to the camera lens and a vertically placed slide rail.
[0008] Preferably, the roller assembly arranged sequentially above the main frame includes a first roller fixedly arranged on the left side of the main frame, a second roller vertically installed on the top of the main frame, a third roller horizontally arranged on one side of the second roller, a fourth roller horizontally arranged on the right side of the third roller and slightly higher than the third roller, and a fifth roller fixedly installed on the far right side of the main frame.
[0009] Preferably, one set of light sources of the light source mechanism is positioned below the camera lens and tilted above the second roller, while the other set of light sources of the light source mechanism is horizontally positioned above the third roller.
[0010] Preferably, the connecting frame consists of two sets of parallel and symmetrically arranged I-shaped structural frames, with a labeling machine component fixedly installed in the center of the two sets of I-shaped structural frames.
[0011] Preferably, the labeling machine assembly includes: two parallel connecting columns, a labeling machine adjustment device evenly nested on the two connecting columns, a labeling machine mechanism connected to the labeling machine adjustment device, and fasteners fixedly installed at both ends of the connecting columns for fixing the I-shaped structural frame.
[0012] Preferably, the labeling machine mechanism includes a label roll mechanism located in the upper right corner, a first small idler roller located in the central area, an optical sensor fixedly installed at the entrance of the first small idler roller, a second small idler roller located below the entrance of the first small idler roller, a label peeling plate located diagonally below the second small idler roller, a third small idler roller located behind the label peeling plate and responsible for recycling the label paper, a fourth small idler roller located diagonally above and to the left of the third small idler roller, and a label roll recycling mechanism located in the upper left corner.
[0013] As can be seen from the above technical solution, compared with the prior art, the nonwoven fabric visual inspection equipment disclosed in this utility model has high-precision recognition: through high-resolution cameras, optical sensors, and AI algorithms, it can detect minute defects (such as holes, stains, uneven fibers, etc.) that are difficult to detect with the naked eye, with an accuracy of up to the micrometer level, eliminating human error and ensuring the consistency and reliability of inspection results. At the same time, it improves production efficiency; the equipment can handle real-time inspection on high-speed production lines (such as hundreds of meters per minute), significantly increasing inspection speed and adapting to the needs of large-scale industrial production. It replaces the traditional process relying on manual visual inspection, reducing reliance on skilled workers. Furthermore, through real-time defect location and classification, it can promptly remove defective products or mark them for repair, avoiding raw material waste. Through high-standard defect inspection (such as nonwoven fabrics for medical and hygiene products), it improves product qualification rates and meets international quality certification requirements. It promotes the transformation of the nonwoven fabric industry from traditional manufacturing to intelligent manufacturing, and improves the overall technical level of the industrial chain. Attached Figure Description
[0014] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.
[0015] Figure 1 The attached figure is a schematic diagram of the main structure of this utility model.
[0016] Figure 2 The attached figure is a schematic diagram of the main side structure of this utility model.
[0017] Figure 3 The attached figure is a schematic diagram of the labeling machine component structure of this utility model.
[0018] Figure 4 The attached figure is a schematic diagram of the structural composition of the labeling machine of this utility model. Detailed Implementation
[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.
[0020] This utility model discloses a nonwoven fabric visual inspection device, comprising: a main frame 1 and feet 2 and rollers 3 fixedly installed at the bottom of the main frame 1; a roller assembly is arranged sequentially above the main frame 1 for tightening and unwinding the nonwoven fabric; a light source mechanism 30 is fixedly installed above the roller assembly; a support frame 4 is fixedly installed above the main frame 1; a set of camera lenses 10 is respectively provided at the bottom of the main frame 1 and the top of the support frame 4; a set of camera height adjustment modules 50 is fixedly connected to the camera lenses 10; a connecting frame 5 is fixedly installed on the right side of the support frame 4; and a labeling machine assembly 20 is fixedly installed on the connecting frame 5.
[0021] The main frame 1 has a rectangular overall structure with a hollow interior. A camera height adjustment module 50 is fixedly installed at the bottom. The camera height adjustment module 50 includes a slider 501 connected to the camera lens 10 and a vertically placed slide rail 502. Precise adjustment of the camera height is achieved by adjusting the vertical movement of the slider 501 connected to the camera lens 10. The position is then fixed by a mechanical locking device (locking pin) 503 to prevent camera lens displacement due to equipment vibration or movement, ensuring imaging stability during the inspection process. The camera height adjustment module 50, used in conjunction with the camera lens 10, can adapt to different inspection needs, such as adjusting the field of view. Specifically, raising the camera expands the shooting coverage width, while lowering it increases resolution, making it easier to capture minute defects (such as fiber breaks and impurities). Focal length optimization: Matching the lens's depth-of-field characteristics ensures clear imaging of the non-woven fabric surface texture.
[0022] The roller assembly arranged sequentially above the main frame 1 includes a first roller 41 fixedly installed on the left side of the main frame 1, a second roller 42 vertically installed on the top of the main frame, a third roller 43 horizontally installed on one side of the second roller 42, a fourth roller 44 horizontally installed on the right side of the third roller 43 and slightly higher than the third roller 43, and a fifth roller 45 fixedly installed on the far right side of the main frame 1.
[0023] Specifically, the first idler roller 41 is located at the feed end of the equipment and serves as the initial guide roller for the nonwoven fabric. It is responsible for guiding the nonwoven fabric into the detection area and applying initial tension to the material. The second idler roller 42 vertically turns to change the direction of movement of the nonwoven fabric, causing it to change from horizontal feeding to upward movement, forming a "climbing" path. This design can reduce friction between the material and the components below, while increasing the space utilization of the detection area. The third idler roller 43 acts as a transition roller, readjusting the nonwoven fabric from vertical movement to horizontal movement, providing stable planar support for subsequent detection. The fourth idler roller 44 forms an inclined tension gradient with the third idler roller 43, applying uniform tensile force to the nonwoven fabric through the height difference, eliminating wrinkles or slack, ensuring that the material is completely flattened in the detection area, and avoiding imaging distortion caused by local deformation. The fifth idler roller 45 acts as an exit guide roller, guiding the detected nonwoven fabric downstream (such as to a winding or slitting device), while maintaining end tension to prevent material rebound or accumulation. The nonwoven fabric passes around each idler roller in an S-shaped path (41→42→43→44→45), forming a natural tension distribution through multiple turns. The vertical turn of the second idler roller 42 increases the material wrap angle, using gravity to assist in tensioning. The height difference between the third and fourth idler rollers (44 is slightly higher than 43) generates passive tension adjustment, adapting to nonwoven fabrics of different elasticity or thickness, and avoiding excessive stretching that could damage the material.
[0024] A light source mechanism 30 is fixedly installed above the idler roller assembly for lighting when the camera lens 10 is detecting. One set of light sources of the light source mechanism 30 is located below the camera lens 10 and is tilted above the second idler roller 42. The other set of light sources of the light source mechanism 30 is horizontally located above the third idler roller 43.
[0025] A set of light sources, tilted and mounted above the second idler roller 42, faces the ramp section where the nonwoven fabric enters the detection area (the nonwoven fabric moves upward after a vertical turn on the second idler roller 42). The light sources are at a low angle (e.g., 30°–45°) to the surface of the nonwoven fabric, forming grazing illumination. The low-angle light sweeps across the surface of the nonwoven fabric, and uneven defects (such as fiber clumps, fuzz, and scratches) will form obvious shadows due to obstruction or differences in reflection, significantly improving the contrast of surface defects. The nonwoven fabric experiences slight tension fluctuations at the second idler roller 42 due to the vertical turn; the grazing angle of the tilted light sources avoids blind spots caused by instantaneous material fluctuations. A set of light sources, horizontally mounted above the third idler roller 43, covers the initial section where the nonwoven fabric enters the horizontal detection area. The light sources are perpendicular to the surface of the nonwoven fabric, forming uniform frontal illumination. The horizontal light sources provide shadowless uniform illumination for the camera lens 10, ensuring consistent overall brightness on the material surface and avoiding false detections due to uneven illumination.
[0026] The light source mechanism 30 achieves multi-angle defect coverage and adapts to complex motion states. At the second roller 42, the non-woven fabric undergoes non-planar motion due to vertical turning; the low-angle illumination from the tilted light source reduces motion blur. At the horizontal section of the third roller 43, the material is flattened, and the horizontal light source provides stable illumination, ensuring image clarity. The tilted light source covers the curved area where the material rises, while the horizontal light source covers the horizontal detection plane, avoiding blind spots caused by height changes.
[0027] The support frame 4 fixedly installed above the main frame 1 is used to support a set of camera lenses 10 and a set of camera height adjustment modules 50. A connecting frame 5 is fixedly installed at the center of the right side of the support frame 4. The connecting frame 5 is composed of two sets of parallel and symmetrical I-shaped structural frames. A labeling machine component 20 is fixedly installed in the center of the two sets of I-shaped structural frames.
[0028] The labeling machine assembly 20 includes: two parallel connecting columns 21, a labeling machine adjustment device 23 evenly nested on the two connecting columns 21, a labeling machine mechanism 22 connected to the labeling machine adjustment device 23, and fasteners 24 fixedly installed at both ends of the connecting columns 21 for fixing the I-shaped structural frame.
[0029] The two parallel connecting columns 21 serve as the supporting structure for the entire labeling machine assembly, ensuring the stability of the labeling machine adjustment device 23 and the labeling machine mechanism 22 during operation. The labeling machine adjustment device 23 is evenly nested on the two connecting columns 21, allowing adjustment of the position of the labeling machine mechanism 22. This enables the labeling machine mechanism 22 to be flexibly adjusted according to the width of the non-woven fabric and the position of the label, ensuring that the label is accurately attached to the predetermined position. The labeling machine mechanism 22 is responsible for labeling areas with defects in the non-woven fabric.
[0030] The labeling machine mechanism 22 includes a label roll mechanism 221 located in the upper right corner, a first small roller 222 located in the central area, an optical sensor 223 fixedly installed at the entrance of the first small roller 222, a second small roller 224 located below the entrance of the first small roller 222, a label peeling plate 225 located diagonally below the second small roller 224, a third small roller 226 located behind the label peeling plate 225 and responsible for recycling the label paper, a fourth small roller 227 located diagonally above and to the left of the third small roller 226, and a label roll recycling mechanism 228 located in the upper left corner.
[0031] The labeling machine assembly 22, through the coordinated operation of multi-stage rollers and sensors, achieves precise label positioning, peeling, application, and backing paper recycling. Its core function is to automatically mark the location when a defect in the non-woven fabric is detected. Specifically, the label roll mechanism 221 is used to store unused label rolls (labels attached to the backing paper) and smoothly releases the label paper through tension control. The first small roller 222 serves as the main guide roller for the label paper, adjusting the direction of movement of the label paper to ensure that it enters the optical sensor area horizontally. The optical sensor 223 is used to detect gaps between adjacent label papers to determine the presence of a label paper, and when the camera lens 10 captures the defect location, it sends a signal to the control system to trigger the label peeling and application actions. The second small roller 224 forms a tension clamping area with the first roller 222, fixing the position of the label paper, and, in conjunction with the label peeling plate 225, peels the label from the backing paper. The third small roller 226 is used to guide the peeled backing paper into the recycling path and maintain the tension of the backing paper. The fourth small idler roller 227 further adjusts the path direction of the backing paper to ensure its smooth entry into the recycling roll mechanism 228. The recycling roll mechanism 228 is used to recycle the peeled backing paper, maintaining the continuity of label paper supply.
[0032] The label roll recycling mechanism 228 and the label roll mechanism 221 are driven in a linked manner, and speed matching is achieved through a servo motor to prevent paper breakage.
[0033] During the label peeling and labeling process, the synchronous control vision inspection system (camera lens 10) identifies defects and sends the coordinate information to the labeling machine. When the optical sensor 223 detects the label positioning mark (the gap between adjacent label sheets), it triggers the labeling mechanism to affix the label at the defect location.
[0034] This utility model discloses a nonwoven fabric visual inspection device with high-precision recognition: through a high-resolution camera, optical sensors, and AI algorithms, it can detect minute defects (such as holes, stains, and uneven fibers) that are difficult to detect with the naked eye, achieving micron-level accuracy. This eliminates human error and ensures the consistency and reliability of inspection results. Simultaneously, it improves production efficiency, handling real-time inspection on high-speed production lines (e.g., hundreds of meters per minute), significantly increasing inspection speed and adapting to the needs of large-scale industrial production. It replaces the traditional process relying on manual visual inspection, reducing reliance on skilled workers. Furthermore, through real-time defect location and classification, it promptly removes or marks for repair of defective products, avoiding raw material waste. Through high-standard defect inspection (e.g., for medical and hygiene nonwoven fabrics), it improves product qualification rates, meeting international quality certification requirements. This promotes the transformation of the nonwoven fabric industry from traditional manufacturing to intelligent manufacturing, enhancing the overall technological level of the industrial chain.
[0035] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims
1. A visual inspection device for nonwoven fabrics, characterized in that, include: The main frame (1) and the feet (2) and rollers (3) are fixedly installed at the bottom of the main frame (1). The roller assembly is arranged in sequence above the main frame (1) to tighten and unfold the nonwoven fabric. At the same time, the light source mechanism (30) is fixedly installed above the roller assembly. The support frame (4) is fixedly installed above the main frame (1). A set of camera lenses (10) is provided at the bottom of the main frame (1) and the top of the support frame (4). The camera lens (10) is fixedly connected to a set of camera height adjustment modules (50). The connecting frame (5) is fixedly installed on the right side of the support frame (4). The labeling machine assembly (20) is fixedly installed on the connecting frame (5).
2. The nonwoven fabric vision inspection apparatus according to claim 1, wherein The camera height adjustment module (50) includes a slider (501) connected to the camera lens (10) and a vertically placed slide rail (502).
3. The nonwoven fabric visual inspection equipment according to claim 1, characterized in that, The roller assembly arranged sequentially above the main frame (1) includes a first roller (41) fixedly arranged on the left side of the main frame (1), a second roller (42) vertically installed on the top of the main frame, a third roller (43) horizontally arranged on one side of the second roller (42), a fourth roller (44) horizontally arranged on the right side of the third roller (43) and slightly higher than the third roller (43), and a fifth roller (45) fixedly installed on the rightmost side of the main frame (1).
4. The nonwoven fabric visual inspection apparatus according to claim 1 or 3, wherein One set of light sources of the light source mechanism (30) is located below the camera lens (10) and is tilted above the second roller (42). The other set of light sources of the light source mechanism (30) is horizontally located above the third roller (43).
5. The nonwoven fabric vision inspection apparatus according to claim 1, wherein The connecting frame (5) consists of two sets of parallel and symmetrically arranged I-shaped structural frames, with the labeling machine component (20) fixedly installed in the center of the two sets of I-shaped structural frames.
6. The nonwoven fabric visual inspection apparatus according to claim 1 or 5, wherein The labeling machine assembly (20) includes: two parallel connecting columns (21), a labeling machine adjustment device (23) evenly nested on the two connecting columns (21), a labeling machine mechanism (22) connected to the labeling machine adjustment device (23), and fasteners (24) fixedly installed at both ends of the connecting columns (21) for fixing the I-shaped structural frame.
7. The nonwoven fabric vision inspection apparatus according to claim 6, wherein The labeling machine mechanism (22) includes a label roll mechanism (221) located in the upper right corner, a first small roller (222) located in the central area, an optical sensor (223) fixedly installed at the entrance of the first small roller (222), a second small roller (224) located below the entrance of the first small roller (222), a label peeling plate (225) located diagonally below the second small roller (224), a third small roller (226) located behind the label peeling plate (225) responsible for recycling the label paper, a fourth small roller (227) located diagonally above the left of the third small roller (226), and a label roll recycling mechanism (228) located in the upper left corner.