Filament oil content and wool fibre detection system

Abstract

The application provides a filament oil content and lint detection system, which comprises a support, a filament detection channel arranged on the support, an infrared detection device arranged at one end of the filament detection channel and used for emitting infrared rays to a detected filament and receiving infrared signals passing through the detected filament, a lint detection device arranged at the other end of the filament detection channel and used for collecting image signals of the detected filament, and a controller arranged on the support and connected with the infrared detection device and the lint detection device, which is used for determining the oil content of the detected filament and the length of the lint according to the received infrared signals and image signals. The application integrates the oil content detection and the lint detection, realizes the synchronous online monitoring of the key quality parameters of the filament, non-contact measures the oil content through the infrared transmission method, combines the image recognition technology to accurately detect the length of the lint, and improves the detection efficiency and accuracy.

Description

Technical Field

[0001] This utility model relates to the field of filament production and testing technology, specifically to a filament oil content and fuzz detection system. Background Technology

[0002] In the production of filaments, oil content and lint are key indicators that directly affect product quality. The oil content directly impacts the filament's frictional properties, antistatic ability, and the smoothness of subsequent textile processing. Excessive oil content can lead to fiber adhesion, while insufficient oil content can generate static electricity and cause filament breakage. Meanwhile, lint (i.e., loose, fine filaments on the fiber surface or at the ends) not only affects the appearance of the filament but can also increase the breakage rate during weaving, severely impacting product quality and production efficiency.

[0003] Currently, the detection of oil content and fuzziness in filaments is typically performed using independent equipment. Oil content detection generally relies on offline sampling followed by chemical extraction or weighing analysis in a laboratory. This method suffers from significant lag and cannot reflect the dynamic changes in oil content during production in real time, making it difficult to meet the needs of online quality control. Although some online oil content detection devices have adopted technologies such as infrared and microwave to achieve non-contact measurement, their functions are limited, only capable of monitoring oil content. On the other hand, fuzziness detection is mostly achieved through vision inspection systems, using light sources and image sensors to acquire images of the filament surface, thereby identifying and assessing fuzziness defects. However, these devices also operate independently and have no data correlation with the oil content detection system.

[0004] In existing technologies, multiple testing devices need to be installed in parallel on the production line, which takes up a lot of space, increases the complexity of equipment layout, and interferes with the production process. Furthermore, since the oil content and lint detection systems are independent of each other, the test data are scattered and lack a unified data processing platform, making it impossible to achieve synchronous acquisition and correlation analysis of multiple parameters, which is not conducive to a comprehensive and holistic evaluation of product quality.

[0005] Therefore, there is an urgent need to develop an integrated testing device that combines online detection of filament oil content and online detection of filament fibers, so as to achieve synchronous, real-time and efficient monitoring of key quality parameters, improve the integration and intelligence level of the testing system, and meet the needs of modern filament production for high-quality and high-efficiency online quality control. Summary of the Invention

[0006] To address the aforementioned problems in the prior art, the purpose of this paper is to provide a filament oil content and fuzz detection system, thereby solving the problem that the existing oil content and fuzz detection equipment are independent of each other, requiring multiple devices to be installed in parallel on the production line.

[0007] To solve the above-mentioned technical problems, the specific technical solution presented in this paper is as follows: This article provides a system for detecting the oil content and fuzziness of filaments, including: support; A filament detection channel is provided on the bracket; An infrared detection device is installed at one end of the filament detection channel to emit infrared rays to the filament being tested and to receive infrared signals passing through the filament being tested. A filament detection device is located at the other end of the filament detection channel and is used to acquire image signals of the filament being tested. A controller, mounted on the bracket and connected to the infrared detection device and the filament detection device, is used to determine the oil content and filament length of the filament being tested based on the received infrared signal and the image signal.

[0008] Furthermore, the support includes a vertical fixing frame and a horizontal fixing frame, the filament detection channel is disposed on the horizontal fixing frame, and the filament detection channel is parallel to the vertical fixing frame.

[0009] Furthermore, the controller is located at one end of the transverse fixing frame.

[0010] Furthermore, the hair detection device includes: a light source and an image sensor respectively connected to the controller; The light source is used to illuminate the filament, and the image sensor is used to acquire the image signal of the filament after it has been illuminated, and send the image signal to the controller.

[0011] Furthermore, the image sensor is a CCD camera.

[0012] Furthermore, the infrared detection device includes: an infrared transmitter and an infrared receiver respectively connected to the controller. The infrared transmitter and the infrared receiver are located on opposite sides of the filament being measured.

[0013] Furthermore, the infrared emitter emits infrared light with a wavelength of 2.7 μm to 3.0 μm.

[0014] Furthermore, it also includes: an alarm, which is connected to the controller and is used to issue an alarm after receiving an alarm signal sent by the controller.

[0015] Furthermore, the alarm includes: an audible prompting component and / or an optical prompting component.

[0016] Furthermore, it also includes: a human-computer interaction device, which is connected to the controller and is used to input parameters and display detection results.

[0017] The technical solution provided in this application integrates oil content detection and filament detection into one unit, enabling simultaneous online monitoring of key filament quality parameters. Oil content is measured non-contactly using infrared transmission method, combined with image recognition technology for precise filament length detection, improving detection efficiency and accuracy. The integrated design saves space, reduces equipment costs, facilitates production line layout and unified data management, and helps in the timely detection of quality problems, thereby improving product quality control.

[0018] To make the above and other objects, features and advantages of this document more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments or prior art described herein, the accompanying drawings used in the description of the embodiments or prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this article. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This paper presents a topological schematic diagram of a filament oil content and filament detection system according to an embodiment of the invention. Figure 2 This paper presents a schematic diagram of a filament oil content and fuzz detection system according to an embodiment of the invention. 1-Staff; 2-Fiber detection channel; 3-Infrared detection equipment; 4- Wool detection equipment; 5-Controller; 6-Alarm; 7-Human-computer interaction devices; 11-Vertical fixing bracket; 12-Horizontal fixing bracket; 31-Infrared emitter; 32-Infrared receiver; 41-Light source; 42 - Image sensor. Detailed Implementation

[0021] The technical solutions in the embodiments described below will be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments described herein, and not all of the embodiments. Based on the embodiments described herein, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this document.

[0022] It should be noted that the terms "first," "second," etc., used in the specification, claims, and accompanying drawings herein are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, apparatus, product, or device that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or devices.

[0023] To solve the above problems, such as Figure 1 and Figure 2 As shown, this application provides a filament oil content and fuzz detection system, including: a support 1, a filament detection channel 2, an infrared detection device 3, a fuzz detection device 4, a controller 5, an alarm 6, and a human-machine interface device 7. This system can be applied in industries such as chemical fibers and textiles to detect the oil content and presence of fuzz defects in filaments in real time during filament production or processing, and to issue timely warnings for abnormalities, thereby improving product quality control.

[0024] The bracket 1 serves as the support structure for the entire system, used to fix and install other functional components. In this embodiment, the bracket 1 may include a vertical fixing frame 11 and a horizontal fixing frame 12. The vertical fixing frame 11 is set perpendicular to the ground and is made of high-strength metal material to ensure the stability and vibration resistance of the overall structure. The horizontal fixing frame 12 is horizontally set above the vertical fixing frame 11 and is firmly connected to it, forming an "L"-shaped support structure. The filament detection channel 2 is installed on the horizontal fixing frame 12, and its extension direction is parallel to the vertical fixing frame 11, that is, the filament detection channel 2 is arranged horizontally. The horizontal fixing frame 12 is provided with multiple mounting holes and a slide rail structure to facilitate the adjustment of the position of the filament detection channel 2 to adapt to the detection needs of filaments with different diameters or tensions.

[0025] The filament detection channel 2 is a hollow tubular structure, forming an internal space for the filament to pass through. The inner wall of this channel is smooth to prevent scratches or friction on the filament surface. Guide wheels or guide rings are provided at both ends of the channel to guide the filament accurately into the detection area and maintain its stable trajectory. The length of the filament detection channel 2 is set according to the actual detection accuracy requirements; in this embodiment, it is approximately 30 cm, sufficient to accommodate the space required for infrared detection and image acquisition.

[0026] An infrared detection device 3 is installed at one end of the filament detection channel 2. This device is used to detect the oil content of the filament. The infrared detection device 3 may include an infrared emitter 31 and an infrared receiver 32, which are respectively arranged on both sides of one end of the filament detection channel 2 and are opposite to each other. The infrared emitter 31 emits infrared light of a specific wavelength into the filament being tested, and the infrared light is received by the infrared receiver 32 located on the opposite side after passing through the filament.

[0027] Specifically, the infrared emitter 31 uses a wavelength-tunable infrared light source, with its emission wavelength range set between 2.7 μm and 3.0 μm. This band precisely covers the characteristic absorption peaks of CH and OH bonds in oily substances, especially the strong absorption band near 2.8 μm, making it extremely sensitive to oil. In this embodiment, the operating wavelength of the infrared emitter 31 is fixed at 2.85 μm to obtain optimal detection sensitivity. The infrared emitter 31 is connected to the controller 5 via a circuit, and the controller 5 controls its start / stop and emission intensity adjustment. The infrared receiver 32 is a high-sensitivity infrared photodetector, such as an InGaAs detector, which has a good signal-to-noise ratio and fast response capability. The receiver converts the received optical signal into an electrical signal and transmits it to the controller 5 for processing in real time.

[0028] When the filament passes through the detection channel, if its surface oil content is high, the infrared light will be partially absorbed by the oil film as it passes through the filament, resulting in a weakened transmitted light intensity; conversely, if the oil content is low, the transmitted light will be stronger. The controller 5 pre-stores transmittance data of standard oil content samples. By comparing the current measured transmittance with the standard curve, the actual oil content of the filament being measured can be calculated. To improve measurement accuracy, the system can also be configured with a temperature compensation module to eliminate the influence of ambient temperature changes on infrared detection.

[0029] At the other end of the filament detection channel 2, a fuzz detection device 4 is installed to identify whether the filament has fuzz (i.e., scattered fine filaments formed after fiber breakage) and its length. Fuzz can affect the quality of subsequent weaving processes, so timely detection is crucial. The fuzz detection device 4 includes a light source 41 and an image sensor 42, both of which are electrically connected to the controller 5.

[0030] A light source 41 is positioned on one side of the filament to provide uniform illumination to the filament under test. In this embodiment, the light source 41 is a high-brightness LED cold light source with a color temperature of approximately 6500K, close to natural white light, which effectively highlights the surface details of the filament. The illumination angle of the light source is adjustable, preferably incident at a 45-degree angle to enhance the shadow effect on the edges of the filaments, facilitating image recognition. Simultaneously, the light source has a constant current drive circuit to ensure stable light intensity and avoid image brightness changes caused by voltage fluctuations.

[0031] Image sensor 42 is positioned on the side opposite to light source 41 and is used to acquire image signals of the irradiated filament. In this embodiment, image sensor 42 is a CCD (charge-coupled device) camera with a resolution of 2048×1536 pixels and a frame rate of up to 120fps, meeting the real-time inspection requirements of high-speed production lines. CCD cameras have the advantages of wide dynamic range, clear imaging, and low noise, making them particularly suitable for capturing minute defects. The camera lens is equipped with autofocus and zoom functions and is fitted with a filter to remove stray light interference. Image sensor 42 communicates with controller 5 through an industrial camera interface (such as GigE Vision or CameraLink), transmitting the acquired raw image data to controller 5 in real time.

[0032] The controller 5 is mounted at one end of the horizontal mounting bracket 12 for easy wiring and maintenance. The controller 5 adopts an embedded industrial computer structure, with a built-in high-performance processor (such as an Intel Core i7 or ARM multi-core chip), large-capacity memory, and a real-time operating system. Internally, it integrates a data acquisition card, a communication interface module, and an image processing algorithm engine. The controller 5 is connected to the infrared transmitter 31, infrared receiver 32, light source 41, image sensor 42, alarm 6, and human-machine interface device 7 via signal lines, enabling the coordinated operation of all components.

[0033] After receiving the transmitted photoelectric signal from the infrared receiver 32, the controller 5 first performs analog-to-digital conversion and signal filtering, and then calculates the current oil content value of the filament according to the preset oil content calibration model. This calibration model can be established experimentally: take several standard samples with known oil content, measure their transmittance under the same conditions, fit the nonlinear relationship curve between oil content and transmittance (such as polynomial fitting or neural network model), and store it in the controller 5.

[0034] For image signal processing, controller 5 runs image analysis algorithms, mainly including image preprocessing, edge detection, morphological operations, and feature extraction. First, the received raw image is converted to grayscale, denoised (e.g., by median filtering), and contrast enhanced. Then, edge detection is performed using Canny or Sobel operators to identify the main filament outline and possible filament branches. Next, morphological methods such as opening and closing operations are used to remove isolated noise points and connect broken edges. Finally, connected component analysis is used to determine the number, position, and length of the filaments. The filament length is defined as the maximum projected distance of the fine filaments extending from the edge of the main filament, in millimeters. Controller 5 compares the identification results with a preset threshold; if the filament length exceeds the allowable range (e.g., greater than 2 mm), it is deemed unqualified.

[0035] To further improve detection reliability, the system can employ multi-view imaging technology. For example, multiple light sources and CCD cameras can be arranged around the filament to capture images from different angles. Then, an image fusion algorithm can be used to comprehensively determine the state of the filament, reducing the false detection rate.

[0036] Alarm 6 is connected to controller 5 and is used to issue a warning signal when an abnormality is detected. When controller 5 determines that the oil content of the filament exceeds the set range (e.g., below 0.8% or above 1.5%), or detects that the filament length exceeds the threshold, it immediately sends an alarm signal to alarm 6. Alarm 6 activates upon receiving the signal, alerting the operator to intervene promptly.

[0037] In this embodiment, the alarm 6 includes an audible alert component and an optical alert component. The audible alert component is a buzzer or speaker that can emit different frequencies of beeping sounds; for example, short, continuous beeps indicate abnormal oil content, while long, intermittent beeps indicate excessive lint. The optical alert component is a multi-color LED warning light, typically displaying red, yellow, and green: green indicates normal operation, yellow indicates minor deviation (warning), and red indicates a serious malfunction (shutdown). The combination of these two alert methods ensures effective communication of warning information even in noisy environments.

[0038] In addition, alarm signals can be uploaded to the factory's central control system (such as MES or SCADA system) via communication interface to achieve remote monitoring and data traceability.

[0039] The human-computer interaction device 7 is connected to the controller 5, providing operators with a parameter setting and result display interface. In this embodiment, the human-computer interaction device 7 is a touch screen all-in-one machine, integrated on the outside of the bracket 1 for easy operation. The screen size is 10.1 inches, with a resolution of 1280×800, and supports multi-touch. Its software interface is divided into multiple functional modules: Parameter setting module: Allows users to set parameters such as upper and lower limits of oil content, alarm threshold for hair length, detection speed, light source brightness, and camera exposure time; Real-time monitoring module: Dynamically displays the current oil content, fiber distribution, and trend changes in the form of numbers, graphs, or pseudo-color images; Historical records module: Stores and queries test data over a period of time, supporting retrieval by time, batch, or product model; Alarm log module: Records the time, type, parameter value, and processing status of each alarm, facilitating quality analysis and accountability. System settings module: Provides functions such as user permission management, language switching, time calibration, and communication configuration.

[0040] The human-computer interaction device 7 also supports exporting data via USB interface, or sending the test report to a designated email address or server via Ethernet / Wi-Fi.

[0041] In practical applications, the operation procedure of this detection system is as follows: After powering on, the system performs a self-check to ensure that all components are functioning properly, including light source brightness, camera focus, and infrared signal strength. Operators input relevant parameters for this production task through the human-machine interface device 7, such as filament type, target oil content, and filament tolerance. Start the production line, and the filaments pass through the filament detection channel 2 at a constant speed (e.g., 200m / min); Infrared detection device 3 continuously emits and receives infrared signals, and controller 5 calculates oil content in real time; The hair detection device 4 synchronously acquires images, and the controller 5 performs image analysis to identify hairs; If the test results are within the normal range, the system will keep the green indicator light on and the data will be recorded automatically. If an abnormality occurs, the controller 5 will trigger the alarm 6 to issue an audible and visual alarm and display a fault message on the human-machine interface. Operators can check the equipment's operating status or adjust process parameters according to the prompts; After the test is completed, the system generates a test report, which can be viewed or exported through the human-computer interaction device 7.

[0042] To ensure detection accuracy, the system requires periodic calibration. The oil content detection section can be calibrated using a standard oil film, while the filament detection section is verified using simulated filament samples with artificial defects of known length. Calibration data is stored in controller 5, and an expiration date reminder is set.

[0043] The solution provided in this application integrates filament oil content detection and filament defects detection into a single unit, enabling online real-time synchronous monitoring, saving equipment space, and simplifying production line layout. It utilizes non-contact infrared transmission to measure oil content, combined with high-resolution image recognition technology for precise detection of filament defects, resulting in high efficiency and accuracy. The system features audible and visual alarms and human-machine interaction functions, enabling timely detection of quality anomalies, facilitating rapid adjustment of production parameters, effectively improving product quality control, and reducing equipment maintenance and management costs.

[0044] It should also be understood that, in the embodiments herein, the term "and / or" is merely a description of the relationship between associated objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following associated objects have an "or" relationship.

[0045] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this document.

[0046] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0047] In the embodiments provided herein, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and 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 couplings or direct couplings or communication connections shown or discussed may be indirect couplings or communication connections through some interfaces, apparatuses, or units, or they may be electrical, mechanical, or other forms of connection.

[0048] 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 the embodiments described herein, depending on actual needs.

[0049] This document uses specific embodiments to illustrate the principles and implementation methods of this document. The descriptions of the embodiments above are only for the purpose of helping to understand the methods and core ideas of this document. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this document. Therefore, the content of this specification should not be construed as a limitation of this document.

Claims

1. A system for detecting oil content and fuzziness in filaments, characterized in that, include: support; A filament detection channel is provided on the bracket; An infrared detection device is installed at one end of the filament detection channel to emit infrared rays to the filament being tested and to receive infrared signals passing through the filament being tested. A filament detection device is located at the other end of the filament detection channel and is used to acquire image signals of the filament being tested. A controller, mounted on the bracket and connected to the infrared detection device and the filament detection device, is used to determine the oil content and filament length of the filament being tested based on the received infrared signal and the image signal.

2. The filament oil content and fuzz detection system according to claim 1, characterized in that, The support includes a vertical fixing frame and a horizontal fixing frame. The filament detection channel is disposed on the horizontal fixing frame and is parallel to the vertical fixing frame.

3. The filament oil content and fuzz detection system according to claim 2, characterized in that, The controller is located at one end of the horizontal fixing frame.

4. The filament oil content and fuzz detection system according to claim 1, characterized in that, The hair detection device includes a light source and an image sensor, which are respectively connected to the controller. The light source is used to illuminate the filament, and the image sensor is used to acquire the image signal of the filament after it has been illuminated, and send the image signal to the controller.

5. The filament oil content and fuzz detection system according to claim 4, characterized in that, The image sensor is a CCD camera.

6. The filament oil content and fuzz detection system according to claim 1, characterized in that, The infrared detection device includes an infrared transmitter and an infrared receiver, which are respectively connected to the controller. The infrared transmitter and the infrared receiver are located on opposite sides of the filament being measured.

7. The filament oil content and fuzz detection system according to claim 6, characterized in that, The infrared emitter emits infrared light with a wavelength of 2.7 μm to 3.0 μm.

8. The filament oil content and fuzz detection system according to claim 1, characterized in that, Also includes: An alarm, connected to the controller, is used to issue an alarm upon receiving an alarm signal from the controller.

9. The filament oil content and fuzz detection system according to claim 8, characterized in that, The alarm includes: an audible alert component and / or an optical alert component.

10. The filament oil content and fuzz detection system according to claim 9, characterized in that, Also includes: A human-computer interaction device is connected to the controller and is used to input parameters and display detection results.

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