Fabric quality control method and system, electronic device, and storage medium

Abstract

The present application relates to the technical field of automatic control, and in particular to a fabric quality control method and system, an electronic device, and a storage medium. The method comprises: S1, on the basis of order information, matching and selecting historical production data to determine actual production parameters; S2, monitoring the actual production parameters and fabric surface conditions; S3, setting a fabric inspection function with a corresponding number of revolutions, and controlling a production device to rotate the corresponding number of revolutions and then stopping operation; S4, monitoring and recording the service cycles of accessories; and S5, carrying out weight measurement on a produced fabric, and obtaining image data of the produced fabric. The present application has the effect of investigating factors affecting fabric defects so as to improve the fabric production efficiency and yield.

Description

A cloth quality control method, system, electronic device and storage medium Technical Field

[0001] The present application relates to the field of automatic control technology, and in particular to a cloth quality control method, system, electronic device and storage medium. Background Art

[0002] In the textile industry, the cloth produced may have defects, which requires checking each link in the production process to find out the problem. Traditionally, manual visual inspection is the most common way to control cloth quality. Generally, the machine operator checks whether there are defects in the grey cloth on the production equipment during the inspection. However, since a machine operator is in charge of multiple production equipment at the same time, it is easy to miss inspections, and there are many factors that affect the defects of cloth. Simply relying on manual inspection of each production link one by one, finding problems and taking corresponding solutions to correct them, this series of processes requires a lot of manpower and time costs, which not only reduces the efficiency of the inspection, but also easily leads to missed inspections, resulting in low accuracy, thus affecting the production efficiency of cloth production companies. Summary of the Invention

[0003] In order to identify the factors that affect cloth defects and make corresponding adjustments to production, improve cloth production efficiency and increase the yield rate, this application provides a cloth quality control method, system, electronic equipment and storage medium.

[0004] In the first aspect, the present application provides a method for controlling the quality of cloth, which adopts the following technical solutions:

[0005] A cloth quality control method, comprising:

[0006] S1. Based on order information, match and filter historical production data to determine actual production parameters;

[0007] S2. Monitor actual production parameters and fabric conditions;

[0008] S3. Set the cloth checking function for the corresponding number of turns to control the production equipment to stop running after the corresponding number of turns;

[0009] S4. Monitor and record the usage cycle of accessories;

[0010] S5. Perform weight detection on the produced cloth and obtain image data of the produced cloth.

[0011] By adopting the above technical solution, historical production data is matched against orders to be put into production, and the actual production parameters of the cloth for the order are determined. When producing the same type of cloth, the staff can be provided with a reference for cloth production parameters. During the cloth production process, the actual production parameters, cloth surface defects and cloth weight are monitored, and cloth abnormalities are discovered and adjusted in time. The completed cloth is analyzed based on image data, and the cloth is quality-checked again to ensure that every link before, during and after the cloth production is traceable, thereby making the cloth quality stable and controllable, reducing the defective rate and improving production efficiency.

[0012] Preferably, the monitoring of actual production parameters and fabric conditions includes the following steps:

[0013] Preset production parameter ranges based on matched historical production data;

[0014] Determine whether the actual production parameters are within the allowable range. If the actual production parameters exceed the preset production parameter range, an alarm will be issued and the production equipment will be controlled to stop running and check the fabric.

[0015] By adopting the above technical solution, the historical production data that meets the requirements is analyzed according to the needs of different orders, so as to more accurately determine the actual production parameters, reduce the situation where production parameter errors due to factors such as human error, and control the production parameters in real time, thereby improving the efficiency of production adjustments.

[0016] Preferably, the monitoring of actual production parameters and fabric conditions includes the following steps:

[0017] Preset defect detection threshold range and defect type deduction score;

[0018] Make score deductions and record the fabric surface;

[0019] Compare all recorded deduction score data with the preset defect detection threshold range to determine whether the production equipment should stop running.

[0020] By adopting the above technical solution, the score of the fabric is deducted by the preset defect type deduction score, and the score is compared with the defect detection threshold range. The fabric condition is timely monitored during the fabric production process. If defects appear on the fabric, the problem can be discovered as early as possible to avoid wasting resource costs by continuing production when defects have already occurred.

[0021] Preferably, the preset defect detection threshold range is a score range that is deducted according to the defect type, and the defect detection threshold range includes a high-quality product range, a good product range, and a poor product range.

[0022] By adopting the above technical solution and presetting the defect detection threshold range, it is easy to determine the quality of the produced cloth.

[0023] Preferably, the setting of the cloth checking function for the corresponding number of revolutions and controlling the production equipment to stop running after rotating the corresponding number of revolutions comprises the following steps:

[0024] Obtaining a single length value corresponding to each type of thread required to produce the cloth, a unit length value of each type of thread required to complete each unit pattern, a pattern length value of each unit pattern, and a cloth length value for each roll of cloth; and determining a circle array required to complete each roll of cloth based on the single length value, the unit length value, the pattern length value, and the cloth length value, wherein the circle array sequentially stores the number of rotations required for each rotation;

[0025] When the production equipment rotates to the current corresponding number of revolutions, it automatically stops running;

[0026] When the production equipment stops running, the cloth is inspected to determine whether adjustment is needed. If no adjustment is needed, the production equipment is started. If adjustment is needed, the production equipment is started after processing according to the condition of the cloth.

[0027] By adopting the above technical solution, the number of rotations required for each line change of the production equipment is determined by the single length value, unit length value, pattern length value and cloth length value, and a circle array is formed, so that the production equipment is stopped only when the line change is required during the cloth production process. On the one hand, it can reduce the occurrence of cloth quality reduction due to line change. On the other hand, it can also allow the machine operator to check the cloth surface during the line change, reducing the occurrence of production efficiency affected by the production equipment stopping for an additional fixed number of rotations, that is, indirectly ensuring the quality and efficiency of the produced cloth. And when the production equipment stops running, the staff can check the cloth surface to ensure that each cloth is fully inspected or processed in a timely manner.

[0028] Preferably, the monitoring and recording of the use cycle of the accessories includes the following steps:

[0029] Number the accessories required for cloth production and record the usage cycle and replacement time of the accessories;

[0030] Read the accessory record information to determine whether the accessory has reached the replacement period.

[0031] By adopting the above technical solutions to monitor accessories, companies can promptly detect accessory problems and take corresponding measures without affecting actual cloth production, thereby improving product quality and production efficiency.

[0032] Preferably, the weight detection of the produced cloth includes the following steps:

[0033] Determine a set of deduction defects existing in the cloth based on all recorded deduction score data, and determine a standard weight range corresponding to the cloth based on the set of deduction defects;

[0034] Weigh the cloth and record the weight.

[0035] The weight of the cloth is compared with the standard weight range. If the weight of the cloth exceeds the standard weight range, it is considered abnormal cloth and the operator checks various production parameters.

[0036] By adopting the above technical solution, the standard weight range corresponding to each roll of cloth is first determined based on the actual defects found, making the determined standard weight range more accurate. The weight test results of the completed cloth are then compared with the standard weight range, thereby more accurately analyzing whether the cloth meets the production standards. This allows for timely identification and resolution, adjustment of production plans, and ensuring timely delivery of cloth. The finished cloth is then weighed and tested, and the weighing results can be used to determine whether there are any production parameter adjustments errors, such as density, thereby controlling the quality of the cloth.

[0037] In a second aspect, the present application provides a cloth quality control system, which adopts the following technical solutions:

[0038] A cloth quality control system, comprising:

[0039] Control module, used to control the input and output of the cloth quality control system;

[0040] a data processing module connected to the control module, configured to receive control signals from the control module, perform matching analysis on the order information and the historical production data, and transmit the matching analysis results to the control module;

[0041] A monitoring module, connected to the control module, for receiving control signals from the control module, monitoring the cloth during the production process, and transmitting monitoring results to the control module;

[0042] The image processing module is connected to the control module, and is used to receive the control signal of the control module, obtain the image data of the cloth produced, analyze the cloth through the image data, and transmit the analysis result to the control module.

[0043] By adopting the above technical solution, the quality of cloth can be controlled through the control module, data processing module, monitoring module and image processing module.

[0044] Preferably, the monitoring module includes:

[0045] Parameter monitoring unit, used to monitor actual production parameters;

[0046] The fabric surface monitoring unit is used to monitor the fabric surface condition during the production process.

[0047] By adopting the above technical solution, the actual production parameters are monitored through the parameter monitoring unit, so that the cloth production quality is not affected by parameter errors, and the cloth surface monitoring unit can detect and deal with defects in time.

[0048] Preferably, the fabric surface monitoring unit includes:

[0049] The revolution monitoring subunit is used to preset the revolution number of the production equipment and control the production equipment to stop running after it has rotated to the preset number of revolutions;

[0050] Accessory monitoring subunit, used to monitor and record the usage cycle of accessories;

[0051] The weight monitoring subunit is used to detect and record the weight of the finished cloth.

[0052] By adopting the above technical solution, the monitoring of cloth during and after production is achieved through the circle monitoring subunit, the accessories monitoring subunit and the weight monitoring subunit.

[0053] Compared with the related art, the embodiments of the present application provide a cloth quality control method, system, electronic device and storage medium, which realize intelligent monitoring of cloth before, during and after production. By matching historical data with order information, and screening and analyzing, as well as monitoring and processing the cloth surface condition, accessories, weight and other aspects, abnormal situations can be discovered and handled in a timely manner. It not only optimizes the cloth production process and makes the entire cloth production process traceable, but also ensures the stability of cloth quality and improves the yield rate. Moreover, by controlling the cloth quality and making timely adjustments, it reduces the situation where delivery is affected by cloth quality problems, can greatly shorten the production cycle, ensure the delivery period, and improve cloth production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0054] FIG1 is a flow chart of a method for controlling cloth quality according to an embodiment of the present application;

[0055] FIG2 is a flowchart of step S1 in the cloth quality control method according to an embodiment of the present application;

[0056] FIG3 is a flowchart of step S2 in the cloth quality control method according to an embodiment of the present application;

[0057] FIG4 is a structural block diagram of the cloth quality control system according to an embodiment of the present application.

[0058] Explanation of the accompanying drawings: 1. Control module; 2. Data processing module; 21. Matching unit; 22. Analysis unit; 3. Monitoring module; 31. Parameter monitoring unit; 32. Fabric monitoring unit; 321. Number of laps monitoring subunit; 322. Accessory monitoring subunit; 323. Weight monitoring subunit; 4. Image processing module. DETAILED DESCRIPTION

[0059] The present application is further described in detail below with reference to Figures 1 to 4.

[0060] Although certain embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be construed as limited to the embodiments described herein. Instead, these embodiments are provided to provide a more thorough and complete understanding of the present disclosure. It should be understood that the drawings and embodiments of the present disclosure are for illustrative purposes only and are not intended to limit the scope of protection of the present disclosure.

[0061] To make the purpose, technical solutions, and advantages of the embodiments of this application more clear, the technical solutions in the embodiments of this application will be clearly and completely described below in conjunction with the drawings in the embodiments of this application. Obviously, the described embodiments are part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0062] 1 , 2 and 3 , a cloth quality control method disclosed in the present application, which is applied in cloth production, includes the following steps:

[0063] S1. Based on order information, match and filter historical production data to determine actual production parameters.

[0064] Specifically, a production plan is created based on the received cloth production order information. The order information includes the type, specifications and data of the cloth, and may also include the cloth type, production equipment parameters, raw material parameters, process information, gram weight parameters, width parameters, reasonable loop weight, average unit output, abnormal update information, etc. The historical production data is matched, and historical production data similar to the current order is found by screening, comparing and counting all historical production data. That is, the matched historical production data is cleaned and outliers or unreliable data are removed to ensure data quality. Then, according to the characteristics and requirements of the current order, similar historical data are screened. For example, historical data with similar conditions such as the same specifications, yarn density and fabric type are selected, and the screened historical production data are analyzed to determine the actual production parameters for the machine operator to refer to, so as to ensure the production of cloth that meets the order requirements. In this application, historical data is screened using a big data algorithm. That is, by continuously collecting information on cloth production orders during the production process, a big data model is formed to form a variety of vector process models based on cloth name, width, weight, machine model, and process parameters. Data comparison and model matching are performed when new orders are entered, providing production parameter reference suggestions for the machine operator, and issuing reminders when large differences appear in the data comparison.

[0065] Among them, historical production data includes the following:

[0066] Production parameters, including yarn density and loom speed;

[0067] Production time and equipment: record the production time and equipment used to produce each piece of cloth in order to trace and troubleshoot problems.

[0068] The above step S1 further includes:

[0069] S11. Analyze the selected historical production data.

[0070] Specifically, the screened historical production data are compared to find out the similarities and differences between the screened historical production data, and statistical analysis is performed on the historical production data from multiple aspects such as production parameters and test results. During the statistical analysis process, data mining or machine learning algorithms can be used to assist the analysis, so as to predict the optimal setting values ​​of the production parameters for reference by the operator.

[0071] For example, suppose a manufacturer needs to produce a batch of wool blended fabric with specifications of 140cm×100m, a density of 30 / 2S×16, a weight of 320GSM, and a dark gray color. By matching historical production data, 18 historical production data items similar to the order information are obtained. These 18 historical production data items need to be compared, including loom speed, revolutions, etc. After comparison, it is found that the production parameters of most historical production data items are similar, but there are also a few outliers. Therefore, further screening and removal of outliers are carried out to determine the appropriate production parameters. The test results of historical production data similar to the order are then compared. If the test results of the historical production data meet the requirements, they can be used as a reference to determine the optimal test standards. If the test results of the historical production data are different, the reasons for the differences need to be further analyzed and the production parameters or test standards need to be adjusted accordingly to promptly correct the problems in the production process.

[0072] S2. Monitor actual production parameters and fabric conditions.

[0073] Specifically, during the production process of the cloth, the actual production parameters and the condition of the cloth are monitored so that the workers can promptly discover and correct problems that arise during the production process. This method can also effectively detect defects in the cloth and ensure product quality.

[0074] The above step S2 further includes:

[0075] S21. Preset a production parameter range based on the matched historical production data, and determine whether the actual production parameters exceed the preset production parameter range.

[0076] Specifically, based on matched historical production data, production parameter ranges are pre-set before different fabrics are put into production. For example, for textiles, appropriate production parameter ranges for temperature, humidity, yarn density, and other parameters can be preset. Furthermore, monitoring equipment, such as sensors and testing instruments, is installed on production equipment to continuously monitor actual production parameters and determine whether they exceed the preset ranges. Whenever actual production parameters change, they are automatically compared with the preset ranges to determine whether they are within the permitted range. If they exceed the range, an alarm is issued and the production equipment is shut down. For example, suppose a fabric manufacturer needs to produce a batch of blended fabric with a required blend ratio of 40% cotton and 60% polyester. To ensure fabric quality, preset production parameter ranges are established before production begins, including a temperature range of 120°C to 140°C, a humidity range of 50% to 70%, and a yarn density range of 10s to 60s. During actual production, monitoring equipment monitors production parameters in real time and compares them with the preset ranges. If it is found that the actual production parameters are outside the preset range, such as the temperature is too high or the humidity is too low, an alarm will be issued immediately and the production equipment will be stopped to notify the operator to promptly investigate the problem, thereby reducing product quality problems and safety risks caused by abnormal production parameters.

[0077] S22. Preset a defect detection threshold range, deduct points based on the defect type, and determine whether the production equipment should stop running.

[0078] Specifically, before production begins, manufacturers need to set a defect detection threshold range, or the deduction score range. This range includes a superior, good, and poor quality range to determine whether the fabric produced is superior, good, or poor quality. The defect detection threshold range can be adjusted based on actual fabric production conditions. Deduction scores are also preset for each defect type, including holes, staining, pilling, and loose threads. Each defect type is assigned a corresponding deduction score, and different defect types receive different deductions based on their severity. During the fabric production process, optical sensors, high-resolution cameras, and other equipment monitor the fabric surface in real time to determine if there are any defects or which defects are present. A score is deducted and recorded for each defect type. The recorded data is then transmitted to a computer system for processing and analysis. The deduction scores for all defect types are compared with the preset defect detection threshold ranges to determine which defect detection threshold range the total deduction score falls within. This determines the quality of the fabric. When the deduction score falls within the good or poor quality range, production equipment is stopped.

[0079] For example, suppose a fabric company wants to produce a batch of wool blended fabrics. The manufacturer has established a defect detection threshold range of 0-20 points for excellent products, 20-40 points for good products, and 40-60 points for poor products. The defect types are 10 points for holes, 5 points for stains, and 2 points for pilling and thread ends. During the production process, the fabric surface is monitored in real time by a high-resolution camera, and the monitoring situation is transmitted to the computer system for processing and analysis. Points are deducted for each defect type. Among them, if one hole, stain, pilling, and thread end is detected on the fabric, it is considered to be deducted 19 points. The total deduction score is compared with the preset defect detection threshold range. If the deduction score is between 0-20 points, the fabric is judged to be excellent. If two holes, two stains, three pillings, and three thread ends are detected on the fabric, it is considered to be deducted 42 points. If the deduction score is between 40-60 points, the fabric is judged to be poor quality, and the production equipment is stopped for further inspection by the machine operator.

[0080] S3. Set the cloth checking function for the corresponding number of turns to control the production equipment to stop running after rotating the corresponding number of turns.

[0081] Specifically, during the cloth production process, it often takes several days to complete the production of a single piece of cloth. If a unified quality inspection is conducted after the cloth is produced, it will not only increase the workload of the cloth stopper, but also if the cloth is found to be unqualified after the cloth is produced, the corresponding cloth order will not be delivered on time. Therefore, during the cloth production process, the production equipment needs to be stopped several times. At this time, the cloth stopper will inspect the cloth on the production equipment. Based on the inspection results, the cloth stopper will decide whether to continue processing the cloth or make adjustments to the cloth. The production equipment is equipped with a card swiping device. The cloth stopper can place his employee card or other authorized card on the card swiping device to control the start and stop of the production equipment. When the production equipment stops, the cloth stopper checks the cloth surface and determines whether the produced cloth needs to be adjusted. If no adjustment is required, the cloth stopper can swipe the card to start the production equipment and continue production. If adjustment is required, the cloth stopper takes appropriate measures based on the actual situation of the cloth surface. The cloth stopper swipes the card to start the production equipment for processing and production. The inspection results and all the operation information of the cloth stopper are recorded for future reference.

[0082] Among them, the basis for each stoppage of the production equipment is that a certain type of thread needs to be changed during the cloth production process, and by setting the number of revolutions that the production equipment needs to rotate each time, the production equipment stops running each time it reaches the set number of revolutions. In this way, when the production equipment is stopped, it can not only achieve a smoother and more accurate thread change operation, reduce the occurrence of poor thread change effects due to rapid thread change, and reduce the occurrence of fabric quality reduction due to thread change when the equipment is operating normally; but also allow the operator to check the condition of the fabric surface during the interval of changing the thread that is about to be used up, thereby completing the detection of fabric quality during the production process without affecting the actual production efficiency of the fabric.

[0083] Specifically determining the number of revolutions that the production equipment needs to rotate each time includes: obtaining the single length value corresponding to each type of thread required to produce the cloth, the unit length value of each type of thread required to complete each unit pattern, the pattern length value of each unit pattern and the cloth length value of each roll of cloth, and determining the circle array required to complete each roll of cloth based on the single length value, unit length value, pattern length value and cloth length value, wherein the circle array sequentially stores the number of revolutions required each time; when the production equipment rotates to the current corresponding number of revolutions, it automatically stops running.

[0084] Each type of thread is delivered to the production equipment in rolls. The single length value mentioned above refers to the total length of the thread in that roll. During the production process, fabric is processed lengthwise based on the set width parameters. The unit pattern mentioned above refers to the smallest repeating pattern in the fabric's length. The unit length value of each type of thread refers to the length of thread required to complete that unit pattern. The pattern length value refers to the length of each unit pattern in the length direction. The fabric ultimately produced by the production equipment is output in rolls. The above-mentioned fabric length value refers to the length of fabric contained in each roll produced for this order. Single length, unit length, pattern length, and fabric length values ​​can be obtained by viewing the stored parameters or by inquiring with the relevant personnel. The methods for obtaining single length, unit length, pattern length, and fabric length values ​​are not further specified here.

[0085] First, divide the cloth length by the pattern length to determine the number of unit patterns required. Then, divide the length of each thread by the unit length to determine how many unit patterns each thread can provide. The number of revolutions required for the production equipment to generate the minimum number of unit patterns among the obtained unit patterns that each thread can provide is determined as the first number of revolutions in the revolution array. Then, subtract the minimum number from all non-minimum numbers of unit patterns that each thread can provide to determine the number of new unit patterns that each thread can provide. Repeat this process until the sum of all minimum numbers equals the number of unit patterns required for the fabric. This ensures that the production equipment is stopped only when a thread needs to be changed during the fabric production process. This reduces the chances of fabric quality being compromised by thread changes and allows operators to inspect the fabric surface during changes, reducing the impact of additional, fixed-number pauses on production efficiency, thus indirectly ensuring the quality and efficiency of fabric production.

[0086] For example, four types of thread are required to produce a piece of cloth. By dividing the cloth length by the pattern length, we determine that the cloth needs to produce 50 unit patterns. By dividing the single length of the same type of thread by the unit length, we can determine that the first type of thread can produce 3 unit patterns, the second type of thread can produce 3.5 unit patterns, the third type of thread can produce 2.5 unit patterns, and the fourth type of thread can produce 4 unit patterns. The minimum number is 2.5, so the production equipment needs to stop running when 2.5 unit patterns are completed. At this time, the number of revolutions required to complete 2.5 unit patterns is determined as the first number of revolutions in the revolution array. Then, 2.5 is subtracted from 3, 3.5, and 4, respectively, to obtain four new numbers: 0.5, 1, 2.5, and 4. The smallest number is 0.5. Therefore, the production equipment must stop when it completes 0.5 unit patterns. At this point, the number of revolutions required to complete 0.5 unit patterns is determined as the second number of revolutions in the revolution array. 2.5 + 0.5 = 3 unit patterns have been completed. At this point, 3 is less than 50. The above process continues until 50 unit patterns have been completed, at which point the production equipment stops for the final time for producing that roll of cloth. By sequentially storing each of the aforementioned revolutions in a blank array, the revolution array required to complete that roll of cloth can be obtained. The number of revolutions required to complete each unit pattern is fixed and pre-set. Based on the correspondence between the pre-set number of revolutions and the completion of each unit pattern, the number of unit patterns required for the production equipment to stop can be converted into the corresponding number of revolutions and stored sequentially in the revolution array to obtain the revolution array required to complete each roll of cloth.

[0087] S4. Monitor and record the usage cycle of accessories.

[0088] Specifically, in cloth production enterprises, different cloth production requires different production equipment accessories. For example, the accessories commonly used in the production of cotton fabrics include yarn, etc., and accessories such as fast bobbins, increased number of shuttles, and cloth clamping devices can be added to the production equipment according to the delivery deadline. Each accessory has a specific shelf life or service life, so the accessories required for the production of each type of cloth must be numbered and their service life and replacement time must be recorded to facilitate subsequent accessory failure analysis and replacement plans. When analyzing cloth defect problems, the accessory service life is added as a factor to determine whether the defect is caused by an accessory problem. For example, if there are defects on the cloth, the accessory number can be used to find the shelf life or service life of the accessory. By comparing it with the accessory service life, it can be determined whether the accessory has reached its recommended replacement period. If so, it can be determined that the problem is caused by an accessory failure.

[0089] For example, the use cycle of accessories is recorded, that is, all accessories are accompanied by batch numbers and numbers. The replacement application and distribution of all accessories are completed on the computer system. The replacement of accessories on each production equipment requires swiping the card on the card swiping device of the production equipment to log in and enter the accessory replacement application interface to apply for replacement. The computer system distributes the required accessories to the corresponding production equipment according to the replacement application and records the batch number and number of the accessories. Even if the computer system distributes accessories independently, it will record the production equipment number and the batch number and number of the accessories. In this way, each replacement of accessories will have data and time records. At the same time, the production time of each production equipment and the number of cycles after which the accessories are replaced will be recorded. The computer system can analyze and record the service life of different accessories based on the records, provide the use cycle of accessories, and issue prompts before the relevant accessories need maintenance and replacement.

[0090] S5. Perform weight detection on the produced cloth and obtain image data of the produced cloth.

[0091] Specifically, the weight detection of the finished cloth includes the following steps:

[0092] Step S51, determining a set of deduction defects existing in the cloth based on all recorded deduction score data, and determining a standard weight range corresponding to the cloth based on the set of deduction defects.

[0093] Step S52: weigh the cloth and record the weight.

[0094] In step S53, the weight of the cloth is compared with the standard weight range. If the weight of the cloth exceeds the standard range, it is regarded as abnormal cloth and various production parameters are checked.

[0095] In this embodiment, the purpose of weight testing the finished cloth rolls is to determine whether each roll of cloth meets quality standards. Step S22 above already discloses the four types of cloth defects: holes, staining, pilling, and thread ends. Furthermore, the monitoring of the cloth surface condition in step S2 has already recorded all the deduction score data for the cloth. Therefore, by reviewing this recorded deduction score data, we can determine which defects exist in the cloth. By summarizing all defects, we can obtain the deduction defect set for the cloth.

[0096] Each type of defect has a fixed impact on fabric weight. For example, holes reduce fabric weight, while threads increase it. Dyeing and pilling do not change the weight. Each type of defect also has a limited impact on fabric weight. For example, holes have a specific range of holes. Combined with the fabric's required craftsmanship, the weight loss range can be determined. Similarly, threads have a specific length range. Combined with the required craftsmanship, the weight gain range can be determined.

[0097] Each roll of cloth originally has an ideal weight based on its length and process information, corresponding to whether or not there are any defects. Then, based on the deduction defect set, the weight range caused by each thread end defect in the deduction defect set is added to the ideal weight, and the weight range caused by each hole defect in the deduction defect set is subtracted to obtain the standard weight range corresponding to the cloth. Subsequent work on the corresponding roll of cloth is then performed based on this standard weight range. Compared to using the same standard weight range for every roll of cloth, this embodiment specifically determines the standard weight range corresponding to each roll of cloth based on the actual defects it has. This can make the determined standard weight range corresponding to the cloth more accurate, thereby improving the accuracy of subsequent determination of whether the cloth is abnormal.

[0098] For example, the ideal weight of a roll of cloth is 10 kg. If the same standard weight range is used, the set standard weight range is 9 to 11 kg. The weight reduction caused by a hole defect is 0.02 kg. Based on the same range standard, with a fluctuation of 10%, the weight reduction caused by a hole defect is 0.018 to 0.022 kg. The weight reduction caused by a thread end defect is 0.01 kg, and the weight reduction caused by a thread end defect is 0.009 to 0.011 kg. If there are 5 thread ends and 1 hole in the cloth, the standard weight range determined by this example is 9.937 to 10.077 kg. Compared with the same standard weight range of 9 to 11 kg, the standard weight range corresponding to the cloth can be made more accurate, and it is beneficial to the accuracy of the subsequent determination of whether the cloth is abnormal.

[0099] After cloth production is completed, each piece of cloth is weighed and recorded. The weight of each piece is then compared to the standard weight range. If any piece of cloth is found to be outside the weight range, it is considered abnormal. The operator can then examine various production parameters, including raw materials, production equipment, and worker operation, to identify and troubleshoot possible factors that may have caused the abnormality. This troubleshooting identifies the abnormality point—the specific factor causing the abnormal weight, such as an improper production process or equipment failure—and corrects it. For example, suppose a cloth manufacturer produces 50 meters of cotton cloth, with a standard weight of 300 grams per meter. During weighing, five pieces of cloth are found to be underweight (less than 300 grams per meter). These five pieces need to be inspected and troubleshooted for possible abnormalities, such as the addition of substandard raw materials or equipment problems. Ultimately, the specific cause of the abnormality is determined, and appropriate corrective measures are taken to ensure that the cloth meets quality standards.

[0100] Using cameras and other equipment to photograph or record cloth, image data of the finished cloth is obtained. The captured images are pre-processed and converted into two-dimensional or three-dimensional images for subsequent processing and analysis. Computer vision technology is used to extract features from the cloth images, such as texture, color, and shape. Based on the feature extraction results, the cloth is analyzed to identify defects and areas for improvement. The analysis results are output as a report to help operators determine whether the cloth quality meets standards. This report serves as a basis for improving cloth quality and provides a reference for subsequent production of similar cloth. For example, cloth manufacturers use image acquisition equipment to obtain image data for each piece of cloth during the actual production process. The image data is then preprocessed, such as adjusting the image brightness and contrast, and converted into a two-dimensional or three-dimensional image. Computer vision technology is then used to extract features from the cloth image, such as color and texture, to analyze existing defects and areas for improvement. If it is found that some cloth surfaces have defects or uneven colors, improvement measures can be taken to address these problems, such as adjusting production equipment, replacing raw materials, etc. The analysis results are finally output as a report for staff to refer to and take corresponding measures to improve the quality of cloth production.

[0101] Based on the above method, the present application also discloses a cloth quality control system. Referring to FIG. 4 , the system includes the following modules:

[0102] Control module 1, used to control the input and output of the cloth quality control system;

[0103] The data processing module 2 is connected to the control module 1 and is used to receive the control signal of the control module 1, match and analyze the order information with the historical production data, and transmit the matching analysis results to the control module 1;

[0104] Furthermore, the data processing module 2 further includes a matching unit 21 and an analyzing unit 22.

[0105] Matching unit 21, used to match historical production data with order information;

[0106] The analysis unit 22 is connected to the matching unit 21 and is used to analyze and filter the historical production data matched by the matching unit 21 to generate actual production parameters;

[0107] The monitoring module 3 is connected to the control module 1 and is used to receive the control signal of the control module 1, monitor the cloth in the production process, and transmit the monitoring results to the control module 1;

[0108] Furthermore, the monitoring module 3 also includes a parameter monitoring unit 31 and a fabric surface monitoring unit 32.

[0109] Parameter monitoring unit 31, used to monitor actual production parameters;

[0110] The cloth surface monitoring unit 32 is used to monitor the cloth surface condition during the production process;

[0111] Furthermore, the cloth surface monitoring unit 32 also includes a circle number monitoring subunit 321, an accessory monitoring subunit 322 and a weight monitoring subunit 323.

[0112] The revolution monitoring subunit 321 is used to obtain the single length value corresponding to each type of thread required for cloth production, the unit length value of each type of thread required to complete each unit pattern, and the cloth length value of each roll of cloth. Based on the single length value, the unit length value, and the cloth length value, the revolution array required to complete each roll of cloth is determined, wherein the revolution array sequentially stores the number of revolutions required for each rotation. When the production equipment rotates to the current corresponding number of revolutions, it automatically stops operation.

[0113] The accessory monitoring subunit 322 is used to monitor and record the usage cycle of the accessory;

[0114] The weight monitoring subunit 323 is used to detect and record the weight of the finished cloth;

[0115] The image processing module 4 is connected to the control module 1, and is used to receive the control signal of the control module 1, obtain the image data of the cloth produced, analyze the cloth through the image data, and transmit the analysis results to the control module 1.

[0116] In other embodiments, the following method can also be used to set a cloth checking function corresponding to a number of revolutions, so that the production equipment is controlled to stop after rotating a corresponding number of revolutions. That is, during the cloth production process, a preset number of revolutions is set, i.e., the computer system automatically calculates the number of revolutions for each roll of cloth. The operator can preset the ratio of the number of revolutions to be stopped for cloth checking and the time for stopping for cloth checking according to the ratio of the number of revolutions of the entire roll of cloth. The number of revolutions can be changed according to actual conditions. A revolution monitoring sensor is provided on the production equipment, and the production equipment automatically stops when it reaches the preset number of revolutions.

[0117] For example, a roll of cloth rotates 1000 times, the preset ratio of the number of turns for cloth checking is 30%, and the time for cloth checking is 30 seconds. Then the roll of cloth will automatically stop and enter the cloth checking period at the 300th and 600th turns. The operator swipes the card to enter the cloth checking countdown, and the cloth checking time will count down from 30 seconds to 0 seconds. After the operator completes the 30-second cloth checking work, he can swipe the card again to complete the cloth checking without adjusting the production work, and the production equipment will start to continue production.

[0118] In some other embodiments, each type of cloth may be preset with the same standard weight range.

[0119] The embodiment of the present application also discloses an electronic device.

[0120] Specifically, the electronic device includes one or more processors and a memory, and the memory stores the above-mentioned computer programs that can be loaded and executed by the processor. When the one or more computer programs are executed by one or more processors, the one or more processors implement the steps of the above-mentioned cloth quality control method.

[0121] The embodiment of the present application also discloses a computer-readable storage medium.

[0122] Specifically, the computer-readable storage medium stores a computer program that can be loaded by a processor and executed by a method for controlling cloth quality as described above. The computer-readable storage medium includes, for example, various media that can store program codes, such as a USB flash drive, a mobile hard disk, a read-only memory (ROM), a random access memory (RAM), a magnetic disk or an optical disk.

[0123] The above description is merely a preferred embodiment of the present application and an illustration of the technical principles employed. Those skilled in the art should understand that the scope of disclosure in this application is not limited to technical solutions formed by a specific combination of the aforementioned technical features. It also encompasses other technical solutions formed by any combination of the aforementioned technical features or their equivalents, without departing from the aforementioned disclosed concepts. For example, a technical solution formed by replacing the aforementioned features with (but not limited to) technical features with similar functions disclosed in this application.

Claims

1. A cloth quality control method, characterized in that: include: S1. According to the order information, match and filter the historical production data to determine the actual production parameters; S2. Monitor the actual production parameters and fabric conditions; S3, set the cloth checking function of the corresponding number of circles, and control the production equipment to stop running after rotating the corresponding number of circles; S4. Monitor and record the use cycle of accessories; S5. Perform weight detection on the produced cloth and obtain image data of the produced cloth.

2. A cloth quality control method according to claim 1, characterized in that: The monitoring of actual production parameters and fabric conditions comprises the following steps: Preset production parameter ranges based on matching historical production data; Determine whether the actual production parameters are within the allowable range. If the actual production parameters exceed the preset production parameter range, an alarm will be issued and the production equipment will be controlled to stop running and check the fabric.

3. A cloth quality control method according to claim 1, characterized in that: The monitoring of actual production parameters and fabric conditions comprises the following steps: Preset defect detection threshold range and defect type deduction score; Points are deducted and recorded for the fabric; All recorded deduction score data are compared with the preset defect detection threshold range to determine whether the production equipment should be stopped.

4. A cloth quality control method according to claim 3, characterized in that: The preset defect detection threshold range is a score range that is deducted according to the defect type, and the defect detection threshold range includes a superior product range, a good product range, and a poor product range.

5. A cloth quality control method according to claim 1, characterized in that: The setting of the cloth checking function of the corresponding number of turns and controlling the production equipment to stop running after rotating the corresponding number of turns comprises the following steps: Obtaining the single length value corresponding to each type of thread required to produce the cloth, the unit length value of each type of thread required to complete each unit pattern, the pattern length value of each unit pattern, and the cloth length value of each roll of cloth, and determining the circle array required to complete each roll of cloth based on the single length value, the unit length value, the pattern length value, and the cloth length value, wherein the circle array sequentially stores the number of rotations required each time; When the production equipment rotates to the current corresponding number of revolutions, it automatically stops running; When the production equipment stops running, check the cloth to determine whether adjustment is needed. If no adjustment is needed, start the production equipment. If adjustment is needed, start the production equipment after processing according to the cloth surface condition.

6. A cloth quality control method according to claim 1, characterized in that: The monitoring and recording of the use cycle of the accessories includes the following steps: Number the accessories needed for cloth production and record the accessories usage cycle and replacement time information; Read the accessory record information to determine whether the accessory has reached the replacement period.

7. A cloth quality control method according to claim 3, characterized in that: The weight detection of the produced cloth comprises the following steps: Determine the set of deduction points defects existing in the cloth based on all recorded deduction point data, and determine the standard weight range corresponding to the cloth based on the set of deduction points defects; Weigh the cloth and record the weight. Compare the weight of the cloth with the standard weight range. If the weight of the cloth exceeds the standard weight range, it is considered abnormal cloth and various production parameters are checked.

8. A cloth quality control system, characterized in that: include: A control module (1), used to control the input and output of the cloth quality control system; A data processing module (2) connected to the control module (1) and used for receiving a control signal from the control module (1), performing matching analysis on the order information and the historical production data, and transmitting the matching analysis result to the control module (1); A monitoring module (3) connected to the control module (1) and used to receive control signals from the control module (1), monitor the cloth during the production process, and transmit the monitoring results to the control module (1); An image processing module (4) is connected to the control module (1) and is used to receive a control signal from the control module (1), obtain image data of the produced cloth, analyze the cloth through the image data, and transmit the analysis result to the control module (1).

9. A cloth quality control system according to claim 8, characterized in that: The monitoring module (3) comprises: A parameter monitoring unit (31), used for monitoring actual production parameters; The fabric surface monitoring unit (32) is used to monitor the fabric surface condition during the production process.

10. A cloth quality control system according to claim 9, characterized in that: The fabric surface monitoring unit (32) comprises: The number of turns monitoring subunit (321) is used to obtain the single length value corresponding to each type of thread required for producing the cloth, the unit length value of each type of thread required for completing each unit pattern, and the cloth length value of each roll of cloth, and determine the number of turns required to complete each roll of cloth based on the single length value, the unit length value and the cloth length value, wherein the number of turns required each time is sequentially stored in the number of turns; when the production equipment rotates to the current corresponding number of turns, it automatically stops running; An accessory monitoring subunit (322), used to monitor and record the usage cycle of the accessory; The weight monitoring subunit (323) is used to detect and record the weight of the produced cloth.

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