Dual-Camera Circular Knitting Machine for Needle Defect Detection
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Solution Overview
Problem
Conventional circular knitting machines lack real-time detection of knitting needle status during operations, leading to inefficient quality assessment and unnecessary replacement of all needles, resulting in resource waste and increased production costs.
Innovation Solution
A circular knitting machine equipped with a main and auxiliary camera module system that captures images of the tubular fabric, using encoder-generated pulse signals to synchronize image capture and a data processor for real-time analysis of loop images to identify defective needles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single camera module is used for image recognition, then the device complexity is reduced, but the measurement precision deteriorates due to blocking by connecting rods
Solution Approach 1:
The single camera module is segmented into two functional units: a main camera module for continuous monitoring and an auxiliary camera module for capturing images during connecting rod movement. This segmentation allows the system to maintain high measurement precision by switching between cameras based on the operational phase, while keeping the overall device complexity manageable through modular design.
Solution Approach 2:
The system dynamically switches between the main camera module and auxiliary camera module based on the position and movement of the connecting rods. When connecting rods are in motion, the auxiliary camera activates to capture unobstructed fabric images; when rods are stationary, the main camera continues monitoring. This dynamic adaptation ensures continuous high-precision image recognition without requiring both cameras to operate simultaneously, thus controlling device complexity.
2Device complexity
If quality inspection is performed after knitting completion, then the device complexity is reduced, but the loss of time increases due to inability to identify specific defective needles
Solution Approach 1:
The dual camera system performs preliminary quality inspection during the knitting process itself, capturing fabric images at multiple stages. The main camera continuously monitors fabric formation, while the auxiliary camera captures additional views when connecting rods move. This preliminary detection identifies defective needles in real-time, allowing targeted replacement before knitting completion, thus reducing the time loss associated with replacing all needles after inspection.
Solution Approach 2:
The system establishes a feedback loop where images captured by both camera modules are analyzed to identify knitting defects and trace them to specific needles. This real-time feedback enables operators to immediately address problematic needles rather than waiting for post-knitting inspection, significantly reducing downtime and improving productivity while maintaining a relatively simple device structure.
3Reliability
If all knitting needles are replaced upon defect detection, then the reliability of fabric quality is improved, but the loss of substance increases due to replacement of functional needles
Solution Approach 1:
The dual camera system enables local quality assessment by identifying defects at specific needle positions rather than assuming universal needle failure. The main camera provides continuous monitoring to detect local anomalies, and the auxiliary camera confirms findings during connecting rod movement. This localized detection allows operators to replace only the specific defective needles while keeping functional needles in service, thus maintaining fabric quality reliability while minimizing needle inventory loss.
Solution Approach 2:
The system facilitates selective discarding of only defective needles while recovering and continuing to use functional needles. By providing precise defect localization through coordinated imaging from both camera modules, the system enables operators to identify and replace only the necessary needles, thereby reducing waste of functional knitting needles and lowering operational costs while maintaining consistent fabric quality.
Data Source
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AI summary
A circular knitting machine (20) with real-time prompt of a knitting machine status. The circular knitting machine (20) includes a base (21), a cloth rolling machine (23) that rotates relative to the base during knitting operation process, a main camera module (24) fixed on the base (21), and an auxiliary camera module (25) fixed on the base (21) and disposed close to the main camera module (24). The main camera module (24) includes a first central axis (241), and the main camera module (24) takes pictures of a tubular fabric (30) knitted by the circular knitting machine (20). The auxiliary camera module (25) includes a second central axis (251) intersecting with the first central axis (241). The auxiliary camera module (25) and the main camera module (24) face a same side of the tubular fabric (30). A startup timing of the auxiliary camera module (25) only occurs when one of the plurality of connecting rods (232) passes between the main camera module (24) and the tubular fabric (30).