Automated Color Shift Detection in Textile Production
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Solution Overview
Problem
In textile fiber production, particularly in carpet manufacturing, it is challenging to accurately determine when and where a color shift occurs during the transition from one color to another, leading to inefficiencies and waste due to the reliance on manual inspection or incomplete automation.
Innovation Solution
A system comprising a camera for capturing color data points and a processing unit for statistical analysis is used to automate the detection of color shifts, allowing for precise determination of the time and location of color changes on textile materials, enabling efficient segmentation and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used to detect color shifts, then device complexity is reduced, but measurement precision and productivity deteriorate
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system comprising a camera and computer. The camera captures images of the textile material, and the computer analyzes color values to detect shifts automatically, eliminating the need for manual inspection while improving precision.
Solution Approach 2:
The system creates a digital copy of the textile material's appearance through camera imaging. Instead of directly observing the material, the computer analyzes captured images and color data, allowing for precise automated detection without complex mechanical intervention.
2Measurement precision
If automated detection system is implemented, then measurement precision improves, but device complexity increases
Solution Approach 1:
The camera and computer system serves multiple functions: capturing images, analyzing color values, detecting color shifts, and providing location information. This multi-functionality reduces the need for separate specialized devices, thereby limiting the increase in device complexity while maintaining high measurement precision.
3Productivity
If complete automation is achieved, then productivity improves, but device complexity increases
Solution Approach 1:
The detection system operates autonomously without requiring continuous human intervention. The camera automatically captures images and the computer independently analyzes color data to detect shifts and provide location information, enabling complete automation that improves productivity while keeping the system relatively simple.
4Loss of time
If color shift detection is delayed, then device complexity is reduced, but loss of time increases
Solution Approach 1:
The camera continuously captures images of the textile material as it moves through the production process, and the computer continuously analyzes these images for color shifts. This continuous operation enables real-time detection without interruption, minimizing time loss while maintaining manageable device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively automates the detection of color shifts, reducing waste and ensuring uniformity in textile products by providing accurate and timely data for operators to segment production runs, thereby improving manufacturing efficiency and product consistency.
Implementation Method 1
a camera for creating data points of color values on the textile material
Data Source
AI summary
Apparatus, methods, and textile materials created thereby or there from, in which the approximate location of a color shift along a run of textile material is determined. In one aspect, a plurality of color measure data points from the textile material is acquired and processed to determine color difference measures, which are compared to a predetermined threshold value in order to determine the approximate location of the color shift on the textile material.