On-loom Fabric Inspection Trigger Mechanism
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Solution Overview
Problem
Current on-loom fabric inspection systems are inefficient in detecting faults during the weaving process, as they either focus on specific regions of the loom or rely on manual inspection, leading to subjective assessments and missed defects.
Innovation Solution
An on-loom fabric inspection system with an imaging device and an image-capture trigger-mechanism that captures images at specific instants during the weaving cycle, using heald-frame detection and synchronization with the weaving cycle to identify irregularities in both the shed and fell regions, enabling real-time fault detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection is used to detect fabric faults, then inspection can be performed with simple equipment, but inspection efficiency is low and defect detection is incomplete
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system using imaging devices (cameras) to capture fabric images during the weaving process. The system uses image processing algorithms to automatically detect defects, eliminating the need for manual visual inspection and significantly improving inspection efficiency while maintaining relatively simple device complexity.
Solution Approach 2:
The inspection system performs self-inspection by automatically capturing images, processing them through algorithms, and identifying defects without human intervention. The system serves itself by integrating the imaging device, trigger mechanism, and image processing capabilities into a unified automated workflow that continuously monitors fabric quality during production.
2Reliability
If imaging devices capture images continuously during weaving, then complete fabric coverage is achieved, but image capture timing synchronization becomes difficult
Solution Approach 1:
The system uses periodic triggering based on the cyclic nature of the weaving process. The trigger mechanism is synchronized with the loom's operational cycle, capturing images at specific periodic intervals when the fabric passes through the imaging zone. This ensures consistent coverage of critical areas (shed and fell regions) while maintaining synchronization with the weaving rhythm, improving defect detection reliability without requiring overly complex trigger mechanisms.
3Reliability
If imaging devices focus on specific regions only, then device complexity is reduced, but defect detection coverage is insufficient
Solution Approach 1:
The imaging system divides the fabric inspection task into segments by capturing images of different critical regions (shed region and fell region) at different timing points in the weaving cycle. The trigger mechanism coordinates multiple image captures to cover these segmented areas comprehensively, ensuring complete defect detection coverage while managing imaging system complexity through structured regional focus.
4Loss of time
If inspection is performed on finished fabric only, then inspection equipment is simple, but defects remain undetected until after production
Solution Approach 1:
The system performs preliminary inspection during the weaving process itself rather than after production. By integrating imaging devices and trigger mechanisms into the loom, the system captures and analyzes fabric images in real-time during manufacturing, enabling early defect detection that allows for immediate corrective action and prevents defective fabric from completing production.
Data Source
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AI summary
On-loom fabric inspection system (500) including an imaging device (522) configured to collect images of a weaving area (518) of a loom (502). An image-capture trigger-mechanism (529) triggers the imaging device (522) to capture images at required instants during the weaving cycle. An image processor (524) receives data from the imaging device (522) and further detects irregularities in the data.