On-Loom Fabric Inspection Using Multiple Image Capture Per Weft Cycle
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Solution Overview
Problem
Existing on-loom fabric inspection systems are limited in their ability to detect faults in real-time during the weaving process, relying on manual inspection or capturing images at inappropriate moments, which leads to inefficiencies and subjective quality assessments.
Innovation Solution
An on-loom fabric inspection system that includes at least one imaging device, an image-capture trigger-mechanism, and an image processor, capable of capturing multiple images during each weft insertion cycle at specific instants to detect irregularities in warp and weft threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used for finished fabric, then quality assessment can be performed, but inspection efficiency is low and quality assessment is subjective
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated image-based inspection system. The system uses imaging devices to capture fabric images and automated image processing algorithms to detect defects, eliminating subjective human assessment and significantly improving both measurement precision and productivity.
Solution Approach 2:
The patent introduces image processing technology as an intermediary between the fabric and the inspection result. The image processing system acts as a mediator that objectively analyzes fabric defects based on captured images, providing standardized quality assessment without direct human intervention.
2Productivity
If single image capture is used during weft insertion, then inspection speed is improved, but detection precision is insufficient due to inappropriate timing
Solution Approach 1:
The patent uses preliminary action by triggering image capture at specifically predetermined instants during the weaving cycle. The system anticipates when defects are most visible and captures images at those optimal moments, ensuring both high inspection speed and accurate defect detection.
Solution Approach 2:
The patent implements periodic action by capturing multiple images at different instants throughout the weaving cycle. Instead of a single continuous capture, the system periodically triggers image acquisition at strategically chosen moments when warp and weft threads are most distinguishable, improving detection precision while maintaining productivity.
3Measurement precision
If multiple images are captured at different instants, then fault detection precision is improved, but system complexity increases
Solution Approach 1:
The patent applies universality by using a single imaging device that performs multiple functions - capturing images of both warp and weft threads at different instants. This multi-functional approach improves detection precision without requiring multiple separate imaging systems, thereby limiting the increase in device complexity.
Solution Approach 2:
The patent merges the image capture function for different weaving stages into a single integrated system. The imaging device is combined with a control system that coordinates multiple captures at different instants, achieving high detection precision while maintaining relatively simple system architecture through functional integration.
Data Source
AI summary
Systems and methods for on-loom detection of faults in fabric. An image-capture trigger-mechanism triggers an imaging device to capture a first image of a section of the weaving area at a first instant during each weft insertion cycle and a second image of the section of weaving area may be captured at a second instant during each weft insertion cycle. The images may be timed to provide images of the warp yarns and the weft yarns at optimal instants during the weft insertion cycle. An image processor detects irregularities in the data received from the imaging device.