Optical Yarn Quality Monitoring Using Diffraction and Interference
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Solution Overview
Problem
In the textile industry, yarn quality monitoring, particularly for evenness and foreign fibers, is challenging due to the impracticality of manual inspection in high-volume, rapid production, and existing methods are affected by dust particles and require separate detectors for diameter and color analysis.
Innovation Solution
A system using a primary artificial light source, a diffraction element, and a monochromatic image sensor to create an interference pattern for simultaneous yarn diameter and foreign fiber detection, with a secondary light source for enhanced image clarity and low power consumption, allowing for accurate analysis even in dusty environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate independent light detectors are used for color analysis and diameter measurements, then specialized detection for each parameter is achieved, but device complexity increases and data synchronization becomes necessary
Solution Approach 1:
The patent combines color analysis and diameter measurement functions into a single image sensor system. The diffraction grating disperses light onto the image sensor such that both spectral information (for color analysis) and spatial information (for diameter measurement) are captured simultaneously by the same detector, eliminating the need for separate detectors and synchronization mechanisms
Solution Approach 2:
The image sensor serves multiple functions: it detects both the diffraction pattern for color analysis and the yarn image for diameter measurement. This multi-functional approach allows one device to perform what previously required two separate detection systems, reducing overall system complexity
2Reliability
If conventional optical systems are used without focusing elements, then simpler optical paths are achieved, but dust particles on optical surfaces significantly affect measurement accuracy
Solution Approach 1:
The patent introduces a focusing element as an intermediary component in the optical path. This element creates a focused image plane where dust particles on optical surfaces have minimized impact, as the critical measurement information is captured at the focal plane rather than being affected by scattered light from dust on upstream optical components
Solution Approach 2:
The system uses a diffraction grating that creates both a focused zero-order image and dispersed first-order spectra. By capturing both simultaneously on the image sensor, the system obtains redundant information that compensates for dust interference, effectively using excessive optical action to ensure measurement reliability
3Illumination intensity
If high power light sources are used for reflected light capture, then sufficient light intensity for measurement is achieved, but energy consumption increases
Solution Approach 1:
The patent replaces the conventional approach of using high-power light sources with a diffraction-based optical system. The diffraction grating efficiently directs and concentrates available light onto the image sensor, achieving sufficient illumination intensity through optical manipulation rather than increasing light source power, thereby reducing energy consumption
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
Enables reliable and cost-effective simultaneous measurement of yarn diameter and foreign fiber detection from the same image, improving accuracy and feasibility in high-volume yarn production while resisting dust interference.
Implementation Method 1
Light rays, which are reflected from the yarn, are focused on the image sensor and diffracted by diffraction element. The diffracted light creates interference pattern on the image sensor, which is used for color analysis and ultimately foreign fiber detection.
Implementation Method 2
The diffracted light creates interference pattern on the image sensor, which is used for color analysis and ultimately foreign fiber detection.
Implementation Method 3
Light rays, which are reflected from the yarn, are focused on the image sensor and diffracted by diffraction element.
Implementation Method 4
Light rays, which are reflected from the yarn, are focused on the image sensor
Data Source
AI summary
The invention relates to a method and apparatus for monitoring yarn quality in the textile industry. Textile yarn is checked for quality to meet the required criteria such as diameter evenness and unwanted foreign fiber presence. The invention utilizes an artificial light illuminating the yarn, focusing element, diffraction element and the image sensor for capturing of focused diffracted rays from illuminated yarn image. The presence of foreign fibres in yarn and yarn diameter is determined by processing of captured image.