Porous Detection System for Textile Nozzle Blockage Analysis
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Solution Overview
Problem
Conventional methods for detecting blockages in densely packed nozzle holes in the textile industry, such as those using CCD imaging devices, are time-consuming and lack accuracy due to increased hole density and reduced distances between them.
Innovation Solution
A system employing a porous plate with non-circular holes and corresponding photosensitive units that emit light through the holes of an object, allowing for precise detection of luminous flux signals to analyze the status of each hole, improving detection accuracy by preventing stray light and ensuring each hole is assessed individually.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If CCD imaging device is used to detect nozzle holes, then detection can be performed, but detection accuracy deteriorates and time consumption increases due to increased hole density and smaller distances between holes
Solution Approach 1:
The detection system divides the detection process into discrete segments by using individual photosensitive units corresponding to each non-circular hole. Each photosensitive unit independently detects light transmission through its corresponding hole, enabling parallel processing of multiple holes simultaneously. This segmentation approach maintains high detection accuracy for densely packed holes while reducing overall detection time through concurrent measurements.
Solution Approach 2:
A porous plate with non-circular holes serves as an intermediary component between the light source and the photosensitive units. The non-circular holes in the porous plate are specifically designed to correspond to the circular nozzle holes, creating a one-to-one mapping relationship. This intermediary structure ensures that each photosensitive unit receives light only from its corresponding hole, preventing cross-contamination of light signals and maintaining high detection accuracy even when holes are densely packed.
2Measurement precision
If conventional circular holes are used in porous plate, then structure is simple, but detection accuracy deteriorates due to stray light interference when holes are densely packed
Solution Approach 1:
The porous plate uses non-circular holes (such as rectangular, triangular, or polygonal shapes) instead of conventional circular holes. This asymmetric design creates a specific geometric relationship where each non-circular hole corresponds to exactly one circular nozzle hole. The non-circular shape prevents stray light from adjacent holes from entering the photosensitive unit, as the geometry blocks oblique light paths. This asymmetric configuration significantly reduces stray light interference and improves detection accuracy, while the regular arrangement of non-circular holes keeps the overall structure relatively simple.
3Productivity
If hole density is increased for high-performance textiles, then productivity improves, but detection accuracy deteriorates due to smaller distances between holes
Solution Approach 1:
The system transitions from two-dimensional imaging detection to a three-dimensional spatial arrangement by introducing a porous plate with non-circular holes positioned between the nozzle holes and photosensitive units. This dimensional change creates a spatial filtering effect where the non-circular holes act as optical apertures that block stray light from adjacent holes. The three-dimensional configuration allows for high hole density in the textile while maintaining detection accuracy through geometric light path control.
Solution Approach 2:
Each photosensitive unit is configured with a specific local quality - it corresponds to exactly one non-circular hole in the porous plate, which in turn corresponds to one circular nozzle hole. This local one-to-one mapping ensures that each detection point maintains high accuracy independently. The local quality approach allows the system to handle high-density hole configurations because each local detection point is optimized to receive light only from its corresponding hole, preventing interference from neighboring holes.
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 provides cleaner and more accurate luminous flux signals, enabling better determination of blockages and improving detection efficiency in high-density nozzle configurations.
Implementation Method 1
The light emitting module is used for emitting light onto an object to be measured such that the light passes through a plurality of holes of the object
Implementation Method 2
The plurality of photosensitive units respectively sense luminous flux of the light passing through the plurality of non-circular holes of the porous plate to generate a luminous flux signal
Data Source
AI summary
A system, apparatus and method for detecting a porous object are provided. The system includes a light emitting module, a detecting module and an analyzing module. The light emitting module emits light onto an object to be measured such that the light passes through a plurality of holes of the object. The detecting module has a porous plate having a plurality of non-circular holes and a plurality of photosensitive units respectively corresponding to the non-circular holes. Each of the non-circular holes corresponds to at most one of the holes at one time point. The light passes through the plurality of non-circular holes corresponding to the plurality of holes. The photosensitive units respectively sense luminous flux of the light passing through the plurality of non-circular holes to produce a luminous flux signal. The analyzing module analyzes a status of the plurality of holes corresponding to the plurality of non-circular holes.