Yarn Defect Detection with Dynamic Removal Length
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Solution Overview
Problem
Conventional yarn defect detection systems require repetitive removal processes when defects exceed a predetermined length, leading to inefficiencies and quality deterioration in yarn products.
Innovation Solution
A yarn defect detecting device that identifies and measures defects longer than a reference length as a single entity, allowing for collective removal and improving production efficiency by determining the length of yarn to be removed based on the defect length, thereby reducing the number of removal operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a predetermined length removal method is used, then the removal process is simple, but production efficiency deteriorates and quality deteriorates when defect length exceeds the predetermined length
Solution Approach 1:
The system dynamically changes the removal length parameter from a fixed predetermined value to a variable value based on the actual defect length. When a defect is detected, the removal length is adjusted to match the defect length plus a predetermined margin, ensuring complete removal while minimizing unnecessary yarn removal and joining operations.
Solution Approach 2:
The system performs preliminary measurement of the defect length before executing the removal operation. By measuring the defect length in advance using the detection device, the system can plan the optimal removal strategy, determining whether to remove the entire defect at once or in segments, thereby avoiding multiple repetitive removal operations.
2Reliability
If repetitive removal processes are performed, then complete defect removal is achieved, but the number of yarn joining points increases
Solution Approach 1:
The system adjusts the removal length parameter dynamically based on the measured defect length. By setting the removal length to be slightly longer than the actual defect length (adding a predetermined margin), the system ensures complete defect removal in a single operation, eliminating the need for repetitive removal processes that would create multiple joining points.
3Device complexity
If defect length is not measured, then the detection process is simple, but multiple removal operations are required
Solution Approach 1:
The system performs preliminary measurement of the defect length as part of the detection process. By measuring the defect length before removal, the system can determine the optimal removal strategy in advance, preventing the need for multiple removal operations and thereby improving production efficiency despite the added measurement step.
Data Source
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AI summary
A yarn defect detecting device (10) includes a yarn defect determining section (22) that determines, as a defect, a part of a yarn having a thickness falling outside a thickness threshold specified as a determination threshold and having a length equal to or larger than a reference length, an end point identifying section (21) that identifies an end point of the defect in a longitudinal direction when the part of the yarn is determined as the defect by the yarn defect determining section (22), and a cutter (9) that cuts the yarn when the end point identifying section (21) identifies the longitudinal direction end point of the defect.