CN103437061B - Real-time monitoring device and real-time monitoring method for knitting needles - Google Patents
Real-time monitoring device and real-time monitoring method for knitting needles Download PDFInfo
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- CN103437061B CN103437061B CN201310391005.7A CN201310391005A CN103437061B CN 103437061 B CN103437061 B CN 103437061B CN 201310391005 A CN201310391005 A CN 201310391005A CN 103437061 B CN103437061 B CN 103437061B
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Abstract
The invention relates to a real-time monitoring device and a real-time monitoring method for knitting needles. The device comprises a Y-shaped optical fiber bundle, a zoom imaging optical lens group, a detection light source module, a photoelectric detector and a signal processing module. The device disclosed by the invention can accurately detect damaged knitting needles in time, such as knitting needles with broken needle hooks and broken or excessively bending needle heads, and give the alarm in time, and the quality of knit goods can be obviously improved; the device has the characteristics of long working distance, small volume, strong real-time performance and low cost.
Description
Technical field
The present invention relates to the knitting machine of textile industry, particularly a kind of knitting needle real-time monitoring device and method, can the deterioration extent of knitting needle in Real-Time Monitoring knitting machine operation process, comprise pinhock fracture, syringe needle fracture or overbending, and give the alarm in time.
Background technology
Knitting machine is that modern textile produces the equipment generally used.In the operation process of knitting machine, the knitting needle reciprocating motion that on knitting lathe, one end has a pinhock hooks up yarn, and yarn tractive is entered coil or various structure and form knitted fabric.Once damaging appears in knitting needle, such as pinhock, syringe needle fracture or excessively partially curved and undiscovered, then hook up and do not complete with the action of tractive yarn, fabric can produce continuous print fault or gap, have a strong impact on fabric quality, article rate declines.Therefore, be necessary in the knitting machine course of work to monitor in real time knitting needle state, detect knitting needle damage or abnormal after report to the police immediately and stop the operation of knitting machine, to carry out knitting needle replacing or reinspection.
In first technology one (see " fabric defects online automatic detection method and device thereof based on machine vision ", China Patent No. 201110052541.5, inventor Xue Yun is bright, just build merit, Yang Qiwen, Sun Ning, Shen Jidong) utilize industrial camera online acquisition textile image and with standard picture template matching, judge fault type and report to the police.After this device produces by fault, shutdown inspection syringe needle state has judged whether that damaging knitting needle occurs, but this method has the following disadvantages:
1, Real-time Feedback is more weak.This technology by the indirect detection knitting needle state to the detection of fabric defects, find fabric there is fault after again shutdown inspection damage knitting needle, the reaction time is longer, and the fabric percent defective caused is high.
2, detection technique difficulty is large.This technology is realized by real time image processing, needs special algorithm and standard picture template matching, needs to develop special image processing software, and amount of calculation is large, needs Large Copacity, high speed computer system.
In first technology two (see " circular knit knitting machine needle defect detection device ", U.S. Patent No. 3904529, village in inventor) according to reverberation detect method, an illuminating source is set near knitting machine neilsbed, adopt an optical fiber or fibre bundle as reverberation receiving transducer, outside alignment probe knitting needle pinhock, the light of pinhock reflection, by after optical fiber or fibre bundle short distance reception, is converted to the signal of telecommunication by photodetector and processes.When pinhock damages, intensity of reflected light changes.Thus, signal processing system differentiates knitting needle state.This device has the following disadvantages:
1, operating distance is excessively near.For ensureing that more reverberation enters optical fiber, to be processed by photoelectric detector, optical fiber or fibre bundle one end distance knitting needle must be close, and within 3mm, installing, debugging comparatively easily contacts with knitting needle firmly with optical fiber during use, causes the damage of optical fiber or knitting needle.
2, adopt Split type structure, installation procedure is more, takes up room large.Because light source and optical fiber or fibre bundle need to aim at outside knitting needle pinhock simultaneously, therefore need to reserve enough large space outside knitting needle pinhock and place light source and optical fiber or fibre bundle.
Summary of the invention
The object of the invention is to overcome the above-mentioned deficiency in first technology, a kind of knitting needle real-time monitoring device and method are provided, this device can detect the knitting needle of damage timely and accurately, comprise pinhock fracture, syringe needle ruptures or the knitting needle of overbending also gives the alarm in time, can significantly improve the quality of knitwear, this device has the advantages that operating distance is long, volume is little, real-time and cost is low.
Technical solution of the present invention is as follows:
A kind of knitting needle real-time monitoring device, feature is that this device comprises Y-shaped fibre bundle, zoom optical imaging lens group, probe source module, photodetector and signal processing module, described Y-shaped fibre bundle merges the other end by one end of two-beam fibre bundle and keeps three ends separately: fibre bundle merges end, detection light optical fiber end and reverberation optical fiber end are formed, the light beam coupling that the end face of described detection light optical fiber end and probe source module send, the end face of reverberation optical fiber end is coupled with described photodetector, described fibre bundle merges the object plane that the end face held is placed in zoom optical imaging lens group.
Rectangular or the strip of the end surface shape of the merging end of described Y-shaped fibre bundle, formed by multifiber end face close-packed arrays, the end surface shape at the two ends that described fibre bundle separates is rounded, is still formed by multifiber end face close-packed arrays.
The end surface shape that described fibre bundle merges end be two long limits near rectangle or strip, comprise three kinds of structures:
The fiber end face of described detection light optical fiber end and reverberation optical fiber end respectively close-packed arrays becomes two rectangles;
Described detection light optical fiber end and the optical fiber of reverberation optical fiber end interlaced, close-packed arrays becomes a rectangle;
Fiber distribution corresponding to described detection light optical fiber end is in the approximate centerline being parallel to long limit, and fiber distribution corresponding to reverberation optical fiber end is in both sides, and close-packed arrays is orthogonal.
Described zoom optical imaging lens group is made up of the first convex lens successively and the second convex lens, and the first described convex lens and the second convex lens have zoom imaging function.
The described optical axis of zoom optical imaging lens group and the shank of knitting needle are that 45° angle is placed, and hot spot image space is just overlapped to the outer surface that pinhock is bending.
Described probe source module comprises light source and light source driving circuit, and the square-wave signal being sent certain frequency by light source driving circuit carries out intensity modulated to light source.
Described signal processing module comprises comparator, microcontroller, display and alarm, the input of described comparator is connected with the output of microcontroller, the output of photodetector respectively, the output of comparator is connected with the input of microcontroller, the input of described display is connected with the output of microcontroller, and the input of described alarm is connected with the output of microcontroller.
The input of described light source driving circuit is connected with the output of microcontroller, and the control signal sent according to microcontroller sets frequency and the dutycycle of described square-wave signal.
Knitting needle real-time monitoring device described in utilization carries out the method for Real-Time Monitoring to knitting needle, its feature is that the method comprises the following steps:
1. opening power, by the picture of zoom optical imaging lens group preceding article shaped laser spot just to the outer surface that pinhock is bending, makes its overlapping area reach maximum;
2. utilize described photodetector to gather the intensity of reflected light signal of a static knitting needle, the zoom optical imaging lens group position according to the signal magnitude fine setting of display display, makes intensity of reflected light signal meet or exceed the measurement threshold value of device setting;
3. activation pin loom, the photodetector described in utilization changes time dependent voltage signal into time dependent intensity of reflected light signal, then voltage signal is input to described comparator;
Input voltage signal, for reference voltage, is changed into square-wave signal and inputs in microcontroller by the threshold voltage that 4. described comparator is arranged with described microcontroller;
5. according to square-wave signal change in duty cycle, described microcontroller judges whether knitting needle exists pinhock, syringe needle fracture or the excessive damage such as partially curved:
When square-wave signal dutycycle is less than normal duty cycle scope, then microprocessor control alarm gives the alarm, and display display types of damage is pinhock, syringe needle fracture; When square-wave signal dutycycle is greater than normal duty cycle scope, then microprocessor control alarm gives the alarm, and display display types of damage is that syringe needle is excessively partially curved.
With compared with first technology, the present invention has following advantage:
1. directly monitor knitting needle state, real-time is better.Signal processing module mainly carries out the work such as signal madulation, voltage compare;
2. operating distance is long, not easily causes damage.Zoom optical imaging lens group of the present invention has larger optical numerical aperture, the basis ensureing reverberation reception Space Angle still has longer operating distance, distance knitting needle is comparatively far away, avoids the damage causing optical head in installing, debug and using because of maloperation;
3. optical fiber fabrication cost is low.It is regular size that optical fiber used herein passes light beam, and manufacturing procedure is simple, and cost is lower.
Accompanying drawing explanation
Fig. 1 is knitting needle real-time monitoring device structural representation of the present invention
Fig. 2 is Y-shaped fibre bundle schematic diagram of the present invention
Fig. 3 is optical system schematic diagram of the present invention
Fig. 4 is principles of signal processing figure of the present invention
Fig. 5 is embodiment of the present invention square-wave signal testing result figure
Detailed description of the invention
Below in conjunction with drawings and Examples, the present invention is described in detail, but should limit the scope of the invention with this.
First refer to Fig. 1, Fig. 1 is the structured flowchart of knitting needle real-time monitoring device embodiment of the present invention.As seen from the figure, knitting needle real-time monitoring device of the present invention, comprise Y-shaped fibre bundle 1, zoom optical imaging lens group 2, probe source module 3, photodetector 4 and signal processing module 5, described Y-shaped fibre bundle 1 merges the other end by one end of two-beam fibre bundle and keeps three ends separately: fibre bundle merges end, detection light optical fiber end and reverberation optical fiber end are formed, the light beam coupling that the end face of described detection light optical fiber end and probe source module 3 send, the end face of reverberation optical fiber end is coupled with described photodetector 4, described fibre bundle merges the object plane that the end face held is placed in zoom optical imaging lens group 2.
Described Y-shaped fibre bundle 1 designs as shown in the first design of Fig. 2, the end surface shape that fibre bundle merges end be two long limits near rectangle or strip, each rectangle or strip are formed by multifiber end face close-packed arrays, end face corresponding detection light optical fiber end and the reverberation optical fiber end respectively of these two rectangles or strip.The end surface shape of detection light optical fiber end and reverberation optical fiber end is circular, is still formed by multifiber end face close-packed arrays.
Described zoom optical imaging lens group 2 is made up of the first convex lens 201 successively and the second convex lens 202.The first described convex lens 201, second convex lens 202 have zoom imaging function in a device.In order to the knitting needle signal that clear differentiation is adjacent, imaging facula width need be less than or equal to the gap length of thickness of the stems and pin and pin.With reference to People's Republic of China (PRC) textile industry standard FZ/T90105-1999, knitting machine plane No. scope is 2 to 50, and thickness of the stems scope is 0.26mm ~ 2.2mm, and between pin and pin, space scope is 0.248mm ~ 10.5mm.For mating knitting needle corresponding to different plane No., imaging multiplying power will be determined according to the gap length of thickness of the stems and pin and pin, realizes zoom imaging function by changing different focal lens.Described zoom optical imaging lens group 2 is that 45° angle is placed with shank, and hot spot image space is just also overlapped as far as possible to the outer surface that pinhock is bending.
Described probe source module 3 comprises light source 301 and light source driving circuit 302.The output beam of described light source 301 is coupled with the detection light optical fiber end of described Y-shaped fibre bundle 1, and their relative position will ensure that the light that light source 301 sends enters detection light optical fiber end as much as possible.The effect of described light source driving circuit 302 is that the square-wave signal sending certain frequency carries out intensity modulated to light source.
The input of described photodetector 4 is coupled with the reverberation optical fiber end of described Y-shaped fibre bundle 1, and their relative position will ensure that the light of reverberation optical fiber end enters photodetector 4 as much as possible.
Described signal processing system comprises comparator 501, microcontroller 502, display 503 and alarm 504.The input of described comparator is connected with the output of microcontroller, the output of photodetector respectively, the output of comparator is connected with the input of microcontroller, the input of described display is connected with the output of microcontroller, and the input of described alarm is connected with the output of microcontroller.
Described comparator 501 for the voltage signal of input being transformed into the square-wave signal with different duty, and is input in described microcontroller 502.When a knitting needle before zoom optical imaging lens group 2 through out-of-date, the voltage signal magnitude of input comparator 501 can first be decreased to the reference voltage being less than comparator, then increase to and be greater than reference voltage, in process, comparator exports square wave and produces twice saltus step, and the voltage signal of each root knitting needle all will change the square-wave signal that has different duty into thus.
According to the square-wave signal change in duty cycle of input, described microcontroller 502 judges whether knitting needle exists pinhock, syringe needle fracture or the excessive damage such as partially curved.When square-wave signal dutycycle is less than normal duty cycle scope, then microcontroller 502 controls alarm 504 and gives the alarm, and it is pinhock, syringe needle fracture that display 503 shows types of damage; When square-wave signal dutycycle is greater than normal duty cycle scope, then microcontroller 502 controls alarm 504 and gives the alarm, and it is that syringe needle is excessively partially curved that display 503 shows types of damage.
Described light source 301, light source driving circuit 302, comparator 501, microcontroller 502, display 503 and alarm 504, because the connection of these circuit and element is all existing routine, I beg your pardon that I does not repeat them here.
The structure of most preferred embodiment of the present invention as shown in Figure 1, Figure 2, Figure 3, Figure 4, its concrete structure and parameter as follows:
Light source 301 is red light-emitting diode (LED), and centre wavelength is 680nm.Y-shaped fibre bundle 1 adopts core diameter 50 μm of glass optical fiber arrangements to form, numerical aperture >=0.6.Zoom optical imaging lens group adopts optics 4F system architecture, and comprise the first convex lens 201 and the second convex lens 202, effective focal length 21.3mm, back work distance is from 18.0mm, and imaging multiplying power is 1 times.The end face that Y-shaped fibre bundle 1 merges end is placed in the first 18.0mm place, convex lens 201 left, and hot spot is imaged on the second 18.0mm place, convex lens 202 right.Photodetector 4 is PIN diode.The amplifier model of the pre-amplification circuit in photodetector is OPA637.Comparator model is LM393, and microcontroller adopts STM32 series.
Above-described embodiment device is utilized to carry out Real-Time Monitoring to the knitting needle on the knitting machine neilsbed of 32 pins/inch:
According to single needle static measurement values U
1, comparator reference voltage U is set
0=U
1× 40%; Plane No. according to knitting machine arranges and differentiates that the normal dutycycle dynamic range of knitting needle state is 30% ~ 70%.
Its actual monitor signal as shown in Figure 5, is the square-wave signal of comparator output in figure.Monitoring result shows, the recognition accuracy of described device to the damage knitting needle in the knitting needle on this knitting needle needle bed and askew pin reaches 100%.
Claims (8)
1. a knitting needle real-time monitoring device, be characterised in that this device comprises Y-shaped fibre bundle (1), zoom optical imaging lens group (2), probe source module (3), photodetector (4) and signal processing module (5), described Y-shaped fibre bundle (1) merges the other end by one end of two-beam fibre bundle and keeps three ends separately: fibre bundle merges end, detection light optical fiber end and reverberation optical fiber end are formed, the light beam coupling that the end face of described detection light optical fiber end and probe source module (3) send, the end face of reverberation optical fiber end is coupled with described photodetector (4), described fibre bundle merges the object plane that the end face held is placed in zoom optical imaging lens group (2), the output of described photodetector (4) is connected with the input of described signal processing module (5).
2. knitting needle real-time monitoring device according to claim 1, it is characterized in that the rectangular or strip of the end surface shape of the merging end of described Y-shaped fibre bundle (1), formed by multifiber end face close-packed arrays, the end surface shape at the two ends that described fibre bundle separates is rounded, is still formed by multifiber end face close-packed arrays.
3. knitting needle real-time monitoring device according to claim 2, it is characterized in that end surface shape that described fibre bundle merges end be two long limits near rectangle or strip, comprise three kinds of structures:
The fiber end face of described detection light optical fiber end and reverberation optical fiber end respectively close-packed arrays becomes two rectangles;
Described detection light optical fiber end and the optical fiber of reverberation optical fiber end interlaced, close-packed arrays becomes a rectangle;
Fiber distribution corresponding to described detection light optical fiber end is in the approximate centerline being parallel to long limit, and fiber distribution corresponding to reverberation optical fiber end is in both sides, and close-packed arrays is orthogonal.
4. knitting needle real-time monitoring device according to claim 1, it is characterized in that described zoom optical imaging lens group (2) is made up of the first convex lens (201) successively and the second convex lens (202), described the first convex lens (201) and the second convex lens (202) have zoom imaging function.
5. knitting needle real-time monitoring device according to claim 1, it is characterized in that the optical axis of described zoom optical imaging lens group (2) and the shank of knitting needle (6) are that 45° angle is placed, hot spot image space is just overlapped to the outer surface that pinhock is bending.
6. knitting needle real-time monitoring device according to claim 1, is characterized in that described probe source module (3) comprises light source (301) and light source driving circuit (302).
7. knitting needle real-time monitoring device according to claim 1, it is characterized in that described signal processing module (5) comprises comparator (501), shaping circuit (502), microcontroller (503), display (504) and alarm (505), the input of described comparator respectively with the output of microcontroller, the output of photodetector is connected, the output of comparator is connected with the input of microcontroller, the input of described display is connected with the output of microcontroller, the input of described alarm is connected with the output of microcontroller.
8. utilize the knitting needle real-time monitoring device described in claim 1 knitting needle to be carried out to the method for Real-Time Monitoring, it is characterized in that the method comprises the following steps:
1. opening power, by the picture of zoom optical imaging lens group preceding article shaped laser spot just to the outer surface that pinhock is bending, makes its overlapping area reach maximum;
2. utilize photodetector to gather the intensity of reflected light signal of a static knitting needle, the zoom optical imaging lens group position according to the signal magnitude fine setting of display display, makes intensity of reflected light signal meet or exceed the measurement threshold value of device setting;
3. activation pin loom, described photodetector changes time dependent voltage signal into time dependent intensity of reflected light signal, then voltage signal is input to comparator;
Input voltage signal, for reference voltage, is changed into square-wave signal and inputs in microcontroller by the threshold voltage that 4. described comparator is arranged with microcontroller;
5. according to square-wave signal change in duty cycle, described microcontroller judges whether knitting needle exists pinhock, syringe needle fracture or excessively partially curved damage:
When square-wave signal dutycycle is less than normal duty cycle scope, then microprocessor control alarm gives the alarm, and display display types of damage is pinhock, syringe needle fracture; When square-wave signal dutycycle is greater than normal duty cycle scope, then microprocessor control alarm gives the alarm, and display display types of damage is that syringe needle is excessively partially curved.
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Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109881356B (en) * | 2018-12-25 | 2021-03-16 | 西安工程大学 | Hosiery machine knitting needle online detection device and method based on SVM image classification |
| CN109632817B (en) * | 2019-01-15 | 2021-04-09 | 天津大学 | Fabric weaving on-line defect detection method based on collimated laser beam |
| CN112834523B (en) * | 2021-01-03 | 2022-10-28 | 福建省万物智联科技有限公司 | Broken yarn detection circuit |
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| US3937038A (en) * | 1972-06-15 | 1976-02-10 | Firma Erwin Sick Optik-Elektronik | Device for the continuous monitoring of the condition of the needle heads on a circular knitting machine |
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