Journal of Textile Research ›› 2022, Vol. 43 ›› Issue (10): 176-182.doi: 10.13475/j.fzxb.20210101107

• Machinery & Accessories • Previous Articles     Next Articles

Needle selector detection system based on image processing

YUAN Yanhong1(), ZENG Hongming1, MAO Muquan2   

  1. 1. Key Laboratory of Modern Textile Machinery Technology of Zhejiang Province, Zhejiang Sci-Tech University,Hangzhou, Zhejiang 310018, China
    2. Hangzhou Golden Mechanical and Electronic Technology Co., Ltd.,Hangzhou, Zhejiang 310018, China
  • Received:2021-01-07 Revised:2022-05-19 Online:2022-10-15 Published:2022-10-28

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Abstract:

In order to improve the inspection efficiency for needle selectors, a set of automatic needle selector inspection system based on image processing was designed. The system was composed of an ordinary industrial camera, a needle selector controller, a needle selector placement platform and a personal computer. The needle selector is checked by the gray value of the knife head at the two extreme positions. By analyzing the swing rule of the needle selector knife head, the feasibility of using the gray value of the needle selector knife head to judge the knife head swing operation was verified. The Python software was adopted to achieve image acquisition and cropping, and gray value of each cutter head was efficiently extracted by combine Otsu, contour detection, image erosion and other algorithms. The results were compared with the pre-solved threshold to achieve normal operation of the cutter head measurement and judgment. The designed human-computer interaction interface can display the inspection status in real time, and it saves the pictures of the error frames of the needle selector in the designated directory and the error log in the designated file for reference and analysis. The completed system has low cost and no special experimental environment requirements. The actual test of the needle selector that simulates error indicates that the inspection system can effectively realize the detection of the needle selector blade.

Key words: needle selector, trouble shooting, image processing, grayscale value, global shutter, circular weft knitling machine

CLC Number: 

  • TS103.1

Fig.1

Schematic diagram of needle selector"

Fig.2

Swing timing diagram of needle selector in laboratory (needle selection frequency of 100 Hz)"

Fig.3

Schematic diagram of test system"

Fig.4

Overall flow chart of software part of system"

Fig.5

Diagram of camera sensor exposure control in global mode"

Fig.6

Processing process of cutter head analysis area. (a)Needle selector housing analysis box;(b)Minimum circumscribed rectangle;(c)Cutter head analysis area"

Fig.7

Diagram of cutter head after binaried"

Fig.8

Interactive interface"

Fig.9

Needle selector head swings normally"

Fig.10

Swing failure of needle selector"

Tab.1

Gray value of needle selector head under 200 ms exposure time"

类型 左1 右1 左2 右2 左3 右3 左4 右4 左5 右5 左6 右6 左7 右7 左8 右8
背景值 19 20 19 22 24 20 16 19 24 23 15 18 23 24 16 16
刀头左极限位,不摆动 191 0 169 0 182 0 189 0 184 0 199 0 207 0 209 0
刀头右极限位,不摆动 0 191 0 174 0 182 0 194 0 189 0 190 0 194 0 209
摆动频率10 Hz 103 102 93 94 101 99 101 103 102 105 106 103 112 107 111 111
摆动频率20 Hz 102 100 90 94 99 97 99 103 99 102 104 101 110 106 108 109
摆动频率40 Hz 98 97 87 91 96 95 95 99 96 102 100 100 105 106 102 108
摆动频率100 Hz 94 92 83 87 89 93 91 96 90 99 95 97 100 107 95 96
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