A high-speed moving high-definition camera is installed above the row of looms to capture the defects on the fabric surface by "flying shots", and then "stop" the looms and locate them with infrared rays, and "inform" the operator to repair the defects...Suzhou Zhongke Shuttle The "Textile Eagle" intelligent inspection robot developed by Intelligent Technology Co., Ltd. has been officially "on duty" in July this year. It has achieved remarkable results. This equipment saves two-thirds of manpower and has an inspection rate of over 92%, and the earth helps fabrics Quality improvement, leading the re-transformation of the famous textile city.
Fabric flaws will never escape "Eagle Eye" flying shots
In a large weaving enterprise in Shengze, Wujiang, Suzhou City, above the row of water jet looms, a large "projector" moves at high speed on the guide rail, and when it moves to the top of the cloth banner of the loom, the "projector" presses Lower the shutter. Once "discovered" defects such as broken warp and weft on the fabric, immediately lock it with infrared rays and "command" the machine to stop and notify the operator. The person in charge of the workshop said that by replacing human eyes and legs with high-speed moving robots, it is easier to stop the car and the yield rate is higher.
At present, intelligent manufacturing has become an important starting point for Shengze textile industry to upgrade and upgrade, and the world's top looms have accounted for more than half of the total. However, with labor shortages and rising labor costs, Shengze textile industry is still facing constraints. Especially in the weaving link, the turning workers are affected by working time, environment, mood, energy, etc., and the manual inspection rate is less than 20%.
"The weaving link needs to be further'machine substitution', so that the detection rate and yield rate can be effectively improved, and'Shengze Weaving' and'Made in Suzhou' can be more competitive." Jinstar Textile Machinery, which has been developed and manufactured by the deep cultivation textile machine for more than 20 years Hou Jingkui, the chairman of the company, got inspiration from the eagle eyes of the football field and the track high-speed camera for the 100-meter track and field. "If the high-speed camera can replace the human eye and the orbital movement can replace the manual inspection, the problem will be solved!"
Overcome difficulties and develop textile intelligent inspection robots
After many inquiries, Hou Jingkui learned that the Suzhou Institute of Automation, Chinese Academy of Sciences has a high-speed camera. To this end, the two parties hit it off and jointly established the Zhongke Flying Shuttle to develop an intelligent textile inspection robot.
The goal is clear, the direction is clear, and the process is extremely difficult. Lu Wei, general manager of Feisuo, said that in order to achieve the expected results, two major problems must be solved: one is high-speed movement, and the other is "flying shooting." For chemical fiber silk weaving, the warp and weft are between millimeters, and the movement is too fast, the higher the requirements for anti-shake and capture, the higher the cost; the movement is too slow, and it cannot keep up with the weaving speed of advanced looms.
After 2 years of research and development, Fraxel finally overcome the difficulties and successfully launched two products. One is a linear guide rail, a single-sided camera, and can inspect up to 5 looms. The inspection speed is 3 meters/second, and the return distance is 5 meters/second. It accurately matches the weaving speed of each banner of the loom to ensure that there is no missed inspection; the other is a ring guide rail, dual-side cameras, and an average speed of 2 meters/second. . By encrypting the number of robots, more loom loop detection can also be achieved.
"Mobile'flying shooting', image recognition, big data comparison, infrared locking... With the help of algorithms such as image analysis and target tracking, we can make our cloth inspection smarter." Hou Jingkui said that they have now completed the basics of defective images Information collection. In the future, with the continuous update and iteration of the database, the robot inspection rate will be close to 100%, which will better solve the problem of labor shortage for high-quality textile enterprises.
In the textile manufacturing process, quality inspection and control is an important operation step, and the core process in the quality inspection process is the capture and repair of textile defects. At present, it is the inspection method of most light industry factories to find defects by the operator only by eye observation. There have always been some problems in this, such as the excessive intensity of this working method, the high rate of missed detection and false detection, and the manual inspection is operated. The subjective factors of workers have a relatively large influence, so higher accuracy cannot be guaranteed, and it is easy to cause certain damage to the workers’ own vision. A good “turnover worker” may have a monthly income of 10,000 or more, with greater liquidity and higher costs.
Textile defect detection is currently a research hotspot in the field of computer vision. There have been many research results at home and abroad, but in terms of effectiveness, real-time and applicability, the current detection technology cannot fully meet the requirements of actual production. Further explore the new technology of fabric defect detection.
Digital empowerment sets a new benchmark for industrial transformation and upgrading
From the perspective of the bosses of textile enterprises, the profit rate of the industry is getting lower and lower, and the labor costs are getting higher and higher. From a market economy perspective, if wages are not paid in place, workers will be lost. Especially for skilled workers, many factories have to get a salary increase, so the wage level of workers is gradually going up. In the textile industry, the boss begs workers and begs them to stay. How to solve this pain and difficulty is the direction that Suzhou Siso Intelligent Technology Co., Ltd. has been committed to.
Suzhou Sisuo Intelligent Technology Co., Ltd. relies on the scientific research strength of the Suzhou Institute of Automation, Chinese Academy of Sciences, the School of Textile and Clothing Engineering, Soochow University, and the State Key Laboratory of Textile and Clothing of Qingdao University. Based on the transformation and upgrading of the textile industry, it focuses on R&D and manufacturing based on artificial intelligence. Online real-time detection equipment for textile defects and big data analysis is committed to becoming the leading driving force for digitalization in the textile industry. The company's products use guide rail technology to realize a flying shuttle automatic detection equipment that can simultaneously detect more than 10 textile equipment in real time. According to different defect conditions, it automatically controls the operation status of the textile equipment, realizes alarms, shutdowns, etc., and improves the detection of textile defects The detection rate has been increased from 20% to 95%, improving the quality of fabrics and increasing the unit price of finished products.
At present, this enterprise has become a benchmark enterprise for the transformation and upgrading of the textile industry in Shengze Town, with huge development potential and good development trends. At present, the company has received key support from the Shengze government. It plans to provide 30 acres of land with a total investment of 500 million yuan to build big data centers, factories and office buildings. It is expected that the annual output value will exceed 100 million yuan and the tax revenue per mu will exceed 600,000 yuan. /mu.
Through digital empowerment, Sissot has empowered the economic transformation of Shengze, a millennium-renowned textile city and ancient silk town, and provided Shengze enterprises with data-supported reform plans to reduce corporate costs and enhance the image of the company’s digital transformation. Textile, a traditional and fashionable industry, provides new momentum.
Suzhou textile enterprises ove
