WO2016140635A1

WO2016140635A1 - Fabric nep removing machine and removing method

Info

Publication number: WO2016140635A1
Application number: PCT/TR2016/050044
Authority: WO
Inventors: Ali KIRECCI
Original assignee: Kirecci Ali
Priority date: 2015-03-04
Filing date: 2016-02-24
Publication date: 2016-09-09

Abstract

The invention relates to a cleaning machine and a cleaning method for determining and cleaning/removing of neps formed on fabrics during production.

Description

FABRIC NEP REMOVING MACHINE AND REMOVING METHOD

DESCRIPTION

Subject of the Invention

The invention relates to a machine for determining and removing small ball-shaped fabric defects called as neps formed on surfaces of woven and knitted fabrics, and a method for describing this operation.

State of the Art

Cleaning/removal of defects found on fabric surface, especially on wool fabric surface is a labour intensive work which requires high costs as well as qualified and highly attentive personnel. While there are various kinds of fabric defects (such as double weft, warp breakage, loose weft, tight weft, weft run, nep(s), sparse weft, and tie) , among these, neps are frequently encountered defects. Said neps are not the neps found within yarn structure, but they are ball-shaped defects of generally about 3- 4 mm² size, formed on fabric surface by short fibres found on fabric or yarn, due to the friction between the yarns, or between the yarn and the machine while weaving fabric. Since neps are accumulation of fibres jammed into yarns within the fabric, their removal by means of a tool does not damage the fabric structure. In the state of the art, neps and other defects are manually removed/cleaned by personnel on fabric control tables found in special departments of production units, using tweezers, scissors etc. simple tools. Since nep removing operation depends on personnel skills, it is a frequently encountered situation where workers lose their attention for a short while and thus are not able to determine some of the neps, and therefore the fabric quality is negatively affected. As a result, the nep removing operations carried out according to the state of the art cause significant labour costs as well as differences in quality as a result of a non-standard process.

In the research, it was seen that there are some patent documents, which are not related to our invention, but explain the state of the art and contain automatic fabric cleaning or automatic fabric defect determination embodiments; The first example for the state of the art is the document No. 2008 00377 which relates to cleaning of foreign substances from fabric surface before printing process. It is based on removing of foreign substances from fabric surface by means of a cylinder on which an adhesive is applied.

Patent No. US 5283623 A can be given as an example for the state of the art. In this invention, a system is disclosed, through which fabric passes and the fabric surface is scanned by an optical sensor head during this passage in order to determine surface defects, and the defects are sorted according to their sizes. However, removal of the determined defects is not intended .

Another example for the state of the art is the patent No. WO 9208967 Al, which only relates to determination of fabric defects, and is based on formation of an image with the help of a raster scan camera during the flow of the fabric, and determining defects from analysis of this image. This system is not intended for removal of fabric surface defects either.

Another patent document is US 006750466 B2, which relates to determination of fabric defects via image analysis method. In the relevant patent study, a large number of raster scan cameras are used for obtaining the required resolution, and the images retrieved from these cameras are combined in a central computer to obtain the image of the fabric. Following image analysis, the defects found on the fabric surface are determined and sorted.

Another example for the state of the art is the patent application No. US 2014036061 A. This application relates to analysis of an image retrieved from a digital camera positioned on a loom (shedding region) , and determination and classification of defects. However, it is not intended for removal of the determined defects.

In order to eliminate the above disclosed problems, need has occurred for a machine and a removing method for determining and removing/cleaning the neps found on fabric surfaces.

Technical problems aimed to be solved with the present invention

The purpose of the invention is to develop a machine and a method for automatic removal of neps, which are formed on fabric surfaces and defined as frequently encountered defects. In this method, fabric surface is scanned by cameras and the image obtained as a result of scanning is analysed by software in order to determine the coordinates of the neps. Afterwards, a computer controlled removing apparatus is moved to the determined coordinates one by one to remove the neps. The invention has potential for improving fabric quality, reducing labour costs, and also providing saving from time due to its higher speed compared to the state of the art. Moreover, a standard nep removal operation with previously known characteristics would also be obtained with the present invention.

Detailed Description of the Invention

The machine according to the present invention aims to determine neps found on fabric surfaces with the help of image analysis, and to clean (remove) these neps by means of an apparatus, after their coordinates are calculated. The nep removing machine is basically formed of a fabric imaging unit (1), a fabric transfer unit (8), a nep removing apparatus positioning unit (19), and a nep removing apparatus (25) .

The fabric imaging unit (1) consists of one or more camera (s) (2) (preferably a raster scan camera) , an illumination component (3) , an imaging unit actuator (4) enabling back-and-forth movement of the cameras (2), imaging unit linear slides (5), an imaging unit motion transfer shaft (6), and an imaging unit chassis (7) on which these components are mounted. The number of cameras (2) to be used may vary according to the characteristics of the cameras (2) . Camera (2) resolution can be 1024, 2048, 4096, 8192, or 16384 pixels or more. The required resolution for determining neps is 300 pixels/inch, which is close to human eye sensitivity. The number of cameras (2) required can be calculated with regard to the length of the fabric (or width, depending on the camera (2) arrangement plan) to be imaged via scanning. The illumination component (3) illuminates the relevant fabric surface in accordance with the image capturing principle of the camera (2), and thus ensures obtaining clearer images. One or more illumination component (s) (3) can be used depending on the intensity of the light. Since the cameras (2) and the illumination component (3), which are mounted on the imaging unit linear slides (5) connected to the imaging unit actuator (4), can move back-and-forth, it is possible to capture the whole image of the fabric found within the machine. The imaging unit actuator (4) can preferably be a computer-controlled servo motor or a step motor or a hydraulic piston in order to perform position and speed control on the cameras (2) and the illumination component (3) in X-axis. An imaging unit motion transfer shaft (6) is used in order to ensure simultaneous motion and stopping of the imaging unit linear slides (5) . In this way, the slides can move in parallel and reciprocally with each other.

Scanning of the fabric by the cameras (2) forms the first stage of the operation. By means of analysis of the images retrieved from the cameras (2), the neps found on the fabric are determined and their coordinates are calculated. Since nep removal operation would be made following image analysis, the fabric is required to remain immobile during imaging and nep removing operations.

Following nep removal operation, the fabric is transferred onto the machine and the machine is prepared for a new operation by the fabric transfer unit (8) . This unit ensures that the fabric enters into the machine in a smooth (completely open) state and maintains the fabric in desired tightness during the operations. The fabric transfer unit (8) structure comprises a fabric support component (9), a fabric centering apparatus (10), a fabric expander spiral (11), a spiral motor (12), a fabric stretching cylinder (13), a fabric stretching cylinder actuator (14), a cylinder pressure adjusting apparatus (15), a fabric take up cylinder (16), a fabric take up cylinder actuator (17), and a fabric transfer unit chassis (18) .

The fabric support component (9) forms a flat surface below the fabric and between the fabric stretching cylinders (13) and the fabric take up cylinders (16) . This flat surface is for preventing the fabric from stretching during nep removing operations and ensure easier holding by the nep removing apparatus (25) . Moreover, in order to prevent the nep removing apparatus (25) from hitting hard surfaces during the nep removing operations, a foam layer of 1-2 cm thickness is found at the upper part of this flat surface. The upper portion of the foam surface is coated by a lining in order to facilitate sliding of the fabric while in motion on this surface. Fabric centering apparatus (10) restricts movement of the fabric towards the sides

(in width direction) while the fabric is in motion, and fixes the entrance position of the fabric into the machine. By means of the fabric expander spiral (11), fabric is prevented from getting wrinkled and folded while entering into the machine. Moreover, present wrinkles and folds are opened. The spiral motor (12) used for driving the fabric expander spiral (11) only while the fabric enters into the machine and keeping it still at other times is preferably a computer-controlled servo motor or a step motor. In this way, during imaging and nep removing operations, vibrations of the machine are reduced and better results are obtained.

Fabric tightness, which is very important both during imaging and nep removing operations, is ensured via fabric take up cylinders (16) and fabric stretching cylinders (13) . The fabric take up cylinder (16) driven by a fabric take up cylinder actuator (17), which is preferably a computer-controlled torque motor or a servo motor, and consisting of a pair of metal cylinders coated with plastic or rubber and placed on top of each other, ensures inlet of sufficient amount of fabric into the machine. The fabric stretching cylinder (13) found at the side where the fabric enters into the machine, and consisting of a pair of metal cylinders coated with plastic or rubber and placed on top of each other, ensures that the fabric continuously stays tight between the cylinders, by means of applying a continuous pulling force on the fabric, since it is driven by a fabric stretching cylinder actuator (14), which is preferably a torque motor or a servo motor. A cylinder pressure adjusting apparatus (15) is used for adjusting the pressure between the cylinders in order to prevent fabric from forming position defects by sliding between the cylinders. The cylinder pressure adjusting apparatus (15) pneumatically or mechanically adjusts the pressure between the cylinders . The nep removing apparatus positioning unit (19) is used for carrying the nep removing apparatus (25) to the desired point on the fabric found in the machine. The nep removing apparatus positioning unit (19) structure comprises an X axis linear slide

(20) , an X axis motion transfer shaft (21), an X axis actuator

(22) , a Y axis linear slide (23) , and a Y axis actuator (24) . A pair of X axis linear slides (20) mounted on the nep removing apparatus positioning unit (19) in parallel to each other are connected to each other via the X axis motion transfer shaft

(21) , and in this way, both slides are positively driven and thus started and stopped at the same moment. Moreover, possible mechanical contractions are avoided. The X axis actuator (22), which is preferably a computer-controlled servo motor or a step motor or a hydraulic piston, ensures back-and-forth movement of the X axis linear slide (20) along the X axis. Moreover, control of position and speed during this motion is also ensured by the X axis actuator (22) .

The direction of the Y axis linear slide (23) positioned on the X axis linear slides (20) is arranged to be perpendicular to the X axis. The Y axis actuator (24) can be a computer-controlled servo motor or a step motor or a hydraulic piston in order to provide back-and-forth movement of the Y axis linear slide (23) along the Y axis. In this way, the table found on the Y axis linear slide

(23) and the nep removing apparatus (25) mounted on this table can be positioned at any point on the fabric in the machine. The nep removing apparatus (25) is successively positioned at the points where the neps are found at the coordinates determined at the image analysis stage, removes the neps found at these points from the fabric surface and then take away from the machine via vacuum. The part of the fabric cleaned off of neps is taken out of the machine with the help of the transfer unit (8) and then the above disclosed steps are repeated after taking in a new part of fabric.

Description of the Figures

Figure 1: is the perspective view of the automatic nep removing machine .

Figure 2: is the perspective view of the fabric imaging unit. Figure 3: is the side view of the fabric imaging unit.

Figure 4: is the perspective view of the fabric transfer unit. Figure 5: is the perspective view of the nep removing apparatus positioning unit.

Figure 6: is the perspective view showing the fabric transfer unit and the nep removing apparatus positioning unit.

References

1. Fabric imaging unit

2. Camera

3. Illumination component

4. Imaging unit actuator

5. Imaging unit linear slide

6. Fabric imaging unit motion transfer shaf"

7. Imaging unit chassis

8. Fabric transfer unit

9. Fabric support component

10. Fabric centering apparatus

11. Fabric expander spiral

12. Spiral motor

13. Fabric stretching cylinder

14. Fabric stretching cylinder actuator

15. Cylinder pressure adjusting apparatus

16. Fabric take up cylinder

17. Fabric take up cylinder actuator

18. Fabric transfer unit chassis

19. Nep removing apparatus positioning unit

20. X axis linear slide

21. X axis motion transfer shaft

22. X axis actuator

23. Y axis linear slide

24. Y axis actuator

25. Nep removing apparatus

Claims

A machine for determining the coordinates of neps which are known as small faults on fabric surface, and removing these neps, characterized by comprising;

- a fabric imaging unit (1) comprising a camera (2), an illumination component (3), an imaging unit actuator (4), an imaging unit linear slide (5), an imaging unit motion transfer shaft (6), and an imaging unit chassis (7),

- a fabric transfer unit (8) comprising a fabric support component (9), a fabric centering apparatus (10), a fabric expander spiral (11), a spiral motor (12), a fabric stretching cylinder (13), a fabric stretching cylinder actuator (14), a cylinder pressure adjusting apparatus (15), a fabric take up cylinder (16), a fabric take up cylinder actuator (17), and a fabric transfer unit chassis (18) ,

- a nep removing apparatus positioning unit (19) comprising an X axis linear slide (20), an X axis motion transfer shaft (21), an X axis actuator (22), a Y axis linear slide (23), and a Y axis actuator (24),

- a nep removing apparatus (25) .

The machine for determining and removing neps found on fabric surface, according to Claim 1, characterized in that the fabric imaging unit (1) which takes the image of fabric and transfers it to a computer comprises; a camera (2), an illumination component (3), an imaging unit actuator (4), an imaging unit linear slide (5), an imaging unit motion transfer shaft (6), and an imaging unit chassis (7) .

The machine for determining and removing neps found on fabric surface, according to Claim 1, characterized in that; the fabric transfer unit (8) which feeds unprocessed fabric into the machine for a new process and takes the processed fabric from the machine comprises; a fabric support component (9), a fabric centering apparatus (10), a fabric expander spiral (11), a spiral motor (12), a fabric stretching cylinder (13), a fabric stretching cylinder actuator (14), a cylinder pressure adjusting apparatus (15), a fabric take up cylinder (16), a fabric take up cylinder actuator (17), and a fabric transfer unit chassis (18) .

The machine for determining and removing neps found on fabric surface, according to Claim 1, characterized in that; the nep removing apparatus positioning unit (19), which positions the nep removing apparatus (25) onto the points where the neps are found on the fabric, comprises an X axis linear slide (20), an X axis motion transfer shaft (21), an X axis actuator (22), a Y axis linear slide (23), and a Y axis actuator (24 ) .

The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 2, characterized by comprising; one or more camera (s) (2) depending on the size (length) of the line scanned for transferring the fabric image into digital media.

The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 2, characterised by comprising; one or more illumination component (s) (3) depending on the intensity of the light, in order to illuminate the region where the raster scan cameras (2) capture images .

The machine for determining and removing neps found on fabric surface according to any one of Claims 1 or 2, characterised by comprising; the imaging unit actuator (4) is a computer- controlled servo motor or a step motor or a hydraulic piston for performing position and speed control on the cameras (2) and the illumination component (3) in X-axis.

The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 2, characterised by comprising; a pair of imaging unit linear slides (5) preferably positioned in parallel to each other in order to allow back-and-forth movement of the cameras (2) and the illumination component (3) above the fabric.

The machine for determining and removing neps found on fabric surface, according to any one of Claims 1, 2, or 8, characterised by comprising; an imaging unit motion transfer shaft (6) used for allowing simultaneous starting and stopping of the imaging unit linear slides (5) that are positioned in parallel to each other.

10. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 2, characterised by comprising; an imaging unit chassis (7) on which cameras

(2) and an illumination component (3), an imaging unit actuator (4), an imaging unit linear slide (5), and an imaging unit motion transfer shaft (6) are mounted.

11. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 3, characterised by comprising; a fabric support component (9) for restricting the downward motion of fabric during nep removing operations.

12. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 3, characterised by comprising; a fabric centering apparatus (10) restricting the motion of the fabric in width direction, while entering into the machine.

13. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 3, characterised by comprising; at least one fabric expander spiral (11) for opening/expanding the wrinkles found on the fabric while entering into the machine.

14. The machine for determining and removing neps found on fabric surface according to any one of Claims 1 or 3, characterized in that; the spiral motor (12) minimizing the vibrations to be caused by the fabric expander spiral (11) on the machine, by moving only while the fabric enters into the machine, is preferably a computer-controlled servo motor or a step motor.

15. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 3, characterised by comprising; a fabric take up cylinder (13) consisting of a pair of metal cylinders coated with plastic or rubber and placed on top of each other in order to ensure that the fabric found in the machine stays in a tight state.

16. The machine for determining and removing neps found on fabric surface according to any one of Claims 1 or 3, and it is characterized in that; it comprises a fabric stretching cylinder actuator (14), which drives one of the fabric stretching cylinders (13) , and which is preferably a torque motor or a servo motor.

17 . The machine for determining and removing neps found on fabric surface according to any one of Claims 1 or 3, characterised by comprising; a cylinder pressure adjusting apparatus (15) mechanically or pneumatically adjusting the pressure between the fabric stretching cylinders (13) and the fabric take up cylinders (16) .

18 . The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 3, characterised by comprising; a fabric take up cylinder (16) consisting of a pair of metal cylinders coated with plastic or rubber and placed on top of each other and taking up fabric from the machine following the cleaning operation.

19 . The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 3, characterised by comprising; a fabric take up cylinder actuator (17), which drives one of the fabric take up cylinders (16), and which is preferably a computer-controlled torque motor or a servo motor .

20 . The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 3, characterised by comprising; a fabric transfer unit chassis (18) on which a fabric support component (9), a fabric centering apparatus

(10), a fabric expander spiral (11), a spiral motor (12), a fabric stretching cylinder (13), a fabric stretching cylinder actuator (14), a cylinder pressure adjusting apparatus (15), a fabric take up cylinder (16), and a fabric take up cylinder actuator (17) are mounted.

21 . The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 4, characterised by comprising; a pair of X axis linear slides (20) preferably positioned in parallel to each other in order to allow back-and-forth motion of the nep removing apparatus

(25) along X axis.

22. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1, 4, or 21, characterised by comprising; an X axis motion transfer shaft (21) used for allowing simultaneous starting and stopping of the X axis linear slides (20) that are positioned in parallel to each other.

23. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 4, characterised by comprising; an X axis actuator (22), which is preferably a computer-controlled servo motor or a step motor or a hydraulic piston, and which ensures position and speed control of the X axis linear slide (20) during back-and-forth movement .

24. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 4, characterised by comprising; a pair of Y axis linear slides (23) which allow back-and-forth motion of the nep removing apparatus (25) along Y axis.

25. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 4, characterised by comprising; a Y axis actuator (24), which is preferably a computer-controlled servo motor or a step motor or a hydraulic piston, and which ensures position and speed control of the Y axis linear slide (23) during back-and-forth movement .

26. The machine for determining and removing neps found on fabric surface, according to any one of Claims 1 or 4, characterised by comprising; a nep removing apparatus (25), which is positioned on the fabric at the points of neps by means of the X axis linear slides (20) and Y axis linear slides (23) .

27. A method for determining and removing neps found on fabric surface, characterised by;

- taking the fabric into the machine by means of fabric take up cylinders (16) and tightening the fabric via fabric stretching cylinders (13) ,

- while the fabric is taken into the machine, movement of the imaging unit linear slides (5), on which the camera (2) and the illumination component (3) are found, towards the other side of the machine with the drive provided by the imaging unit actuator (4), after the fabric is tightened, while returning, capturing of images by scanning of the fabric surface, and transfer of the captured images to a computer,

determination of neps on the captured images via image analysis software and determination of their coordinates ,

by using the coordinate information, positioning of the nep removing apparatus (25) found on the nep removing apparatus positioning unit (19) successively on the points where neps are found, starting from the nearest nep, and removing of the neps from the fabric surface via nep removing apparatus (25),

taking the neps removed from the fabric surface away from the machine with the help of a vacuum hose found on the nep removing apparatus (25), and

taking the fabric cleaned off of neps out of the machine with the help of the fabric transfer unit (8), taking in a fabric that is not cleaned, and repeating these operations in a cycle.