CN110672209A - Online detection method for warp knitting cloth color difference - Google Patents
Online detection method for warp knitting cloth color difference Download PDFInfo
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- 238000012545 processing Methods 0.000 claims abstract description 7
- 238000012797 qualification Methods 0.000 claims abstract description 7
- 238000004364 calculation method Methods 0.000 claims description 16
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J3/00—Spectrometry; Spectrophotometry; Monochromators; Measuring colours
- G01J3/46—Measurement of colour; Colour measuring devices, e.g. colorimeters
- G01J3/50—Measurement of colour; Colour measuring devices, e.g. colorimeters using electric radiation detectors
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J3/00—Spectrometry; Spectrophotometry; Monochromators; Measuring colours
- G01J3/46—Measurement of colour; Colour measuring devices, e.g. colorimeters
- G01J3/462—Computing operations in or between colour spaces; Colour management systems
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
- G01J3/00—Spectrometry; Spectrophotometry; Monochromators; Measuring colours
- G01J3/46—Measurement of colour; Colour measuring devices, e.g. colorimeters
- G01J2003/466—Coded colour; Recognition of predetermined colour; Determining proximity to predetermined colour
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Abstract
The invention relates to the technical field of weaving, and provides an online detection method for color difference of warp knitting cloth, which comprises the following steps: setting an encoder to generate a trigger signal along with the transmission of the warp knitting cloth; collecting images of warp-knitted cloth in real time through a color line scanning camera; processing the image to obtain a standard color image and a histogram intersection method standard graph; dividing the image into a plurality of sub-images, and calculating color difference values between the plurality of sub-images and the standard color image; dividing the image of the woven cloth into N × N sub-images; and calculating the Papanicolaou distance value of the color difference between the N sub-graphs and the histogram intersection method standard graph, judging whether the color difference exists or not, and calculating the qualification rate of the sub-graphs. The invention can realize on-line detection of chromatic aberration, and not only comprises the qualification rate of the whole chromatic aberration of the cloth, but also comprises the fluctuation condition of the chromatic aberration of the cloth, thereby intuitively and accurately reflecting the chromatic aberration condition of the whole cloth.
Description
Technical Field
The invention relates to the technical field of weaving, in particular to an online detection method for color difference of warp knitting cloth.
Background
The color difference is an important index for evaluating the grade quality of the warp knitting cloth, and directly influences the grade of a product. At the present stage, most of domestic shoe and clothes enterprises adopt a manual spot inspection mode to judge the color difference of the cloth. The method has the advantages of high labor intensity and high false detection rate. With the development of machine vision technology in recent years, the use of machines to replace human eyes for color difference detection is a new way to improve the efficiency of color difference detection and reduce the cost. The core of the machine vision color difference detection method is the calculation of color difference, however, the detection precision of the existing machine vision color difference detection is not enough, and the color difference of the whole cloth cannot be reflected intuitively and accurately. The existing machine vision color difference detection is applied to off-line detection, namely, the whole piece of cloth is knitted and is detected after leaving the knitting equipment, so that the knitting equipment cannot be adjusted in real time according to a detection structure.
Disclosure of Invention
Therefore, an online detection method for the color difference of the warp knitting cloth is needed to be provided, and the technical problems that the online detection cannot be realized by the existing machine vision color difference detection, and the color difference of the whole cloth cannot be reflected intuitively and accurately are solved.
In order to achieve the aim, the inventor provides an online detection method for color difference of warp knitting cloth, which comprises the following steps:
arranging an encoder, enabling the encoder to generate a trigger signal along with the transmission of the warp knitting cloth, wherein the trigger signal is used for triggering the color line scanning camera;
collecting images of the warp-knitted cloth in real time through the color line scanning camera;
processing the image to obtain a standard color image and a histogram intersection method standard graph;
dividing the image of the real-time collected warp knitted cloth into a plurality of sub-images, and calculating the color difference value between the plurality of sub-images and the standard color image by adopting a CMC color difference calculation formula to obtain a color difference fluctuation curve;
segmenting the real-time collected woven cloth image into N x N sub-images;
calculating the Papanicolaou distance value of the color difference between the N × N sub-graphs and the histogram intersection method standard graph;
and if the babbit distance value exceeds a preset threshold value, judging that color difference exists, and calculating the qualification rate of the subgraph.
Further, the step of setting the encoder to generate the trigger signal along with the transmission of the warp-knitted fabric comprises the steps of:
setting the frequency multiplication and the number of discarded encoders to enable the number of pulses per week of the encoders to be M, wherein a pulse calculation formula at the wheels of the encoders is as follows:
the camera trigger position pulse calculation formula:
in the formula: d is the circumference of the encoder wheel, A is the shooting distance of the line scan color camera, p is the number of pulses per week of the encoder, n is the frequency multiplication number, l is the number of discarded encoders per week, and 8192 is the resolution of the camera.
Further, the processing the image comprises the steps of:
black edges in the acquired image are removed, image noise is reduced, and the image size is reduced.
Further, the image noise reduction is realized by combining median filtering and gaussian filtering.
Further, the reducing the image size includes performing more than two down-sampling operations by using an image pyramid principle.
Further, segmenting the real-time captured image of the warp knit fabric into a plurality of sub-images includes:
dividing the warp knitted cloth into at least a left sub-figure, a middle sub-figure and a right sub-figure along the conveying direction of the warp knitted cloth.
Further, before the real-time collecting of the image of the warp-knitted cloth by the color line-scan camera, the method further comprises the following steps:
and performing flat field correction on the color line scan camera.
Further, the flat field correction includes: and performing flat field correction on the line scanning color camera by using the dark field and the bright field.
Further, the resolution of the standard color image is: 1024 pixels 256 pixels, and the resolution of the histogram intersection histogram is 128 pixels 32 pixels.
Different from the prior art, the technical scheme is provided with the encoder, so that the encoder generates a trigger signal along with the transmission of the warp knitting cloth, controls the color line scanning camera to synchronously acquire cloth images, detects the acquired cloth images and realizes the online detection of chromatic aberration by a machine; in the technical scheme, when the color difference is detected, the cloth image is divided into N × N sub-images, the color difference of each sub-image is calculated and judged through a histogram intersection method, so that the qualified rate of the cloth color difference is judged, and the fluctuation condition of the cloth color difference is counted through a CMC color difference calculation formula.
Drawings
FIG. 1 is a flow chart of a warp knitted fabric color difference on-line detection method according to an embodiment;
FIG. 2 is a display interface of the color difference detection system according to an embodiment;
FIG. 3 is a diagram illustrating a fluctuation of chromatic aberration according to an embodiment;
FIG. 4 is a schematic view of a test report interface.
Detailed Description
To explain technical contents, structural features, and objects and effects of the technical solutions in detail, the following detailed description is given with reference to the accompanying drawings in conjunction with the embodiments.
Referring to fig. 1 to 4, the present embodiment provides an online detection method for warp knitting cloth color difference. As shown in fig. 1, the warp knitting cloth color difference online detection method comprises the following steps:
s101, setting an encoder, and enabling the encoder to generate a trigger signal along with the transmission of the warp knitting cloth, wherein the trigger signal is used for triggering a color line scanning camera;
s102, collecting images of the warp-knitted cloth in real time through the color line scanning camera;
s103, processing the image to obtain a standard color image and a histogram intersection method standard graph;
s104, dividing the image acquired in real time through the woven cloth into a plurality of sub-images, and calculating color difference values between the plurality of sub-images and the standard color image by adopting a CMC (carboxy methyl cellulose) color difference calculation formula to obtain a color difference fluctuation curve;
s105, segmenting the image collected in real time through the woven cloth into N × N sub-images by adopting a histogram intersection method;
s106, calculating a Pasteur distance value between the N × N sub-graphs and the histogram intersection method standard graph;
and S107, if the Pasteur distance value exceeds a preset threshold value, judging that color difference exists, and calculating the qualification rate of the subgraph.
The warp knitting refers to a weaving method for knitting a fabric by utilizing warp wale looping, and the warp knitting cloth refers to cloth obtained by a warp knitting mode. The warp-knitted fabric forms the loop winding knot, has stable structure and good air permeability, and is widely applied to the fabric of shoes and clothes.
In step S101, a code wheel of an encoder (encoder) may contact the warp knitted cloth through a guide wheel, so that the code wheel and the cloth rotate synchronously, and therefore, a linear displacement of the warp knitted cloth may be converted into an electrical signal through the encoder, and the linear scanning camera is controlled to operate, so that the linear scanning camera is triggered to acquire an image every time the warp knitted cloth is conveyed a certain distance. The line scan camera is also called a line scan camera, and is a camera using a line image sensor. The line image sensor is mainly based on a CCD, and an image acquired by a line scanning camera is usually in a line shape, although the image is also a two-dimensional image, the length of the image is long, and the width of the image is only a few pixels. Therefore, in step S101, in order to make the line scan camera not drop frames and not compress the image (stretch or squeeze the image), the frequency conversion and the number of dropped encoder pulses are adjusted to make the encoder pulse per cycle M, where the pulse at the encoder wheel is calculated as:
the camera trigger position pulse calculation formula:
in the formula: d is the circumference of the encoder wheel, A is the shooting distance of the line scan color camera, p is the number of pulses per week of the encoder, n is the frequency multiplication number, l is the number of discarded encoders per week, and 8192 is the resolution of the camera.
In step S102, a cloth inspecting platform may be set up, and the line scan color camera and the encoder are disposed on the cloth inspecting platform. The cloth inspecting platform can be arranged at the cloth outlet end of warp knitting cloth weaving equipment (namely a warp knitting machine), so that the color difference of the warp knitting cloth can be detected in real time. In order to ensure the accuracy of the cloth color difference detection, the light intensity and the light color of the cloth inspecting platform are required to be kept stable and unchanged in the color difference detection process (namely, in the surface inspection process). Because of the influence of light, lens, background image noise of an imaging device and the like, the imaging chromaticity of the same image of the line scanning color camera may have small-range deviation, so that in order to reduce the influence of environment or camera hardware on a chromatic aberration detection structure, the line scanning color camera needs to be subjected to flat field correction before detection. The flat field correction can make the response straight lines of all the pixels identical by changing the slope (i.e. signal Gain) and the Offset (i.e. signal Offset) of the response straight line of each pixel. In the present embodiment, the lower flat field correction of the line scan color camera may be a flat field correction of the line scan color camera using a dark field and a bright field. Specifically, a white background image is acquired by using a line-scan color camera, dark field correction is used, the soldier uses the background image in the white background, and the threshold value of the line-scan color camera can be set to 200.
Also in step S103, since the length of the image captured by the line scan color camera is long, the captured image will typically include an image other than a warp knit cloth (cloth transfer stage, etc.), and the size of the image will be large, with an image size of 8192 pixels 2048 pixels. The images outside these warp-knitted fabrics are usually located at the edges of the fabric and are mainly black, hence the short name black edge. The presence of a black border affects the color difference detection result, and therefore the image is processed, including image black border reduction, noise reduction, image size reduction, and the like. The method comprises the steps of conducting black edge removing operation on an acquired image of the cloth, removing redundant background, and finding out a maximum inscribed rectangle in the acquired image by using an automatic threshold method.
The image noise can be reduced by combining median filtering and Gaussian filtering. In an embodiment, the image size is reduced to 1024 pixels by 256 pixels by performing more than two down-sampling operations using the image pyramid principle. The image pyramid is a kind of multi-scale representation of an image, and is an effective but conceptually simple structure to interpret an image in multi-resolution. A pyramid of an image is a series of image sets of progressively lower resolution arranged in a pyramid shape and derived from the same original image. It is obtained by down-sampling in steps, and sampling is not stopped until a certain end condition is reached. We compare the images one level at a time to a pyramid, with the higher the level, the smaller the image and the lower the resolution.
By processing the image in step S103, a standard color image and a histogram intersection method standard chart can be obtained. The resolution of the standard color image can be 1024 pixels by 256 pixels, the standard color image is mainly calculated by applying subsequent color difference fluctuation, the resolution of the histogram intersection method standard graph can be 128 pixels by 32 pixels, and the histogram intersection method standard graph can also be obtained by performing more than two times of image pyramid principle down-sampling operation on the standard color image.
Before step S103 (including S103), the image captured by the line scan color camera is used to generate a standard color image and a histogram intersection standard chart, i.e. to prepare for the subsequent color difference detection of the cloth, and in the subsequent step of step S104, the line scan color camera captures the image of the cloth in real time for the color difference detection. In step S104, the line scan color camera performs real-time image acquisition of the cloth according to the control of the encoder output signal, divides the real-time image acquired through the cloth into a plurality of sub-images, and calculates color difference values between the plurality of sub-images and the standard color image to obtain a color difference fluctuation curve. When the subgraph segmentation is carried out, the collected image can be segmented into a left subgraph, a middle subgraph and a right subgraph along the cloth conveying direction, and the color difference calculation is carried out on the left subgraph, the middle subgraph and the right subgraph, specifically, the color difference value of the subgraph (namely, the color difference value between each subgraph and a standard color image) can be calculated by adopting a CMC (2: 1) color difference calculation formula, so that the color difference fluctuation condition of the cloth is obtained. The color difference fluctuation curve of the cloth can be established through color difference calculation of images of a plurality of continuous cloth.
In an embodiment, all image color spaces can be converted into an LAB color space, the color difference of the LAB color space can be calculated by using a CMC (2: 1) color difference calculation formula, a color difference calculation algorithm can be written by using C + +, a DILL algorithm file is generated at the same time, and when the color difference detection system is used, the generated DILL algorithm file is called by a cloth color difference detection software system to perform color difference calculation.
In other embodiments, the acquired image of the cloth may be divided into four or more sub-images, and the color difference value of each sub-image may be calculated.
As shown in fig. 1, steps S105 to S106 and step S104 may be performed in parallel, wherein the real-time acquired woven image is segmented into N × N sub-graphs in step S105. The histogram intersection method may be used to further segment the image acquired through the woven fabric into N × N sub-graphs, for example, into 8 × 8 sub-graphs. In steps S106 and S107, the interval between the N × N sub-graphs and the histogram intersection method standard graph is calculatedColor differenceWherein the baryta distance (Bhattacharyyadistance) is used to measure two discrete probability distributionsSeparability between classes is often measured in classification. If between subgraph and histogram intersection method standard graphColor differenceIf the babbit distance value exceeds the preset threshold value, the color difference exists (namely the subgraph is unqualified), and the qualification rate of the subgraph can be calculated by counting the number of the subgraphs with the color difference.
The warp knitting cloth color difference online detection method further comprises the following steps: generating detection information such as a color difference fluctuation chart and color difference qualification rate in a detection report and uploading the detection information to a server
As shown in fig. 2, the display interface of the color difference detection system using the warp knitted cloth color difference online detection method is shown, wherein a real-time color difference fluctuation curve of a left sub-graph, a middle sub-graph and a right sub-graph is displayed. FIG. 3 is a drawing showing
Fig. 4 is a sample of a color difference detection report of a warp knitted fabric, in which the fabric yield of the warp knitted fabric, the number of real-time color difference overproof codes of the left, middle and right subgraphs, and the final detection result of the fabric are displayed.
The technical scheme is that the encoder is arranged, so that the encoder generates a trigger signal along with the transmission of the warp knitting cloth, controls the color line scanning camera to synchronously acquire cloth images, detects the acquired cloth images and realizes the online detection of chromatic aberration of the machine; in the technical scheme, when the color difference is detected, the cloth image is divided into N × N sub-images, the color difference of each sub-image is calculated and judged through a histogram intersection method, so that the qualified rate of the cloth color difference is judged, and the fluctuation condition of the cloth color difference is counted through a CMC color difference calculation formula.
It should be noted that, although the above embodiments have been described herein, the invention is not limited thereto. Therefore, based on the innovative concepts of the present invention, the technical solutions of the present invention can be directly or indirectly applied to other related technical fields by making changes and modifications to the embodiments described herein, or by using equivalent structures or equivalent processes performed in the content of the present specification and the attached drawings, which are included in the scope of the present invention.
Claims (9)
1. An on-line detection method for warp knitting cloth color difference is characterized by comprising the following steps:
arranging an encoder, enabling the encoder to generate a trigger signal along with the transmission of the warp knitting cloth, wherein the trigger signal is used for triggering the color line scanning camera;
collecting images of the warp-knitted cloth in real time through the color line scanning camera;
processing the image to obtain a standard color image and a histogram intersection method standard graph;
dividing an image acquired in real time through the woven cloth into a plurality of sub-images, and calculating color difference values between the plurality of sub-images and the standard color image by adopting a CMC (carboxy methyl cellulose) color difference calculation formula to obtain a color difference fluctuation curve;
segmenting the real-time collected woven cloth image into N x N sub-images;
calculating bus distance values between the N × N sub-graphs and the histogram intersection method standard graph;
and if the babbit distance value exceeds a preset threshold value, judging that color difference exists, and calculating the qualification rate of the subgraph.
2. The method for detecting color difference of woven cloth according to claim 1, wherein said step of setting the encoder to generate the trigger signal with the transmission of the woven cloth comprises the steps of:
setting the frequency multiplication and the number of discarded encoders to enable the number of pulses per week of the encoders to be M, wherein a pulse calculation formula at the wheels of the encoders is as follows:
the camera trigger position pulse calculation formula:
in the formula: d is the circumference of the encoder wheel, A is the shooting distance of the line scan color camera, p is the number of pulses per week of the encoder, n is the frequency multiplication number, l is the number of discarded encoders per week, and 8192 is the resolution of the camera.
3. The method for detecting color difference of warp knitted cloth according to claim 1, wherein said processing said image comprises the steps of:
black edges in the acquired image are removed, image noise is reduced, and the image size is reduced.
4. The method for detecting color difference of warp knitted cloth according to claim 3, wherein the image noise reduction is realized by combining median filtering and Gaussian filtering.
5. The method as claimed in claim 3, wherein the reducing of the image size comprises performing more than two down-sampling operations by using the image pyramid principle.
6. The method for detecting color difference of warp knitted cloth according to claim 1, wherein segmenting the image of the real-time collected warp knitted cloth into a plurality of sub-images comprises:
dividing the warp knitted cloth into at least a left sub-figure, a middle sub-figure and a right sub-figure along the conveying direction of the warp knitted cloth.
7. The method for detecting color difference of warp knitted cloth according to claim 1, wherein before the real-time collecting of the image of warp knitted cloth by the color line scan camera, the method further comprises the steps of:
and performing flat field correction on the color line scan camera.
8. The method for detecting color difference of warp knitted cloth according to claim 7, wherein the flat field correction comprises: and performing flat field correction on the line scanning color camera by using the dark field and the bright field.
9. The method for detecting color difference of warp knitted cloth according to claim 1, wherein the resolution of the standard color image is as follows: 1024 pixels 256 pixels, and the resolution of the histogram intersection histogram is 128 pixels 32 pixels.
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