Abstract:
An apparatus for evaluating a fiber web running in a card includes a camera for scanning the fiber web along a length and width portion thereof to detect useful fibers and empty locations in the fiber web and to generate signals representing the useful fibers and empty locations; and an evaluating device connected to the camera for determining a distribution of useful fibers per area unit in the fiber web from the signals.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]    This application is a continuation of U.S. application Ser. No. 09/658,718 filed Sep. 11, 2000.  
     
    
     
         [0002]    This application claims the priority of German Application No. 199 43 079.9 filed Sep. 9, 1999, which is incorporated herein by reference.  
         BACKGROUND OF THE INVENTION  
         [0003]    This invention relates to a method and an apparatus for examining a fiber web advanced in a fiber processing machine such as a card or a roller card unit. The material of the web is cotton, chemical fibers or the like. The fiber web has useful fibers with intermediate, empty spaces therebetween (hereafter also referred to as empty locations). The apparatus includes a measuring track for the fiber material. The measuring track is associated with a camera, such as a diode matrix camera which is connected with an evaluating device such as an image processing computer.  
           [0004]    German Offenlegungsschrift (application published without examination) 39 28 279 to which corresponds U.S. Pat. No. 5,130,559, describes an apparatus in which foreign particles are recognized in the fiber flow in order to determine the degree of soiling (trash content) of the fiber material by optical and electronic means. For this purpose a sensor detects each foreign individual particle in the running fiber web and, by means of an evaluating device, for each individual particle specific characterizing magnitudes are determined (particularly gray scale and edge detection) to identify the matter as a foreign particle. In this manner, the foreign particles are differentiated from the useful fibers. The foreign particles form locally sharply delimited defective locations which are concentrated in a very small space. Further, such foreign particles display a different behavior with respect to the useful fibers; for example, neps (fiber knots which have a diameter less than 1 mm) appear as dots of increased reflection and may therefore be separated from the other signals. The individual particles are determined as differing from the remaining fiber web which only represents a background. The smaller the selection of the scanned surface region of the fiber web, the more conspicuous the appearance of a nep.  
           [0005]    It is a disadvantage of the above-outlined conventional arrangement that a detection and determination of the degree of homogeneity of the fiber web is not feasible. Also, such conventional arrangement is not concerned with a determination of the distribution and orientation of the useful fibers.  
         SUMMARY OF THE INVENTION  
         [0006]    It is an object of the invention to provide an improved method an apparatus of the above-outlined type which eliminates the discussed disadvantages and which, in particular, improves a detection and determination of the homogeneity of the fiber web, particularly the distribution and orientation of useful fibers and furthermore improves the degree of fiber web uniformity.  
           [0007]    This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the apparatus for evaluating a fiber web running in a card includes a camera for scanning the fiber web along a length and width portion thereof to detect useful fibers and empty locations in the fiber web and to generate signals representing the useful fibers and empty locations; and an evaluating device connected to the camera for determining a distribution of useful fibers per area unit in the fiber web from the signals.  
           [0008]    According to the invention, the useful fibers and voids, that is, the spaces (empty locations) between the useful fibers are detected and evaluated. From the ratio between the useful fibers and the empty locations per area unit the homogeneity and the web irregularity (cloudiness) is determined, whereby the distribution and orientation of the useful fibers in the fiber web are ascertained. The measuring values permit an image display and an optical and electronic evaluation. By examining the homogeneity, defects in the region of the roll clothings or an incorrect fiber feed may be detected and thus the quality of the produced fiber web may be improved. The homogeneity of the web produced by the carding machine or the roller card unit is automatically and continuously detected and evaluated so that by means of the machine control and setting members the processing of the fiber material may be affected. The greater the selected scanned surface area, the better the detectability of the distribution of the useful fibers.  
           [0009]    The invention has the following additional advantageous features:  
           [0010]    Determining the numerical distribution of the useful fibers;  
           [0011]    Determining the spatial distribution of the useful fibers;  
           [0012]    Detecting impurities, such as neps and distinguishing such impurities from the useful-fibers;  
           [0013]    Disregarding impurities, such as neps, when determining the distribution of useful fibers;  
           [0014]    Determining the area share of useful fibers and empty locations per unit area;  
           [0015]    Determining the distribution of dense and thin areas of useful fibers per unit area and comparing such distributions with stored comparison values for the fiber web;  
           [0016]    Determining the distribution of dense and thin areas of useful fibers per unit area and comparing such distributions with a homogeneous fiber web; and  
           [0017]    Utilizing a digital image data processing in the evaluating device.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWING  
       [0018]    [0018]FIG. 1 is a schematic side elevational view of a carding machine including a web supporting and guiding body housing a camera and an illuminating assembly for practicing the method according to the invention.  
         [0019]    [0019]FIG. 2 is a schematic sectional side elevational view of the apparatus for practicing the method according to the invention, including a block diagram.  
         [0020]    [0020]FIG. 2 a  is a schematic top plan view of a back-and-forth travelling carriage on which the camera and the illuminating assembly are mounted.  
         [0021]    [0021]FIG. 3 is a fragmentary schematic sectional view of the carding machine and also showing a computer and a display device illustrating a distribution of usable fibers and spaces therebetween.  
         [0022]    [0022]FIG. 4 is a block diagram of the apparatus according to the invention.  
         [0023]    [0023]FIG. 5 is a schematic to plan view of the fiber web indicating captured regions in the longitudinal and transverse direction.  
         [0024]    [0024]FIG. 6 a  is a diagram showing the homogeneity of the fiber web as a function of time (longitudinal direction for a defined track).  
         [0025]    [0025]FIG. 6 b  is a diagram showing the homogeneity of the fiber web as a function of time (in a transverse direction and illustrating a mean value for all tracks).  
         [0026]    [0026]FIG. 6 c  is a bar diagram illustrating the homogeneity of the fiber web (width distribution).  
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0027]    [0027]FIG. 1 illustrates a high performance carding machine CM which may be, for example, a DK 903 model manufactured by Trützschler GmbH &amp; Co. KG, Mönchengladbach, Germany.  
         [0028]    The carding machine CM has a feed roll  1 , a feed table  2  cooperating with the feed roll, licker-ins  3   a,    3   b  and  3   c,  a main carding cylinder  4 , a doffer  5 , a stripping roll  6 , cooperating crushing rolls  7  and  8 , a web guiding element  9 , a web trumpet  10 , cooperating pull-off rolls  11  and  12  and a traveling flats assembly  13 . Underneath the stripping roll  6  a web supporting and guiding body  14  is provided. The upper crushing roll  7  is in a close proximity to the stripping roll  6 . The direction of rotation of the main carding cylinder  4  and the rolls are shown by the curved arrows drawn thereinto.  
         [0029]    Turning to FIG. 2, in the region  15  of the carding machine the fiber web  16  leaves the stripping roll  6  and advances, as indicated by the arrow A, toward the crushing rolls  7 ,  8  on the surface  14   a  of the supporting and guiding body  14  which has a generally rectangular cross-sectional outline. The web supporting surface  14   a  is slightly concave and has a radius of curvature which is greater than the radius of the stripping roll  6 .  
         [0030]    The supporting and guiding body  14  is configured as a housing, and its upper wall, which includes the web supporting surface  14   a,  is provided with a transparent window  17 . The fiber web as it progresses from the main carding cylinder  4 , is first positioned on the clothing of the doffer  5  and then taken over by the clothing  6   a  of the stripping roll  6 . Slightly beyond a vertical center plane of the stripping roll  6 , oriented perpendicularly to the advancing direction A, the web  16  leaves the stripping roll  6  and, guided over the window  17 , enters the nip between the crushing rolls  7 ,  8  and passes therethrough. At the supporting surface  14   a,  one end of the body  14  extends into the gap zone between the doffer  5  and the stripping roll  6 , while its other end projects into the gap zone between the stripping roll  6  and the crushing rolls  7 ,  8 .  
         [0031]    The body  14  is an extruded hollow member made, for example, of aluminum and also functions as a housing. Also referring to FIG. 2 a,  a camera  18 , such as a diode matrix camera, an illuminating assembly composed of illuminating devices  19   a,    19   b  and a mirror  20  are mounted on a carriage  21  disposed in the inner space  14   b  of the body  14 . The camera  18  may be a diode line camera, it may have an optical component and an electronic component with a CCD chip. The reflecting mirror  20  is positioned at an angle between an objective  18   a  of the camera  18  and the illuminating assembly, on the one hand, and the inner face of the window  17 , on the other hand. The carriage  21  runs, on wheels  22   a,    22   b  engaging rails on the inner wall of the body  14 , perpendicularly to the drawing plane of FIG. 2, along the width of the carding machine, that is, transversely to the advancing direction A. Such a web supporting and guiding body, accommodating an equipment for taking pictures of a running fiber web in a carding machine is generally also disclosed in U.S. Pat. No. 5,692,267.  
         [0032]    As the camera  18  reciprocates along the width of the carding machine, it delivers sharp images of the fiber web  16  even in case of a card output of 300 m/min and transmits the image signals to an image processing computer  23  such as a microcomputer with microprocessor. The latter evaluates the images  32   a - 32   g  as shown in FIG. 5, based on the distribution of the useful fibers in the web  16  per surface unit. The results are shown in a display  25  via a machine control  24  which may be, for example, a Card-Commander model manufactured by Trützschler GmbH &amp; Co. KG. Additionally or as an alternative, the image signals are for further processing transmitted to an information system  28  which may be a KIT model manufactured by Trützschler GmbH &amp; Co. KG. The machine control  24  is followed by a control element  26  and a setting device  27  for affecting the distribution of the useful fibers in the fiber web  16 . The setting device  27  may trigger measures for changing the fiber distribution in the web  16 , for example, it may effect a change in the distance between the flat clothings and the cylinder clothing of the card, or the rpm of the cylinder or the distance between a guide element of a roll or may initiate a sharpening of the roll clothings.  
         [0033]    The apparatus according to the invention may be installed in, and removed from, a carding machine in a simple manner and thus a periodic measurement on different cards with the same apparatus may be carried out.  
         [0034]    As the fiber web  16  passes over the window  17 , the camera  18  takes pictures under reflected flash light illumination, as shown in FIG. 2. The evaluation is effected in principle as a desired value/actual value comparison. The reflection intensity related to the incident ray intensity is utilized as a desired parameter. A reflected light producing module includes a semiconductor flash device with high homogeneity and the command-controlled high speed measuring camera  18 . The camera  18  may have a digital data output as described, for example, in German Offenlegungsschrift No. 43 13 621. In case a transmitted light assembly is used, the latter includes a large-surface semiconductor flash device of high intensity.  
         [0035]    During operation, light flashes are produced as controlled by the camera  18  or the camera control. For the individual exposures light of different wavelengths may be used. Also, more than one illuminating device may be used for each exposure. For example, a reflected light assembly may use more than one illuminating device. The illumination may occur from different directions. Further, illumination may be effected from different sides (transillumination and reflection). For the illumination light sources with different wavelengths may be used. Further, various exposure times (flash duration) may be set.  
         [0036]    By means of the apparatus according to the invention an automatic detection and reduction of the irregularities of the fiber web  16  may be effected. It is of importance to detect the fiber web as it advances freely after its removal from the stripping roll  6 . While the invention has been described in connection with a carding machine, it will be understood that it may find application in other machines in which a fiber web is produced, such as a roller card unit.  
         [0037]    [0037]FIG. 3 shows an image screen  25  on which the fiber web  16  is reproduced, illustrating useful fibers and intermediate spaces therebetween. The homogeneity (cloudiness), that is, the distribution and orientation of the useful fibers is represented. The objective  18   a  of the camera  18  is, according to FIG. 3, oriented upwardly toward the fiber web  16  without a deflecting mirror as opposed to the arrangement according to FIG. 2 a.    
         [0038]    The block diagram of FIG. 4 shows the camera  18  followed by the image processing computer  23 , the card control device  24  and the display device  25 . When the obtained information data are, for example, transmitted to the card control  24  and therefrom to other superordinated monitoring systems such as the device  28 , a comparative monitoring of several machines is feasible and also, comparisons with earlier results may be made.  
         [0039]    As shown in FIG. 5, the camera  18  continuously delivers samples in the longitudinal and transverse direction of the web  16 . The evaluation of the images is effected according to the methods of digital image processing. Statistically supported determinations, for example, concerning the quality of the web (homogeneity) is feasible by applying suitable mathematical methods.  
         [0040]    The shaded area  31  indicates the scanning surface of the camera  18 , moved parallel to the width of the machine, in the direction of the arrows B and C. The sample images taken are designated at  32   a - 32   g.    
         [0041]    Based on known fiber web structures a normalization factor may be determined so that both for the length and for the width of the fiber web  16  time-dependent quality data may be obtained. For example, a highly satisfactory fiber web may be designated with the factor 10 and a very inferior quality may be assigned the factor 0. In this manner, respective assertions may be made (FIGS. 6 a - 6   c ). A similar process may be performed for the width distribution.  
         [0042]    It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.