Monitoring Contamination in a Stream of Fiber Flocks

Abstract

The method is for monitoring contamination in a stream of fiber flocks transported pneumatically in an airflow. Characteristics of entities, including contamination, in the stream of fiber flocks are detected and evaluated. Values of a first parameter and a second parameter of the entities are determined from the characteristics of the entities. An event field is provided, which contains a quadrant or a part of a quadrant of a two-dimensional Cartesian coordinate system, wherein a first axis defines the first parameter and a second axis defines the second parameter. The values of the first parameter and the second parameter determined for an entity are entered in the event field as coordinates of an event representing the entity. Thus, entities can be handled in a differentiated way.

Claims

1. A method for monitoring contamination in a stream of fiber flocks transported pneumatically in an airflow, wherein characteristics of entities, including contamination, in the stream of fiber flocks are detected and evaluated, comprising: determining values of a first parameter and a second parameter of the entities from the characteristics of the entities, providing an event field, which contains at least a part of a quadrant of a two-dimensional Cartesian coordinate system, wherein a first axis defines the first parameter and a second axis defines the second parameter, and the determined values of the first parameter and the second parameter for an entity are entered in the event field as coordinates of an event representing the entity.

2. The method according to claim 1, wherein: the first parameter is related to a geometric characteristic of the entities, and the second parameter is related to an optical characteristic of the entities.

3. The method according to claim 1, wherein: at least two classes of entities in form of non-overlapping areas in the event field are predetermined, and an entity is classified in one of the at least two classes when the coordinates of an event representing the entity lie in the corresponding area.

4. The method according to claim 3, wherein entities classified in at least one of the at least two classes are counted and individual numbers of entities counted are output for each of the at least one of the at least two classes.

5. The method according to claim 1, wherein: at least two event fields are provided, each of the at least two event fields containing at least a part of a quadrant of a two-dimensional Cartesian coordinate system, wherein a first axis defines the first parameter and a second axis defines the second parameter, in each of the at least two event fields at least two classes of entities in form of non-overlapping areas in the event field are predetermined, a criterion related to at least a third parameter of entities is assigned to each of the at least two event fields, values of the least a third parameter are determined from the characteristics of the entities, and an entity is classified in one of the at least two event fields, depending on the fulfillment of the criterion by the value of the at least third parameter determined for said entity.

6. The method according to claim 5, wherein the third parameter is related to an optical characteristic of the entities.

7. The method according to claim 1, wherein: a removal limit in form of a removal curve in the event field is predetermined as a criterion for the permissibility or impermissibility of the entities, and entities represented by events with coordinates on one side of the removal curve are left in the stream of fiber flocks, whereas entities represented by events with coordinates on another side of the removal curve are removed from the stream of fiber flocks.

8. The method according to claim 1, wherein: at least two classes of entities in form of non-overlapping areas in the event field are predetermined, and an entity is classified in one of the at least two classes when the coordinates of an event representing the entity lie in the corresponding area, a removal limit in form of a removal curve in the event field is predetermined as a criterion for the permissibility or impermissibility of the entities, and entities represented by events with coordinates on one side of the removal curve are left in the stream of fiber flocks, whereas entities represented by events with coordinates on another side of the removal curve are removed from the stream of fiber flocks, and the event field, including a scatter plot showing coordinates of events representing entities, the removal curve, and the at least two areas are graphically represented.

9. The method according to claim 8, wherein: a statistical representation of the stream of fiber flocks is determined from the values of the first parameter and the second parameter of the entities, a removal limit is predetermined on the basis of the statistical representation, at least one of a time-related and a mass-related number of impermissible entities is calculated from the statistical representation and the removal limit, at least one of the time-related and mass-related number of impermissible entities is output on an output unit, an operator is requested to enter a comment on the output time-related or mass-related number of impermissible entities by means of an input unit, and the removal limit is set automatically according to the entered comment.

10. The method according to claim 8, wherein a second monitoring of contamination is subsequently performed in at least one of the stream of fiber flocks and a product containing fibers from the stream of fiber flocks, and the removal limit in the monitoring of contamination in the stream of fiber flocks is changed depending on a result of the second monitoring of contamination.

11. The method according to claim 8, wherein a second monitoring of contamination is subsequently performed in at least one of the stream of fiber flocks and a product containing fibers from the stream of fiber flocks, and a removal limit in the second monitoring of contamination is changed depending on a result of the monitoring of contamination in the stream of fiber flocks.

12. The method according to claim 11, wherein the second monitoring is performed by means of a yarn clearer in a yarn containing fibers from the stream of fiber flocks.

13. A device for monitoring contamination in a stream of fiber flocks, comprising: a pneumatic fiber transport conduit for transporting the stream of fiber flocks, a sensor system for detecting characteristics of entities, including contamination, in the stream of fiber flocks, the sensor system being arranged on the pneumatic fiber transport conduit, and an evaluation unit for evaluating output signals of the sensor system, the evaluation unit configured for, determining from the output signals of the sensor system values of a first parameter and a second parameter of the entities, providing an event field, which contains a quadrant or a part of a quadrant of a two-dimensional Cartesian coordinate system, wherein a first axis defines the first parameter and a second axis defines the second parameter, and entering the values of the first parameter and the second parameter determined for an entity in the event field as coordinates of an event representing the entity.

14. The device according to claim 13, wherein the device further comprises an output unit for outputting a result of the evaluation, the output unit being configured for outputting a graphical representation of the event field, including a scatter plot showing the coordinates of events representing entities.

15. The device according to claim 13, wherein the sensor system comprises a camera for taking images of the stream of fiber flocks.

16. The device according to claim 13, further comprising a removal unit for selectively removing entities from the stream of fiber flocks is disposed on the pneumatic fiber transport conduit downstream of the sensor system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The invention is now explained in closer detail by references to the attached drawings.

[0035] FIG. 1 schematically shows a device according to the invention.

[0036] FIG. 2 shows graphical representations of event fields with scatter plots.

[0037] FIG. 3 shows a flow chart of an embodiment of the method according to the invention.

[0038] FIG. 4 shows examples of three different spectral distributions in optical signals obtained from three different types of contaminants.

[0039] FIG. 5 shows a block diagram of a system for carrying out an embodiment of the method according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] FIG. 1 schematically shows a device 100 according to the invention. The device 100 is for monitoring contamination in a stream of fiber flocks 9. It comprises a pneumatic fiber transport conduit 101 for pneumatically transporting the stream of fiber flocks 9 in an airflow. The transport direction of the stream of fiber flocks 9 and the airflow is indicated in FIG. 1 by arrows 91.

[0041] Four light sources 103, such as fluorescent tubes, are arranged in the vicinity of windows 102 in a wall of the fiber transport conduit 101. The light sources 103 illuminate from various directions the stream of fiber flocks 9 in the fiber transport conduit 101.

[0042] A sensor system 105 is arranged on the fiber transport conduit 101. It detects characteristics of entities, including contamination, in the stream of fiber flocks 9. In the embodiment of FIG. 1, the sensor system 105 comprises two cameras 106, e.g., CCD cameras, that take images of the stream of fiber flocks 9 through the windows 102 from two different directions. After interaction with the stream of fiber flocks 9, the light can be deflected between the windows 102 and the cameras 106 by means of tilted mirrors 104. It should be understood that the cameras 106 are only an example of a sensor system 105, and that alternative or additional sensor systems can be used in the device 100 according to the invention. Such alternative or additional sensor systems could detect characteristics of entities based on electromagnetic waves other than light, such as microwaves, on acoustic waves, etc. Some of the alternative sensor systems do not need any light sources.

[0043] The cameras 106 are connected to an evaluation unit 107 for evaluating output signals of the sensor system 105. The evaluation unit 107 is configured for determining from the output signals of the sensor system 105 values of a first parameter and a second parameter of the entities. The evaluation unit 107 is further configured for providing an event field 200 as discussed below with reference to FIG. 2, and for entering the values of the first parameter and the second parameter determined for an entity in the event field 200 as coordinates of an event 203, 204 representing the entity. The evaluation unit is preferably a computer.

[0044] The evaluation unit 107 is connected to an output unit 108 for outputting a result of the evaluation. The output unit 108 is configured for outputting a graphical representation of the event field 200 as discussed below with reference to FIG. 2. The output unit 108 can be, for instance, a display screen or a printer. In one embodiment, it is a touchscreen and thus serves as an input and output unit.

[0045] A removal unit 109 for selectively removing entities from the stream of fiber flocks 9 is arranged on the pneumatic fiber transport conduit 101 downstream of the sensor system 105 with regard to the transport direction 91. Such a removal unit 109 is known as such, e.g., from WO-2006/079426 A1. In a preferred embodiment, it comprises a plurality of pressurized air nozzles which are individually controllable by the evaluation unit 107. When the sensor system 105 detects an impermissible contamination 90 in the stream of fiber flocks 9, the appropriate air nozzle of the removal unit 109 is caused to blow pressurized air perpendicularly to the transport direction 91 of the stream of fiber flocks 9 when the contamination 90 has arrived at the removal unit 109. Thus, the contamination 90 is blown out into a removal channel 110 leading away from the fiber transport conduit 101 in a removal direction 92 essentially perpendicular to the transport direction 91 of the stream of fiber flocks 9. The uncontaminated fiber flocks continue on their way with the stream of fiber flocks 9.

[0046] The removal unit 109 can be controlled by the evaluation unit 107 and/or directly by the sensor system 105. In the latter case, a microprocessor can be associated with each camera 106, and the cameras 106 can be directly connected with the removal unit 109. Such direct connections are not drawn in FIG. 1 for the sake of simplicity. In a further alternative, the removal unit 109 is controlled by a microprocessor associated with the removal unit 109 itself.

[0047] As mentioned above, a graphical representation of the event field 200 provided by the evaluation unit 107 can be output on the output unit 108. Two examples of graphical representations of the event field 200 are shown in FIG. 2. The event field 200 contains a quadrant or a part of a quadrant of a two-dimensional Cartesian coordinate system. A first axis 201, e.g., the abscissa, defines the first parameter and a second axis 202, e.g., the ordinate, defines the second parameter. The first parameter can be related to a geometric characteristic of the entities, and preferably is a length or an area of the entities. The second parameter can be related to an optical characteristic of the entities, and preferably is an intensity of light reflected and/or transmitted by the entities. The values of the first parameter and the second parameter determined for an entity are entered in the event field 200 as coordinates of the entity. Thus, an entity is represented by a graphical symbol 203, 204 such as a dot lying at the location corresponding to its coordinates. Such a representation of an entity in the event field 200 is hereinafter called an event 203, 204. A plurality of events 203, 204 constitutes a scatter plot 205 showing the coordinates of the corresponding entities.

[0048] According to an embodiment of the invention, a plurality of classes of entities in form of non-overlapping areas 210 in the event field 200 are predetermined. In the example according to FIG. 2, the areas 210 are adjacent rectangles delimited from each other by straight lines 211, 212 parallel to the first axis 201 and the second axis 202, respectively. In the exemplified embodiment of FIG. 2, there are 45=20 classes 210; other classifications with other shapes and/or other numbers of classes 210 are possible. An event 203, 204 is classified in one of the at least two classes 210 when the coordinates of the event 203, 204 lie in the corresponding area 210. Events 203, 204 classified in at least one of the at least two classes 210 are counted, and the individual numbers of events 203, 204 counted are output for each of the at least one of the at least two classes 210. The numbers of events 203, 204 counted can be output instead of or in addition to the graphical representation shown in FIG. 2. The classification is helpful in numerically characterizing the contamination contained in the stream of fiber flocks 9.

[0049] A removal curve 220 representing a removal limit for contamination can be drawn in in the event field 200 and graphically represented together with the event field 200. The removal limit is predetermined as a criterion for the permissibility or impermissibility of the entities. Entities represented by events 203 with coordinates on the one side of the removal curve 220 are left in the stream of fiber flocks 9, whereas entities represented by events 204 with coordinates on the other side of the removal curve 220 are removed from the stream of fiber flocks 9. Events 203, 204 corresponding to the permissible and impermissible entities, respectively, can be represented by different graphical symbols, such as different shapes, different colors and/or different fillings. In the exemplified embodiment of FIG. 2, permissible events 203 are represented by blank circles, whereas impermissible events 204 are represented by filled circles.

[0050] The removal limit can be predetermined by an operator's input, can be taken over from a database containing various types of removal limits, or can be calculated automatically as described below with reference to FIG. 3.

[0051] In the embodiment of FIG. 2(a), the removal curve 220 follows the class boundaries 211, 212. Alternatively, the removal curve 220 can be independent of the classes 210 and can thus be defined by an operator in an essentially free manner. An example of the latter alternative is shown in FIG. 2(b).

[0052] FIG. 3 shows a flow chart of an embodiment of the method according to the invention for automatically predetermining the removal limit. The calculations in this method are preferably performed by the evaluation unit 107 (see FIG. 1).

[0053] The method is started in the simplest possible way. For this purpose a start button is provided, which can be labeled for example with smart limit, auto setup or the like, on a user interface. The start button can be realized either by hardware or by software. In the latter case it can be displayed symbolically on the output unit 108 (see FIG. 1) and can be actuated by means of an input unit such as a keyboard or a computer mouse, or by contact if there is a touchscreen 108.

[0054] A statistical representation of the test material is determined in a calibration process 301. The statistical representation concerns a scatter plot 205 of events 203, 204 as shown in FIG. 2. The statistical representation is preferably obtained by detecting and evaluating a sufficiently large number of entities.

[0055] The removal limit and the removal curve 220 as its graphical representation (see FIG. 2) are automatically calculated 302 on the basis of the determined statistical representation. The removal curve 220 can be calculated for example based on a predefined curve shape, which is then fitted into an appropriate position by means of a similarity transformation such as scaling, translation and/or rotation. The position of the removal curve 220 depends on the desired removal rate. In the simplest of cases, the initial removal rate can be a fixedly predetermined value such as 5000 removals per hour for example. The operator can be offered a number of choices for the selection of the initial removal rate, e.g.: [0056] Low for a low removal rate (e.g. 1000 removals per hour) or low quality; [0057] Medium for a medium removal rate (e.g. 5000 removals per hour) or medium quality, and [0058] High for a high removal rate (e.g. 15,000 removals per hour) or high quality.

[0059] Selection buttons realized by hardware or software can be provided for selection. For the purpose of complete freedom of selection, the operator can be provided with a possibility of free entry of a desired removal rate.

[0060] On the basis of the determined statistical representation and the calculated removal limit, a number of removals relating to time or to the mass of the stream of fiber flocks 9 is calculated automatically 303. This removal rate is obtained from the sum total of all events which are impermissible according to the removal limit.

[0061] The operator must be provided with the possibility to provide a comment on the removal rate which follows from the calculated removal limit. For this purpose the removal rate is output 304 on the output unit 108 after its calculation 303. The operator is asked 305 to confirm or change the displayed removal rate. A confirmation button for confirmation of the current removal limit and the removal rate is provided. The removal rate can be changed 306 for instance by means of incremental buttons by an increment, e.g. by 1000 removals per hour. The increment can be proposed or calculated automatically, preferably as a specific fraction, e.g. 20%, of the removal rate. The removal limit is changed automatically 307 as a result of the entered change command for the removal rate. A new removal rate which follows to the changed removal limit is calculated 303. The previously determined statistical representation is used as the basis for this calculation. The operator will be given an opportunity 305 to provide a comment on the new removal rate and to change the same optionally 306 if necessary. The described loop for the optimization of the removal limit or the removal rate can be passed as often until the operator is satisfied and confirms the same 308. The removal limit is only then set 309 so as to be effective for removing contamination 310 from the stream of fiber flocks 9. The setting 309 the removal limit comprises transmitting the removal limit to the unit that controls the removal unit 109, and storing it there. The controlling unit can be the sensor system 105, the evaluation unit 107 and/or the removal unit 109 itself.

[0062] It can be advantageous to repeat 311 the process described above periodically or after a major change in the production process. Such a repetition 311 includes a recalculation of the removal rate 303, its output 304 and, if necessary, a change 306 of the removal rate.

[0063] A graphical representation of the event field 200, including the scatter plot 205 of events 203, 204, the areas 210 representing the classes of entities and/or the removal curve 220 representing the removal limit is preferably output on the output unit 108 (see FIG. 1).

[0064] A classification of contaminants as described with reference to FIG. 2 can be done for each of various types of contaminants. Examples of types of contaminants comprise the following: [0065] (a) Vegetable and other organic contaminants; [0066] (b) White and transparent contaminants; and [0067] (c) Colored contaminants.

[0068] Such types of contaminants can be distinguished from each other by determining values of a third parameter of the entities. For each type of contaminants, an event field 200 as discussed with reference to FIG. 2 is provided. Thus, there are separate event fields 200 and/or separate classification results for, e.g., (a) vegetable and other organic contaminants, (b) white and transparent contaminants and (c) colored contaminants, respectively. A criterion related to the third parameter of the entities is assigned to each of the event fields 200. An entity is classified in one of the event fields 200, depending on the fulfillment of the criterion by the value of the at least third parameter determined for said entity. The criterion can depend solely on the third parameter of the entities. Alternatively, it can depend on the third parameter and additionally on one or several further parameters of the entities. For instance, a geometric characteristic of the entities (i.e., the first parameter as discussed with reference to FIG. 2) can be entered into the criterion in addition to the third parameter.

[0069] The third parameter can be, for instance, a color of the entities, i.e., a spectral distribution of broadband electromagnetic radiation after interaction with the entities. In this case, the following criteria can be predetermined: [0070] (a) For vegetable and other organic contaminants: the spectral distribution has a peak in the green and/or yellow range (light wavelengths between about 495 nm and 590 nm), and no other significant peak in the visible range. [0071] (b) For white and transparent contaminants: the spectral distribution has values significantly different from zero in the blue range (between about 435 nm and 495 nm), in the green range (between about 495 nm and 570 nm) and in the red range (between about 630 nm and 770 nm). [0072] (c) For colored contaminants: all other cases.

[0073] Three examples of different spectral distributions 401-403, as could be determined from optical signals from different entities, are shown in FIG. 4. Each graph 401-403 shows an intensity of light reflected on an entity as a function of the light wavelength X. The spectral distribution 401 of FIG. 4(a) fulfills the above criterion (a); therefore, the corresponding entity would be classified in a first event field for vegetable and organic contaminants. The spectral distribution 402 of FIG. 4(b) fulfills the above criterion (b); therefore, the corresponding entity would be classified in a second event field for white and transparent contaminants. The spectral distribution 403 of FIG. 4(c) fulfills neither the above criterion (a) nor (b); therefore, the corresponding entity is probably a red contaminant and would be classified in a third event field for colored contaminants.

[0074] FIG. 5 shows a block diagram of a system 500 for carrying out a further embodiment of the method according to the invention. A horizontal arrow 510 symbolizes a flow of material in a production site such as a spinning mill. The material in the flow 510 can have the same structure, namely, fiber flocks, throughout the whole flow 510, or can change its structure from left to right, e.g., from fiber flocks to a fibrous web, then to a sliver, then to a roving, then to a yarn, etc. Thus, the arrow 510 can encompass the whole textile production chain, all types of textile structures and all types of textile production machines.

[0075] A first monitoring device 501 monitors contamination in a stream of fiber flocks, which stream is part of the material flow 510. The first monitoring device 501 is a device 100 according to the invention, as schematically depicted in FIG. 1. A second monitoring device 502 is arranged in the material flow 510 downstream of the first monitoring device 501. The second monitoring device 502 subsequently monitors contamination in the material flow 510, i.e., in the stream of fiber flocks or in an intermediate or a product containing fibers from the stream of fiber flocks monitored by the first monitoring device 501. At the location of the second monitoring device 502, the material flow 510 can still be a stream of fiber flocks. In this case, the second monitoring device 502 can be similar to the first monitoring device 501, depicted as a monitoring device 100 in FIG. 1, except for the removal unit 109, which can be present, but is not necessarily needed in the second monitoring device 502. Alternatively, the second monitoring device 502 can be arranged at a further stage of the textile production chain. It can be, for instance, a yarn clearer with a contamination-clearing capability, arranged on a yarn-winding machine winding yarn containing fibers from the stream of fiber flocks 9 monitored by the first monitoring device 501. Yarn clearers as such are known, e.g., from U.S. Pat. No. 6,244,030 B1.

[0076] A control unit 503 is connected via a first connection 504 and a second connection 505 with the first monitoring device 501 and the second monitoring device 502, respectively. The control unit 503 collects data from the first monitoring device 501 and the second monitoring device 502, processes them statistically and outputs reports generated therefrom to an operator, which outputs are indicated in FIG. 5 by an output arrow 506. It also receives inputs from the operator, e.g., requirements with regard to quality, which inputs are indicated in FIG. 5 by an input arrow 507. The control unit 503 can be realized as a computer with corresponding input and/or output peripheral devices. It can also be connected with other devices in the material flow 510, which are, however, not shown in FIG. 5.

[0077] According to an embodiment of the invention, the removal limit in the first monitoring device 501 is changed depending on a monitoring result of the second monitoring device 502. Thus, there is a closed control loop controlling the removal of contamination by the first monitoring device 501. The feedback in the closed control loop is indicated in FIG. 5 by a separate arrow 508; however, it can be realized via the connections 504, 505 between the control unit 503 and the monitoring devices 501, 502, which connections 504, 505 are preferably bidirectional. The control unit 503 can act as a controller within the closed control loop. If, for example, the second monitoring device 502 finds too many contaminants in a certain class 210, the control unit 503 can automatically adapt the removal limit in the first monitoring device 501 so as to remove more of the contaminants in said class 210.

[0078] According to another embodiment of the invention, the removal limit in the second monitoring device 502 is changed depending on a monitoring result of the first monitoring device 501. In this embodiment, the first monitoring device 501 controls the second monitoring device 502 in an open control loop, which is indicated in FIG. 5 by an arrow 509. The open control loop 509 can be realized via the preferably bidirectional connections 504, 505 between the control unit 503 and the monitoring devices 501, 502. The control unit 503 can act as a controller within the open control loop.

[0079] It is understood that the present invention is not limited to the embodiments as discussed above. The person skilled in the art will be able to derive further variants with knowledge of the invention which shall also belong to the subject matter of the present invention.

LIST OF REFERENCE NUMERALS

[0080] 100 Device according to the invention [0081] 101 Fiber transport conduit [0082] 102 Windows in wall of fiber transport conduit [0083] 103 Light sources [0084] 104 Mirrors [0085] 105 Sensor system [0086] 106 Cameras [0087] 107 Evaluation unit [0088] 108 Output unit [0089] 109 Removal unit [0090] 110 Removal channel [0091] 200 Event field [0092] 201, 202 First and second axes of the event field [0093] 203 Permissible event [0094] 204 Impermissible event [0095] 205 Scatter plot [0096] 210 Areas in the event field representing classes of contaminants [0097] 211 Horizontal class boundaries [0098] 212 Vertical class boundaries [0099] 220 Removal curve [0100] 401-403 Spectral distributions [0101] 501, 502 First and second monitoring devices [0102] 503 Control unit [0103] 504, 505 First and second connections [0104] 506 Output from the control unit [0105] 507 Input into the control unit [0106] 508 Feedback in closed control loop [0107] 509 Control in open control loop [0108] 510 Flow of material [0109] 9 Stream of fiber flocks [0110] 90 Contaminant [0111] 91 Transport direction of the stream of fiber flocks [0112] 92 Removal direction