Fiber orientation control of high tailoring yarns with machine vision.
For a major client in the tailoring industry, in 2015 Vision Device implemented a vision system for the control and correct orientation of fibers during the production of yarns (in horsehair) intended for tailoring jacket fabrics.
The vision system was proposed in different configurations in pairs of 2, 4 and 12 matrix cameras, suitable for parallel and real-time verification of the two left and right yarns.
The LinceoONE software is able to detect the twist direction of the fibers that make up the yarn, the type (light or dark) and, of course, also the possible absence of the components; the system is also equipped with digital signals, fully configurable, to report each error and interface with the production line.
Control occurs with a high frequency of image acquisition and is "multiplexed" to manage multiple cameras and multiple lines simultaneously from a single operator interface.
Considering the forward speed (700 meters/minute) and to better highlight the winding of the yarns, it was necessary to shoot at very high resolution with a very short exposure time (about 1 microsecond).
This was made possible by using custom LED illuminators and a special controller capable of handling such short exposure times.
Two different methods were used to be able to control the twist direction of different types of yarns.
For light yarns, a diffuse light. For dark yarns, a grazing illumination so as to highlight the texture of the yarns regardless of color. A different processing goes to analyze the high-frequency components in the direction of the intended orientation showing how this frequency component is distinctly different for yarns spinning in the two directions:
Like all Vision Device systems, the delivery was inclusive of a compact industrial computer-based central unit (fanless), 1290x960-pixel resolution monochrome cameras with Gigabit Ethernet interface, and all necessary accessories such as high-power LED illuminators, optics, cables, and a sophisticated dedicated "strobe" controller, which enables exposure time of 1-2 millionths of a second (necessary to obtain sufficiently still images with the wire traveling at high speeds).