Suzhou textile enterprises develop intelligent inspection robots to lead the transformation of the famous textile city
Install high-speed moving high-definition cameras above the rows of looms to capture defects on the cloth through “flying shots”, then “stop” the looms and locate them with infrared rays, and “notify” the workers to repair the defects… …The “Textile Eagle” intelligent inspection robot developed by Suzhou Zhongke Feixuo Intelligent Technology Co., Ltd. has achieved remarkable results since it was officially “launched” in July this year. While saving two-thirds of manpower, the equipment has an inspection rate of over 92% %, and Dadi help improve the quality of fabrics and lead the transformation of the famous textile city.
Fabric defects will no longer escape the “Eagle Eye” flying photography
In a large weaving enterprise in Shengze, Wujiang City, Suzhou City, above the rows of water-jet looms, a large “projector” moves at high speed on the guide rail. When it moves above the cloth banner of the loom, the “projector” ” Then press the shutter. Once defects such as broken warp and weft are “discovered” on the fabric surface, infrared locks will be immediately issued and the machine will be “ordered” to stop and the operator will be notified. The person in charge of the workshop said that by replacing human eyes and legs with high-speed moving robots, workers can relax and the yield rate is higher.
At present, intelligent manufacturing has become an important starting point for the upgrading of Shengze’s textile industry, and the world’s top looms account for more than half of the total. However, with the shortage of labor and rising labor costs, Shengze Textile Industry still faces constraints. Especially in the weaving process, workers are affected by working hours, environment, emotions, energy, etc., and the manual inspection rate is less than 20%.
“The weaving process needs to further ‘machine replacement‘, so that the detection rate and yield rate can be effectively improved, and ‘Shengze Weaving’ and ‘Made in Suzhou’ will be more competitive. Hou Jingkui, chairman of KingstarTextile Machinery Co., Ltd., who has been involved in the research and development and manufacturing of textile machinery for more than 20 years, looks at the eagle eye of the football field and the track high-speed camera of the 100-meter track and field run. I was inspired by, “If we can replace human eyes with high-speed cameras and replace manual inspections with orbital movement, the problem will be solved!”
Overcoming difficulties to develop intelligent textile inspection robots
After many inquiries, Hou Jingkui learned that the Suzhou Research Institute of the Institute of Automation of the Chinese Academy of Sciences has a high-speed camera. To this end, the two parties hit it off and joined hands to establish Zhongke Feixuo to develop intelligent textile inspection robots.
The goal is clear, the direction is clear, and the process is extremely arduous. Lu Wei, general manager of Zhongke Feixuo, said that to achieve the expected results, two major problems must be solved: one is high-speed movement, and the other is “flying shooting”. The longitude and weft of chemical fiber weaving are within millimeters. If it moves too fast, the requirements for anti-shake and snapshots will be higher, and the cost will be higher; if it moves too slowly, it will not be able to keep up with the weaving speed of advanced looms.
After two years of research and development, Zhongke Feixuo finally overcame the difficulties and successfully launched two products. One has a linear guide and a single-sided camera, which can inspect up to 5 looms. The inspection speed is 3 meters/second, and the return run is 5 meters/second, which accurately matches the weaving speed of each banner of the loom to ensure that no inspection is missed; the other one has a circular guide rail and double-sided cameras, with an average moving speed of 2 meters/second. . By encrypting the number of robots, more loom cycle detection can also be achieved.
“Mobile ‘flying shots’, image recognition, big data comparison, infrared locking… With the help of algorithms such as image analysis and target tracking, our fabric inspection is more intelligent.” Hou Jingkui said that they have now completed the inspection of fabrics. Based on the basic information collection of pictures, as the database continues to be updated and iterated in the future, the robot inspection rate will be close to 100%, which will better solve the problem of labor shortage for high-quality textile companies.
In the textile manufacturing process, quality detection and control is an important operation step, and the core process in the quality inspection process is the detection of textile defects. Capture and repair. At present, the inspection method of most light industrial factories is to find defects by operators only by visual observation. There are always some problems in this, such as the intensity of this working method is too high, the rate of missed detection and false detection is high, and manual inspection is subject to manipulation. The subjective factors of workers have a relatively large impact, so higher accuracy cannot be guaranteed, and it is easy to cause certain damage to the workers’ own vision. A good “turn-stopper” may have a monthly income of 10,000 yuan or more, and has high liquidity and high costs.
Textile defect detection is currently a research hotspot in the field of computer vision. There have been many research results at home and abroad. However, in terms of effectiveness, real-timeness and applicability, the current detection technology cannot fully meet the needs of actual production. Requirements, new technologies for fabric defect detection need to be further explored.
Digital empowerment sets industry transformation and upgrading new benchmark
From the perspective of the owners of textile companies, industry profit margins are getting lower and lower, and labor costs are getting higher and higher. From a market economy perspective, if wages are not paid enough, workers will be lost. Especially for skilled workers, many factories are looking for salary increases, so workers’ wages are gradually going up. In the textile industry, bosses are begging workers to stay. How to solve this pain point and difficulty is what Suzhou Sisuo Intelligent Technology Co., Ltd. has always been trying to do.The direction of force.
Suzhou Sisuo Intelligent Technology Co., Ltd. relies on the scientific research strength of the Suzhou Institute of Automation of the Chinese Academy of Sciences, the School of Textile and Clothing Engineering of Soochow University, and the State Key Laboratory of Textile and Clothing of Qingdao University. It is based on the transformation and upgrading of the textile industry and focuses on R&D and manufacturing. Online real-time detection equipment for textile defects based on artificial intelligence and big data analysis is committed to becoming the leading driving force for digitalization in the textile industry. The company’s products use guide rail technology to realize that a flying shuttle automated inspection equipment can conduct real-time inspection of more than 10 textile equipment at the same time. According to different defect conditions, it can automatically control the operating status of textile equipment, implement alarms, shutdowns, etc., and improve the detection of textile defects. rate, the detection rate has increased from 20% to 95%, improving the quality of cloth and increasing the unit price of finished products.
At present, the enterprise has become a benchmark enterprise for the transformation and upgrading of the textile industry in Shengze Town, with huge development potential and good development trends. At present, the company has received key support from the Shengze government. It plans to provide 30 acres of land and invest a total of 500 million yuan to build a big data center, factory and office building. It is expected that the annual output value will exceed 100 million yuan after reaching full capacity, and the tax revenue per mu will exceed 600,000 yuan. /mu.
Through digital empowerment, Sisuo Intelligence empowers the economic transformation of Shengze, a thousand-year-old textile city and silk ancient town, and continuously provides data support for Shengze enterprises. The reform plan will reduce corporate costs, enhance the company’s digital transformation image, and provide new momentum for the traditional and fashionable textile industry.
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