簇绒机开放式数控系统及图像处理技术的试验研究
|
摘要
目前,数控簇绒机的使用越来越多,相对于传统的簇绒机,它既可大大减少传统印花工艺所带来的环境污染,同时所制作的地毯产品质量明显提高。限于控制系统的缺乏,国内企业所使用的数控簇绒机,大部分从国外进口,不仅价格昂贵,而且维修不便,严重制约了地毯企业的市场竞争能力。为此,本论文进行了簇绒机开放式数控系统及其图像处理技术的研究与开发,以促进电脑提花簇绒机的快速发展。
首先,论文对国内外机织地毯生产的现状进行了综述,介绍了地毯簇绒的方法、原理及相关设备,阐述了数控技术的发展及其在簇绒行业的应用,提出了以工控机为上位机,以雷赛DMC1000 PCI总线4轴运动控制卡为下位机核心,以研华PCI-1762数字输入输出卡为辅件的控制系统方案。在对地毯簇绒机机械结构原理分析的基础上,进行了簇绒机控制系统的总体方案设计,给出了簇绒机数控系统试验装置硬件实现的连接方法。详细分析了上位机软件原理结构、下位机子系统结构以及控制系统的功能。
其次,论文基于开放式数控系统研究了操作软件的设计。论证决定以Visual C++为开发工具,采用通用的位图格式文件作为地毯花型文件,大大提高了簇绒机的柔性,使其可以利用广泛存在的位图资源,并且可以利用数目众多的商业软件进行地毯图案设计。论文对位图颜色的处理和由位图到控制文件的转换以及下位机如何调用控制文件进行了阐述。由于簇绒工艺的特点,必须对位图进行减色处理,为使减色后的图像失真度尽可能小,使用一种改善后的K-means聚类算法对BMP图像进行分色处理,用集中的少量颜色来代替分散的、丰富的色彩。根据处理后位图的数据将控制信息以二进制形式写入文件,供下位机读取。控制文件第一个字节表示列数,第二个字节表示行数;由于四个二进制位可以表示十六种颜色,可以满足簇绒机的要求,所以从第三个字节开始表示像素的颜色信息,每四位表示一种颜色,一个字节表示两个像素的颜色。这样的文件结构紧凑,包含信息量大,有利于提高簇绒机的效率。
最后,通过对簇绒机的试验系统各个部分的连接和调试。结果表明:所研制的试验系统能满足簇绒要求。
本簇绒机开放式数控系统及其图像处理技术的成功开发,对开发其它类型簇绒机控制系统有借鉴作用,并可有效提升我国地毯企业的装备技术水平。
Numerical Control Tufting Machine(NCTM) is currently used in textile industry more and more popularly. Compared with traditional tufting machine, NCTM reduces pollution and produces higher quality carpet. For lacking of NCTM's control system, many NCTMs have to be imported with high price and potential maintenance inconvenience. This greatly restricts the market competency of domestic textile factories. For that, this paper presents the research and development of Tufting Machine’s open numerical control system and digital image processing technique. This research may accelerate the development of NCTM.
Firstly, this paper summarizes the status quo of carpet manufacture at home and abroad, presents the method、principle and correlational equipment of tufting, expatiates the development of open numerical control system and the application of open numerical control system on tufting machines. After that, the blue print of control system is put forward. In the blue print, An Industry PC(IPC) acts as the upper computer, a Leadshine DMC1000 control card as the core of lower computer, and an Advantech PCI-1762 digital I/O card as accessory. Based on the analysis of tufting machine machinery structure principle, the blue print of control system is designed. The software architecture, lower computer subsystem and functions of control system are all detailed.
Secondly, the applications based on open numerical control of the upper computer are studied. The paper chooses Visual C++ as the development facility and BMP file as the storage format of pattern files, and this greatly enhances the flexibleness of tufting machine. The system may use existed mass BMP file resource and may use all sorts of commercial software to desire carpet patterns. Next, the paper expatiate the method of how to dispose colors of a BMP image and convert a BMP file to a control file along with means of transferring the file by lower computer. We must reduce the quantity of colors for the tufting technics. For abating the distortion of BMP file as far as possible, the paper presents an improved K-means colors separation method of the clustering analysis to process BMP image, plenty of colors are replaced by a small amount colors. According to the data of processed BMP image, the control data is put into control file by binary and the file will be read by lower computer. The first byte of control file is the number of columns and the second byte is the number of rows. For four bits can express sixteen colors, and the point can meets the tufting machine's requirement, from the third byte of the control file onward, one byte expresses two pixel, it means that four bits express one pixel. The structure of the control file is compact, and is propitious to increase efficiency of the tufting machine.
Finally, this paper presents the experiment control system interconnection and the test of control system. The test results make clear that the experiment system meets the requirer of tufting.
The development and research on the open numerical control system of the tufting machine and the image processing technique may have reference value to develop other similar system and improve the level of equipment technology in domestic carpet factories.
首先,论文对国内外机织地毯生产的现状进行了综述,介绍了地毯簇绒的方法、原理及相关设备,阐述了数控技术的发展及其在簇绒行业的应用,提出了以工控机为上位机,以雷赛DMC1000 PCI总线4轴运动控制卡为下位机核心,以研华PCI-1762数字输入输出卡为辅件的控制系统方案。在对地毯簇绒机机械结构原理分析的基础上,进行了簇绒机控制系统的总体方案设计,给出了簇绒机数控系统试验装置硬件实现的连接方法。详细分析了上位机软件原理结构、下位机子系统结构以及控制系统的功能。
其次,论文基于开放式数控系统研究了操作软件的设计。论证决定以Visual C++为开发工具,采用通用的位图格式文件作为地毯花型文件,大大提高了簇绒机的柔性,使其可以利用广泛存在的位图资源,并且可以利用数目众多的商业软件进行地毯图案设计。论文对位图颜色的处理和由位图到控制文件的转换以及下位机如何调用控制文件进行了阐述。由于簇绒工艺的特点,必须对位图进行减色处理,为使减色后的图像失真度尽可能小,使用一种改善后的K-means聚类算法对BMP图像进行分色处理,用集中的少量颜色来代替分散的、丰富的色彩。根据处理后位图的数据将控制信息以二进制形式写入文件,供下位机读取。控制文件第一个字节表示列数,第二个字节表示行数;由于四个二进制位可以表示十六种颜色,可以满足簇绒机的要求,所以从第三个字节开始表示像素的颜色信息,每四位表示一种颜色,一个字节表示两个像素的颜色。这样的文件结构紧凑,包含信息量大,有利于提高簇绒机的效率。
最后,通过对簇绒机的试验系统各个部分的连接和调试。结果表明:所研制的试验系统能满足簇绒要求。
本簇绒机开放式数控系统及其图像处理技术的成功开发,对开发其它类型簇绒机控制系统有借鉴作用,并可有效提升我国地毯企业的装备技术水平。
Numerical Control Tufting Machine(NCTM) is currently used in textile industry more and more popularly. Compared with traditional tufting machine, NCTM reduces pollution and produces higher quality carpet. For lacking of NCTM's control system, many NCTMs have to be imported with high price and potential maintenance inconvenience. This greatly restricts the market competency of domestic textile factories. For that, this paper presents the research and development of Tufting Machine’s open numerical control system and digital image processing technique. This research may accelerate the development of NCTM.
Firstly, this paper summarizes the status quo of carpet manufacture at home and abroad, presents the method、principle and correlational equipment of tufting, expatiates the development of open numerical control system and the application of open numerical control system on tufting machines. After that, the blue print of control system is put forward. In the blue print, An Industry PC(IPC) acts as the upper computer, a Leadshine DMC1000 control card as the core of lower computer, and an Advantech PCI-1762 digital I/O card as accessory. Based on the analysis of tufting machine machinery structure principle, the blue print of control system is designed. The software architecture, lower computer subsystem and functions of control system are all detailed.
Secondly, the applications based on open numerical control of the upper computer are studied. The paper chooses Visual C++ as the development facility and BMP file as the storage format of pattern files, and this greatly enhances the flexibleness of tufting machine. The system may use existed mass BMP file resource and may use all sorts of commercial software to desire carpet patterns. Next, the paper expatiate the method of how to dispose colors of a BMP image and convert a BMP file to a control file along with means of transferring the file by lower computer. We must reduce the quantity of colors for the tufting technics. For abating the distortion of BMP file as far as possible, the paper presents an improved K-means colors separation method of the clustering analysis to process BMP image, plenty of colors are replaced by a small amount colors. According to the data of processed BMP image, the control data is put into control file by binary and the file will be read by lower computer. The first byte of control file is the number of columns and the second byte is the number of rows. For four bits can express sixteen colors, and the point can meets the tufting machine's requirement, from the third byte of the control file onward, one byte expresses two pixel, it means that four bits express one pixel. The structure of the control file is compact, and is propitious to increase efficiency of the tufting machine.
Finally, this paper presents the experiment control system interconnection and the test of control system. The test results make clear that the experiment system meets the requirer of tufting.
The development and research on the open numerical control system of the tufting machine and the image processing technique may have reference value to develop other similar system and improve the level of equipment technology in domestic carpet factories.
引文
[1]顾钰良,王震生.地毯[M].北京:纺织工业出版社.19-23.
[2] Owen, Phil. Danley Pioneers novel applications for tufting technology[J]. Textiles International. 2005, 14(l): 41—43.
[3] http://www.tuftco.com
[4] http://www.cobble.co.uk/chinese.html
[5]北京纺织学报[J].第23卷第3期.
[6] [英国]D.T.沃德.簇绒生产入门[M].北京:纺织工业出版社, 12-19.
[7]于涛,范云霄.数字控制技术与数控机床[M].北京:中国计量出版社, 2004: 35-40.
[8] Prof. M. Week, Dipl-Ing. A standard providing data for modern Ncmachining enabling enhanced functionality[J],Laboratory for Machine Tools and Production. February 12th,2003.
[9]曹凤.微机数控技术及其应用[M].西安:西北工业大学出版社,2002: 36-37.
[10] Muell , T.Hyum. STEP-Compliant Data Interface for Numerical Control [J]. STEP-NC Final Report, 2003.1.
[11] Lastina Rippol. Windows2000 Driver Developer’s Guide[J]. Computers and Graphics, 2003, 20(2):231-242.
[12] Martin Hardwick. STEP into Automatic Machining. Journal of MaterialsSeienee,2004,32(3):1894一1896.
[13] Clipper Garel. ISO and ICE common database for Graphic symbol[J]. New York: Fresco&Brother Press, 2004: 45-47.
[14] Ricoh Prmma. Deeply Develop in ISO 12100-11[J]. Master Thesis,Institute of Textile Engineering, Feng Chia University:2002(5):18-23
[15]关美华,周建华.数控技术原理及现代控制系统[M].成都:西南交通大学出版社, 2003: 63-64.
[16]单岩,王慧强.实用数控编程技术与应用实例[M].北京:机械工业出版社, 2003: 72-73.
[17]范玉庆,田建君.现代数控机床[M].北京:化学工业出版社工业装备与信息工程出版中心, 2004: 36-38.
[18]邱霍,王爱玲.现代数控原理及控制系统[M].北京:国防工业出版社, 2000: 51-55.
[19]张国锋,周利莉. Windows设备驱动程序开发实务[M].北京:电子工业出版社,2002: 28.
[20]仉晓娟.开放式数控系统研究综述[J],组合机床与自动化加工技术. 2001(12): 8—10.
[21]胡增,杨克,郑国刚等.计算机数控系统的构建[J],组合机床与自动化加工技术. 2001(3): 66—67.
[22]何力伟,张鹏.开放式数控体系结构的初步研究[J],中国机械工程. 1999, 9(12): 893—894.
[23]王慧君,毕晓峰,李启瑞.基于软件PLC的I/0控制研究[J].机械制造. 2002(3): 24—25.
[24]刘锐宁,宋坤. Visual C++从入门到精通[M].北京:清华大学出版社, 2008: 4—5.
[25]陈兵旗,孙明. Visual C++实用图像处理专业教程[M].北京:清华大学出版社, 2004: 5—6, 12, 164—180, 88.
[26]王绍霖,数字图像处理[M].长沙国防科技大学出版社, 1987.
[27]郎锐.数字图像处理学——Visual C++实现[M].北京:北京希望电子出版社, 2003: 1—7, 134—140.
[28]陆宗骐,金登楠. Visual C++.NET图像处理编程[M].北京:清华大学出版社,2006: 5—6.
[29]高晓丽.传能光纤激光雕刻机图像处理技术的研究[D].秦皇岛:燕山大学, 2003.4.
[30]孙艳梅.机器人直线轨迹测量中的图像处理方法研究[D].沈阳:沈阳工业大学,2003. 6.
[31]杨淑莹. VC++图像处理程序设计[M].北京:北方交通大学出版社, 2003:1—9, 16—17, 119—139, 185—202.
[32]张宏林.精通Visual C++数字图像处理典型算法及实现[M].北京:人民邮电出版社,2008.7: 16—18.
[33] Ruggero Milanesey. A Rotation,Translation and Scale-Invariant Approach to Content-Based Image Retrieval[J]. Journal of Visual Communication and Image Representation, 1999(10): 186—196.
[34] Guo Dong, Ming Xie. Color clustering and learning for image segmentation based on neural networks. IEEE Transactions on Neural Networks, 2005, 16(4): 925, 936.
[35]王琴,王卫星.基于K均值聚类的厚壁组织区域自动提取[J].农机化研究. 2006,10(10):197—199.
[36] Jiawei Han, Micheline Kamber. Data Mining: Concepts and Techniques[M]. USA: Morgan Kanfmann, 2005.
[37]梁道雷,黄国兴,金健,聚类分析在彩色像景织物分色处理中的应用[J].计算机科学,2006Vol.33No.11: 154—156.
[38]郭欣,赵淑清.概率模型下的K-means算法在SAR图像分类中的应用[J].遥感技术与应用, 2005, 20(2):295—298.
[39]孙鑫. VC++深入详解[M].北京:电子工业出版社, 2006, 447.
[2] Owen, Phil. Danley Pioneers novel applications for tufting technology[J]. Textiles International. 2005, 14(l): 41—43.
[3] http://www.tuftco.com
[4] http://www.cobble.co.uk/chinese.html
[5]北京纺织学报[J].第23卷第3期.
[6] [英国]D.T.沃德.簇绒生产入门[M].北京:纺织工业出版社, 12-19.
[7]于涛,范云霄.数字控制技术与数控机床[M].北京:中国计量出版社, 2004: 35-40.
[8] Prof. M. Week, Dipl-Ing. A standard providing data for modern Ncmachining enabling enhanced functionality[J],Laboratory for Machine Tools and Production. February 12th,2003.
[9]曹凤.微机数控技术及其应用[M].西安:西北工业大学出版社,2002: 36-37.
[10] Muell , T.Hyum. STEP-Compliant Data Interface for Numerical Control [J]. STEP-NC Final Report, 2003.1.
[11] Lastina Rippol. Windows2000 Driver Developer’s Guide[J]. Computers and Graphics, 2003, 20(2):231-242.
[12] Martin Hardwick. STEP into Automatic Machining. Journal of MaterialsSeienee,2004,32(3):1894一1896.
[13] Clipper Garel. ISO and ICE common database for Graphic symbol[J]. New York: Fresco&Brother Press, 2004: 45-47.
[14] Ricoh Prmma. Deeply Develop in ISO 12100-11[J]. Master Thesis,Institute of Textile Engineering, Feng Chia University:2002(5):18-23
[15]关美华,周建华.数控技术原理及现代控制系统[M].成都:西南交通大学出版社, 2003: 63-64.
[16]单岩,王慧强.实用数控编程技术与应用实例[M].北京:机械工业出版社, 2003: 72-73.
[17]范玉庆,田建君.现代数控机床[M].北京:化学工业出版社工业装备与信息工程出版中心, 2004: 36-38.
[18]邱霍,王爱玲.现代数控原理及控制系统[M].北京:国防工业出版社, 2000: 51-55.
[19]张国锋,周利莉. Windows设备驱动程序开发实务[M].北京:电子工业出版社,2002: 28.
[20]仉晓娟.开放式数控系统研究综述[J],组合机床与自动化加工技术. 2001(12): 8—10.
[21]胡增,杨克,郑国刚等.计算机数控系统的构建[J],组合机床与自动化加工技术. 2001(3): 66—67.
[22]何力伟,张鹏.开放式数控体系结构的初步研究[J],中国机械工程. 1999, 9(12): 893—894.
[23]王慧君,毕晓峰,李启瑞.基于软件PLC的I/0控制研究[J].机械制造. 2002(3): 24—25.
[24]刘锐宁,宋坤. Visual C++从入门到精通[M].北京:清华大学出版社, 2008: 4—5.
[25]陈兵旗,孙明. Visual C++实用图像处理专业教程[M].北京:清华大学出版社, 2004: 5—6, 12, 164—180, 88.
[26]王绍霖,数字图像处理[M].长沙国防科技大学出版社, 1987.
[27]郎锐.数字图像处理学——Visual C++实现[M].北京:北京希望电子出版社, 2003: 1—7, 134—140.
[28]陆宗骐,金登楠. Visual C++.NET图像处理编程[M].北京:清华大学出版社,2006: 5—6.
[29]高晓丽.传能光纤激光雕刻机图像处理技术的研究[D].秦皇岛:燕山大学, 2003.4.
[30]孙艳梅.机器人直线轨迹测量中的图像处理方法研究[D].沈阳:沈阳工业大学,2003. 6.
[31]杨淑莹. VC++图像处理程序设计[M].北京:北方交通大学出版社, 2003:1—9, 16—17, 119—139, 185—202.
[32]张宏林.精通Visual C++数字图像处理典型算法及实现[M].北京:人民邮电出版社,2008.7: 16—18.
[33] Ruggero Milanesey. A Rotation,Translation and Scale-Invariant Approach to Content-Based Image Retrieval[J]. Journal of Visual Communication and Image Representation, 1999(10): 186—196.
[34] Guo Dong, Ming Xie. Color clustering and learning for image segmentation based on neural networks. IEEE Transactions on Neural Networks, 2005, 16(4): 925, 936.
[35]王琴,王卫星.基于K均值聚类的厚壁组织区域自动提取[J].农机化研究. 2006,10(10):197—199.
[36] Jiawei Han, Micheline Kamber. Data Mining: Concepts and Techniques[M]. USA: Morgan Kanfmann, 2005.
[37]梁道雷,黄国兴,金健,聚类分析在彩色像景织物分色处理中的应用[J].计算机科学,2006Vol.33No.11: 154—156.
[38]郭欣,赵淑清.概率模型下的K-means算法在SAR图像分类中的应用[J].遥感技术与应用, 2005, 20(2):295—298.
[39]孙鑫. VC++深入详解[M].北京:电子工业出版社, 2006, 447.