印染错花在线智能监测系统的研究
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摘要
印染行业在我国国民经济中占有重要地位,对花精度是提高印花产品质量与产量的关键技术所在。本文以圆网印花机为对象,在论述国内外圆网印花机对花系统的研究发展状况和趋势的基础上,对各种对花系统的特点及性能进行了分析比较,提出了采用新型花位标记检测法,应用机器视觉技术的印染错花在线智能监测系统,以实现对花精度的实时检测、自动调整及控制。
本文通过分析圆网印花机印花系统的工艺流程和错花原因,确定了印染错花在线智能监测系统的具体功能和要求。应用机器视觉技术,研究并设计了印染错花在线智能监测系统的总体结构组成及工作原理,规划了系统的具体实现方法。采用了基于CV-5501控制器的嵌入式视觉系统,经过分析比较各种机器视觉组件,设计了由反射照明方式的直环型白色LED光源CA-DRW10F,高分辨率、低失真镜头CA-LH16和24万像素逐行扫描倍速彩色摄像机CV-035C组成的图像采集设备,完成了视觉系统的硬件设计。设计了基于STC89C52单片机的主控制系统;研究了基于E6B2-CWZ1X、MC3486和TLP521-1的触发信号控制电路;提出了基于CD4052选通控制的设计方法,实现了单片机与视觉系统控制器、PLC和触摸屏的串口通信;设计了基于7805的稳压电源;完成了主控制系统的硬件设计。研究视觉系统的软件功能,采用VC6.0程序设计了视觉系统软件界面,进行了图像处理算法的研究,规划了数据、图像的收集与通讯以及检查/测量等图像处理程序的流程。研究主控制系统程序功能,设计程序流程图,采用C语言和汇编语言编写了主程序、串口通信程序和触发信号控制程序。
通过对上述系统的调试与实验,证明了基于控制器CV-5501的嵌入式视觉系统的运行具有良好的稳定性和流畅性;验证了图像检测程序的准确性和可行性及其软件的实时性和可靠性;还验证了单片机控制系统的正确性。
The dyeing and printing industry plays a magnificent role in the national economy. And the register precision is the key technology to improve the quality and quantity of the printing products. Taking the rotary screen printing machine as the object, and based on description of the current research status and the development trend about registration system of rotary screen printing machine at home and abroad, the characteristics and performances about various registration system are analysed, and then on-line intelligent monitoring system about register precision of printing and dyeing which adopts the new pattern position marks based detection method and the technology of machine vision is put forward in the paper, to achieve real-time detection, automatic adjustment and control of the register precision during printing.
Based on research and analysis of the production process flow and the reasons of bad register of printing system of rotary screen printing machine, the functions and requirements of on-line intelligent monitoring system about register precision of printing and dyeing are stated. According to the research on machine vision, the overall structure composition of the system is designed, the operation principle of the system is studied, and the method to carry out this system is offered in detail. As a result, embedded vision system based on the CV-5501 controller is adopted. By analyzing and comparing the characteristics of all kinds of modules of machine vision, the image acquisition system is designed and it is composed of the CA-DRW10F white direct-ring LED light which uses the way of reflected illumination, the CA-LH16 lens with high-resolution and low distortion, and the CV-035C progressive scanning double-speed color camera which owns 240,000 pixels. After that the hardware design of the vision system is completed. Then STC89C52 MCU based main control system is studied and designed. Based on the offering of the design scheme of CD4052 based gated control, the serial port communications between MCU and the controller of the vision system, between MCU and PLC, and between MCU and touch screen are accomplished. Based on the application of E6B2-CWZ1X, MC3486 and TLP521-1, the control circuit of the trigger signal is designed. Based on the research of 7805, stabilized voltage power supply is provided. After that the hardware design of the main control system is accomplished. Studying the software functions of the vision system, the software interface of the vision system is programmed applying VC 6.0, some algorithms of digital image processing used in the system are studied and discussed, the collection and communication of the data and the images, and the procedure of the image processing program related to inspection and measurement are programmed. Studying the functions of the programs of the main control system, the program flow charts are designed, the main program, the serial port communication program, and the control program of the trigger signal are written with the application of C language and assemblerlanguage.
Finally, the debug and the experiments to the system referred above are carried out, sothat the operating stability and smooth of the embedded vision system based on the CV-5501 controller has been confirmed. The experiment of the image detection program is finished, in order that the accuracy and the feasibility of the programs, the real time ability and the reliability of the software are validated. The debug of the MCU control panel is completed, then the reliability of the transmitting and receiving of signal is tested, the exactness of the serial port communication program and the control program of the trigger signal is verified, and the reliability of the circuit is checked simultaneously.
本文通过分析圆网印花机印花系统的工艺流程和错花原因,确定了印染错花在线智能监测系统的具体功能和要求。应用机器视觉技术,研究并设计了印染错花在线智能监测系统的总体结构组成及工作原理,规划了系统的具体实现方法。采用了基于CV-5501控制器的嵌入式视觉系统,经过分析比较各种机器视觉组件,设计了由反射照明方式的直环型白色LED光源CA-DRW10F,高分辨率、低失真镜头CA-LH16和24万像素逐行扫描倍速彩色摄像机CV-035C组成的图像采集设备,完成了视觉系统的硬件设计。设计了基于STC89C52单片机的主控制系统;研究了基于E6B2-CWZ1X、MC3486和TLP521-1的触发信号控制电路;提出了基于CD4052选通控制的设计方法,实现了单片机与视觉系统控制器、PLC和触摸屏的串口通信;设计了基于7805的稳压电源;完成了主控制系统的硬件设计。研究视觉系统的软件功能,采用VC6.0程序设计了视觉系统软件界面,进行了图像处理算法的研究,规划了数据、图像的收集与通讯以及检查/测量等图像处理程序的流程。研究主控制系统程序功能,设计程序流程图,采用C语言和汇编语言编写了主程序、串口通信程序和触发信号控制程序。
通过对上述系统的调试与实验,证明了基于控制器CV-5501的嵌入式视觉系统的运行具有良好的稳定性和流畅性;验证了图像检测程序的准确性和可行性及其软件的实时性和可靠性;还验证了单片机控制系统的正确性。
The dyeing and printing industry plays a magnificent role in the national economy. And the register precision is the key technology to improve the quality and quantity of the printing products. Taking the rotary screen printing machine as the object, and based on description of the current research status and the development trend about registration system of rotary screen printing machine at home and abroad, the characteristics and performances about various registration system are analysed, and then on-line intelligent monitoring system about register precision of printing and dyeing which adopts the new pattern position marks based detection method and the technology of machine vision is put forward in the paper, to achieve real-time detection, automatic adjustment and control of the register precision during printing.
Based on research and analysis of the production process flow and the reasons of bad register of printing system of rotary screen printing machine, the functions and requirements of on-line intelligent monitoring system about register precision of printing and dyeing are stated. According to the research on machine vision, the overall structure composition of the system is designed, the operation principle of the system is studied, and the method to carry out this system is offered in detail. As a result, embedded vision system based on the CV-5501 controller is adopted. By analyzing and comparing the characteristics of all kinds of modules of machine vision, the image acquisition system is designed and it is composed of the CA-DRW10F white direct-ring LED light which uses the way of reflected illumination, the CA-LH16 lens with high-resolution and low distortion, and the CV-035C progressive scanning double-speed color camera which owns 240,000 pixels. After that the hardware design of the vision system is completed. Then STC89C52 MCU based main control system is studied and designed. Based on the offering of the design scheme of CD4052 based gated control, the serial port communications between MCU and the controller of the vision system, between MCU and PLC, and between MCU and touch screen are accomplished. Based on the application of E6B2-CWZ1X, MC3486 and TLP521-1, the control circuit of the trigger signal is designed. Based on the research of 7805, stabilized voltage power supply is provided. After that the hardware design of the main control system is accomplished. Studying the software functions of the vision system, the software interface of the vision system is programmed applying VC 6.0, some algorithms of digital image processing used in the system are studied and discussed, the collection and communication of the data and the images, and the procedure of the image processing program related to inspection and measurement are programmed. Studying the functions of the programs of the main control system, the program flow charts are designed, the main program, the serial port communication program, and the control program of the trigger signal are written with the application of C language and assemblerlanguage.
Finally, the debug and the experiments to the system referred above are carried out, sothat the operating stability and smooth of the embedded vision system based on the CV-5501 controller has been confirmed. The experiment of the image detection program is finished, in order that the accuracy and the feasibility of the programs, the real time ability and the reliability of the software are validated. The debug of the MCU control panel is completed, then the reliability of the transmitting and receiving of signal is tested, the exactness of the serial port communication program and the control program of the trigger signal is verified, and the reliability of the circuit is checked simultaneously.
引文
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