CN114302112B - Textile machine productivity monitoring device - Google Patents
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Abstract
The invention provides a textile machine productivity monitoring device, which comprises an audio acquisition module, an audio analysis module, a video monitoring module and a productivity calculation module, wherein the audio acquisition module is used for acquiring audio data of a textile machine in a workshop during operation, the audio analysis module is used for analyzing the acquired audio data to obtain the working state of the textile machine, the video monitoring module is used for assisting in judging the working state of the textile machine, and the productivity calculation module is used for calculating the productivity in the workshop according to the working state of the textile machine; the device mainly monitors the sound of the textile machine during working to obtain the working state of the textile machine, calculates the productivity according to the duration distribution of the working state, and has the characteristics of low error rate and high efficiency compared with image monitoring.
Description
Technical Field
The present disclosure relates generally to the field of production monitoring, and more particularly to a textile machine capacity monitoring device.
Background
In industrial production, monitoring equipment is needed to acquire the capacity condition in a factory in real time, most of the monitoring equipment is in a video acquisition and analysis mode at present, but the mode has higher requirements on the processing capacity of video analysis and is easy to misjudge, the textile machine can generate sound with a fixed period in the production process, the stability and the discernability are higher, the working state of the textile machine is monitored in an audio acquisition and analysis mode, and a better monitoring effect is achieved.
A number of monitoring systems have now been developed, through extensive search and reference, and found that existing monitoring systems have a system as disclosed by publication nos. KR1020090008018a, KR100844862B1, CN105821537B and KR100589880B1, comprising one or two rows of individual rectangular-shaped optical elements, which at their outputs provide an analog signal proportional to the irradiance level of the optical elements, the analog signals of all individual optical elements, which are irradiated in all modes of operation of the quality optical detector and which are not obscured by the yarn, are sensed for each individual optical element and stored in an electronic memory according to predefined criteria as initial, run or working values of the individual optical elements, which values are then compared to each other for the purpose of evaluating the correct functioning of the sensor and eliminating manufacturing and running defects and malfunctions. However, the system needs to monitor each textile machine individually, requires higher cost, and is not suitable for large-scale monitoring.
Disclosure of Invention
The invention aims to provide a textile machine productivity monitoring device aiming at the existing defects,
The invention adopts the following technical scheme:
The production capacity monitoring device of the textile machine comprises an audio acquisition module, an audio analysis module, a video monitoring module and a production capacity calculation module, wherein the audio acquisition module is used for acquiring audio data of the textile machine in a workshop during working, the audio analysis module is used for analyzing the acquired audio data to obtain the working state of the textile machine, the video monitoring module is used for assisting in judging the working state of the textile machine, and the production capacity calculation module is used for calculating the production capacity in the workshop according to the working state of the textile machine;
The audio analysis module processes one period of the audio data to obtain m peak point coordinates (Wp i,tpi) and n valley point coordinates (Wv i,tvi),tpi refers to the time of the ith peak point coordinate, wp i refers to the intensity of the ith peak point coordinate, tv i refers to the time of the ith valley point coordinate, wv i refers to the intensity of the ith valley point coordinate), and the audio analysis module calculates an original peak value Vw i of the ith peak point according to the peak point and the valley point:
The original peak value refers to the peak value of the audio frequency when the single textile machine works;
Wherein, T' is a period of the audio data processed by the audio analysis module, j represents the serial numbers of the rest peak points in the influence range of the ith peak point, [ n 1,n2 ] is the serial number interval of the peak points, k is the serial number of the valley points in the influence range of the ith peak point, [ n 3,n4 ] is the serial number interval of the valley points, lambda 1 is a first mixing parameter, lambda 2 is a second mixing parameter;
The influence range refers to a time range in which the audio wave peaks of the two textile machines are mutually interfered;
the ith original peak value is compared with the ith Pairing the original peaks in pairs to obtain a plurality of groups of peak pairs, wherein each group of peak pairs corresponds to a working textile machine, comparing and pairing the peak pairs with recorded characteristic data of the textile machines, wherein the characteristic data refer to two wave peaks in one period in audio data when one textile machine works independently, the textile machine which is successfully paired and has the same data is in a normal working state, the textile machine which is successfully paired but has deviation in data is in an abnormal working state, the unpaired textile machine is in a pause state, and the textile machine which looks up the pause state through the video monitoring module judges whether the textile machine is in a maintenance state or a shipment state;
The productivity calculation module calculates and obtains the productivity index P of the textile machine according to the time of the state of the textile machine:
Wherein, T Positive direction represents the time of normal operation in a shipment period, T Different species represents the time of abnormal operation in a shipment period, T Repair tool represents the time of maintenance in a shipment period, T Out of represents the time of shipment in a shipment period, k 1 is a spinning efficiency coefficient, k 2 is a lossy efficiency coefficient, and k 3 is a maintenance coefficient;
the shipment period refers to the time interval between two shipments of a textile machine;
The productivity calculation module accumulates the productivity indexes of all the textile machines in the workshop to obtain the productivity condition of the workshop;
Further, the device also comprises a data input module, wherein the data input module is used for inputting the serial numbers of the textile machines and independently starting the corresponding textile machines, the audio acquisition module acquires data and then sends the data to the audio analysis module, the audio analysis module records the first wave crest, the second wave crest and the period value in one period as the characteristic data of the corresponding textile machines, and the operation is repeated until the characteristic data of all the textile machines are recorded in the audio analysis module;
further, the input module is used for inputting numbers of the two textile machines and starting the corresponding two textile machines, the audio acquisition module acquires mixed audio data, the mixed audio data comprises four main peaks and two troughs in one period, and the audio analysis module calculates a first mixed parameter lambda 1 and a second mixed parameter lambda 2 according to the mixed audio data:
Wherein, W 11、W12 and T 1 are respectively a first peak value, a second peak value and a cycle time of one textile machine audio data, W 21、W22 and T 2 are respectively a first peak value, a second peak value and a cycle time of the other textile machine audio data, wz 11 and Wz 12 are respectively two first main peak values of the mixed audio, wz 21 and Wz 22 are respectively two second main peak values of the mixed audio, wg 1 and Wg 2 are respectively a first valley value and a second valley value of the mixed audio, T 1、t2 and T 3 are respectively times corresponding to a first main peak, a first valley and the other first main peak, and T 4、t5 and T 6 are respectively times corresponding to a second main peak, a second valley and the other second main peak;
further, when the audio analysis module calculates the original peak value, the influence range of the ith peak point is [ tp i-ΔT,tpi +Δt ], and the calculation formula of the half-time domain Δt is as follows:
ΔT＝δ·lg(10·Wpi)；
Wherein delta is a time domain coefficient;
Further, the audio collection module comprises a filtering unit, and the filtering unit can filter collected noise to prevent the noise from interfering with the analysis processing of the audio analysis module.
The beneficial effects obtained by the invention are as follows:
The system monitors the working state of the textile machine by monitoring the audio instead of video monitoring based on the audio with high recognition degree and the high stability of the audio when the textile machine works, and only one audio acquisition device is needed in one workshop due to the high coverage range of the audio, so that the cost is greatly reduced, and meanwhile, the video monitoring module is used for assisting in monitoring by recognizing whether the textile machine is in a maintenance state or a shipment state when the textile machine is in a suspended state, so that the accuracy of the recognition of the working state of the textile machine is further ensured.
For a further understanding of the nature and the technical aspects of the present invention, reference should be made to the following detailed description of the invention and the accompanying drawings, which are provided for purposes of reference only and are not intended to limit the invention.
Drawings
FIG. 1 is a schematic diagram of the overall structural framework of the present invention;
FIG. 2 is a schematic view of an audio image of a single textile machine of the present invention in operation;
FIG. 3 is a schematic view of audio images of two textile machines of the present invention in operation;
FIG. 4 is a diagram of the pairing of raw peak and characteristic data during normal and pause operation of the textile machine according to the present invention;
FIG. 5 is a diagram showing the pairing of the original peak values and the characteristic data of the textile machine according to the present invention during normal operation and abnormal operation.
Detailed Description
The following embodiments of the present invention are described in terms of specific examples, and those skilled in the art will appreciate the advantages and effects of the present invention from the disclosure herein. The invention is capable of other and different embodiments and its several details are capable of modification and variation in various respects, all without departing from the spirit of the present invention. The drawings of the present invention are merely schematic illustrations, and are not intended to be drawn to actual dimensions. The following embodiments will further illustrate the related art content of the present invention in detail, but the disclosure is not intended to limit the scope of the present invention.
Embodiment one.
The embodiment provides a textile machine productivity monitoring device, which comprises an audio acquisition module, an audio analysis module, a video monitoring module and a productivity calculation module, wherein the audio acquisition module is used for acquiring audio data of a textile machine in a workshop during operation, the audio analysis module is used for analyzing the acquired audio data to obtain the working state of the textile machine, the video monitoring module is used for assisting in judging the working state of the textile machine, and the productivity calculation module is used for calculating the productivity in the workshop according to the working state of the textile machine;
The audio analysis module processes one period of the audio data to obtain m peak point coordinates (Wp i,tpi) and n valley point coordinates (Wv i,tvi),tpi refers to the time of the ith peak point coordinate, wp i refers to the intensity of the ith peak point coordinate, tv i refers to the time of the ith valley point coordinate, wv i refers to the intensity of the ith valley point coordinate), and the audio analysis module calculates an original peak value Vw i of the ith peak point according to the peak point and the valley point:
The original peak value refers to the peak value of the audio frequency when the single textile machine works;
Wherein, T' is a period of the audio data processed by the audio analysis module, j represents the serial numbers of the rest peak points in the influence range of the ith peak point, [ n 1,n2 ] is the serial number interval of the peak points, k is the serial number of the valley points in the influence range of the ith peak point, [ n 3,n4 ] is the serial number interval of the valley points, lambda 1 is a first mixing parameter, lambda 2 is a second mixing parameter;
The influence range refers to a time range in which the audio wave peaks of the two textile machines are mutually interfered;
the ith original peak value is compared with the ith Pairing the original peaks in pairs to obtain a plurality of groups of peak pairs, wherein each group of peak pairs corresponds to a working textile machine, comparing and pairing the peak pairs with recorded characteristic data of the textile machines, wherein the characteristic data refer to two wave peaks in one period in audio data when one textile machine works independently, the textile machine which is successfully paired and has the same data is in a normal working state, the textile machine which is successfully paired but has deviation in data is in an abnormal working state, the unpaired textile machine is in a pause state, and the textile machine which looks up the pause state through the video monitoring module judges whether the textile machine is in a maintenance state or a shipment state;
The productivity calculation module calculates and obtains the productivity index P of the textile machine according to the time of the state of the textile machine:
Wherein, T Positive direction represents the time of normal operation in a shipment period, T Different species represents the time of abnormal operation in a shipment period, T Repair tool represents the time of maintenance in a shipment period, T Out of represents the time of shipment in a shipment period, k 1 is a spinning efficiency coefficient, k 2 is a lossy efficiency coefficient, and k 3 is a maintenance coefficient;
the shipment period refers to the time interval between two shipments of a textile machine;
The productivity calculation module accumulates the productivity indexes of all the textile machines in the workshop to obtain the productivity condition of the workshop;
the device also comprises a data input module, wherein the data input module is used for inputting the serial numbers of the textile machines and independently starting the corresponding textile machines, the audio acquisition module acquires data and then sends the data to the audio analysis module, the audio analysis module records the first wave crest, the second wave crest and the period value in one period as the characteristic data of the corresponding textile machines, and the operation is repeated until the characteristic data of all the textile machines are recorded in the audio analysis module;
The method comprises the steps that the input module is used for inputting numbers of two textile machines and starting the corresponding two textile machines, the audio acquisition module acquires mixed audio data, the mixed audio data comprises four main peaks and two troughs in one period, and the audio analysis module calculates a first mixed parameter lambda 1 and a second mixed parameter lambda 2 according to the mixed audio data:
Wherein, W 11、W12 and T 1 are respectively a first peak value, a second peak value and a cycle time of one textile machine audio data, W 21、W22 and T 2 are respectively a first peak value, a second peak value and a cycle time of the other textile machine audio data, wz 11 and Wz 12 are respectively two first main peak values of the mixed audio, wz 21 and Wz 22 are respectively two second main peak values of the mixed audio, wg 1 and Wg 2 are respectively a first valley value and a second valley value of the mixed audio, T 1、t2 and T 3 are respectively times corresponding to a first main peak, a first valley and the other first main peak, and T 4、t5 and T 6 are respectively times corresponding to a second main peak, a second valley and the other second main peak;
When the audio analysis module calculates an original peak value, the influence range of the ith peak point is [ tp i-ΔT,tpi +delta T ], and the calculation formula of the half-time domain delta T is as follows:
ΔT＝δ·lg(10·Wpi)；
Wherein delta is a time domain coefficient;
the audio acquisition module comprises a filtering unit, and the filtering unit can filter acquired noise to prevent the noise from interfering with the analysis processing of the audio analysis module.
Embodiment two.
The embodiment comprises the whole content of the first embodiment, and provides a textile machine productivity monitoring device, which comprises an audio acquisition module, an audio analysis module, a data input module, a video monitoring module and a productivity calculation module, wherein the audio acquisition module is used for acquiring audio data of a textile machine in operation, the audio analysis module is used for analyzing the audio data to obtain a corresponding working state, the data input module is used for inputting the serial number of the textile machine, the video monitoring module is used for acquiring image data of the work of the textile machine, and the productivity calculation module is used for calculating productivity according to the time distribution of the working state of the textile machine;
The device comprises 2 modes, namely a learning mode and a monitoring module, in the learning mode, each textile machine in a workshop is independently operated, the audio data of the individual operation is collected by the audio collection module, the characteristic data of each audio data is recorded by the audio analysis module, then two textile machines are simultaneously operated, the serial numbers of the textile machines which are simultaneously operated are input by the input module, the audio collection module is used for collecting mixed audio data, the audio analysis module is combined with the mixed audio and the corresponding textile machine characteristic data to obtain audio mixing parameters of the plurality of textile machines which are simultaneously operated, in the monitoring mode, the audio collection module is used for continuously collecting the audio data of the textile machines, the audio analysis module is combined with the audio mixing parameters and the audio data to analyze the operation number of the textile machines, and when the operation number is less than a preset number, the video monitoring module is used for checking the state of the standby textile machines;
The audio acquisition module comprises a filtering unit, and the filtering unit can filter acquired noise to prevent the noise from interfering with the analysis processing of the audio analysis module;
Referring to fig. 2, in a learning mode, the characteristic data of the audio data of each textile machine includes a first peak, a second peak and a period value, one period includes a first peak and a second peak, a time interval between every two adjacent first peaks or second peaks is a period, the audio analysis module records and numbers the characteristic data of each textile machine, and each time after recording the characteristic data of one textile machine, the video monitoring module is aligned to the corresponding textile machine, and meanwhile, the positioning data of the video monitoring module is recorded and bound with the number of the characteristic data;
Referring to fig. 3, the mixed audio data includes four main peaks and two wave troughs in a period, the main peaks are divided into two first main peaks and two second main peaks, the wave troughs are divided into first wave troughs and second wave troughs, the first wave troughs are located between the two first main peaks, the second wave troughs are located between the two second main peaks, and the audio analysis module obtains corresponding feature data according to the number information input by the input module and calculates mixed parameters lambda 1 and lambda 2 by combining the mixed audio data:
Wherein, W 11、W12 and T 1 are respectively a first peak value, a second peak value and a cycle time of one textile machine audio data, W 21、W22 and T 2 are respectively a first peak value, a second peak value and a cycle time of the other textile machine audio data, wz 11 and Wz 12 are respectively two first main peak values of the mixed audio, wz 21 and Wz 22 are respectively two second main peak values of the mixed audio, wg 1 and Wg 2 are respectively a first valley value and a second valley value of the mixed audio, T 1、t2 and T 3 are respectively times corresponding to a first main peak, a first valley and the other first main peak, and T 4、t5 and T 6 are respectively times corresponding to a second main peak, a second valley and the other second main peak;
The audio analysis module respectively averages the mixing parameters lambda 1 and lambda 2 obtained by calculating all the mixed audios as final mixing parameters;
In a monitoring mode, the audio acquisition module acquires audio data, the audio data periodically changes when the textile machine works normally, and the audio analysis module analyzes one period;
The audio analysis module processes one period of the audio data to obtain m peak points (Wp i,tpi) and n valley points (Wv i,tvi), and calculates an original peak value Vw i of the ith peak point according to the peak points and the valley points:
Wherein T' is a period of processing audio data by the audio analysis module, (Wp j,tpj) is the rest peak points in the influence range of the ith peak point, and [ n 1,n2 ] is the sequence number interval of the peak points,
(Wv k,tvk) is the valley point in the influence range of the ith peak point, and [ n 3,n4 ] is the sequence number interval of the valley points;
the half-time domain Δt of the range of influence of the ith peak point is:
ΔT＝δ·lg(10·Wpi)；
Wherein delta is a time domain coefficient;
The influence range of the ith peak point is [ tp i-ΔT,tpi +delta T ];
The audio analysis module pairs the original peaks Vw i in pairs according to the corresponding time, and then compares the original peaks Vw i with the stored characteristic data of each textile machine, when one group of original peaks are consistent with one characteristic data, the corresponding textile machine is indicated to work normally, when one group of original peaks are inconsistent with all the characteristic data, the corresponding textile machine is indicated to work abnormally, and the number of the paired original peaks is the number of the working textile machines;
when the characteristic data of the textile machine does not have a corresponding group of original peaks, the video monitoring module adjusts the visual angle according to the positioning data of the textile machine and confirms the actual state of the textile machine;
referring to fig. 4 and 5, the final state of the textile machine is divided into four cases of normal operation, abnormal operation, pause operation-maintenance and pause operation-shipment, when the audio analysis module processes to obtain a set of original peaks corresponding to the characteristic data of the textile machine, the state is the normal operation state, when the audio analysis module processes to obtain a set of original peaks different from the characteristic data of the textile machine, the state is the abnormal operation state, when the audio analysis module processes to obtain no set of original peaks corresponding to the characteristic data of the textile machine, the state is the pause operation state, and when the textile machine is the pause operation state, the video monitoring module confirms whether the state is the maintenance state or the shipment state;
The textile machine enters a pause work-maintenance state after in an abnormal working state, and the pause work-shipment state is immediately after in a normal working state, the audio analysis module can directly judge the four states, and the video monitoring module is used for secondary judgment to prevent the situation of judging errors;
in another case, when the number of the original peak value groups which are not matched is less than the number of the characteristic data groups which are not matched, the part of the textile machines are in an abnormal working state, and the part of the textile machines are in a suspended working state, the audio analysis module cannot accurately judge, and the video monitoring module is required to check the textile machines one by one and confirm the actual state;
By combining the audio analysis module and the video monitoring module, the time of four states of each textile machine is recorded, T Positive direction represents the time of normal operation in a shipment period, T Different species represents the time of abnormal operation in a shipment period, T Repair tool represents the time of maintenance in a shipment period, T Out of represents the time of shipment in a shipment period, and the productivity index of the textile machine is P:
Wherein k 1 is a weaving efficiency coefficient, k 2 is a lossy efficiency coefficient, and k 3 is a maintenance coefficient;
And the productivity calculation module accumulates the productivity indexes of all the textile machines in the workshop to obtain the productivity condition of the workshop.
The foregoing disclosure is only a preferred embodiment of the present invention and is not intended to limit the scope of the invention, so that all equivalent technical changes made by applying the description of the present invention and the accompanying drawings are included in the scope of the present invention, and in addition, elements in the present invention can be updated as the technology develops.
Claims (5)
1. The production capacity monitoring device of the textile machine is characterized by comprising an audio acquisition module, an audio analysis module, a video monitoring module and a production capacity calculation module, wherein the audio acquisition module is used for acquiring audio data of the textile machine in a workshop during operation, the audio analysis module is used for analyzing the acquired audio data to obtain the working state of the textile machine, the video monitoring module is used for assisting in judging the working state of the textile machine, and the production capacity calculation module is used for calculating the production capacity in the workshop according to the working state of the textile machine;
the audio analysis module processes one period of the audio data to obtain m peak point coordinates And n valley coordinatesTp i denotes the time of the ith peak point coordinate, wp i denotes the intensity of the ith peak point coordinate, tv i denotes the time of the ith valley point coordinate, wv i denotes the intensity of the ith valley point coordinate, and the audio analysis module calculates the original peak value of the ith peak point according to the peak point and the valley point：
；
The original peak value refers to the peak value of the audio frequency when the single textile machine works;
Wherein, Processing one period of audio data for the audio analysis module, j representing the remaining peak numbers within the range of influence of the ith peak,For the number intervals of these peaks, k is denoted as the number of the valley point in the range of influence of the ith peak,For the sequence number intervals of these dips,As a result of the first mixing parameter,Is a second mixing parameter;
The influence range refers to a time range in which the audio wave peaks of the two textile machines are mutually interfered;
the ith original peak value is compared with the ith Pairing the original peaks in pairs to obtain a plurality of groups of peak pairs, wherein each group of peak pairs corresponds to a working textile machine, comparing and pairing the peak pairs with recorded characteristic data of the textile machines, wherein the characteristic data refer to two wave peaks in one period in audio data when one textile machine works independently, the textile machine which is successfully paired and has the same data is in a normal working state, the textile machine which is successfully paired but has deviation in data is in an abnormal working state, the unpaired textile machine is in a pause state, and the textile machine which looks up the pause state through the video monitoring module judges whether the textile machine is in a maintenance state or a shipment state;
The productivity calculation module calculates and obtains the productivity index P of the textile machine according to the time of the state of the textile machine:
；
Wherein, Indicating the time of normal operation in a shipment cycle,Indicating the time of abnormal operation in one shipment cycle,Indicating the time of maintenance during a shipment cycle,Indicating the time of shipment in a shipment cycle,As the coefficient of the spinning efficiency, the yarn is in contact with the yarn,In order to be able to compromise the efficiency coefficient,Is a maintenance coefficient;
the shipment period refers to the time interval between two shipments of a textile machine;
And the productivity calculation module accumulates the productivity indexes of all the textile machines in the workshop to obtain the productivity condition of the workshop.
2. The device for monitoring productivity of textile machines according to claim 1, further comprising a data input module, wherein the data input module is used for inputting the serial numbers of the textile machines and independently starting the corresponding textile machines, the audio acquisition module acquires data and sends the data to the audio analysis module, the audio analysis module records the first wave crest, the second wave crest and the period value in one period as the characteristic data of the corresponding textile machines, and the operation is repeated until the characteristic data of all the textile machines are recorded in the audio analysis module.
3. The apparatus for monitoring capacity of textile machines according to claim 2, wherein the input module is used to input numbers of two textile machines and turn on the corresponding two textile machines, the audio acquisition module acquires mixed audio data, the mixed audio data includes four main peaks and two valleys in one period, and the audio analysis module calculates a first mixing parameter according to the mixed audio dataAnd a second mixing parameter：
；
；
Wherein,、And T 1 are the first peak value, the second peak value and the cycle time of the audio data of one textile machine respectively,、And T 2 are the first peak value, the second peak value and the cycle time of the audio data of another textile machine respectively,AndFor mixing the two first main peaks of the audio,AndFor mixing the two second main peaks of the audio,AndFor mixing the first and second valley values of the audio, t 1、t2 and t 3 are the times corresponding to the first main peak, the first valley and the other first main peak, respectively, and t 4、t5 and t 6 are the times corresponding to the second main peak, the second valley and the other second main peak, respectively.
4. A textile machine productivity monitoring device according to claim 3, wherein the audio analysis module calculates the original peak value, and the influence range of the ith peak point isHalf of the time domainThe calculation formula of (2) is as follows:
；
Wherein, Is a time domain coefficient.
5. The textile machine productivity monitoring device according to claim 4, wherein the audio collection module comprises a filtering unit, and the filtering unit can filter collected noise to prevent the noise from interfering with the analysis processing of the audio analysis module.
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| EP3696637A1 (en) * | 2019-02-18 | 2020-08-19 | Maschinenfabrik Rieter AG | Textile machine management system and method |
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| CN101515166A (en) * | 2009-03-19 | 2009-08-26 | 杭州嘉拓科技有限公司 | Device for monitoring yarn moving state and monitoring method for same |
| CN111161756A (en) * | 2020-02-13 | 2020-05-15 | 北京天泽智云科技有限公司 | Method for extracting and identifying abnormal whistle contour in wind sweeping sound signal of fan blade |
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