JPH07119710B2 - Tatami mat inspection device - Google Patents

Description

The present invention relates to a tatami mat inspection method and apparatus for inspecting the quality of tatami mats.

[Conventional technology]

Traditionally, tatami mats that have been woven, finished and dried by igusa producers and shipped as long rolls (usually 20.8 m) are inspected at the inspection site (Kumamoto prefecture, which accounts for about 80% of the national tatami mat production, There were 30 facilities operated by a trade union) and the grade was judged by visual inspection by inspectors.

[Problems to be solved by the invention]

By the way, the actual condition of the inspection at the inspection site is performed as described below.

A. Due to the processing capacity, one of the inspection units (1 mountain, 16 to 20 long pieces) brought to the inspection site is a sampling extraction inspection except for the weight.

B. Furthermore, since it is a visual inspection, it takes a long time to check various inspection items. Therefore, only a part of the tatami mat is inspected.

C. A group of multiple inspectors visits each inspection site to perform inspections, but the inspectors are those appointed by a voluntary organization, the trade union, and have no qualifications.

Therefore, there are the following problems.

Defective products may be mixed in the products that are not subject to sampling inspection.

b. Even if it is escaped and inspected, one (20.8m) is not inspected, so even if there is a defective part in the center of the roll tatami mat, it will be overlooked.

c. Inspectors perform inspections based on their experience and intuition, and their judgments vary, and their reliability is poor.

This has caused a serious situation in which the returned goods rate with respect to the shipment amount reaches 5 to 6%, widening the quality gap between production sites and increasing the distrust of the inspection by the inspector. An object of the present invention is to solve these problems, and it is an object of the present invention to provide a tatami mat inspection method and a device therefor that can perform quality inspection of all tatami mats accurately in a short time.

[Means for solving problems]

In order to achieve the above object, the tatami mat inspection apparatus of the present invention comprises: A conveying device is provided for expanding the tatami mat and transferring it in the warp direction.

B. A plurality of detecting devices for detecting the main elements of quality judgment are provided along the carrying device.

C. Further, an arithmetic unit and an indicator for calculating the quality judgment value of the tatami mat based on the detection signal of each detecting unit are provided.

D. A rotary drum which rotates with the transfer of the tatami mat is provided, and an auxiliary roller for pressing the tatami mat against the peripheral surface of the rotary drum is provided.

E. Thus, a part of the plurality of detection devices is provided so as to face the tatami mat which is pressed against the peripheral surface of the rotating drum.

I took the technical means.

The inspection device provided opposite to the tatami mat pressed against the peripheral surface of the rotary drum may be an optical detection device including a light source and a light receiving element that are provided laterally in the width direction of the tatami mat.

It is also effective to make the peripheral surface of the rotary drum white.

[Work]

While the tatami mat is transferred in the warp direction by rollers etc., the weight, moisture, density, which are the main elements for quality judgment,
Color irregularity, alignment, roughness, length, width, etc. are detected, and this detection signal is processed by the arithmetic unit, and the judgment result is immediately displayed on the display unit as grade, but it is rotated by the auxiliary roller. The tatami mat that is pressed against the peripheral surface of the drum does not have wrinkles, and the surface of the tatami mat is inspected by a detection device that is provided opposite to the wrinkle.

When this detection device is used as an optical detection device, the arrangement and color unevenness of the tatami mat are measured more accurately, and auto zero is performed by the white color of the rotating roller when the measurement of one tatami mat is completed. .

Example of Invention

A preferred embodiment of the present invention will be described below with reference to FIGS.

Conveying rollers 1A to 1D, which are formed by vertically arranging a pair of rollers rotatably side by side, are continuously arranged at appropriate intervals in a substantially horizontal direction, and one of the conveying rollers 1A to 1D has one roller.
Feeding motors 2A to 2D for feeding the tatami mat A to one side at a speed of, for example, about 6 m / sec. Are respectively connected. Next, each detection device will be described in order.

A weight sensor 4 including a load cell is provided below the transport roller 1A on the transport start end side. The weight sensor 4 is connected to the arithmetic and control unit 3 via an amplifier and an A / D converter (not shown), performs measurement in units of 10 g, and has a so-called auto-zel function.

A moisture sensor 5 is provided between the transport roller 1A and the transport roller 1B. The moisture sensor 5 uses a capacitance method, and an electrode 5a is attached to the surface of the tatami mat A that contacts the surface. The moisture sensor 5 is connected to the arithmetic and control unit 3, and
Formed to measure in%.

A density sensor 6 having an electrode 6a is provided between the transport roller 1B and the transport roller 1C, similarly to the moisture sensor 5.
To provide. The density sensor 6 determines the density or thickness of the tatami mat A, and determines whether or not there is uneven tightening.

Next, the color unevenness detection sensor 7 and the alignment detection sensor 8 which are provided above the rotating drum 17 which has a white peripheral surface and which is rotatably supported, will be described. Color spot detection sensor 7
The light source is provided across the width direction of the tatami mat A, and three light-receiving elements (all not shown) are provided parallel to the light source, and R. G / B filter is installed. Further, each light receiving element is communicated with the arithmetic and control unit 3 to be processed, data at three locations are compared, and color unevenness is numerically displayed for each sheet. By making the peripheral surface of the rotating drum 17 white, so-called auto-zero is performed when the tatami mat is not passing.

The line-up detection sensor 8 is the color unevenness detection sensor 7 described above.
Compared with a small area, it is a line sensor that mainly detects lines (because two or more rushes are woven side by side due to a poor weaving machine, also referred to as double feeding and double feeding). , Which mainly consists of a contamination sensor that detects contamination (oil stains and dirt), both of which are parallel to the background (reference color plate having a brightness similar to that of the tatami mat) that is installed across the width direction of tatami mat A. A light source is installed horizontally (may be shared), and 80 sensors are arranged in series in the width direction of the tatami mat. Then, in the line sensor, each rush is compared with the background over its entire length, and a signal due to a light amount difference between the abnormal portion such as line and the background is detected. On the other hand, the pollution sensor is provided with a sensor corresponding to the R / G / B filter or the R / G filter, and the amount of light passing through each filter is compared with a reference threshold value, and when it is darker than the reference or when it is a reference. When it is whiter, it is polluted, cut (weaving grass cut during weaving), piece (weaving with the root or tip of the grass gathering on one side = out of pieces) or dead (through insect damage etc.) It will be counted as a mixed weave of withering etc.).

Next, regarding the roughness detecting device 9, the roughness detecting device 9 includes a light projecting side 9A and a light receiving side 9B, and the tatami table A is irradiated with laser light which is not affected by color from the light projecting side 9A. It is formed so that the amount of reflected light or the angle of reflection of the light receiving element provided on the light receiving side 9B is detected, and the surface roughness is detected by the difference in the amount of reflected light or the change in the reflection angle. Since both the laser light and the light receiving element reciprocate in the width direction of the tatami mat A, the locus on the surface of the tatami mat A becomes zigzag.

On the rotating drum 17, the auxiliary rollers 10 are provided on the right and left upper sides.
A and 10B are provided so that the tatami mat A can be rotated 17
When the tatami mat A is pressed against the peripheral surface of the roller A and is transferred by the transfer rollers 1A to 1D, the rotary drum 17 is formed so as to be rotated accordingly. A length sensor 11 such as a rotary encoder is provided on the axis of the rotary drum 17, and is formed so as to detect the length of one tatami mat A depending on the number of rotations of the rotary drum 17 and the angle at the time of stop.

Width sensors 12A and 12B including photosensor diodes are provided at both ends of the tatami mat A in the width direction, and the width (c) of the tatami mat A is detected by detecting reflected light from both ends of the tatami mat A.
m) is calculated and obtained.

The arithmetic and control unit 3 includes a display unit 13, a printer 14,
The alarm device 15 and the sequencer 16 of the feed motors 2A to 2 are connected.

Since the present embodiment is configured as described above, the weight sensor 4
The upper tatami mat A is inserted into a pair of roll gaps of the transport roller 1A on the transport start end side, and has an appropriate guide (a table-shaped or roll-shaped one on the back side, and a transport path on both sides from the transport path). A guide plate should be provided so that it does not come off.)
It is transferred to the end of the carrier while being guided by
In the meantime, various sensors detect the main elements for the quality determination of the tatami mat A.

That is, the weight sensor 4 provides the weight Wk of one tatami mat A.
g (10 g unit) is determined, and then the moisture sensor 5 measures the change in moisture every moment to determine the average moisture value, the upper limit value, and the lower limit value in 0.1% units.

Next, when the tatami mat A passes through the density sensor 6, the density or the thickness between the electrodes is detected, and thereby the tightening unevenness or the like is discriminated.

When the tatami mat A reaches the rotary drum 17, the rotary drum 17 rotates to start the length detection, and the irregular color detection sensor 7 and the alignment detection sensor 8 are detected. That is, in the color nonuniformity detection sensor 7, the light reflected from the tatami mat A from the light source is spectrally captured by the R, G, and B filters, captured, processed, and compared at three positions in the width direction. The degree of color unevenness (color step) is expressed by a number. On the other hand, in the alignment detection sensor 8, the background is compared with the small area of the tatami mat A (for each one of the rushes) to determine the misalignment of the rushes, contamination, and the like.

Next, in the roughness detection sensor 9, the light source (laser light) and the light receiving element are reciprocally moved to the left and right, and the amount of reflected light or the position of the reflected light is detected to determine the roughness of the surface of the tatami mat A and the defective oak ( Deteriorate humidification).

When the end portion of the tatami mat A passes through the rotary drum 17, the rotation of the rotary drum 17 stops, and the length sensor 11 detects the angle and the number of rotations at the time of stop, while the width sensor 12 detects the tatami mat by the optical sensor. The width of A is continuously detected.

In this way, the signal detected by each sensor is amplified, A / D converted, converted into a voltage corresponding to the detected signal, and further becomes a signal that can be easily processed by the arithmetic and control unit 3 and is calculated. The processed tatami mat A is ranked and the display device 13 and the printer are immediately processed.
Copied to 14.

Although the tatami mat A is supplied as a long product in the above embodiment, the tatami mat A may be cut one by one, and the tatami mat A may be continuously supplied by the automatic supply device. Good to do.

〔The invention's effect〕

As described above, according to the present invention, the harmful effects of visual inspection by the inspector are eliminated, and the entire tatami mat is inspected quickly and accurately over the entire length, so the inspection becomes fair and fair, and in a short time. Since individual inspection can be performed, defective products can be easily and completely removed, and the return rate is greatly reduced.

In particular, a rotary drum that rotates with the transfer of the tatami mat is provided, and an auxiliary roller for pressing the tatami mat against the peripheral surface of the rotary drum is provided, while facing the tatami mat that is pressed against the peripheral surface of the rotary drum. Since a part of the plurality of detection devices is provided, it is possible to inspect a tatami mat which is prone to wrinkles along the weft thread without wrinkles, and obtain an accurate detection value. Further, this is remarkable in the optical detecting device, and in addition, by making the peripheral surface of the rotating drum white, it is possible to perform auto zero every time the inspection object changes.

[Brief description of drawings]

FIG. 1 is a conceptual diagram showing an embodiment of the present invention, and FIG. 2 is a control block diagram thereof. 1A to 1D …… Transport roller, 2A to 2D …… Feed motor,
3 ... Arithmetic control device, 4 ... Weight sensor, 5 ... Moisture sensor, 6 ... Density sensor, 7 ... Color unevenness detection sensor, 8 ... Alignment detection sensor, 9 ... Roughness detection sensor, 10A , 10B ... Auxiliary roller, 11 ... Length sensor, 12,12A, 12B ... Width sensor, 13 ... Display device, 14 ...
... printer, 15 ... alarm device, 16 ... sequencer, 17 ... rotating drum.

Claims (3)

[Claims] 1. A conveying device for expanding a tatami mat and transferring it in the warp direction is provided, and a plurality of detecting devices for detecting the main elements of quality judgment are provided along the conveying device, and further, a detecting device for each detecting device is provided. In a tatami mat inspection device provided with a computing device and a display device for computing the quality judgment value of the tatami mat based on the detection signal, a tatami mat is provided with a rotary drum which rotates with the transfer of the tatami mat, and A tatami mat inspection device, characterized in that an auxiliary roller for pressing against the peripheral surface is provided, while a part of the plurality of detecting devices is provided so as to face the tatami mat pressed against the peripheral surface of the rotary drum. 2. The detection device provided facing the tatami mat pressed against the peripheral surface of the rotary drum is an optical detection device provided with a light source and a light receiving element which are laterally provided in the width direction of the tatami mat. The tatami mat inspection device of 1). 3. The tatami mat inspection device according to claim 2, wherein the peripheral surface of the rotary drum is white.