TAP CHi KHOA HQC & C6NG NGH$ CAC TRlTCfNG D^l HQC KY THU-jkT * S6 86 - 2012 BQ OIEU KHIEN DANH D A U LOI TV B O N G TREN VAI DET A STUDY ON THE DESIGN OF AN AUTOMATED FABRIC DEFECT MARKING CONTROLLER Phgni Thi Ngoc Yen, Pham Ngpc Hdi Tnr&ng Dgi hoL Bdch Khoa Hd Ngt Nhan bai 15 thing nim 2011 T6M TAT Nhieu phuxyng phap phdt hiin l6i trin san phim dit may cho thiy ring viic dp dgng cdc ky thudt xu- ly anh, nhin d^ng, hoc mdy mang lai kit qua tot vd cd tiim ning cao v^o cdc img dung thi/c ti Bii bao trinh bay viic nghien cuv, phit tnen va chi tao hi thing danh diu Idi vai ttr ddng He thing nhan thdng tin vi vi tri muc dd nghiem tmng vi lo^i l5i tir hi thong phit hiin Idi vai tw d0ng Du-a vdo nhOng thdng tin nhin dm?€, hi thing thur: hiin viic dinh dau t^i vi tri md loi duxyc phdt hien Bin canh dd, he thing cung cip thdng tin cho h$ thong phit hiin l5i vii vi tie tai vai nhim giup cho qui trinh dinh vi Idi duxyc chinh xdc Hi thong duxyc thiit ki v&i dq> tin cay va tinh linh ddng cao cho phip thda man nhdng yiu ciu cai dat da dang die thii cua nganh dit may ABSTR.ACT Many methods of defect detecting on plain or patterned textile products show that the application of image processing techniques, identification, learning machine brings good results and has high potential Into practical applications This paper aims at the research, design and development of an automated fabric defect marking system The system receives the information including the position, the level of seriousity and the type of fabric defects from the automated defect detection system Based on such information, it will automatically make a mark on the fabric surface at the position where the defect is identified Besides, the system sends the information of winch velocity to the defect detection system in order to guarantee the accuracy of defect localization This system is designed with high reliability and flexibility that satisfies various installing requirements of textile industry I GIOI THIEU Det may dugc coi la mot nhiing nganh trpng diem ciia nSn cong nghiep Viet Nam Trong thdi ky day manh cdng nghiep hda hien dai hoa dat nude, del may dugc xem la nganh san xuat miii nhpn va co mpt tiem lire phat trien kha manh Tir nam 2001, Viet Nam cd hon 1000 nha may det may, thu hut tren 50 van lao ddng, chiem den 22% long sd lao dong loan nganh cdng nghiep Cho den nam 2007, nganh del may da dem lai viec lam cho hang trieu nguoi lao dpng [2] Vdi nhung Igi the rieng biet nhu vdn dau tu khdng Idn, thdi gian thu hdi von nhanh, nganh del may^ cd the thu hilt duac nhilu lao dpng va co nhieu dieu kien md rpng thi trudng va ngoii nude vdi sir tham gia ciia nhieu phan kinh te khac Tuy vay, xu the hpi nhap kinh tk khu vuc va qudc te, nginh det may dang phai ddi mat vdi nhieu thich thirc ldn, phai canh tranh ngang bing vdi cic cudng qudc xuit khau Idn nhu Trung Qudc, An Dp, Inddnexia, Pakixtan, Han Qudc Thach thirc doi vdi nganh det may Viet nam la rat ldn De vugl qua nhiing thich thuc niy, chiing ta phii giai quyet lirng khd khan mpt viec dam bao chat lugng sin pham det vi sin pham may la hai yeu to hang dau quyet djnh sir cong cua nganh det may Viet Nam Tgi Viet Nam, qua trao doi vai cic can bp tai cac cong ty del may, chung tdi dugc biet rang hien tai chiing ta van ip dung quy trinh kiem tra chit lugng vai del bang mat thudng, chua cd mpt he thong phai hien vi dinh dau tu dpng Idi tren vai det Vdi di6u kien kiem tra nhu vay sS anh hudng rit Idn den chit lugng vi nang suit cua san pham Tu dd chiing toi manh dan nghien ciru, che tao va dua vao img dung thuc te cho he thong tu dpng dinh dau loi vai He thong nhan cic thdng lin ve loi vii tir he thdng nh|n dang Idi vai tu dpng Bii bao se gidi thieu qua nhung net chung ve he thdng nhan T^P CHi KHOA HQC & C6NG NGHf CAC TRU6NG B^l HQC K? THU^T * S686-Z' d^ng 16i vai ty dgng v i di sau vio thi^t ke, che h? thong danh dau 16i vii ty dgng [2] II X A Y D V N G PHAN CtTNG Q »I^tl Diy chuyen kiem tra chit lugng vii tv dpng bao gom (Hinh 1): Phin cdng dugc x§y d\mg dva tren mach truyin tin qua cic cip ndi nhim muc dich tiSn thay the va gh^p n6i: K H i t N DANH DAU L VAI Tl, ©ONG | Miy tdi vai H? thong nh^n d^ing 16i vii H^ thong dinh diu Idi vai • Mgch diiu khien: thu nh^n, phan tich vi xii' ly thong tin • Mach truyen thdng va hien thj: gom cic chip truyen thdng, LCD, led de hien thj trpji thil h? thdng • Mgch cong suit: gom cic thiet bj cicb|y va dieu khien dong cit cac thiet bj cong suit ^ 2.1 Phan tkh mirc d^ nhieu y^ anh hirong Trudc dua giai phap chong nhi& ta cin xic djnh cic thinh phan nhieu chinh c6 inh hudng den bp dieu khien: • Nhilu cac kenh truyin tin cua bp dik khiln: cac kenh truyin tin su dyng tin hi?u rat nhd nen rat de g5p can nhieu, thong thiidm nhit li nhilu ciia dien Iudi SOHz ho$c cic thiet bj cong suit xung quanh Vi^c chong nhieu khdng tot sg lam bg dieu khien khong the trao doi hoac trao doi nham thong tin, lam mat on dinh h6 thong Hiah Sa dS khdi h$ thdng nh^n dgng vd dtinh ddu loi vdi [2] He thong tu d^ng danh dau 16i vii d^t dugc thiit ke dua tren ca sd h? thong phat hipn tu dpng loi vii det Yeu ciu chung dugc dat thiet k^ he thong [ ]: • Nhieu tir phan cong suit inh huong 1^ phin diiu khien: tinh chat dong cit dimg cho vipc dinh diu Idi vai nen phan cong suat se thu6ng xuyen tgo cac hai tin s6 b§c cao Mat khac, t^i hi?n trudng co rat nhieu thiet bj cong suit Ion lim vi^c sg gay cic hai song Iudi di^n Vi|c chong nhieu khong ^ (each ly) sS gay treo hoic hdng bp di^ khien ^ • Dam bio chay an toin, dn djnh: tinh toan va dua cic bien phip chong nhieu tai hi^n trudng dk tang tinh on djnh cua h? thong • Dp chinh xac: lech khong qua 5% khd vai, viec chpn thiet bj chap hanh viec dinh diu s€ quyet djnh vi^c • Tiiy bien linh ho^t, de ding ghep noi vdi thiet bj san cd tai hipn trudng: vipc thiet ke bg chan de dpc l^p c6 the thio ghep, thay doi dp rpng vi dp cao giiip cho h? thong cd the ga vio cic loai may vdi dp nghieng be m§t \k kich thudc khac Do moi trudng cong nghipp vi$c chpn cac tin hi^u ve bg dieu khien dang sd ho$c d ^ g xung li giii phip tranh dugc anh hudng cija nhilu vi the chung ta khong chgn cac cai^ bien dua ve cic tin hi?u tucmg ty Cic thong hn dugc dua v l h? thong bao gom: RS485, ban phim, encoder Ven kenh truyen tm RS485, bac chit dudng truyin v^t ly niy da dugc thii nghi?m nhieu cong nghifp v i cho thaj ch6ng nhilu t6t n§n chung ta can chonf nhilu tr€n phin mIm bing cich dua dugt cau tnic goi tin kiim tra dugc 161 va tdc di truyin tin hgp ly • Ngoai ra, y4u td gii cung dugc luu y toi vi day chinh \k diem m^nh cua h? thong !im tai Viet Nam Trong khuon kho bii bao chiing toi t§p trung phan tich va xay d^mg bp di^u khien dinh diu loi, khong di sau vao xay dung b$ chan de va thi€t bi chap hanh dinh diu 16i cua h$ thong 38 TAP CHI KHOA HQC & CONG NGH$ CAC TRUCfNG DAI HQC KY THU^T •!• S6 86 - 2012 Vdi ban phim, viec chdng nhieu da duoc ap dung tai hiu het cic bp dieu khien Tren mach cung, bo Iri tu tai cac phim de chdng nhieu xung O phan mem, phai xac dinh chu ky quet phim hgp ly Encoder la thiet bj van tdc va dua ve dang xung ti le vdi van tdc Viec dugc chinh xac van toe la dieu quan irgng Nhiem vu nhin dang loi va luu vao co sd dii' lieu dua tren tpa dp dai cua vai nen van toe dugc sai so cang ldn thi viec tpa dp dai co sd dii lieu se sai sd cang Idn Do lin hieu ve cua encoder da la dang xung nen chi can su dung cic cua sd ihdi gian de Ipc mpt each don gian nham chong viec thang giing bat ngd ciia s6 lugng xung ve tam Nhu vay bp dieu khien can thiet l^p mpt dudng truyen on dinh vai may tinh Vdi h% thdng bang tdi, v^n tdc tdi la vin de quan trong, tdc dp niy cd the thing giing phu thupc vao diiu kien ngoii nhieu nen chiing toi sir dyng bp encoder de tdc dp tire thdi ciia vai Phan danh dau 161 vii vi phan ddng cit tdi vii la phan cong suit nen thuc hien giao tiep vdi bp dieu khien dugc thilt ke cich ly an loan va chong nhieu tdt Tir dd chiing toi dua so khdi ihiel ke bp diiu khien nhu sau (Hinh 2): Viec chong nhieu tii' phan cong suat danh ngugc lai bp dieu khien chinh la phan thiet ke each ly hgp ly Trong phan 2.2, chung toi se ndi rd hon ve viec chpn thiet bj each ly phin cimg Ben canh phan thiet ke mach in, can phii dua cic dudng dat so va dai tuong tu di dpc lap khdng lim inh hudng len Viec chdng nhilu bing phin mIm se dugc ndi chi tiet d phan 2.2 Thiet bi phan ciing tren bo dieu khien De tien cho ngudi sir dung, tai vi tri giam sat can dua cic thdng sd giim sit de biet dugc tinh trang miy ciing nhu mirc dp loi, chit lugng vai Tir chung toi dua vao LCD de hi6n thi cac thdng so va led de hien thi cac trang thai He thdng dinh diu Idi vai hoan toin cd thi thuc hien dpc lap ma khong can thdng tin tir he thdng tu ddng nh|n dang Idi Khi dd, cin thiet ke hai che dp cho he thdng: dieu khien tu dpng (nhan thong tin tir he thong phat hien) va dieu khien bang tay (ngudi cdng nhan giim sit tu tim 16i vai) Ben canh d6, bp dieu khien cho phep dl dang can chinh de phii hgp thuc tl sir dung nhu cai dat thong so thdi gian tri hay thong so ngudng canh bao fai cho Tir ta CO the thay viec dua ban phim vao bp dieu khien la can thiet Nham de dang giam sit, dieu khien cung nhu luu giiJ sd lieu, bg dieu khien can giao tiep vdi may tinh de cung cap thong lin giim sat cung nhu nhan lenh diiu khien tir tram trung Hinh Sa khdi phdn ciing bd dieu khien [IJ Tir cac phan tich tren chung toi chpn cac thiet bj phan ciing phii hgp cho ba mach nhu sau: • Mach dieu khien: vi dieu khien ATmegal28, dn ap nguon 5V 7805 va chip thdi gian thyc DSI307 • Mach truyen thong va hien thi: tan dung viec ATmegal28 cd hai cdng USART nen bg dieu khien dugc thiet ke de cd the dung ci hai chuan truyin thong RS232 va RS485 voi hai chip MAX232 va SN75176 Ben canh vdi phan hien thi, ngoai nhihig LED don nham hien thj cic trang thai cua bp dieu khien, chiing tdi sir dung LCD 16*2 de hien thj cae thong so vi keypad de ngudi sii dyng nhap cic s6 lieu mach hien thj • Mach cong suat: duoc xay dung Vol muc tieu cd the ghep noi nhieu mach khd vii ldn, can nhi6u thiet bi danh dau Chung tdi sir dung chip 74HC595 truyen tin noi tiep de ndi cac mach vdi Phuong phap dinh dau dua tren ddng cat cic thiet bi dinh dau vdi thiet bj dugc chgn de dira dong cat li BTA12, phan TAP CHi KHOA HQC & C6NG NGHf CAC TRUQNG DAI HQC KYTHUAT * S 86miy trang thii the hign thuat toin r idi hgp mir hinh hiin thj va bin phim cach ly hai phin diiu khiln vi dinh diu sir dung MOC3020 III THUAT TOAN DI^U KHifeN Thuat toin dugc cii dat tren vi diiu khien bao g6m ba nhi?m vy co bin: ludng, xu ly vi dieu khien Cic thu^l toin vi dieu khien ve CO ban li giong nhau, bii bio ngoii vi?c dua cic thu?t toin chung dugc sir dyng diiu khiln chiing tdi se tgp trung trinh b^y mpt s6 chii y nhim log! bo nhieu bSng phan mem va dua thdi diem dinh diu hgp ly Cic modul chinh phin mem ciia bp dieu khien: Hinh Sa mdy trgng thdi Nam man hinh dugc su dung vdi ck nhi^m vy dgc lap: Modul giao tiep bin phim vi hien thj Modul truyen thdng • Min hinh chinh: hien thj cic thong so co ban nhu van t6c mil vii, che dp chay, ngiy, gia Modul thu nh^n thdng tin tir encoder Modul dieu khien danh dau • Man hinh truy cap: bugc nguai dung phai cd mat khau neu muon truy cap bp dieu khien 3.1 Modul giao tiep bin phim vi hien thi Thuat toin giao tilp vdi ban phim vi dua thdng tin LCD duoc xay dung dua tren so dd may trang thii mieu ta tren hinh Ngoii viec cai dat co bin nhu cic che dp lam viec, ihdi gian tre, nguong cinh bio , chung l6i dua phan cii dat bao mat cho bp dieu khien Phan cii dat chi cho phep ngudi c6 mat khau tucmg-tac cii dat bp dieu khien trinh viec bp dieu khien bj cai dat sai Hinh bieu dien so • Man hinh cai dit che dp: cd hai chi dp cai dai la ty dpng vi bing tay • Min hinh hieu chinh thcri gian: cai datth6i gian irl tir luc nhan dugc thong tin I6i din Iik dinh dau 16i Man hinh cii dit mat khau: cho phep nguoi sir dung cai dit Igi mat khau Header Dadd Data CRC Footer I byte ! byte 27 bytes bytes ] t^te OxAA MS loi 1 Kieu iSi I Cij M§t khiu Co tre khiu Th&i gian ire Mut d? loi Canh bao D6ng cil Dv phong 0x55 Hinh Cdu trite goi tin tir mdy tinh xudng bg dieu khien 3.2 Modul truyen thdng Phuong thlic truyen tin tren dudng truyen RS485/RS232 dugc phat trien vdi co che hoi dip vdi miy tinh li Master vi bp diiu khiln li Slave Phuong phap truyen tin se giup ma rpng he thdng co them nhilu bp dieu khien Cau triic gdi tin dugc trinh bay tren hinh 3.3 Modul thu nhan thdng tin tir encoder Hinh trinh bay vl cich thiic lap trinh dem xung tra ve ciia encoder Theo ta se tao mot cira so thdi gian vai Ihgi gian co dinh, ciia so sg chay dpc theo true thdi gian dg dgm sd lugng xung cira so Phuong phip niy giong nhu tgo mpt bp tich phan don gian thdri gian ngin nhim loai bd cac ihinh phin xung nhilu thing giang dot ngpt Voi idc dp khoing 30m/min, cd the chgn ciras5 thdi gian khoing 0.5s - Is vai encoder dua ve khoang lOOpulses/m r • Hinh Cira sd th&i gian de dem xung encodi T^.? CHi KHOA HQC & CONG NGHE; CAC TRlTCfNG DAI HQC KY THU^T * S6 86 - 2012 3.4 Modul dieu khiSn dinh diu Mpt phin quan trpng khac phii xir ly phin mem li phii dua dap irng danh dau chinh xic voi khoang thdi gian tri cii dit De han che anh hudng cua ngQ canh boat dpng cua bp diiu khiln ta sg diiu khien hoat dpng ddng cat niy theo cd Dg xic djnh trang thii ciia CO ta dat cac bp timer cua vi digu khien chii khdng dat him main() chinh, tiiy timg dieu kien ngii cinh khic thi chu ky ciia ham main() se khac Khi dgt timer ciing ta se cd chu ky quel cd djnh, de ciSn chinh thdi gian chinh xic ta chi can chinh offset ve thdi gian IV KET QUA DAT DU'