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Textile Fabric Inspection

The textile industry world-wide has experienced dramatic technological changes during the last decades. These changes brought about an increase in yield and in the quality of fabrics, along with a reduction in expenses and labor.

However, with all of this modernization, the textile quality fabric inspection and monitoring process is still performed today by traditional human inspection methods, involving high costs and a relatively low level of efficiency and accuracy.

It is the mission of EVS to modernize and automate the textile quality inspection process, by supplying a comprehensive line of AOI (automatic optical inspection) solutions, covering all textile inspection needs, increasing accuracy, quality and yield while decreasing labor and expenses.

Over 400 installations of griege and finished fabric inspection systems confirm that this mission is achievable. Our solution is designed to automate the entire existing quality process at the customer’s site. It is based on 3 stages, which together provide a complete solution. At the same time, our systems can also be implemented partially, in accordance with the needs of each specific site.

Textile Fabrics Inspection Process

EVS systems can be installed in any, or all, of the following 3 stages in the production process:

Stage 1 - Off-line inspection of dyed & finished fabrics
EVS inspection system (IQ-TEX), together with our shade variation analyzer (SVA), can be installed at the exit of the processing line (at the exit of the Stenter). At this stage the fabric is inspected for the detection of weaving, dyeing and finishing defects. All relevant data about detected defects (location, type, size, severity, image and map) is recorded for each large roll, and saved in an archive (Post Inspection Unit), for the 2nd stage.

The Shade Variation Analyzer (SVA) can be integrated in the line, or as a stand alone unit. The purpose of this system is to alert of color variation (side-to-side, or beginning–to-end). In case of a stand alone unit, the SVA provides color data for the specific cutting table, prior to cutting the big roll into small, final rolls.

Stage 2 – Post inspection unit
At this stage the system allows the operator/quality inspector to review the defects data, and operate the Cutting Plan Optimization software, in order to increase the amount of first choice small rolls (by better planning for stage 3, as described here below). This review and planning can be performed in a separate location on the plant (e.g. in the quality manager’s office).

Stage 3 - Automating the existing cutting tables
The purpose of this stage is to automatically stop the specific cutting table at the points of interest (cutting points). After reviewing defects & color problematic zones in the Video Album, and creating a cutting map, by implementing the Cutting Plan Optimization Program, the rolls’ data is transferred via network to the DMSS-T unit installed on the cutting table.

General Inspection Process

 

Fabric Inspection

 


Detectable Defects

  • Spinning defects (Knots, slab, un-even yarn, etc.)
  • Weaving Defects (miss pick, miss reed, yarn brake, etc.)
  • Dyeing and Finishing Defects (oil stain, color spot, different shade, etc)

 

Inspection results example: (Rip stop fabric)
Textile inspection

 

System Benefits

  • Improved quality of final product
  • Reduced labor costs
  • Roll grading and fabric routing
  • Replacing final inspection of greige fabric
  • Collecting defects data
  • Central control on the finishing line operation
  • Simpler plant operation
  • Increased automation of plant

System Highlights

  • Modular, compact, cost-effective
  • Centralized control over multiple inspection points
  • Inspection of images is performed inside smart cameras; central computer receives only inspection results
  • No special knowledge of image processing is required for system operation or maintenance
  • Operating System is based on Windows NT, with customized application programs
  • Fast Ethernet communication
  • Each camera is equipped with a Local Control Unit, capable of transmitting or receiving standard signals to or from external electronic devices