Cost effective online colour monitoring system for real time inspection of patterned textiles

~1-6%的纺织品由于颜色差异而被拒绝，导致成本高昂的生产延迟，客户索赔和限制进入新兴和快速发展的零售商市场进行动态库存管理。现有的质量控制方法主要是离线检测实物样品，速度慢，检测率<0.25%，造成昂贵的产品浪费。虽然存在在线分光光度计检测系统，但由于成本和无法处理图案纺织品，它们没有被广泛采用。该项目以最近推出的MEMS传感器技术为基础，通过采用新颖的数字技术方法，将开发一种市场首创的解决方案，用于对图案纺织品进行实时在线连续和完整的颜色检测。该系统将生成颜色数据卷图，从而保证质量，根据颜色相似度对卷进行分组，并制定先进的生产计划。系统开发和测试将与两家英国纺织品制造商合作进行。新的解决方案将导致英国制造业竞争力和生产力的逐步变化：i)通过提供“快速，小批量生产，错误最少”来解决新兴零售商的需求，从而获得与国外折扣批量生产的竞争优势；ii)通过应用过程中质量控制来提高生产率，确保只对正确着色的材料增加价值，从而提高首次产量（制造能力）并降低工艺成本。该技术也可转移到其他行业，包括塑料，包装薄膜和涂料

~1-6% of textiles are rejected due to colour variance resulting in costly production delays, customer claims and limiting access to the emerging & rapidly developing retailer market for dynamic stock management. Existing quality control methods are primarily off-line inspection of physical samples which are slow, inspect <0.25% of the textile and result in costly product waste. Whilst online spectrophotometer inspection systems exist, they are not widely adopted due to cost and inability to process patterned textiles. Building on a recently launched MEMS sensor technology and through the adoption of a novel digital technology approach, the project will develop a market first solution for real time online continuous and complete colour inspection of patterned textiles. The system will result in colour data roll maps enabling quality assurance, grouping of rolls based on similarity of colour, and advanced production planning. System development and testing will be undertaken in collaboration with two UK textile manufacturers. The new solution will lead to step changes in competitiveness and productivity for UK manufacturing: i) competitive advantage against discounted bulk manufacture abroad through the offer of ‘fast, small batch production with minimal errors’ addressing emerging retailer needs; and ii) enhanced productivity through application for mid-process quality control ensuring value is only added to correctly coloured materials thereby increasing first time yield (manufacturing capacity) and reducing process costs. The technology is also transferable to other sectors including plastics, packaging films & coatings