Line-laser-based yarn shadow sensing break sensor

In this paper, a line-laser-based yarn break sensor is proposed. In the proposed sensor, yarns are illuminated by a line laser placed on one side of the yarn plane. A screen is placed on the other side and the image formed on the screen is detected by a camera. The total number of yarns is compared with the total number of shadows formed by the yarns or the total number of light spots formed due to the distances between yarns. If the total number of yarns to be detected is greater than the total number of shadows or light spots formed due to the distances between the yarns, the sensor warns of breaking. In the proposed method, evaluation is made using only light spots or shadows formed by the yarns. Consequently, the yarn type, structure, color, or dimensions do not affect the results.Design principles of the line-laser-based yarn break sensor, which consists of a screen and a Charged Coupled Device (CCD) camera, are presented. The screen displays the shadows formed by the yarns and the light spots formed due to the distances between them. The CCD camera detects the image on the screen. Formation of the shadows by the yarns is explained and an analytical formula that expresses the dimensions of the shadows is obtained. The detection area of the sensor is expressed relative to the total number of yarns, yarn thickness, and distances between the yarns. Line laser radiation angle and light spot intensity equations are obtained relative to the width of the detection area and the height of the line laser placement. The screen length is obtained relative to the number of yarns and the placement of the laser, the yarn plane, and the screen.Different placement situations of the line laser (transmitter), the screen, and the CCD camera (receiver) relative to the yarn plane are discussed. An experimental setup is developed to test the system. The image formed on the screen is studied.