Research On Online Detection Method And Experiments Of Carbon Black's Dispersion

Carbon black is the most widely used reinforcing material in the rubber industry,the dispersion of carbon black affects the processing performance and physical and mechanical properties of the mixed rubber.If carbon black is not uniformly dispersed,it is easy to form large secondary aggregates,which is not conducive to the subsequent processing process,therefore,the dispersion of carbon black is an important indicator to measure the quality of rubber compounding.At present,there are two kinds of detection methods for carbon black dispersion,one is manual visual detection,which is influenced by the subjective factors of the quality inspector and the results are inaccurate.The other is the use of carbon black dispersion automatic rating equipment,although this kind of equipment has been applied to a certain extent in the rubber industry,there are some obvious problems,specifically,the detection process of these equipment is offline,and the carbon black dispersion can only be detected after mixing;the identification method of carbon black aggregates is not perfect enough to accurately identify low-contrast carbon black aggregates in the image;the inability to screen the scratches in the rubber image,resulting in certain errors in the detection results.In response to these problems,this paper has developed an online carbon black dispersion detection system,which uses a line scan camera to collect the continuously discharged rubber and analyze and identify the carbon black in the image,so as to realized the continuous online detection of carbon black dispersion in blended rubber.(1)To address the problem of low-contrast carbon black aggregates identification,a background estimation-based carbon black aggregates identification algorithm is proposed,which can effectively detect low-contrast carbon black aggregates and improve the accuracy of carbon black dispersion detection.(2)A scratch detection algorithm based on morphological algorithm and skeleton extraction method is proposed to address the problem of interference of carbon black dispersion detection by scratches in blended rubber images.(3)In response to the problem of large throughput of online detection data,the carbon black dispersion online detection mechanism is studied,and a carbon black dispersion detection pipeline model is constructed.Based on multi-threaded programming,the image acquisition part of the algorithm,the image processing part and the result evaluation part run in parallel.(4)Developed an online carbon black dispersion detection hardware system.By analyzing the optical characteristics of the test object,the line scan camera,line light source,and encoder are selected appropriately.The inspection system built in this paper has proven to be capable of continuously collecting images of the surface of the blended rubber,which are accurate,clear and rich in detail.(5)Developed a carbon black dispersion online detection upper machine control software,realized the key functions of image acquisition,chart dynamic drawing,image processing,database interaction,etc.The software's user interface is friendly and functional,integrated with historical data retrieval,report export,online software upgrade and other practical functions.(6)To address the problem of noise in the surface image of the compound,based on the analysis of noise sources and characteristics,the analysis and comparison of commonly used image denoising algorithms to determine the use of median filtering to denoise the image,this method protects the details of the image while denoising.The experimental results show that the online carbon black dispersion detection system developed in this paper can detect the carbon black aggregates on the surface of the blended rubber in real time,which provides a reference for the rubber industry to realize automatic detection and a basis for the development of online detection systems for other defects of blended rubber.