A Cotton Module Feeder Plastic Contamination Inspection System

Abstract

The removal of plastic contamination in cotton lint is an issue of top priority to the U.S. cotton industry. One of the main sources of plastic contamination showing up in marketable cotton bales, at the U.S. Department of Agriculture’s classing office, is plastic from the module wrap used to wrap cotton modules produced by the new John Deere round module harvesters. Despite diligent efforts by cotton ginning personnel to remove all plastic encountered during unwrapping of the seed cotton modules, plastic still finds a way into the cotton gin’s processing system. To help mitigate plastic contamination at the gin; an inspection system was developed that utilized low-cost color cameras to see plastic on the module feeder’s dispersing cylinders, that are normally hidden from view by the incoming feed of cotton modules. This technical note presents the design of an automated intelligent machine-vision guided cotton module-feeder inspection system. The system includes a machine-learning program that automatically detects plastic contamination in order to alert the cotton gin personnel as to the presence of plastic contamination on the module feeder’s dispersing cylinders. The system was tested throughout the entire 2019 cotton ginning season at two commercial cotton gins and at one gin in the 2018 ginning season. This note describes the over-all system and mechanical design and provides an over-view and coverage of key relevant issues. Included as an attachment to this technical note are all the mechanical engineering design files as well as the bill-of-materials part source list. A discussion of the observational impact the system had on reduction of plastic contamination is also addressed.