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Plastic contamination in cotton lint poses significant challenges to the U.S. cotton industry, with plastic wrap from John Deere round module harvesters being a primary contaminant. Despite efforts to manually remove this plastic during module unwrapping, some inevitably enters the cotton gin’s processing system. To address this, a machine-vision detection and removal system has been developed. This system uses inexpensive color cameras to identify plastic on the gin stand feeder apron, triggering a mechanism that expels the plastic from the cotton stream. However, the system, composed of 30–50 Linux-based ARM computers, requires substantial effort for calibration and tuning and presents a technological barrier for typical cotton gin workers. This research aims to transition the system to a more user-friendly, plug-and-play model by implementing an auto-calibration function. The proposed function dynamically tracks cotton colors while excluding plastic images that could hinder performance. A critical component of this auto-calibration algorithm is the hand intrusion detector, or “HID”, which is discussed in this paper. In the normal operation of a cotton gin, the gin personnel periodically have to clear the machine, which entails running a stick or their arm/hand under the detection cameras. This results in the system capturing a false positive, which interferes with the ability of auto-calibration algorithms to function correctly. Hence, there is a critical need for an HID to remove these false positives from the record. The anticipated benefits of the auto-calibration function include reduced setup and maintenance overhead, less reliance on skilled personnel, and enhanced adoption of the plastic removal system within the cotton ginning industry.

Plastic contamination in marketable cotton bales, predominantly from plastic wraps used in John Deere round module harvesters, poses a significant challenge to the U.S. cotton industry. Despite rigorous manual efforts, the intrusion of plastic into the cotton gin’s processing system persists. We have developed a machine-vision detection and removal system aimed at mitigating this problem. This system employs inexpensive color cameras to detect plastic on the gin-stand feeder apron and subsequently removes it, reducing contamination. This system, built around low-cost ARM computers running Linux, comprises 30–50 machines and requires considerable effort to calibrate and tune. Moreover, its operation represents a technological challenge to typical cotton gin workers. This research presents a solution to this calibration operational hurdle by introducing an auto-calibration algorithm that has potential to simplify the system into a plug-and-play device. The auto-calibration system is designed to dynamically track the cotton color and utilizes frequency statistics to avoid plastic images that could compromise the system’s performance if incorporated into the auto-calibration process. We detail the design of the auto-calibration algorithm, which is expected to significantly reduce the setup overhead and facilitate the system’s continuous use. This innovation minimizes the need for skilled personnel and, therefore, is expected to expedite the system’s adoption across the cotton ginning industry.

The removal of plastic contamination from 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 is plastic used to wrap cotton modules produced by John Deere round module harvesters. Despite diligent efforts by cotton ginning personnel to remove all plastic encountered during module unwrapping, plastic still finds a way into the cotton gin’s processing system. To help mitigate plastic contamination at the gin, a machine-vision detection and removal system was developed that utilizes low-cost color cameras to see plastic coming down the gin-stand feeder apron, which upon detection, blows plastic out of the cotton stream to prevent contamination. This paper presents the software design of this inspection and removal system. 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. The focus of this report is to describe the software design and discuss relevant issues that influenced the design of the software.

The removal of plastic contamination in cotton lint is an issue of top priority for the U.S. cotton industry. One of the main sources of plastic contamination appearing in marketable cotton bales is plastic used to wrap cotton modules on cotton harvesters. To help mitigate plastic contamination at the gin, automatic inspection systems are needed to detect and control removal systems. Due to significant cost constraints in the U.S. cotton ginning industry, the use of low-cost color cameras for detection of plastic contamination has been successfully adopted. However, some plastics of similar color to background are difficult to detect when utilizing traditional machine learning algorithms. Hence, current detection/removal system designs are not able to remove all plastics and there is still a need for better detection methods. Recent advances in deep learning convolutional neural networks (CNNs) show promise for enabling the use of low-cost color cameras for detection of objects of interest when placed against a background of similar color. They do this by mimicking the human visual detection system, focusing on differences in texture rather than color as the primary detection paradigm. The key to leveraging the CNNs is the development of extensive image datasets required for training. One of the impediments to this methodology is the need for large image datasets where each image must be annotated with bounding boxes that surround each object of interest. As this requirement is labor-intensive, there is significant value in these image datasets. This report details the included image dataset as well as the system design used to collect the images. For acquisition of the image dataset, a prototype detection system was developed and deployed into a commercial cotton gin where images were collected for the duration of the 2018–2019 ginning season. A discussion of the observational impact that the system had on reduction of plastic contamination at the commercial gin, utilizing traditional color-based machine learning algorithms, is also included.

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.

One of the main hurdles standing in the way of optimal cleaning of cotton lint isthe lack of sensing systems that can react fast enough to provide the control system withreal-time information as to the level of trash contamination of the cotton lint. This researchexamines the use of programmable graphic processing units (GPU) as an alternative to thePC’s traditional use of the central processing unit (CPU). The use of the GPU, as analternative computation platform, allowed for the machine vision system to gain asignificant improvement in processing time. By improving the processing time, thisresearch seeks to address the lack of availability of rapid trash sensing systems and thusalleviate a situation in which the current systems view the cotton lint either well before, orafter, the cotton is cleaned. This extended lag/lead time that is currently imposed on thecotton trash cleaning control systems, is what is responsible for system operators utilizing avery large dead-band safety buffer in order to ensure that the cotton lint is not undercleaned.Unfortunately, the utilization of a large dead-band buffer results in the majority ofthe cotton lint being over-cleaned which in turn causes lint fiber-damage as well assignificant losses of the valuable lint due to the excessive use of cleaning machinery. Thisresearch estimates that upwards of a 30% reduction in lint loss could be gained through theuse of a tightly coupled trash sensor to the cleaning machinery control systems. Thisresearch seeks to improve processing times through the development of a new algorithm forcotton trash sensing that allows for implementation on a highly parallel architecture.Additionally, by moving the new parallel algorithm onto an alternative computing platform,the graphic processing unit “GPUâ€Â, for processing of the cotton trash images, a speed up ofover 6.5 times, over optimized code running on the PC’s central processing unit “CPUâ€Â, wasgained. The new parallel algorithm operating on the GPU was able to process a 1024x1024image in less than 17ms. At this improved speed, the image processing system’s performance should now be sufficient to provide a system that would be capable of realtimefeed-back control that is in tight cooperation with the cleaning equipment.