CN101509881B - On-line electrical leakage detecting method for enameled wire - Google Patents
On-line electrical leakage detecting method for enameled wire Download PDFInfo
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- CN101509881B CN101509881B CN2009100374598A CN200910037459A CN101509881B CN 101509881 B CN101509881 B CN 101509881B CN 2009100374598 A CN2009100374598 A CN 2009100374598A CN 200910037459 A CN200910037459 A CN 200910037459A CN 101509881 B CN101509881 B CN 101509881B
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Abstract
The invention relates to the technical field of electric leakage detection, in particular to an online electric leakage detection method for an enameled wire. The detection method comprises the following steps of: step one, configuring a detection circuit; and step two, obtaining voltage detection data of AD modules corresponding to each head of the detection circuit by an integrated control system, and processing the obtained voltage detection data. The detection method can effectively and integratedly process the detection data, play the roles of online detection and statistics, reduce the cost, and achieve the effects of intellectualized bare wire detection and online pinhole detection.
Description
Technical field:
The present invention relates to the detection of electrical leakage technical field, relate in particular to on-line electrical leakage detecting method for enameled wire.
Background technology:
Receive evaporating area, center and each section of curing area Influence of Temperature in the Production of Enamel Wires process, and the influence of factors such as japanning homogeneity and drawing lines scratch, various painting quality problems possibly appear.Because enameled wire is the very long product of quantity-produced length, the traditional final product insulating property detect and can only carry out end to end, therefore leak great painting quality problem easily and get into finished product.And the consequence that the painting quality problem is brought is very serious, can give with products such as the motor of Production of Enamel Wires or transformers like the enameled wire of paint film defective insulation and bring great potential safety hazard.For fear of great painting quality problem occurring, the method for best assurance painting quality is to adopt the online detection of enameled wire that can accomplish full inspection.
At present, on-line detection method has: online bare wire is reported to the police, online line directly detects and online pin hole and detection of particles.
Online bare wire is reported to the police, and is about to enameled wire core ground connection (core is a natural grounding in the production run), with the bare wire warning guide wheel of machine insulation on apply a voltage; Enameled wire at bare wire warning guide wheel through out-of-date; If have paint film or pull-away promptly can produce electric leakage, to send warning when detecting electric leakage and can prevent that the serious bad enameled wire of paint film from getting into finished product, this technology is widely used because of cost is low; Generally with the detection that is connected in parallel of about 20 statures; Its shortcoming is: 1) report to the police with the form of switching value and export, precision is insensitive, can only handle more serious bare wire or pull-away problem; 2) in the production run; The warning of normal bare wire through causing often arranged, make the operative employee, ignored real abnormal alarm easily the numbness of reporting to the police; Promptly this method is not only limited to the sensing range of paint film problem, and is easy to leak detected problem because of absent minded.Online line directly detects; Promptly detect the enameled wire external diameter with laser diameter measuring instrument, it mainly acts on is to detect film thickness, can detect the too thick problem such as too thin of bare wire or paint film; Because the laser diameter measuring instrument price comparison is expensive; If wanting 20 statures all to assort uninterruptedly detects, the expense that is equipped with laser diameter measuring instrument will be very high, and cost performance is lower.Online pin hole and detection of particles; Adopt pin hole and particle detection apparatus, pin hole and surface lacquer pearl on can online detection enameled wire coat be the desirable checkout equipments of wire enamel film quality; But this equipment price is expensive; Same its expense will be very high if will assort the equipment of 20 statures, and cost performance is lower.Above-described three kinds of online test method are the checkout equipment of monomer, are difficult for handling detecting data integration, and performance detects and the effect of statistics.
Summary of the invention:
The objective of the invention is to deficiency to prior art; A kind of on-line electrical leakage detecting method for enameled wire is provided, and this method can be carried out integrated processing to detecting data effectively, brings into play the effect of online detection and statistics; Reduce cost, reach the effect that intelligent bare wire detects and online pin hole detects; And provide another kind of on-line electrical leakage detecting method for enameled wire, this method can reach the effect that intelligent bare wire detects.
For realizing above-mentioned purpose, the present invention realizes through following technical scheme:
On-line electrical leakage detecting method for enameled wire, it may further comprise the steps:
The first step, the configuration detection circuit, this testing circuit be configured to minus earth with high-voltage DC power supply, the positive pole of high-voltage DC power supply connects current-limiting resistance one end of each correspondence; The current-limiting resistance other end connects corresponding detection wheel, and an end that connects corresponding divider resistance; On detection wheel, enameled wire core ground connection makes enameled wire coat bear detection voltage with enameled wire; The other end of divider resistance connects an end of corresponding voltage dependent resistor (VDR), and the AD module voltage analog quantity input anode that connects corresponding PLC; The other end ground connection of voltage dependent resistor (VDR); The input negativing ending grounding of the AD module of PLC;
Second step; The AD module voltage that integrated control system obtains the PLC of each correspondence of testing circuit detects data; Voltage detecting data to being obtained are handled, and processing procedure comprises: have or not when calculating the detection of electrical leakage voltage drop and judging each each enameled wire of first-born product bare wire to occur; Maximum segment pinhole number when adding up each each enameled wire of first-born product, average segmentation pinhole number and enameled wire weight; Detection of electrical leakage voltage drop during each each enameled wire of first-born product of online demonstration; Current segmentation pinhole number, maximum segment pinhole number, average segmentation pinhole number; Enameled wire weight and quality status, and continuous recording detection of electrical leakage voltage drop curves and enameled wire weight distribution curve; No.1 when writing down each each enameled wire of first-born product and rolling off the production line; Roll off the production line the time maximum segment pinhole number, average segmentation pinhole number; Enameled wire weight and quality status are with detection of electrical leakage voltage drop curves and the enameled wire weight distribution curve archives as each first-born each enameled wire of product.
In said second step, the voltage drop of said calculating detection of electrical leakage also has or not the step that bare wire occurs to be when judging each each enameled wire of first-born product:
Steps A judges whether this take-up motor starts,
Start, then get into step B;
Do not start, then get into step K;
Step B writes down the maximum of each and detects voltage, and in the detection of electrical leakage voltage drop of each scan period calculating real-time of PLC, computing formula is: detection of electrical leakage voltage drop=(maximum voltage-detect the in real time voltage that detects) maximum voltage * 100% that detects of ÷;
Judge whether this detection of electrical leakage voltage drop falls greater than the bare wire critical voltage of setting, if then be labeled as bare wire;
Get into step C;
In said second step, the maximum segment pinhole number during each each enameled wire of first-born product of said statistics, the step of average segmentation pinhole number and enameled wire weight is:
Step C detects length according to speed of production with the segmentation of setting and is scaled segmentation detection time and segmentation enameled wire weight, behind the take-up electric motor starting by the segmentation timing that circulates detection time; This circulation timing will detect the zero clearing of pin hole quantity earlier during to the m section, get into step D;
Step D judges in each scan period of PLC whether this detection of electrical leakage voltage drop falls greater than the pin hole critical voltage of setting, and adds one if then will detect pin hole quantity, otherwise does not add, and so judges and finishes up to m section circulation timing; When m section circulation timing finishes, get into step e;
Step e will detect pin hole quantity and maximum segment pinhole number relatively, if detect pin hole quantity greater than the maximum segment pinhole number, then make the maximum segment pinhole number equal to detect pin hole quantity; To detect pin hole quantity and be added to accumulative total pin hole quantity; Segmentation is detected number of times add one; To add up pin hole quantity and draw average segmentation pinhole number divided by segmentation detection number of times; Segmentation enameled wire weight is added to enameled wire weight; Carry out the detection of m+1 section, get into step F;
In said second step; Detection of electrical leakage voltage drop during each each enameled wire of first-born product of said online demonstration; Current segmentation pinhole number, maximum segment pinhole number, average segmentation pinhole number; Enameled wire weight and quality status, and the step of continuous recording detection of electrical leakage voltage drop curves and enameled wire weight distribution curve is:
Step F, with the detection of electrical leakage voltage drop, current segmentation pinhole number, the maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and the data upload that has or not bare wire get into step G to host computer;
Step G is when having or not bare wire to be labeled as bare wire, if enameled wire weight then is labeled as little bare wire, not output alarm with quality status less than the minimum finished weight of setting; If when enameled wire weight greater than the minimum finished weight of setting, exists bare wire to get into the risk of finished product, then quality status is labeled as big bare wire, output alarm stops up to this take-up motor; Get into step H;
Step H is if the maximum segment pinhole number then is labeled as quality status defective greater than the qualified maximum segment pinhole number of setting; If the maximum segment pinhole number is less than the qualified maximum segment pinhole number of setting, and on average the segmentation pinhole number is greater than excellent average segmentation pinhole number, it is qualified then quality status to be labeled as; If the maximum segment pinhole number is less than the qualified maximum segment pinhole number of setting, and average segmentation pinhole number then is labeled as quality status excellent less than excellent average segmentation pinhole number; Get into step I;
Step I, the detection of electrical leakage voltage drop during each each enameled wire of first-born product of online demonstration, current segmentation pinhole number, maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and quality status; Get into step J;
Step J, voltage drop of continuous recording detection of electrical leakage and enameled wire weight are forever preserved data and are supplied to check at any time detection of electrical leakage voltage drop curves and enameled wire weight distribution curve in database; Get into steps A;
In said second step, No.1 when each each enameled wire of first-born product of said record rolls off the production line rolled off the production line the time, the maximum segment pinhole number, and average segmentation pinhole number, the step of enameled wire weight and quality status is:
Step K, if the take-up motor just cuts out, then should be No.1, roll off the production line the time, the maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and the specifications and models of being produced record in the database; To have or not bare wire to be labeled as no bare wire then, the maximum segment pinhole number, accumulative total pin hole quantity, segmentation detects number of times, and average segmentation pinhole number and the zero clearing of enameled wire weight prepare to start next time.
In said second step, said detection of electrical leakage voltage drop is scaled the insulation resistance of tested enameled wire, and insulation resistance is used to represent the film thickness and the painting quality of tested enameled wire, and as the reference data of monitoring film thickness in the production run, conversion method is:
Detect voltage=supply voltage * (voltage drop of 100-detection of electrical leakage) ÷ 100;
Parallel resistance=current-limiting resistance ÷ (supply voltage ÷ detects voltage-1);
Insulation resistance=parallel resistance * (divider resistance+PLC internal resistance) ÷ (parallel resistance-divider resistance-PLC internal resistance).
In said second step, said processing procedure also comprises the online verification and measurement ratio of acquisition, and the computing method of online verification and measurement ratio are:
Contact length=enameled wire is around the detection wheel number of turns * detection wheel diameter * 3.14;
The duration of contact=contact length ÷ speed of production;
Sense cycle=MAX of PLC (every point sampling cycle of AD module, PLC main frame scan period);
The sense cycle of online verification and measurement ratio=duration of contact ÷ PLC.
On-line electrical leakage detecting method for enameled wire, it may further comprise the steps:
The first step, the configuration detection circuit, being configured to PLC switching value common end grounding of this testing circuit externally provides+negative pole of 24Vdc accessory power supply PLC; The PLC switching value input end of correspondence is connected the detection wheel of each correspondence, PLC is externally provided+positive pole of 24Vdc accessory power supply; On detection wheel, enameled wire core ground connection is born+24Vdc voltage enameled wire coat with enameled wire; Make that the PLC switching value input end of correspondence is a conducting state when wire enamel film resistance during less than 400 ohm;
In second step, integrated control system obtains the PLC switching value input end make-and-break signal of each correspondence of testing circuit, and the make-and-break signal that is obtained is handled, and processing procedure comprises:
Step L judges whether this take-up motor starts,
Start, then get into step M;
Do not start, then get into step R;
Step M judges whether this PLC switching value input end is conducting state, if, then will have or not bare wire to be labeled as bare wire, get into step N;
Step N detects length according to speed of production with the segmentation of setting and is scaled segmentation detection time and segmentation enameled wire weight, behind the take-up electric motor starting by the segmentation timing that circulates detection time; This circulation timing is added to enameled wire weight with segmentation enameled wire weight during to the m section; Carry out the detection of m+1 section, get into step O;
Step O is when having or not bare wire to be labeled as bare wire, if enameled wire weight then is labeled as little bare wire, not output alarm with quality status less than the minimum finished weight of setting; If when enameled wire weight greater than the minimum finished weight of setting, exists bare wire to get into the risk of finished product, then quality status is labeled as big bare wire, output alarm stops up to this take-up motor; Get into step P;
Step P, enameled wire weight and quality status during each each enameled wire of first-born product of online demonstration; Get into step Q;
Step Q, continuous recording enameled wire weight is forever preserved data and is supplied to check at any time the enameled wire weight distribution curve in database; Get into step L;
Step R, if the take-up motor just cuts out, then should be No.1, roll off the production line the time, enameled wire weight and the specifications and models of being produced record in the database; To have or not bare wire to be labeled as no bare wire then, the zero clearing of enameled wire weight prepares to start next time.
Beneficial effect of the present invention: the present invention promotes traditional bare wire alarm technique and is the online detection of electrical leakage technology of a kind of enameled wire; Data-handling capacity in conjunction with integrated control system; It is intelligent that original bare wire measuring ability is realized; Simultaneously but online record and the insulation resistance of analyzing enameled wire change and pin hole distributes; For Production of Enamel Wires provides a kind of integrated on-line detecting system of height that less input conveniently uses again and manage, therefore a kind of on-line electrical leakage detecting method for enameled wire of the present invention can carry out integrated processing to detecting data effectively, brings into play the effect of online detection and statistics; Reduce cost, reach the effect that intelligent bare wire detects and online pin hole detects; Another kind of on-line electrical leakage detecting method for enameled wire then adopts the testing circuit of simplification, can reach the effect that intelligent bare wire detects.
Description of drawings:
Accompanying drawing 1 is a testing circuit elementary diagram of the present invention;
Accompanying drawing 2 is a detection wheel synoptic diagram of the present invention.
Embodiment:
With embodiment the present invention is further described below.
Shown in accompanying drawing 1 and accompanying drawing 2, on-line electrical leakage detecting method for enameled wire, it may further comprise the steps:
The first step, the configuration detection circuit, this testing circuit be configured to minus earth with high-voltage DC power supply, the positive pole of high-voltage DC power supply connects current-limiting resistance one end of each correspondence; The current-limiting resistance other end connects corresponding detection wheel, and an end that connects corresponding divider resistance; On detection wheel, enameled wire core ground connection makes enameled wire coat bear detection voltage with enameled wire; The other end of divider resistance connects an end of corresponding voltage dependent resistor (VDR), and the AD module voltage analog quantity input anode that connects corresponding PLC; The other end ground connection of voltage dependent resistor (VDR), the AD module of protection PLC is not born too high voltages; The input negativing ending grounding of the AD module of PLC; Wherein another Chinese patent of the detection wheel and the inventor number is that 200720061044.0 described bare wire warning guide wheels are similar; Its difference is that the trough 3 of guide wheel 1 is U font rather than V font, and wear-resistant coating 2 is conducted electricity in addition to increase the service life in trough 3 surfaces.U font trough 3 allow enameled wires on the detection wheel more than a circle, thereby increased the contact length of enameled wire and detection wheel, the duration of electric leakage signal when also promptly having extended the pin hole detection.
Second step; The AD module voltage that integrated control system obtains the PLC of each correspondence of testing circuit detects data; Voltage detecting data to being obtained are handled, and processing procedure comprises: have or not when calculating the detection of electrical leakage voltage drop and judging each each enameled wire of first-born product bare wire to occur; Maximum segment pinhole number when adding up each each enameled wire of first-born product, average segmentation pinhole number and enameled wire weight; Detection of electrical leakage voltage drop during each each enameled wire of first-born product of online demonstration; Current segmentation pinhole number, maximum segment pinhole number, average segmentation pinhole number; Enameled wire weight and quality status, and continuous recording detection of electrical leakage voltage drop curves and enameled wire weight distribution curve; No.1 when writing down each each enameled wire of first-born product and rolling off the production line; Roll off the production line the time maximum segment pinhole number, average segmentation pinhole number; Enameled wire weight and quality status are with detection of electrical leakage voltage drop curves and the enameled wire weight distribution curve archives as each first-born each enameled wire of product.
In said second step, the voltage drop of said calculating detection of electrical leakage also has or not the step that bare wire occurs to be when judging each each enameled wire of first-born product:
Steps A judges whether this take-up motor starts,
Start, then get into step B;
Do not start, then get into step K;
Step B writes down the maximum of each and detects voltage, and in the detection of electrical leakage voltage drop of each scan period calculating real-time of PLC, computing formula is: detection of electrical leakage voltage drop=(maximum voltage-detect the in real time voltage that detects) maximum voltage * 100% that detects of ÷;
Judge whether this detection of electrical leakage voltage drop falls greater than the bare wire critical voltage of setting, if then be labeled as bare wire;
Get into step C;
In said second step, the maximum segment pinhole number during each each enameled wire of first-born product of said statistics, the step of average segmentation pinhole number and enameled wire weight is:
Step C detects length according to speed of production with the segmentation of setting and is scaled segmentation detection time and segmentation enameled wire weight, behind the take-up electric motor starting by the segmentation timing that circulates detection time; This circulation timing will detect the zero clearing of pin hole quantity earlier during to the m section, get into step D;
Step D judges in each scan period of PLC whether this detection of electrical leakage voltage drop falls greater than the pin hole critical voltage of setting, and adds one if then will detect pin hole quantity, otherwise does not add, and so judges and finishes up to m section circulation timing; When m section circulation timing finishes, get into step e;
Step e will detect pin hole quantity and maximum segment pinhole number relatively, if detect pin hole quantity greater than the maximum segment pinhole number, then make the maximum segment pinhole number equal to detect pin hole quantity; To detect pin hole quantity and be added to accumulative total pin hole quantity; Segmentation is detected number of times add one; To add up pin hole quantity and draw average segmentation pinhole number divided by segmentation detection number of times; Segmentation enameled wire weight is added to enameled wire weight; Carry out the detection of m+1 section, get into step F;
In said second step; Detection of electrical leakage voltage drop during each each enameled wire of first-born product of said online demonstration; Current segmentation pinhole number, maximum segment pinhole number, average segmentation pinhole number; Enameled wire weight and quality status, and the step of continuous recording detection of electrical leakage voltage drop curves and enameled wire weight distribution curve is:
Step F, with the detection of electrical leakage voltage drop, current segmentation pinhole number, the maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and the data upload that has or not bare wire get into step G to host computer;
Step G is when having or not bare wire to be labeled as bare wire, if enameled wire weight then is labeled as little bare wire, not output alarm with quality status less than the minimum finished weight of setting; If when enameled wire weight greater than the minimum finished weight of setting, exists bare wire to get into the risk of finished product, then quality status is labeled as big bare wire, output alarm stops up to this take-up motor; Get into step H;
Step H is if the maximum segment pinhole number then is labeled as quality status defective greater than the qualified maximum segment pinhole number of setting; If the maximum segment pinhole number is less than the qualified maximum segment pinhole number of setting, and on average the segmentation pinhole number is greater than excellent average segmentation pinhole number, it is qualified then quality status to be labeled as; If the maximum segment pinhole number is less than the qualified maximum segment pinhole number of setting, and average segmentation pinhole number then is labeled as quality status excellent less than excellent average segmentation pinhole number; Get into step I;
Step I, the detection of electrical leakage voltage drop during each each enameled wire of first-born product of online demonstration, current segmentation pinhole number, maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and quality status; Get into step J;
Step J, voltage drop of continuous recording detection of electrical leakage and enameled wire weight are forever preserved data and are supplied to check at any time detection of electrical leakage voltage drop curves and enameled wire weight distribution curve in database;
Get into steps A;
In said second step, No.1 when each each enameled wire of first-born product of said record rolls off the production line rolled off the production line the time, the maximum segment pinhole number, and average segmentation pinhole number, the step of enameled wire weight and quality status is:
Step K, if the take-up motor just cuts out, then should be No.1, roll off the production line the time, the maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and the specifications and models of being produced record in the database; To have or not bare wire to be labeled as no bare wire then, the maximum segment pinhole number, accumulative total pin hole quantity, segmentation detects number of times, and average segmentation pinhole number and the zero clearing of enameled wire weight prepare to start next time.
In said second step; Said detection of electrical leakage voltage drop is scaled the insulation resistance of tested enameled wire, and insulation resistance is used to represent the film thickness and the painting quality of tested enameled wire, as the reference data of monitoring film thickness in the production run; In addition; Will be not after detection of electrical leakage voltage drop intuitively is converted into intuitively insulation resistance, can help to confirm that rational bare wire critical voltage falls with the pin hole critical voltage falls, these two controlled variable are set up with actual enameled wire electrical characteristics got in touch.Concrete conversion method is:
Detect voltage=supply voltage * (voltage drop of 100-detection of electrical leakage) ÷ 100;
Parallel resistance=current-limiting resistance ÷ (supply voltage ÷ detects voltage-1);
Insulation resistance=parallel resistance * (divider resistance+PLC internal resistance) ÷ (parallel resistance-divider resistance-PLC internal resistance).
In said second step, said processing procedure also comprises and obtains online verification and measurement ratio, can be through increasing the number of turns of enameled wire on the detection wheel to improve online verification and measurement ratio, and the computing method of online verification and measurement ratio are:
Contact length=enameled wire is around the detection wheel number of turns * detection wheel diameter * 3.14;
The duration of contact=contact length ÷ speed of production;
Sense cycle=MAX of PLC (every point sampling cycle of AD module, PLC main frame scan period);
The sense cycle of online verification and measurement ratio=duration of contact ÷ PLC; Wherein, every point sampling cycle of AD module and PLC main frame scan period are limited by market optional equipment ability and equipment input cost, are difficult for shortening significantly; Speed of production will be considered efficiency, more can not slow down; Enameled wire is thin more, and the detection wheel diameter must be more little, otherwise enameled wire is broken easily; And usually enameled wire the detailed rules and regulations speed of production is fast more more, so cause the thin more online verification and measurement ratio of enameled wire low more; Usually enameled wire on detection wheel only around 1/4 circle, for the problem that solves online verification and measurement ratio can only increase the number of turns of enameled wire on the detection wheel.
The elementary diagram of testing circuit is seen accompanying drawing 1, and when disposing this testing circuit, when the detection wheel resistance to earth was infinitely great, detection wheel place voltage was the detection voltage of standard code; Detection wheel over the ground during short circuit the electric current through detection wheel be no more than 25uA.According to the requirement that detects voltage, can calculate different high-voltage DC power supply magnitude of voltage, current-limiting resistance resistance and the divider resistance resistances that voltage need dispose that detect.See the testing circuit configured list shown in the table 1 for details.
What time what should be noted that in the table 1 has: one, detect voltage and confirmed by IEC standard or GB according to production model specification; Two, the PLC internal resistance is confirmed by the voltage detecting internal resistance of used AD module, and the voltage dependent resistor (VDR) threshold values of protection PLC is confirmed by PLC voltage detecting end withstand voltage; Three, the current-limiting resistance electric current is defined as 25uA by GB during the detection wheel shorted to earth, and is injury-free to guarantee enameled wire to be detected.
To different detection of electrical leakage voltage drops (usually PLC detect the precision of voltage be 1%), can calculate the virtual voltage at detection wheel place, and the parallel resistance of insulation resistance and divider resistance+AD module internal resistance, can draw the insulation resistance of tested enameled wire thus.Insulation resistance tabulation when seeing the voltage drop of table 2 to the part shown in the table 4 difference detection of electrical leakage for details.
Usually thicker enameled wire or thicker paint film insulation resistance are bigger, need select bigger detection voltage for use according to standard, otherwise can not detect the bigger little defective of resistance, and use also can debase the standard when being inconvenient to change detection voltage.Thinner enameled wire or thin paint film should be selected less detection voltage for use, otherwise the risk that paint film is punctured is arranged, because electric current has been limited in below the 25uA, the destructiveness of puncture can be very not big yet.So in the ordinary course of things, the detection voltage of an enamelling machine configuration can be selected in the corresponding intermediate value that respectively detects voltage of model specification that this enamelling machine is produced, and also can change testing circuit when having relatively high expectations as required and change detection voltage.Online verification and measurement ratio does not reach 100% expression and has only the part enameled wire to be detected, uses but 100% the situation of not reaching also can be used as a kind of online detection of lower standard.The detection wheel that provides with patent figures 2 can be with enameled wire winding number circle on detection wheel, thereby the contact length that increases enameled wire and detection wheel improves online verification and measurement ratio.Table 5 and table 6 have been listed some and have been detected the online verification and measurement ratio of allocation plan.
| Detect voltage (V) | Supply voltage (V) | PLC internal resistance (M Ω) | The voltage dependent resistor (VDR) threshold values (V) of protection PLC | Divider resistance (M Ω) | Current-limiting resistance (M Ω) | Current-limiting resistance electric current (uA) during the detection wheel insulation against ground | Detect voltage (V) during the detection wheel insulation against ground | PLC voltage (V) during the detection wheel insulation against ground | Current-limiting resistance electric current (uA) during the detection wheel shorted to earth | Detect voltage (V) during the detection wheel shorted to earth | PLC voltage (V) during the detection wheel shorted to earth |
| 350 | 1750 | 0.2 | 10 | 17.30 | 70 | 20 | 350 | 4 | 25 | 0 | 0 |
| 500 | 2500 | 0.2 | 10 | 24.80 | 100 | 20 | 500 | 4 | 25 | 0 | 0 |
| 750 | 3750 | 0.2 | 10 | 37.30 | 150 | 20 | 750 | 4 | 25 | 0 | 0 |
| 1000 | 5000 | 0.2 | 10 | 49.80 | 200 | 20 | 1000 | 4 | 25 | 0 | 0 |
| 1250 | 6250 | 0.2 | 10 | 62.30 | 250 | 20 | 1250 | 4 | 25 | 0 | 0 |
| 1500 | 7500 | 0.2 | 10 | 74.80 | 300 | 20 | 1500 | 4 | 25 | 0 | 0 |
| 2000 | 10000 | 0.2 | 10 | 99.80 | 400 | 20 | 2000 | 4 | 25 | 0 | 0 |
| 2500 | 12500 | 0.2 | 10 | 124.80 | 500 | 20 | 2500 | 4 | 25 | 0 | 0 |
| 3000 | 15000 | 0.2 | 10 | 149.80 | 600 | 20 | 3000 | 4 | 25 | 0 | 0 |
Table 1
Table 2
Table 3
Table 4
| Speed of production (rice/minute) | Detection wheel diameter (millimeter) | Enameled wire is around the detection wheel number of turns | Contact length (millimeter) | Duration of contact (millisecond) | Every point sampling cycle of AD module (millisecond) | The PLC main frame scan period (millisecond) | The PLC main frame scan period (millisecond) | Online verification and measurement ratio |
| 300 | 78 | 0.25 | 61.23 | 12.25 | 96 | 70 | 96 | 12.76％ |
| 300 | 78 | 1.25 | 306.15 | 61.23 | 96 | 70 | 96 | 63.78％ |
| 300 | 78 | 2.25 | 551.07 | 110.21 | 96 | 70 | 96 | 114.81％ |
| 150 | 78 | 0.25 | 61.23 | 24.49 | 96 | 70 | 96 | 25.51％ |
| 150 | 78 | 1.25 | 306.15 | 122.46 | 96 | 70 | 96 | 127.56％ |
| 150 | 78 | 2.25 | 551.07 | 220.43 | 96 | 70 | 96 | 229.61％ |
| 150 | 78 | 0.25 | 61.23 | 24.49 | 96 | 70 | 96 | 25.51％ |
| 150 | 78 | 1.25 | 306.15 | 122.46 | 96 | 70 | 96 | 127.56％ |
| 50 | 78 | 0.25 | 61.23 | 73.48 | 96 | 70 | 96 | 76.54％ |
| 50 | 78 | 1.25 | 306.15 | 367.38 | 96 | 70 | 96 | 382.69％ |
Table 5
| Speed of production (rice/minute) | Detection wheel diameter (millimeter) | Enameled wire is around the detection wheel number of turns | Contact length (millimeter) | Duration of contact (millisecond) | Every point sampling cycle of AD module (millisecond) | The PLC main frame scan period (millisecond) | The PLC main frame scan period (millisecond) | Online verification and measurement ratio |
| 450 | 48 | 0.25 | 37.68 | 5.02 | 96 | ?70 | ?96 | 5.23％ |
| 450 | 48 | 1.25 | 188.40 | 25.12 | 96 | ?70 | ?96 | 26.17％ |
| 450 | 48 | 2.25 | 339.12 | 45.22 | 96 | ?70 | ?96 | 47.10％ |
| 450 | 48 | 3.25 | 489.84 | 65.31 | 96 | ?70 | ?96 | 68.03％ |
| 450 | 48 | 4.25 | 640.56 | 85.41 | 96 | ?70 | ?96 | 88.97％ |
| 450 | 48 | 5.25 | 791.28 | 105.50 | 96 | ?70 | ?96 | 109.90％ |
| 400 | 48 | 0.25 | 37.68 | 5.65 | 96 | ?70 | ?96 | 5.89％ |
| 400 | 48 | 1.25 | 188.40 | 28.26 | 96 | ?70 | ?96 | 29.44％ |
| 400 | 48 | 2.25 | 339.12 | 50.87 | 96 | ?70 | ?96 | 52.99％ |
| 400 | 48 | 3.25 | 489.84 | 73.48 | 96 | ?70 | ?96 | 76.54％ |
| 400 | 48 | 4.25 | 640.56 | 96.08 | 96 | ?70 | ?96 | 100.09％ |
| 350 | 48 | 0.25 | 37.68 | 6.46 | 96 | ?70 | ?96 | 6.73％ |
| 350 | 48 | 1.25 | 188.40 | 32.30 | 96 | ?70 | ?96 | 33.64％ |
| 350 | 48 | 2.25 | 339.12 | 58.13 | 96 | ?70 | ?96 | 60.56％ |
| 350 | 48 | 3.25 | 489.84 | 83.97 | 96 | ?70 | ?96 | 87.47％ |
| 350 | 48 | 4.25 | 640.56 | 109.81 | 96 | ?70 | ?96 | 114.39％ |
| 300 | 48 | 0.25 | 37.68 | 7.54 | 96 | ?70 | ?96 | 7.85％ |
| 300 | 48 | 1.25 | 188.40 | 37.68 | 96 | ?70 | ?96 | 39.25％ |
| 300 | 48 | 2.25 | 339.12 | 67.82 | 96 | ?70 | ?96 | 70.65％ |
| 300 | 48 | 3.25 | 489.84 | 97.97 | 96 | ?70 | ?96 | 102.05％ |
Table 6
Wherein, pitch of the laps not on detection wheel, enameled wire and detection wheel contact length are 1/4 detection wheel girth; Around a circle, enameled wire and detection wheel contact length are 5/4 detection wheel girth on detection wheel; Around two circles, enameled wire and detection wheel contact length are 9/4 detection wheel girth on detection wheel; Around three circles, enameled wire and detection wheel contact length are 13/4 detection wheel girth on detection wheel.When enameled wire was thin, detection wheel too conference was broken; When enameled wire was thick, the too little meeting of detection wheel made the enameled wire strain hardening.
Utilize the present invention when each production, intelligence to send the bare wire warning, stop bare wire and get into finished product; Also can when producing, be presented at the heavy and detection of electrical leakage voltage drop curves of drum, pin hole statistics and quality status instruct the production quality control; Heavy and the detection of electrical leakage voltage drop curves of history dish of each product also can be provided after producing completion; And each product is No.1, rolls off the production line the time maximum segment pinhole number; Average segmentation pinhole number; Enameled wire weight and the data such as specifications and models of being produced make things convenient for Tracing back of quality questions and quality control situation analysis, are the strong instruments that improves the enameled wire quality.Utilize the present invention can assort a plurality of heads, as assorting 20 statures, cost performance is high.Can know that by the above the present invention can carry out integrated processing to detecting data effectively, brings into play the effect of online detection and statistics, reduces cost, and reaches the effect that intelligent bare wire detects and online pin hole detects.
In addition, for practicing thrift cost of investment, also can said method be simplified to the on-line electrical leakage detecting method for enameled wire of identical invention thinking, it may further comprise the steps:
The first step, the configuration detection circuit, being configured to PLC switching value common end grounding of this testing circuit externally provides+negative pole of 24Vdc accessory power supply PLC; The PLC switching value input end of correspondence is connected the detection wheel of each correspondence, PLC is externally provided+positive pole of 24Vdc accessory power supply; On detection wheel, enameled wire core ground connection is born+24Vdc voltage enameled wire coat with enameled wire; Make that the PLC switching value input end of correspondence is a conducting state when wire enamel film resistance during less than 400 ohm;
In second step, integrated control system obtains the PLC switching value input end make-and-break signal of each correspondence of testing circuit, and the make-and-break signal that is obtained is handled, and processing procedure comprises:
Step L judges whether this take-up motor starts,
Start, then get into step M;
Do not start, then get into step R;
Step M judges whether this PLC switching value input end is conducting state,
If, then will have or not bare wire to be labeled as bare wire, get into step N;
Step N detects length according to speed of production with the segmentation of setting and is scaled segmentation detection time and segmentation enameled wire weight, behind the take-up electric motor starting by the segmentation timing that circulates detection time; This circulation timing is added to enameled wire weight with segmentation enameled wire weight during to the m section; Carry out the detection of m+1 section, get into step O;
Step O is when having or not bare wire to be labeled as bare wire, if enameled wire weight then is labeled as little bare wire, not output alarm with quality status less than the minimum finished weight of setting; If when enameled wire weight greater than the minimum finished weight of setting, exists bare wire to get into the risk of finished product, then quality status is labeled as big bare wire, output alarm stops up to this take-up motor; Get into step P;
Step P, enameled wire weight and quality status during each each enameled wire of first-born product of online demonstration; Get into step Q;
Step Q, continuous recording enameled wire weight is forever preserved data and is supplied to check at any time the enameled wire weight distribution curve in database; Get into step L;
Step R, if the take-up motor just cuts out, then should be No.1, roll off the production line the time, enameled wire weight and the specifications and models of being produced record in the database; To have or not bare wire to be labeled as no bare wire then, the zero clearing of enameled wire weight prepares to start next time.
On-line electrical leakage detecting method for enameled wire after this simplification neither needs high-voltage power supply; Do not need testing circuit and AD module yet; Deleted the program that relevant pin hole detects; Only need through a plurality of each detection wheel of PLC switching value input ends detection make-and-break signal over the ground, judge with make-and-break signal over the ground to have or not bare wire, can realize intelligent bare wire warning function.
The above only is preferred embodiment of the present invention, so all equivalences of doing according to the described structure of patent claim of the present invention, characteristic and principle change or modify, includes in patent claim of the present invention.
Claims (5)
1. on-line electrical leakage detecting method for enameled wire is characterized in that, it may further comprise the steps:
The first step, the configuration detection circuit, being configured to of this testing circuit connects the negative pole of high-voltage DC power supply
Ground, the positive pole of high-voltage DC power supply connects current-limiting resistance one end of each correspondence; The current-limiting resistance other end connects corresponding detection wheel, and the current-limiting resistance other end connects an end of corresponding divider resistance; On detection wheel, enameled wire core ground connection makes enameled wire coat bear detection voltage with enameled wire; The other end of divider resistance connects an end of corresponding voltage dependent resistor (VDR), and the other end of divider resistance connects the AD module voltage analog quantity input anode of corresponding PLC; The other end ground connection of voltage dependent resistor (VDR); The input negativing ending grounding of the AD module of PLC;
In second step, integrated control system obtains the AD module voltage of the PLC of each correspondence of testing circuit
Detect data, the voltage detecting data that obtained are handled, processing procedure comprises: have or not when calculating the detection of electrical leakage voltage drop and judging each each enameled wire of first-born product bare wire to occur; Maximum segment pinhole number when adding up each each enameled wire of first-born product, average segmentation pinhole number and enameled wire weight; Detection of electrical leakage voltage drop during each each enameled wire of first-born product of online demonstration; Current segmentation pinhole number, maximum segment pinhole number, average segmentation pinhole number; Enameled wire weight and quality status, and continuous recording detection of electrical leakage voltage drop curves and enameled wire weight distribution curve; No.1 when writing down each each enameled wire of first-born product and rolling off the production line; Roll off the production line the time maximum segment pinhole number, average segmentation pinhole number; Enameled wire weight and quality status are with detection of electrical leakage voltage drop curves and the enameled wire weight distribution curve archives as each first-born each enameled wire of product.
2. on-line electrical leakage detecting method for enameled wire according to claim 1 is characterized in that: said
In second step, the voltage drop of said calculating detection of electrical leakage also has or not the step that bare wire occurs to be when judging each each enameled wire of first-born product:
Steps A judges whether this take-up motor starts,
Start, then get into step B;
Do not start, then get into step K;
Step B writes down the maximum of each and detects voltage, and in the detection of electrical leakage voltage drop of each scan period calculating real-time of PLC, computing formula is: detection of electrical leakage voltage drop=(maximum voltage-detect the in real time voltage that detects) maximum voltage * 100% that detects of ÷;
Judge whether this detection of electrical leakage voltage drop falls greater than the bare wire critical voltage of setting,
If then be labeled as bare wire;
Get into step C;
In said second step, the maximum segment pinhole number during each each enameled wire of first-born product of said statistics,
The step of average segmentation pinhole number and enameled wire weight is:
Step C detects length according to speed of production with the segmentation of setting and is scaled segmentation detection time and branch
Section enameled wire weight, behind the take-up electric motor starting by the segmentation timing that circulates detection time; Should
Circulation timing will detect the zero clearing of pin hole quantity earlier during to the m section, get into step D;
Step D judges in each scan period of PLC whether this detection of electrical leakage voltage drop falls greater than the pin hole critical voltage of setting, and adds one if then will detect pin hole quantity, otherwise does not add, and so judges and finishes up to m section circulation timing; When m section circulation timing finishes, get into step e;
Step e will detect pin hole quantity and maximum segment pinhole number relatively, if detect pin hole quantity greater than the maximum segment pinhole number, then make the maximum segment pinhole number equal to detect pin hole quantity; To detect pin hole quantity and be added to accumulative total pin hole quantity; Segmentation is detected number of times add one; To add up pin hole quantity and draw average segmentation pinhole number divided by segmentation detection number of times; Segmentation enameled wire weight is added to enameled wire weight; Carry out the detection of m+1 section, get into step F;
In said second step, the detection of electrical leakage during each each enameled wire of first-born product of said online demonstration
Pressure drop, current segmentation pinhole number, the maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and quality status, and the step of continuous recording detection of electrical leakage voltage drop curves and enameled wire weight distribution curve is:
Step F, with the detection of electrical leakage voltage drop, current segmentation pinhole number, the maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and the data upload that has or not bare wire get into step G to host computer;
Step G is when having or not bare wire to be labeled as bare wire, if enameled wire weight then is labeled as little bare wire, not output alarm with quality status less than the minimum finished weight of setting; If when enameled wire weight greater than the minimum finished weight of setting, exists bare wire to get into the risk of finished product, then quality status is labeled as big bare wire, output alarm stops up to this take-up motor; Get into step H;
Step H, if the maximum segment pinhole number greater than the qualified maximum segment pinhole number of setting, then will article
The matter condition flag is defective; If the maximum segment pinhole number is less than the qualified maximum segment pinhole number of setting, and on average the segmentation pinhole number is greater than excellent average segmentation pinhole number, it is qualified then quality status to be labeled as; If the maximum segment pinhole number is less than the qualified maximum segment pinhole number of setting, and average segmentation pinhole number then is labeled as quality status excellent less than excellent average segmentation pinhole number; Get into step I;
Step I, the detection of electrical leakage voltage drop during each each enameled wire of first-born product of online demonstration, current segmentation pinhole number, maximum segment pinhole number, average segmentation pinhole number, enameled wire weight and quality status; Get into step J;
Step J, voltage drop of continuous recording detection of electrical leakage and enameled wire weight are forever preserved data and are supplied to check at any time detection of electrical leakage voltage drop curves and enameled wire weight distribution curve in database;
Get into steps A;
In said second step, No.1 when each each enameled wire of first-born product of said record rolls off the production line rolled off the production line the time, the maximum segment pinhole number, and average segmentation pinhole number, the step of enameled wire weight and quality status is:
Step K, if the take-up motor just cuts out, then should be No.1, roll off the production line the time maximum branch
The section pinhole number, average segmentation pinhole number, enameled wire weight and the specification type of being produced
Number record in the database; To have or not bare wire to be labeled as no bare wire, maximum segment then
Pinhole number, accumulative total pin hole quantity, segmentation detects number of times, average segmentation pinhole number and
The zero clearing of enameled wire weight prepares to start next time.
3. on-line electrical leakage detecting method for enameled wire according to claim 1; It is characterized in that: in said second step; Said detection of electrical leakage voltage drop is scaled the insulation resistance of tested enameled wire; Insulation resistance is used to represent the film thickness and the painting quality of tested enameled wire, and as the reference data of monitoring film thickness in the production run, conversion method is:
Detect voltage=supply voltage * (voltage drop of 100-detection of electrical leakage) ÷ 100;
Parallel resistance=current-limiting resistance ÷ (supply voltage ÷ detects voltage-1);
Insulation resistance=parallel resistance * (divider resistance+PLC internal resistance) ÷ (parallel resistance-divider resistance-PLC internal resistance).
4. on-line electrical leakage detecting method for enameled wire according to claim 1 is characterized in that: in said second step, said processing procedure also comprises the online verification and measurement ratio of acquisition, and the computing method of online verification and measurement ratio are:
Contact length=enameled wire is around the detection wheel number of turns * detection wheel diameter * 3.14;
The duration of contact=contact length ÷ speed of production;
Sense cycle=MAX of PLC (every point sampling cycle of AD module, PLC main frame scan period);
The sense cycle of online verification and measurement ratio=duration of contact ÷ PLC.
5. on-line electrical leakage detecting method for enameled wire is characterized in that, it may further comprise the steps:
The first step, the configuration detection circuit, being configured to PLC switching value common end grounding of this testing circuit externally provides+negative pole of 24Vdc accessory power supply PLC; The PLC switching value input end of correspondence is connected the detection wheel of each correspondence, PLC is externally provided+positive pole of 24Vdc accessory power supply; On detection wheel, enameled wire core ground connection is born+24Vdc voltage enameled wire coat with enameled wire; Make that the PLC switching value input end of correspondence is a conducting state when wire enamel film resistance during less than 400 ohm;
In second step, integrated control system obtains the PLC switching value input end make-and-break signal of each correspondence of testing circuit, and the make-and-break signal that is obtained is handled, and processing procedure comprises:
Step L judges whether this take-up motor starts,
Start, then get into step M;
Do not start, then get into step R;
Step M judges whether this PLC switching value input end is conducting state,
If, then will have or not bare wire to be labeled as bare wire, get into step N;
Step N detects length according to speed of production with the segmentation of setting and is scaled segmentation detection time and branch
Section enameled wire weight, behind the take-up electric motor starting by the segmentation timing that circulates detection time; Should
Circulation timing is added to enameled wire weight with segmentation enameled wire weight during to the m section;
Carry out the detection of m+1 section, get into step O;
Step O is when having or not bare wire to be labeled as bare wire, if enameled wire weight then is labeled as little bare wire, not output alarm with quality status less than the minimum finished weight of setting; If when enameled wire weight greater than the minimum finished weight of setting, exists bare wire to get into the risk of finished product, then quality status is labeled as big bare wire, output alarm stops up to this take-up motor; Get into step P;
Step P, enameled wire weight and quality status during each each enameled wire of first-born product of online demonstration; Get into step Q;
Step Q, continuous recording enameled wire weight is forever preserved data and is supplied to check at any time the enameled wire weight distribution curve in database; Get into step L;
Step R, if the take-up motor just cuts out, then should be No.1, roll off the production line the time, enameled wire weight and the specifications and models of being produced record in the database; To have or not bare wire to be labeled as no bare wire then, the zero clearing of enameled wire weight prepares to start next time.
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| CN102999997A (en) * | 2011-09-14 | 2013-03-27 | 吴江市神州机械有限公司 | Bare wire guide wheel alarm |
| CN102539483A (en) * | 2012-02-10 | 2012-07-04 | 铜陵鑫晟源工业技术有限责任公司 | On-line detection equipment for enameled wire |
| CN103744003B (en) * | 2013-12-23 | 2016-10-19 | 广东威奇电工材料有限公司 | Automatically enamel-covered wire continuous detection apparatus and the method for detection enamel-covered wire breakdown voltage |
| CN104236609A (en) * | 2014-10-17 | 2014-12-24 | 珠海格力电工有限公司 | Enameled wire detection head assembly |
| CN104965007A (en) * | 2015-06-28 | 2015-10-07 | 无锡锡洲电磁线有限公司 | Transposed conductor film continuity on-line detecting device |
| CN106530601A (en) * | 2016-12-15 | 2017-03-22 | 鹤山市江磁线缆有限公司 | Monitoring and alarming device for bare wire of enameled wire |
| CN109142445B (en) * | 2018-08-13 | 2021-06-25 | 珠海格力电工有限公司 | Enameled wire defect online detection method and detection device, computer device and computer readable storage medium |
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| CN2482697Y (en) * | 2001-04-28 | 2002-03-20 | 梁月明 | Enamel-covered wire on-line detecting apparatus |
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| US3451013A (en) * | 1966-08-25 | 1969-06-17 | Communications Patents Ltd | Low leakage inductance transformer for conductive parallel plate ballanced transmission lines |
| CN1041460A (en) * | 1988-09-19 | 1990-04-18 | 常州市自动化仪表厂 | Enamel covering thickness of enamel covered wire dynamic monitoring instrument and method for supervising |
| JP2001349923A (en) * | 2000-06-07 | 2001-12-21 | Totoku Electric Co Ltd | Tester and testing device for judging uniformity of insulation film |
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