CN101718530B - On-line detection system of electromagnetic wire lapping - Google Patents
On-line detection system of electromagnetic wire lapping Download PDFInfo
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- CN101718530B CN101718530B CN2009101989547A CN200910198954A CN101718530B CN 101718530 B CN101718530 B CN 101718530B CN 2009101989547 A CN2009101989547 A CN 2009101989547A CN 200910198954 A CN200910198954 A CN 200910198954A CN 101718530 B CN101718530 B CN 101718530B
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Abstract
The invention relates to an on-line detection system of electromagnetic wire lapping, comprising a position sensor, an induction baffle plate, a non-daylight light source, an image acquiring module, a processing module, an input and output module and a monitoring computer, wherein the position sensor is fixed on a lapping machine body and can send positioning signals; the induction baffle plate is arranged on a lapping machine; the non-daylight light source is arranged above an electromagnetic wire lapping working area; the image acquiring module is arranged above the electromagnetic wire lapping working area and used for acquiring images of lapped electromagnetic wires; the processing module is used for processing according to acquired images so as to obtain space deviations and directions between splice sections; the input and output module is connected with the position sensor and the processing module and used for outputting processing results and sending lapping deviation adjustment information to outside; and the monitoring computer is communicated with a communication module so as to realize the real-time monitoring and the overall monitoring of electromagnetic wire lapping production.
Description
Technical field
The lapping that the present invention relates to lapping electromagnetic wire detects, and is specifically related to use the wrapped position dimension of the online detection electromagnetic wire of machine vision technique and the system of deviation thereof.
Background technology
Electromagnetic wire is the critical material of electric equipment products such as motor, high-voltage large-capacity transformer, electromagnetic wire mainly divides two kinds in winding wire and enameled wire, winding wire be a kind of on conductor with wrapped insulated conductors that forms of various insulation films such as natural fiber, alkali-free glass wool, mica tapes.Wrapped mode has two kinds: Ping Bao and stacked package; The flat single flat bag that is surrounded by, double-deck flat bag, three layers of flat bag.Wrapped mode, interlayer position dimension parameter and homogeneity then are the key factors that influences the electric property of electromagnetic wire.
Because the wrapped of electromagnetic wire finished under the insulation film high speed rotating, therefore the detection of dynamic of lapping is one and has challenging technical barrier, the measuring method that adopts any contact extremely difficulty obtains measurement data accurately, but also causes line disconnected easily.At present, the lapping of electromagnetic wire mainly relies on the performance of wrapped machine and the stability and the reliability of work thereof, that is: in the production work process, at first make wrapped machine be operated in the wrapped preset state of low speed rotation, operating personnel adjust the parameter of wrapped machine according to the wrapped concrete condition of real-time monitored, make wrapped position dimension and deviation stable and meet the product quality requirement; Make wrapped machine be operated in the wrapped production status of high speed rotating then, after this lapping of electromagnetic wire decides with the duty by machine fully, judges after operating personnel can only observe the wrapped situation in postpartum whether decision needs to intervene again.As seen, rely on artificial visually examine's method of this kind hysteresis to detect difficult quality and in time pinpoint the problems, cause unnecessary waste very easily, and artificial visually examine's method precision is difficult to also guarantee, therefore, press for a kind of automatic monitoring system and realize detection electromagnetic wire lapping.
Summary of the invention
Present situation at above-mentioned electromagnetic wire lapping artificial visually examine adjustment and judgement, the object of the present invention is to provide a kind of on-line detection system of electromagnetic wire lapping, it realizes the position dimension that electromagnetic wire is wrapped and real-time, dynamic, the non-contacting accurate measurement of deviation thereof based on machine vision technique, really to accomplish real-time monitoring, complete monitoring to producing.
For reaching above-mentioned purpose and other purposes, on-line detection system of electromagnetic wire lapping of the present invention comprises: be fixed in wrapped machine fuselage and can send the position transducer of positioning signal; Be installed on the wrapped machine with respect to the position of described position transducer and the induction catch that can rotate with wrapped machine, described position transducer can send positioning signal when itself and described position transducer are superimposed; Be arranged on the non-daylight source of top, the wrapped perform region of electromagnetic wire; Be arranged on top, the wrapped perform region of electromagnetic wire and be used for the auxiliary acquisition module of gathering the image of wrapped electromagnetic wire down at described non-daylight source; Be used for after receiving described positioning signal starting that acquisition module begins to gather and according to the result of processing module wrapped deviation adjustment information is delivered to outside input/output module; Be used for according to the image that described acquisition module is gathered comprise that cutting is cut apart, filtering, equilibrium, extraction projecting edge characteristic information and the processing of obtaining the splicing contour feature of electromagnetic wire, and be benchmark with horizontal center transversal, add up the pixel number that each splice sections comprises according to described splicing contour feature, and then the spacing deviation between the acquisition splice sections and the processing module of direction; Be connected with acquisition module with supervisory control comuter and be used to accept the setup parameter of supervisory control comuter and the communication module that the result of described processing module is sent to the interface of supervisory control comuter; Be connected with described communication module, the result that is used for described communication module is sent to is shown in the web mode, also be used to provide a parameter that the interface is set and the running parameter of described acquisition module be set, and form corresponding adjustment information is back to described acquisition module by communication module supervisory control comuter after setting completed as operating personnel for operating personnel.
Described non-daylight source can be red area source, further can be the LED lamp that can send red light.
Described acquisition module, input/output module, processing module, and the function of communication module all finish by smart camera.
Described supervisory control comuter is connected with described communication module by the RJ-45 standard interface.
The equalization methods that described processing module adopts can be histogram equalization, can adopt many structural elements of small size mathematical morphology edge detection algorithm to obtain the splicing contour feature of electromagnetic wire, and described small size can be 3 * 3 size.
In sum, on-line detection system of electromagnetic wire lapping of the present invention is by the collection and the analysis of the image of opposing connection bag workspace, can realize the position dimension that electromagnetic wire is wrapped and real-time, dynamic, the non-contacting accurate measurement of deviation thereof, really accomplish producing real-time monitoring, complete monitoring.
Description of drawings
Fig. 1 is the principle schematic of on-line detection system of electromagnetic wire lapping of the present invention.
The double-deck flat bag image synoptic diagram of the electromagnetic wire that Fig. 2 on-line detection system of electromagnetic wire lapping of the present invention is gathered.
Fig. 3 is the workflow synoptic diagram of on-line detection system of electromagnetic wire lapping of the present invention.
Fig. 4 is the monitoring interface synoptic diagram that the supervisory control comuter of on-line detection system of electromagnetic wire lapping of the present invention provides.
Embodiment
Below with reference to accompanying drawing on-line detection system of electromagnetic wire lapping of the present invention is described in detail.
See also Fig. 1, on-line detection system of electromagnetic wire lapping of the present invention comprises at least: position transducer 3, induction catch 4, non-daylight source 2, smart camera 1 and supervisory control comuter 9 etc.
Described position transducer 3 is fixed on the wrapped machine fuselage 10, and it can send positioning signal.
Described induction catch 4 is installed on the wrapped machine with respect to the position of described position transducer 3, and it can rotate with wrapped machine, and when it turns to described position transducer when superimposed, described position transducer will send positioning signal.
Described non-daylight source is arranged on top, the wrapped perform region of electromagnetic wire.In the present embodiment, the red face light that employing LED lamp sends also can adopt other can effectively prevent the light source that external ambient light is disturbed as light source in addition.
Described smart camera is arranged on top, the wrapped perform region of electromagnetic wire, lapping electromagnetic wire 6 be can absorb and film 7 and 8 wrapped images are insulated, it is not a simple camera, but a kind of microminiature Vision Builder for Automated Inspection of Highgrade integration, it can be with the collection of image, handle with communication function and be integrated in the single camera, thereby provide have multi-functional, modularization, high reliability, the machine vision solution that is easy to realize, being different from traditional camera is transferred to computing machine with image and handles, smart camera can independently be finished collection, handle three links of result's output, the complexity of system greatly reduces, and is more suitable for the applied environment of industry spot than the vision system of computer architecture.In the present embodiment, NI 1722 smart cameras of employing, it possesses the two-port gigabit ethernet interface, and therefore, operation or managerial personnel can monitor on-the-spot testing process at long-range use standard browser based on NI Web publishing technology.The red area source of described LED can make lapping electromagnetic wire obtain stable uniform irradiation in the smart camera field range, and overall size and wrapped sharpness of border are outstanding.
Described smart camera comprises: acquisition module, input/output module, processing module, and communication module etc.Wherein, described acquisition module is arranged on top, the wrapped perform region of electromagnetic wire, is used for the auxiliary image of gathering wrapped electromagnetic wire down at the red area source of described LED; Described input/output module is used for after receiving described positioning signal starting that acquisition module begins to gather and according to the result of processing module wrapped deviation adjustment information is delivered to the outside; Described processing module be used for according to the image that described acquisition module is gathered comprise that cutting is cut apart, filtering, equilibrium, extraction projecting edge characteristic information and the processing of obtaining the splicing contour feature of electromagnetic wire, and be benchmark with horizontal center transversal, add up the pixel number that each splice sections comprises according to described splicing contour feature, and then obtain spacing deviation and direction between the splice sections; Described communication module is connected with supervisory control comuter with described acquisition module, is used to accept the setup parameter of supervisory control comuter, and the interface that the result of described processing module is sent to supervisory control comuter;
Described supervisory control comuter 9 is connected with described communication module, the result that is used for described communication module is sent to is shown in the web mode, also be used to provide a parameter that the interface is provided with described acquisition module for operating personnel running parameter is set, and form corresponding adjustment information after setting completed and be back to described communication module as operating personnel, it is connected with described communication module by the RJ-45 standard interface.
The course of work of described on-line detection system of electromagnetic wire lapping is as follows:
The first step, smart camera 1 and LED lighting source place the top of the wrapped perform region of electromagnetic wire, adjust the luminous intensity and the irradiating angle of light source, regulate attitude, focal length and the aperture of smart camera simultaneously, make the image information feature in the smart camera field range clear and legible.
Second step, install and adjust position transducer 3 and induction catch 4, position transducer is fixed and is responded to catch and rotatablely moves with wrapped machine 5, when position transducer in each all wrapped process overlapped with the induction catch, position transducer 4 obtained responding to the also control module of output pulse signal triggering smart camera, and the acquisition module of smart camera is gathered the wrapped image of moment this moment, as shown in Figure 2, wherein, 71 expression insulation films, 72 expressions are as the horizontal center transversal of benchmark.
In the 3rd step, image processing and detection: Figure 2 shows that the image of the double-deck flat packet mode of electromagnetic wire, when ground floor was wrapped, insulation film was simple parallel connecting method; When the second layer was wrapped, the parallel splicing of insulation film covered on the ground floor, but required the center of insulation film width to overlap with the splicing line of ground floor.
As shown in Figure 2, d represents the spacing of wrapped splicing line of the second layer and the wrapped splicing line of ground floor, and D is the spacing between the wrapped splicing line of ground floor, also is the width of insulation film.The technical requirement of production technology and detection is: when the deviation of d during smaller or equal to 5%D, export two states signal indication overgauge or minus deviation respectively; When the deviation of d during simultaneously smaller or equal to 10%D, is exported the third status signal greater than 5%D.
Is earlier judging whether to receive positioning signal by smart camera (that the position sensor is responded to?), just do not continue to wait for, when smart camera receives that trigger pip promptly starts acquisition module and carves images acquired, with post-processing module image being carried out cutting cuts apart, extract the effective coverage (ROI zone) of wrapped detection, and auto adapted filtering, histogram equalization are carried out in the ROI zone handle, improve picture quality projecting edge characteristic information; Utilization small size (3 * 3) many structural elements mathematical morphology edge detection algorithm extracts the contour feature of wrapped splicing line, edge accurate positioning, traditional edge extracting operator that speed is fast, robustness is better than; Again by edge of image refinement and binary conversion treatment, obtain the wrapped splicing line profile of single pixel, horizontal center transversal with electromagnetic wire is a benchmark again, the number of pixels of statistical distance parameter d and D, and, judge whether deviation goes beyond the limit of scope with this deviation of calculating d, if, overload alarm then, otherwise the digitally encoded signal of output expression lapping testing result, and detect next time.
Repeat above step, process flow diagram can be realized real-time detection, the complete monitoring of electromagnetic wire lapping as shown in Figure 3.
In sum, on-line detection system of electromagnetic wire lapping of the present invention has adopted the smart camera based on machine vision technique, the wrapped image of online shooting electromagnetic wire, and image analyzed, can realize the position dimension that electromagnetic wire is wrapped and real-time, dynamic, the non-contacting accurate measurement of deviation thereof thus, wrapped deviation state and the direction of output digitally encoded signal indication, simultaneously can be presented at testing result on the monitoring computer screen synchronously, really accomplish producing real-time monitoring, complete monitoring.In addition, wrapped machine also can carry out dynamic real-time adjustment, compensation work parameter according to the numerical coding that supervisory control comuter provides, and revises in real time wrapped, realizes that the closed loop of wrapped production run is controlled automatically, controls and improves the quality of products, promotes production efficiency.
Claims (8)
1. on-line detection system of electromagnetic wire lapping is characterized in that comprising:
Be fixed in wrapped machine fuselage and can send the position transducer of positioning signal;
Be installed on the wrapped machine induction catch with respect to the position of described position transducer, it can rotate with wrapped machine, and when itself and described position transducer were superimposed, described position transducer sent positioning signal;
Non-daylight source is arranged on top, the wrapped perform region of electromagnetic wire;
Acquisition module is arranged on top, the wrapped perform region of electromagnetic wire, is used for the auxiliary image of gathering wrapped electromagnetic wire down at described non-daylight source;
Input/output module is used for after receiving described positioning signal starting that acquisition module begins to gather and according to the result of processing module wrapped deviation adjustment information is delivered to the outside;
Processing module, be used for according to the image that described acquisition module is gathered comprise that cutting is cut apart, filtering, equilibrium, extraction projecting edge characteristic information and the processing of obtaining the splicing contour feature of electromagnetic wire, and be benchmark with horizontal center transversal, add up the pixel number that each splice sections comprises according to described splicing contour feature, and then obtain spacing deviation and direction between the splice sections;
Communication module is connected with acquisition module with supervisory control comuter, is used to accept the setup parameter of supervisory control comuter, and the interface that the result of described processing module is sent to supervisory control comuter;
Supervisory control comuter, be connected with described communication module, the result that is used for described communication module is sent to is shown in the web mode, also be used to provide a parameter that the interface is set and the running parameter of described acquisition module be set, and reach acquisition module by described communication module when operating personnel form corresponding adjustment information after setting completed for operating personnel.
2. on-line detection system of electromagnetic wire lapping according to claim 1 is characterized in that: described non-daylight source is red area source.
3. on-line detection system of electromagnetic wire lapping according to claim 2 is characterized in that: described red area source is for sending the LED lamp of red light.
4. on-line detection system of electromagnetic wire lapping according to claim 1 is characterized in that: described acquisition module, input/output module, processing module, and the function of communication module all finish by smart camera.
5. according to claim 1 or 4 described on-line detection system of electromagnetic wire lapping, it is characterized in that: described supervisory control comuter is connected with described communication module by the RJ-45 standard interface.
6. according to claim 1 or 4 described on-line detection system of electromagnetic wire lapping, it is characterized in that: the equalization methods that described processing module adopts is a histogram equalization.
7. according to claim 1 or 4 described on-line detection system of electromagnetic wire lapping, it is characterized in that: described processing module adopts many structural elements of small size mathematical morphology edge detection algorithm to obtain the splicing contour feature of electromagnetic wire.
8. on-line detection system of electromagnetic wire lapping according to claim 7 is characterized in that: described small size is 3 * 3 size.
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| CN2009101989547A CN101718530B (en) | 2009-11-18 | 2009-11-18 | On-line detection system of electromagnetic wire lapping |
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| CN2009101989547A CN101718530B (en) | 2009-11-18 | 2009-11-18 | On-line detection system of electromagnetic wire lapping |
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| CN101718530B true CN101718530B (en) | 2011-05-18 |
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Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN103413633A (en) * | 2013-08-15 | 2013-11-27 | 吴江固德电材系统股份有限公司 | Electromagnetic wire horizontal tape wrapping device |
| CN103512892B (en) * | 2013-09-22 | 2016-02-10 | 上海理工大学 | The detection method that electromagnetic wire thin-film is wrapped |
| CN108831636B (en) * | 2018-06-05 | 2021-03-26 | 浙江正泰电缆有限公司 | Double-strip winding equipment |
| CN108735396B (en) * | 2018-06-05 | 2020-12-11 | 浙江正泰电缆有限公司 | Double-strip winding process |
| CN114022378A (en) * | 2021-11-04 | 2022-02-08 | 中天智能装备有限公司 | Copper strip shielding layer overlapping rate detection method based on vision |
| CN118799823B (en) * | 2024-09-14 | 2025-01-10 | 广州澳通电线电缆有限公司 | Temperature-rise-resistant curve cable production quality online monitoring method and system |
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| EP1057545A3 (en) * | 1999-06-02 | 2004-06-23 | Kirin Techno-System Corporation | Automatic inspecting apparatus by image processing |
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| CN101216293A (en) * | 2007-12-27 | 2008-07-09 | 中国计量学院 | Device for non-contact on-line detection of piston pin outer diameter |
| JP2009058377A (en) * | 2007-08-31 | 2009-03-19 | Hitachi Kokusai Electric Inc | Inspection apparatus |
| CN201218723Y (en) * | 2008-05-30 | 2009-04-08 | 上海锡明光电科技有限公司 | Optoelectronic non-contact type image detection apparatus |
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Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1057545A3 (en) * | 1999-06-02 | 2004-06-23 | Kirin Techno-System Corporation | Automatic inspecting apparatus by image processing |
| CN1837746A (en) * | 2005-03-11 | 2006-09-27 | 株式会社明电舍 | Aerial line wear detection device base on image processing |
| JP2009058377A (en) * | 2007-08-31 | 2009-03-19 | Hitachi Kokusai Electric Inc | Inspection apparatus |
| CN101216293A (en) * | 2007-12-27 | 2008-07-09 | 中国计量学院 | Device for non-contact on-line detection of piston pin outer diameter |
| CN201218723Y (en) * | 2008-05-30 | 2009-04-08 | 上海锡明光电科技有限公司 | Optoelectronic non-contact type image detection apparatus |
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