CN109378207B - Winding machine process control method based on online visual detection - Google Patents
Winding machine process control method based on online visual detection Download PDFInfo
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- CN109378207B CN109378207B CN201811354930.1A CN201811354930A CN109378207B CN 109378207 B CN109378207 B CN 109378207B CN 201811354930 A CN201811354930 A CN 201811354930A CN 109378207 B CN109378207 B CN 109378207B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/064—Winding non-flat conductive wires, e.g. rods, cables or cords
- H01F41/066—Winding non-flat conductive wires, e.g. rods, cables or cords with insulation
Abstract
The invention relates to a winding machine process control method based on online visual detection, which is realized by a winding process control system, wherein the winding process control system comprises a winding machine, a stroke measuring sensor, a shooting device and a processor, the stroke measuring sensor is installed on the winding machine, the winding machine comprises a translation table and a wire arranging device, and the shooting device is installed on the translation table; meanwhile, a winding quality control method is designed, so that the quality problems of overlapping winding, gaps and the like in the winding process are effectively avoided, and the product quality is obviously improved.
Description
Technical Field
The invention relates to a winding machine process control method based on online visual detection, and belongs to the technical field of intelligent equipment.
Background
The winding machine is a special machine tool for winding various magnetic induction coils, and structurally comprises a main shaft, a chuck, a translation table and a wire arranging device, wherein the chuck is used for clamping a coil framework, the chuck is driven by the main shaft to rotate to wind an enameled wire, the wire arranging device extracts the enameled wire from a material roller with certain tension and is driven by the translation table to walk along with the winding of the coil, so that the wire to be wound and the framework keep a proper relative position, the relative uniformity of the wire arranging and winding of a solenoid is ensured, and the movement speed of the translation table and the rotation speed of the main shaft are preset according to different wire diameters. The winding machine has some problems, and because the diameter of the enameled wire is slightly changed within the tolerance range, and the movement speed of the translation table and the rotation speed of the main shaft are fixed, the quality defects of uneven winding, overlapping winding, sinking and the like can be caused; when a plurality of layers of solenoids are wound, the traditional winding machine lacks an automatic reversing function, needs a special person to continuously operate and has high labor cost; some coils need to measure the winding length, and also need to be manually measured off-line, so that the efficiency is low.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide a winding machine process control method based on online visual inspection.
The above purpose of the invention is mainly realized by the following technical scheme:
the utility model provides a coiling machine process control method based on online visual detection, realizes through wire winding process control system, wire winding process control system includes the coiling machine, surveys stroke sensor, shoots device and treater, and wherein survey stroke sensor and install on the coiling machine, the coiling machine includes translation platform and winding displacement ware, shoots the device and installs on the translation platform, specifically realizes the method as follows:
the method comprises the steps that a shooting device shoots an image of a to-be-wound framework, the pixel coordinate of a winding starting point on the to-be-wound framework is obtained from the image, meanwhile, the winding starting point reading of a stroke measuring sensor is read, and the pixel coordinate of the winding starting point and the winding starting point reading of the stroke measuring sensor are sent to a processor;
the processor controls the winding machine to start, the translation table drives the wire arranging device to move, and winding is started from a winding starting point of the framework to be wound;
step three, the shooting device sends the winding process image shot in real time to the processor, and the stroke measuring sensor sends the read winding process reading to the processor; the processor calculates the length of a winding coil on the to-be-wound framework in real time according to the winding process image, the winding process reading, the pixel coordinate of the winding starting point and the winding starting point reading of the stroke measuring sensor;
judging the length of the winding coil by the processor, and controlling the winding machine to stop winding operation by the processor if the length of the winding coil reaches the set coil length; if the length of the winding coil does not reach the set coil length and does not reach the commutation starting point of the framework to be wound, the processor controls the winding machine to continue winding operation; and if the length of the winding coil does not reach the set coil length and reaches the starting point of the commutation of the framework to be wound, the processor controls the winding machine to commutate, and continues the next layer of winding operation.
In the winding machine process control method for online visual detection, the specific method for calculating the length of the winding coil on the to-be-wound framework in real time by the processor in the step (three) according to the winding process image, the winding process reading, the pixel coordinate of the winding starting point and the winding starting point reading of the stroke measuring sensor is as follows:
L＝(s-s0)+(y-y0)×p
wherein:
l is the length of the winding coil;
s is the winding process reading of the stroke measuring sensor along the axial direction of the framework to be wound;
s0reading the winding starting point of the stroke measuring sensor along the axial direction of the bobbin to be wound;
y is a pixel coordinate of the current winding position along the axis direction of the bobbin to be wound;
y0the pixel coordinates of the winding starting point along the axis direction of the framework to be wound are taken as the pixel coordinates;
and p is an affine transformation coefficient from pixel coordinates to world coordinates.
In the winding machine process control method for online visual detection, a hough edge linear edge detection method is used for identifying the current winding position from a winding process image, and the coordinate y of the current winding position along the axis direction of a to-be-wound framework is determined.
In the winding machine process control method for online visual detection, the stroke measuring sensor is a grating ruler, a magnetic grating ruler or a laser range finder.
In the winding machine process control method for online visual inspection, the distance between the reversing starting point of the to-be-wound framework and the tail end of the to-be-wound framework in the step (IV) is 3-5 mm.
In the winding machine process control method for online visual inspection, the specific method for controlling the winding machine to commutate by the processor in the step (four) is as follows:
(4.1) when the processor detects that the current winding position reaches the reversing starting point of the frame to be wound, sending a control instruction to decelerate the winding machine;
(4.2) when the distance between the current winding position and the tail end of the to-be-wound bobbin is 2-3 mm, the translation table is inching to enable the current winding angle to be perpendicular to the axis of the to-be-wound bobbin;
(4.3) when the current winding position contacts the tail end of the framework to be wound, the current winding is automatically wound to the next layer, the winding direction is automatically turned back, the winding displacement device still keeps moving in the original winding direction, and when the current winding angle reaches a set angle, the winding displacement device is controlled to reverse; and the current winding angle is an included angle between the current winding and the axis of the bobbin to be wound along the winding direction.
In the winding machine process control method for online visual inspection, the angle is set to be 75-85 degrees in the step (4.3).
In the winding machine process control method for online visual inspection, the speed of the winding machine after deceleration in the step (4.1) is 30-50% of the original speed.
The winding machine process control method for online visual detection further comprises a winding quality control method, and the specific method comprises the following steps:
(1) in the winding process, the processor obtains a current winding angle from an image shot by the shooting device, wherein the current winding angle is an included angle between a current winding and the axis of the bobbin to be wound along the winding direction;
(2) and judging whether the current winding angle is within a set angle range, if so, not intervening, if so, controlling the translation table to inching towards the direction opposite to the winding direction by the processor, and if not, controlling the translation table to inching towards the winding direction by the processor.
In the winding machine process control method for online visual inspection, the angle range set in the step (2) is 75-85 degrees.
In the winding machine process control method for online visual detection, the processor in the step (1) extracts the current winding angle from the image shot by the shooting device by using a Hough Edge linear Edge detection algorithm.
Compared with the prior art, the invention has the following beneficial effects:
(1) the invention innovatively improves the original winding machine, adds a stroke measuring sensor, a shooting device and a processor, measures key parameters in the winding process in a real-time and non-contact mode, obtains the coil length in the winding process according to the key parameters, automatically judges when to stop winding, commutates when to complete winding and commutates automatically, realizes the automation of the winding process and greatly saves the labor cost.
(2) According to the invention, by carrying out closed-loop control on the winding angle in the winding process, the quality problems of lap winding, gaps and the like in the winding process are effectively avoided, and the product quality is obviously improved.
(3) The invention can automatically measure and control the length of the wound coil, can be used for producing coils with any length, and does not need manual intervention in the production process;
(4) the invention controls the length of the coil through real-time detection, improves the control precision of the coil, eliminates the randomness of manual measurement and improves the production efficiency;
(5) the process control method is online measurement, realizes the automatic reversing function, optimizes the automatic reversing process, finishes the winding reversing with high quality, obviously improves the automation level and saves labor;
(6) the invention realizes process control by adopting non-contact measurement, and avoids damaging the surface of a product.
Drawings
FIG. 1 is a schematic diagram of a process control implemented by the winding process control system of the present invention;
FIG. 2 is a schematic diagram of a stroke sensor of the present invention as a grating ruler;
FIG. 3 is a schematic view of a camera according to the present invention;
FIG. 4 is a schematic diagram of the commutation process of the winding of the present invention.
Detailed Description
The invention is described in further detail below with reference to the following figures and specific examples:
as shown in fig. 1, the process control schematic diagram of the winding process control system according to the present invention is realized by the winding process control system, and it can be seen that the winding process control method according to the present invention is realized by the winding process control system, and the winding process control system includes a winding machine 1, a stroke measuring sensor 2, a shooting device 3, a processor 4, a to-be-wound bobbin 5, a material roll 10, a coil 7, an industrial IO card 12, a machine button box 13, and a touch terminal 11. The winding machine 1 comprises a translation table 1-1, a wire arranging device 1-2, a spindle 8 and a chuck 9, wherein a touch terminal 11 is used for providing a human-computer interface and selecting products and parameters.
The stroke measuring sensor 2 may adopt a grating ruler, a magnetic grating ruler, a laser range finder, or the like, and in this embodiment, the grating ruler is selected, as shown in fig. 2. The body of the grating ruler is arranged on the body of the winding machine 1, and the reading head is arranged on the translation table 1-1 of the winding machine 1. The photographing device 3 is also mounted on the translation stage 1-1.
In the invention, the processor 4 carries out real-time image processing, determines the current state of the winding coil 7 and sends a control signal to the industrial IO card 12, and the industrial IO card 12 is connected with the machine tool button box 13 in parallel, so that the processor 4 can control the winding machine 1 to start, stop, accelerate, decelerate, jog, reverse and the like.
The winding machine process control method based on-line visual detection comprises the following specific implementation steps:
the method comprises the steps that firstly, a shooting device 3 shoots an image of a to-be-wound framework 5, the pixel coordinate of a winding starting point on the to-be-wound framework 5 is obtained from the image, meanwhile, the winding starting point reading of a stroke measuring sensor 2 is read, and the pixel coordinate of the winding starting point and the winding starting point reading of the stroke measuring sensor 2 are sent to a processor 4.
The pixel coordinate of the winding starting point is the pixel coordinate of the winding starting point along the axis direction of the to-be-wound bobbin, the coordinate origin point is the pixel point at the leftmost end of the image, and the coordinate direction is the winding direction. And the winding starting point reading is the winding starting point reading along the axial direction of the bobbin to be wound.
And (II) the processor 4 controls the winding machine 1 to start, the main shaft 8 drives the to-be-wound framework 5 to rotate, the translation table 1-1 drives the wire arranging device 1-2 to move, winding is started from a winding starting point of the to-be-wound framework 5, the material roller 10 rotates, and the coil 7 is wound on the to-be-wound framework 5.
Step three, the shooting device 3 sends the winding process image shot in real time to the processor 4, and the grating ruler 2 sends the read winding process reading to the processor 4; the processor 4 calculates the length of the winding coil on the frame 5 to be wound in real time according to the winding process image, the winding process reading, the pixel coordinate of the winding start point and the winding start point reading of the grating ruler 2. Fig. 3 is a schematic diagram of the photographing apparatus according to the present invention.
The winding process image is a winding process image along the axis direction of the winding framework to be wound, and the winding process reading is a winding process reading along the axis direction of the winding framework to be wound. The origin of coordinates is the leftmost pixel point of the image, and the direction of the coordinates is the winding direction.
The specific method for calculating the length of the winding coil on the to-be-wound bobbin 5 is as follows:
L＝(s-s0)+(y-y0)×p
wherein:
l is the length of the winding coil;
s is the reading of the grating ruler in the winding process along the axis direction of the framework to be wound;
s0reading the winding starting point of the grating ruler along the axial direction of the to-be-wound bobbin;
y is a pixel coordinate of the current winding position along the axis direction of the bobbin to be wound;
y0the pixel coordinates of the winding starting point along the axis direction of the framework to be wound are taken as the pixel coordinates;
and p is a conversion coefficient between the pixel coordinate and the world coordinate, and the value of p in the embodiment is 0.0104 mm/pixel.
And the pixel coordinate y of the current winding position along the axis direction of the frame to be wound is obtained from the winding process image. In the embodiment, a hough edge linear edge detection method is used for identifying the current winding position from the winding process image, and determining the coordinate y of the current winding position along the axis direction of the bobbin to be wound 5.
And step (IV), the processor 4 judges the length of the winding coil 7, and if the length of the winding coil reaches the set coil length, the processor 4 controls the winding machine 1 to stop the winding operation. If the length of the winding coil does not reach the set coil length and does not reach the commutation starting point of the frame 5 to be wound, the processor 4 controls the winding machine 1 to continue winding operation; if the length of the winding coil does not reach the set coil length and reaches the starting point of the commutation of the frame 5 to be wound, the processor 4 controls the winding machine 1 to commutate, and continues the next layer of winding operation.
In the embodiment, the distance between the reversing starting point of the to-be-wound bobbin 5 and the tail end A of the to-be-wound bobbin 5 is 3-5 mm.
As shown in fig. 4, which is a schematic diagram of the winding direction changing process of the present invention, the specific method for the processor 4 to control the winding machine 1 to change the direction is as follows:
(4.1) when the processor 4 detects that the current winding position reaches the reversing starting point of the bobbin 5 to be wound, sending a control instruction to decelerate the winding machine 1; the speed of the winding machine 1 after the speed reduction is 30-50% of the original speed.
(4.2) when the distance between the current winding position and the tail end A of the to-be-wound bobbin 5 is 2-3 mm, inching the translation table 1-1 to enable the current winding angle to be perpendicular to the axis of the to-be-wound bobbin 5;
(4.3) when the current winding position contacts the tail end A of the framework 5 to be wound, the current winding is automatically wound to the next layer, the winding direction is automatically turned back, the winding arrangement device 1-2 still keeps moving in the original winding direction, and when the current winding angle reaches a set angle, the winding arrangement device 1-2 is controlled to be reversed; and the current winding angle is an included angle between the current winding and the axis of the bobbin to be wound along the winding direction. The set angle is 75-85 degrees, and the traverse 1-2 is controlled to be reversed when the winding angle is 83 degrees in the embodiment.
The process control method also comprises a winding quality control method, and the specific method comprises the following steps:
(1) in the winding process, the processor 4 obtains a current winding angle from an image shot by the shooting device 3, wherein the current winding angle is an included angle between a current winding and the axis of the bobbin to be wound along the winding direction; in this embodiment, the processor 4 extracts the current winding angle from the image captured by the capturing device 3 by using a Hough Edge linear Edge detection algorithm.
(2) And judging whether the current winding angle is within a set angle range, wherein the set angle range is 75-85 degrees in the embodiment, if the current winding angle is within the set angle range, no intervention is performed, if the current winding angle is greater than the set angle range, namely greater than 85 degrees, the processor 4 controls the translation table 1-1 to jog towards the direction opposite to the winding direction, and if the current winding angle is less than the set angle range, namely less than 75 degrees, the processor 4 controls the translation table 1-1 to jog towards the winding direction.
The step can judge the quality of the coil at the current position, control the machine tool to stop when the coil is wound and loosened, and send out an alarm to call a worker for processing.
In the quality control of the winding product, the control of the wire inlet angle is the key for ensuring the uniform winding of the product, and the measurement of the wire inlet position is the key for detecting the length of the coil and the reversing process on line. The invention adopts machine vision to solve the problem, the servo camera of the wire arranging device is provided with a high-magnification optical lens, the winding details of a product are amplified, measuring software adopts a hough edge algorithm to detect the edge of an incoming wire, a straight line is fitted, the angle and the position of the incoming wire are judged in an image, the angle and the position correspond to a camera coordinate system through affine transformation, and the stroke of a grating ruler is added, so that the current winding length is obtained. The processor can control the traveling speed of the wire arranging device according to the wire inlet angle, perform inching operation if necessary, judge the current coil state according to the winding length, execute reversing or not and control the coil length to reach a set value to stop automatically.
The above description is only for the best mode of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are included in the scope of the present invention.
Those skilled in the art will appreciate that the invention may be practiced without these specific details.
Claims (10)
1. A winding machine process control method based on-line visual detection is characterized in that: the winding process control system comprises a winding machine (1), a stroke measuring sensor (2), a shooting device (3) and a processor (4), wherein the stroke measuring sensor (2) is installed on the winding machine (1), the winding machine (1) comprises a translation table (1-1) and a wire arranging device (1-2), the shooting device (3) is installed on the translation table (1-1), and the specific implementation method comprises the following steps:
the method comprises the steps that firstly, a shooting device (3) shoots an image of a to-be-wound framework (5), the pixel coordinate of a winding starting point on the to-be-wound framework (5) is obtained from the image, meanwhile, the winding starting point reading of a stroke measuring sensor (2) is read, and the pixel coordinate of the winding starting point and the winding starting point reading of the stroke measuring sensor (2) are sent to a processor (4);
step two, the processor (4) controls the winding machine (1) to start, the translation table (1-1) drives the wire arranging device (1-2) to move, and winding is started from a winding starting point of the to-be-wound framework (5);
step three, the shooting device (3) sends the winding process image shot in real time to the processor (4), and the stroke measuring sensor (2) sends the read winding process reading to the processor (4); the processor (4) calculates the length of a winding coil on the to-be-wound framework (5) in real time according to the winding process image, the winding process reading, the pixel coordinate of the winding starting point and the winding starting point reading of the stroke measuring sensor (2);
judging the length of the winding coil by the processor (4), and controlling the winding machine (1) to stop winding operation by the processor (4) if the length of the winding coil reaches the set coil length; if the length of the winding coil does not reach the set coil length and does not reach the commutation starting point of the framework (5) to be wound, the processor (4) controls the winding machine (1) to continue winding operation; if the length of the winding coil does not reach the set coil length and reaches the starting point of the commutation of the framework (5) to be wound, the processor (4) controls the winding machine (1) to commutate, and continues the next layer of winding operation;
the specific method for calculating the length of the winding coil on the to-be-wound framework (5) in real time by the processor (4) according to the winding process image, the winding process reading, the pixel coordinate of the winding starting point and the winding starting point reading of the stroke measuring sensor (2) in the step (three) is as follows:
L＝(s-s0)+(y-y0)×p
wherein:
l is the length of the winding coil;
s is the winding process reading of the stroke measuring sensor along the axial direction of the framework to be wound;
s0reading the winding starting point of the stroke measuring sensor along the axial direction of the bobbin to be wound;
y is a pixel coordinate of the current winding position along the axis direction of the bobbin to be wound;
y0the pixel coordinates of the winding starting point along the axis direction of the framework to be wound are taken as the pixel coordinates;
and p is an affine transformation coefficient from pixel coordinates to world coordinates.
2. The winding machine process control method according to claim 1, characterized in that: and identifying the current winding position from the winding process image by using a hough edge linear edge detection method, and determining the coordinate y of the current winding position along the axis direction of the framework (5) to be wound.
3. The winding machine process control method according to claim 1 or 2, characterized in that: the stroke measuring sensor (2) is a grating ruler, a magnetic grating ruler or a laser range finder.
4. The winding machine process control method according to claim 1 or 2, characterized in that: and in the step (IV), the distance between the reversing starting point of the to-be-wound framework (5) and the tail end of the to-be-wound framework (5) is 3-5 mm.
5. The winding machine process control method according to claim 1 or 2, characterized in that: the specific method for controlling the winding machine (1) to commutate by the processor (4) in the step (IV) is as follows:
(4.1) when the processor (4) detects that the current winding position reaches the reversing starting point of the to-be-wound bobbin (5), sending a control instruction to decelerate the winding machine (1);
(4.2) when the distance between the current winding position and the tail end of the to-be-wound bobbin (5) is 2-3 mm, the translation table (1-1) is inching, so that the current winding angle is perpendicular to the axis of the to-be-wound bobbin (5);
(4.3) when the current winding position contacts the tail end of the to-be-wound bobbin (5), the current winding is automatically wound to the next layer, the winding direction is automatically turned back, the winding arrangement device (1-2) still keeps moving in the original winding direction at the moment, and when the current winding angle reaches a set angle, the winding arrangement device (1-2) is controlled to be switched; and the current winding angle is an included angle between the current winding and the axis of the bobbin to be wound along the winding direction.
6. The winding machine process control method according to claim 5, characterized in that: and (4) setting the angle to be 75-85 degrees in the step (4.3).
7. The winding machine process control method according to claim 5, characterized in that: in the step (4.1), the speed of the winding machine (1) after deceleration is 30-50% of the original speed.
8. The winding machine process control method according to claim 1 or 2, characterized in that: the winding quality control method comprises the following specific steps:
(1) in the winding process, the processor (4) obtains a current winding angle from an image shot by the shooting device (3), wherein the current winding angle is an included angle between a current winding and the axis of the bobbin to be wound along the winding direction;
(2) and judging whether the current winding angle is within a set angle range, if so, not intervening, if so, controlling the translation table (1-1) to inching towards the direction opposite to the winding direction by the processor (4), and if not, controlling the translation table (1-1) to inching towards the winding direction by the processor (4).
9. The winding machine process control method according to claim 8, characterized in that: the angle range set in the step (2) is 75-85 degrees.
10. The winding machine process control method according to claim 8, characterized in that: and (2) in the step (1), the processor (4) extracts the current winding angle from the image shot by the shooting device (3) by adopting a Hough Edge linear Edge detection algorithm.
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| JP3268153B2 (en) * | 1995-01-11 | 2002-03-25 | 住友電気工業株式会社 | Method and apparatus for winding linear body |
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