CN113484357A - Cable quality visual detection method and system based on raw material shrinkage coefficient - Google Patents
Cable quality visual detection method and system based on raw material shrinkage coefficient Download PDFInfo
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Abstract
The invention relates to a cable quality visual detection method and a system based on a raw material shrinkage coefficient, wherein the method comprises the following steps: an X-ray real-time imaging system is arranged in the three-layer co-extrusion device for the insulated wire cores; when the insulated wire core three-layer co-extrusion device is used for producing a power cable, scanning a section image of the power cable through an X-ray real-time imaging system, and respectively acquiring thickness change parameters of an insulating layer, a conductor shielding layer and an insulating shielding layer in the power cable, the temperature of a machine head of an extruder and the temperature of a wire core cooling section; and judging whether the standard raw material shrinkage coefficient of the power cable is met or not according to the thickness variation parameter, the temperature of the extruder head and the temperature of the wire core cooling section, and if not, alarming and feeding back. Compared with the prior art, the method has the advantages of reducing manual intervention, improving the production quality of the power cable, facilitating workers to visually see the change data of the whole power cable production process and the like.
Description
Technical Field
The invention relates to the technical field of cable quality detection, in particular to a cable quality visual detection method and system based on a raw material shrinkage coefficient.
Background
The production quality detection of the power cable generally comprises electrical property detection, mechanical property detection and insulation and sheath material property tests; the electrical property detection mainly comprises conductor direct current resistance, insulation resistance, finished product voltage test, voltage test between insulated wire cores and the like; the mechanical property detection mainly comprises the examination of the tensile strength and the elongation at break of the insulating and sheath plastic materials, including before and after aging, and also the bending test, the load core breaking test, the insulation core tearing test, the static bending test and the like of the finished flexible cable. The performance tests of the insulating and sheath materials comprise thermal weight loss, thermal shock, high-temperature pressure, low-temperature bending, low-temperature stretching, low-temperature impact, flame retardant performance and the like, and the performance of the plastic materials of the insulating and sheath is examined.
When the power cable is used, the power cable can thermally stretch along with the change of load current and the change of environmental temperature, wherein very large thermo-mechanical force is generated due to the expansion caused by heat and the contraction caused by cold of the wire core, and the larger the section of the wire core of the cable is, the larger the generated thermo-mechanical force is; meanwhile, the wire core metal sheath can generate creep deformation due to repeated circulation of expansion with heat and contraction with cold. Thermal expansion poses great threat to the operation of the power cable, can cause the displacement and the sliding of the operating cable, and even damage the cable and accessories.
Limited by the current state of the art, engineers can only be sent to the cable manufacturing site for on-site monitoring. The cable production line is usually operated all day after being started, so that a monitoring engineer is required to perform shift work, and time and labor are wasted. Meanwhile, the method sends the engineer supervision and artificial personnel to require higher professional knowledge background and stronger responsibility, and has high labor cost.
Disclosure of Invention
The invention aims to provide a method and a system for visually detecting the quality of a cable based on the shrinkage coefficient of raw materials, aiming at overcoming the defects of time and labor waste and high labor cost in the prior art.
The purpose of the invention can be realized by the following technical scheme:
a cable quality visual detection method based on a raw material shrinkage coefficient comprises the following steps:
an X-ray real-time imaging system is arranged in the three-layer co-extrusion device for the insulated wire cores; when the insulated wire core three-layer co-extrusion device is used for producing a power cable, scanning a section image of the power cable through an X-ray real-time imaging system, and respectively acquiring thickness change parameters of an insulating layer, a conductor shielding layer and an insulating shielding layer in the power cable, the temperature of a machine head of an extruder and the temperature of a wire core cooling section;
and judging whether the standard raw material shrinkage coefficient of the power cable is met or not according to the thickness change parameter, the temperature of the extruder head and the temperature of the wire core cooling section, and if not, alarming and feeding back.
Further, the specific steps of judging whether the shrinkage coefficient of the raw material meets the standard of the power cable are as follows:
and calculating the upper and lower limits of the standard data of each parameter at the next moment in real time according to the standard raw material shrinkage coefficient of the power cable, if the parameter at the next moment is within the range of the corresponding upper and lower limits of the standard data, conforming to the standard raw material shrinkage coefficient of the power cable, and if not, not conforming to the standard raw material shrinkage coefficient of the power cable.
Further, the thickness variation parameters of the insulating layer, the conductor shielding layer and the insulation shielding layer comprise:
the average thickness, the thinnest part thickness, the thickest part thickness and the insulation eccentricity of the insulation layer;
the average thickness and thinnest part thickness of the conductor shielding layer;
average thickness, thinnest thickness and wire core outer diameter of the insulation shielding layer.
Further, the visual detection method for the cable quality further comprises the following steps:
storing the thickness variation parameters collected by the X-ray real-time imaging system, the temperature of the extruder head and the temperature of the wire core cooling section in a multi-dimensional database,
slicing the data in the multidimensional database according to the actual production time, and removing non-production data;
and simulating and displaying a cross section of the power cable according to the data in the multi-dimensional database, and judging whether the power cable has the characteristics of symmetry, regularity, smoothness and the like.
Further, the visual detection method for the cable quality further comprises the following steps:
and monitoring the change process of the wrapping copper strip shielding layer, the whole cabling process and the sheath extrusion process in the cabling process by a camera, and storing.
Further, the visual detection method for the cable quality further comprises the following steps:
the partial discharge test process and the voltage withstand test process are monitored through the camera, and the cross section picture of the power cable is collected and stored.
Further, the multi-dimensional database includes a plurality of attributes, each attribute corresponding to a plurality of elements, the plurality of attributes including an insulation layer, a conductor shield layer, an insulation shield layer, an extruder head temperature, and a core cooling section temperature, the plurality of elements including an average thickness, a thinnest thickness, a thickest thickness, an insulation eccentricity, and/or a temperature.
The invention also provides a cable quality visual detection system adopting the cable quality visual detection method based on the raw material shrinkage coefficient, which comprises a network camera, an X-ray real-time imaging system, a control unit, a system database and a host server;
the network camera is arranged in a cable production line, monitors the change process of a wrapping copper strip shielding layer, the whole cabling process and the sheath extrusion process in the cabling process, and transmits data to the host server;
the X-ray real-time imaging system is arranged in the insulated wire core three-layer co-extrusion device and used for scanning a section image of the power cable and transmitting the section image to the control unit;
the control unit is used for acquiring thickness change parameters of an insulating layer, a conductor shielding layer and an insulating shielding layer in the power cable and temperature data of a head of the extruder and a wire core cooling section in the power cable according to a section image of the power cable, judging whether the standard raw material shrinkage coefficient of the power cable is met, and if the standard raw material shrinkage coefficient of the power cable is not met, performing alarm feedback; and stores the data in the system database.
Furthermore, the control unit comprises a real-time image processor, a scanning control circuit, a controller and a display screen, wherein the controller is respectively connected with the real-time image processor, the scanning control circuit and the display screen, and the real-time image processor and the scanning control circuit are both connected with the X-ray real-time imaging system;
the real-time image processor is used for preprocessing the cross-sectional image of the X-ray;
the controller is used for carrying out cable detection according to the preprocessed section image;
the scanning control circuit is used for controlling the X-ray real-time imaging system according to the instruction of the controller;
the display screen is used for outputting and displaying the detection result of the cable.
Furthermore, the network camera is connected with the host server through a wireless network, and the X-ray real-time imaging system is connected with the control unit through a wireless network.
Compared with the prior art, the invention has the following advantages:
(1) the shrinkage coefficient refers to the volume shrinkage of some objects caused by self composition change, external temperature change, self structure change and phase change, and refers to the ratio of the shrinkage rate to the shrinkage factor; the method and the device automatically identify the average thickness, the thinnest part thickness, the thickest part thickness and the insulation eccentricity in the cable production process by combining the X-ray picture of the section of the power cable, thereby judging whether the shrinkage coefficient of the raw material is met or not, carrying out alarm display and reminding on the non-conformance, reducing manual intervention in the whole process and improving the production quality of the power cable.
(2) The invention also carries out multidimensional storage, slicing processing, non-production data elimination, visual display and the like on the data, and is convenient for workers to visually see the change data of the whole power cable production process.
(3) The invention also monitors the change process of the wrapping copper strip shielding layer, the whole cabling process, the sheath extrusion process, the partial discharge test process, the voltage resistance test process and the cross section picture of the power cable in the cabling process by the camera, and the pictures are stored by the host server;
the data of a large number of cable production lines and delivery tests can be stored, and the production history data and the test history data of products can be tracked and traced; the system analyzes data, experimental data and delivery data in production, performs data trend benchmarking, finds out problems, gradually optimizes production process and improves product percent of pass.
Drawings
FIG. 1 is a flow chart of a method for visual inspection of cable quality based on shrinkage factor of raw materials according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of a cable quality visual inspection system based on a raw material shrinkage coefficient according to an embodiment of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. The components of embodiments of the present invention generally described and illustrated in the figures herein may be arranged and designed in a wide variety of different configurations.
Thus, the following detailed description of the embodiments of the present invention, presented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of selected embodiments of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that: like reference numbers and letters refer to like items in the following figures, and thus, once an item is defined in one figure, it need not be further defined and explained in subsequent figures.
Example 1
Referring to fig. 1, the present embodiment provides a method for visually inspecting cable quality based on shrinkage coefficient of raw material, including the following steps:
s1: an X-ray real-time imaging system is arranged in the three-layer co-extrusion device for the insulated wire cores; when the insulated wire core three-layer co-extrusion device is used for producing the power cable, scanning a section image of the power cable through an X-ray real-time imaging system;
s2: respectively collecting thickness variation parameters of an insulating layer, a conductor shielding layer and an insulating shielding layer in the power cable, and the temperature of a machine head of an extruder and the temperature of a wire core cooling section;
s3: judging whether the standard raw material shrinkage coefficient of the power cable is met or not according to the thickness variation parameter, the temperature of the extruder head and the temperature of the wire core cooling section, and if not, alarming and feeding back;
s4: monitoring the change process of the wrapping copper strip shielding layer, the whole cabling process and the sheath extrusion process in the cabling process through a camera, and storing;
s5: the partial discharge test process and the voltage withstand test process are monitored through the camera, and the cross section picture of the power cable is collected and stored.
The steps are described in detail below.
1.1, step S1
The monitoring of the three-layer co-extrusion device for the insulated wire core of the power cable is scanned through an X-ray real-time imaging system, and an X-ray real-time imaging detection technology is taken as a novel nondestructive detection technology and has entered the field of practical application of industrial product detection. Like other detection technologies, the X-ray real-time imaging detection technology needs a set of equipment (hardware and software) as a support to form a complete detection system, which is referred to as an X-ray real-time imaging system for short. The real-time X-ray imaging system uses an X-ray machine or an accelerator as a ray source, X-rays are attenuated after passing through an object to be detected, the X-rays are received by a ray receiving/converting device and converted into analog signals or digital signals, a detected image is directly displayed on a display screen by utilizing a semiconductor sensing technology, a computer image processing technology and an information processing technology, evaluation is carried out by utilizing a computer program, and then image data is stored on a storage medium. The X-ray real-time imaging system can be used for nondestructive detection of metal welding seams, metal or nonmetal devices.
1.2, step S2
The thickness variation parameters of the insulating layer, the conductor shielding layer and the insulating shielding layer comprise:
the average thickness, the thinnest part thickness, the thickest part thickness and the insulation eccentricity of the insulation layer;
the average thickness and thinnest part thickness of the conductor shielding layer;
average thickness, thinnest thickness and wire core outer diameter of the insulation shielding layer.
1.3, step S3
The specific steps for judging whether the shrinkage coefficient of the raw materials meets the standard of the power cable are as follows:
and calculating the upper and lower limits of the standard data of each parameter at the next moment in real time according to the standard raw material shrinkage coefficient of the power cable, if the parameter at the next moment is within the range of the corresponding upper and lower limits of the standard data, conforming to the standard raw material shrinkage coefficient of the power cable, and if not, not conforming to the standard raw material shrinkage coefficient of the power cable.
The cable quality visual inspection method further comprises the following steps:
storing the thickness variation parameters collected by the X-ray real-time imaging system, the temperature of the extruder head and the temperature of the wire core cooling section in a multi-dimensional database,
slicing the data in the multidimensional database according to the actual production time, and removing non-production data;
and simulating and displaying a cross section of the power cable according to the data in the multi-dimensional database, and judging whether the power cable has the characteristics of symmetry, regularity, smoothness and the like.
Specifically, in the present embodiment, a multidimensional information space is created according to various parameters, wherein the multidimensional information space is composed of a data set composed of n-dimensional attributes (an insulating layer, a conductor shielding layer, an insulating shielding layer, an extruder head temperature, a core cooling section temperature) and m elements (an average thickness, a thinnest part thickness, a thickest part thickness, and an insulating eccentricity); carrying out quantitative deduction and calculation on the data according to the upper and lower limits of the technical standard data; on the basis, the multidimensional data are sliced (data are separated according to actual production time, invalid alarms caused by non-production data are avoided), data are analyzed through gray level difference and graph difference, data can be observed in multiple angles and multiple sides, whether the images have the characteristics of symmetry, rules, smoothness and the like is judged, finally, the data in the large data set are represented in a graph image mode, unknown information is found by a data analysis and development tool, the alarms are prompted to the corresponding graph interface, and workers can find problems at the first time conveniently.
Referring to fig. 2, the present embodiment further provides a cable quality visual inspection system using the cable quality visual inspection method based on the raw material shrinkage coefficient, including a webcam, an X-ray real-time imaging system, a control unit, a system database, and a host server;
the network camera is arranged in a cable production line, monitors the change process of the wrapping copper strip shielding layer, the whole cabling process and the sheath extrusion process in the cabling process, and transmits data to the host server;
the X-ray real-time imaging system is arranged in the insulated wire core three-layer co-extrusion device and used for scanning the section image of the power cable and transmitting the section image to the control unit;
the control unit is used for acquiring thickness change parameters of an insulating layer, a conductor shielding layer and an insulating shielding layer in the power cable and temperature data of a head of the extruder and a core cooling section in the power cable according to a section image of the power cable, judging whether the standard raw material shrinkage coefficient of the power cable is met, and if the standard raw material shrinkage coefficient of the power cable is not met, performing alarm feedback; and stores the data in the system database.
The components are described in detail below.
2.1 control Unit
The control unit comprises a real-time image processor, a scanning control circuit, a controller and a display screen, wherein the controller is respectively connected with the real-time image processor, the scanning control circuit and the display screen, and the real-time image processor and the scanning control circuit are both connected with the X-ray real-time imaging system;
the real-time image processor is used for preprocessing the cross-sectional image of the X-ray;
the controller is used for carrying out cable detection according to the preprocessed section image;
the scanning control circuit is used for controlling the X-ray real-time imaging system according to the instruction of the controller;
the display screen is used for outputting and displaying the detection result of the cable.
2.2 real-time image processor
The real-time image processor should have image data acquisition and processing functions. The image data acquisition mode can be an image acquisition card or other digital image synthesis devices. The image acquisition resolution is not lower than 768 x 576 pixels, and the ratio of the horizontal resolution to the vertical resolution is ensured to be 4: 3; the dynamic range, i.e. the grey scale, should be no less than 256 levels.
The image acquisition card is installed in the computer and mainly used for carrying out A/D conversion, converting analog signals acquired by the imaging system into digital signals which can be recognized by the computer to form digital images. The acquisition resolution of a common image acquisition card is mostly 768 × 576 pixels, the dynamic range is 8 bit-256 gray scale, with the development of the technology, the current high-resolution image acquisition resolution can reach 1K × 1K, and the dynamic range can reach 12 bit-4096 gray scale.
The image processing software has the basic functions of noise reduction, brightness contrast enhancement, edge enhancement and the like. The image processing software can adapt to the technical standard specified by a corresponding detection product and has the functions of image geometric dimension calibration and measurement and defect positioning; the error between the position of the defect calibrated in the detected image and the actual position is less than or equal to 2mm, and the measurement precision of a single defect is +/-0.5 mm.
The image processing software basically needs two types, one is control software, and the function of the control software is to send commands through a data bus to control the imaging system, wherein the commands comprise workpiece action instructions, calibration of the imaging device, image obtaining from an acquisition card, image plane size calibration, image real-time acquisition, synchronous processing of images, image storage and the like. According to the video technology theory, the image acquisition speed of 25 frames/second is regarded as real-time imaging. If the workpiece is only generally checked, instructions such as image acquisition and the like can not be used. The other is imaging software, which has the functions of displaying image on computer, evaluating the defect level based on the detected workpiece quality standard, generating workpiece detecting data base file, outputting the evaluation report and storing the detected image and the data base file in CD and other storage medium. If the acquisition resolution of the detected image is high and the dynamic range of acquisition is large, the data capacity of the image is large, therefore, the imaging software also has a data compression function, and since the detected image is important technical material, lossless compression is adopted, and good decompression and playback reproduction functions are adopted. The expansion coefficient in the production process can be monitored in real time in an online remote manner, the system can automatically judge and warn the production condition which does not accord with the process parameters;
the data stored in the system can be remotely viewed in real time through the Internet technology or called later.
2.3 connection mode
The network camera is connected with the host server through a wireless network, and the X-ray real-time imaging system is connected with the control unit through a wireless network.
In this example. Embedding the programmed sequence into a control program of a host by using a control host of the insulated wire core three-layer co-extrusion device, and capturing the head data of the three-layer co-extrusion in real time, wherein the head data comprises the average thickness of an insulating layer, the thickness of the thinnest part, the thickness of the thickest part and the insulating eccentricity; the average thickness and the thinnest part thickness of the conductor shielding layer; the average thickness, the thinnest part thickness and the wire core outer diameter of the insulation shielding layer; the temperature of the extruder head and the temperature of the wire core cooling section; and save the data stream to the system database.
And storing the on-site video data into a system host server through a network by using a high-definition camera installed on a factory production line.
And the data and video image storage and calling system receives the data and video collected on the production line through a compiling software system and intelligently analyzes and judges the received data. And then provided to the remote user for querying and backtracking.
The embodiment is specifically applied as follows: the method is used in a medium-voltage cable production and manufacturing workshop of a certain cable plant, and realizes the monitoring and storage of various production parameters of the high-voltage cross-linking three-layer co-extrusion extruder; monitoring the copper strip shielding layer, cabling and sheath extrusion process in the power cable cabling process; and monitoring a partial discharge test and a voltage withstand test in a power cable delivery test.
Meanwhile, the system host is accessed through the Internet, the production line data of each cable product is directly accessed and called, and the monitoring personnel can judge the cable quality through vision through image curve display.
The foregoing detailed description of the preferred embodiments of the invention has been presented. It should be understood that numerous modifications and variations could be devised by those skilled in the art in light of the present teachings without departing from the inventive concepts. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should be within the scope of protection defined by the claims.
Claims (10)
1. A cable quality visual detection method based on a raw material shrinkage coefficient is characterized by comprising the following steps:
an X-ray real-time imaging system is arranged in the three-layer co-extrusion device for the insulated wire cores; when the insulated wire core three-layer co-extrusion device is used for producing a power cable, scanning a section image of the power cable through an X-ray real-time imaging system, and respectively acquiring thickness change parameters of an insulating layer, a conductor shielding layer and an insulating shielding layer in the power cable, the temperature of a machine head of an extruder and the temperature of a wire core cooling section;
and judging whether the standard raw material shrinkage coefficient of the power cable is met or not according to the thickness change parameter, the temperature of the extruder head and the temperature of the wire core cooling section, and if not, alarming and feeding back.
2. The visual inspection method for cable quality based on raw material shrinkage factor according to claim 1, wherein the determining whether the standard raw material shrinkage factor of the power cable is met is specifically as follows:
and calculating the upper and lower limits of the standard data of each parameter at the next moment in real time according to the standard raw material shrinkage coefficient of the power cable, if the parameter at the next moment is within the range of the corresponding upper and lower limits of the standard data, conforming to the standard raw material shrinkage coefficient of the power cable, and if not, not conforming to the standard raw material shrinkage coefficient of the power cable.
3. The visual cable quality detection method based on the shrinkage coefficient of raw materials as claimed in claim 1, wherein the thickness variation parameters of the insulation layer, the conductor shielding layer and the insulation shielding layer comprise:
the average thickness, the thinnest part thickness, the thickest part thickness and the insulation eccentricity of the insulation layer;
the average thickness and thinnest part thickness of the conductor shielding layer;
average thickness, thinnest thickness and wire core outer diameter of the insulation shielding layer.
4. The visual cable quality detection method based on the shrinkage coefficient of raw materials as claimed in claim 1, further comprising:
storing the thickness variation parameters collected by the X-ray real-time imaging system, the temperature of the extruder head and the temperature of the wire core cooling section in a multi-dimensional database,
slicing the data in the multidimensional database according to the actual production time, and removing non-production data;
and simulating and displaying a cross section of the power cable according to the data in the multi-dimensional database, and judging whether the power cable has the characteristics of symmetry, regularity, smoothness and the like.
5. The visual cable quality detection method based on the shrinkage coefficient of raw materials as claimed in claim 1, further comprising:
and monitoring the change process of the wrapping copper strip shielding layer, the whole cabling process and the sheath extrusion process in the cabling process by a camera, and storing.
6. The visual cable quality detection method based on the shrinkage coefficient of the raw material as set forth in claim 5, wherein the visual cable quality detection method further comprises:
the partial discharge test process and the voltage withstand test process are monitored through the camera, and the cross section picture of the power cable is collected and stored.
7. The visual cable quality detection method based on the raw material shrinkage coefficient as claimed in claim 4, wherein the multidimensional database comprises a plurality of attributes, each attribute corresponding to a plurality of elements, the plurality of attributes comprising an insulation layer, a conductor shielding layer, an insulation shielding layer, an extruder head temperature and a core cooling section temperature, the plurality of elements comprising an average thickness, a thinnest thickness, a thickest thickness, an insulation eccentricity and/or a temperature.
8. A cable quality visual inspection system adopting the raw material shrinkage coefficient-based cable quality visual inspection method according to claim 1, comprising a network camera, an X-ray real-time imaging system, a control unit, a system database and a host server;
the network camera is arranged in a cable production line, monitors the change process of a wrapping copper strip shielding layer, the whole cabling process and the sheath extrusion process in the cabling process, and transmits data to the host server;
the X-ray real-time imaging system is arranged in the insulated wire core three-layer co-extrusion device and used for scanning a section image of the power cable and transmitting the section image to the control unit;
the control unit is used for acquiring thickness change parameters of an insulating layer, a conductor shielding layer and an insulating shielding layer in the power cable and temperature data of a head of the extruder and a wire core cooling section in the power cable according to a section image of the power cable, judging whether the standard raw material shrinkage coefficient of the power cable is met, and if the standard raw material shrinkage coefficient of the power cable is not met, performing alarm feedback; and stores the data in the system database.
9. The system of claim 8, wherein the control unit comprises a real-time image processor, a scanning control circuit, a controller and a display screen, the controller is respectively connected with the real-time image processor, the scanning control circuit and the display screen, and the real-time image processor and the scanning control circuit are both connected with the X-ray real-time imaging system;
the real-time image processor is used for preprocessing the cross-sectional image of the X-ray;
the controller is used for carrying out cable detection according to the preprocessed section image;
the scanning control circuit is used for controlling the X-ray real-time imaging system according to the instruction of the controller;
the display screen is used for outputting and displaying the detection result of the cable.
10. The system of claim 8, wherein the webcam is connected to the host server through a wireless network, and the X-ray real-time imaging system is connected to the control unit through a wireless network.
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