JPH0382906A - Detection of disturbance in aligned winding - Google Patents

Abstract

PURPOSE:To make it possible to detect the occurrence of disturbance in winding automatically, quickly and highly accurately by projecting the light from a light source, and performing judgment based on the pitch of the intensity of the detected signal of the reflected light which is detected with a one- dimensional image sensor. CONSTITUTION:Light is projected from a light projecting member 17 on a wire 20 around a winding frame 4. The reflected light from the wire 20 is condensed through a condenser lens 16. The light is inputted into an image sensor 21. Then, the sensor 21 detects the intensity of the reflected light. At this time, the reflected light from the center of the coil of the wire 20 is intense. The light reflected from the boundary (valley part) between the neighboring coils is weak. Therefore, in the output signal from the sensor 21, the intense and weak pattern having the same number of pulses as the number of the coils appears at the same pitch as the arranging pitch P of the coils of the wire 20. When the coils of the wire 20 are in close contact, the pitch P of the coil is approximately equal to the diameter D of the coil. When the interval of the coils is opened, the interval between the pulses of the output signals from the sensor 21 is opened.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention is an alignment method for detecting irregular winding of wire when it occurs in the winding process of winding welding wire, etc. onto a winding frame in an aligned state. This invention relates to a winding disorder detection method.

[Prior Art] When manufacturing welding wires such as flux-cored wires and solid wires, the wires that have undergone processes such as flux filling are wound in an aligned state around a spool-like winding frame to become a product. In this case, the wire is fed to the core (winding drum) of the winding frame, which is rotationally driven by a motor, while moving its feeding point in the width direction of the winding frame, and is deposited in layers on the core of the winding frame. It is lined up and wound.

[Problems to be Solved by the Invention] However, due to disturbances in the rotational drive of the motor or disturbances in the movement of the wire supply position, winding disturbances may occur in the wire wound around the winding frame. . However, in the past, no equipment was installed to automatically detect when this winding disorder occurred, so workers had to visually monitor the winding condition, making the work extremely complicated. there were. In addition, it is difficult to quickly detect winding irregularities, and there are problems such as a delay in detecting winding irregularities resulting in the need to rewind.

The present invention has been made in view of such problems, and includes:
It is an object of the present invention to provide an aligned winding disorder detection method that can automatically detect winding disorder of a wire and can quickly and accurately detect the occurrence of winding disorder.

[Means for Solving the Problems] A method for detecting disorder in aligned winding according to the present invention is a method for detecting disorder in winding when wire is wound in an aligned manner around a winding frame. A one-dimensional image sensor that converts the intensity of light incident on a pixel into an electrical signal, and a one-dimensional image sensor that irradiates the light from the light source onto a wire wound around a winding frame, and transmits the light reflected from the wire onto the winding frame. A light guiding means for causing light to enter each pixel of the image sensor in correspondence with the width direction, and a determining means for determining winding irregularity by comparing a pitch at which intensity appears based on an output signal of the image sensor with a reference pitch. It is characterized by having.

[Operation] In the present invention, the wire is irradiated with light from a light source, the reflected light is detected by a one-dimensional image sensor, and winding irregularities are detected based on the pitch of the strength and weakness of the detection signal of the image sensor. .

That is, the wires wound around the winding frame are arranged in such a manner that the wire rings are adjacent to each other in the width direction of the winding frame. When this train of wires is irradiated with light, a strong reflected light is obtained at the center 5- of each wire, and a weak reflected light is obtained at the boundaries between the wires.

Therefore, when this reflected light is detected continuously in the width direction of the winding frame by a one-dimensional image sensor, the output signal will alternately show continuous parts and weak parts in one scan of the image sensor.

The pitch of the intensity of this output signal has an interval determined by the arrangement pitch of the train wheel train. Therefore, based on the intensity pitch of the output signal of this image sensor, it is possible to detect the alignment state of the wire wound around the winding frame and to detect the winding irregularity.

[Example code] Examples of the present invention will be specifically described below.

FIG. 1 is a front view showing an apparatus used in an embodiment method of the present invention. In the wire winding machine 1, a pair of bearings 3a, 3b are installed upright on a stand 2, and a winding frame (spool) 4 is placed between the bearings 3a, 3b with its center axis horizontal. supported. This winding frame 4 is rotatably supported by bearings 3a and 3b with its central axis as a rotation axis.

-〇- This winding frame 4 is rotationally driven by a motor 5 connected to a bearing 3b. Also, in one bearing 3b, a winding frame 4 is provided.
A rotation detector 6 is installed to detect the number of rotations.

A support 7 is erected on the side of the winder 1, and a light source 18 such as a lamp is installed at the head of the support 7. Further, an air cylinder 8 is installed at the upper part of the support column 7 with its piston 9 horizontal. A camera elevating device 10 is attached to the tip of the piston 9.

The camera elevating device 10 includes a support member 11 fixed to the tip of a piston 9 with its longitudinal direction vertical, and an insert pin rotatably attached to both longitudinal ends of the support member 11, that is, the upper and lower ends. 12. This insert pin 12 is installed with its longitudinal direction vertical, and the support member 11
It is rotated by a predetermined angle by a stepping motor 13 installed at the upper end. An elevating member 14 having a screw hole is disposed on the insert pin 12 by screwing the screw hole into the insert pin 12.

This elevating member 14 slides on a guide (not shown) extending parallel to the longitudinal direction of the support member 11, and is restrained from rotating by this guide. Therefore, when the insert pin 12 rotates due to the rotation of the stepping motor 3, the elevating member 14 moves up or down depending on the direction of rotation of the insert pin 12.

A camera 15 is attached to the elevating member 14 with its light detection direction facing vertically downward. A lens 16 is disposed below the camera 15, and the lens 6 condenses incident light and guides it to the camera 15.

Further, a light projecting member 17 is attached to the lower end of the lens 16, and this light projecting member 17 is connected to a light source 18 installed at the head of the support column 7 by an optical fiber 19. Thereby, the light emitted from the light source 18 is given to the light projecting member 17 via the optical fiber cable 19, and the wire 20 wound from the light projecting member 17 to the winding frame 4 below.
The beam is irradiated with an appropriate spread toward the target area.

The camera 15 is provided with a -dimensional image sensor (not shown), and receives reflected light from the light projection member 17 reflected by the wire 20 of the winding frame 4. This image sensor detects reflected light from the wire 20 in correspondence with the width direction of the winding frame 4. That is,
This one-dimensional image sensor is configured such that each pixel arranged in one direction can receive reflected light from each ring of the wire 20 arranged in the width direction of the winding frame 4 over the entire width of the winding frame 4. The image sensor photoelectrically converts the received light and outputs it as an electrical signal having an intensity corresponding to the intensity of the received light.

The output signal of this image sensor is input to an arithmetic unit (not shown) and is used to determine whether the windings are in alignment or not.

Next, the principle for determining winding disorder of the wire 20 in the present invention will be explained.

As shown in FIG. 2, wire loops of wires 20 are arranged in close contact with each other in the width direction of the winding frame 4, and light is projected onto the wires 20 on the winding frame 4. Light is irradiated from the member 17, and the reflected light from the wire 2o is collected by the condensing lens 16 and sent to the image sensor 21.
When the reflected light is incident on the winding frame 4, the image sensor 21 detects the intensity of the reflected light in correspondence with the width direction of the winding frame 4. In this case, the light reflected from the center of the wire loop of the wire 20 is strong, and the light reflected from the boundary (trough) between adjacent wire loops is weak. Therefore, the output signal of the image sensor 21 has the same number of pulses as the number of coils at the same pitch as the arrangement pitch P of the coils of the wire 20, as its voltage characteristic is shown in the graph of FIG. A pattern of strength and weakness emerges.

In addition, the pitch P of this wire is approximately equal to the diameter of the wires of the wire 20 when they are in close contact with each other, and when the wires are spaced apart, the pitch P of the output signal of the image sensor 2 is approximately equal to the diameter of the wires. The spacing will be widened as well. As shown in FIG. 2, when the wire rings are regularly aligned, the output signal of the image sensor 21 also has pulses appearing at equal intervals.

As shown in FIGS. 3(a) to 3(C), in the process of winding the wire 20 around the winding frame 4, the winding position of the wire 20 with respect to the winding frame 4 is indicated by the arrow 10- When moved as shown, when the wire 20 is wound in the first layer, output signal pulses are obtained at a constant pitch according to the number of turns [Fig. 3(a)].

However, as shown in FIG. 3(b), the wire 20
Immediately after the coil moves to the second layer, a pulse based on the light reflected from the coil at the tip position (winding position) and a coil from the first layer adjacent to the coil at the tip position are generated. The pulses based on the reflected light have a pitch interval of approximately 1/2P. Pulses in other parts appear at a pitch of P.

Further, as shown in FIG. 3(C), just before the wire of the wire 20 moves to the third layer, reflected light is emitted from the wire of the first layer adjacent to the wire at the winding position at the tip. is blocked by the upper layer of the coil and does not enter the image sensor 21, so the output signal of the image sensor 21 is about 3 at the tip of the coil.
/2P pitch.

In this way, when the wires 20 are wound in an aligned state, the pulse interval of the output signal 11- of the image sensor 21 is normally P, and depending on the winding position, the interval is 1/2P or 1/2P or One pulse with a pitch of 3/2P appears over the entire width of the winding frame 4.

However, if a winding disorder such as skipping or rolling occurs, the output signal of the image sensor 21 will be 1/1 at the winding position, as shown in FIG. 4 (,a) or (b). In addition to 2P or 3/2P pitch pulses, 1/2P or 3/2P pitch pulses are also generated at winding disturbance positions.
A pulse with a pitch of . Therefore, when winding disorder exists, a signal having a total of three characteristics (a signal in which the pitch between adjacent pulses is not P) is detected. Therefore, if the pitch P of the output signal when the wire is tightly wound is determined in advance and set as a reference value, if winding disorder occurs, the entire width of the winding frame 4 will be used to generate the output signal. There will be three or more pulses that deviate from the reference pitch.

Furthermore, as shown in FIGS. 5(a) and 5(b), if a single loop skips at the end of the winding frame 4, there is no pulse in the output signal at the skipped position. . Therefore, 1/2P or 3/2P at the winding position.
Only one pulse appears with a pitch of , and there is only one pulse that deviates from the reference pitch, so the occurrence of winding disturbance cannot be detected from the number of pulses that deviate from the reference pitch. However, if skipping occurs at the ends of the winding frame 4 in the width direction, the number of pulses detected across the entire width of the winding frame 4 will be greater than the number of pulses detected when the winding is done in an aligned state. 1 or 2 less than the number of pulses. Therefore, by using the number of pulses detected over the entire width of the winding frame 4 to determine winding irregularities, it is also possible to detect winding irregularities that occur particularly at the ends of the winding frame 4 as described above.

Furthermore, if there is a slight gap 23 between adjacent coils as shown in FIG. 6, although it is not a winding disorder, the reflected light from the coils of the previous layer is detected through this gap 23. be done.

Therefore, the pulse pitch of the output signal is approximately 1 in this part.
/2P, and three or more pulses with a pitch other than P will appear as in the case where winding disorder occurs. However, the detection signal of the light reflected from this small gap has an extremely narrow width, as shown in Figure 6, and is markedly different from the detection signal of the light reflected from other wire rings. Therefore, the detection signal of the light reflected from this gap can be electrically distinguished from other signals. Therefore, even if the gap 23 exists in this way, it will not be mistaken as winding disorder.

The present invention determines winding irregularity from the detection signal of the image sensor 21 based on the above-mentioned principle.

Next, the embodiment method of the present invention using the above-mentioned device will be explained in detail with reference to FIG. 7 showing the processing flow of the arithmetic device and FIG. 8 showing the timing chart of the output signal of the image sensor 21. explain.

First, the empty winding frame 4 is mounted on the bearings 3a, 31), and the air cylinder 8 is operated to advance its piston 9.
A camera 15 is positioned directly above the winding frame 4. Then, the stepping motor 13 is operated to adjust the vertical position of the camera 15 to a position such that the entire width of the reel 4 is focused by the lens 16 and detected by the image sensor 14- within the camera 15.

Note that, of course, in order to input a sharp image to the image sensor, it is necessary to install the image sensor at the focal position of the lens 16.

Next, the wire 20 is wound around one end of the winding frame 4, and the winding starts υN. Then, the scan start signal of the image sensor 21 (see FIG. 8) is input to the control device that controls the drive of the image sensor, and is also input to the arithmetic device.

In addition to the output signal of the image sensor, the arithmetic device also receives a clock and a start signal that instructs the image sensor to start scanning.

Then, this calculation device determines whether (1) there are three or more pitches that deviate from the standard pitch in the entire width of the winding frame 4, or (2)
If the number of pulses over the entire width of the winding frame 4 is two or more fewer than the number of wire wheels that are wound in alignment across the entire width of the winding frame 4 (standard number of winding wheels), winding irregularity occurs. It is determined that this has occurred. That is, as shown in FIG. 8, when the arithmetic unit inputs a scan start signal of the image sensor 21, a signal having a pulse corresponding to each wire is input as an output signal of the image sensor 21. In the arithmetic unit, a threshold is provided for the output signal of the image sensor, and this threshold causes the output signal of the image sensor to
Valued. That is, a binarized signal is obtained in which the portion where the reflected light is bright becomes a high signal and the portion where the reflected light is dark becomes a low signal. Then, the rising and falling edges of the pulse are detected from this binary signal to obtain an edge signal. This edge signal is input to the counter of the arithmetic unit, the clock between the edges is counted, and the counted value of the bright part, the counted value of the dark part, and the total thereof are stored.

Furthermore, after the start of scanning, the number of times the binarized signal becomes high, ie, the number of bright parts, is stored. Then, as shown in FIG. 7, the arithmetic device first determines whether the count value of the bright area (2 in the case of FIG. 8) is greater than or equal to the reference value (step 81).

If the count value in this bright area is smaller than the basic value, the width of the pulse of the output signal of the image sensor is small, so this pulse has been reflected from the previous layer through the gap 23 shown in Figure 6. Yes, and will not be taken into account when counting the number of wires later. On the other hand, if the count value of the bright area is less than the reference value, this pulse is reflected from the wire ring to be detected, so the number of pulses is then integrated (step S2).
. This integrated value indicates the number of coils existing in the entire width direction of the winding frame 4 after one scan of the image sensor is completed.

Next, the arithmetic device determines whether the clock count value is within a predetermined range of the reference value for one pulse, that is, for one bright area and the following dark area (step S3).

For example, in Figure 8, the clock count value in the bright area is 2.
, the clock count value for the dark part is 8, so the clock count value for one pulse is 10. Then, the reference value is the number of clocks corresponding to the pitch P, and if the clock count value is within a predetermined range of the number of clocks corresponding to the pitch P, the process moves to step S5. On the other hand, if the clock count values of the bright and dark areas do not fall within the predetermined range 17-, the pitch of this pulse is not P but 1/2P or 3/2P, and therefore it is determined that the pitch is an deviant pitch. and integrates the number (step S4).

After performing this work for one scan of the image sensor (step S5), it is determined whether the integrated value of the number of wire wheels is less than or equal to a value obtained by subtracting 2 from a predetermined reference value (step S6). In this case, the reference value is the number of wires obtained when the wire 20 is wound tightly around the winding frame 4, that is, in an aligned state, and the integrated value of the number of wires is less than or equal to this (reference value - 2). If this is the case, skipping has occurred at the end of the winding frame 4, so it is determined that the winding is disordered. On the other hand, if the integrated value of the number of coils is larger than (reference value - 2), skipping has not occurred at the end of the winding frame 4, so the process moves to step S6.

In step 6, it is determined whether the integrated value of deviation pitches is 3 or more.

If the integrated value of the deviation pitch is 3 or more, it is determined that winding is disordered because skipping or rolling has occurred in areas other than the ends of the winding frame 4.

8. On the other hand, if the cumulative value of this deviation pitch is less than 3,
At the winding position, only a pulse is generated at a pitch other than the standard pitch P, and there is no winding disorder.
It is determined that the state is aligned.

In this way, it is determined whether winding disorder has occurred (alignment state) for each scan of the image sensor. Therefore, if winding disorder occurs during the winding operation of the wire 20, this can be detected extremely quickly and with high precision.

As shown in FIG. 9(a), if the distance between the surface of the wire 20 and the lens 16 when the image of the wire 20 is formed on the image sensor 21 is d, then the layer of the wire 20 is When the layer is increased by one layer, the distance between the lens t6 and the surface of the wire 20 is 1.
/−r/2D decreases. In this case, the magnification of the image formed on the image sensor changes and the focus shifts, making it impossible to obtain a clear image. Therefore, Fig. 9 (
As shown in b), in order to always maintain a constant distance d between the lens 16 and the surface of the wire 20,
image sensor 21 and lens 1 each time transfers to the next layer.
6 is preferably moved by a predetermined amount. This is based on the detection result of the reel rotation detector 6.
3 should be rotated. That is, the number of coils that can be wrapped around the entire width of the winding frame 4 is usually determined by the width of the winding frame 4 and the diameter of the wire 20, and is constant for each layer. Therefore, by detecting the amount of rotation of the winding frame 4 by the rotation speed detector 6, it can be recognized that the wire 20 has transferred to the next layer. Therefore, when it is detected that the wire 20 has moved to the next layer based on the detection result of the detector 6, the stepping motor 13 is rotated by a predetermined angle to raise the camera 15, the lens 16, etc. by a predetermined distance, and the lens 16 is moved up by a predetermined distance. and the surface of the wire 20 is kept constant.

In addition, as mentioned above, the light reflected from the gap between the wire rings is detected as an extremely narrow pulse signal, so
By counting the pulse intervals (step Sl), such signals can be excluded from the winding disturbance determination. However, as shown in FIG. 10(a), even if the coils are tightly wound, the intensity of the reflected light may vary depending on the surface condition of the coils. and,
If the intensity of the reflected light is weak, the pulse corresponding to the ring will have a narrow width. Furthermore, as shown in FIG. 10(b), light that is primarily reflected by a specific wire ring may be secondarily reflected by an adjacent wire ring and then enters the image sensor. In this case, a signal with an extremely narrow width is generated near the light signal reflected at the center of the wire ring. Therefore, in order to exclude these exceptional signals from the calculation of the pulse pitch, it is preferable to convert the output signal of the image sensor into a pattern in which these narrow pulses do not exist according to a predetermined standard.

In addition, as shown in FIG. 11, the field of view 2 of the image sensor
4 may include an inflection point where the wire 20 intersects on the bobbin. At this inflection point, the amount of movement of the wire in the width direction of the winding frame increases as the winding frame rotates. For this reason, if the time required for one scan of the image sensor21- is increased, or if the rotation speed of the reel is fast, the amount of movement during the photoelectric accumulation time in the image sensor increases, resulting in a signal with unclear contrast between light and dark. Become. Therefore, the signal pitch and the number of signals may not be detected accurately, and it may be determined that winding disorder has occurred even though winding disorder has not occurred.

Therefore, as in this example, if there are three or more pitches that deviate from the standard pitch, or if the number of pulses in the entire width of the winding frame is smaller than the standard pulse number when the coils are arranged in close contact, If there are two or more wheels, it is determined that winding disorder has occurred, but this determination of winding disorder is not made when the condition ■ or ■ appears once, but when the condition ■ or ■ appears multiple times. By performing this when the winding disorder occurs continuously, it is possible to prevent erroneous detection of winding disorder, and accurate determination becomes possible.

[Effects of the Invention] As explained above, according to the present invention, winding irregularities of welding wire, etc. are determined based on the output signal of the image sensor, so that the wire winding operation can be carried out quickly and at high speed. The occurrence of winding disturbance can be detected with high accuracy.

[Brief explanation of drawings]

FIG. 1 is a front view showing a device used in an embodiment method of the present invention, FIG. 2 is a diagram illustrating the winding disorder detection principle of the present invention,
Figures 3 (a) to (c) are diagrams explaining the winding disturbance detection principle, Figures 4 (a) and (b) are diagrams showing the behavior of pulses when winding irregularity occurs, and Figure 5 ( a) and (b) are also diagrams showing the behavior of the pulse when winding disturbance occurs, No. 6
7 is a flowchart explaining the operation of the arithmetic device of this embodiment, FIG. 8 is a timing chart showing the timing of signals in the arithmetic device, and FIG. Figures (a) and (b) are diagrams showing a modification of this embodiment, Figures 10 (a) and (b) are diagrams showing modes of false recognition detection, and Figure 11 is a diagram explaining the cause of false detection. It is. 1; Winding device, 4: Winding frame, 15; Camera, 16; Lens, 17; Light projecting member, 20; Wire, 21; Image sensor □□-4 =37- Figure (a) Figure 1 Figure 10 figure

Claims (10)

[Claims] (1) In the alignment winding disorder detection method that detects winding disorder when wire is wound in an aligned manner around a winding frame, a one-dimensional method that converts the intensity of light incident on a light source and pixels arranged in a specific direction into electrical signals an image sensor; and a light guide that irradiates light from the light source onto a wire wound around a winding frame, and causes the light reflected from the wire to enter each pixel of the image sensor in correspondence with the width direction of the winding frame. and determining means for determining winding irregularity by comparing the pitch at which the intensity appears based on the output signal of the image sensor with a reference pitch. (2) The determining means counts the number of locations where the intensity pitch of the output signal of the image sensor deviates from the reference pitch, and determines that the winding is disordered when the number of deviations exceeds the reference number. The method for detecting alignment winding disturbance according to claim 1. (3) The determining means counts the number of locations where the intensity pitch of the output signal of the image sensor deviates from the reference pitch, and if the number of scans in which the number of deviations exceeds the reference number is two or more times. 2. The method for detecting alignment winding disturbance according to claim 1, wherein the winding disturbance is determined to be winding disturbance. (4) The alignment winding disturbance detection method according to claim 2 or 3, wherein the reference number is three or more. (5) The method for detecting alignment winding disturbance according to claim 1, wherein the light guiding means includes a condensing lens that condenses reflected light from the wire wound around the winding frame onto the image sensor. . (6) The alignment winding disturbance detection method according to claim 5, wherein the light source, the condenser lens, and the image sensor are fixed to each other and are integrally arranged. (7) The method for detecting alignment winding disturbance according to claim 6, characterized in that a distance between the condensing lens and the surface of the wire is maintained constant. (8) The method for detecting alignment winding disturbance according to claim 1, wherein the wire is a welding wire. (9) The method for detecting alignment winding disturbance according to claim 8, wherein the wire is a flux-cored wire for welding. (10) The method for detecting alignment winding disorder according to claim 8, wherein the wire is a Cu-plated solid wire for welding.