Metal wire doubling and breaking detection device and control method thereof

Abstract

The invention discloses a metal wire doubling and breaking detection device and a control method thereof, and the detection device is characterized in that metal wires to be detected are wound on the side wall of a reel assembly in the circumferential direction of the reel assembly, the adjacent metal wires are spaced by a first preset distance, and the reel assembly and an eddy current sensor assembly are electrically connected with a control assembly; the eddy current sensor assembly is arranged at the corresponding position of the side wall of the reel assembly, and the control assembly controls the eddy current sensor assembly to reciprocate in the axial direction of the reel assembly. When the eddy current sensor assembly moves in the axial direction of the reel assembly, voltage detection signals of the two adjacent detection positions are obtained and subjected to differential operation, voltage difference value signals are obtained, and if the voltage difference value signals deviate from the preset voltage value range, it is judged that the metal wires wound around the reel assembly are doubled or broken. By constructing a high-precision defect recognition mechanism, common-mode noise such as reel rotation vibration and environmental electromagnetic interference is effectively filtered based on spatial position differential operation, and the defect recognition accuracy is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of eddy current sensor detection, and in particular to a metal wire parallel and disconnection detection device and a control method thereof. Background Art

[0002] In the industrial production of metal wire, wire jaggedness and breakage are key defects affecting product quality. Current mainstream inspection technologies include optical inspection, contact mechanical inspection, and single-point eddy current testing. While optical inspection enables non-contact inspection by scanning the surface topography with a camera or laser, the highly reflective nature of metal wire can easily lead to image noise. This is particularly true when inspecting micron-sized wires (e.g., 55μm diameter), where sensitivity to even small variations in the spacing of adjacent wires, as small as 0.3mm, is insufficient, making it difficult to distinguish between wire breakage (partial loss) and jaggedness (overlapping wires). Contact inspection relies on mechanical feedback to detect defects, using a probe or roller to contact the wire surface. However, mechanical friction can damage the wire surface and makes it difficult to adapt to the real-time requirements of high-speed continuous production. While single-point eddy current testing avoids contact issues, its single sensor design is susceptible to environmental interference such as temperature drift and mechanical vibration, leading to signal drift or fluctuation, making it difficult to reliably capture subtle changes in sparsity. Furthermore, existing methods generally lack the ability to accurately distinguish between broken and doubled wires. They typically rely on a single threshold to identify anomalies and are unable to dynamically adjust the criteria based on defect type (increase or decrease in sparsity), resulting in a high rate of false positives. Regarding detection coverage, traditional technologies often use fixed sensors or unidirectional scanning, which cannot achieve full coverage of the reel's circumference and axial direction. Frequent equipment adjustments or manual intervention are required, resulting in low efficiency. These issues severely restrict the demand for defect detection in high-precision, automated production scenarios. A non-contact detection solution with high sensitivity, strong anti-interference capabilities, and the ability to distinguish between multiple defect types is urgently needed. Summary of the Invention

[0003] The purpose of the embodiments of the present invention is to provide a metal wire parallel and break detection device and a control method thereof. By constructing a high-precision defect recognition mechanism and differential operations based on spatial position relationships, common mode noise such as reel rotation vibration and environmental electromagnetic interference can be effectively filtered out, and only differential mode signals caused by changes in metal wire spacing are retained, greatly improving the accuracy of defect recognition.

[0004] To solve the above technical problems, a first aspect of an embodiment of the present invention provides a metal wire paralleling and disconnection detection device, comprising: a reel assembly, an eddy current sensor assembly, and a control assembly; The side wall of the reel assembly is wound with metal wires to be detected along its circumference, and adjacent metal wires are spaced apart by a first preset distance. The reel assembly and the eddy current sensor assembly are electrically connected to the control assembly. The eddy current sensor assembly is arranged at a corresponding position on the side wall of the reel assembly, and the control assembly controls the eddy current sensor assembly to reciprocate along the axial direction of the reel assembly; When the eddy current sensor assembly moves axially along the reel assembly, it respectively obtains the voltage detection signals of two adjacent detection positions and performs differential operation to obtain a voltage difference signal. If the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire wound on the reel assembly is parallel or broken.

[0005] Furthermore, if the voltage difference signal deviates from a preset voltage value range, it is determined that the metal wire wound on the reel assembly is parallel or broken, including: When the difference is greater than the upper limit of the preset voltage value range, it is determined that the metal wires at the corresponding positions of the reel assembly and the eddy current sensor assembly are parallel; When the difference is less than the lower limit of the preset voltage value range, it is determined that the metal wires at corresponding positions of the reel assembly and the eddy current sensor assembly are broken.

[0006] Furthermore, when the difference is less than the lower limit of the preset voltage value range and the original output signal of the eddy current sensor assembly at the current position is lower than the calibrated minimum effective value, it is determined that the metal wire (21) at the corresponding position of the reel assembly and the eddy current sensor assembly is broken.

[0007] Furthermore, the eddy current sensor comprises: an eddy current sensor unit, a guide rail, a sensor bracket and a reciprocating drive unit; The eddy current sensor unit is disposed at one end of the sensor bracket and is spaced apart from the side wall of the reel assembly by a second preset distance; The reciprocating drive unit is electrically connected to the control assembly and drives the other end of the sensor bracket to reciprocate along the guide rail under the control of the control assembly; The guide rail is arranged parallel to the axial direction of the reel assembly.

[0008] Further, the eddy current sensor unit includes a first eddy current sensor unit and a second eddy current sensor unit; The first eddy current sensor unit and the second eddy current sensor unit are arranged axially apart from each other along the reel assembly; The first eddy current sensor unit and the second eddy current sensor unit are electrically connected to the control component respectively, and the first eddy current sensor unit and the second eddy current sensor unit respectively obtain voltage detection signals of two adjacent detection positions and send them to the control component; The control component performs a differential operation based on the voltage detection signals of the two detection positions to obtain the voltage difference signal.

[0009] Furthermore, a spacing distance between the first eddy current sensor unit and the second eddy current sensor unit along the axial direction of the reel assembly is the same as a distance between two adjacent detection positions on the reel assembly.

[0010] Furthermore, under the control of the control assembly, the reciprocating drive unit drives the sensor bracket to move along the guide rail in a single movement distance that is the same as the distance between two adjacent metal wires on the reel assembly.

[0011] Furthermore, the reel assembly comprises: a reel wound with a metal wire, a reel support and a rotation drive unit; The rotation drive unit is electrically connected to the control assembly, and both ends of the reel are rotationally connected to the reel bracket; The rotation driving unit drives the reel to rotate along its own axial direction under the control of the control component.

[0012] Furthermore, the metal wire parallel and disconnection detection device further comprises: a base; The eddy current sensor assembly and the reel assembly are both fixed on the base and are spaced apart by a second preset distance.

[0013] Accordingly, a second aspect of an embodiment of the present invention provides a method for controlling a metal wire parallel and break detection device, which performs parallel and break detection on metal wires on a reel assembly based on the metal wire parallel and break detection device, comprising the following steps: Step S100: Controlling the eddy current sensor assembly to move successively along the axial direction of the reel assembly from one end to the other end according to a first preset distance, acquiring voltage detection signals at corresponding detection positions and performing differential operations to obtain voltage difference signals, comparing the voltage difference signals with a preset voltage value range, and determining whether the metal wires at corresponding positions of the reel assembly are broken or parallel; In step S200, the reel assembly is controlled to rotate successively according to a preset angle value, and step S100 is repeated after each rotation to determine whether the metal wire at the corresponding position after the reel assembly rotates is broken or parallel, until the reel assembly completes one rotation.

[0014] The above technical solutions of the embodiments of the present invention have the following beneficial technical effects: 1. The use of a differential eddy current sensor assembly significantly improves the sensitivity and anti-interference capability of metal wire defect detection through the symmetrical arrangement of dual sensor units and differential signal processing technology. Traditional single-point sensors are susceptible to interference from environmental noise, but differential measurement effectively offsets common-mode interference through real-time differential calculations, while also amplifying effective signal differences caused by variations in metal wire sparsity. Combined with preset positive and negative threshold judgment logic, it can stably identify minute spacing anomalies in micron-level wires under complex working conditions. Detection accuracy and stability are significantly improved compared to traditional methods, and the risk of misjudgment is significantly reduced. 2. By collaboratively controlling the axial scanning of the eddy current sensor assembly and the circumferential rotation of the reel, full coverage of the metal wire surface is achieved, eliminating the blind spot problem existing in traditional inspections. The sensor moves sequentially along the reel's axis at preset intervals while the reel rotates in steps, forming a coordinated axial and circumferential scanning path. This dynamic inspection mechanism covers the entire reel surface without manual intervention, significantly improving inspection efficiency and adapting to the needs of high-speed continuous production. In addition, real-time positioning and alarm functions reduce production interruptions caused by accumulated defects, providing reliable support for automated production lines. 3. Based on the positive and negative threshold judgment and intelligent analysis algorithm of the differential signal, it can accurately distinguish between broken and parallel wire defects. Traditional methods rely on a single threshold or subjective experience, making it difficult to distinguish the direction of sparsity changes. By presetting the voltage threshold range and combining the polarity characteristics of the differential signal, it can clearly distinguish between broken wires (abnormally increased sparsity) and parallel wires (abnormally increased density). It can also be adapted to metal wires of different materials or specifications through experimental calibration, flexibly responding to diverse detection needs, and providing a highly reliable classification basis for process optimization and quality traceability, significantly enhancing the accuracy and practicality of defect identification. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 2. It is a schematic diagram of the principle of a metal wire parallel and break detection device provided by an embodiment of the present invention; Figure 2 This is a flow chart of a control method for a metal wire parallel and break detection device provided by an embodiment of the present invention.

[0016] Reference numerals: 1. Base, 21. Metal wire, 22. Reel, 23. Reel bracket, 31. Eddy current sensor unit, 32. Guide rail, 33. Sensor bracket. DETAILED DESCRIPTION

[0017] To make the objectives, technical solutions, and advantages of the present invention more clearly understood, the present invention will be further described in detail below in conjunction with specific embodiments and with reference to the accompanying drawings. It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the present invention. In addition, in the following description, descriptions of well-known structures and technologies are omitted to avoid unnecessary confusion of the concepts of the present invention.

[0018] Please refer to Figure 1 A first aspect of an embodiment of the present invention provides a device for detecting parallel or broken wires of a metal wire, comprising: a reel assembly, an eddy current sensor assembly, and a control assembly; a metal wire 21 to be detected is wound around the side wall of the reel assembly along its circumference, and adjacent metal wires 21 are spaced apart by a first preset distance, and the reel assembly and the eddy current sensor assembly are electrically connected to the control assembly; the eddy current sensor assembly is arranged at a corresponding position on the side wall of the reel assembly, and the control assembly controls the eddy current sensor assembly to move back and forth along the axial direction of the reel assembly; when the eddy current sensor assembly moves axially along the reel assembly, it respectively obtains voltage detection signals of two adjacent detection positions and performs differential operation to obtain a voltage difference signal; if the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire 21 wound on the reel assembly is parallel or broken.

[0019] The above-mentioned metal wire parallel and broken wire detection device is constructed through a modular design to construct a detection system that integrates mechanical transmission, signal acquisition and intelligent judgment. The reel assembly serves as the carrier of the metal wire to be tested. The metal wires 21 uniformly wound around its side walls are arranged at a first preset distance to form a regular detection reference array. On the one hand, the control component drives the rotation of the reel assembly and the axial movement of the eddy current sensor assembly through electrical connection to achieve full surface coverage of the detection area. On the other hand, it receives the voltage signal collected by the sensor in real time and performs differential operations through the built-in algorithm to convert the physical level spacing changes into quantifiable electrical signal differences. The reciprocating accuracy of the eddy current sensor assembly along the axial direction of the reel 22 directly affects the detection resolution. By coordinating with the control component, it ensures that the step size of each movement is consistent with the spacing between adjacent metal wires, so that the sensor can be accurately aligned with each group of adjacent detection positions to avoid missed detection or repeated detection.

[0020] By constructing a mapping relationship between "spatial position and electrical signal characteristics": when the metal wires 21 are arranged normally, the eddy current signals at adjacent detection positions produce a stable voltage difference due to the same material properties and spacing, which is within a preset reasonable range; if a wire break occurs, the missing wire causes a sharp drop in the signal at the detection position on one side, and the voltage difference after differentiation exceeds the preset upper limit in the positive direction due to the missing signal on one side; if a line is paralleled, the spacing between adjacent metal wires decreases, thereby enhancing the superposition of electromagnetic induction, and the differential result negatively exceeds the preset lower limit. This detection mechanism based on differential operation has significant anti-interference ability and can filter out common-mode interference such as vibration noise and environmental electromagnetic fluctuations during the rotation of the reel 22, retaining only the effective differential-mode signal caused by the change in metal wire spacing, making defect identification highly specific.

[0021] The above-mentioned detection device breaks through the multiple limitations of traditional detection methods: First, it realizes accurate distinction between parallel lines and broken lines through differential operation, solves the problem that the existing technology cannot identify two defects at the same time, and avoids misjudgment caused by a single threshold judgment; Second, with the help of the axial movement of the sensor and the circumferential rotation of the reel 22, a spiral scanning coverage of the surface of the reel 22 is formed, which greatly improves the comprehensiveness of detection compared with fixed position detection; Third, the automatic coordination of the non-contact measurement and control components of the eddy current sensor makes it suitable for high-speed production scenarios. When the wire winding speed reaches 50m / s, it can still maintain a spacing change detection accuracy of 0.05mm, which is significantly higher than the 1mm resolution of traditional contact devices; Fourth, the real-time processing of differential operation controls the detection delay within 5ms, meeting the instant feedback needs of online production, and fundamentally improving the quality control efficiency of the metal wire 21 production process.

[0022] Furthermore, if the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire 21 wound on the reel assembly is parallel or broken, including: when the difference is greater than the upper limit of the preset voltage value range, it is determined that the metal wire 21 at the corresponding positions of the reel assembly and the eddy current sensor assembly is parallel; when the difference is less than the lower limit of the preset voltage value range, it is determined that the metal wire 21 at the corresponding positions of the reel assembly and the eddy current sensor assembly is broken.

[0023] This wire doubling and breakage detection device uses an eddy current sensor to collect voltage signals (V_A and V_B) at two adjacent detection locations (positions A and B) as it moves axially along the sidewall of a reel assembly. The sensors then perform a differential calculation (ΔV = V_A - V_B). Under normal conditions, with uniform wire spacing, V_A and V_B are similar in value, with ΔV approaching zero and falling within a preset acceptable voltage difference range. When a doubling occurs, reducing the spacing between adjacent wires, electromagnetic field coupling causes V_A and V_B to increase simultaneously, but the difference ΔV between them decreases significantly (increasing negatively), falling below the lower limit of the preset range. When a wire break occurs, resulting in a missing wire at a specific location, the signal at that location (e.g., V_B) drops sharply, causing ΔV = V_A - 0 to increase positively, exceeding the upper limit of the preset range. The preset voltage difference range [V_min, V_max] is calibrated experimentally and is determined based on the stable differential value and its allowable fluctuation range at normal uniform spacing. For example, if ΔV = 0.5V ± 0.1V at a 2mm spacing, the range is set to [0.4V, 0.6V]. An alarm is triggered when ΔV ≤ 0.3V for parallel connection and ΔV ≥ 1.0V for disconnection.

[0024] Furthermore, when the difference is less than the lower limit of the preset voltage value range and the original output signal of the eddy current sensor assembly at the current position is lower than the calibrated minimum effective value, it is determined that the metal wire 21 at the corresponding position of the reel assembly and the eddy current sensor assembly is broken.

[0025] When an eddy-current sensor probe approaches a metal wire, the alternating magnetic field generated by its excitation coil induces closed eddy currents on the wire's surface, causing the probe's impedance characteristics to change. Under normal conditions, the differential signal from the two probes reflects changes in wire displacement, showing an increasing and decreasing pattern. However, if the wire breaks, the loss of the conductor causes the eddy current effects of both probes to decay simultaneously, and the differential signal approaches zero (below the preset lower limit). Simultaneously, the original output signal from a single probe drops to background noise levels due to the lack of a conductor. This dual verification mechanism, combining differential signal anomalies with original signal failures, eliminates false positives caused by environmental interference and ensures reliable wire breakage detection.

[0026] During the calibration phase, the eddy current sensor assembly is moved through a wire-free area to collect the raw output signals of a single probe at each location. Statistical analysis is then used to determine the minimum effective calibration value, which represents the critical threshold for effective measurement. During the real-time detection phase, the two channels' raw output signals and the absolute values ​​of their differential signals are simultaneously collected. A wire break is detected at the current location when both the differential signal is below the lower limit of the preset voltage range and the larger of the two channels' raw signals is still below the minimum effective calibration value. This process utilizes the physical properties of the eddy current effect to identify wire breaks, ensuring both anti-interference capabilities and measurement stability in line with the design principles of differential measurement.

[0027] The dual-condition determination mechanism in this implementation prevents a single signal from being affected by electromagnetic noise or probe anomalies, synergistically enhancing the anti-interference design of differential measurement. The minimum effective value is calibrated based on actual experimental data, without the introduction of external parameters. The wire break determination is based entirely on the physical principle that the absence of a metal conductor causes the eddy current effect to disappear.

[0028] In a specific embodiment of an embodiment of the present invention, the eddy current sensor includes: an eddy current sensor unit 31, a guide rail 32, a sensor bracket 33 and a reciprocating drive unit; the eddy current sensor unit 31 is arranged at one end of the sensor bracket 33 and is spaced from the side wall of the reel assembly by a second preset distance; the reciprocating drive unit is electrically connected to the control component, and drives the other end of the sensor bracket 33 to move back and forth along the guide rail 32 under the control of the control component; the guide rail 32 is arranged parallel to the axial direction of the reel assembly.

[0029] The eddy current sensor includes a transmission mechanism consisting of a guide rail 32, a sensor bracket 33, and a reciprocating drive unit. The guide rail 32 is laid parallel to the axis of the reel 22, providing high-precision guidance for the movement of the sensor bracket 33, ensuring that the sensor unit always maintains a constant second preset distance from the side wall of the reel 22 during the detection process, usually 5-10mm. This distance not only meets the optimal sensing range of the eddy current sensor to avoid saturation caused by being too close or signal attenuation caused by being too far, but also reserves a safe space for radial runout when the reel 22 rotates. The sensor bracket 33 is made of rigid aluminum alloy. One end fixes the eddy current sensor unit 31, and the other end is connected to a reciprocating drive unit such as a servo motor or a screw nut mechanism. It is driven by a pulse signal from the control component to achieve micron-level precision movement and positioning error ≤±5μm along the guide rail 32, ensuring that the trajectory of the sensor during axial movement is strictly parallel to the axis of the reel 22, avoiding detection deviation caused by tilt.

[0030] The electrical connection between the reciprocating drive unit and the control assembly enables fully automated control of the inspection process. When the control assembly issues a movement command, the drive unit drives the sensor bracket 33 to reciprocate along the guide rail 32 at a constant speed, such as 20 mm / s. The distance of each movement exactly matches the spacing between adjacent wires on the spool 22, i.e., the first predetermined distance. This allows the sensor unit to sequentially align with each group of adjacent inspection positions, ensuring that no scans are missed. This linear reciprocating motion, combined with the circumferential rotation of the spool 22, forms a spiral inspection path that covers the entire surface area of ​​the spool 22's sidewall. Compared with traditional fixed sensors or manually adjusted detection devices, the above structural design significantly improves the detection coverage and positioning accuracy. When the length of the reel 22 reaches 500mm, it can still achieve dense sampling at an interval of 0.1mm. Combined with the high-frequency signal acquisition of the eddy current sensor unit 31, such as a 10kHz sampling rate, the device can capture the subtle spacing changes of the metal wire in real time when the reel 22 rotates at 1500rpm in high-speed production scenarios, providing stable and reliable original signals for differential operations, thereby ensuring the accuracy and comprehensiveness of defect detection from the hardware level.

[0031] Furthermore, the eddy current sensor unit 31 includes a first eddy current sensor unit and a second eddy current sensor unit; the first eddy current sensor unit and the second eddy current sensor unit are arranged axially at intervals along the reel assembly; the first eddy current sensor unit and the second eddy current sensor unit are electrically connected to the control assembly respectively, and the first eddy current sensor unit and the second eddy current sensor unit respectively obtain the voltage detection signals of two adjacent detection positions and send them to the control assembly; the control assembly performs differential operation based on the voltage detection signals of the two detection positions to obtain a voltage difference signal.

[0032] The eddy current sensor unit 31 utilizes a dual-sensor parallel layout design. The first and second eddy current sensor units are spaced axially along the reel 22, with the axial spacing between the two sensor units strictly matching the first preset distance between adjacent wires 21 on the reel 22. This ensures that during detection, each sensor unit corresponds exactly to a position directly above a wire, forming a "one-to-one" detection point mapping. This spatial layout enables the dual sensors to simultaneously collect the voltage signals of two adjacent wires. When the wires are properly arranged, they produce voltage signals with similar amplitudes due to the same material, spacing, and sensing distance. In the event of a wire break or a double wire break, the position change of one or both wires is directly reflected as a difference between the two sensor signals, providing accurate raw data for subsequent differential operations. The physical spacing of the dual sensors not only avoids detection blind spots caused by positional offset of a single sensor, but also establishes a dynamic reference baseline through "adjacent comparison," allowing the signal at each detection position to be verified against the adjacent state, ensuring the reliability of signal acquisition from a hardware perspective.

[0033] The control component performs differential processing on the dual sensor signals, converting geometric changes in the spatial dimension into characteristic differences in the electrical signal dimension. After the first and second sensor units acquire voltage signals at adjacent detection locations, the control component uses a built-in algorithm to calculate the difference in real time. Under normal conditions, this difference approaches zero due to symmetrical sensing characteristics. During paralleling, the sensor signal on the side with the missing wire weakens, resulting in a positive shift in the difference. During wire breakage, the reduced spacing increases the signals on both sides, resulting in a negative shift in the difference. This dual-sensor collaborative operation offers inherent common-mode noise rejection. Interference factors such as environmental vibration and temperature drift have essentially the same impact on both sensors, which are largely offset by the differential calculation, retaining only the effective differential-mode signal caused by the wire spacing variation. Compared to traditional single-sensor solutions that rely on threshold judgment, this dual-sensor differential mechanism improves detection resolution from 1mm to 0.05mm and enhances defect detection anti-interference capabilities by over 60%. This makes it particularly suitable for real-time detection in high-speed winding conditions, such as when the reel rotates at 2000rpm, while maintaining signal stability.

[0034] Furthermore, a spacing distance between the first eddy current sensor unit and the second eddy current sensor unit along the axial direction of the reel assembly is the same as a distance between two adjacent detection positions on the reel assembly.

[0035] The axial spacing between the first eddy current sensor unit and the second eddy current sensor unit strictly matches the first preset distance between adjacent metal wires 21 on the reel 22, and a signal acquisition correspondence is established through precise alignment of spatial positions. When the spacing between the two sensor units is exactly the same as the distance between adjacent detection positions, each sensor unit just covers the detection area directly above a single metal wire, ensuring that during uniform movement, the dual sensors always synchronously collect real-time signals from the two adjacent metal wires. Under normal conditions, the two generate stable reference signals due to their symmetrical physical spacing; under abnormal conditions, such as a broken wire resulting in a single-side loss or a parallel wire resulting in a reduced spacing, the signal difference directly corresponds to the actual arrangement change of the metal wires. This precise spatial coupling design avoids signal misalignment caused by sensor spacing deviations, such as collecting signals from non-adjacent metal wires, so that the input data of the differential operation strictly reflects the true state of adjacent detection positions, eliminating detection blind spots and signal confusion problems from the hardware level. Cooperating with the control component to drive the sensor to move in steps at the same spacing along the axial direction, this layout ensures that each group of adjacent metal wires can be accurately covered by the dual sensors during the inspection process, forming a continuous and non-overlapping signal acquisition array. The spatial resolution of defect identification is completely equivalent to the preset spacing accuracy of the metal wires, fundamentally ensuring the accuracy and reliability of the inspection results.

[0036] Furthermore, under the control of the control component, the reciprocating drive unit drives the sensor bracket 33 to move along the guide rail 32 in a single movement distance that is the same as the spacing between two adjacent metal wires 21 on the reel assembly. The single movement distance of the reciprocating drive unit is strictly consistent with the spacing between adjacent metal wires 21, and seamless coverage of the detection points is achieved through precise matching of motion control accuracy. When the control component drives the sensor bracket 33 to move along the guide rail 32, the single movement distance is accurately set to the first preset distance, that is, the spacing between adjacent metal wires. This makes the eddy current sensor unit 31, after each movement, its first and second sensor units are exactly aligned with the next group of adjacent metal wire detection positions, forming a "group-by-group scanning" detection rhythm. This synchronization design avoids signal acquisition misalignment during the detection process, such as cross-group detection or missed detection, and ensures that the dual sensors always perform signal acquisition on two physically adjacent metal wires. In conjunction with the circumferential rotation of the reel assembly, this motion control mechanism enables the sensor to form an evenly spaced spiral scanning track on the surface of reel 22. This not only covers the entire sidewall inspection area, but also ensures that the signal acquisition density at each inspection position fully matches the wire arrangement density. In precision inspection scenarios with a wire pitch of 0.5mm, the drive unit can achieve a movement accuracy of ±2μm, enabling the inspection system to capture subtle defects with a pitch variation of less than 1%, such as a 0.005mm parallel offset. This lays the hardware foundation for high-precision defect detection from the motion control level. Keeping the sensor's spatial positioning error within 1 / 100 of the inspection pitch significantly improves the reliability and data consistency of the inspection results, making it particularly suitable for online, real-time inspection in high-density wire winding scenarios.

[0037] In a specific embodiment of an embodiment of the present invention, the reel assembly includes: a reel 22 wound with a metal wire 21, a reel bracket and a rotation drive unit; the rotation drive unit is electrically connected to the control component, and both ends of the reel 22 are rotationally connected to the reel bracket; the rotation drive unit drives the reel 22 to rotate along its own axis under the control of the control component.

[0038] The specific structure of the reel assembly creates a dynamic load-bearing and angle-control platform for the metal wire 21 to be tested, and the coordinated cooperation of the rotation drive unit and the control assembly achieves circumferential detection coverage. The reel 22 around which the metal wire 21 is wound is stably supported by reel brackets at both ends. The rotation drive unit, such as a servo motor or a stepper motor, is coaxially connected to the reel 22 and rotates precisely at a preset angle value, such as 1° / time, under the command of the control assembly, so that the metal wire 21 on the side wall of the reel 22 enters the detection area in sequence as it rotates circumferentially. The rotation of the reel assembly forms an orthogonal motion trajectory with the axial reciprocating movement of the eddy current sensor assembly. The sensor scans line by line along the axial direction, and the reel 22 rotates synchronously to achieve circumferential line feed, together forming a spiral full-coverage detection of the surface of the reel 22. The high-precision position control angle error of the rotation drive unit, ≤±0.1°, ensures that the sensor is aligned with the undetected wire loop after each rotation, avoiding duplicate or missed detections. Furthermore, the stable rotation speed, such as 5 rpm, matches the sensor's movement speed, allowing the eddy current sensor unit 31 to maintain a constant detection rhythm when collecting adjacent row signals, providing a time-synchronized voltage signal for differential operations. This component converts the circumferential arrangement of the wire 21 into controllable rotational motion, which, combined with the sensor's axial scanning, forms a three-dimensional detection space. This allows the device to perform blind spot detection on reels 22 of arbitrary length and diameter. This makes it particularly suitable for quality inspection of multi-layer windings or large-sized wire 21 reels, ensuring the comprehensiveness and automation of the inspection process from a mechanical transmission perspective.

[0039] In addition, the metal wire parallel and broken wire detection device further includes: a base 1; the eddy current sensor assembly and the reel assembly are both fixed on the base 1 and are spaced apart by a second preset distance.

[0040] The base 1 serves as the basic supporting structure of the device, providing a stable installation reference for the eddy current sensor assembly and the reel assembly, and ensuring the relative position accuracy of the two major components through rigid fixation. The eddy current sensor assembly and the reel assembly are usually set at a second preset distance based on the effective detection range of the sensor, such as 5-15mm intervals, fixed on the base 1, which not only ensures that the sensing distance between the eddy current sensor unit 31 and the side wall of the reel 22 is in the optimal working range, but also reserves sufficient movement space for the rotation of the reel 22 and the reciprocating movement of the sensor. The base 1 is usually made of high-strength aluminum alloy or cast iron. The flatness error of the precision-machined mounting surface is ≤0.01mm to eliminate mechanical installation deviations. Accessories such as shock-absorbing foot pads are used to reduce the interference of environmental vibration on the detection signal, so that the relative position of the sensor and the reel 22 remains stable during high-speed movement.

[0041] Accordingly, please refer to Figure 2A second aspect of an embodiment of the present invention provides a method for controlling a metal wire parallel and break detection device, wherein the method performs parallel and break detection on the metal wire 21 on the reel assembly based on the metal wire parallel and break detection device, including the following steps: Step S100, control the eddy current sensor assembly to move from one end to the other end along the axial direction of the reel assembly according to a first preset distance, respectively obtain the voltage detection signals of the corresponding detection positions and perform differential operations to obtain a voltage difference signal, compare the voltage difference signal with the preset voltage value range, and determine whether the metal wire 21 at the corresponding position of the reel assembly is broken or parallel.

[0042] A defect detection mechanism for a single layer of metal wire is constructed through axial point-by-point scanning and differential operations. The control component drives the eddy current sensor assembly to move at a constant speed along the axis of the reel 22 at a first preset distance, i.e., the distance between adjacent metal wires, so that the dual sensor units are aligned with each group of adjacent detection positions in turn, ensuring that the collected voltage signal strictly corresponds to two physically adjacent metal wires. During the movement process, the first and second eddy current sensor units synchronously acquire the voltage signals of the detection positions on both sides in real time. The control component extracts the signal difference through differential operations. When the difference is greater than the upper limit of the preset voltage value range, it is determined that the metal wire 21 at the corresponding position of the reel assembly and the eddy current sensor assembly is parallel; when the difference is less than the lower limit of the preset voltage value range, it is determined that the metal wire 21 at the corresponding position of the reel assembly and the eddy current sensor assembly is broken. This combination of successive movement and real-time calculation enables the detection system to perform high-density scanning of the single-layer surface of reel 22 with the minimum resolution of wire spacing. When the sensor movement speed reaches 100mm / s, it still maintains a signal acquisition density of every 0.5mm spacing, ensuring the accurate identification of axial defects from the detection process.

[0043] In step S200, the reel assembly is controlled to rotate successively according to a preset angle value, and step S100 is repeated after each rotation to determine whether the metal wire 21 at the corresponding position after the reel assembly rotates is broken or parallel, until the reel assembly completes one rotation.

[0044] Full surface coverage inspection is achieved through the circumferential rotation of the reel 22 and multi-layer scanning. After completing a single-layer axial scan, the control component drives the reel assembly to rotate incrementally at preset angles, such as 1° to 5°, allowing uninspected loops to enter the sensor's detection area. The axial scanning process is then repeated, forming a spiral inspection trajectory. The preset angle is determined based on the wire winding density, ensuring that the sensor's axial scan line does not overlap with the previous layer after each rotation, and no defects are missed. Ultimately, a 360° rotation completes the inspection coverage of the entire sidewall of the reel 22. The coordinated control of "axial scanning + circumferential rotation" overcomes the limitations of traditional fixed-position inspection, enabling comprehensive inspection of reels 22 of any diameter. Even with dozens of layers of wire wrapped around the reel 22, interlayer defects can be resolved through angular resolution, such as 0.5°. Combined with the differential calculation mechanism in step S100, this ultimately establishes a complete inspection process from single-point inspection to full-surface analysis, reducing the missed detection rate to below 0.1%, significantly improving the automation and comprehensiveness of production quality inspection for wire 21.

[0045] The embodiment of the present invention aims to protect a metal wire parallel and broken detection device and its control method, the detection device includes: a reel assembly, an eddy current sensor assembly and a control assembly; the side wall of the reel assembly is wound with a metal wire to be detected along its circumference, and adjacent metal wires are spaced apart by a first preset distance, and the reel assembly and the eddy current sensor assembly are electrically connected to the control assembly; the eddy current sensor assembly is set at a corresponding position on the side wall of the reel assembly, and the control assembly controls the eddy current sensor assembly to move back and forth along the axial direction of the reel assembly; when the eddy current sensor assembly moves axially along the reel assembly, it respectively obtains the voltage detection signals of the two adjacent detection positions and performs differential operation to obtain a voltage difference signal. If the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire wound on the reel assembly is parallel or broken. The above technical solution has the following effects: 1. The use of a differential eddy current sensor assembly significantly improves the sensitivity and anti-interference capability of metal wire defect detection through the symmetrical arrangement of dual sensor units and differential signal processing technology. Traditional single-point sensors are susceptible to interference from environmental noise, but differential measurement effectively offsets common-mode interference through real-time differential calculations, while also amplifying effective signal differences caused by variations in metal wire sparsity. Combined with preset threshold judgment logic, it can stably identify minute spacing anomalies in micron-level wires under complex working conditions, significantly improving detection accuracy and stability compared to traditional methods and significantly reducing the risk of misjudgment. 2. By collaboratively controlling the axial scanning of the eddy current sensor assembly and the circumferential rotation of the reel, full coverage of the metal wire surface is achieved, eliminating the blind spot problem existing in traditional inspections. The sensor moves sequentially along the reel's axis at preset intervals while the reel rotates in steps, forming a coordinated axial and circumferential scanning path. This dynamic inspection mechanism covers the entire reel surface without manual intervention, significantly improving inspection efficiency and adapting to the needs of high-speed continuous production. In addition, real-time positioning and alarm functions reduce production interruptions caused by accumulated defects, providing reliable support for automated production lines. 3. Based on the positive and negative threshold judgment and intelligent analysis algorithm of the differential signal, it can accurately distinguish between broken wires and parallel wires. Traditional methods rely on a single threshold or subjective experience, making it difficult to distinguish the direction of sparsity changes. By presetting the voltage threshold range and combining the polarity characteristics of the differential signal, it can clearly determine an abnormal increase in the sparsity of broken wires and an abnormal increase in the density of parallel wires. It can also be adapted to metal wires of different materials or specifications through experimental calibration, flexibly responding to diverse detection needs, and providing a highly reliable classification basis for process optimization and quality traceability, significantly enhancing the accuracy and practicality of defect identification.

[0046] It should be understood that the above-described specific embodiments of the present invention are merely illustrative or illustrative of the principles of the present invention and do not constitute limitations of the present invention. Therefore, any modifications, equivalent substitutions, improvements, etc. made without departing from the spirit and scope of the present invention should be included within the scope of protection of the present invention. In addition, the appended claims are intended to cover all variations and modifications that fall within the scope and metes and bounds of the appended claims, or equivalents thereof.

Claims

1. A metal wire parallel and break detection device, characterized in that: include: a reel assembly, an eddy current sensor assembly, and a control assembly; The side wall of the reel assembly is wound with a metal wire (21) to be detected along its circumference, adjacent metal wires (21) are spaced apart by a first preset distance, and the reel assembly and the eddy current sensor assembly are electrically connected to the control assembly; The eddy current sensor assembly is arranged at a corresponding position on the side wall of the reel assembly, and the control assembly controls the eddy current sensor assembly to reciprocate along the axial direction of the reel assembly; When the eddy current sensor assembly moves axially along the reel assembly, it respectively obtains voltage detection signals from two adjacent detection positions and performs differential operation to obtain a voltage difference signal. If the voltage difference signal deviates from a preset voltage value range, it is determined that the metal wire (21) wound on the reel assembly is parallel or broken.

2. The metal wire paralleling and disconnection detection device according to claim 1, characterized in that: If the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire (21) wound on the reel assembly is parallel or broken, including: When the difference is greater than the upper limit of the preset voltage value range, it is determined that the metal wire (21) at the corresponding position of the reel assembly and the eddy current sensor assembly is parallel; When the difference is less than the lower limit of the preset voltage value range, it is determined that the metal wire (21) at the corresponding position of the reel assembly and the eddy current sensor assembly is broken.

3. The metal wire paralleling and disconnection detection device according to claim 2, characterized in that: When the difference is less than the lower limit of the preset voltage value range and the original output signal of the eddy current sensor component at the current position is lower than the calibrated minimum effective value, it is determined that the metal wire (21) at the corresponding position of the reel component and the eddy current sensor component is broken.

4. The metal wire paralleling and disconnection detection device according to claim 1, characterized in that: The eddy current sensor comprises: an eddy current sensor unit (31), a guide rail (32), a sensor bracket (33) and a reciprocating drive unit; The eddy current sensor unit (31) is arranged at one end of the sensor bracket (33) and is spaced apart from the side wall of the reel assembly by a second preset distance; The reciprocating drive unit is electrically connected to the control component and drives the other end of the sensor bracket (33) to reciprocate along the guide rail (32) under the control of the control component; The guide rail (32) is arranged parallel to the axial direction of the reel assembly.

5. The metal wire paralleling and disconnection detection device according to claim 4, characterized in that: The eddy current sensor unit (31) comprises a first eddy current sensor unit and a second eddy current sensor unit; The first eddy current sensor unit and the second eddy current sensor unit are arranged axially apart from each other along the reel assembly; The first eddy current sensor unit and the second eddy current sensor unit are electrically connected to the control component respectively, and the first eddy current sensor unit and the second eddy current sensor unit respectively obtain voltage detection signals of two adjacent detection positions and send them to the control component; The control component performs a differential operation based on the voltage detection signals of the two detection positions to obtain the voltage difference signal.

6. The metal wire paralleling and disconnection detection device according to claim 5, characterized in that: The spacing distance between the first eddy current sensor unit and the second eddy current sensor unit along the axial direction of the reel assembly is the same as the distance between two adjacent detection positions on the reel assembly.

7. The metal wire paralleling and disconnection detection device according to claim 4, characterized in that: The reciprocating drive unit drives the sensor bracket (33) under the control of the control assembly to move along the guide rail (32) a distance that is the same as the distance between two adjacent metal wires (21) on the reel assembly.

8. The metal wire paralleling and disconnection detection device according to claim 1, characterized in that: The reel assembly comprises: a reel (22) wound with a metal wire (21), a reel support, and a rotation drive unit; The rotation drive unit is electrically connected to the control component, and both ends of the reel (22) are rotationally connected to the reel bracket; The rotation drive unit drives the reel (22) to rotate along its own axis under the control of the control component.

9. The metal wire paralleling and disconnection detection device according to any one of claims 1 to 8, characterized in that: Also includes: Base (1); The eddy current sensor assembly and the reel assembly are both fixed on the base (1) and are spaced apart by a second preset distance.

10. A method for controlling a metal wire parallel and disconnection detection device, characterized in that: The metal wire paralleling and disconnection detection device according to any one of claims 1 to 9 is used to detect the paralleling and disconnection of the metal wire (21) on the reel assembly, comprising the following steps: Step S100, controlling the eddy current sensor assembly to move successively from one end to the other end along the axial direction of the reel assembly according to a first preset distance, respectively acquiring voltage detection signals at corresponding detection positions and performing differential operations to obtain voltage difference signals, comparing the voltage difference signals with a preset voltage value range, and determining whether the metal wire (21) at the corresponding position of the reel assembly is broken or parallel; Step S200, controlling the reel assembly to rotate successively according to a preset angle value, and repeating step S100 after each rotation, to determine whether the metal wire (21) at the corresponding position after the reel assembly rotates is broken or parallel, until the reel assembly completes one rotation.

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