Enameled wire online detection and calibration device and enameled wire online detection and calibration system

Abstract

The present invention provides an enameled wire online detection and calibration device and an enameled wire online detection and calibration system. The enameled wire online detection and calibration device comprises: a base, a pair of bridges spaced relative to each other on the base, and a sensor electrically connected to the bridges; a frame, a turntable mounted on the frame, with a pair of protrusions provided on each side of the turntable; and a drive device for driving the turntable to rotate between the pair of bridges, simulating the passage of particles of the enameled wire between the pair of bridges via the protrusions. The present invention uses an acceleration sensor to sense the protrusions of the calibration bridges as the turntable rotates, thereby simulating the detection of surface defects of the enameled wire film by the online detection device via the detection bridges. The system then verifies whether the sensitivity of the acceleration sensor of the detection head of the online detection device can effectively and accurately identify surface defects of the enameled wire film, distinguishing between normal detection heads and those with abnormal sensitivity or failure. Only abnormal detection heads need to be returned to the factory, reducing maintenance costs, repair cycles, and spare parts requirements.

Description

Technical Field

[0001] The present invention relates to the technical field of enameled wire online detection, and in particular to an enameled wire online detection and calibration device and an enameled wire online detection and calibration system. Background Art

[0002] Large-scale enameled wire manufacturers, due to their large production capacity, own a large number of high-speed enameling machines. These machines are typically equipped with online inspection devices for detecting defects such as raised particles on the wire's outer surface. Consequently, these companies also maintain a large inventory of these devices. However, after extensive production testing and long-term use, these sensors can become insensitive or ineffective in detecting surface defects in the wire. This can lead to increased quality defects and reduced yields, creating quality risks and costly production issues. Regularly returning large quantities of these devices to the manufacturer for inspection and calibration can result in high maintenance costs, lengthy inspection and calibration cycles, and long and expensive shipping times. This necessitates the purchase of additional spare sensor heads to replace those currently in factory repair. The high price of these sensor heads further increases production costs.

[0003] Therefore, the existing online detection devices lack calibration devices, resulting in the need for batch return for overhaul for sensitivity calibration, which increases production costs and cycles, and is a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0004] In order to solve the technical problem in the above-mentioned prior art that the traditional online detection device lacks a calibration device, resulting in the need for batch return for inspection and maintenance, which increases production costs and cycles, the present invention proposes an enameled wire online detection and calibration device and an enameled wire online detection and calibration system.

[0005] In order to solve the above technical problems, the technical solution adopted by the present invention is:

[0006] The present invention provides an enameled wire online detection and calibration device, comprising: a base, a pair of bridge pieces arranged on the base with relative spacing, and a sensor electrically connected to the bridge pieces;

[0007] It also includes: a frame, a turntable installed on the frame, and a pair of convex points are respectively provided on both sides of the turntable; a driving device for driving the turntable to rotate between a pair of bridge pieces, and simulating particles of enameled wire to pass between the pair of bridge pieces through the convex points.

[0008] Furthermore, it also includes:

[0009] A rotating shaft is rotatably mounted on the frame, and a turntable is mounted on one end of the rotating shaft;

[0010] The driving device includes: a motor installed on the frame, and the output shaft of the motor drives the rotating shaft to rotate through the transmission mechanism.

[0011] Preferably, the pair of protrusions are arranged symmetrically about the center of mass of the turntable.

[0012] Furthermore, the transmission mechanism adopts a gear synchronous belt mechanism, including: a driving wheel installed on the output shaft, a driven wheel installed on the other end of the rotating shaft, and a synchronous belt connected between the driving wheel and the driven wheel.

[0013] Furthermore, it also includes: a pair of bearings installed on the frame at intervals, and the rotating shaft is rotatably installed on the pair of bearings.

[0014] Furthermore, the bridge piece includes: a detection bridge piece and a calibration bridge piece detachably mounted on the base, wherein the calibration bridge piece is used to replace the detection bridge piece when the enameled wire online detection and calibration device is operating.

[0015] Preferably, a pair of detection bridges are installed vertically and spaced apart at the top of the base, and the side of the detection bridge facing the other detection bridge is serrated; a pair of calibration bridges are used to replace the pair of detection bridges respectively, and the calibration bridges are rectangular.

[0016] The present invention also provides an enameled wire online detection and calibration system, comprising: an online detection device, a calibration device, and a detection and control system connected to the online detection device and the calibration device, and also comprising: the above-mentioned enameled wire online detection and calibration device, the detection and control system receives the feedback signal of the sensor and determines its fault based on the feedback signal.

[0017] Furthermore, it also includes: a detection head provided with a sensor, the sensor adopts an acceleration sensor, the detection head is provided with a data interface electrically connected to the sensor, and the data interface is electrically connected to the detection control system through a data line.

[0018] Furthermore, it also includes: a speed regulating switch installed on the frame, and the speed regulating switch is electrically connected to the driving device.

[0019] Compared with the prior art, the enameled wire online detection and calibration device and the enameled wire online detection and calibration system provided by the present invention use an acceleration sensor to sense the convex points of the calibration bridge when the turntable rotates, that is, to simulate the online detection device to detect the surface defects of the paint film of the enameled wire through the detection bridge. Therefore, the detection head can be calibrated by convex point simulation particles, and the acceleration sensor of the detection head can be detected, so as to confirm whether the sensitivity of the acceleration sensor of the detection head of the online detection device is accurate, whether it can effectively and accurately identify the surface defects of the paint film of the enameled wire, and calibrate to distinguish between the detection head and the detection head and its sensor that are working normally and those with abnormal sensitivity and failure, so that the calibration status of each online detection device can be directly measured at the production site, so that the entire batch does not need to be returned to the factory for regular inspection and maintenance. Only the detection head and its sensor of the online detection device with abnormal status need to be returned to the factory after regular calibration, thereby reducing the maintenance cost, inspection and calibration cycle, and spare detection head demand of the online detection device. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0021] Figure 1 This is a front view of the enameled wire online detection and calibration system of the present invention;

[0022] Figure 2 A top view of the enameled wire online detection and calibration system of the present invention;

[0023] Figure 3 for Figure 1 A schematic diagram of the enlarged structure of the online detection device of the online detection and calibration system for enameled wire;

[0024] Figure 4 It is a schematic structural diagram of the turntable of the calibration device of the present invention.

[0025] Among them, the main marks of the drawings in the figure are:

[0026] 1-Host terminal; 2-Display terminal; 3-Input terminal; 4-Detection terminal; 5-Workbench; 6-Online detection device; 7-Base; 8-Turntable; 9-Bump; 10-Shaft; 11-Bearing; 12-Speed ​​control switch; 13-Frame; 14-Timing pulley; 15-Timing belt; 16-Motor; 17-Guide wheel; 18-Bridge; 19-Data interface; 20-Detection head. DETAILED DESCRIPTION

[0027] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clear, the following is a summary of the technical problems, technical solutions and beneficial effects to be solved by the present invention. Figure 1-4 It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0028] Please also refer to Figure 1-4 The present invention proposes an online detection and calibration device for enameled wire, comprising: an online detection device 6, the online detection device 6 comprising: a base 7, the base 7 is preferably a rectangular plate, and can also be a trapezoidal or other shaped plate; a pair of bridge pieces relatively spaced apart on the base 7, and a sensor electrically connected to the bridge pieces; in this embodiment, it also includes a pair of detection heads 20 with sensors, the detection heads 20 are preferably rectangular blocks, and can also be trapezoidal or other shaped blocks; a transmission assembly installed on the base 7 along the axial direction of the base 7, for guiding the enameled wire to pass between the pair of bridge pieces; in this embodiment, the transmission assembly includes a pair of guide wheels 17, the installation height of the guide wheels 17 can ensure that the enameled wire is driven by a power device set on the head of the high-speed enameling machine and passes between the pair of bridge pieces along the guidance of the pair of guide wheels 17.

[0029] In this embodiment, the bridges include: a detection bridge and a calibration bridge 18 detachably mounted on the base 7 . The detection bridge is used to perform online inspection of surface defects (such as raised particles) on the enameled wire coating at the head of a high-speed enameling machine. The calibration bridge 18 is used to replace the detection bridge during operation of the enameled wire online inspection and calibration device to calibrate the sensitivity of the sensor of the online inspection device 6 . In a preferred embodiment, a pair of detection bridges are vertically spaced apart and mounted on the top of the base 7 . The detection bridges are zigzag-shaped on the side facing the other detection bridge. The corresponding zigzag structures of the pair of detection bridges completely surround the circumference of the enameled wire, thereby detecting the presence of raised particles on the enameled wire coating surface within a full 360° circumference. This improves the detection rate of the online inspection device 6 for surface defects on the enameled wire coating during normal operation of the online inspection device (during normal production). The pair of calibration bridges 18 are used to replace the corresponding pair of detection bridges. The calibration bridges 18 are rectangular and spaced apart on the base 7 .

[0030] This embodiment also includes a calibration device, comprising: a frame 13, which can be a frame structure or a base structure; a turntable 8 mounted on the frame 13, with a pair of protrusions 9 provided on each side of the turntable 8; a drive device for driving the turntable 8 to rotate between a pair of bridges, with the protrusions 9 simulating the protrusions of enameled wire passing between the gaps between the bridges. In a preferred embodiment, the pair of protrusions 9 are arranged symmetrically about the center of mass of the turntable 8. In one embodiment, the device also includes: a rotating shaft 10 rotatably mounted on the frame 13, with the turntable 8 mounted on one end of the rotating shaft 10; and a drive device comprising: a motor 16 mounted on the frame 13, with the output shaft of the motor 16 driving the rotating shaft 10 to rotate via a transmission mechanism. In a preferred embodiment, the transmission mechanism employs a gear synchronous belt 15 mechanism, comprising: a synchronous pulley 14, comprising a driving pulley mounted on the output shaft and a driven pulley mounted on the other end of the rotating shaft 10; and a synchronous belt 15 connected between the driving pulley and the driven pulley. As another embodiment, the transmission mechanism may employ a speed change device (e.g., a gear train) that cooperates with the output shaft of the motor 16, instead of the gear timing belt 15 mechanism. As a more preferred embodiment, the transmission mechanism further comprises: a pair of bearings 11 spaced apart and mounted on the frame 13, the rotating shaft 10 being rotatably mounted on the pair of bearings 11, and the mounting height of the bearings 11 on the turntable 8 ensuring that the protrusion 9 passes between the pair of bridges when the turntable 8 rotates.

[0031] The present invention also provides an online inspection and calibration system for enameled wire, comprising: an online inspection device 6, a calibration device, and a detection and control system connected to the online inspection device 6 and the calibration device. The system also includes the aforementioned online inspection and calibration device for enameled wire, wherein the detection and control system receives feedback signals from sensors and determines faults based on the feedback signals. In a preferred embodiment, the sensor is an accelerometer, and the inspection head 20 is provided with a data interface 19 electrically connected to the sensor. The data interface 19 is electrically connected to the detection and control system via a data cable. The detection and control system includes a workbench 5, a display terminal 2 mounted on the workbench 5, a host terminal 1, an input terminal 3 (which may be a keyboard, touch screen, etc.), and a detection terminal 4.

[0032] As a more preferred embodiment, the apparatus further includes a speed control switch 12 mounted on a frame 13, the speed control switch 12 being electrically connected to the drive device. In this embodiment, the rotational speed of the turntable 8 is preferably 40 rpm, with a tolerance of 40±5 rpm to ensure that the output voltage of the bump 9 after conversion by the sensor is 0.9±0.1V. The online detection device 6 is calibrated by the output signal feedback detection control system.

[0033] The working principles of the enameled wire online detection and calibration device and the enameled wire online detection and calibration system provided by the present invention are as follows:

[0034] According to the prescribed cycle, the online detection device 6 on the enameled wire production equipment is removed to check whether it is normal: first, the online detection equipment is installed on the frame 13 of the calibration device, and a pair of detection bridge pieces are removed and replaced with a pair of calibration bridge pieces; the central axis of the pair of detection heads 20 is parallel to the turntable 8, and the convex points 9 on both sides of the turntable 8 are located at the center of the pair of calibration bridge pieces; the motor 16 is started, and the rotation speed of the rotating shaft 10 is adjusted by the speed control switch 12 to make the turntable 8 rotate at the set speed, and the detection head 20 and the calibration bridge piece 18 of the online detection device 6 are used to cooperate with the detection of the convex points 9 of the turntable 8 to simulate the online detection device 6 to detect the paint film surface of the enameled wire through the detection head 20 and the detection bridge piece. When there are particles on the paint film surface, the particles will pass through the bridge of the detection head 20 to make the sensor produce an acceleration change, thereby generating a particle signal, which will be reflected in the online detection software system, and the number of particles can be checked on the computer; similarly, there should be a feedback value for each rotation of the turntable 8, and the sensed signal will be transmitted to the detection terminal 4, and the detection terminal 4 will transmit the signal to the host terminal 1. The user can check whether the detection operation status of the online detection device 6 is normal by operating the input terminal 3 and the display terminal 2; if the detection is normal, the device can be used normally; if the detection is abnormal, the online detection device 6 will be sent back to the manufacturer for repair.

[0035] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An enameled wire online detection and calibration device, comprising: A base, a pair of bridge pieces spaced apart from each other on the base, and a sensor electrically connected to the bridge pieces; It is characterized by further comprising: A frame, a turntable mounted on the frame, wherein two sides of the turntable are respectively provided with a pair of protrusions; The driving device is used to drive the turntable to rotate between the pair of bridge pieces, and to simulate the particles of the enameled wire passing through the pair of bridge pieces through the convex points.

2. The enameled wire online detection and calibration device according to claim 1, characterized in that: The enameled wire online detection and calibration device also includes: A rotating shaft rotatably mounted on the frame, the turntable being mounted on one end of the rotating shaft; The driving device includes a motor installed on the frame, and the output shaft of the motor drives the rotating shaft to rotate through a transmission mechanism.

3. The enameled wire online detection and calibration device according to claim 2, characterized in that: A pair of protrusions are arranged symmetrically about the center of mass of the turntable.

4. The enameled wire online detection and calibration device according to claim 2, characterized in that: The transmission mechanism adopts a gear synchronous belt mechanism, which includes: a driving wheel installed on the output shaft, a driven wheel installed on the other end of the rotating shaft, and a synchronous belt connected between the driving wheel and the driven wheel.

5. The enameled wire online detection and calibration device according to claim 2, characterized in that: The enameled wire online detection and calibration device also includes: A pair of bearings are installed on the frame at intervals, and the rotating shaft is rotatably installed on the pair of bearings.

6. The enameled wire online detection and calibration device according to claim 1, characterized in that: The bridge piece includes: a detection bridge piece and a calibration bridge piece detachably mounted on the base, wherein the calibration bridge piece is used to replace the detection bridge piece when the enameled wire online detection and calibration device is operating.

7. The enameled wire online detection and calibration device according to claim 6, characterized in that: A pair of detection bridges are installed vertically and spaced apart at the top of the base, and the side of the detection bridge facing the other detection bridge is serrated; a pair of calibration bridges are used to replace a pair of detection bridges respectively, and the calibration bridges are rectangular.

8. An enameled wire online detection and calibration system, characterized in that: include: The online detection device, the calibration device, and the detection and control system connected to the online detection device and the calibration device also include: the enameled wire online detection and calibration device as described in any one of claims 1 to 7, the detection and control system receives the feedback signal of the sensor and determines its fault based on the feedback signal.

9. The enameled wire online detection and calibration system according to claim 8, characterized in that: Also includes: A detection head is provided with the sensor, the sensor is an acceleration sensor, the detection head is provided with a data interface electrically connected to the sensor, and the data interface is electrically connected to the detection control system through a data line.

10. The enameled wire online detection and calibration system according to claim 8, characterized in that: Also includes: A speed regulating switch is installed on the frame, and the speed regulating switch is electrically connected to the driving device.

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