A transformer comprehensive detection device based on visual detection
By combining a visual inspection device and a positioning clamping device, real-time monitoring and automatic alarm of surface defects in enameled wire are achieved, solving the problem of low inspection efficiency in traditional winding machines and improving the level of automation and accuracy of inspection.
Patent Information
- Application Number
- CN202210411030.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- Filing Date
- 2022-04-19
- Publication Date
- 2025-12-05
- Estimated Expiration
- 2042-04-19
AI Technical Summary
Traditional automatic winding machines cannot monitor surface defects of enameled wire in real time, resulting in low detection efficiency and failure to issue timely alarms. Furthermore, manual detection methods are inefficient and lack effective measurement data.
A comprehensive inspection device based on vision inspection is adopted, which combines digital image technology and positioning clamping device to monitor surface defects of enameled wire in real time. When a defect is detected, an alarm is triggered and the winding machine automatically stops working. At the same time, the positioning clamping device keeps the enameled wire in a fixed position, reducing image acquisition errors.
It improves the speed and convenience of detection, ensures the reliability of image acquisition, avoids damage to the surface of enameled wire, and realizes automated and rapid defect detection and processing.
Smart Images
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Abstract
Description
TECHNICAL FIELD
[0001] The application belongs to detection devices, and particularly relates to a transformer comprehensive detection device based on visual detection. BACKGROUND
[0002] The transformer is a device for changing AC voltage by using the principle of electromagnetic induction, and is widely applied in the fields of industry, agriculture, transportation and urban community.
[0003] The winding of the transformer is one of core components, and the external coil of the winding is usually wound by a winding machine according to certain rotation direction, rotation distance and number of turns.
[0004] The enameled wire is a main variety of winding wire, and generally consists of a conductor and an insulation layer. The bare wire is annealed and softened, and then baked after being coated with paint for multiple times. Generally, the quality characteristics of various enameled wires are different, but all have four performances of mechanical performance, chemical performance, electrical performance and thermal performance, and have high utilization value. The cost of the enameled wire is different according to the process quality. The surface (appearance) of the enameled wire should be smooth, uniform in color, free of particles and oxidation. The defects such as hairiness, positive and negative surfaces and black spots affecting the performance need to be monitored.
[0005] The traditional automatic winding machine does not use digital image technology to collect images, cannot monitor the surface of the enameled wire on the automatic winding machine, cannot timely find defects on the surface of the enameled wire, immediately alarm and make the winding machine stop working, and has poor use effect, and needs to be improved.
[0006] The traditional detection method is manually or visually detected by workers. This detection method is not only low in efficiency, but also has no effective measurement basis. SUMMARY
[0007] The above invention purpose of the application is realized by the following technical scheme:
[0008] A transformer comprehensive detection device based on visual detection, comprising a winding machine, an enameled wire detection device and a wire feeding mechanism, wherein: the enameled wire detection device is installed on the wire feeding mechanism, the enameled wire is used in series with the winding machine through the wire feeding mechanism, the winding machine comprises a main body, a main machine box, a rotating turntable, a wire outlet mechanism, the main body is internally provided with the main machine box, the main machine box internally comprises a power supply and a control device, the control device is connected with the rotating turntable, the rotating turntable is provided with a fixed seat at the right end, the fixed seat is provided with a slide rail below, the slide rail is fixed on the main body, the main body is further provided with an operation panel, and the main body is provided with the wire feeding mechanism at the rear end.
[0009] Preferably, the outgoing line mechanism comprises a support frame, a guide rail is arranged on the support frame, and a drive shaft is arranged on the guide rail and controlled by the main box control device.
[0010] Preferably, the outgoing line mechanism comprises a main frame, a machine box is arranged at the right end of the main frame, the machine box is connected with a control panel, a enameled wire detection device is arranged at the left end of the main frame, guide rollers are uniformly arranged at the upper end of the main frame, and enameled wire rollers are arranged at the right end of the main frame; the control panel controls the operation of the enameled wire detection device and the enameled wire rollers.
[0011] Preferably, the enameled wire detection device comprises a positioning and clamping device and a visual detection device, the positioning and clamping device is arranged above and below the visual detection device, the positioning and clamping device is rotatably fixed on the outgoing line mechanism, the visual detection device is fixed on the outgoing line mechanism through a fixing rod, the visual detection device comprises a dark box, a light camera group is arranged in the dark box, the light transmission group is connected with the control panel, and the light transmission group can compare the captured picture with a standard enameled wire picture to obtain a signal indicating whether the enameled wire is abnormal.
[0012] Preferably, the positioning and clamping device comprises a fixed disc, the fixed disc is rotatably fixed on the outgoing line mechanism, the other end of the fixed disc is connected with a support shell, an embedded groove is arranged in the upper layer of the support shell, a movable hole is arranged in the embedded groove, a fixed screw rod is arranged in the movable hole, the fixed screw rod can move up and down in the movable hole, a one-way corrugated groove is arranged in the lower layer of the support shell, a one-way support seat is arranged in the one-way corrugated groove in a matched mode, the one-way support seat is in the form of a cross-shaped middle disc, a fixed clamping push rod is arranged in the one-way support seat, the fixed clamping push rod is rotatably connected with a rotating rod, a clamping hole is arranged at the other end of the rotating rod, the clamping hole is matched with the fixed screw rod, limit inclined blocks are arranged around the one-way support seat in a cross-shaped mode, the lower end of the limit inclined blocks is rotatably connected through a pin, springs are arranged between the limit inclined blocks and the one-way support seat, and the springs are connected with the limit inclined blocks and the fixed clamping push rod through connecting rods.
[0013] In summary, the present application has at least one of the following beneficial technical effects:
[0014] The present application adopts digital image technology to collect images, monitor the surface of enameled wire on an automatic winding machine, and immediately alarms when defects are found on the surface of the enameled wire, and the winding machine stops working; the operator can quickly process the enameled wire with defects, such as coating an insulating layer, to eliminate quality problems of the enameled wire, greatly improving the quickness and convenience of detection of the device and the use effect of the overall device.
[0015] The present application is also aimed at the situation that the digital image acquisition technology will cause false alarm due to the error of the digital image caused by the irregularity of the enameled wire moving on the roller, and the positioning and clamping device is arranged, so that the enameled wire can keep fixed position when passing through the image acquisition area, and the reliability of image acquisition is ensured.
[0016] By arranging the positioning and clamping device, the different states of the rotating rod after the up-down rotation of the positioning and clamping device can realize the self-adaptive adjustment of the clamping tightness of the enameled wire, so that the enameled wire is in a suitable range when clamped, the surface of the enameled wire is not damaged due to the clamping during image acquisition, and the clamping effect of the enameled wire is not lost due to the clamping looseness, when in another rotating state, the rotating rod will fall down due to the gravity, so that the limiting inclined block and the fixed clamping push rod are loosened, and the one-way supporting seat can be taken out from the fixed disc to replace the enameled wire of different models. BRIEF DESCRIPTION OF DRAWINGS
[0017] Figure 1 is the overall structure schematic diagram of a transformer comprehensive detection device based on visual detection of the present application;
[0018] Figure 2 is the unwinding mechanism schematic diagram of a transformer comprehensive detection device based on visual detection of the present application;
[0019] Figure 3 is the unwinding mechanism sectional view schematic diagram of a transformer comprehensive detection device based on visual detection of the present application;
[0020] Figure 4 is the positioning and clamping device schematic diagram of a transformer comprehensive detection device based on visual detection of the present application;
[0021] Figure 5 is the positioning and clamping device sectional view schematic diagram of a transformer comprehensive detection device based on visual detection of the present application;
[0022] Figure 6 is the visual detection device schematic diagram of a transformer comprehensive detection device based on visual detection of the present application;
[0023] Figure 7 is the visual detection device schematic diagram of a transformer comprehensive detection device based on visual detection of the present application; Figure 5 is the "E" enlarged schematic diagram of the present application;
[0024] Figure 8 is the "F" enlarged schematic diagram of the present application; Figure 5 is the "F" enlarged schematic diagram of the present application.
[0025] In the figure: 1 winding machine, 101 main body, 102 main machine box, 103 rotating turntable, 104 wire outlet mechanism, 105 fixed seat, 106 slide rail, 107 operation panel, 2 enameled wire detection device, 201 visual detection device, 203 dark box, 204 light camera group, 205 light transmission group, 3 wire unwinding mechanism, 301 main frame, 302 machine box, 303 guide roller, 304 enameled wire roller, 5 positioning and clamping device, 501 fixed disc, 502 supporting shell, 503 embedded groove, 504 movable hole, 505 fixed screw, 506 one-way corrugated groove, 507 one-way supporting seat, 508 fixed clamping push rod, 509 rotating rod, 511 limiting inclined block, 512 spring. DETAILED DESCRIPTION
[0026] The above invention purpose of the application is realized by the following technical scheme: a transformer comprehensive detection device based on visual detection, comprising a winding machine 1, an enameled wire detection device 2 and a wire unwinding mechanism 3, wherein: the enameled wire detection device 2 is installed on the wire unwinding mechanism 3, the enameled wire is used in series with the winding machine 1 through the wire unwinding mechanism 3, the winding machine 1 comprises a main body 101, a main machine box 102, a rotating turntable 103 and a wire outlet mechanism 104, the main body 101 is internally provided with the main machine box 102, the main machine box 102 internally comprises a power supply and a control device, the control device is connected with the rotating turntable 103, the right end of the rotating turntable 103 is provided with a fixed seat 105, the lower portion of the fixed seat 105 is provided with a slide rail 106, the slide rail 106 is fixed on the main body 101, the main body 101 is further provided with an operation panel 107, and the rear end of the main body 101 is provided with the wire unwinding mechanism 3.
[0027] Specifically, the wire outlet mechanism 104 comprises a supporting frame, the supporting frame is provided with a guide rail, the guide rail is provided with a driving shaft, and the driving shaft is controlled by the main machine box control device.
[0028] Specifically, the wire unwinding mechanism 3 comprises a main frame 301, the right end of the main frame 301 is provided with a machine box 302, the machine box 302 is connected with a control panel, the left end of the main frame 301 is provided with the enameled wire detection device 2, the upper end of the main frame 301 is uniformly provided with a guide roller 303, the right end of the main frame 301 is provided with an enameled wire roller 304, and the control panel controls the operation of the enameled wire detection device 2 and the enameled wire roller 304.
[0029] Specific, the enameled wire detection device 2 including positioning clamping device 5, visual detection device 201, the positioning clamping device 5 is set with visual detection device 201 above and below, the positioning clamping device 5 can be rotatably fixed on the pay-off mechanism 3, the visual detection device 201 is fixed on the pay-off mechanism 3 through the fixed rod, the visual detection device 201 includes a dark box 203, the dark box 203 is internally provided with a light camera group 204, the light transmission group 205 is connected with the control panel, the light transmission group 205 can compare the picture taken with the enameled wire standard picture to obtain the signal whether the enameled wire appears abnormally.
[0030] Specific, the positioning clamping device 5 includes a fixed disc 501, the fixed disc 501 can be rotatably fixed on the pay-off mechanism 3, the other end of the fixed disc 501 is connected with a support housing 502, the support housing 502 is internally provided with an embedded groove 503 on the upper layer, the embedded groove 503 is internally provided with a movable hole 504, the movable hole 504 is provided with a fixed screw rod 505, the fixed screw rod 505 can move up and down in the movable hole 504, the support housing 502 is internally provided with a one-way corrugated groove 506 on the lower layer, a one-way support seat 507 is arranged in matching with the one-way corrugated groove 506, the one-way support seat 507 is a cross-shaped structure of a middle disc, the one-way support seat 507 is internally provided with a fixed clamping push rod 508, the fixed clamping push rod 508 is rotatably connected with a rotating rod 509, the other end of the rotating rod 509 is provided with a clamping hole, the clamping hole is matched with the fixed screw rod 505, the one-way support seat 507 is respectively provided with a limiting inclined block 511 around the cross, the limiting inclined block 511 is rotatably connected through a pin at the lower end, the limiting inclined block 511 and the one-way support seat 507 are provided with a spring 512, and the spring is connected with the limiting inclined block and the fixed clamping push rod through a connecting rod.
[0031] Working principle: when the work starts, the enameled wire roller 304 rotates, the enameled wire passes through the upper positioning clamping device 5 through the guide roller 303, and passes through the visual detection device 201 and the lower positioning clamping device 5, at this time the rotating rod 509 will be opened outward due to the influence of gravity and will be embedded in the embedded groove 503, at this time the movable hole 504 will slide downward in the movable hole 504 due to the influence of gravity, and will be clamped into the embedded groove 503, so that the embedded groove 503 is limited, at this time the one-way support seat 507 is at the uppermost of the one-way corrugated groove 506, at this time the rotating rod 509 will move the fixed clamping push rod 508 to the middle to clamp the enameled wire, at this time the enameled wire cannot move up and down under the action of the fixed clamping push rod 508, then the enameled wire moves, at this time due to the clamping action of the fixed clamping push rod 508, the fixed clamping push rod 508 will move downward in the one-way corrugated groove 506 until the fixed clamping push rod 508 is in the appropriate position, so that the enameled wire can slide under the clamping of the fixed clamping push rod 508, so that the enameled wire is in a state of not loose or tight in the fixed clamping push rod 508, at the same time, due to the limiting state of the four around the fixed clamping push rod 508 and the action of the upper and lower two positioning clamping devices 5, the enameled wire can always be in the middle position, which can reduce the error as much as possible for subsequent visual detection, at the same time, the visual detection device detects the light and shadow position and light and dark contrast of the enameled wire in the dark box, and transmits the obtained data to the control panel, when the light and shadow contrast of the enameled wire is inconsistent with the standard enameled wire, the control panel controls the enameled wire to stop and informs the worker to check or take the next action.
[0032] Then the enameled wire passes through the wire outlet mechanism 104 into the winding machine and works on the rotating disc 103.
[0033] When the type of enameled wire needs to be replaced, the diameters of different enameled wires are different, the fixed clamping push rod 508 needs to be replaced to adjust the clamping device, at this time only need to rotate the positioning clamping device 5 by 180° through the fixed disc 501, at this time the positioning clamping device 5 is in an inverted state, due to the influence of gravity, the fixed screw 505 will slide in the movable hole 504, due to the sliding of the fixed screw 505, the fixed screw 505 and the rotating rod 509 are no longer limited to each other, at this time the rotating rod 509 will rotate to the middle due to the influence of gravity, then the spring 512 will contract under the driving of the fixed clamping push rod 508, and the limiting inclined block 511 will rotate inward, at this time the one-way support seat 507 can fall from the support shell 502 to replace the fixed clamping push rod 508 of appropriate size.
[0034] Finally, it should be noted that the above only describes the preferred embodiments of the present application and is not intended to limit the present application. Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art will appreciate that the technical solutions described in the foregoing embodiments can be modified or some technical features thereof can be replaced by equivalent features, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.
Claims
1. A transformer comprehensive detection device based on visual detection, comprising a winding machine (1), an enameled wire detection device (2), and a wire unwinding mechanism (3), characterized in that: The enamel wire detection device (2) is installed on the pay-off mechanism (3), the enamel wire is used in series through the pay-off mechanism (3) and the winding machine (1), the winding machine (1) includes a main body (101), a main machine box (102), a rotating turntable (103), a wire outlet mechanism (104), the main machine box (102) is arranged in the main body (101), the main machine box (102) includes a power supply and a control device, the control device is connected with the rotating turntable (103), the rotating turntable (103) is provided with a fixed seat (105) at the right end, the fixed seat (105) is provided with a slide rail (106) below, the slide rail (106) is fixed on the main body (101), the main body (101) is further provided with an operation panel (107), and the main body (101) is provided with a pay-off mechanism (3) at the rear end; the wire outlet mechanism (104) includes a support frame, the support frame is provided with a guide rail, the guide rail is provided with a driving shaft, and the driving shaft is controlled by the control device; the pay-off mechanism (3) includes a main frame (301), the main frame (301) is provided with a machine box (302) at the right end, the machine box (302) is connected with the control panel, the main frame (301) is provided with an enamel wire detection device (2) at the left end, the main frame (301) is uniformly provided with a guide roller (303) at the upper end, the main frame (301) is provided with an enamel wire roller (304) at the right end, and the control panel controls the operation of the enamel wire detection device (2) and the enamel wire roller (304); the enamel wire detection device (2) includes a positioning and clamping device (5) and a visual detection device (201), the positioning and clamping device (5) is arranged above and below the visual detection device (201), the positioning and clamping device (5) is rotatably fixed on the pay-off mechanism (3), the visual detection device (201) is fixed on the pay-off mechanism (3) through a fixing rod, the visual detection device (201) includes a dark box (203), the dark box (203) is provided with a light camera group (204) inside, the control panel is connected with a light transmission group (205), and the light transmission group (205) can compare the captured picture with the standard picture of the enamel wire to obtain the signal whether the enamel wire is abnormal.The positioning and clamping device (5) comprises a fixed disc (501), which is rotatably fixed on the pay-off mechanism (3), and a support shell (502) connected to the other end of the fixed disc (501), wherein an embedded groove (503) is arranged on the upper layer of the inside of the support shell (502), an active hole (504) is arranged in the embedded groove (503), a fixed screw rod (505) is arranged in the active hole (504), the fixed screw rod (505) can move up and down in the active hole (504), a one-way corrugated groove (506) is arranged on the lower layer of the inside of the support shell (502), a one-way support seat (507) is arranged in matching with the one-way corrugated groove (506), the one-way support seat (507) is a cross-shaped structure of a middle disc, a fixed clamping push rod (508) is arranged in the one-way support seat (507), a rotating rod (509) is rotatably connected to the fixed clamping push rod (508), a clamping hole is arranged at the other end of the rotating rod (509), the clamping hole is matched with the fixed screw rod (505), limit inclined blocks (511) are respectively arranged around the one-way support seat (507), the limit inclined blocks (511) are rotatably connected through pins at the lower ends, springs (512) are arranged between the limit inclined blocks (511) and the one-way support seat (507), and the springs are connected with the limit inclined blocks and the fixed clamping push rod through connecting rods.
Citation Information
Patent Citations
Transformer automatic winding machine capable of monitoring enamelled wire defects in real time
CN214175861U