Online monitoring method and system for production quality of temperature rise resistance curve cable

Abstract

The present invention relates to the field of cable production, and more specifically, to a method and system for online monitoring the production quality of a temperature-resistant curve cable, the method comprising: obtaining a cable image after the cable is wrapped by a wrapping machine, and extracting the contour information of the cable; calculating the wrapping overlap rate and the wrapping parallelism of each wrapping overlapping part according to the contour information, and judging the wrapping quality based on a preset standard; calculating the average value of the difference between all two adjacent wrapping masses in the cable image as the average mass offset of the cable image, and judging whether the wrapping angle of the current wrapping machine needs to be corrected; obtaining the sum of the real-time wrapping mass and the average mass offset, and obtaining the wrapping quality when the wrapping angle remains unchanged at the next moment; responding to the wrapping mass at the next moment being equal to 0, no correction is required, otherwise, correction is performed. The present invention dynamically adjusts the wrapping angle through historical data and preset standards, thereby realizing intelligent monitoring and quality optimization of the production process.

Description

Technical Field

[0001] The present invention relates to the field of cable production, and more specifically, to an online monitoring method and system for production quality of temperature rise resistance curve cables. Background Art

[0002] Among the series of processes in cable manufacturing, cable wrapping is an important process in cable production. Through the wrapping process, the cable can be protected from mechanical damage, chemical corrosion or moisture and other adverse effects. The wrapping material can enhance the mechanical properties of the cable such as tensile strength and compressive strength, and can also improve the electrical properties of the cable, improve the insulation and fire resistance of the cable, and reduce electromagnetic interference. In the cable wrapping process, the uniformity and parallelism of each layer of wrapping tape are crucial to the performance of the final product. If there is a deviation in the alignment and uniformity between the layers, it may cause stress concentration when the cable is subjected to force, affecting the mechanical strength and electrical properties of the cable.

[0003] The existing Chinese patent application document with publication number CN114678174A discloses an intelligent production system for low heat release fireproof wires and cables. The low heat release fireproof wires and cables include a conductive core and a mineral insulation layer, a filling layer, a first oxygen insulation layer, a metal sheath layer, a second oxygen insulation layer, a fire-resistant layer and an outer sheath arranged in sequence from the inside to the outside along the radius of the conductive core; the production system includes a collection module, a winding module, a supply module, an evaluation module and a translation module; the supply module is used to supply materials for the mineral insulation layer, the first oxygen insulation layer and the fire-resistant layer to cooperate with the winding module to wrap around the outer periphery of the conductive core; the winding module is used to wrap around the outer periphery of the conductive core to form a protective layer on the outer periphery of the conductive core.

[0004] The above application documents cooperate with the acquisition module through the evaluation module, and evaluate based on the data of the acquisition module to adjust the parameters of the winding module according to the evaluation results. At present, in the actual cable winding operation process, the cable speed and the winding speed always maintain a certain ratio, which will not affect the cable winding overlap rate. At this time, the only factor affecting the cable winding overlap rate is the winding angle. The winding angle will change due to the long-term vibration of the winding machine during operation. As time goes by, the change in the winding angle will become greater and greater, and the impact on the cable winding overlap rate will also become greater and greater, thereby affecting the quality of the cable. Summary of the invention

[0005] In order to solve the problem that due to the long-term vibration of the wrapping machine during operation, the wrapping angle changes more and more with the increase of time, thereby affecting the quality of the cable, the present invention provides solutions in the following aspects.

[0006] In a first aspect, a method for online monitoring of the production quality of a temperature-rise-resistant curve cable comprises: obtaining a cable image after cable wrapping by a wrapping machine, processing the cable image and extracting the contour information of the cable; calculating the wrapping overlap rate and the wrapping parallelism of each wrapping overlapping part according to the contour information, and judging the wrapping quality based on a preset standard according to the wrapping overlap rate and the wrapping parallelism; calculating the average value of the difference between all two adjacent wrapping masses in the cable image as the average mass offset of the cable image, judging whether the wrapping angle of the current wrapping machine needs to be corrected according to the average mass offset, and if correction is required, appropriately correcting the wrapping angle according to the average mass offset to optimize the wrapping quality; wherein the correction method is: obtaining the sum of the real-time wrapping mass and the average mass offset, and obtaining the wrapping quality when the wrapping angle remains unchanged at the next moment; in response to the wrapping mass being equal to 0 when the wrapping angle remains unchanged at the next moment, it is not necessary to adjust the current wrapping angle, otherwise, the wrapping angle at the next moment is corrected.

[0007] The effect is: by automatically extracting contour information from the image and calculating the wrapping overlap rate and wrapping parallelism, the interference of human factors is reduced, the accuracy and consistency of quality assessment are improved, and by predicting the wrapping quality at the next moment, trends that may lead to quality problems can be identified in advance and corresponding adjustment measures can be taken, thereby improving the controllability of the production process and optimizing production efficiency.

[0008] Preferably, processing the image and extracting the contour information of the cable in the cable image includes:

[0009] Each of the cable images includes a complete preset number of wrapping overlap regions, and two adjacent cable images include non-repeating wrapping overlap regions;

[0010] Perform edge detection on the cable image to obtain the cable contour information, perform noise reduction preprocessing on the contour information, and enhance the image contrast and brightness distribution, wherein the contour information includes: the two widths of each wrapping pitch of the wrapping material during wrapping and , two widths of each wrap overlap area and , and the diameter of the cable .

[0011] The effect is: by performing edge detection and preprocessing on the cable image, the cable contour information, including the wrapping pitch and the width of the overlapping area, can be accurately extracted. Automated image processing and contour information extraction reduces the time of manual measurement and data processing, improves production efficiency, and helps reduce production costs by reducing rework and scrap rates caused by quality problems.

[0012] Preferably, the wrapping overlap rate and wrapping parallelism include:

[0013] Taking any package as a target package, calculating the ratio of the sum of the widths of the two overlapping regions of the target package to the sum of the upper and lower widths of the intercept of the target package, and taking the ratio as the package overlap rate of the target package;

[0014] The absolute value of the difference in width between the two overlapping areas of the target wrapping is calculated as the wrapping parallelism of the target wrapping.

[0015] The effect is: through quantitative analysis of the wrapping overlap area and intercept width, deviations in the wrapping process can be discovered in time, possible defects can be prevented, unqualified products can be reduced, and product reliability can be improved. The automated calculation method reduces the need for manual measurement, speeds up quality inspection during the production process, and improves production efficiency.

[0016] Preferably, judging the wrapping quality based on a preset standard according to the wrapping overlap rate and the wrapping parallelism includes:

[0017] The absolute value of the difference between the wrapping overlap rate of the target wrapping and the preset standard is calculated, and the sum of the difference and the wrapping parallelism of the target wrapping is taken as the wrapping quality of the target wrapping.

[0018] Preferably, the wrapping quality also includes:

[0019] The ratio between the product of the wrapping overlap rate and the wrapping parallelism of the target wrapping and a preset standard is calculated as the wrapping quality of the target wrapping.

[0020] Preferably, the wrapping angle at the next moment is corrected, including:

[0021] Obtaining a wrapping overlap rate corresponding to a wrapping angle in historical data, and taking a ratio of the wrapping overlap rate to the wrapping angle as a proportional coefficient;

[0022] A corrected wrapping angle of the wrapping overlap ratio of the current wrapping angle compared to a preset standard is calculated based on the proportional coefficient.

[0023] The effect is: by monitoring the relationship between the wrapping angle and the overlap rate, it can reduce material waste and rework caused by improper wrapping angles, and reduce unexpected shutdowns and waste generation in production.

[0024] Preferably, the modified wrapping angle satisfies the following relationship:

[0025] ;

[0026] In the formula, Indicates the correction of wrapping angle. Indicates the angle corresponding to the wrapping at the current moment, Indicates the proportional coefficient between the wrapping overlap rate and the wrapping angle in the historical data. Indicates The wrapping overlap ratio.

[0027] The effect is: using the proportional coefficient determined by historical data, the adjustment process is based on actual production data, which increases the reliability of the adjustment. Automatic adjustment of the wrapping angle by the machine helps to optimize product quality and reduce defects caused by human factors or equipment errors.

[0028] In a second aspect, a system for online monitoring the production quality of temperature-rise-resistant curve cables includes: a processor and a memory, wherein the memory stores computer program instructions, and when the computer program instructions are executed by the processor, the above-mentioned method for online monitoring the production quality of temperature-rise-resistant curve cables is implemented.

[0029] The present invention has the following effects:

[0030] 1. The present invention accurately extracts cable contour information through automated image processing, calculates wrapping overlap and parallelism in real time, and dynamically adjusts wrapping angles based on historical data and preset standards, thereby realizing intelligent monitoring and quality optimization of the production process and improving production efficiency and product quality.

[0031] 2. The present invention detects the cable wrapping process to facilitate real-time adjustment of the wrapping angle. While ensuring that the cable wrapping overlap rate is qualified when the wrapping machine is working, it predicts the wrapping quality at the next moment, can identify trends that may lead to quality problems in advance, and take corresponding adjustment measures, thereby improving the controllability of the production process and optimizing production efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] By reading the following detailed description with reference to the accompanying drawings, the above and other objects, features and advantages of the exemplary embodiments of the present invention will become readily understood. In the accompanying drawings, several embodiments of the present invention are shown in an exemplary and non-limiting manner, and the same or corresponding reference numerals represent the same or corresponding parts, wherein:

[0033] Figure 1 It is a method flow chart of steps S1 to S3 in the method for online monitoring of production quality of temperature rise resistant curve cables according to an embodiment of the present invention.

[0034] Figure 2 It is a schematic diagram of contour information in a cable image in an online monitoring method for production quality of a temperature rise resistant curve cable according to an embodiment of the present invention.

[0035] Figure 3 It is a structural block diagram of an online monitoring system for production quality of temperature rise resistant curve cables according to an embodiment of the present invention. DETAILED DESCRIPTION

[0036] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0037] The specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0038] The specific scenario targeted by the present invention is: controlling and monitoring the cable production quality by controlling and monitoring the cable wrapping process.

[0039] Reference Figure 1 The method for online monitoring of the production quality of temperature-rise-resistant cable includes steps S1 to S3, which are as follows:

[0040] S1: Obtaining a cable image after the cable is wrapped by a wrapping machine, processing the cable image and extracting the contour information of the cable.

[0041] It can be understood that a light source and an industrial image acquisition device are provided above the cable wrapping working area of ​​the wrapping machine, and the angles of the light source and the image acquisition device are adjusted so that the captured cable is parallel to the x-axis in the image coordinate system, thereby obtaining the contour information of the wrapped cable.

[0042] On this basis, the image acquisition frequency of the image acquisition device is set according to the running speed of the wrapping machine during cable wrapping. For example, it is ensured that the image acquired by the image acquisition device each time can fully display the ten overlapping parts of the front end of the current cable wrapping, and there are a total of twenty non-repetitive overlapping parts of the wrapping captured by two adjacent images.

[0043] Reference Figure 2 , perform edge detection on the cable image to obtain the cable contour information, perform noise reduction preprocessing on the contour information, and enhance the image contrast and brightness distribution. The contour information includes: the two widths of each wrapping pitch of the wrapping material during wrapping and , two widths of each wrap overlap area and , and the diameter of the cable .

[0044] In a feasible implementation, the cable image is detected using the Hough line detection algorithm, and the Gaussian filter and histogram equalization image processing algorithm is used to reduce noise and smooth the image, so that the details and edge features of the cable image are displayed more clearly.

[0045] That is to say, Hough line detection can effectively identify straight line structures in images, except for those parallel to The two straight lines of the axis and In addition to the two straight lines of the axis, there are many Axis and The straight lines where the axes intersect are the outlines of the overlapping parts of the wrapping, and each straight line has a different intercept.

[0046] S2: Calculate the wrapping overlap rate and wrapping parallelism of each wrapping overlapping part according to the contour information, and judge the wrapping quality based on the wrapping overlap rate and wrapping parallelism according to a preset standard.

[0047] Taking any package as a target package, calculating the ratio of the sum of the widths of the two overlapping regions of the target package to the sum of the upper and lower widths of the intercept of the target package, and taking the ratio as the package overlap rate of the target package;

[0048] Specifically, the wrapping overlap rate satisfies the following relationship:

[0049] ;

[0050] In the formula, Indicates The wrapping overlap ratio, and Indicates Two widths of the wrapping overlap area, Indicates Two widths of wrapping pitch.

[0051] It should be noted that Indicates The total overlapping width of the wrapping is obtained by adding the widths of two adjacent overlapping areas to obtain the total width of the wrapping tape in the overlapping area. Indicates The total width of the package can be obtained by the above formula. The ratio of the overlapping area of ​​the package to the total width of the package can be obtained, and then the ratio can be used to determine whether the package is wound smoothly.

[0052] The absolute value of the difference in width between the two overlapping areas of the target wrapping is calculated as the wrapping parallelism of the target wrapping.

[0053] Specifically, the wrapping parallelism satisfies the following relationship:

[0054] ;

[0055] In the formula, Indicates The parallelism of the wrapping, and Indicates Two widths of wrap overlap area.

[0056] It should be noted that when and When equal, the parallelism of the wrapping When 0, it means that the widths of the two overlapping areas are exactly the same and the wrapping tapes are very parallel. and When the difference increases, the parallelism of the wrapping It also increases, indicating that the alignment of the wrapping tape has deteriorated.

[0057] In a feasible implementation, the cable wrapping overlap rate standard is: ,by For the optimal wrapping overlap rate, the wrapping quality of the current wrapping overlap parts is calculated.

[0058] The absolute value of the difference between each wrapping overlap rate and the preset standard is calculated, and the sum of the difference and the corresponding wrapping parallelism is taken as the corresponding wrapping quality.

[0059] Specifically, the wrapping quality satisfies the following relationship:

[0060] ;

[0061] In the formula, Indicates The wrapping quality of each wrapping, Indicates The wrapping overlap ratio, Indicates The parallelism of the wrapping.

[0062] It should be noted that Indicates the actual Wrap overlap ratio The absolute value of the difference between the actual overlap rate and the target overlap rate of 25%. The smaller the value, the The closer the wrapping overlap rate is to the ideal state, the closer the wrapping parallelism is to the ideal state. It reflects the alignment of the wrapping tape. The greater the wrapping parallelism, the worse the alignment of the wrapping tape. The smaller the value, the better the wrapping quality. , then it means The wrapping overlap rate is exactly the target overlap rate, and the wrapping tapes are completely aligned, that is, the wrapping quality is optimal.

[0063] In addition, in another feasible implementation manner, the ratio between the product of the wrapping overlap rate and the wrapping parallelism of the target wrapping and a preset standard is calculated as the wrapping quality of the target wrapping.

[0064] Specifically, the wrapping quality satisfies the following relationship:

[0065] ;

[0066] In the formula, Indicates the wrapping quality, Indicates The wrapping overlap ratio, Indicates The parallelism of the wrapping.

[0067] It should be noted that the wrapping overlap rate Parallelism with wrapping The product of reflects the comprehensive effect of wrapping tape coverage and alignment; if the wrapping overlap rate High, indicating that the coverage area exceeds the preset standard coverage; if the wrapping parallelism Low, indicating good alignment, if the wrap overlap ratio And the parallelism of the wrapping The values ​​are very high, the wrapping quality will be large, which indicates poor wrapping quality. On the contrary, if the wrapping overlap ratio is And the parallelism of the wrapping The values ​​are very low, the wrapping quality will be small, which indicates good wrapping quality.

[0068] S3: Calculate the average value of the difference between all two adjacent wrapping qualities in the cable image as the average quality offset of the cable image. According to the average quality offset, determine whether the wrapping angle of the current wrapping machine needs to be corrected. If correction is required, make appropriate corrections to the wrapping angle according to the average quality offset to optimize the wrapping quality.

[0069] Specifically, the average mass offset satisfies the following relationship:

[0070] ;

[0071] In the formula, Indicates the average mass offset of the overlapping part of the wrapping at the current moment, Indicates The wrapping quality of each wrapping, Indicates The wrapping quality of each wrapping, Indicates the total number of wrap overlap areas in the cable image.

[0072] It should be noted that The cumulative calculation shows the difference in the quality of consecutive wrapping, which reflects the change in quality between adjacent wrappings; if the average quality deviation A smaller value indicates that the wrapping quality is relatively consistent between wrappings with less fluctuation. If the average quality deviation is A large value indicates that the wrapping quality has large fluctuations between different wrappings, and the wrapping process may need to be adjusted.

[0073] The correction method is as follows: obtain the sum of the real-time wrapping quality and the average quality offset, and obtain the wrapping quality at the next moment when the wrapping angle remains unchanged;

[0074] Specifically, the wrapping quality at the next moment when the wrapping angle remains unchanged includes:

[0075] ;

[0076] In the formula, It indicates the wrapping quality of the overlapping part of the wrapping when the wrapping angle does not change at the next moment. Indicates the current moment The wrapping quality, Indicates the average mass offset of the overlapping part of the wrapping at the current moment.

[0077] It should be noted that the average mass offset A positive number indicates that the wrapping quality increases with time, whereas a negative number indicates that the wrapping quality decreases with time.

[0078] In response to the wrapping quality being equal to 0 when the wrapping angle remains unchanged at the next moment, there is no need to adjust the current wrapping angle. Otherwise, the wrapping angle at the next moment is corrected.

[0079] Further explanation: the smaller the wrapping angle is, the more wraps per unit length are, the greater the wrapping overlap rate is, and vice versa, the smaller the wrapping overlap rate is. Therefore, the wrapping angle is inversely proportional to the wrapping overlap rate. By recording the wrapping overlap rate historical data corresponding to multiple wrapping angles, the proportional coefficient between the wrapping angle and the wrapping overlap rate is calculated. , according to the proportionality factor , obtain the wrapping overlap rate corresponding to the wrapping angle in the historical data, and use the ratio of the wrapping overlap rate to the wrapping angle as the proportional coefficient.

[0080] A corrected wrapping angle of the wrapping overlap ratio of the current wrapping angle compared to a preset standard is calculated based on the proportionality coefficient.

[0081] Specifically, the modified wrapping angle satisfies the following relationship:

[0082] ;

[0083] In the formula, Indicates the correction of wrapping angle. Indicates the wrapping angle corresponding to the wrapping at the current moment, Indicates the proportional coefficient between the wrapping overlap rate and the wrapping angle in the historical data. Indicates The wrapping overlap ratio.

[0084] It should be noted that the wrapping overlap rate If it is less than 25%, it means that the overlap is insufficient and the wrapping angle needs to be increased to correct the wrapping angle. Greater than the wrapping angle at the current moment ; If the wrapping overlap ratio If it is greater than 25%, it means there is too much overlap and the wrapping angle needs to be reduced. Smaller than the wrapping angle at the current moment .

[0085] The present invention also provides an online monitoring system for the production quality of temperature-resistant cable. Figure 3 As shown, the system includes a processor and a memory, the memory stores computer program instructions, and when the computer program instructions are executed by the processor, the online monitoring method for the production quality of the temperature rise resistance curve cable according to the first aspect of the present invention is implemented.

[0086] The system also includes other components familiar to those skilled in the art, such as a communication bus and a communication interface. The configuration and functions of these components are known in the art and will not be described in detail here.

[0087] In the present invention, the aforementioned memory may be any tangible medium containing or storing a program that can be used by or in combination with an instruction execution system, apparatus or device. For example, a computer-readable storage medium may be any appropriate magnetic storage medium or magneto-optical storage medium, such as a resistive random access memory RRAM (Resistive Random Access Memory), a dynamic random access memory DRAM (Dynamic Random Access Memory), a static random access memory SRAM (Static Random-Access Memory), an enhanced dynamic random access memory EDRAM (Enhanced Dynamic Random Access Memory), a high-bandwidth memory HBM (High-Bandwidth Memory), a hybrid memory cube HMC (Hybrid Memory Cube), etc., or any other medium that can be used to store the required information and can be accessed by an application, a module, or both. Any such computer storage medium may be part of a device or accessible or connectable to a device. Any application or module described in the present invention may be implemented using computer-readable / executable instructions that may be stored or otherwise maintained by such a computer-readable medium.

[0088] In the description of this specification, "plurality" or "several" means at least two, such as two, three or more, etc., unless otherwise clearly and specifically defined.

[0089] Although this specification has shown and described a number of embodiments of the present invention, it will be apparent to those skilled in the art that such embodiments are provided by way of example only. Those skilled in the art will conceive of many modifications, changes and alternatives without departing from the ideas and spirit of the present invention. It should be understood that in the practice of the present invention, various alternatives to the embodiments of the present invention described herein may be employed.

Claims

1. A method for online monitoring of production quality of temperature-resistant cable, characterized in that: include: Acquire a cable image after the cable is wrapped by a wrapping machine, process the cable image and extract the contour information of the cable; Calculating the wrapping overlap rate and wrapping parallelism of each wrapping overlapped part according to the profile information, including: taking any wrapping as a target wrapping, calculating the ratio of the sum of the widths of the two overlapping areas of the target wrapping to the sum of the upper and lower widths of the pitch of the target wrapping, and using the ratio as the wrapping overlap rate of the target wrapping; using the absolute value of the difference between the widths of the two overlapping areas of the target wrapping as the wrapping parallelism of the target wrapping; judging the wrapping quality according to the wrapping overlap rate and the wrapping parallelism based on a preset standard, including: calculating the absolute value of the difference between the wrapping overlap rate of the target wrapping and the preset standard, and using the sum of the difference and the wrapping parallelism of the target wrapping as the wrapping quality of the target wrapping; Calculate the average value of the difference between all two adjacent wrapping masses in the cable image as the average mass offset of the cable image, and judge whether the wrapping angle of the current wrapping machine needs to be corrected according to the average mass offset. If correction is required, the wrapping angle is appropriately corrected according to the average mass offset to optimize the wrapping quality; The correction method is as follows: obtain the sum of the real-time wrapping quality and the average quality offset to obtain the wrapping quality when the wrapping angle remains unchanged at the next moment; in response to the wrapping quality when the wrapping angle remains unchanged at the next moment being equal to 0, there is no need to adjust the current wrapping angle, otherwise, the wrapping angle at the next moment is corrected.

2. The method for online monitoring of production quality of temperature rise resistant cable according to claim 1, characterized in that: Process the image and extract the cable contour information in the cable image. include: Each of the cable images includes a complete preset number of wrapping overlap regions, and two adjacent cable images include non-repeating wrapping overlap regions; Perform edge detection on the cable image to obtain the cable contour information, perform noise reduction preprocessing on the contour information, and enhance the image contrast and brightness distribution, wherein the contour information includes: the two widths of each wrapping pitch of the wrapping material during wrapping and , two widths of each wrap overlap area and , and the diameter of the cable .

3. The method for online monitoring of production quality of temperature rise resistant cable according to claim 1, characterized in that: The calculation method of the wrapping quality can also be replaced by: The ratio between the product of the wrapping overlap rate and the wrapping parallelism of the target wrapping and a preset standard is calculated as the wrapping quality of the target wrapping.

4. The method for online monitoring of production quality of temperature rise resistant cable according to claim 1, characterized in that: in, Correct the wrapping angle at the next moment, including: Obtaining a wrapping overlap rate corresponding to a wrapping angle in historical data, and taking a ratio of the wrapping overlap rate to the wrapping angle as a proportional coefficient; A corrected wrapping angle of the wrapping overlap ratio of the current wrapping angle compared to a preset standard is calculated based on the proportional coefficient.

5. The method for online monitoring of production quality of temperature rise resistant cable according to claim 4, characterized in that: The modified wrapping angle satisfies the following relationship: ； In the formula, Indicates the correction of wrapping angle. Indicates the angle corresponding to the wrapping at the current moment, Indicates the proportional coefficient between the wrapping overlap rate and the wrapping angle in the historical data. Indicates The wrapping overlap ratio.

6. The online monitoring system for the production quality of temperature-resistant cable is characterized by: include: A processor and a memory, wherein the memory stores computer program instructions, and when the computer program instructions are executed by the processor, the online monitoring method for the production quality of the temperature rise resistant curve cable according to any one of claims 1 to 5 is implemented.

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