A preparation method and system for an isolated mineral insulated flexible cable

Abstract

The present invention relates to the technical field of insulated flexible cables, and discloses a preparation method and system for an isolated mineral insulated flexible cable. The preparation system includes: a copper tape conveying module, a conveying vehicle and a photodetector; a welding module; a welding detection component; a storage module; a processing module configured to adjust the moving speed of the production line carrying the copper tape when the photodetector determines that the copper tape is exhausted, compare the similarity between the unwelded image and each historical pre-welding image, and use the historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity as the initial welding parameter combination; the processing module is further configured to perform primary adjustment and secondary adjustment; and a control module. By means of automatic detection, intelligent adjustment and continuous production, etc., the present invention significantly improves the production efficiency and product quality of the isolated mineral insulated flexible cable, reduces the production cost at the same time, and realizes the efficient production of long-distance cables.

Description

Technical Field

[0001] The present invention relates to the technical field of insulated flexible cables, and more particularly, to a preparation method and system for an isolated type mineral insulated flexible cable. Background Art

[0002] When manufacturing an isolated type mineral insulated flexible cable, a copper strip reel needs to be wrapped around the surface of a copper core to form a copper sheath isolation layer for isolation. However, the length of the copper strip reel is limited. Whenever a cable of kilometer level is produced, the copper strip reel needs to be replaced. At this time, it is necessary to stop the machine for replacement and manually weld the connection between the newly replaced copper strip reel and the original copper strip reel. This step not only reduces production efficiency and fails to meet the requirement of infinite length production, but also due to inappropriate welding parameters during the welding process, the welding quality at the connection is poor.

[0003] In order to improve product quality, reduce production costs and achieve large - batch automated production, it is particularly important to study a process for an isolated type mineral insulated flexible cable that can be continuously prepared without stopping the machine. Summary of the Invention

[0004] In view of this, the present invention provides a preparation method and system for an isolated type mineral insulated flexible cable, aiming to solve the problems in the current technology that the copper strip reel needs to be continuously replaced and the welding quality at the connection between the new and old copper strip reels is poor.

[0005] On the one hand, a preparation system for an isolated type mineral insulated flexible cable proposed by the present invention includes:

[0006] A copper strip conveying module, including a transport vehicle for placing a copper strip reel and a photoelectric detector for detecting the usage status of the copper strip;

[0007] A welding module, configured to weld the connection of the copper sheath isolation layer formed by two copper strip reels;

[0008] A welding detection assembly, configured to collect real - time welding temperature, weld width, object contrast, unwelded image, and welding - end image during the welding process;

[0009] A storage module, configured to store the grayscale historical pre - welding image and historical welding - end image and the corresponding historical welding parameter combinations, and the storage module also stores the standard object contrast of a standard welded part;

[0010] The processing module is configured to adjust the moving speed of the pipeline carrying the copper strip when the photodetector determines that the copper strip is exhausted, compare the similarity between the unwelded image and each of the historical pre-welding images, and use the historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity as the initial welding parameter combination; the initial welding parameter combination includes: the initial welding speed and the initial welding voltage.

[0011] The processing module is further configured to, when starting welding with the initial welding parameter combination, perform a primary adjustment on the real-time welding temperature according to the real-time object contrast during the welding process; perform a secondary adjustment according to the difference between the historical welding end image and the welding end image.

[0012] The control module is configured to control the welding parameters of the welding process according to the instructions of the processing module.

[0013] Among them, the photodetector is arranged between the transporter and the welding module, and the laser beam output end and the receiving end of the photodetector are respectively located on both sides of the copper strip. When the copper strip is exhausted, the receiving end of the photodetector detects the laser signal, and the copper strip conveying module determines that the usage state of the copper strip is the exhausted state.

[0014] Further, when the photodetector determines that the copper strip is exhausted, the processing module obtains the interval distance from the straight line where the laser signal is located to the copper strip on the next transport vehicle, preset the copper strip docking time, and the adjusted moving speed of the pipeline satisfies the following relationship:

[0015] ;

[0016] Among them, V is the adjusted moving speed of the pipeline; v is the average moving speed of the transport vehicle; a is the interval distance, and t is the preset copper strip docking time.

[0017] After the photodetector determines that the copper strip is exhausted, it starts timing. When the copper strip docking time is satisfied, it is set that the welding module moves along the moving direction of the pipeline following the pipeline and starts welding.

[0018] Further, when comparing the similarity between the unwelded image and each of the historical pre-welding images and determining the initial welding parameter combination, it includes:

[0019] Perform graying and denoising processing on the unwelded image, select the unwelded image and the historical pre-welding image to perform feature extraction based on the ORB algorithm. The initial maximum number of feature points in the feature extraction is 500, the scale factor is 1.2, and the number of pyramid layers is 8 layers.

[0020] Feature matching is performed on the unwelded image and the feature descriptors obtained from the historical pre-welding image through the ORB algorithm. The feature matching uses the brute-force matching algorithm, and the similarity between the feature descriptors is measured according to the Hamming distance. A distance threshold is preset in advance, and the matches with a distance lower than the distance threshold are regarded as valid matches;

[0021] The similarity satisfies the following relationship:

[0022] ;

[0023] where S is the similarity, n is the number of matching points that satisfy being lower than the distance threshold, N1 is the number of feature points of the unwelded image, N2 is the number of feature points of the historical pre-welding image, and min(A, B) represents selecting the smaller value between A and B;

[0024] When obtaining the similarity of each historical pre-welding image, the processing module is further configured to: sort all historical pre-welding images according to the magnitude relationship of the similarities;

[0025] Select the historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity as the initial welding parameter combination.

[0026] Further, after the welding process ends, the processing module determines whether to exclude the current pre-welding image, welding end image, and the corresponding welding parameter combination:

[0027] The welding detection component obtains the real-time object contrast of the welding area, and the processing module presets a contrast threshold and compares it with the real-time object contrast;

[0028] When the real-time object contrast is less than or equal to the contrast threshold, the storage module stores the welding end image as the historical welding end image and stores the corresponding historical welding parameter combination. When the real-time object contrast is greater than the contrast threshold, the storage module does not store the welding end image and the welding parameter combination;

[0029] where the contrast threshold is 0.7 - 1.1 times the standard object contrast.

[0030] Further, a primary adjustment is made to the real-time welding temperature according to the real-time object contrast during the welding process, including:

[0031] Obtain the real-time welding temperature during the welding process, and make a primary adjustment to the real-time welding temperature according to the difference between the standard object contrast and the real-time object contrast to obtain a primary temperature adjustment value. The primary temperature adjustment value satisfies the following relationship:

[0032] ;

[0033] Among them, T1 is the primary temperature adjustment value, k1 is the contrast difference adjustment coefficient, C0 is the standard object contrast, C1 is the real-time object contrast, k2 is the contrast change acceleration adjustment coefficient, and t is the time.

[0034] Furthermore, the processing module is further configured to: when the case occurs, the processing module reduces the real-time welding temperature, and the reduction value is the primary temperature adjustment value; when the case occurs, the processing module increases the real-time welding temperature, and the increase value is the primary temperature adjustment value.

[0035] Furthermore, before the secondary adjustment, it further includes:

[0036] After the welding process is completed, obtain the final object contrast obtained based on X-ray detection, compare the final object contrast with the standard object contrast, and determine whether secondary adjustment is required;

[0037] When the difference between the final object contrast and the standard object contrast is less than or equal to ±5%, it is determined that secondary adjustment is not required;

[0038] When the difference between the final object contrast and the standard object contrast is greater than 5%, it is determined that secondary adjustment is required.

[0039] Furthermore, when performing secondary adjustment, it includes:

[0040] Obtain the weld width and the historical weld width respectively according to the welding end image and the historical welding end image, and adjust the initial welding speed according to the relationship between the weld width and the historical weld width, and obtain the adjusted welding speed and satisfy the following relationship:

[0041] ;

[0042] Among them, V2 is the adjusted welding speed, V0 is the initial welding speed, W0 is the historical weld width, W2 is the weld width, α = 0.1, and β = 0.05.

[0043] Furthermore, when performing secondary adjustment, it further includes:

[0044] Adjust the initial welding voltage according to the difference between the final object contrast and the standard object contrast, and obtain the adjusted welding voltage and satisfy the following relationship:

[0045] ;

[0046] Among them, U2 is the adjusted welding voltage, U0 is the initial welding voltage, kD is the welding voltage adjustment coefficient, C2 is the final object contrast, and C0 is the standard object contrast.

[0047] On the other hand, the present invention also provides a method applied to the above preparation system for an isolated mineral insulated flexible cable, and the method includes:

[0048] When the photodetector determines that the copper strip is exhausted, adjust the moving speed of the pipeline carrying the copper strip, compare the similarity between the unwelded image and each pre-welding image in history, and use the historical welding parameter combination corresponding to the pre-welding image with the highest similarity as the initial welding parameter combination;

[0049] When starting welding with the initial welding parameter combination, perform a primary adjustment on the real-time welding temperature according to the real-time object contrast during the welding process; perform a secondary adjustment according to the difference between the historical welding end image and the welding end image;

[0050] The photodetector is arranged between the transport vehicle and the welding area, and the laser beam output end and the receiving end of the photodetector are respectively located on both sides of the copper strip. When the copper strip is exhausted, the receiving end of the photodetector detects the laser signal and determines that the usage state of the copper strip is the exhausted state.

[0051] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0052] The traditional process requires stopping the machine to replace the copper strip reel when it runs out, which not only interrupts the production process but also reduces the overall production efficiency. Through the copper strip conveying module and photoelectric detector in this system, the usage status of the copper strip can be automatically detected, and the conveying speed can be automatically adjusted when the copper strip runs out without stopping the machine, thus realizing the continuity of production and the improvement of efficiency. Through the welding detection component and processing module in this system, the real-time data during the welding process, such as welding temperature, weld width, and object contrast, can be automatically collected and analyzed, and the welding parameters can be automatically adjusted. This eliminates the need for manual intervention, ensures the consistency and stability of welding quality, and makes large-scale automated production possible. This system automatically selects the best combination of initial welding parameters by comparing the similarity between the historical pre-welding image and the non-welded image, and makes primary and secondary adjustments according to the real-time data during the welding process. This intelligent adjustment method can effectively address the problem of poor welding quality caused by inappropriate welding parameters, ensure that the welding quality at the connection meets the requirements, and thus improve the overall quality of the product. By improving production efficiency and automation, this system reduces downtime and manual intervention, thereby reducing production costs. In addition, the optimized welding quality reduces rework and scrap rates, further reducing material and labor costs. In the traditional process, the length of the copper strip reel is limited, and it is necessary to stop the machine to replace it whenever the copper strip runs out, and infinite-length production cannot be achieved. Through the copper strip conveying module and photoelectric detector of this system, the copper strip reel can be replaced without stopping production, realizing the continuous production of infinite-length cables and meeting the production requirements of long-distance cables. The storage module and processing module of this system support the storage and analysis of historical welding data, and through comparison with real-time data, intelligent adjustment of welding parameters is achieved. This data-driven welding method not only improves the accuracy of production but also provides reliable data support for subsequent process optimization. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] By reading the following detailed description of the preferred embodiments, various other advantages and benefits will become clear to those of ordinary skill in the art. The drawings are only for the purpose of illustrating the preferred embodiments and are not considered to be a limitation of the present invention. Moreover, throughout the drawings, the same reference numerals are used to represent the same components. In the drawings:

[0054] Figure 1 is a simplified flowchart of the copper strip welding process for the preparation system of the isolated type mineral insulated flexible cable according to an embodiment of the present invention;

[0055] Figure 2 is a functional block diagram of the preparation system of the isolated type mineral insulated flexible cable according to an embodiment of the present invention.

[0056] In the figure, 1 is a copper strip; 21 is a first transport vehicle; 22 is a second transport vehicle; 31 is a light-emitting end of a photodetector; 32 is a light-receiving end of a photodetector; 4 is a welding module. Detailed implementation manners

[0057] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although the exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments set forth herein. On the contrary, these embodiments are provided so that the present disclosure can be more thoroughly understood and the scope of the present disclosure can be fully conveyed to those skilled in the art. It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the drawings and in conjunction with the embodiments.

[0058] Figure 1 This is a simplified flowchart of the copper strip welding process of the preparation system according to the embodiment of the present invention. Not all structures of the preparation system are shown in the figure. Figure 1 (A) shows the normal working state of the production line. At this time, the first transport vehicle 21 transports the copper strip 1 along the moving direction of the production line; the second transport vehicle 22 waits in standby directly behind the first transport vehicle 21. The laser beam emitted by the light-emitting end 31 of the photodetector is blocked by the copper strip 1 and cannot be captured by the light-receiving end 32 of the photodetector; the welding module 4 is in a standby state. Figure 1 (B) shows the working state when the copper strip 1 on the first transport vehicle 21 is exhausted. When the copper strip 1 on the first transport vehicle 21 is exhausted, the copper strip 1 cannot block the laser beam, and the light-receiving end 32 of the photodetector can receive the laser signal. The system determines that the usage state of the copper strip 1 is an exhausted state. At this time, the first transport vehicle 21 moves backward, and the second transport vehicle 22 moves forward and takes the place of the original first transport vehicle 21. In order to facilitate the second transport vehicle to reach the target position as soon as possible and facilitate the welding process, the moving speed of the production line decreases. a is the distance between the straight line where the laser signal is located and the copper strip on the next transport vehicle; the welding module 4, the copper strip 1, and the production line move at the same speed and in the same direction and start the welding process. Figure 1 (C) is a schematic diagram of the copper strip welding process of the preparation system according to the embodiment of the present invention.

[0059] Refer to Figure 2 As shown, the embodiment of the present invention provides a preparation system for an isolated mineral insulated flexible cable, including:

[0060] A copper strip conveying module, including a transport vehicle for placing a copper strip reel and a photodetector for detecting the usage state of the copper strip;

[0061] A welding module configured to weld the connection of the copper sheath isolation layers formed by two copper strip reels;

[0062] The welding detection component is configured to collect real-time welding temperature, weld width, object contrast, unwelded image, and welded-end image during the welding process;

[0063] The storage module is configured to store the historical pre-welding image and historical welded-end image after grayscale conversion, as well as the corresponding historical welding parameter combinations. The storage module also stores the standard object contrast of the standard welded part;

[0064] The processing module is configured to, when the photodetector determines that the copper strip is exhausted, adjust the moving speed of the pipeline carrying the copper strip, compare the similarity between the unwelded image and each historical pre-welding image, and use the historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity as the initial welding parameter combination; the initial welding parameter combination includes: initial welding speed and initial welding voltage;

[0065] The processing module is also configured to, when starting welding with the initial welding parameter combination, perform a primary adjustment on the real-time welding temperature according to the real-time object contrast during the welding process; perform a secondary adjustment according to the difference between the historical welded-end image and the welded-end image;

[0066] The control module is configured to control the welding parameters of the welding process according to the instructions of the processing module;

[0067] Among them, the photodetector is arranged between the transporter and the welding module, and the laser beam output end and the receiving end of the photodetector are respectively located on both sides of the copper strip. When the copper strip is exhausted, the receiving end of the photodetector detects the laser signal, and the copper strip conveying module determines that the usage state of the copper strip is the exhausted state.

[0068] It should be noted that in this embodiment, the transporter at least includes: the first transporter 21 and the second transporter 22.

[0069] By introducing the automated detection and adjustment module, the continuity and efficiency of the production process are achieved. The system does not need to stop when the copper strip is exhausted, automatically adjusts the pipeline speed, and intelligently selects the best welding parameter combination according to the historical welding data. During the welding process, precise adjustment is performed by real-time monitoring of the welding temperature and object contrast, thereby improving the welding quality, reducing human intervention and errors. This not only improves the production efficiency and product quality but also significantly reduces the production cost and supports large-scale automated production.

[0070] In some embodiments of the present application, when the photodetector determines that the copper strip is exhausted, the processing module obtains the distance between the straight line where the laser signal is located and the copper strip on the next transporter, preset the copper strip docking time, and the adjusted moving speed of the pipeline satisfies the following relationship:

[0071] ;

[0072] Among them, V is the adjusted moving speed of the pipeline; v is the average moving speed of the transport vehicle; a is the interval distance, and t is the preset butt-joint time of the copper strip.

[0073] After the photodetector determines that the copper strip is exhausted, it starts timing. When the butt-joint time of the copper strip is satisfied, it is set that the welding module moves along the moving direction of the pipeline following the pipeline and starts welding.

[0074] It should be noted that by adjusting the speed of the pipeline, the butt-joint time of the copper strip is accurately matched to ensure that the copper strip can be smoothly and seamlessly butt-jointed after exhaustion, avoiding human errors, and improving the continuity and automation level of production. This system automatically adjusts the speed and prepares for welding when the copper strip is exhausted, reducing the downtime caused by copper strip replacement and improving production efficiency. By controlling the welding module to accurately follow the pipeline and start welding when the butt-joint time of the copper strip arrives, the smoothness and consistency of the welding process are ensured, thereby improving the welding quality and reducing the possibility of welding defects. By setting different butt-joint times and interval distances of the copper strip, the system can flexibly adjust the speed to adapt to production tasks of different specifications and requirements, improving the applicability and reliability of the system.

[0075] In some embodiments of the present application, when comparing the similarity between the unwelded image and each historical pre-welding image and determining the initial welding parameter combination, it includes:

[0076] The unwelded image is gray-scaled and denoised, and feature extraction is performed on the unwelded image and the historical pre-welding image based on the ORB algorithm. The initial maximum number of feature points in feature extraction is 500, the scale factor is 1.2, and the number of pyramid layers is 8.

[0077] The feature descriptors obtained from the unwelded image and the historical pre-welding image through the ORB algorithm are used for feature matching. The brute-force matching algorithm is used for feature matching, and the similarity between the feature descriptors is measured according to the Hamming distance. A distance threshold is preset, and the matches below the distance threshold are regarded as valid matches.

[0078] The similarity satisfies the following relationship:

[0079] ;

[0080] Among them, S is the similarity, n is the number of matching points that satisfy being lower than the distance threshold, N1 is the number of feature points of the unwelded image, N2 is the number of feature points of the historical pre-welding image, and min(A, B) represents selecting the smaller value of A and B.

[0081] When obtaining the similarity of each historical pre-welding image, the processing module is further configured to: sort all historical pre-welding images according to the magnitude relationship of the similarities.

[0082] The historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity is selected as the initial welding parameter combination.

[0083] It should be noted that the denoising process in this embodiment adopts Gaussian filtering method.

[0084] It is understandable that by performing feature extraction and feature matching through the ORB algorithm, this method can efficiently and accurately capture the key features in the image, and accurately match the unwelded image with the historical pre-welding image, so as to select the initial parameter combination that best suits the current welding conditions and reduce the error of manually set parameters. The system can automatically adjust the initial welding parameters according to different unwelded images, making the welding process more intelligent, adapting to different production needs, and improving the automation and operation convenience of the production line. Accurate welding parameter selection can not only reduce welding defects, but also improve the stability of welding quality, thereby improving the consistency and reliability of products, reducing the defective rate in production, and further improving production efficiency. Through feature extraction and matching of the ORB algorithm, the system can complete complex image processing tasks with lower computing resource usage, so that the entire system can still work in real time under high-speed production lines.

[0085] In some embodiments of the present application, after the welding process is completed, the processing module determines whether to discard the pre-welding image and the welding end image and the corresponding welding parameter combination:

[0086] The welding detection component obtains the real-time object contrast of the welding area, and the processing module pre-sets the contrast threshold and compares it with the real-time object contrast;

[0087] When the real-time object contrast is less than or equal to the contrast threshold, the storage module stores the welding end image as a historical welding end image and stores the corresponding historical welding parameter combination; when the real-time object contrast is greater than the contrast threshold, the storage module does not store the welding end image and the welding parameter combination;

[0088] The contrast threshold is 0.7-1.1 times the contrast of the standard object.

[0089] It should be noted that for obtaining the real-time object contrast of the welding area: At the end of welding, the welding detection component will obtain the real-time object contrast of the welding area. Object contrast is an important indicator to measure the visual difference between the welding area and the surrounding background, and is usually used to evaluate the quality of the weld. Setting and comparison of the contrast threshold: The processing module has preset a contrast threshold, which is set to be 0.7 to 1.1 times the standard object contrast (i.e., the contrast of an ideal welded part). This range can flexibly adapt to the micro-changes that may occur under different production conditions, ensuring that the evaluation of welding quality is neither too strict nor too lenient. After obtaining the real-time object contrast, the processing module compares it with the preset contrast threshold. Decision-making for storage and rejection: When the real-time object contrast is less than or equal to the preset contrast threshold, it indicates that the quality of this welding meets the requirements. At this time, the storage module will store the welding end image of this time as a historical welding end image, and at the same time store the corresponding welding parameter combination. If the real-time object contrast is greater than the preset contrast threshold, it means that the welding quality is not ideal or there are defects. To avoid the influence of low-quality welding parameter combinations on future welding processes, the system will not save the welding end image of this time and its corresponding welding parameter combination.

[0090] By comparing the real-time contrast with the preset contrast threshold, the system can automatically reject the welding images and parameter combinations that do not meet the quality standards. This ensures that the data in the historical welding parameter library are all of high quality, thereby improving the consistency of welding quality in future welding processes. The system only retains those welding parameter combinations that pass the quality assessment, which can continuously optimize the welding parameter library, eliminate those parameters that may cause welding defects, and thus improve the overall welding efficiency and quality of the production line. By eliminating the parameter combinations of low-quality welding, the system effectively reduces the defective product rate caused by inappropriate welding parameters, thereby increasing the qualified rate of products and reducing the rework and scrap losses in production. The set contrast threshold range (0.7 to 1.1 times the standard object contrast) gives the system a certain degree of flexibility, enabling the system to adapt to different production environments and material differences without evaluating welding quality too rigidly or too leniently. By filtering out the welding data that do not meet the requirements, the system reduces the storage of useless data, saves storage space, and improves the efficiency and accuracy of data processing. This also provides a more reliable data basis for subsequent welding parameter selection and optimization.

[0091] In some embodiments of the present application, a primary adjustment is made to the real-time welding temperature according to the real-time object contrast during the welding process, including:

[0092] Obtain the real-time welding temperature during the welding process, and make a primary adjustment to the real-time welding temperature according to the difference between the standard object contrast and the real-time object contrast to obtain a primary temperature adjustment value. The primary temperature adjustment value satisfies the following relationship:

[0093] ;

[0094] Wherein, T1 is the primary temperature adjustment value, k1 is the contrast difference adjustment coefficient, C0 is the standard object contrast, C1 is the real-time object contrast, k2 is the contrast change acceleration adjustment coefficient, and t is time.

[0095] It should be noted that the method for determining k1 is as follows:

[0096] Select a batch of representative welding conditions (porosity of welding area) to cover various situations that may occur during the production process. Set multiple welding temperatures and record the standard object contrast C0 at each temperature and the real-time object contrast C1 after actual welding. Perform welding experiments at the set welding temperature, collect the real-time object contrast C1 of each welding, record the temperature T, standard contrast C0 and real-time object contrast C1 under each experimental condition, and calculate the difference between them. .

[0097] Using the statistical method of linear regression, the contrast difference The relationship between the welding temperature adjustment value T1 is fitted to obtain a function form: k1 is the slope of the fitting equation, whose value is determined by regression analysis and represents the sensitivity of contrast difference to temperature adjustment.

[0098] The method for determining k2 is the same as k1. Replace with That's it.

[0099] It is understandable that by continuously monitoring the difference between the object contrast and the standard contrast and dynamically adjusting the welding temperature based on this difference, the system can quickly respond and compensate for any quality fluctuations during the welding process. This adjustment mechanism can ensure the stability of the weld quality, thereby reducing the occurrence of welding defects. By introducing the contrast change acceleration adjustment coefficient (k2) and the contrast difference adjustment coefficient (k1), the system not only considers the contrast difference but also comprehensively considers the speed and trend of the contrast change. This multi-dimensional adjustment method makes the control of the welding temperature more precise and helps prevent quality problems caused by excessive temperature fluctuations during the welding process. The real-time adjustment of the welding temperature is based on the real-time data obtained during the welding process, enabling the system to provide instant feedback and make adjustments. This rapid feedback mechanism allows the system to better adapt to the dynamic changes during the welding process and maintain the continuous stability of the welding quality. This adjustment mechanism automatically adjusts the temperature, reducing the need for manual monitoring and intervention, improving the automation level and efficiency of the production process. At the same time, it also reduces the problem of inconsistent welding quality caused by manual operation errors. Since this adjustment mechanism comprehensively considers the contrast difference and its change speed, the system can maintain high consistency of the welding quality under various welding conditions (such as different materials or welding speeds), with strong adaptability and robustness. By precisely controlling the welding temperature, the system can effectively reduce the rejection rate during the welding process, thereby increasing the qualification rate of the product. This not only helps improve production efficiency but also reduces the costs associated with rework or scrap disposal.

[0100] In some embodiments of the present application, the processing module is further configured to: when occurs, the processing module reduces the real-time welding temperature by a first-level temperature adjustment value; when occurs, the processing module increases the real-time welding temperature by a first-level temperature adjustment value.

[0101] It should be noted that according to the change of the real-time contrast, the welding temperature is adjusted in a timely manner to avoid welding defects caused by too high or too low temperature, such as problems like too wide welds, insecure welding, or material damage. It can automatically adapt to copper strips of different materials and different thicknesses, reducing the strict requirements for production conditions and enhancing the flexibility of the production line. It reduces manual intervention, achieves precise welding through an automatic control system, lowers the technical threshold for operators, and improves production efficiency. Through the real-time adjustment of the temperature, it reduces the problem of unstable welding quality caused by environmental changes or equipment fluctuations during the welding process, ensuring production continuity and product consistency.

[0102] In some embodiments of the present application, before the secondary adjustment, it further includes:

[0103] After the welding process is completed, obtain the final object contrast obtained based on X-ray inspection, compare the final object contrast with the standard object contrast, and determine whether secondary adjustment is required;

[0104] When the difference between the final object contrast and the standard object contrast is less than or equal to ±5%, it is determined that secondary adjustment is not required;

[0105] When the difference between the final object contrast and the standard object contrast is greater than 5%, it is determined that secondary adjustment is required.

[0106] It should be noted that after the welding process is completed, an X-ray inspection system is used to obtain the final object contrast. This contrast value reflects the actual quality of the welded joint and the internal structure of the weld. Compare the obtained final object contrast with the preset standard object contrast. The purpose of this step is to determine whether the set quality standard is achieved during the welding process. No secondary adjustment is required: If the difference between the final object contrast and the standard object contrast is within ±5%, it is considered that the welding quality meets the standard, and no secondary adjustment is required at this time. If the difference between the final object contrast and the standard object contrast exceeds 5%, secondary adjustment is required. This means that some parameters during the welding process may not have achieved the expected effect and need to be adjusted to optimize the welding quality.

[0107] By checking the final object contrast after welding is completed, ensure that the welded joint meets the standard. If there are significant deviations, secondary adjustment can specifically correct the problems during the welding process, improving the stability and reliability of the welding quality. Perform secondary adjustment according to the detection result of the final contrast, enabling the continuous optimization of the welding process. This adjustment mechanism helps to identify and correct the deviations of welding parameters, thereby achieving more precise control of the welding process. Through timely secondary adjustment, the waste products caused by welding quality problems can be reduced. This reduces the production cost and the economic losses brought by rework or scrapping of unqualified products. The system automatically determines whether secondary adjustment is required based on the contrast difference, reducing the need for manual intervention and improving the automation level of the production line. This not only improves the production efficiency but also reduces the technical requirements for operators. Secondary adjustment ensures that the contrast of the final welded product meets the standard requirements, ensuring that the product can achieve the required performance and quality in actual applications. This is of great significance for meeting customer needs and market competitiveness. This secondary adjustment method based on contrast difference enables the system to adapt to the welding requirements under different production conditions, enhancing the adaptability and flexibility of the system to production changes.

[0108] In some embodiments of the present application, when performing secondary adjustment, it includes:

[0109] The weld width and the historical weld width are respectively obtained according to the welding end image and the historical welding end image. The initial welding speed is adjusted based on the relationship between the weld width and the historical weld width, and the adjusted welding speed is obtained and satisfies the following relationship:

[0110] ;

[0111] where V2 is the adjusted welding speed, V0 is the initial welding speed, W0 is the historical weld width, W2 is the weld width, α = 0.1, and β = 0.05.

[0112] It should be noted that by adjusting the welding voltage to compensate for the difference between the final object contrast and the standard contrast, the welding quality can be ensured to be closer to the standard requirements. Adjusting the welding voltage enables the welding process to better adapt to the actual welding conditions, thereby improving the quality and consistency of the welded joints. This adjustment mechanism helps to respond in real time to the possible quality deviations during the welding process, making the welding process more stable. By adjusting the voltage according to the contrast difference, welding defects caused by inappropriate voltage, such as uneven welds or insufficient strength, are reduced. Precise adjustment of the welding voltage can reduce welding defects and lower the probability of subsequent repair or rework. This can save time and cost and improve production efficiency. By adjusting the voltage based on the contrast difference, the system can adapt to different welding conditions and material variations. This adaptability is very important for coping with various changes in production and improves the flexibility of the production line. During the production process, adjusting the welding voltage to cope with the contrast difference can ensure that the welding quality of each batch of products is more consistent, reduce quality fluctuations, and improve the overall consistency of the final products. This adjustment mechanism reduces the need for manual intervention, improves the automation level of the production line through an automated adjustment process, reduces the technical requirements for operators, and at the same time improves production efficiency.

[0113] In some embodiments of the present application, when performing secondary adjustment, it further includes:

[0114] The initial welding voltage is adjusted according to the difference between the final object contrast and the standard object contrast, and the adjusted welding voltage is obtained and satisfies the following relationship:

[0115] ;

[0116] where U2 is the adjusted welding voltage, U0 is the initial welding voltage, kD is the welding voltage adjustment coefficient, C2 is the final object contrast, and C0 is the standard object contrast.

[0117] It should be noted that by adjusting the welding voltage to compensate for the difference between the final object contrast and the standard contrast, the welding quality can be ensured to be closer to the standard requirements. Adjusting the welding voltage enables the welding process to better adapt to the actual welding conditions, thereby improving the quality and consistency of the welded joints. This adjustment mechanism helps to respond in real time to the possible quality deviations during the welding process, making the welding process more stable. By adjusting the voltage according to the contrast difference, welding defects caused by inappropriate voltage, such as uneven weld seams or insufficient strength, are reduced. Precise adjustment of the welding voltage can reduce welding defects and lower the probability of subsequent repair or reprocessing. This can save time and costs and improve production efficiency. By adjusting the voltage based on the contrast difference, the system can adapt to different welding conditions and material variations. This adaptability is very important for coping with various changes in production and improves the flexibility of the production line. By adjusting the welding voltage to cope with the contrast difference during the production process, the welding quality of each batch of products can be ensured to be more consistent, reducing quality fluctuations and enhancing the overall consistency of the final products. This adjustment mechanism reduces the need for manual intervention, improves the automation level of the production line through an automated adjustment process, reduces the technical requirements for operators, and at the same time enhances production efficiency.

[0118] Referring to Figure 2 As shown, the embodiment of the present invention also provides a preparation method for an isolated mineral insulated flexible cable, including:

[0119] When the photodetector determines that the copper strip is exhausted, adjust the moving speed of the pipeline carrying the copper strip, compare the similarity between the unwelded image and each historical pre-welding image, and use the historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity as the initial welding parameter combination;

[0120] When starting welding with the initial welding parameter combination, perform a primary adjustment on the real-time welding temperature according to the real-time object contrast during the welding process; perform a secondary adjustment according to the difference between the historical welding end image and the welding end image;

[0121] The photodetector is arranged between the transport vehicle and the welding area, and the laser beam output end and the receiving end of the photodetector are respectively located on both sides of the copper strip. When the copper strip is exhausted, the receiving end of the photodetector detects the laser signal and determines that the usage state of the copper strip is the exhausted state.

[0122] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: it is still possible to modify the specific implementation manners of the present invention or make equivalent replacements, and any modification or equivalent replacement that does not depart from the spirit and scope of the present invention shall be covered by the protection scope of the claims of the present invention.

Claims

1. A preparation system for an isolated mineral insulated flexible cable, characterized in that: include: A copper belt conveying module, comprising a conveying vehicle for placing a copper belt reel and a photoelectric detector for detecting the use status of the copper belt; A welding module is configured to weld the connection of the copper sheath isolation layer formed by two copper tape reels; A welding detection component is configured to collect real-time welding temperature, weld width, object contrast, unwelded images and welded end images during the welding process; A storage module is configured to store grayscaled historical pre-welding images and historical welding end images and corresponding historical welding parameter combinations, and the storage module also stores a standard object contrast of a standard welded part; The processing module is configured to adjust the moving speed of the assembly line carrying the copper strip when the photoelectric detector determines that the copper strip is exhausted, compare the similarity between the unwelded image and each of the historical pre-welding images, and use the historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity as the initial welding parameter combination; the initial welding parameter combination includes: an initial welding speed and an initial welding voltage; The processing module is further configured to, when welding is started with the initial welding parameter combination, perform a primary adjustment on the real-time welding temperature according to the real-time object contrast during the welding process; perform a secondary adjustment according to the difference between the historical welding end image and the welding end image, wherein the secondary adjustment includes: obtaining the weld width and the historical weld width according to the welding end image and the historical welding end image, respectively, adjusting the initial welding speed according to the relationship between the weld width and the historical weld width, and adjusting the initial welding voltage according to the difference between the final object contrast and the standard object contrast; a control module configured to control welding parameters of the welding process according to the instructions of the processing module; The photoelectric detector is arranged between the conveying vehicle and the welding module, and the laser beam output end and the receiving end of the photoelectric detector are respectively located on both sides of the copper belt. When the copper belt is exhausted, the receiving end of the photoelectric detector detects the laser signal, and the copper belt conveying module determines that the copper belt usage status is exhausted.

2. The preparation system for isolated mineral insulated flexible cables according to claim 1, characterized in that: When the photoelectric detector determines that the copper strip is exhausted, the processing module obtains the distance between the straight line where the laser signal is located and the copper strip on the next transport vehicle, and pre-sets the copper strip docking time. The adjusted assembly line moving speed satisfies the following relationship: ； Wherein, V is the adjusted moving speed of the assembly line; v is the average moving speed of the transport vehicle; a is the spacing distance, and t is the pre-set copper strip docking time; The photoelectric detector starts timing after determining that the copper strip is exhausted. When the copper strip docking time is met, the welding module is set to move along the moving direction of the assembly line and start welding.

3. The preparation system for isolated mineral insulated flexible cables according to claim 1, characterized in that: When the similarity comparison is performed between the unwelded image and each of the historical pre-welding images, and an initial welding parameter combination is determined, the method includes: The unwelded image is grayed and denoised, and the unwelded image and the historical pre-welding image are selected for feature extraction based on the ORB algorithm, wherein the initial maximum number of feature points in the feature extraction is 500, the scale factor is 1.2, and the number of pyramid layers is 8; Perform feature matching on the unwelded image and the feature descriptors obtained by the ORB algorithm of the historical pre-welded image, wherein the feature matching adopts a brute force matching algorithm, measures the similarity between the feature descriptors according to the Hamming distance, pre-sets a distance threshold, and regards the matches below the distance threshold as valid matches; The similarity satisfies the following relationship: ； Among them, S is the similarity, n is the matching point that meets the distance threshold, N1 is the number of feature points of the unwelded image, N2 is the number of feature points of the historical image before welding, min ( , ) indicates selection and The smaller value in ; When obtaining the similarity of each of the historical pre-welding images, the processing module is further configured to: sort all the historical pre-welding images according to the magnitude relationship of each similarity; The historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity is selected as the initial welding parameter combination.

4. The preparation system for isolated mineral insulated flexible cables according to claim 3, characterized in that: The processing module determines whether to discard the pre-welding image and the welding end image and the corresponding welding parameter combination after the welding process is completed: The welding detection component obtains the real-time object contrast of the welding area, and the processing module pre-sets a contrast threshold and compares it with the real-time object contrast; When the real-time object contrast is less than or equal to the contrast threshold, the storage module stores the welding end image as a historical welding end image and stores the corresponding historical welding parameter combination; when the real-time object contrast is greater than the contrast threshold, the storage module does not store the welding end image and the welding parameter combination; The contrast threshold is 0.7-1.1 times the contrast of the standard object.

5. The preparation system for isolated mineral insulated flexible cables according to claim 4, characterized in that: One-level adjustment of real-time welding temperature based on real-time object contrast during welding, including: The real-time welding temperature during the welding process is obtained, and the real-time welding temperature is adjusted in a first level according to the difference between the standard object contrast and the real-time object contrast to obtain a first-level temperature adjustment value, and the first-level temperature adjustment value satisfies the following relationship: ； Among them, T1 is the first-level temperature adjustment value, k1 is the contrast difference adjustment coefficient, C0 is the standard object contrast, C1 is the real-time object contrast, k2 is the contrast change acceleration adjustment coefficient, and t is time.

6. The preparation system for isolated mineral insulated flexible cables according to claim 5, characterized in that: The processing module is also configured to: When , the processing module reduces the real-time welding temperature by a first-level temperature adjustment value; when When , the processing module increases the real-time welding temperature, and the increase value is the first-level temperature adjustment value.

7. The preparation system for isolated mineral insulated flexible cables according to claim 6, characterized in that: Before the secondary adjustment, it also includes: When the welding process is completed, the final object contrast obtained based on X-ray detection is obtained, and the final object contrast is compared with the standard object contrast to determine whether secondary adjustment is required; When the difference between the final object contrast and the standard object contrast is less than or equal to ±5%, it is determined that no secondary adjustment is required; When the difference between the final object contrast and the standard object contrast is greater than 5%, it is determined that a secondary adjustment is required.

8. The preparation system for isolated mineral insulated flexible cables according to claim 7, characterized in that: When making secondary adjustments, it includes: The weld width and the historical weld width are obtained according to the welding end image and the historical welding end image, and the initial welding speed is adjusted according to the relationship between the weld width and the historical weld width to obtain the adjusted welding speed and satisfy the following relationship: ； Among them, V2 is the adjusted welding speed, V0 is the initial welding speed, W0 is the historical weld width, W2 is the weld width, α=0.1, β=0.

05.

9. The preparation system for isolated mineral insulated flexible cables according to claim 8, characterized in that: When making secondary adjustments, it also includes: According to the difference between the final object contrast and the standard object contrast, the initial welding voltage is adjusted to obtain the adjusted welding voltage and satisfy the following relationship: ； Among them, U2 is the adjusted welding voltage, U0 is the initial welding voltage, k D is the welding voltage adjustment coefficient, C2 is the final object contrast, and C0 is the standard object contrast.

10. A method for preparing an isolated mineral insulated flexible cable, applied to the preparation system for an isolated mineral insulated flexible cable according to any one of claims 1 to 9, characterized in that: include: When the photoelectric detector determines that the copper strip is exhausted, the moving speed of the assembly line carrying the copper strip is adjusted, and the similarity between the unwelded image and each historical pre-welding image is compared, and the historical welding parameter combination corresponding to the historical pre-welding image with the highest similarity is used as the initial welding parameter combination; When welding is started with the initial welding parameter combination, the real-time welding temperature is adjusted in the first level according to the real-time object contrast during welding; the second level is adjusted according to the difference between the historical welding end image and the welding end image; The photoelectric detector is arranged between the conveyor vehicle and the welding area, and the laser beam output end and the receiving end of the photoelectric detector are respectively located on both sides of the copper belt. When the copper belt is exhausted, the receiving end of the photoelectric detector detects the laser signal and determines that the copper belt is in an exhausted state.

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