Electromagnetic coil winding detection device and detection method thereof

Abstract

The present invention discloses an electromagnetic coil winding detection device and a detection method thereof, which belongs to the field of electromagnetic coil detection technology and solves the problem that the existing technology cannot accurately detect the segment width, segment spacing, segment height, total coil length and number of turns of the electromagnetic coil by relying solely on image acquisition. It includes a flaring component that can be moved back and forth in the horizontal direction, a circular arc rail located on one side of the flaring component that can be moved back and forth in the horizontal and vertical directions, a data acquisition module slidably connected to the circular arc rail, an image acquisition module, a data processing module, and a control module. The flaring component is rotatable and its rotation axis is located on the horizontal plane. The present invention fixes the electromagnetic coil on the flaring component, cooperates with the image acquisition module to obtain an image, identifies the coil type, and the control module adjusts the position distance, collects the number of coil turns, filters the image, and calculates the coil size to improve the accuracy of the electromagnetic coil characteristic judgment.

Description

Technical Field

[0001] The present invention relates to the technical field of electromagnetic coil detection, and in particular to an electromagnetic coil winding detection device and a detection method thereof. Background Art

[0002] An electromagnetic coil is an electrical device that operates on the principle of electromagnetism. It is typically made of one or more solenoids wound from a wire. It generates a magnetic field. When energized, the current within the coil creates a magnetic field that can be used to drive electromagnetic mechanisms or as an electromagnet. Electromagnetic coils are widely used in various electrical and electronic devices, such as relays, solenoid valves, generators, transformers, and electric motors. Their performance parameters, including inductance, resistance, and number of turns, determine the coil's operating characteristics and range of applications. The design and manufacture of electromagnetic coils require precise control of wire diameter, number of turns, coil shape, and material to ensure performance and reliability in specific applications.

[0003] Dimensional inspection of electromagnetic coils is crucial because it directly impacts the coil's electromagnetic performance and mechanical stability. Parameters such as segment width, segment spacing, segment height, total coil length, and number of turns collectively determine key coil characteristics such as inductance, magnetic field strength and distribution, and heat dissipation. Accurate dimensional inspection ensures coil performance and reliability in specific applications, prevents electrical failures such as inter-turn shorts or insulation breakdown, and helps improve production efficiency and product quality. Dimensional inspection is also crucial for electromagnetic compatibility (EMC) compliance, as it affects the distribution of the coil's generated magnetic field and its susceptibility to external electromagnetic interference.

[0004] In the prior art, in order to obtain the above-mentioned inspection data, an image collector is generally used to detect the outer surface of the coil. The image collector generally needs to move back and forth to capture images of the coil. However, this detection method is very dependent on the clarity of the image obtained by the image collector, and has extremely high requirements on the shooting pixels of the image collector itself. Usually, tools such as high-definition cameras are required for shooting. For manufacturers, this undoubtedly greatly increases the cost required for electromagnetic coil testing. In addition, when a high-definition image collector is used for image capture, it is also required to complete the dimming action according to the ambient light conditions in advance. Otherwise, the captured image content will be affected by reflections and other problems. Therefore, considering these problems, the prior art cannot accurately detect the segment width, segment spacing, segment height, total coil length and number of turns of the electromagnetic coil by relying solely on image capture, which leads to the inaccuracy of the key characteristics of the coil, such as inductance, magnetic field strength and distribution, and heat dissipation performance, which are ultimately calculated based on these parameters.

[0005] Therefore, an electromagnetic coil winding detection device and a detection method thereof are proposed to solve or alleviate the above problems. Summary of the Invention

[0006] The purpose of the present invention is to solve the shortcomings of the prior art and to propose an electromagnetic coil winding detection device and a detection method thereof.

[0007] In order to achieve the above object, the present invention adopts the following technical solutions:

[0008] A device for detecting the winding of an electromagnetic coil comprises a flaring component which can be displaced back and forth in the horizontal direction, an arc rail located on one side of the flaring component which can be displaced back and forth in the horizontal and vertical directions, a data acquisition module, an image acquisition module, a data processing module, and a control module which are slidably connected to the arc rail, wherein the flaring component can be rotatably arranged and its rotation axis is located on a horizontal plane, the data acquisition module has a vertical downward state and a horizontal state on the arc rail, the data acquisition module collects the number of turns of the spiral coil and the number of turns of the annular coil in the vertical downward state or the horizontal state respectively, the image acquisition module is used to collect end face images and peripheral images of the electromagnetic coil and feed them back to the data processing module, the data processing module can be used to identify the type of the electromagnetic coil and output the results to the control module, and can be used to identify the dimensional parameters of the electromagnetic coil, the control module can be used to adjust the state of the data acquisition module according to the output results of the data processing module, and can be used to control the orientation of the flaring component and the data acquisition module.

[0009] Preferably, it also includes a base and a bracket, the base is fixedly connected to a first transverse electric slide rail, the slide seat of the first transverse electric slide rail is fixedly connected to a reduction motor, the flaring assembly is fixedly connected to the output shaft of the reduction motor, the bracket is fixedly connected to a horizontally arranged second transverse electric slide rail, the second transverse electric slide rail has the same length direction as the first transverse electric slide rail, the slide seat of the second transverse electric slide rail is fixedly connected to a vertically arranged vertical electric slide rail, and the arc rail is fixedly connected to the slide seat of the vertical electric slide rail through a connecting bracket.

[0010] Preferably, the flaring assembly includes a double-threaded rod coaxially fixedly connected to the output shaft of the reduction motor, a limit plate fixedly connected to the end of the double-threaded rod away from the reduction motor, a threaded sleeve threadedly connected to the two sections of external threads in the double-threaded rod, a hinged seat fixedly connected to the outer ring of the threaded sleeve, a hinged rod with an end rotatably connected to the hinged seat, and a rotating seat. The two sections of external threads on the double-threaded rod have opposite rotation directions, and the ends of the hinged rods on both sides away from the hinged seat are rotatably connected to the rotating seat.

[0011] Preferably, the image acquisition unit includes a stand, a connecting base mounted on the stand, and a camera detachably connected to the connecting base.

[0012] Preferably, the arc angle of the circular arc rail is 90 degrees, and a slide groove with a T-shaped cross section that runs through the two ends and the inner ring of the circular arc rail is provided in the circular arc rail. A T-shaped slide is slidably connected in the circular arc rail, and a guide wheel in contact with the inner side wall of the slide groove is rotatably connected to the slide. A ball groove that is concave upwards is provided at the center of the bottom surface of the guide wheel, and a ball that can contact the bottom surface of the slide groove is movably connected in the ball groove. End plates are fixedly connected to both ends of the circular arc rail by bolts, and a countersunk groove is provided on the side of the end plate facing the circular arc rail. The inner wall of the trough is provided with a through hole that passes through the end plate, and an end return spring that can contact the slide is fixedly connected in the trough, and a mounting seat is fixedly connected to the end plate located at the upper end of the circular arc rail, and a hole that communicates with the outside world with the through hole is provided on the mounting seat, and a servo motor is fixedly connected to the mounting seat, and a take-up drum is fixedly connected to the output shaft of the servo motor, and the outer ring of the take-up drum is fixedly connected with a connecting rope that passes through the hole and is fixedly connected to the slide after the through hole, and the data acquisition module is fixedly connected to one end of the slide that passes through the slide groove.

[0013] Preferably, the data acquisition module includes a connecting tube fixedly connected to one end of the slide through the slide groove, a resistive displacement sensor fixedly connected to one end of the slide through the slide groove and located in the connecting tube, and a cone needle slidably connected in the connecting tube, the outer peripheral wall of the connecting tube is provided with a sliding groove that penetrates the interior and is arranged along the length direction of the connecting tube, the outer peripheral wall of the cone needle is fixedly connected to a slider slidably connected in the sliding groove, and a vertical return spring is fixedly connected between the detection end of the resistive displacement sensor and the upper end of the cone needle.

[0014] Preferably, the control module includes a controller and a motor drive chip, the controller includes an STM32F103RCT6 embedded-microcontroller integrated circuit, and the motor drive chip includes a TB67S109AFTG motor drive chip.

[0015] Preferably, the data processing module can be used to identify the type of electromagnetic coil and output the result to the control module, including the following steps:

[0016] Import the end face and periphery pictures of the electromagnetic coil;

[0017] Grayscale and denoise the end face and periphery images of the electromagnetic coil;

[0018] The processed end face image and periphery image of the electromagnetic coil are used to calculate the gradient and gradient amplitude of the image through the Canny edge detection algorithm, and the edge is determined using non-maximum suppression and double threshold processing;

[0019] The strip-shaped parallel light spot is found in the end face image and the peripheral image after edge detection using the Hough transform formula. The Hough transform formula is ρ = x·cosθ + y·sinθ, where θ is the angle of the line and ρ is the distance from the line to the origin.

[0020] If there is a strip-shaped parallel light spot in the end face image but not in the peripheral image, the output result is a ring coil. If there is no strip-shaped parallel light spot in the end face image but present in the peripheral image, the output result is a spiral coil. If there is a strip-shaped parallel light spot in both the end face image and the peripheral image, the output result is a ring coil.

[0021] Preferably, the data processing module can be used to identify the size parameters of the electromagnetic coil, and further comprises the following steps:

[0022] Import the number of coil turns from the data acquisition module, and import the end face image or peripheral image from the image acquisition module;

[0023] Perform denoising on the end face image or peripheral image;

[0024] Use the findContours function in OpenCV to extract the contour area of ​​the denoised end face image or the peripheral image Among them, P i and P i+1 are two adjacent points on the contour, n is the number of points on the contour, and det is the determinant;

[0025] The contour area A contour Compare with the end face area or side face area of ​​the electromagnetic coil and calculate the contour area A of the end face image or the peripheral image. contour After the area of ​​the end face or side surface of the electromagnetic coil is smaller than that of the electromagnetic coil, the contour in the end face image or the peripheral image is filtered out as a clear image;

[0026] The edge detection algorithm is used to extract each coil in the clear picture, and the pixel distance of each coil is converted to the actual length. Among them, W pixel To clearly define the segment width, segment spacing, and segment height in the image, W real is the actual segment width, segment spacing, and segment height, D is the shooting distance, and f is the focal length of the camera;

[0027] The total coil length is calculated using the number of coil turns, the actual segment width, segment spacing, and segment height.

[0028] The present invention also provides a detection method for an electromagnetic coil winding detection device, which uses the electromagnetic coil winding detection device as described above to perform detection, comprising the following steps:

[0029] The electromagnetic coil is placed on the outside of the flaring component and fixed;

[0030] The image acquisition module acquires the peripheral image and the end face image of the electromagnetic coil and feeds them back to the data processing module;

[0031] The data processing module identifies the electromagnetic coil as a ring coil or a threaded coil based on the peripheral image and the end face image and outputs the result to the control module;

[0032] When the received output result is a ring coil, the control module controls the data acquisition module to be in a horizontal state and controls the detection end of the data acquisition module to contact the end surface of the ring coil, and causes the flaring component to drive the electromagnetic coil to rotate, and outputs the number of coil turns through the number of beats of the detection end of the data acquisition module;

[0033] When the output result is a spiral coil, the control module controls the data acquisition module to be in a vertical downward state and controls the detection end of the data acquisition module to contact the outer end of the spiral coil, and controls the flaring component to drive the electromagnetic coil to move in one direction, and outputs the number of coil turns through the number of times the detection end of the data acquisition module beats;

[0034] The number of coil turns, peripheral image and end face image are transmitted to the data processing module, and the data processing module identifies and exports the size parameters of the electromagnetic coil.

[0035] The present invention has the following beneficial effects:

[0036] When the present invention is actually applied, the electromagnetic coil to be detected can be fixed on the flaring component, and the electromagnetic coil can cooperate with the image acquisition module to obtain the peripheral image and the end face image to enable the data processing module to identify whether the electromagnetic coil is a ring coil or a spiral coil. After outputting the result, the control module is controlled to control the position and distance between the data acquisition module and the electromagnetic coil, and at the same time control the data acquisition module to collect the number of coil turns of the electromagnetic coil, and then filter the peripheral image and the end face image to ensure that the object identified by the data processing module is clearer, and then obtain the segment width, segment spacing, and segment height of a single coil in the electromagnetic coil, and then calculate the total length of the coil in combination with the number of coil turns obtained by actual detection, so that the final output data result is more accurate, so that the detection personnel can use this as a benchmark to make more accurate judgments on key characteristics such as the inductance, magnetic field strength and distribution, and heat dissipation performance of the electromagnetic coil. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. It should be understood that the following drawings only illustrate certain embodiments of the present invention and therefore should not be regarded as limiting the scope. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0038] Figure 1 Schematic diagram of the structure of the electromagnetic coil winding detection device of the present invention;

[0039] Figure 2 It is a cross-sectional view of the circular arc rail and the data acquisition module in the present invention;

[0040] Figure 3 for Figure 2 Enlarged view of point A in the middle;

[0041] Figure 4 for Figure 2 Enlarged view of point B in the middle;

[0042] Figure 5 This is a structural block diagram of the image acquisition module, data acquisition module, data processing module, and control module in the present invention.

[0043] In the figure: 1. base; 2. first horizontal electric slide rail; 3. reduction motor; 4. double threaded rod; 5. limit plate; 6. threaded sleeve; 7. hinge seat; 8. hinge rod; 9. rotating seat; 10. bracket; 11. second horizontal electric slide rail; 12. vertical electric slide rail; 13. connecting bracket; 14. arc rail; 15. mounting seat; 16. servo motor; 17. take-up reel; 18. stand; 19. camera; 20. taper needle; 21. connecting pipe; 22. sliding groove; 23. slider; 24. resistive displacement sensor; 25. vertical return spring; 26. end plate; 27. through hole; 28. sink; 29. ​​end return spring; 30. slide groove; 31. slide; 32. guide wheel; 33. ball; 34. image acquisition module; 35. data acquisition module; 36. data processing module; 37. control module. DETAILED DESCRIPTION

[0044] To make the objectives, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings herein can be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but rather merely represents selected embodiments of the present invention. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without creative effort shall fall within the scope of protection of the present invention.

[0046] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, it does not need to be further defined or explained in subsequent drawings.

[0047] In the description of the present invention, it should be understood that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, or are the orientation or position relationship in which the product of the invention is usually placed when in use, or are the orientation or position relationship commonly understood by those skilled in the art. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or component referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0048] Furthermore, the terms “first,” “second,” “third,” etc., are merely used for distinguishing descriptions and are not to be understood as indicating or implying relative importance.

[0049] In the description of the present invention, it should also be noted that, unless otherwise expressly specified or limited, the terms "disposed," "installed," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; they may refer to mechanical connections or electrical connections; they may refer to direct connections or indirect connections through an intermediate medium; and they may refer to internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0050] An electromagnetic coil winding detection device, such as Figure 1 and Figure 5 As shown, it includes a base 1 and a bracket 10, a flaring component that can be moved back and forth in the horizontal direction, an arc rail 14 located on one side of the flaring component that can be moved back and forth in the horizontal and vertical directions, a data acquisition module 35 slidably connected to the arc rail 14, an image acquisition module 34, a data processing module 36, and a control module 37.

[0051] The flaring component can be rotatably set and its rotation axis is located on the horizontal plane. The data acquisition module 35 exists in a vertical downward state and a horizontal state on the arc rail 14. Specifically, a first transverse electric slide rail 2 is fixedly connected to the base 1, and a reduction motor 3 is fixedly connected to the slide seat of the first transverse electric slide rail 2. The flaring component is fixedly connected to the output shaft of the reduction motor 3. A horizontally set second transverse electric slide rail 11 is fixedly connected to the bracket 10. The second transverse electric slide rail 11 has the same length direction as the first transverse electric slide rail 2. A vertically set vertical electric slide rail 12 is fixedly connected to the slide seat of the second transverse electric slide rail 11. The arc rail 14 is fixedly connected to the slide seat of the vertical electric slide rail 12 through the connecting bracket 13.

[0052] like Figure 1 As shown, the flaring assembly includes a double-threaded rod 4 coaxially fixedly connected to the output shaft of the reduction motor 3, a limit plate 5 fixedly connected to the end of the double-threaded rod 4 away from the reduction motor 3, a threaded sleeve 6 threadedly connected to the two sections of external threads in the double-threaded rod 4, a hinged seat 7 fixedly connected to the outer ring of the threaded sleeve 6, an articulated rod 8 with an end rotatably connected to the articulated seat 7, and a rotating seat 9. The rotation directions of the two sections of external threads on the double-threaded rod 4 are opposite, and the ends of the articulated rods 8 on both sides away from the articulated seat 7 are rotatably connected to the rotating seat 9.

[0053] The data acquisition module 35 collects the number of turns of the spiral coil and the number of turns of the toroidal coil in the vertical downward state or the horizontal state, such as Figure 2-Figure 4 As shown, the arc angle of the circular arc rail 14 is 90°, and a slide groove 30 with a T-shaped cross section that runs through the two ends and the inner ring of the circular arc rail 14 is provided in the circular arc rail 14. A T-shaped slide 31 is slidably connected in the circular arc rail 14, and a guide wheel 32 that contacts the inner side wall of the slide groove 30 is rotatably connected to the slide 31. A ball groove that is concave upward is provided at the center of the bottom surface of the guide wheel 32, and a ball 33 that can contact the inner bottom surface of the slide groove 30 is movably connected in the ball groove. Both ends of the circular arc rail 14 are fixedly connected to end plates 26 by bolts, and a sink groove 28 is provided on the side of the end plate 26 facing the circular arc rail 14. A through hole 27 is provided on the inner wall which passes through the end plate 26. An end return spring 29 which can contact the slide 31 is fixedly connected in the sinking groove 28. A mounting seat 15 is fixedly connected to the end plate 26 at the upper end of the circular arc rail 14. A hole which communicates with the through hole 27 and is connected to the outside world is provided on the mounting seat 15. A servo motor 16 is fixedly connected to the mounting seat 15. A take-up drum 17 is fixedly connected to the output shaft of the servo motor 16. A connecting rope which passes through the hole and the through hole 27 and is fixedly connected to the slide 31 is fixedly connected to the outer ring of the take-up drum 17. A data acquisition module 35 is fixedly connected to one end of the slide 31 which passes through the slide groove 30.

[0054] like Figure 5As shown, the image acquisition module 34 is used to capture end face images and peripheral images of the electromagnetic coil and feed them back to the data processing module 36. The image acquisition unit includes a stand 18, a connecting seat mounted on the stand 18, and a camera 19 detachably connected to the connecting seat.

[0055] like Figures 2 to 5 As shown, the data processing module 36 can be used to identify the type of electromagnetic coil and output the result to the control module 37, and can be used to identify the size parameters of the electromagnetic coil. The data acquisition module 35 includes a connecting tube 21 fixedly connected to one end of the slide 31 passing through the slide groove 30, a resistive displacement sensor 24 fixedly connected to one end of the slide 31 passing through the slide groove 30 and located in the connecting tube 21, and a tapered needle 20 slidably connected in the connecting tube 21. A sliding groove 22 is provided on the outer peripheral wall of the connecting tube 21, which penetrates the interior and is arranged along the length direction of the connecting tube 21. A slider 23 slidably connected to the sliding groove 22 is fixedly connected to the outer peripheral wall of the tapered needle 20. A vertical return spring 25 is fixedly connected between the detection end of the resistive displacement sensor 24 and the upper end of the tapered needle 20.

[0056] like Figure 5 As shown, the data processing module 36 can be used to identify the type of electromagnetic coil and output the result to the control module 37, including the following steps:

[0057] Import the end face and periphery pictures of the electromagnetic coil;

[0058] Grayscale and denoise the end face and periphery images of the electromagnetic coil;

[0059] The processed end face image and periphery image of the electromagnetic coil are used to calculate the gradient and gradient amplitude of the image through the Canny edge detection algorithm, and the edge is determined using non-maximum suppression and double threshold processing;

[0060] The Hough transform formula is used to find the strip-shaped parallel light spot in the end face image and the peripheral image after edge detection. The Hough transform formula is ρ = x·cosθ + y·sinθ, where θ is the angle of the line and ρ is the distance from the line to the origin.

[0061] If there is a strip-shaped parallel light spot in the end face image but not in the peripheral image, the output result is a ring coil. If there is no strip-shaped parallel light spot in the end face image but present in the peripheral image, the output result is a spiral coil. If there is a strip-shaped parallel light spot in both the end face image and the peripheral image, the output result is a ring coil.

[0062] The data processing module 36 can be used to identify the size parameters of the electromagnetic coil, and also includes the following steps:

[0063] Import the number of coil turns from the data acquisition module 35 and import the end face image or peripheral image from the image acquisition module 34;

[0064] Perform denoising on the end face image or peripheral image;

[0065] Use the findContours function in OpenCV to extract the contour area of ​​the denoised end face image or the peripheral image Among them, P i and P i+1 are two adjacent points on the contour, n is the number of points on the contour, and det is the determinant;

[0066] The contour area A contour Compare with the end face area or side face area of ​​the electromagnetic coil and calculate the contour area A of the end face image or the peripheral image. contour After the area of ​​the end face or side surface of the electromagnetic coil is smaller than that of the electromagnetic coil, the contour in the end face image or the peripheral image is filtered out as a clear image;

[0067] The edge detection algorithm is used to extract each coil in the clear picture, and the pixel distance of each coil is converted to the actual length. Among them, W pixel To clearly define the segment width, segment spacing, and segment height in the image, W real is the actual segment width, segment spacing, and segment height, D is the shooting distance, and f is the focal length of the camera 19;

[0068] The total coil length is calculated using the number of coil turns, the actual segment width, segment spacing, and segment height.

[0069] like Figure 5 As shown, the control module 37 can be used to adjust the state of the data acquisition module 35 according to the output results of the data processing module 36, and can be used to control the orientation of the expansion component and the data acquisition module 35. The control module 37 includes a controller and a motor driver chip. The controller includes an STM32F103RCT6 embedded-microcontroller integrated circuit, and the motor driver chip includes a TB67S109AFTG motor driver chip.

[0070] The present invention also provides a detection method for an electromagnetic coil winding detection device, which uses the electromagnetic coil winding detection device as described above to perform detection, comprising the following steps:

[0071] The electromagnetic coil is placed on the outside of the flaring component and fixed;

[0072] The image acquisition module 34 acquires the peripheral image and the end face image of the electromagnetic coil and feeds them back to the data processing module 36;

[0073] The data processing module 36 identifies the electromagnetic coil as a ring coil or a threaded coil based on the peripheral image and the end face image and outputs the result to the control module 37;

[0074] When the received output result is a toroidal coil, the control module 37 controls the data acquisition module 35 to be in a horizontal state and controls the detection end of the data acquisition module 35 to contact the end surface of the toroidal coil, and controls the flaring component to drive the electromagnetic coil to rotate, and outputs the number of coil turns through the number of times the detection end of the data acquisition module 35 beats;

[0075] When the output result is a spiral coil, the control module 37 controls the data acquisition module 35 to be in a vertical downward state and controls the detection end of the data acquisition module 35 to contact the outer end of the spiral coil, and causes the flaring component to drive the electromagnetic coil to move in one direction. The number of turns of the coil is output by the number of times the detection end of the data acquisition module 35 beats;

[0076] The number of coil turns, the peripheral image and the end face image are transmitted to the data processing module 36 , which identifies and derives the size parameters of the electromagnetic coil.

[0077] The electromagnetic coil winding inspection method provided by the present invention can effectively identify and measure key parameters of electromagnetic coils in practical applications. First, the electromagnetic coil to be inspected is securely mounted on the flaring assembly to ensure its position is fixed. Next, the image acquisition module 34 captures a full range of images of the electromagnetic coil, including peripheral and end-face images. These images are then fed into the data processing module 36, which accurately distinguishes whether the electromagnetic coil is a toroidal coil or a helical coil.

[0078] After identifying the coil type, control module 37 intervenes and adjusts the relative position and distance between data acquisition module 35 and the electromagnetic coil to optimize image acquisition quality and accuracy. Control module 37 also instructs data acquisition module 35 to accurately capture the number of turns in the electromagnetic coil. The captured peripheral and end-face images are filtered to enhance image clarity, enabling data processing module 36 to more accurately identify each coil component.

[0079] Through this process, we can obtain the detailed dimensions of a single coil in the electromagnetic coil, including segment width, segment spacing, and segment height. Combined with the number of coil turns obtained in actual detection, we can calculate the total length of the coil.

[0080] This precise data will provide a solid foundation for the final output results, allowing testers to make more accurate assessments and judgments on key characteristics of the electromagnetic coil, such as inductance, magnetic field strength and distribution, and heat dissipation performance.

[0081] The detection method of the present invention not only improves the accuracy of electromagnetic coil detection in conjunction with the detection device, but also simplifies the detection process, allowing detection personnel to complete the detection task quickly and efficiently.

[0082] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. An electromagnetic coil winding detection device, characterized in that: The invention comprises a flaring component that can be reciprocated in the horizontal direction, an arc rail (14) located on one side of the flaring component that can be reciprocated in the horizontal and vertical directions, a data acquisition module (35) slidably connected to the arc rail (14), an image acquisition module (34), a data processing module (36), and a control module (37), wherein the flaring component can be rotatably arranged and its rotation axis is located on a horizontal plane, the data acquisition module (35) is in a vertical downward state and a horizontal state on the arc rail (14), and the data acquisition module (35) is in a vertical downward state or a horizontal state. In a flat state, the number of turns of the spiral coil and the number of turns of the annular coil are collected respectively. The image acquisition module (34) is used to collect an end face picture and a peripheral picture of the electromagnetic coil and feed them back to the data processing module (36). The data processing module (36) can be used to identify the type of the electromagnetic coil and output the result to the control module (37), and can be used to identify the size parameters of the electromagnetic coil. The control module (37) can be used to adjust the state of the data acquisition module (35) according to the output result of the data processing module (36), and can be used to control the orientation of the flaring component and the data acquisition module (35); The data acquisition module (35) includes a connecting tube (21) fixedly connected to one end of the slide (31) and penetrating the slide groove (30), a resistive displacement sensor (24) fixedly connected to one end of the slide (31) and penetrating the slide groove (30) and located in the connecting tube (21), and a cone needle (20) slidably connected in the connecting tube (21), a sliding groove (22) penetrating the interior of the connecting tube (21) and arranged along the length direction of the connecting tube (21) is provided on the outer peripheral wall of the connecting tube (21), a slider (23) slidably connected in the sliding groove (22) is fixedly connected to the outer peripheral wall of the cone needle (20), and a vertical return spring (25) is fixedly connected between the detection end of the resistive displacement sensor (24) and the upper end of the cone needle (20).

2. The electromagnetic coil winding detection device according to claim 1, characterized in that: The utility model also includes a base (1) and a bracket (10), wherein a first transverse electric slide rail (2) is fixedly connected to the base (1), a reduction motor (3) is fixedly connected to the slide seat of the first transverse electric slide rail (2), and the flaring component is fixedly connected to the output shaft of the reduction motor (3); a second transverse electric slide rail (11) arranged horizontally is fixedly connected to the bracket (10), the second transverse electric slide rail (11) and the first transverse electric slide rail (2) have the same length direction, a vertical electric slide rail (12) is fixedly connected to the slide seat of the second transverse electric slide rail (11), and the arc rail (14) is fixedly connected to the slide seat of the vertical electric slide rail (12) through the connecting bracket (13).

3. The electromagnetic coil winding detection device according to claim 2, characterized in that: The flaring assembly comprises a double-threaded rod (4) fixedly connected coaxially with the output shaft of the reduction motor (3), a limit plate (5) fixedly connected to the end of the double-threaded rod (4) away from the reduction motor (3), a threaded sleeve (6) threadedly connected to two sections of external threads in the double-threaded rod (4), a hinge seat (7) fixedly connected to the outer ring of the threaded sleeve (6), a hinged rod (8) whose end is rotatably connected to the hinge seat (7), and a rotating seat (9), wherein the two sections of external threads on the double-threaded rod (4) have opposite rotation directions, and the ends of the hinged rods (8) on both sides away from the hinge seat (7) are rotatably connected to the rotating seat (9).

4. The electromagnetic coil winding detection device according to claim 1, characterized in that: The image acquisition module (34) comprises a stand (18), a connecting seat sleeved on the stand (18), and a camera (19) detachably connected to the connecting seat.

5. The electromagnetic coil winding detection device according to claim 1, characterized in that: The arc angle of the circular arc rail (14) is 90°, and a slide groove (30) with a T-shaped cross section and passing through the two ends and the inner ring of the circular arc rail (14) is provided in the circular arc rail (14), and a T-shaped slide frame (31) is slidably connected in the circular arc rail (14), and a guide wheel (32) in contact with the inner side wall of the slide groove (30) is rotatably connected to the slide frame (31), and a ball groove that is recessed upward is provided at the center of the bottom surface of the guide wheel (32), and a ball (33) that can contact the inner bottom surface of the slide groove (30) is movably connected in the ball groove, and both ends of the circular arc rail (14) are fixedly connected to end plates (26) by bolts, and a sink groove (28) is provided on the side of the end plate (26) facing the circular arc rail (14), and the inner side of the sink groove (28) is provided with a ball (33) that can contact the inner bottom surface of the slide groove (30). A through hole (27) passing through the end plate (26) is opened on the wall, an end return spring (29) that can contact the slide (31) is fixedly connected in the sinking groove (28), a mounting seat (15) is fixedly connected to the end plate (26) at the upper end of the circular arc rail (14), a hole is opened on the mounting seat (15) that is connected to the outside world with the through hole (27), a servo motor (16) is fixedly connected to the mounting seat (15), a take-up drum (17) is fixedly connected to the output shaft of the servo motor (16), an outer ring of the take-up drum (17) is fixedly connected to a connecting rope that passes through the hole and the through hole (27) and is fixedly connected to the slide (31), and the data acquisition module (35) is fixedly connected to one end of the slide (31) passing through the slide groove (30).

6. The electromagnetic coil winding detection device according to claim 1, characterized in that: The control module (37) includes a controller and a motor drive chip, wherein the controller includes an STM32F103RCT6 embedded microcontroller integrated circuit, and the motor drive chip includes a TB67S109AFTG motor drive chip.

7. The electromagnetic coil winding detection device according to claim 1, characterized in that: The data processing module (36) can be used to identify the type of electromagnetic coil and output the result to the control module (37), including the following steps: Import the end face and periphery pictures of the electromagnetic coil; Grayscale and denoise the end face and periphery images of the electromagnetic coil; The processed end face image and periphery image of the electromagnetic coil are used to calculate the gradient and gradient amplitude of the image through the Canny edge detection algorithm, and the edge is determined using non-maximum suppression and double threshold processing; The strip-shaped parallel light spot is found in the end face image and the peripheral image after edge detection by using the Hough transform formula. The Hough transform formula is: ,in, is the angle of the line, is the distance from the straight line to the origin; If there is a strip-shaped parallel light spot in the end face image but not in the peripheral image, the output result is a ring coil. If there is no strip-shaped parallel light spot in the end face image but present in the peripheral image, the output result is a spiral coil. If there is a strip-shaped parallel light spot in both the end face image and the peripheral image, the output result is a ring coil.

8. The electromagnetic coil winding detection device according to claim 7, characterized in that: The data processing module (36) can be used to identify the size parameters of the electromagnetic coil, and further comprises the following steps: Importing the number of coil turns from the data acquisition module (35), and importing the end face image or the peripheral image from the image acquisition module (34); Perform denoising on the end face image or peripheral image; Use the findContours function in OpenCV to extract the contour area of ​​the denoised end face image or the peripheral image ,in, and are two adjacent points on the contour, n is the number of points on the contour, and det is the determinant; The contour area Compare with the end face area or side face area of ​​the electromagnetic coil and the contour area of ​​the end face image or peripheral image After the area of ​​the end face or side surface of the electromagnetic coil is smaller than the area of ​​the end face or side surface, the contour in the end face image or the peripheral image is filtered out as a clear image; The edge detection algorithm is used to extract each coil in the clear picture, and the pixel distance of each coil is converted to the actual length. ,in, To clearly define the segment width, segment spacing, and segment height in the image, is the actual segment width, segment spacing, and segment height, D is the shooting distance, and f is the focal length of the camera (19); The total coil length is calculated using the number of coil turns, the actual segment width, segment spacing, and segment height.

9. A method for detecting an electromagnetic coil winding detection device, using the electromagnetic coil winding detection device according to any one of claims 1 to 8 for detection, characterized in that: The following steps are included: The electromagnetic coil is placed on the outside of the flaring component and fixed; The image acquisition module (34) acquires the peripheral image and the end face image of the electromagnetic coil and feeds them back to the data processing module (36); The data processing module (36) identifies the electromagnetic coil as a ring coil or a threaded coil based on the peripheral image and the end face image and outputs the result to the control module (37); When the received output result is a ring coil, the control module (37) controls the data acquisition module (35) to be in a horizontal state and controls the detection end of the data acquisition module (35) to contact the end face of the ring coil, and causes the flaring component to drive the electromagnetic coil to rotate, and outputs the number of coil turns through the number of beats of the detection end of the data acquisition module (35); When the output result is a spiral coil, the control module (37) controls the data acquisition module (35) to be in a vertical downward state and controls the detection end of the data acquisition module (35) to contact the outer circumference end of the spiral coil, and causes the flaring component to drive the electromagnetic coil to move in one direction, and outputs the number of coil turns through the number of times the detection end of the data acquisition module (35) beats; The number of coil turns, the peripheral image and the end face image are transmitted to the data processing module (36), and the data processing module (36) identifies and exports the size parameters of the electromagnetic coil.

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