Cable welding system and method with welding spot detection device

Abstract

The invention relates to the technical field of cable welding, in particular to a cable welding system and method with a welding spot detection device, and the welding spot detection device collects and processes an image of a cable welding position and detects welding defects in the processed image. The cable welding system comprises a mounting base, a moving assembly, two clamping assemblies, a butt joint assembly, a welding mold, a high-frequency welding assembly and a welding spot detection device. The moving assembly is arranged on the mounting base, the two clamping assemblies are arranged on the moving assembly and used for clamping cables to be connected, the welding mold is fixed to the moving assembly, located between the two clamping assemblies and used for limiting the two cables to be connected, and the high-frequency welding assembly is used for heating and melting the cables to be connected. The butt joint assembly is used for driving the two clamping assemblies to get close to enable the fused cables to be in butt joint. According to the invention, the quality of the welded cable can be automatically detected, so that problems can be found in time, and subsequent improvement is facilitated.

Description

Technical Field

[0001] The present invention relates to the technical field of cable welding, and in particular to a cable welding system and method with a welding point detection device. Background Art

[0002] Cable welding systems are mainly used in power equipment to ensure reliable connection of the secondary circuit of the equipment. When the cable needs to be maintained, expanded or replaced, the welding system provides a safe way to disconnect and reconnect the circuit. The basic structure includes a welding device, which heats the welding material at the cable to make it molten to facilitate the connection of the cable. The control unit is used to operate the welding equipment to connect the cables to reduce the risk of manual operation. Invention CN118920222A discloses a wiring device and a method of using the same. The wiring device includes a housing, a buckle, a stripping mechanism, a welding mechanism and a suction mechanism. The buckle can selectively buckle the housing. The housing is provided with insertion holes on two opposite sides along the length direction. The stripping mechanism and the welding mechanism are both placed in the housing. There are two stripping mechanisms and they are mirror-imaged. The stripping mechanism includes a stripping assembly and a clamping assembly. The stripping assembly can strip the cable inserted into the housing. The clamping assembly can selectively clamp the cable. The clamping assembly faces the insertion hole. The welding mechanism is placed between the two stripping mechanisms and is used to weld two stripped cables. The suction mechanism is placed on the side wall of the housing and is opposite to the welding mechanism and is used to suck heat and dust from the housing. The invention aims to solve the problem of copper core contamination affecting the welding quality and copper core performance when different cables are welded. However, the quality of the weld is not paid attention to or detected, and the actual welding effect cannot be determined.

[0003] After the existing welding system is connected, it is usually necessary to manually use a magnifying glass to inspect the connection part to determine the connection quality. This has low work efficiency and manual inspection is prone to misjudgment.

[0004] Invention CN114594109A discloses a method for on-site detection of main insulation defects of high-voltage cable fusion joints, comprising the following steps: 1) placing a DR flat-panel detector on one side of the high-voltage cable fusion joint to be tested for receiving X-rays; 2) using an X-ray machine to irradiate the high-voltage cable fusion joint to be tested from the other side; 3) the imaging plate of the DR flat-panel detector acquires an image and transmits it to a computer; 4) after receiving the DR photo, the computer processes the image contrast, and observes whether there are dot-like spots of different brightness in the processed DR photo, and whether the width of the main insulation on both sides of the copper core is different; if there are dot-like spots of different brightness, there are pores in the main insulation of the high-voltage cable fusion joint, and if the width of the main insulation on both sides of the copper core is different, there is a core eccentricity defect in the copper core. This invention uses X-rays to non-destructively detect the internal structure of the high-voltage cable, but the detection equipment is relatively expensive, which is not conducive to large-scale rapid operation and detection, and there is a radiation risk for operators who work for a long time.

[0005] Therefore, how to provide a low-cost, high-quality and efficient cable welding technology that can automatically detect the quality of cables after welding and provide timely feedback on problems to avoid welding defects is a technical problem that needs to be solved urgently in this field. Summary of the invention

[0006] The object of the present invention is to provide a cable welding system and method with a welding point detection device, aiming to quickly and effectively realize cable welding and automatically detect the quality of the cable after welding, so as to find problems in time and facilitate subsequent improvements.

[0007] To achieve the above-mentioned object, in a first aspect, the present invention provides a cable welding system having a welding spot detection device, wherein the welding spot detection device collects and processes images of the cable welding points, and detects welding defects in the processed images;

[0008] The cable welding system includes a mounting base, a moving assembly, two clamping assemblies, a docking assembly, a welding mold, a high-frequency welding assembly and a welding point detection device;

[0009] The movable component is arranged on the mounting base, the two clamping components are arranged on the movable component for clamping the cables to be connected, the welding mold is fixed on the movable component and is located between the two clamping components, and is used to limit the two cables to be connected, the high-frequency welding component is used to heat and melt the cables to be connected, and the docking component is used to drive the two clamping components to be close to each other so that the melted cables are docked.

[0010] In the cable welding system of the present invention, the mounting base serves as the supporting structure of the entire system, ensuring that each component can be stably installed and work together. A moving component is arranged on the mounting base, and the component can be moved on the base by a motor drive or other means to adjust the position of the cable to be welded.

[0011] The moving assembly is equipped with two clamping assemblies, which can clamp the two ends of the cable to be welded to ensure that they remain stable during the welding process. The welding mold is fixed on the moving assembly and located between the two clamping assemblies. Its function is to position the cable during the welding process to ensure the accuracy of the welding position.

[0012] Preferably, the high-frequency welding assembly comprises a high-frequency heating head and a protective shell, and the protective shell is arranged outside the high-frequency heating head;

[0013] The high frequency welding assembly further includes at least one of the following:

[0014] 3) a heat dissipation component, which is used to dissipate heat and cool the high-frequency heating head;

[0015] 4) A ceramic fiber cloth layer, wherein the ceramic fiber cloth layer is arranged on the outer side of the protective shell.

[0016] The high-frequency heating head is a key component that uses electromagnetic induction to quickly heat the cable to a molten state. After the heating is completed, the docking assembly will start, driving the clamping assembly to accurately dock the two melted cable ends to form a fusion point. The fusion point described in the present invention does not only represent a one-dimensional point, but is an integral part where the ends of the two cable segments are accurately fused together, and there is actually a point-line-surface connection.

[0017] Preferably, the ceramic fiber cloth layer is provided on the outer side of the protective shell, and the ceramic fiber cloth layer also includes an electromagnetic shielding agent, and the electromagnetic shielding agent includes conductive fibers.

[0018] In order to further improve the safety and thermal insulation effect of the high-frequency heating head, a ceramic fiber cloth layer is also arranged on the outside of the protective shell. As a high-temperature resistant inert material, the ceramic fiber cloth layer can not only effectively isolate heat and reduce heat loss, but also enhance the overall safety of the high-frequency heating head and prevent the external environment from being affected by high temperature. On this basis, since the high-frequency heating head used in the present invention has a certain outward electromagnetic radiation, it is preferred to add an electromagnetic shielding agent to the ceramic fiber cloth. The electromagnetic shielding agent is preferably conductive fiber, and smaller conductive particles can also be selected to be attached to the ceramic fiber cloth layer. However, in order to improve the long-term thermal insulation shielding effect of the fiber layer, it is preferred to use conductive fibers, such as metal fibers (including but not limited to copper fibers, silver fibers and gold fibers, etc.), carbon fibers, etc., in a blended form to form a composite fiber cloth, or in a stacked form, ceramic fiber cloth and conductive fiber cloth are stacked or alternately stacked.

[0019] Preferably, the heat dissipation component includes a heat dissipation water tank, a circulation pump and a cooling pipe, the heat dissipation water tank is arranged on the mounting base plate, the circulation pump is arranged on one side of the heat dissipation water tank, and the cooling pipe is connected to the circulation pump and is located on one side of the high-frequency heating head. The high-frequency welding component, especially the high-frequency heating head, is equipped with a cooling system, which can effectively take away the excess heat generated during the heating process and maintain the working temperature of the high-frequency heating head within a reasonable range, thereby extending the service life of the equipment.

[0020] In view of the high heat and overflow of volatiles during the welding process, which are not conducive to the long-term safe work of operators, it is preferred to set up a shell to surround the above-mentioned system as much as possible, and cooperate with suction equipment to reduce environmental pollution.

[0021] Preferably, the docking assembly includes a screw, a driving gear, a driven gear and a drive motor, the screw having a first thread segment and a second thread segment, the threads of the first thread segment and the second thread segment are opposite, the two clamping assemblies are threadedly connected to the first thread segment and the second thread segment respectively, the driven gear is fixed to the screw, the driving gear is meshed with the driven gear, and the output end of the drive motor is connected to the driving gear.

[0022] Preferably, the solder joint detection device comprises an image acquisition module, an image processing module and a defect detection module;

[0023] The image acquisition module is used to acquire images of the welded portion;

[0024] The image processing module is used to pre-process the image to obtain a processed image;

[0025] The defect detection module is used to detect welding defects in the processed image using a support vector machine model.

[0026] Preferably, the image acquisition module includes a position detection unit, a lighting unit and an acquisition unit. The position detection unit is used to detect the cable position during the return journey of the moving component after the cable welding is completed; the lighting unit is used to illuminate the cable after it moves to a preset value position; and the acquisition unit is used to take a picture of the cable welding position to obtain an image of the welding point.

[0027] Preferably, the image processing module includes a grayscale processing unit, a noise processing unit and an equalization unit;

[0028] The grayscale processing unit is used to convert the color image into a grayscale image;

[0029] The noise processing unit is used to remove random noise in the image using a filter;

[0030] The equalization unit is used to change the pixel intensity distribution to enhance the image clarity.

[0031] Preferably, the defect detection module includes a data annotation unit, a feature extraction unit, a model training unit and a detection unit;

[0032] The data annotation unit is used to collect image data sets with welding defects and normal welding samples, and annotate them;

[0033] The feature extraction unit is used to extract identification features from the image, wherein the identification features include texture features and shape features;

[0034] The model training unit is used to train the SVM model using the identification features and their corresponding labels on the training set;

[0035] The detection unit is used to identify defects in the processed image based on the SVM model.

[0036] To ensure the quality of the weld, the system is also equipped with an image acquisition module that can take photos of the joint area immediately after the weld is completed. These images are then transmitted to the image processing module, which pre-processes the images, such as removing noise and enhancing contrast, to improve the accuracy of subsequent analysis. The defect detection module uses a support vector machine (SVM) model to analyze the processed images and identify possible weld defects. Support vector machine is a supervised learning method used for classification and regression analysis. Here it is used to distinguish between qualified and unqualified weld points.

[0037] Preferably, the two clamping assemblies are rotatably arranged on the moving assembly;

[0038] After the cable is moved to a preset position and photographed to obtain a first image of the weld, the two clamping assemblies rotate and drive the cable to rotate, and photographs are taken to obtain an nth image of the weld, where n is an integer greater than 1;

[0039] The image processing module comprises a splicing processing unit, and the splicing processing unit is used for splicing the first image to the nth image to obtain a complete image of the fusion point.

[0040] Based on the aforementioned detection means, the present invention further improves the structure of the support component to obtain a rotatable support component, which can drive the welded cable to rotate, so that the three-dimensional welded portion of the cable can be captured without moving the weld point detection device. On the other hand, it is also beneficial for the welded cable to be demolded from the surface of the welding mold. Among them, n is preferably 2-4, so that the whole picture can be collected without rotating the cable too much.

[0041] In a second aspect, based on the aforementioned cable welding system with a welding spot detection device, the present invention further provides a cable welding method with a welding spot detection device, comprising:

[0042] Place the two cables to be welded on the two clamping assemblies respectively;

[0043] The cable is driven close to the high-frequency heating head by moving the components;

[0044] The cable is heated by a high-frequency heating head, so that the connecting end of the cable becomes molten;

[0045] Start the docking assembly to bring the two cables closer together for welding;

[0046] The mobile component drives the welded cables to the detection position of the welding point detection device;

[0047] The welding spot detection device collects and processes images of the cable welding points, and uses a support vector machine (SVM) model to detect welding defects in the processed images.

[0048] Wherein, after the mobile component drives the welded cable to the position of the image acquisition module of the welding point detection device, the image of the welding point is collected;

[0049] The image processing module pre-processes the collected image to obtain a processed image;

[0050] The defect detection module uses a support vector machine model to detect welding defects in the processed images.

[0051] The design of the entire system not only improves the efficiency of cable welding, but also greatly improves the reliability of the product through automated defect detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0053] Figure 1 It is a structural diagram of a cable welding system with a welding point detection device of the present invention.

[0054] Figure 2 It is the right side structural diagram of the cable welding system with the welding point detection device of the present invention.

[0055] Figure 3 yes Figure 2 A partial enlargement of detail A.

[0056] Figure 4 It is a cross-sectional structural diagram of a cable welding system with a welding point detection device of the present invention.

[0057] Figure 5 It is a structural diagram of the image acquisition module, image processing module and defect detection module of the present invention.

[0058] Figure 6 It is a structural diagram of the image acquisition module of the present invention.

[0059] Figure 7 It is a structural diagram of the image processing module of the present invention.

[0060] Figure 8 It is a structural diagram of the defect detection module of the present invention.

[0061] Fig. 9 It is a structural diagram of the temperature control module of the present invention.

[0062] Fig.10 The present invention is a flow chart of a cable welding method with a welding point detection device.

[0063] Explanation of the reference numerals: mounting base 101, moving assembly 102, clamping assembly 103, welding mold 104, high-frequency welding assembly 105, docking assembly 106, image acquisition module 107, image processing module 108, defect detection module 109, high-frequency heating head 110, protective shell 111, ceramic fiber cloth layer 112, heat dissipation water tank 113, circulating pump 114, cooling pipe 115, screw 116, driving gear 117, driven gear 118, driving motor 119, position detection unit 120, lighting unit 121, acquisition unit 122, grayscale processing unit 123, noise processing unit 124, balancing unit 125, data annotation unit 126, feature extraction unit 127, model training unit 128, detection unit 129, temperature control unit 131, current control unit 132, deviation compensation unit 133. DETAILED DESCRIPTION

[0064] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0065] In the description of the present invention, it should be understood that the terms "length", "width", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, in the description of the present invention, "multiple" means two or more, unless otherwise clearly and specifically defined.

[0066] See also Figures 1 to 9The present invention provides a cable welding system with a welding spot detection device, including a mounting base 101, a moving component 102, two clamping components 103, a welding mold 104, a high-frequency welding component 105, a docking component 106, an image acquisition module 107, an image processing module 108 and a defect detection module 109, wherein the moving component 102 is arranged on the mounting base 101, and the two clamping components 103 are arranged on the moving component 102 for clamping the cables to be connected, the welding mold is fixed on the moving component 102 and is located between the two clamping components 103, and is used to limit the two cables to be connected, the high-frequency heating head is used to heat and melt the cables to be connected, the docking component 106 is used to drive the two clamping components 103 to approach so that the molten cables are docked, the image acquisition module 107 is used to collect images at the welding point, and the image processing module 108 is used to pre-process the image to obtain a processed image; the defect detection module 109 is used to detect welding defects in the processed image using a support vector machine model.

[0067] In this embodiment, the mounting base 101 serves as a supporting structure for the entire system, ensuring that each component can be stably installed and work together. A moving component 102 is provided on the mounting base 101, which can be moved on the base by a motor drive or other means to adjust the position of the cable to be welded.

[0068] The moving assembly 102 is equipped with two clamping assemblies 103, which can clamp the two ends of the cable to be welded to ensure that they remain stable during the welding process, and the two clamping assemblies 103 can drive the cable to rotate relative to the moving assembly 102. The welding mold 104 is fixed on the moving assembly 102 and is located between the two clamping assemblies 103. Its function is to position the cable during the welding process to ensure the accuracy of the welding position.

[0069] The high-frequency welding assembly 105 is a key component used to heat the cable to a molten state. High-frequency welding is a technology that uses the electromagnetic phenomenon of high-frequency current to locally heat the material to be welded to a molten state, thereby achieving welding. High-frequency welding does not require the use of solvents or adhesives, is easy to operate and has low cost. After heating is completed, the docking assembly 106 will start, driving the clamping assembly 103 to accurately dock the two melted cable ends to form a welding point.

[0070] To ensure the quality of the weld, the system is also equipped with an image acquisition module 107, which can take pictures of the joint area immediately after the weld is completed. These images are then transmitted to the image processing module 108, which pre-processes the images, such as removing noise and enhancing contrast, to improve the accuracy of subsequent analysis. The defect detection module 109 uses a support vector machine (SVM) model to analyze the processed images and identify possible weld defects. Support vector machine is a supervised learning method used for classification and regression analysis. Here it is used to distinguish between qualified and unqualified weld points.

[0071] The design of the entire system not only improves the efficiency of cable welding, but also greatly improves the reliability of the product through automated defect detection.

[0072] The high-frequency welding assembly 105 includes a high-frequency heating head 110 and a protective shell 111, and the protective shell 111 is arranged outside the high-frequency heating head 110. The high-frequency heating head 110 is directly used to heat the cable, and the protective shell 111 is wrapped around the outside of the high-frequency heating head 110 to protect it from heat dissipation and accidental contact of operators with high-temperature components.

[0073] The high-frequency welding component 105 also includes a ceramic fiber cloth layer 112, and the ceramic fiber cloth layer 112 is arranged on the outside of the protective shell 111. In order to further improve the safety and thermal insulation effect of the high-frequency heating head, a ceramic fiber cloth layer 112 is also arranged on the outside of the protective shell 111. As a high-temperature resistant material, the ceramic fiber cloth layer 112 can not only effectively isolate heat and reduce heat loss, but also enhance the overall safety of the high-frequency heating head and prevent the external environment from being affected by high temperature. In addition, the ceramic fiber cloth layer also includes conductive fibers blended with ceramic fibers, such as metal fibers and carbon fibers, to form a composite fiber cloth layer with thermal insulation and shielding functions. The composite fiber cloth layer has the advantages of light weight, broadband, and high electromagnetic shielding efficiency. In the high-frequency range of 30MHz to 18GHz, the electromagnetic shielding efficiency can reach more than 60dB. The conductive fiber content and layer thickness are set as needed, and the electromagnetic shielding efficiency can be further improved to more than 80dB.

[0074] The high-frequency welding assembly 105 also includes a heat dissipation water tank 113, a circulation pump 114 and a cooling pipe 115. The heat dissipation water tank 113 is arranged on the mounting base plate, the circulation pump 114 is arranged on one side of the heat dissipation water tank 113, and the cooling pipe 115 is connected to the circulation pump 114 and is located on one side of the high-frequency heating head 110.

[0075] The high-frequency welding assembly 105 is also equipped with a cooling system, including a heat dissipation water tank 113, a circulation pump 114 and a cooling pipe 115. The heat dissipation water tank 113 is installed on the installation base plate to store cooling water, and the circulation pump 114 is placed on one side of the heat dissipation water tank 113 to transport the cooling water to the vicinity of the high-frequency heating head 110 through the cooling pipe 115. The cooling pipe 115 is arranged on one side of the high-frequency heating head 110, which can effectively take away the excess heat generated during the heating process, maintain the working temperature of the high-frequency heating head within a reasonable range, and thus extend the service life of the equipment.

[0076] The docking assembly 106 includes a screw rod 116, a driving gear 117, a driven gear 118 and a driving motor 119. The screw rod 116 has two opposite threads. The screw rod 116 is threadedly connected to the two clamping assemblies 103. The driven gear 118 is fixed to the screw rod 116. The driving gear 117 is meshed with the driven gear 118. The output end of the driving motor 119 is connected to the driving gear 117.

[0077] The docking assembly 106 is a key mechanism for achieving the docking after cable welding, and mainly includes a screw 116, a driving gear 117, a driven gear 118 and a driving motor 119. The screw 116 has two sections of threads in opposite directions. This design is to simultaneously push the two clamping assemblies 103 to move closer to or apart from the center when the screw 116 rotates. The two ends of the screw 116 are respectively threadedly connected to the two clamping assemblies 103, and the driven gear 118 is fixed on the screw 116 and meshes with the driving gear 117. The output end of the driving motor 119 is connected to the driving gear 117. When the motor is started, the driven gear 118 is driven to rotate through the driving gear 117, thereby rotating the screw 116, realizing the synchronous movement of the clamping assembly 103, and finally completing the docking of the cables. This design not only ensures the stability and accuracy of the docking action, but also improves the efficiency of the welding operation.

[0078] The image acquisition module 107 includes a position detection unit 120, a lighting unit 121 and a collection unit 122. The position detection unit 120 is used to detect the cable position during the return journey of the moving component 102 after the cable welding is completed; the lighting unit 121 is used to illuminate the cable after it moves to a preset value position; the collection unit 122 is used to take a picture of the cable welding position to obtain an image of the welding point.

[0079] The position detection unit 120 plays a key role after the welding is completed. When the mobile component 102 completes the welding operation and starts the return journey, the position detection unit 120 will monitor the position information of the cable to be welded in real time. This function ensures that even in a complex industrial environment, the position change of the welding point can be accurately captured, providing an accurate data basis for subsequent image acquisition.

[0080] The lighting unit 121 is activated after the position detection unit 120 determines that the cable has moved to the preset photographing position. It provides a stable light source to ensure that clear, shadow-free, high-quality images can be obtained when capturing images. Good lighting conditions are crucial for subsequent image processing and defect detection, because any lack of light or overexposure may lead to a decrease in image quality, thereby affecting the accuracy of defect detection.

[0081] The acquisition unit 122 is the part that actually performs the image capture task. Once the position detection unit 120 confirms the correct position and the lighting unit 121 is ready for shooting, the acquisition unit 122 will aim at the welding position to take a picture. The captured image will fully reflect the situation at the welding point, including the quality of the welding point. These images will then be transmitted to the image processing module 108 for preprocessing and finally sent to the defect detection module 109 for analysis.

[0082] Through the close cooperation of these three units, the image acquisition module 107 can efficiently and accurately complete the image acquisition task, providing reliable data support for the subsequent quality control process. This not only helps to improve production efficiency, but also significantly improves product quality and ensures that each welding point meets strict standard requirements.

[0083] The image processing module 108 includes a grayscale processing unit 123, a noise processing unit 124 and an equalization unit 125; the grayscale processing unit 123 is used to convert a color image into a grayscale image; the noise processing unit 124 is used to use a filter to remove random noise in the image; the equalization unit 125 is used to change the pixel intensity distribution to enhance the image clarity.

[0084] The grayscale processing unit 123 is used to convert the original collected color image into a grayscale image. This is because many image processing algorithms are more efficient when processing grayscale images, and in many cases, grayscale images can provide enough information to complete subsequent analysis. Through grayscale conversion, the image processing process can be simplified, the computational complexity can be reduced, and in some cases, grayscale images are ideal for pattern recognition and feature extraction.

[0085] The task of the noise processing unit 124 is to use filtering technology to remove random noise in the image. Due to the complexity of the acquisition environment, there may be various forms of interference in the original image, such as electronic noise, lighting changes, etc. These noises will affect the clarity of the image and interfere with subsequent defect detection. Therefore, the noise processing unit 124 reduces the impact of noise and improves the purity and readability of the image by applying appropriate filters, such as median filtering, Gaussian filtering, etc.

[0086] The main responsibility of the equalization unit 125 is to enhance the clarity of the image by changing the distribution of pixel intensities in the image. Image equalization usually involves techniques such as histogram equalization, which can expand the dynamic range of the image, so that the contrast of the image is enhanced and the details are richer. In this way, even some relatively blurred or low-contrast areas in the original image can become more obvious after processing, which is conducive to the subsequent defect detection module 109 to more accurately identify potential problem points.

[0087] Through the collaboration of these three units, the image processing module 108 is able to convert the original image into a form suitable for further analysis, providing high-quality data input for defect detection of the support vector machine model, and ensuring the performance and reliability of the entire system.

[0088] The defect detection module 109 includes a data annotation unit 126, a feature extraction unit 127, a model training unit 128 and a detection unit 129; the data annotation unit 126 is used to collect and annotate image data sets with welding defects and normal welding samples; the feature extraction unit 127 is used to extract identification features from the image, and the identification features include texture features and shape features; the model training unit 128 is used to train the SVM model using the identification features on the training set and their corresponding labels; the detection unit 129 is used to identify defects in the processed image based on the SVM model.

[0089] The data annotation unit 126 is responsible for collecting a large number of image data sets, which include samples with welding defects and normal welding samples. By annotating these images in detail, that is, indicating which samples are defective and which are normal, the necessary training data can be provided for the machine learning model. Data annotation is a meticulous task that requires a high degree of accuracy because it directly affects the effect of subsequent model training.

[0090] The feature extraction unit 127 focuses on extracting useful identification features from the image. These features can be divided into different types, such as texture features and shape features. Texture features can help identify surface characteristics in the image, such as roughness, smoothness, etc., while shape features focus on the geometric properties of objects, such as edge contours, area size, etc. By extracting these features from the image, the model can be provided with richer information, enabling it to more accurately distinguish different types of samples.

[0091] The model training unit 128 uses the extracted features and their corresponding labels to train a support vector machine (SVM) model. At this stage, a large amount of labeled data is used to adjust the parameters in the SVM model so that the model can learn how to distinguish between normal welds and defective welds. Through repeated iterative training processes, the model gradually optimizes its performance until it can also show a high accuracy rate on new, unseen data.

[0092] The detection unit 129 is the process of applying the trained SVM model to the actual detection. After the image processing module 108 completes the preprocessing of the newly collected images, the detection unit 129 will use the trained SVM model to analyze these images and identify the possible welding defects. This process not only depends on the training quality of the model, but also requires the effective work of the feature extraction unit 127 to ensure that each input to the model is high-quality feature information.

[0093] In summary, the defect detection module 109 realizes the effective identification of cable welding point defects through the four steps of data labeling, feature extraction, model training and final detection, ensuring the quality control and automation level of the welding process.

[0094] In another embodiment, the image processing module 108 further includes a splicing processing unit, and the two clamping components are rotatably disposed on the moving component;

[0095] After the cable is moved to the preset position and photographed to obtain the first image of the weld, the two clamping assemblies 103 rotate and drive the cable to rotate, and photographs are taken to obtain the second and third images of the weld;

[0096] The stitching processing unit is used to stitch the first image to the third image to obtain a complete image of the welded portion, and then the same operation method as in the embodiment can be adopted.

[0097] The cable welding system with a welding point detection device also includes a temperature control module, which includes a temperature control unit 131, a current control unit 132 and a deviation compensation unit 133. The temperature control unit 131 uses a high-precision thermocouple to detect the welding temperature, and the current control unit 132 is used to control the high-frequency heating head current based on the welding temperature to perform deviation compensation.

[0098] The temperature control unit 131 is the core part of the temperature control module, which uses high-precision thermocouples to detect the temperature during the welding process in real time. Thermocouples are a commonly used temperature measuring element, which is widely used in industrial applications due to its fast response speed and high measurement accuracy. In this system, thermocouples are installed near the welding area to accurately capture the actual temperature during welding. These temperature data will be fed back to the control system in real time to provide a basis for subsequent temperature adjustment.

[0099] The current control unit 132 adjusts the working current of the high-frequency heating head according to the real-time temperature data provided by the temperature control unit 131. Since the temperature required in the welding process needs to be precisely controlled, the current control unit 132 can adjust the current output of the high-frequency heating head in a timely manner according to the feedback signal of the temperature sensor to ensure that the welding temperature is always within the set ideal range. This closed-loop control system can effectively cope with temperature fluctuations caused by changes in the external environment or differences in material properties.

[0100] The function of the deviation compensation unit 133 is to compensate for the temperature deviation during the heating process. In the actual welding process, due to the influence of various factors, there may be a deviation between the set temperature and the actual temperature. The deviation compensation unit 133 closely cooperates with the current control unit 132 to adjust the heating current in time according to the size of the temperature deviation, thereby achieving fine temperature regulation. This can not only improve the consistency of welding, but also reduce welding defects caused by temperature instability.

[0101] Through the coordinated work of these three units, the temperature control module can achieve precise control of the welding temperature, ensuring that the optimal temperature conditions are always maintained during the welding process, thereby improving the quality and stability of the welding. This is especially important for application scenarios such as cables that have strict requirements on welding quality.

[0102] See also Fig.10 Based on the above-mentioned embodiments, the present invention further provides a cable welding method with a welding point detection device, comprising:

[0103] S201: Place two cables to be welded on two clamping assemblies 103 respectively.

[0104] The operator needs to accurately place the two cable ends to be welded on the pre-set clamping components 103. The two clamping components 103 can firmly fix the cables to ensure that they will not be displaced during the subsequent welding process.

[0105] S202 drives the cable closer to the high-frequency heating head 110 by moving the component 102 .

[0106] Under the instruction of the control system, the moving component 102 will smoothly move the two clamping components 103 and the cables therein toward the high-frequency heating head 110 until the fusion ends of the cables are located within the heating area of ​​the high-frequency heating head 110 .

[0107] S203 heats the cable through the high-frequency heating head 110 so that the connecting end of the cable becomes molten. At this time, the high-frequency heating head 110 is started to generate enough heat to melt the connecting end of the cable. This process requires precise control of the heating time and temperature to ensure that the cable material can be fully melted without being damaged by overheating.

[0108] S204 starts the docking assembly 106 to bring the two cables closer together for welding.

[0109] When the connecting end of the cable reaches an appropriate temperature and is in a molten state, the docking assembly 106 is activated, driving the cable ends on the two clamping assemblies 103 to slowly approach each other until they contact and fuse together in a molten state, completing the welding.

[0110] S205 drives the welded cables to the position of the image acquisition module 107 by the moving component 102 to acquire an image of the welded portion.

[0111] After the welding is completed, the moving assembly 102 plays a role again, and moves the cable that has just been welded to a predetermined position of the image acquisition module 107. Here, the image acquisition module 107 will take a picture of the welding point to obtain the image data of the welding point.

[0112] S206 pre-processes the image to obtain a processed image. After the image acquisition is completed, the image processing module 108 pre-processes the acquired image, including but not limited to grayscale conversion, denoising and histogram equalization operations to enhance the contrast and clarity of the image and provide better input for subsequent defect detection.

[0113] S207 uses a support vector machine model to detect welding defects in the processed image. The pre-processed image is input into the support vector machine model, which identifies whether there is a welding defect by analyzing the image features. If a defect is found, the system can mark it for further manual inspection or automatic processing.

[0114] Through the above steps, the method realizes the automation of the whole process from cable fixing, heating, welding to image acquisition and defect detection, which not only improves the accuracy and speed of welding, but also ensures the consistency and reliability of welding quality.

[0115] Based on the aforementioned another embodiment, the cable welding method with the welding spot detection device is slightly different, that is, in S205, the moving component 102 drives the welded cable to the position of the image acquisition module 107 to capture the first image of the welding point, and then the two clamping components 103 rotate and drive the cable to rotate, and take pictures to obtain the second image and the third image of the welding point;

[0116] Here, the image acquisition module 107 actually takes a stereoscopic full-view photo of the welded portion, and then the stitching processing unit of the image processing module 108 stitches the first image to the third image, thereby obtaining complete image data of the welded point.

[0117] The above disclosure is only a preferred embodiment of the present invention and does not constitute a limitation on the protection scope of the present invention. Ordinary technicians in this field can understand that all or part of the processes of implementing the above preferred embodiments and equivalent changes made according to the technical contents disclosed in the present invention are still within the scope covered by the present invention.

Claims

1. A cable welding system with a welding point detection device, characterized in that: The welding spot detection device collects and processes images of the cable welding points, and detects welding defects in the processed images; The cable welding system includes a mounting base, a moving assembly, two clamping assemblies, a docking assembly, a welding mold, a high-frequency welding assembly and a welding point detection device; The movable component is arranged on the mounting base, the two clamping components are arranged on the movable component for clamping the cables to be connected, the welding mold is fixed on the movable component and is located between the two clamping components, and is used to limit the two cables to be connected, the high-frequency welding component is used to heat and melt the cables to be connected, and the docking component is used to drive the two clamping components to be close to each other so that the melted cables are docked.

2. The cable fusion splicing system according to claim 1, characterized in that: The high-frequency welding assembly includes a high-frequency heating head and a protective shell, wherein the protective shell is arranged outside the high-frequency heating head; The high frequency welding assembly further includes at least one of the following: 1) a heat dissipation component, which is used to dissipate heat and cool the high-frequency heating head; 2) A ceramic fiber cloth layer, wherein the ceramic fiber cloth layer is arranged on the outer side of the protective shell.

3. The cable fusion system according to claim 2, characterized in that: The ceramic fiber cloth layer is disposed on the outer side of the protective shell, and the ceramic fiber cloth layer also includes an electromagnetic shielding agent, and the electromagnetic shielding agent includes conductive fibers.

4. A cable welding system with a welding point detection device according to any one of claims 1 to 3, characterized in that: The docking assembly includes a screw, a driving gear, a driven gear and a driving motor. The screw has a first thread segment and a second thread segment. The threads of the first thread segment and the second thread segment are opposite. The two clamping assemblies are threadedly connected to the first thread segment and the second thread segment respectively. The driven gear is fixed to the screw, the driving gear is meshed with the driven gear, and the output end of the driving motor is connected to the driving gear.

5. The cable fusion splicing system according to any one of claims 1 to 3, characterized in that: The solder joint detection device comprises an image acquisition module, an image processing module and a defect detection module; The image acquisition module is used to acquire images of the welded portion; The image processing module is used to pre-process the image to obtain a processed image; The defect detection module is used to detect welding defects in the processed image using a support vector machine model.

6. The cable fusion splicing system according to claim 5, characterized in that: The image acquisition module includes a position detection unit, an illumination unit and an acquisition unit, wherein the position detection unit is used to detect the position of the cable on the return journey of the mobile assembly after the cable welding is completed; The lighting unit is used to illuminate the cable after it moves to a preset position; The acquisition unit is used to take pictures of the cable welding position to obtain an image of the welding position.

7. The cable fusion system according to claim 6, characterized in that: The image processing module includes a grayscale processing unit, a noise processing unit and an equalization unit; The grayscale processing unit is used to convert the color image into a grayscale image; The noise processing unit is used to remove random noise in the image using a filter; The equalization unit is used to change the pixel intensity distribution to enhance the image clarity.

8. The cable fusion splicing system according to claim 7, characterized in that: The defect detection module includes a data annotation unit, a feature extraction unit, a model training unit and a detection unit; The data annotation unit is used to collect image data sets with welding defects and normal welding samples, and annotate them; The feature extraction unit is used to extract identification features from the image, wherein the identification features include texture features and shape features; The model training unit is used to train the SVM model using the identification features and their corresponding labels on the training set; The detection unit is used to identify defects in the processed image based on the SVM model.

9. The cable fusion splicing system according to any one of claims 6 to 8, characterized in that: The two clamping components are rotatably arranged on the moving component; After the cable is moved to a preset position and photographed to obtain a first image of the weld, the two clamping assemblies rotate and drive the cable to rotate, and photographs are taken to obtain an nth image of the weld, where n is an integer greater than 1; The image processing module comprises a splicing processing unit, and the splicing processing unit is used for splicing the first image to the nth image to obtain a complete image of the fusion point.

10. A cable welding method with a welding spot detection device, using the cable welding system according to any one of claims 1 to 9, characterized in that: include: Place the two cables to be welded on the two clamping assemblies respectively; The cable is driven close to the high-frequency heating head by moving the components; The cable is heated by a high-frequency heating head, so that the connecting end of the cable becomes molten; Start the docking assembly to bring the two cables closer together for welding; The mobile component drives the welded cables to the detection position of the welding point detection device; The welding spot detection device collects and processes images of the cable welding points, and uses a support vector machine (SVM) model to detect welding defects in the processed images.

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