Cable welding system and method with welding point detection device

Abstract

The present invention relates to the field of cable welding technology, and specifically to a cable welding system and method with a welding point detection device, wherein the welding point detection device collects and processes images of cable welding points and detects welding defects in the processed images. The cable welding system includes a mounting base, a moving component, two clamping components, a docking component, a welding mold, a high-frequency welding component, and a welding point detection device; the moving component is arranged on the mounting base, the two clamping components are arranged on the moving component for clamping the cables to be connected, the welding mold is fixed on the moving component and is located between the two clamping components for limiting 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 close together so that the molten cables are docked. The present invention can automatically detect the quality of the cables after welding, so that problems can be discovered in time, which is convenient for subsequent improvements.

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 splicing systems are primarily used in power equipment to ensure reliable connections in the secondary circuits of these devices. When cables require maintenance, expansion, or replacement, the system provides a safe method for disconnecting and reconnecting the circuit. The basic structure consists of a splicing device, which heats the wires to a molten state, facilitating the connection. A control unit operates the splicing device to connect the cables, minimizing the risks associated with manual operation. Invention CN118920222A discloses a wiring device and its use method. The wiring device includes a housing, a fastening member, a wire stripping mechanism, a welding mechanism, and a suction mechanism. The fastening member selectively fastens the housing. The housing has insertion holes on two opposing sides along its length. The wire stripping mechanism and the welding mechanism are both located within the housing. The wire stripping mechanism is dual and mirror-imaged. The wire stripping mechanism includes a wire stripping assembly and a clamping assembly. The wire stripping assembly can strip the wire inserted into the housing. The clamping assembly can selectively clamp the wire, with the clamping assembly facing the insertion hole. The welding mechanism is located between the two wire stripping mechanisms and is used to weld the two stripped cables. The suction mechanism is located on the side wall of the housing, opposite the welding mechanism, and is used to extract heat and dust from the housing. This invention aims to address the problem of copper core contamination affecting the quality and performance of the weld when welding different cables. However, the quality of the weld is not monitored or tested, and the actual welding effect cannot be determined.

[0003] After the existing welding system is completed, it is usually necessary to manually use a magnifying glass to inspect the connection parts to judge the connection quality. This is inefficient and manual inspection is prone to misjudgment.

[0004] Invention CN114594109A discloses a method for on-site detection of main insulation defects in 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 illuminate 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 varying 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 varying brightness, then the main insulation of the high-voltage cable fusion joint has pores, and if the width of the main insulation on both sides of the copper core is different, then the copper core has a core eccentricity defect. This invention uses X-rays to non-destructively detect the internal structure of the high-voltage cable, but the detection equipment is expensive, which is not conducive to large-scale rapid operation and detection, and there is a radiation risk for operators working 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 the cable 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 purpose of the present invention is to provide a cable welding system and method with a weld spot detection device, aiming to quickly and effectively realize cable welding and automatically detect the quality of the welded cables, so that problems can be discovered in time and facilitate subsequent improvements.

[0007] To achieve the above objectives, in a first aspect, the present invention provides a cable welding system having a weld spot detection device, wherein the weld spot detection device collects and processes images of cable welding locations 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 close together so that the melted cables can be docked.

[0010] In the cable splicing system of the present invention, the mounting base serves as the supporting structure for the entire system, ensuring that all components can be stably installed and work together. A movable assembly is provided on the mounting base, which can be moved on the base via a motor or other means to facilitate adjustment of the position of the cables to be spliced.

[0011] The moving assembly is equipped with two clamping assemblies that clamp the ends of the cable to be spliced, ensuring they remain stable during the splicing process. The splicing die is fixed to the moving assembly and located between the two clamping assemblies. Its function is to position the cable during the splicing process and ensure the accuracy of the splice.

[0012] Preferably, the high-frequency welding assembly includes 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, which is arranged on the outside of the protective shell.

[0016] The high-frequency heating head is a key component that uses electromagnetic induction to rapidly heat the cable, bringing it to a molten state. Once heating is complete, the docking assembly activates, driving the clamping assembly to precisely align the two melted cable ends, forming a weld joint. The weld joint described in this invention is not simply a one-dimensional point; it represents the integral location where the two cable ends are precisely welded together, representing a physical connection involving points, lines, and surfaces.

[0017] Preferably, the outer side of the protective shell is provided with the ceramic fiber cloth layer, 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 provided 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 amount of 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, with ceramic fiber cloth and conductive fiber cloth stacked or alternately stacked.

[0019] Preferably, the heat dissipation assembly includes a heat dissipation water tank, a circulation pump, and a cooling pipe. The heat dissipation water tank is disposed on the mounting base plate, the circulation pump is disposed 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 assembly, especially the high-frequency heating head, is equipped with a cooling system to effectively remove excess heat generated during the heating process, maintain the operating temperature of the high-frequency heating head within a reasonable range, and thus extend 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 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 engaged 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 includes 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 joint;

[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 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 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 in the training set;

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

[0036] To ensure weld quality, the system is also equipped with an image acquisition module that takes photos of the joint area immediately after welding. These images are then transmitted to the image processing module, which performs preprocessing operations such as noise removal and contrast enhancement 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 machines are a supervised learning method used for classification and regression analysis, and here they are used to distinguish between acceptable and unacceptable 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 includes a splicing processing unit, which is used to splice the first image to the nth image to obtain a complete image of the welded portion.

[0040] Based on the aforementioned detection methods, the present invention further improves the structure of the holding assembly to provide a rotatable holding assembly. This allows the welded cable to rotate, allowing for a complete three-dimensional image of the weld without moving the weld detection device. Furthermore, it facilitates the release of the welded cable from the welding mold surface. Preferably, n is 2-4, allowing for a complete image without excessive cable rotation.

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

[0042] Place the two cables to be spliced ​​on the two clamping components 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, causing the connecting end of the cable to become 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 cable welding points, and uses a support vector machine (SVM) model to detect welding defects in the processed images.

[0048] The moving component drives the welded cable to the position of the image acquisition module of the welding point detection device, and collects the image of the welding point;

[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 splicing, but also greatly enhances product reliability 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 following briefly introduces the drawings required for use in the embodiments or the description of the prior art. 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 any 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 a right side structural diagram of the cable welding system with a 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 according to 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] Figure 9 It is a structural diagram of the temperature control module of the present invention.

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

[0063] Explanation of the accompanying drawings: 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, drive motor 119, position detection unit 120, lighting unit 121, acquisition unit 122, grayscale processing unit 123, noise processing unit 124, balancing unit 125, data labeling 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] The following describes embodiments of the present invention in detail, 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 are not to 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, indicating positions or location relationships, are based on the positions or location relationships shown in the accompanying drawings and are intended only to facilitate the description of the present invention and simplify the description. They do not indicate or imply that the devices or elements referred to must have a specific orientation, be constructed, or operate in a specific orientation. Therefore, they should not be construed as limiting the present invention. Furthermore, in the description of the present invention, "plurality" means two or more, unless otherwise expressly and specifically defined.

[0066] See also Figures 1 to 9The present invention provides a cable welding system with a weld 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, 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, for limiting 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 melted cables are docked, the image acquisition module 107 is used to capture images of the welding point, the image processing module 108 is used to preprocess the images to obtain processed images; the defect detection module 109 is used to detect welding defects in the processed images using a support vector machine model.

[0067] In this embodiment, the mounting base 101 serves as the support structure of the entire system, ensuring that the various components can be stably installed and work together. The mounting base 101 is provided with a moving component 102, which can be moved on the base by a motor or other means to facilitate adjustment of the position of the cables to be welded.

[0068] The moving assembly 102 is equipped with two clamping assemblies 103. These clamping assemblies 103 clamp the two ends of the cable to be welded, ensuring their stability during the welding process. The two clamping assemblies 103 also drive the cable to rotate relative to the moving assembly 102. The welding mold 104 is fixed to the moving assembly 102 and located between the two clamping assemblies 103. Its function is to position the cable during the welding process and ensure the accuracy of the welding point.

[0069] High-frequency welding assembly 105 is a key component used to heat the cable to a molten state. High-frequency welding utilizes the electromagnetic phenomenon of high-frequency current to locally heat the materials being welded until they are molten, thereby achieving a weld. High-frequency welding does not require the use of solvents or adhesives, making it simple to operate and cost-effective. After heating is complete, docking assembly 106 activates, driving clamping assembly 103 to precisely dock the two melted cable ends, forming a weld point.

[0070] To ensure weld quality, the system is also equipped with an image acquisition module 107, which takes photos of the joint area immediately after welding. These images are then transmitted to the image processing module 108, which performs preprocessing operations such as noise removal and contrast enhancement 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 machines are a supervised learning method used for classification and regression analysis, and here they are used to distinguish between acceptable and unacceptable weld points.

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

[0072] The high-frequency welding assembly 105 includes a high-frequency heating head 110 and a protective shell 111, which is disposed outside the high-frequency heating head 110. The high-frequency heating head 110 is directly used to heat the cable, while 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 between operators and 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 heat preservation effect of the high-frequency heating head, a ceramic fiber cloth layer 112 is also provided 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 heat preservation and shielding functions. The composite fiber cloth layer has the advantages of light weight, broadband, and high electromagnetic shielding performance. In the high-frequency range of 30MHz to 18GHz, the electromagnetic shielding performance can reach more than 60dB. The electromagnetic shielding performance can be further improved to more than 80dB by setting the conductive fiber content and layer thickness as needed.

[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 mounted on the mounting base and is used to store cooling water. The circulation pump 114 is placed on one side of the heat dissipation water tank 113 and is responsible for transporting 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 the side of the high-frequency heating head 110. This can effectively remove excess heat generated during the heating process, maintain the operating 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 116, a driving gear 117, a driven gear 118 and a drive motor 119. The screw 116 has two opposite threads. The screw 116 is threadedly connected to the two clamping assemblies 103. The driven gear 118 is fixed to the screw 116. The driving gear 117 is meshed with the driven gear 118. The output end of the drive motor 119 is connected to the driving gear 117.

[0077] The docking assembly 106 is a key mechanism for achieving docking after cable welding, and mainly includes a screw 116, a driving gear 117, a driven gear 118 and a drive motor 119. The screw 116 has two sections of threads in opposite directions. This design is so that when the screw 116 rotates, it can simultaneously push the two clamping assemblies 103 to move closer to or apart from the center. 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 drive 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 smoothness 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 position; and the collection unit 122 is used to take a picture of the cable welding position to obtain an image of the welding point.

[0079] Position detection unit 120 plays a key role after the splice is complete. When mobile assembly 102 completes the splice operation and begins its return journey, position detection unit 120 monitors the position of the spliced ​​cables in real time. This function ensures accurate capture of splice location changes, even in complex industrial environments, providing accurate data 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 capture position. It provides a stable light source, ensuring clear, shadow-free, high-quality images during image capture. Good lighting conditions are crucial for subsequent image processing and defect detection, as insufficient or overexposure can degrade image quality, affecting the accuracy of defect detection.

[0081] The acquisition unit 122 actually performs the image capture task. Once the position detection unit 120 confirms the correct position and the lighting unit 121 is ready for capture, the acquisition unit 122 will align the weld location and take a picture. The captured image fully reflects the weld, including the quality of the weld point. These images are then transmitted to the image processing module 108 for preprocessing and ultimately to the defect detection module 109 for analysis.

[0082] Through the close collaboration of these three units, the image acquisition module 107 can efficiently and accurately complete image acquisition tasks, providing reliable data support for subsequent quality control processes. This not only helps improve production efficiency but also significantly enhances product quality, ensuring that every weld point meets strict standards.

[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; and the equalization unit 125 is used to change the pixel intensity distribution to enhance the image clarity.

[0084] Grayscale processing unit 123 converts the original captured 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 sufficient information for subsequent analysis. Grayscale conversion can simplify the image processing process and reduce computational complexity. In some cases, grayscale images are ideal for pattern recognition and feature extraction.

[0085] The noise processing unit 124 uses filtering techniques to remove random noise from images. Due to the complexity of the acquisition environment, the original image may contain various forms of interference, such as electronic noise and lighting variations. This noise can affect image clarity and, in turn, interfere with subsequent defect detection. Therefore, the noise processing unit 124 applies appropriate filters, such as median filtering and Gaussian filtering, to reduce the impact of noise and improve image purity and readability.

[0086] The primary responsibility of the equalization unit 125 is to enhance image clarity by altering the distribution of pixel intensities within the image. Image equalization typically involves techniques such as histogram equalization, which can expand the image's dynamic range, enhancing contrast and detail. This allows even blurry or low-contrast areas in the original image to become more distinct after processing, enabling the subsequent defect detection module 109 to more accurately identify potential problem areas.

[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 in 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 datasets, including samples with both defective and normal welds. By annotating these images in detail, identifying which samples contain defects and which are normal, it provides the necessary training data for the machine learning model. Data annotation is a meticulous task requiring a high degree of accuracy, as it directly impacts the effectiveness of subsequent model training.

[0090] The feature extraction unit 127 focuses on extracting useful identification features from the image. These features can be categorized into different types, such as texture features and shape features. Texture features can help identify surface characteristics in an image, such as roughness and smoothness, while shape features focus on geometric properties of objects, such as edge contours and area size. 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] Model training unit 128 uses the extracted features and their corresponding labels to train a support vector machine (SVM) model. During this phase, a large amount of labeled data is used to adjust the parameters of the SVM model, enabling the model to learn how to distinguish between normal welds and defective welds. Through repeated iterative training, the model gradually optimizes its performance until it can demonstrate high accuracy even on new, unseen data.

[0092] Detection unit 129 ultimately applies the trained SVM model to actual inspection. After image processing module 108 completes preprocessing of newly acquired images, detection unit 129 uses the trained SVM model to analyze these images and identify potential weld defects. This process relies not only on the quality of model training but also on the effective functioning of feature extraction unit 127 to ensure that high-quality feature information is always input into the model.

[0093] In summary, the defect detection module 109 achieves 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 a preset position and photographed to obtain a first image of the weld, the two clamping assemblies 103 rotate and drive the cable to rotate, and photographs are taken to obtain a second image and a third image 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 weld 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 current of the high-frequency heating head based on the welding temperature to perform deviation compensation.

[0098] The temperature control unit 131 is the core component of the temperature control module. It uses high-precision thermocouples to monitor the temperature during the welding process in real time. Thermocouples are a common temperature measurement component, widely used in industrial applications due to their fast response speed and high measurement accuracy. In this system, thermocouples are installed close to the welding area to accurately capture the actual temperature during welding. This temperature data is fed back to the control system in real time, providing a basis for subsequent temperature adjustments.

[0099] The current control unit 132 adjusts the operating current of the high-frequency heating head based on the real-time temperature data provided by the temperature control unit 131. Because the temperature required during the welding process requires precise control, the current control unit 132 can adjust the current output of the high-frequency heating head in a timely manner based on the feedback signal from the temperature sensor to ensure that the welding temperature remains 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 temperature deviations during the heating process. During the actual welding process, a variety of factors may cause deviations between the set temperature and the actual temperature. By closely coordinating with the current control unit 132, the deviation compensation unit 133 adjusts the heating current according to the magnitude of the temperature deviation, thereby achieving fine temperature regulation. This not only improves welding consistency but also reduces welding defects caused by temperature instability.

[0101] Through the coordinated operation 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 in applications such as cables, where welding quality is strictly required.

[0102] See also Figure 10 Based on the above 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 onto 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 move 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 welded ends of the cables are located within the heating area of ​​the high-frequency heating head 110 .

[0107] S203 heats the cable using the high-frequency heating head 110, causing the cable's connecting end to become molten. At this point, the high-frequency heating head 110 is activated, generating sufficient heat to melt the cable's connecting end. This process requires precise control of heating time and temperature to ensure that the cable material is fully melted without overheating and damage.

[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: The moving component 102 drives the welded cables to the position of the image acquisition module 107 to capture 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 the predetermined position of the image acquisition module 107. Here, the image acquisition module 107 will take a picture of the welding point and obtain the image data of the welding point.

[0112] S206 pre-processes the image to obtain a processed image. After 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 weld defects in the processed image. The pre-processed image is fed into the support vector machine model, which analyzes the image features to identify weld defects. If a defect is found, the system can flag it for further manual inspection or automated processing.

[0114] Through the above steps, this method realizes the automation of the entire 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 alternative embodiment, the cable welding method with a weld spot detection device is slightly different. Specifically, in S205, the moving assembly 102 moves the welded cable to the position of the image acquisition module 107 to capture a first image of the weld. Thereafter, the two clamping assemblies 103 rotate and drive the cable to rotate, capturing second and third images of the weld.

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

[0117] The above disclosure is only a preferred embodiment of the present invention and does not constitute a limitation on the scope of protection of the present invention. Ordinary technicians in this field can understand that all or part of the processes of the above preferred embodiments and equivalent changes made according to the technical content disclosed in the present invention are still within the scope of 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 assembly is arranged on the mounting base, the two clamping assemblies are rotatably arranged on the movable assembly for clamping the cables to be connected, the welding mold is fixed on the movable assembly and is located between the two clamping assemblies for limiting the position of the two cables to be connected, the high-frequency welding assembly is used to heat and melt the cables to be connected, and the docking assembly is used to drive the two clamping assemblies close together so that the melted cables can be docked; The solder joint detection device includes 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 joint; 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; 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 includes a splicing processing unit, which is used to splice the first image to the nth image to obtain a complete image of the welded portion.

2. The cable fusion splicing system according to claim 1, wherein: 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, which is arranged on the outside of the protective shell.

3. The cable fusion splicing system according to claim 2, wherein: 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.

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 drive 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 drive 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 image acquisition module includes a position detection unit, an illumination unit, and an acquisition unit. 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.

6. The cable fusion splicing system according to claim 5, wherein: 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 image clarity.

7. The cable fusion splicing system according to claim 6, wherein: 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 support vector machine model using the identification features and their corresponding labels in the training set; The detection unit is used to identify defects in the processed image based on a support vector machine model.

8. A cable welding method with a welding point detection device, using the cable welding system according to any one of claims 1 to 7, characterized in that: include: Place the two cables to be spliced ​​on the two clamping components 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, causing the connecting end of the cable to become 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 cable welding points, and uses a support vector machine model to detect welding defects in the processed images.

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