Insulator production system and production method

Abstract

The invention relates to the technical field of insulator manufacturing, and discloses an insulator production system and method, a production preparation stage is composed of physical equipment for insulator production, the equipment executes specific production operation and is hardware support of the equipment, a full-process automatic and intelligent management and control system is constructed, and the production efficiency is improved. The links of production preparation, raw material stirring, forming, firing, surface treatment, quality detection and the like are covered, all the links are closely coordinated and follow strict standard specifications, the defects of unsmooth connection, efficiency loss and the like in a traditional production mode are effectively overcome, the production efficiency is greatly improved, the modern large-scale and high-efficiency production demands are met, ordered and efficient production promotion is guaranteed, and the production cost is reduced. Advanced means such as a machine vision system are adopted, insulator surface defects are recognized in a multi-dimensional mode, whether products are qualified or not is judged according to an accurate calculation formula through image collection, preprocessing, feature extraction and database comparison, the quality is strictly controlled, and the defective product outflow risk is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of insulator manufacturing, and in particular to an insulator production system and a production method. Background Art

[0002] At present, the power industry is in a stage of vigorous development. With the continuous growth of economic and social demand for electricity and the continuous expansion of the scale of power grid construction, the requirements for the stability and safety of the power transmission system are also increasing. Insulators, as a key component in the power transmission system, play an indispensable role in ensuring the safe transmission of electricity. Specifically, they can achieve electrical insulation and provide reliable mechanical support for the line. Insulators are common components in transformers and motors. When in use, the copper rod is passed through the upper part of the insulator axis and fixed to the cable or busbar through screws to isolate the steel structure, increase the creepage distance, and improve the safety performance of operation. At present, the insulators used in transformers are generally made of ceramic as the material. The material will age and crack in the wind and sun, affecting the electrical performance and causing failures. Based on the above aspects, the system improves the material's aging resistance, voltage rating, corrosion resistance and impact resistance; achieving stability and safety of the motor system.

[0003] There are many problems with the traditional insulator production method. From the perspective of the production process, the connection mechanism between the various links is not perfect. For example, there may be problems such as untimely material transportation and inconsistent connection rhythm between the raw material processing link and the molding link, which will cause efficiency loss in the entire production process and cannot meet the needs of modern large-scale and high-efficiency production. In terms of quality control, the quality monitoring and control methods under the traditional production model are relatively backward, making it difficult to achieve accurate and real-time quality control of the entire production process. Due to the lack of highly sensitive testing equipment and intelligent quality monitoring systems, key factors affecting quality such as raw material mixing ratio deviation, dimensional accuracy error in the molding process, and temperature fluctuation in the firing link cannot be discovered and effectively adjusted in a timely and accurate manner, which undoubtedly increases the risk of producing unqualified products. In addition, the traditional insulator production method has serious deficiencies in data utilization. A large amount of data generated during the production process, such as equipment operating parameters, process execution status, quality inspection results, etc., has not been deeply mined and integrated through effective data analysis methods, resulting in the inability of these data to fully realize their potential value. It is also difficult to achieve accurate optimization of the production process based on data feedback, which restricts the further improvement of the quality and efficiency of insulator production. Summary of the invention

[0004] The object of the present invention is to provide an insulator production system and a production method to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: an insulator production system, the method comprising: Step 1: The production preparation stage consists of physical equipment for the production of each insulator. The physical equipment performs specific production operations and is the hardware support of the equipment; Step 2: The raw materials enter the stirring device through the input device, and the stirring of the raw materials is completed and reaches the predetermined standard; Step 3: The mold cavity is used to transport the raw materials to the molding equipment for calcination. The insulator blank is fired according to the preset heating, insulation and cooling curves to ensure that the insulator achieves the ideal density and insulation performance: Step 4: Grind and clean the fired insulator to remove surface flaws and impurities so that the surface finish meets the use requirements; Step 5: The preliminary features are input into a feature deepening path consisting of multiple depthwise separable convolutional layers to capture the fine texture and composition characteristics of the insulator; Step 6: Use a machine vision inspection system to quickly identify defects such as cracks and pores on the surface of the insulator.

[0006] Preferably, step 6 comprises: S1: The formed insulator is collected at different angles through an image extraction device, and then preprocessed, including image size adjustment, normalization, etc.; S2: At this time, the system is responsible for extracting the shape, texture and other features of the input insulator defect image, and performing a series of processing on it to form a feature map, adjust the number of channels, size and other parameters of the feature map, and provide working conditions for subsequent detection. The feature map calculation amount is w, and the calculation formula is: Where R, Z, B, N are the number of channels, height and width of the input feature map and the output feature map, and L is the convolution kernel size; S3: The processed feature map and signal are then compared with the data in the original database to complete the detection of the insulator, wherein the detection is compared in three directions, namely, angle deviation Q, unequal distance, and shape missing P; The calculation formula for the angle offset Q is: ; The calculation formula for unequal distances is: , where x and y are the vertical and horizontal positions, and w is the distance difference compared to the actual distance; The calculation formula of shape missing P is: , where w and h are the lateral and longitudinal deflection angle differences; The three calculated data are compared with the database to determine whether the insulator is a complete and qualified product.

[0007] Preferably, the step 2 comprises: S1: Different sensors are set inside the mixer, and the stirring shaft speed and torque sensor monitor the stirring torque, etc. are monitored. By analyzing such data, it is determined whether the final required mixing degree is achieved.

[0008] Preferably, the step 2 comprises: S2: During the stirring process, the speed value H and torque value K are recorded every 0.5 seconds, and then the standard deviation T is calculated. , where r is the speed series. The smaller the calculated speed fluctuation, the more stable the equipment and the higher the raw material mixing degree.

[0009] Preferably, the step 4, S1: According to the established process parameters, a series of operations such as surface grinding, cleaning and coating are carried out in an orderly manner for the fired insulators. At the same time, the surface treatment quality traceability module will record and retain the parameters involved in each operation link in real time. The grinding speed u is defined as: ,in is the instantaneous rotation speed, and m is the number of grinding times.

[0010] Preferably, in step 4, S2: During the entire surface treatment stage, the surface treatment quality traceability module will collect and organize the above-mentioned operating parameters in real time, and then store them in the database, thereby building a complete data record chain to facilitate subsequent query, analysis, and data-driven quality traceability and process optimization.

[0011] Preferably, in step 3, During the firing process, it is necessary to compare the difference between the actual temperature and the preset temperature curve in real time to control the temperature. The temperature error calculation formula is as follows: , where T is the temperature error, is the target temperature value in a certain temperature curve, It is the temperature value actually measured at the sampling moment.

[0012] Preferably, a method for producing an insulator comprises: Production planning and parameter input module: Production management personnel use the human-computer interaction interface of the application layer to input the model, quantity and various indicators of insulators, providing clear guidance for subsequent orderly production; Raw material conveying and mixing module: According to the specific specifications and quality requirements of the insulator, the corresponding parameter setting work is completed in the system to determine the raw material formula, clarify the various proportions of raw materials such as porcelain clay, feldspar, quartz, etc. in the production process, and then the system discharges the materials from the corresponding silo according to the set raw material formula, and accurately conveys the different raw materials to the inside of the mixer according to the proportion, and realizes the mixing of the raw materials. The mixing situation is tested and the data analysis algorithm is used to determine whether it meets the preset standard. When the standard is met, the module sends a signal to the control layer to control the automatic feeding device to feed the mixed raw materials into the model; Forming module: The pressure forming machine sends the optimal parameters such as pressure and holding time. The pressure forming machine presses the raw materials in the mold according to the instructions to form an insulator blank, and transports it to the firing subsystem to prepare for the calcination step; Firing module: The firing furnace temperature precision control module strictly follows the preset firing temperature curve and performs operations such as heating, heat preservation and cooling on the insulator blank through temperature-controlled heating power, thereby forming the insulator preliminary product; Surface treatment module: The surface of the insulator is polished, cleaned, coated and other operations are performed according to the set process to improve the surface quality and comprehensive performance of the insulator; Quality inspection and sorting module: The quality inspection equipment conducts comprehensive inspections on the appearance, insulation performance, mechanical properties, etc. of the post-processed insulators in turn to strictly control product quality. The quality inspection data analysis module collects the inspection result data, analyzes and processes it according to quality standards, and automatically sorts and removes unqualified products to ensure that only qualified products enter the packaging stage and wait for shipment, thereby ensuring that the quality of the products leaving the factory is qualified.

[0013] Compared with the prior art, the present invention has the following beneficial effects: The present invention builds a full-process automated and intelligent management and control system, covering production preparation, raw material mixing, molding, firing, surface treatment and quality inspection. Each link is closely coordinated and follows strict standards and specifications, effectively avoiding the drawbacks of poor connection and efficiency loss in traditional production methods, greatly improving production efficiency, meeting the demands of modern large-scale and high-efficiency production, and ensuring orderly and efficient production.

[0014] The present invention uses advanced means such as machine vision systems to identify insulator surface defects in multiple dimensions. After image acquisition, preprocessing, feature extraction and database comparison, the product is determined to be qualified or not based on an accurate calculation formula, strictly controlling the quality and reducing the risk of defective products flowing out. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 A flowchart for constructing an insulator production system and production method; Figure 2The invention is a step diagram of an insulator production system and a production method. DETAILED DESCRIPTION

[0016] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0017] See also Figure 1-2 The present invention provides a technical solution: an insulator production system, the method comprising: Step 1: In the overall process of insulator production, the production preparation stage is crucial. This stage consists of a hardware system composed of physical equipment for the production of various insulators. These physical equipments are based on their different functions in the production process and strictly follow the relevant engineering technical standards and production process requirements. By performing specific production operations, they provide a hardware support architecture for insulator production. Step 2: In the insulator production process, the raw materials enter the stirring device for uniform mixing and meet the requirements of subsequent production processes. The input equipment and stirring device involved follow strict engineering design standards to achieve the goal of accurate delivery and sufficient stirring of the raw materials to meet the predetermined standards; Step 3: In the insulator production process, the mold cavity is used to accurately transport the pre-treated raw materials to the molding equipment, and then the insulator blank is fired according to the preset heating, insulation and cooling curves through a calcination process with precise temperature control, which causes a series of complex physical and chemical changes in the blank under the action of heat, and finally achieves the ideal density and insulation performance indicators, meeting the strict quality requirements of the power system for insulator products: Step 4: In the insulator production process, after the firing process is completed, the surface is polished, and the operation strictly follows professional process standards and quality specifications to thoroughly remove all kinds of defects and impurities on the surface of the insulator caused by the firing process, thereby improving its surface finish to a level that meets the conditions of use; Step 5: After the insulator feature analysis, the fine texture and composition features of the insulator surface are obtained in depth. The feature deepening path is composed of multiple deep separable convolution layers in an orderly manner. This path uses the cutting-edge feature extraction technology of deep separable convolution to achieve in-depth analysis and accurate capture of insulator features, thereby providing various application scenarios related to insulators, such as quality control, performance evaluation, and product classification. Step 6: During the entire process of insulator production and quality control, to ensure that insulator products meet strict industry standards and actual use requirements, advanced detection technology based on machine vision systems is used to quickly and reliably identify various subtle defects on the insulator surface such as cracks and pores, providing strong technical support for the precise control of insulator product quality.

[0018] The present invention will be further described below in conjunction with Examples 1 to 3: Embodiment 1: The formed insulator is collected at different angles by an image extraction device, and then preprocessed, including image size adjustment, normalization and other operations; S2: At this time, the system is responsible for extracting the shape, texture and other features of the input insulator defect image, and performing a series of processing on it to form a feature map, adjust the number of channels, size and other parameters of the feature map, and provide working conditions for subsequent detection. The feature map calculation amount is w, and the calculation formula is: Where R, Z, B, N are the number of channels, height and width of the input feature map and the output feature map, and L is the convolution kernel size; S3: The processed feature map and signal are then compared with the data in the original database to complete the detection of the insulator, wherein the detection is compared in three directions, namely, angle deviation Q, unequal distance, and shape missing P; The calculation formula for the angle offset Q is: ; The calculation formula for unequal distances is: , where x and y are the vertical and horizontal positions, and w is the distance difference compared to the actual distance; The calculation formula of shape missing P is: , where w and h are the lateral and longitudinal deflection angle differences; In the insulator quality assessment process, the data obtained from the three specific aspects of the calculation are comprehensively compared and analyzed with the standard reference data stored in the database to determine whether the insulator is a complete and qualified product. Based on precise data comparison, an objective and accurate judgment is made on the quality status of the insulator.

[0019] Embodiment 2: Different sensors are arranged inside the mixer, and the stirring shaft speed and the stirring torque are monitored by the torque sensor, and the data are analyzed to determine whether the final desired mixing degree is achieved; In specific implementation, during the stirring process, the speed value H and the torque value K are recorded every 0.5 seconds, and then the standard deviation T is calculated. , where r is the speed series. The smaller the calculated speed fluctuation, the more stable the equipment and the higher the raw material mixing degree.

[0020] Step 4, S1: According to the established process parameters, a series of operations such as surface grinding, cleaning and coating are carried out in order for the fired insulators. At the same time, the surface treatment quality traceability module will record and retain the parameters involved in each operation link in real time, among which the grinding speed u is defined as: ,in is the instantaneous rotation speed, and m is the number of grinding times.

[0021] In step 4, S2: during the entire surface treatment stage, the surface treatment quality traceability module will collect and organize the above-mentioned operating parameters in real time, and then store them in the database, thereby building a complete data record chain, which is convenient for subsequent query, analysis and data-driven quality traceability and process optimization. Based on advanced data collection, organization and storage technology, and in compliance with professional quality management specifications and data management standards, real-time, comprehensive and accurate collection, organization and storage operations are implemented for various operating parameters involved in the surface treatment stage, building a complete data record chain, including query, analysis and data-driven quality traceability and process optimization, providing solid technical support.

[0022] Embodiment 3: Step 3 includes the following steps: During the firing process, it is necessary to compare the difference between the actual temperature and the preset temperature curve in real time to control the temperature. The temperature error calculation formula is as follows: , where T is the temperature error, is the target temperature value in a certain temperature curve, A temperature monitoring and control mechanism is established for the temperature value actually measured at the sampling moment. The difference between the actual temperature and the preset temperature curve is compared in real time. The temperature control operation is guided by the corresponding temperature error calculation formula. The whole process strictly follows thermal engineering principles and relevant professional technical specifications.

[0023] The present invention also includes a method for producing an insulator, the method comprising: Production planning and parameter input module: Production management personnel use the human-computer interaction interface of the application layer to input the model, quantity and various indicators of insulators, providing clear guidance for subsequent orderly production; Raw material conveying and mixing module: According to the specific specifications and quality requirements of the insulator, the corresponding parameter setting work is completed in the system to determine the raw material formula, clarify the various proportions of raw materials such as porcelain clay, feldspar, quartz, etc. in the production process, and then the system discharges the materials from the corresponding silo according to the set raw material formula, and accurately conveys the different raw materials to the inside of the mixer according to the proportion, and realizes the mixing of the raw materials. The mixing situation is tested and the data analysis algorithm is used to determine whether it meets the preset standard. When the standard is met, the module sends a signal to the control layer to control the automatic feeding device to feed the mixed raw materials into the model; Forming module: The pressure forming machine sends the optimal parameters such as pressure and holding time. The pressure forming machine presses the raw materials in the mold according to the instructions to form an insulator blank, and transports it to the firing subsystem to prepare for the calcination step; Firing module: The firing furnace temperature precision control module strictly follows the preset firing temperature curve and performs operations such as heating, heat preservation and cooling on the insulator blank through temperature-controlled heating power, thereby forming the insulator preliminary product; Surface treatment module: The surface of the insulator is polished, cleaned, coated and other operations are performed according to the set process to improve the surface quality and comprehensive performance of the insulator; Quality inspection and sorting module: The quality inspection equipment conducts comprehensive inspections on the appearance, insulation performance, mechanical properties, etc. of the post-processed insulators in turn to strictly control product quality. The quality inspection data analysis module collects the inspection result data, analyzes and processes it according to quality standards, and automatically sorts and removes unqualified products to ensure that only qualified products enter the packaging stage and wait for shipment, thereby ensuring that the quality of the products leaving the factory is qualified.

[0024] The implementation of the system refers to the above embodiment and will not be described in detail in the specification.

[0025] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0026] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for producing an insulator, characterized in that: The method comprises: Step 1: The production preparation stage consists of physical equipment for the production of each insulator. The physical equipment performs specific production operations and is the hardware support of the equipment; Step 2: The raw materials enter the stirring device through the input device, and the stirring of the raw materials is completed and reaches the predetermined standard; Step 3: Use the mold cavity to transport the raw materials into the molding equipment for calcination, and fire the insulator blank according to the preset heating, insulation and cooling curves to ensure that the insulator achieves the ideal density and insulation performance: Step 4: Grind and clean the fired insulator to remove surface flaws and impurities so that the surface finish meets the use requirements; Step 5: The preliminary features are input into a feature deepening path consisting of multiple depthwise separable convolutional layers to capture the fine texture and composition characteristics of the insulator; Step 6: Use a machine vision inspection system to quickly identify defects such as cracks and pores on the surface of the insulator.

2. The insulator production method according to claim 1, characterized in that: The step 6 comprises: S1: The formed insulator is collected at different angles through an image extraction device, and then preprocessed, including image size adjustment, normalization, etc.; S2: At this time, the system is responsible for extracting the shape, texture and other features of the input insulator defect image, and performing a series of processing on it to form a feature map, adjust the number of channels, size and other parameters of the feature map, and provide working conditions for subsequent detection. The feature map calculation amount is w, and the calculation formula is: Where R, Z, B, N are the number of channels, height and width of the input feature map and the output feature map, and L is the convolution kernel size; S3: The processed feature map and signal are then compared with the data in the original database to complete the detection of the insulator. The detection is compared in three directions, namely, angle offset Q, unequal distance, and shape missing P. The calculation formula of angle offset Q is: ; The calculation formula for unequal distances is: ， Where x and y are the vertical and horizontal positions, and w is the distance difference compared to the actual distance. The calculation formula of shape loss P is: ， Where w and h are the lateral and longitudinal deflection angle differences; The three calculated data are compared with the database to determine whether the insulator is a complete and qualified product.

3. The insulator production method according to claim 1, characterized in that: The step 2 comprises: S1: Different sensors are set inside the mixer, and the stirring shaft speed and torque sensor monitor the stirring torque, etc. are monitored. By analyzing such data, it is determined whether the final required mixing degree is achieved.

4. The insulator production method according to claim 3, characterized in that: The step 2 comprises: S2: During the stirring process, the speed value H and torque value K are recorded every 0.5 seconds, and then the standard deviation T is calculated. , where r is the speed series. The smaller the calculated speed fluctuation, the more stable the equipment and the higher the raw material mixing degree.

5. The insulator production method according to claim 1, characterized in that: Step 4, S1: According to the established process parameters, a series of operations such as surface grinding, cleaning and coating are carried out in an orderly manner for the fired insulators. At the same time, the surface treatment quality traceability module will record and retain the parameters involved in each operation link in real time. The grinding speed u is defined as: ,in is the instantaneous rotation speed, and m is the number of grinding times.

6. The insulator production method according to claim 5, characterized in that: In step 4, S2: During the entire surface treatment stage, the surface treatment quality traceability module will collect and organize the above-mentioned operating parameters in real time, and then store them in the database, thereby building a complete data record chain to facilitate subsequent query, analysis, and data-driven quality traceability and process optimization.

7. The insulator production method according to claim 1, characterized in that: In step 3, during the firing process, it is necessary to compare the difference between the actual temperature and the preset temperature curve in real time to control the temperature. The temperature error calculation formula is as follows: , where T is the temperature error, is the target temperature value in a certain temperature curve, It is the temperature value actually measured at the sampling moment.

8. An insulator production system, characterized in that: An insulator production method applicable to any one of claims 1 to 7, wherein the system comprises: Production planning and parameter input module: Production management personnel use the human-computer interaction interface of the application layer to input the model, quantity and various indicators of insulators, providing clear guidance for subsequent orderly production; Raw material conveying and mixing module: According to the specific specifications and quality requirements of the insulator, the corresponding parameter setting work is completed in the system to determine the raw material formula, clarify the various proportions of raw materials such as porcelain clay, feldspar, quartz, etc. in the production process, and then the system discharges the materials from the corresponding silo according to the set raw material formula, and accurately conveys the different raw materials to the inside of the mixer according to the proportion, and realizes the mixing of the raw materials. The mixing situation is tested and the data analysis algorithm is used to determine whether it meets the preset standard. When the standard is met, the module sends a signal to the control layer to control the automatic feeding device to feed the mixed raw materials into the model; Forming module: The pressure forming machine sends the optimal parameters such as pressure and holding time. The pressure forming machine presses the raw materials in the mold according to the instructions to form an insulator blank, and transports it to the firing subsystem to prepare for the calcination step; Firing module: The firing furnace temperature precision control module strictly follows the preset firing temperature curve and performs operations such as heating, heat preservation and cooling on the insulator blank through temperature-controlled heating power, thereby forming the insulator preliminary product; Surface treatment module: The surface of the insulator is polished, cleaned, coated and other operations are performed according to the set process to improve the surface quality and comprehensive performance of the insulator; Quality inspection and sorting module: The quality inspection equipment conducts comprehensive inspections on the appearance, insulation performance, mechanical properties, etc. of the post-processed insulators in turn to strictly control product quality. The quality inspection data analysis module collects the test result data, analyzes and processes it according to quality standards, and automatically sorts and removes unqualified products to ensure that only qualified products enter the packaging stage and wait for shipment, thereby ensuring that the quality of the products leaving the factory is qualified.

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