Laser vision linkage enameled wire on-line monitoring system

Abstract

The invention provides a laser vision linkage enamelled wire on-line monitoring system, and relates to the field of data processing, and the system comprises a laser monitoring module which is used for obtaining the size information of a plurality of continuous positions of an enamelled wire through laser, and determining the size change position of the enamelled wire according to the obtained size information of the plurality of continuous positions of the enamelled wire; the visual monitoring module is used for acquiring a color image of the enameled wire according to the size change position of the enameled wire and determining a defect position, a defect type and a defect size according to the color image of the enameled wire; and the defect marking module is used for marking the enameled wire according to the defect position, the defect type and the defect size, and has the advantage of improving the accuracy of quality detection of the enameled wire.

Description

Technical Field

[0001] The invention relates to the field of quality monitoring, and in particular to an online monitoring system for enameled wires linked by laser and vision. Background Art

[0002] During the production of enameled wire, occasional quality problems may occur due to molds, paints, and foreign matter, such as air bubbles, surface impurities, etc. These defects will cause the electrical insulation performance of the enameled wire to drop significantly, far below the product design requirements. Therefore, in order to ensure the safety and reliability of the enameled wire, online monitoring technology must be used to conduct a full inspection of the enameled wire.

[0003] With the development of online monitoring technology, laser online monitoring technology and visual online monitoring technology have been widely used, but these technologies still have some shortcomings. The laser monitoring system has high measurement accuracy, but it is greatly affected by wire fluctuations, prone to false alarms, and cannot distinguish the size of particles, and it is difficult to verify the accuracy of particle positioning; the visual monitoring system is good at identifying color difference defects, but there are many false alarms for oil pollution, and it is impossible to detect defects with height, and it is easy to miss some small particles.

[0004] Therefore, it is necessary to provide a laser vision-linked enameled wire online monitoring system to improve the accuracy of enameled wire quality detection. Summary of the invention

[0005] The present invention provides a laser vision linkage enameled wire online monitoring system, comprising: a laser monitoring module, used for acquiring the size information of multiple continuous positions of the enameled wire through laser, and determining the size change position of the enameled wire according to the acquired size information of multiple continuous positions of the enameled wire; a visual monitoring module, used for collecting a color image of the enameled wire according to the size change position of the enameled wire, and determining the defect position, defect type and defect size according to the color image of the enameled wire; a defect marking module, used for marking the enameled wire according to the defect position, defect type and defect size.

[0006] Furthermore, the laser monitoring module includes a diameter gauge, a meter counter and a data processing device, wherein the diameter gauge includes a laser emitter and a photoelectric detector, wherein the laser emitter is used to emit a laser beam to irradiate the enameled wire, the photoelectric detector is used to receive a laser signal, and the meter counter is used to obtain the meter position of the enameled wire irradiated by the laser beam; the data processing device is used to associate the size of each position of the enameled wire with the meter position according to the signal output by the photoelectric detector, the built-in time synchronization mechanism and the meter position of the enameled wire irradiated by the laser beam obtained by the meter counter, and determine the size information of multiple consecutive positions of the enameled wire; the data processing device is also used to determine the size change position of the enameled wire based on the size information of multiple consecutive positions of the enameled wire obtained.

[0007] Furthermore, the size information includes at least an outer diameter value; the laser monitoring module determines the size change position of the enameled wire based on the size information of multiple continuous positions of the enameled wire obtained, including: for each meter-counting position, determining the size change parameter of the meter-counting position based on the outer diameter value of the meter-counting position and the outer diameter values ​​of multiple adjacent meter-counting positions; determining the size change position and the first defect height based on the size change parameter of each meter-counting position.

[0008] Furthermore, the laser monitoring module determines the size change position and the first defect height according to the size change parameters of each metering position, including: determining the abnormal metering position according to the size change parameters of each metering position; dividing multiple abnormal metering positions into multiple abnormal metering position units according to the distance between any two abnormal metering positions; for each abnormal metering position unit, determining the size change position corresponding to the abnormal metering position unit according to the multiple abnormal metering positions included in the abnormal metering position unit, and determining the first defect height corresponding to the abnormal metering position unit according to the maximum distance between the multiple abnormal metering positions of the abnormal metering position unit.

[0009] Furthermore, the visual monitoring module collects a color image of the enameled wire according to the size change position of the enameled wire, including: determining an image acquisition position according to the size change position; and determining an image acquisition parameter according to the first defect height.

[0010] Furthermore, the image acquisition parameters include at least focal length, resolution, aperture and / or pixel depth.

[0011] Furthermore, the visual monitoring module determines the defect type and defect size based on the color image of the enameled wire, including: performing color difference analysis on the color image of the enameled wire to extract the defect image from the color image of the enameled wire; and determining the defect type and defect size based on the defect image.

[0012] Furthermore, the visual monitoring module performs color difference analysis on the color image of the enameled wire and extracts a defective image from the color image of the enameled wire, including: converting the color image of the enameled wire into a grayscale image; calculating the mean grayscale value of pixels in the grayscale image; determining a defective area based on the mean grayscale value of pixels in the grayscale image; and extracting a defective image from the color image of the enameled wire based on the defective area.

[0013] Furthermore, the visual monitoring module determines the defect type and defect size according to the defect image, including: calculating a height difference parameter according to the defect image; determining the defect type according to the height difference parameter; and determining the defect size according to the defect image.

[0014] Furthermore, the defect marking module includes a marking moving device and an inkjet printer arranged on the marking moving device, wherein the marking moving device is used to drive the inkjet printer to move to the defect position, and the inkjet printer is used to mark the defect position of the enameled wire according to the defect type and defect size.

[0015] Compared with the prior art, the laser vision linkage enameled wire online monitoring system provided by the present invention has at least the following beneficial effects: 1. Through the laser monitoring module, the system can obtain the size information of the enameled wire in real time and continuously, so as to find the location of the size change in time. Laser technology is usually highly accurate, so the accuracy of the detection results can be ensured. The visual monitoring module can collect color images for the location of the size change, so as to further identify the defect location, defect type and defect size. This comprehensive defect recognition capability helps quality control in the production process and ensures that the product quality meets the standards. When the laser finds a defect, it is required to take a photo of the defect location and record the defect height. On the other hand, when the visual finds a defect, it will also take a photo and record it immediately. If the laser finds that the defect height fluctuates, the result of the laser measurement will be assigned to the defect. In this way, each defect will be recorded twice, which effectively prevents the omission of defects and false alarms. The defect marking module can mark the enameled wire according to the identified defect information, which helps to quickly identify and isolate defective products on the production line. The marking information can also be used for subsequent product traceability to help manufacturers understand the links where defects occur so as to make improvements. The online monitoring system can automatically complete the detection, identification and marking process, reduce manual intervention, and thus improve production efficiency. By detecting and addressing defects at an early stage, the system helps reduce scrap and rework costs, further lowering production costs.

[0016] 2. The combination of laser emitter and photodetector can accurately measure the outer diameter of enameled wire and ensure the accuracy of data. The meter provides accurate measurement of the laser beam irradiation position, which helps to accurately associate the size information with the position information. The data processing device can integrate the signal output by the photodetector, the time synchronization mechanism and the meter data to generate the size and position association information of each position of the enameled wire. This provides a solid foundation for subsequent defect identification and analysis.

[0017] 3. The system is able to determine the image acquisition position based on the size change position, which means that the camera or image sensor can accurately focus on the area where defects may exist. This reduces unnecessary image acquisition, improves monitoring efficiency, and ensures the relevance of image data. By considering the first defect height to determine the image acquisition parameters, the system is able to capture the detailed characteristics of the defect more accurately. This facilitates subsequent defect analysis and classification and improves the accuracy of monitoring. By adjusting image acquisition parameters such as focal length, resolution, aperture and / or pixel depth, the system can optimize image quality to display defects more clearly. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] This specification will be further described in the form of exemplary embodiments, which will be described in detail by the accompanying drawings. These embodiments are not restrictive, and in these embodiments, the same number represents the same structure, wherein: Figure 1 It is a module schematic diagram of a laser vision-linked enameled wire online monitoring system according to some embodiments of this specification; Figure 2 is a schematic diagram of a color image of an enameled wire according to some embodiments of the present specification; Figure 3 is a schematic diagram of a defect image according to some embodiments of the present specification. DETAILED DESCRIPTION

[0019] In order to more clearly illustrate the technical solutions of the embodiments of this specification, the following is a brief introduction to the drawings required for the description of the embodiments. Obviously, the drawings described below are only some examples or embodiments of this specification. For ordinary technicians in this field, this specification can also be applied to other similar scenarios based on these drawings without creative work. Unless it is obvious from the language environment or otherwise explained, the same reference numerals in the figures represent the same structure or operation.

[0020] Figure 1 is a module schematic diagram of a laser vision linkage enameled wire online monitoring system according to some embodiments of this specification, such as Figure 1 As shown, a laser-vision-linked enameled wire online monitoring system may include a laser monitoring module, a vision monitoring module and a defect marking module.

[0021] The laser monitoring module is used to obtain the size information of multiple continuous positions of the enameled wire through laser, and determine the size change position of the enameled wire based on the obtained size information of multiple continuous positions of the enameled wire.

[0022] In some embodiments, the laser monitoring module includes a diameter gauge, a meter and a data processing device, wherein the diameter gauge includes a laser emitter and a photoelectric detector, wherein the laser emitter is used to emit a laser beam to irradiate the enameled wire, the photoelectric detector is used to receive the laser signal, and the meter is used to obtain the metering position of the enameled wire irradiated by the laser beam.

[0023] Specifically, when the enameled wire passes through the diameter gauge, a high-frequency scanning laser is rapidly irradiated onto the enameled wire. The photodetector captures the reflected laser signal at a high-speed sampling frequency and converts it into an electrical signal. The meter records the position of the enameled wire passing through the diameter gauge in real time.

[0024] In some embodiments, the data processing device is used to associate the size of each position of the enameled wire with the metering position according to the signal output by the photodetector, the built-in time synchronization mechanism and the metering position of the enameled wire irradiated by the laser beam obtained by the meter counter, and determine the size information of multiple consecutive positions of the enameled wire. The size information includes at least the outer diameter value.

[0025] The data processing device is also used to determine the size change position of the enameled wire according to the size information of multiple continuous positions of the enameled wire obtained.

[0026] Specifically include: For each meter counting position, determining a size change parameter of the meter counting position according to an outer diameter value of the meter counting position and outer diameter values ​​of a plurality of adjacent meter counting positions; According to the dimension change parameter of each meter position, the dimension change position and the first defect height are determined.

[0027] As an example only, the adjacent metering position of the metering position may be a metering position whose distance from the metering position is less than the first distance threshold. The outer diameter value of the metering position and the variance of the outer diameter values ​​of multiple adjacent metering positions may be calculated as the size change parameter of the metering position.

[0028] In some embodiments, the laser monitoring module determines the size change position and the first defect height according to the size change parameter of each meter position, including: Determine an abnormal metering position according to the size change parameter of each metering position. For example, a metering position whose size change parameter is greater than a size change parameter threshold may be regarded as an abnormal metering position. According to the distance between any two abnormal metering positions, the multiple abnormal metering positions are divided into multiple abnormal metering position units, wherein the distance between any two adjacent abnormal metering positions included in the abnormal metering position unit is less than a second distance threshold; For each abnormal metering position unit, the size change position corresponding to the abnormal metering position unit is determined according to the multiple abnormal metering positions included in the abnormal metering position unit, and the first defect height corresponding to the abnormal metering position unit is determined according to the maximum distance between the multiple abnormal metering positions of the abnormal metering position unit.

[0029] Specifically, an average of multiple abnormal metering positions included in the abnormal metering position unit may be calculated as the size change position corresponding to the abnormal metering position unit.

[0030] The two endpoints of the abnormal metering location unit may be determined, and the distance between the two endpoints may be taken as the maximum distance, and the maximum distance may be taken as the first defect height corresponding to the abnormal metering location unit.

[0031] The visual monitoring module is used to collect the color image of the enameled wire according to the size change position of the enameled wire, and determine the defect position, defect type and defect size based on the color image of the enameled wire.

[0032] In some embodiments, the visual monitoring module collects a color image of the enameled wire according to the size change position of the enameled wire, including: Determine the image acquisition position according to the size change position; According to the first defect height, image acquisition parameters are determined, wherein the image acquisition parameters at least include focal length, resolution, aperture and / or pixel depth.

[0033] Specifically, resolution refers to the number of pixels in the horizontal and vertical directions of the pixel point on the camera sensor, which directly affects the clarity of the image. The smaller the first defect height, the higher the required resolution is, so that the details of the defect can be clearly captured. For example, if the first defect height is only a few microns, a high-resolution camera, such as megapixels or higher, needs to be selected to ensure that the image is clear enough to identify these tiny defects. Focal length determines the magnification and field of view of the lens. According to the first defect height, select a suitable focal length to ensure that the defect occupies an appropriate proportion in the image. If the first defect height is small, a telephoto lens may be needed to magnify the defect; conversely, if the first defect height is large, a short-focus lens may be used. The aperture controls the amount of light entering the lens, affecting the brightness and depth of field of the image. If the first defect height is small, the aperture can be appropriately increased to increase the amount of light entering, improve the brightness and contrast of the image. The pixel depth determines how many bits are used to represent each pixel, affecting the ability to express image details and the color depth. If the first defect height is small, selecting a higher pixel depth can more accurately identify and distinguish defects. For example, a pixel depth of 12 or 16 bits can provide more gray levels than 8 bits, making it easier to identify subtle grayscale changes.

[0034] As an example only, the image acquisition parameters can be determined by a parameter determination model according to the first defect height and the variance of the outer diameter values ​​of multiple abnormal metering positions included in the abnormal metering position unit. The parameter determination model can be a convolutional neural network model.

[0035] In some embodiments, the visual monitoring module determines the defect type and defect size based on the color image of the enameled wire, including: Perform color difference analysis on the color image of the enameled wire and extract defect images from the color image of the enameled wire; Determine the defect type and defect size based on the defect image.

[0036] In some embodiments, the visual monitoring module performs color difference analysis on the color image of the enameled wire and extracts a defect image from the color image of the enameled wire, including: Converting the color image of the enameled wire into a grayscale image, for example, assigning different weights to red, green, and blue, and then calculating the weighted sum as the grayscale value of the pixel, thereby converting the color image of the enameled wire into a grayscale image; Calculate the mean grayscale value of the pixels in the grayscale image; Determine the defect area according to the mean grayscale value of the pixels in the grayscale image. For example, pixels whose grayscale values ​​are greater than the mean grayscale value of the pixels may be regarded as pixels in the defect area, thereby determining the defect area. According to the defect area, a defect image is extracted from the color image of the enameled wire.

[0037] In some embodiments, the visual monitoring module determines the defect type and defect size according to the defect image, including: Calculate height difference parameters based on defect images; Determine the defect type based on the height difference parameter; Determine the defect size based on the defect image.

[0038] Specifically, the height difference parameter and the color difference parameter can be calculated according to the defect image through the defect detection model. When the height difference parameter is greater than the height difference parameter threshold and the color difference parameter is greater than the color difference parameter threshold, the defect type is determined to be a particle defect with height difference and color difference. If the height difference parameter is less than or equal to the height difference parameter threshold and the color difference parameter is greater than the color difference parameter threshold, the defect type is determined to be a particle defect with no height difference and color difference. If the height difference parameter is greater than the height difference parameter threshold and the color difference parameter is less than or equal to the color difference parameter threshold, the defect type is determined to be a particle defect with height difference and no color difference.

[0039] The defect size may be determined based on the defect image by a size determination model, wherein the defect size may include at least width, length, area and height. The size determination model may be a convolutional neural network model.

[0040] The defect marking module is used to mark the enameled wire according to the defect location, defect type and defect size.

[0041] In some embodiments, the defect marking module includes a marking moving device and an inkjet printer disposed on the marking moving device, wherein the marking moving device is used to drive the inkjet printer to move to the defect position, and the inkjet printer is used to mark the defect position of the enameled wire according to the defect type and defect size.

[0042] As an example only, the preset laser vision linkage enameled wire online monitoring system records the position where the height difference parameter is ≥ 0.010 mm. Therefore, during the production process, the laser monitoring module locates the defect with height fluctuation information. Five consecutive alarms appear near 1411.469~1411.476 mm, such as Figure 2 As shown, the visual monitoring module is in the left and right direction or the up and down direction, and the defect height ranges from 0.010 to 0.230. The position information is sent to the visual monitoring module, requiring it to take a photo at the corresponding position. Each photo can take ≥5*5 mm 2 If the distance is too close, only one image needs to be kept.

[0043] Figure 3 is a schematic diagram of a defect image according to some embodiments of this specification, such as Figure 3 As shown, the preset laser vision linkage enameled wire online monitoring system defines the position with large image color difference as a defect and takes a photo, which is on the left side of 1411.479 and below 1411.484. The visual monitoring module can only identify defects based on color difference, calculate the plane size of the defect, and assign the height of the defect by comparing the laser data. Here, the defect width exceeds 0.5mm, and the defects less than 0.5mm on the same side in the laser data are judged as one defect by default, and the maximum height is assigned to the visual monitoring defect.

[0044] For defects that meet the marking requirements, the ink marking signal is sent to the inkjet printer for marking.

[0045] Finally, it should be understood that the embodiments described in this specification are only used to illustrate the principles of the embodiments of this specification. Other variations may also fall within the scope of this specification. Therefore, as an example and not a limitation, alternative configurations of the embodiments of this specification may be considered consistent with the teachings of this specification. Accordingly, the embodiments of this specification are not limited to the embodiments explicitly introduced and described in this specification.

Claims

1. A laser vision linkage enameled wire online monitoring system, characterized in that: include: A laser monitoring module, used to obtain the size information of multiple continuous positions of the enameled wire by laser, and determine the size change position of the enameled wire according to the obtained size information of multiple continuous positions of the enameled wire; A visual monitoring module, for collecting a color image of the enameled wire according to the size change position of the enameled wire, and determining a defect position, defect type and defect size according to the color image of the enameled wire; The defect marking module is used to mark the enameled wire according to the defect location, defect type and defect size.

2. The laser vision linkage enameled wire online monitoring system according to claim 1 is characterized in that: The laser monitoring module includes a caliper, a meter counter and a data processing device, wherein the caliper includes a laser emitter and a photoelectric detector, wherein the laser emitter is used to emit a laser beam to irradiate the enameled wire, the photoelectric detector is used to receive a laser signal, and the meter counter is used to obtain the meter position of the enameled wire irradiated by the laser beam; The data processing device is used to associate the size of each position of the enameled wire with the metering position according to the signal output by the photoelectric detector, the built-in time synchronization mechanism and the metering position of the enameled wire irradiated by the laser beam obtained by the meter counter, and determine the size information of multiple consecutive positions of the enameled wire; The data processing device is also used to determine the size change position of the enameled wire according to the size information of multiple continuous positions of the enameled wire obtained.

3. The laser vision linkage enameled wire online monitoring system according to claim 1 is characterized in that: The size information at least includes an outer diameter value; The laser monitoring module determines the size change position of the enameled wire according to the size information of multiple continuous positions of the enameled wire obtained, including: For each meter counting position, determining a dimension change parameter of the meter counting position according to the outer diameter value of the meter counting position and the outer diameter values ​​of a plurality of adjacent meter counting positions; According to the dimension change parameter of each meter position, the dimension change position and the first defect height are determined.

4. The laser vision linkage enameled wire online monitoring system according to claim 3 is characterized in that: The laser monitoring module determines the size change position and the first defect height according to the size change parameter of each meter position, including: Determine the abnormal metering position according to the size change parameter of each metering position; According to the distance between any two abnormal metering positions, the multiple abnormal metering positions are divided into multiple abnormal metering position units; For each abnormal metering position unit, the size change position corresponding to the abnormal metering position unit is determined according to the multiple abnormal metering positions included in the abnormal metering position unit, and the first defect height corresponding to the abnormal metering position unit is determined according to the maximum distance between the multiple abnormal metering positions of the abnormal metering position unit.

5. The laser vision linkage enameled wire online monitoring system according to claim 4 is characterized in that: The visual monitoring module collects a color image of the enameled wire according to the size change position of the enameled wire, including: Determining an image acquisition position according to the size change position; Image acquisition parameters are determined according to the first defect height.

6. The laser vision linkage enameled wire online monitoring system according to claim 5 is characterized in that: The image acquisition parameters include at least focal length, resolution, aperture and / or pixel depth.

7. A laser vision-linked enameled wire online monitoring system according to any one of claims 1 to 6, characterized in that: The visual monitoring module determines the defect type and defect size according to the color image of the enameled wire, including: Performing color difference analysis on the color image of the enameled wire, and extracting a defect image from the color image of the enameled wire; Determine the defect type and defect size according to the defect image.

8. The laser vision linkage enameled wire online monitoring system according to claim 7 is characterized in that: The visual monitoring module performs color difference analysis on the color image of the enameled wire and extracts a defect image from the color image of the enameled wire, including: Converting the color image of the enameled wire into a grayscale image; Calculating the mean grayscale value of pixels of the grayscale image; Determining a defect area according to a mean value of the pixel grayscale values ​​of the grayscale image; A defect image is extracted from the color image of the enameled wire according to the defect area.

9. The laser vision linkage enameled wire online monitoring system according to claim 8 is characterized in that: The visual monitoring module determines the defect type and defect size according to the defect image, including: Calculating a height difference parameter according to the defect image; Determining the defect type according to the height difference parameter; The defect size is determined according to the defect image.

10. A laser vision-linked enameled wire online monitoring system according to any one of claims 1 to 6, characterized in that: The defect marking module includes a marking moving device and an inkjet printer arranged on the marking moving device, wherein the marking moving device is used to drive the inkjet printer to move to the defect position, and the inkjet printer is used to mark the defect position of the enameled wire according to the defect type and defect size.

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