An online monitoring method and system for the production of wet-winding water-resistant cables

Abstract

This application relates to the technical field of cable production, and discloses an online monitoring method and system for the production of wet-winding water-resistant cables. It continuously captures images of the cable surface after winding through a high-speed industrial camera, obtains an image frame sequence, and transmits it to an online monitoring industrial control computer for processing. Then, image recognition technology is used to analyze the cable surface in each frame of the image to extract the time series of the pitch. By analyzing the pitch time series, its uniformity is evaluated to see if it meets the preset standard. Once a non-compliant situation is found, an abnormal production status warning prompt is automatically generated. In this way, high-precision real-time monitoring of the cable pitch uniformity is achieved, significantly improving the production efficiency and product quality control level, and overcoming the defect that it is difficult to achieve real-time and accurate detection in the prior art.

Description

Technical Field

[0001] The present application relates to the technical field of cable production, and more specifically, to an online monitoring method and system for the production of wet-wound water-resistant cables. Background Art

[0002] In the production of wet-wound, water-resistant cables, ensuring cable uniformity is crucial for maintaining their electrical performance and mechanical strength. Cable pitch, the distance between adjacent winding turns, is a key parameter for measuring cable quality. An ideal cable should have a uniform pitch, which not only improves water resistance and durability but also ensures stability and safety during use. However, in actual production, variations in equipment precision, material properties, and process conditions can lead to uneven cable pitch, impacting the quality of the final product. Therefore, effectively detecting cable uniformity has become a pressing issue in the production process.

[0003] Traditional cable quality inspection methods primarily rely on manual inspection or offline measurement techniques. These methods typically require operators to manually measure the pitch of the cable surface and determine its uniformity based on experience. While this approach can meet basic quality control requirements to a certain extent, it has significant limitations. First, manual inspection is inefficient and difficult to adapt to the needs of large-scale production. Second, due to human factors such as operator experience and fatigue, inspection results often lack consistency and reliability. Furthermore, while offline measurement technology can improve inspection accuracy to a certain extent, its non-real-time nature prevents timely detection and correction of production process problems, which can easily lead to increased defective product rates. More importantly, both manual inspection and offline measurement methods struggle to fully monitor the entire production process, leading to potential quality issues being overlooked and impacting the overall quality of the final product.

[0004] Therefore, an optimized online monitoring solution for the production of wet-wound water-resistant cables is expected. Summary of the Invention

[0005] The present application is proposed to address the above-mentioned technical issues. The embodiments of the present application provide an online monitoring method and system for wet-wound water-resistant cable production, which uses image recognition and processing technology to monitor cable pitch uniformity in real time, significantly improving production efficiency and product quality control, and overcoming the drawback of existing technologies that make it difficult to achieve real-time and accurate detection.

[0006] According to one aspect of the present application, an online monitoring method for the production of wet-winding water-resistant cables is provided, including: continuously capturing images of the surface of the cable after winding by a high-speed industrial camera to obtain an image frame sequence of the surface of the cable after winding; transmitting the image frame sequence of the surface of the cable after winding to an online monitoring industrial control computer; in the online monitoring industrial control computer, respectively performing image recognition processing on each image of the surface of the cable after winding in the image frame sequence of the surface of the cable after winding to obtain a time series of pitches; in the online monitoring industrial control computer, determining whether the pitch uniformity meets a preset requirement based on the time series of pitches; in the online monitoring industrial control computer, in response to the pitch uniformity not meeting the preset requirement, generating an early warning prompt for abnormal production status.

[0007] In the above online monitoring method for the production of wet-winding water-resistant cables, in the online monitoring industrial control computer, respectively performing image recognition processing on each image of the surface of the cable after winding in the image frame sequence of the surface of the cable after winding to obtain a time series of pitches includes: performing edge detection on the image of the surface of the cable after winding to obtain an edge map of the cable after winding; performing line fitting based on the Hough transform on the edge map of the cable after winding to obtain an equation of the winding edge line; based on the equation of the winding edge line, identifying key positioning points from the edge map of the cable after winding; based on the key positioning points, identifying corresponding edges of two adjacent winding turns; based on the corresponding edges of the two adjacent winding turns, calculating the pitch.

[0008] In the above online monitoring method for the production of wet-winding water-resistant cables, performing edge detection on the image of the surface of the cable after winding to obtain an edge map of the cable after winding includes: performing edge detection on the image of the surface of the cable after winding based on the Canny operator to obtain the edge map of the cable after winding.

[0009] In the above online monitoring method for the production of wet-winding water-resistant cables, based on the equation of the winding edge line, identifying key positioning points from the edge map of the cable after winding includes: selecting the vertical center line of the image of the edge map of the cable after winding as a reference line; calculating the intersection point between the equation of the reference line and the equation of the winding edge line as the key positioning point.

[0010] In the above online monitoring method for the production of wet-winding water-resistant cables, based on the corresponding edges of the two adjacent winding turns, calculating the pitch includes: setting the two adjacent winding turns as the i-th winding turn and the (i + 1)-th winding turn; selecting a point P1 on the i-th winding turn and searching for the point P2 corresponding to the point P1 on the (i + 1)-th winding turn along the direction perpendicular to the winding direction; calculating the axial pixel distance between the point P1 and the point P2; multiplying the axial pixel distance by the pixel size ratio to obtain the pitch.

[0011] In the above online monitoring method for the production of wet-winding water-resistant cables, calculating the pitch based on the corresponding edges of two adjacent wrapping coils includes: setting the two adjacent wrapping coils as the i-th wrapping coil and the (i + 1)-th wrapping coil; selecting point P1 on the i-th wrapping coil and finding the point P2 corresponding to point P1 on the (i + 1)-th wrapping coil along the direction perpendicular to the wrapping direction; calculating the axial pixel distance between point P1 and point P2; multiplying the axial pixel distance by the pixel size ratio to obtain the initial pitch; and performing coordinate geometric relationship constraints on the initial pitch to obtain the pitch.

[0012] In the above online monitoring method for the production of wet-winding water-resistant cables, performing coordinate geometric relationship constraints on the initial pitch to obtain the pitch includes: for the key points P1 and P2 corresponding to each initial pitch, calculating the Hough transform angular space representation corresponding to the key points P1 and P2 according to the following formula to obtain the key point angular space representation corresponding to each initial pitch, where the formula is: ; where and are the spatial coordinate representations of key points P1 and P2 respectively, and are the key point angular space representations corresponding to each initial pitch.

[0013] Based on the key point angular space representation corresponding to each initial pitch, calculating the vertical slope reference correction amount corresponding to each initial pitch according to the following formula, where the formula is: ; where represents the initial pitch, represents the vertical slope reference correction amount.

[0014] Based on the key point angular space representation corresponding to each initial pitch, calculating the axial intersection constraint correction amount corresponding to each initial pitch according to the following formula, where the formula is: ; where represents the axial intersection constraint correction amount.

[0015] Based on the vertical slope reference correction amount and the axial intersection constraint correction amount, correcting the initial pitch according to the following formula, where the formula is: ; where represents the pitch.

[0016] In the above online monitoring method for the production of wet-winding water-resistant cables, on the online monitoring industrial control computer, determining whether the pitch uniformity meets the preset requirements based on the time series of the pitch includes: defining a target pitch and an absolute tolerance band; calculating an acceptable range of the pitch based on the target pitch and the absolute tolerance band; judging whether each pitch in the time series of the pitch is within the acceptable range of the pitch to obtain a set of out-of-tolerance judgment results; if the proportion of the number of out-of-tolerance judgment results in the set of out-of-tolerance judgment results that are not within the acceptable range of the pitch exceeds the preset threshold, determining that the pitch uniformity does not meet the preset requirements.

[0017] According to another aspect of the present application, there is also provided an online monitoring system for the production of wet-winding water-resistant cables. The online monitoring system for the production of wet-winding water-resistant cables includes: a cable surface image acquisition module for continuously capturing images of the cable surface after winding through a high-speed industrial camera to obtain an image frame sequence of the cable surface after winding; a cable surface image transmission module for transmitting the image frame sequence of the cable surface after winding to the online monitoring industrial control computer; a cable surface image recognition and processing module for, on the online monitoring industrial control computer, performing image recognition and processing on each cable surface image after winding in the image frame sequence of the cable surface image after winding to obtain a time series of pitches; a pitch uniformity evaluation module for, on the online monitoring industrial control computer, determining whether the pitch uniformity meets the preset requirements based on the time series of the pitches; and a production status abnormal warning module for, on the online monitoring industrial control computer, generating a production status abnormal warning prompt in response to the pitch uniformity not meeting the preset requirements.

[0018] Compared with the prior art, the online monitoring method and system for the production of wet-winding water-resistant cables provided by the present application continuously capture images of the cable surface after winding through a high-speed industrial camera, obtain an image frame sequence, and transmit it to the online monitoring industrial control computer for processing. Then, image recognition technology is used to analyze the cable surface in each frame of the image to extract the time series of pitches. By analyzing the time series of pitches, whether its uniformity meets the preset standard is evaluated. Once a situation that does not meet the requirements is found, a production status abnormal warning prompt is automatically generated. In this way, high-precision real-time monitoring of the cable pitch uniformity is achieved, significantly improving the production efficiency and the product quality control level, and overcoming the defect that it is difficult to achieve real-time and accurate detection in the prior art. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above and other objects, features, and advantages of the present application will become more apparent by describing the embodiments of the present application in more detail with reference to the accompanying drawings. The drawings are used to provide a further understanding of the embodiments of the present application and constitute a part of the specification. They are used to explain the present application together with the embodiments of the present application and do not constitute a limitation to the present application. In the drawings, the same reference numerals generally represent the same components or steps.

[0020] Figure 1 The schematic flowchart of an on - line monitoring method for the production of wet - winding water - resistant cables according to an embodiment of the present application is illustrated.

[0021] Figure 2 The schematic flowchart of S3 in the on - line monitoring method for the production of wet - winding water - resistant cables according to an embodiment of the present application is illustrated.

[0022] Figure 3 The schematic flowchart of S33 in the on - line monitoring method for the production of wet - winding water - resistant cables according to an embodiment of the present application is illustrated.

[0023] Figure 4 The schematic flowchart of S35 in the on - line monitoring method for the production of wet - winding water - resistant cables according to an embodiment of the present application is illustrated.

[0024] Figure 5 The schematic flowchart of a preferred embodiment of S35 in the on - line monitoring method for the production of wet - winding water - resistant cables according to an embodiment of the present application is illustrated.

[0025] Figure 6 The schematic flowchart of S4 in the on - line monitoring method for the production of wet - winding water - resistant cables according to an embodiment of the present application is illustrated.

[0026] Figure 7 The schematic block diagram of an on - line monitoring system for the production of wet - winding water - resistant cables according to an embodiment of the present application is illustrated. Detailed Description of the Specific Embodiment

[0027] Hereinafter, exemplary embodiments of the present application will be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present application, rather than all of the embodiments of the present application. It should be understood that the present application is not limited by the exemplary embodiments described herein.

[0028] Figure 1 The schematic flowchart of an on - line monitoring method for the production of wet - winding water - resistant cables according to an embodiment of the present application is illustrated. As Figure 1As shown, the present application provides an online monitoring method for the production of wet-winding water-resistant cables, including: S1, continuously capturing images of the surface of the cable after winding by a high-speed industrial camera to obtain an image frame sequence of the surface of the cable after winding; S2, transmitting the image frame sequence of the surface of the cable after winding to an online monitoring industrial control computer; S3, in the online monitoring industrial control computer, respectively performing image recognition processing on each image of the surface of the cable after winding in the image frame sequence of the surface of the cable after winding to obtain a time series of pitches; S4, in the online monitoring industrial control computer, determining whether the pitch uniformity meets the preset requirements based on the time series of pitches; S5, in the online monitoring industrial control computer, in response to the pitch uniformity not meeting the preset requirements, generating a warning prompt for abnormal production status.

[0029] Exemplarily, in step S1, continuously capturing images of the surface of the cable after winding by a high-speed industrial camera to obtain an image frame sequence of the surface of the cable after winding. It should be understood that compared with traditional manual inspection or off-line measurement methods, the high-speed industrial camera can, without affecting the production line speed, conduct a detailed inspection on every meter or even shorter length of the cable. This high-frequency data acquisition method enables any subtle changes to be recorded, thus providing a solid foundation for subsequent quality control. In addition, due to the adoption of digital image processing technology, the data can be quickly analyzed and it can be immediately determined whether the cable quality meets the preset standards according to the preset criteria. Therefore, this method greatly improves the detection efficiency and accuracy and reduces the defective rate.

[0030] In one embodiment, a high-speed industrial camera system is directly installed on the production line. This system generally includes one or more high-speed industrial cameras, light sources, and a computer system connected thereto. The high-speed industrial camera should be installed at key positions on the cable production line to ensure that the entire area to be monitored can be covered. In order to obtain clear images, appropriate lighting is essential. The selection of the light source needs to consider the reflection characteristics of the cable material to avoid overexposure or shadows, which may affect the image quality. Once the hardware is set up, the high-speed industrial camera will continuously capture images of the cable surface at a predetermined frame rate (such as hundreds of frames per second) and transmit these image frames to the online monitoring industrial control computer for further processing. In this way, it can be seamlessly integrated into the existing production line without significantly modifying the existing equipment layout.

[0031] Exemplarily, in step S2, the image frame sequence of the surface image of the cable after winding is transmitted to the on-line monitoring industrial control computer. It should be understood that a large amount of image data captured by the high-speed industrial camera needs to be processed and analyzed by powerful computing resources. The on-line monitoring industrial control computer has sufficient computing power and storage space, can efficiently process these high-resolution image frame sequences, and execute complex image recognition algorithms to extract key information, such as the cable pitch, etc. In addition, the on-line monitoring industrial control computer can also immediately judge whether the cable quality meets the standard according to the preset criteria, and quickly generate a warning prompt when problems are found, so as to take corrective measures in time. This not only improves the detection efficiency, but also greatly reduces the defective rate and improves the overall performance of the production line.

[0032] In one embodiment, wireless communication technology is used to complete the transmission of the image frame sequence. With the development of 5G and other high-speed wireless communication technologies, it is now possible to use a wireless network to send image frames from a high-speed industrial camera to an on-line monitoring industrial control computer without sacrificing transmission speed and data integrity. This method is particularly suitable for scenarios where it is difficult to lay cables or where the device positions need to be adjusted frequently. For example, in some temporary production lines, or when production equipment needs to be moved regularly, the wireless transmission solution provides great flexibility.

[0033] Exemplarily, in step S3, in the on-line monitoring industrial control computer, image recognition processing is respectively performed on each surface image of the cable after winding in the image frame sequence of the surface image of the cable after winding to obtain a time series of pitches. It should be understood that in the production process of wet-winding water-resistant cables, ensuring uniform cable pitch is crucial for ensuring product quality. By continuously capturing the surface images of the cable after winding with a high-speed industrial camera and transmitting these image frame sequences to the on-line monitoring industrial control computer for further processing, real-time monitoring and evaluation of the cable quality can be achieved. The core of this process lies in using image recognition technology to analyze the surface features of the cable in each frame of the image to extract the time series of pitches.

[0034] In one embodiment, as Figure 2 shown, in step S3, in the on-line monitoring industrial control computer, image recognition processing is respectively performed on each surface image of the cable after winding in the image frame sequence of the surface image of the cable after winding to obtain a time series of pitches, including: S31, performing edge detection on the surface image of the cable after winding to obtain an edge map of the cable after winding; S32, performing line fitting based on the Hough transform on the edge map of the cable after winding to obtain a winding edge line equation; S33, identifying key positioning points from the edge map of the cable after winding based on the winding edge line equation; S34, identifying the corresponding edges of two adjacent winding circles based on the key positioning points; S35, calculating the pitch based on the corresponding edges of the two adjacent winding circles.

[0035] Specifically, first, edge detection is performed on the surface image of the cable after winding to obtain the edge map of the cable after winding. In one embodiment, performing edge detection on the surface image of the cable after winding to obtain the edge map of the cable after winding includes: performing edge detection on the surface image of the cable after winding based on the Canny operator to obtain the edge map of the cable after winding. Specifically, the Canny operator is a classic edge detection algorithm. It calculates the gradient direction and magnitude of each pixel point in the image, and then applies non-maximum suppression and double-threshold processing to determine the edge positions.

[0036] Then, since the winding is usually spiral, the edges presented in the local image are approximately straight lines or slightly curved curves. Therefore, the Hough transform can be used to detect and fit these lines. Specifically, the Hough transform is a line detection algorithm that can map points in the image space to the parameter space and then find all possible lines. Assume the form of the winding edge line equation is: ; then the values of and can be solved through the Hough transform. Specifically, for each point in the edge image , an equation about and can be constructed, and the equation is: ; and it is mapped to the parameter space. By counting the number of times each point in the parameter space is mapped, the point with the highest frequency can be found as the optimal solution. Therefore, the winding edge line equation can be obtained in the following way: ; where is the Dirac function, which is used to indicate that the count is incremented by one when .

[0037] Based on the above winding edge line equation, key positioning points are identified from the edge map of the cable after winding. In one embodiment, as shown in Figure 3 , in step S33, identifying key positioning points from the edge map of the cable after winding based on the winding edge line equation includes: S331, selecting the vertical center line of the image of the edge map of the cable after winding as the reference line, and its equation can be expressed as , where is half of the image width; S332, calculating the intersection point between the equation of the reference line and the winding edge line equation as the key positioning point. Assume the winding edge line equation is , then the key positioning point satisfies: ; Then, based on the key positioning points, identify the corresponding edges of two adjacent wrapping loops. Specifically, group them according to the slope and position of the fitted straight line / curve, and classify the lines that are approximately parallel into one category. Search in the direction perpendicular to the wrapping direction (or approximately perpendicular) to find the nearest same-type edge belonging to the next loop (for example, both are front edges or both are rear edges).

[0038] Finally, based on the corresponding edges of the two adjacent wrapping loops, calculate the pitch. In one embodiment, as Figure 4 shown, in step S35, calculating the pitch based on the corresponding edges of the two adjacent wrapping loops includes: S351, setting the two adjacent wrapping loops as the i-th wrapping loop and the (i + 1)-th wrapping loop; S352, selecting a point P1 on the i-th wrapping loop, and searching for the corresponding point P2 on the (i + 1)-th wrapping loop along the direction perpendicular to the wrapping direction; S353, calculating the axial pixel distance between point P1 and point P2; S354, multiplying the axial pixel distance by the pixel size ratio to obtain the pitch.

[0039] Specifically, for the time series of the pitch, for example, expressed as , each of which corresponds to the wrapping edge line equations of a pair of key positioning points, and the pair of wrapping edge line equations will have discreteness based on the line features in the image space, that is, the discrete peak distribution of the line space fitting based on the Hough transform. Therefore, due to the mapping from the discrete points in the parameter space to the distribution in the time series space, the time series distribution is no longer limited to the discreteness assumption of the original parameter space. In order to make the time series distribution of the pitch based on the axial distance more accurate, it is necessary to establish the coordinate geometric relationship constraint of the pitch.

[0040] Therefore, in a preferred embodiment, as Figure 5 shown, in step S35, calculating the pitch based on the corresponding edges of the two adjacent wrapping loops includes: S351, setting the two adjacent wrapping loops as the i-th wrapping loop and the (i + 1)-th wrapping loop; S352, selecting a point P1 on the i-th wrapping loop, and searching for the corresponding point P2 on the (i + 1)-th wrapping loop along the direction perpendicular to the wrapping direction; S353, calculating the axial pixel distance between point P1 and point P2; S354, multiplying the axial pixel distance by the pixel size ratio to obtain the initial pitch; S355, performing coordinate geometric relationship constraint on the initial pitch to obtain the pitch.

[0041] In a specific embodiment, performing coordinate geometric relationship constraint on the initial pitch to obtain the pitch includes: for the key points P1 and P2 corresponding to each initial pitch, calculating the angular space representation of the Hough transform formula corresponding to the key points P1 and P2 as follows to obtain the key point angular space representation corresponding to each initial pitch, where the formula is: ; wherein, and are respectively the spatial coordinate representations of key points P1 and P2, and are the angular spatial representations of key points corresponding to each initial pitch.

[0042] Based on the angular spatial representations of key points corresponding to each initial pitch, calculate the vertical slope reference correction amount corresponding to each initial pitch according to the following formula, wherein the formula is: ; wherein, represents the initial pitch, represents the vertical slope reference correction amount.

[0043] Based on the angular spatial representations of key points corresponding to each initial pitch, calculate the axial intersection constraint correction amount corresponding to each initial pitch according to the following formula, wherein the formula is: ; wherein, represents the axial intersection constraint correction amount.

[0044] Based on the vertical slope reference correction amount and the axial intersection constraint correction amount, correct the initial pitch according to the following formula, wherein the formula is: ; wherein, represents the pitch.

[0045] That is, introduce the vertical slope reference into the explicit geometric reference standard of the axial intersection constraint, so as to limit the search space of the timing distribution, reduce the timing correlation mis-matching caused by continuous fracture or ambiguity caused by discreteness, and thus improve the timing distribution accuracy of the pitch.

[0046] In one embodiment, as Figure 6 shown, in step S4, on the online monitoring industrial control computer, determine whether the pitch uniformity meets the preset requirements based on the time series of the pitch, including: S41, define the target pitch and the absolute tolerance band; S42, calculate the acceptable range of the pitch based on the target pitch and the absolute tolerance band; S43, judge whether each pitch in the time series of the pitch is within the acceptable range of the pitch to obtain a set of out-of-tolerance judgment results; S44, if the proportion of the number of out-of-tolerance judgment results in the set of out-of-tolerance judgment results that are not within the acceptable range of the pitch exceeds the preset threshold, determine that the pitch uniformity does not meet the preset requirements.

[0047] Specifically, first, defining the target pitch and the absolute tolerance band is the basis of the entire evaluation process. The target pitch refers to the distance that should be maintained between adjacent wrapping turns under ideal conditions. Usually, this value is determined by the production process design. For example, a specific model of cable may be designed with a target pitch of 50 millimeters. The absolute tolerance band is the allowable pitch deviation range, usually expressed as plus or minus a percentage or a fixed value. In a specific embodiment, for the case where the target pitch is 50 millimeters as mentioned above, assuming the maximum allowable deviation is ±2 millimeters, the absolute tolerance band is [-2, +2] millimeters.

[0048] Based on the target pitch and the absolute tolerance band, the acceptable range of the pitch can be calculated. The target pitch is , and the absolute tolerance band is , then the acceptable range of the pitch is . In the above embodiment, . This means that any pitch value falling within this range is considered qualified, while a pitch outside this range is considered unqualified.

[0049] Next, the on-line monitoring industrial control computer will judge each pitch value in the time series of the pitch to see if it falls within the acceptable range. Specifically, for each pitch value , check if it meets the following conditions: . If a certain pitch value does not meet the above conditions, it is marked as out of tolerance. To better understand this process, in a specific embodiment, assume that the pitch time series of a certain section of cable is [50.1 mm, 49.9 mm, 52.3 mm, 47.8 mm, 50.5 mm], the target pitch is 50 mm, and the absolute tolerance band is ±2 mm. According to the above conditions, the following conclusions can be drawn: 50.1 mm: qualified; 49.9 mm: qualified; 52.3 mm: unqualified (out of tolerance); 47.8 mm: unqualified (out of tolerance); 50.5 mm: qualified.

[0050] Finally, count the number of out-of-tolerance pitches and compare it with a preset threshold to determine whether the pitch uniformity meets the preset requirements. In this specific embodiment, the set preset threshold is 5%, that is, no more than 5% of the pitch values are allowed to exceed the acceptable range. In this example, there are a total of 5 pitch values, and 2 of them are out-of-tolerance pitches, accounting for 40%. Obviously, 40% is much higher than the preset threshold of 5%, so it can be determined that the pitch uniformity of this section of cable does not meet the preset requirements. Of course, the above is only an example, and the specific values can be adjusted according to the actual situation or experiments, and this application does not make specific limitations.

[0051] Exemplarily, in step S5, on the online monitoring industrial control computer, in response to the pitch uniformity not meeting the preset requirements, a production status abnormal warning prompt is generated. It should be understood that by automatically generating a production status abnormal warning prompt, not only the detection efficiency and accuracy are improved, but also a quick response can be made when problems occur, avoiding the further production of defective products. At the same time, through continuous monitoring and timely adjustment, the production process can be optimized, and the overall production efficiency and product quality can be improved. In addition, the warning prompt can also be integrated with other automated control systems to achieve more efficient production management and quality control. In other examples, when the system detects that the pitch uniformity does not meet the requirements, not only can a warning be issued, but also the parameters of the production equipment can be automatically adjusted to reduce the need for human intervention and further improve the automation level of production.

[0052] In summary, the online monitoring method for the production of wet-winding water-resistant cables provided by the present application continuously captures the surface images of the cable after winding through a high-speed industrial camera, obtains an image frame sequence, and transmits it to the online monitoring industrial control computer for processing. Then, image recognition technology is used to analyze the surface of the cable in each frame of the image to extract the time series of the pitch. By analyzing the pitch time series, it is evaluated whether its uniformity meets the preset standard. Once a situation that does not meet the requirements is found, a production status abnormal warning prompt is automatically generated. In this way, high-precision real-time monitoring of the cable pitch uniformity is achieved, significantly improving the production efficiency and the level of product quality control, and overcoming the defect in the prior art that it is difficult to achieve real-time and accurate detection.

[0053] The present application also provides an online monitoring system for the production of wet-winding water-resistant cables, as Figure 7 shown. The online monitoring system 700 for the production of wet-winding water-resistant cables includes: a cable surface image acquisition module 710, which is used to continuously capture the surface images of the cable after winding through a high-speed industrial camera to obtain an image frame sequence of the surface images of the cable after winding; a cable surface image transmission module 720, which is used to transmit the image frame sequence of the surface images of the cable after winding to the online monitoring industrial control computer; a cable surface image recognition and processing module 730, which is used to perform image recognition and processing on each surface image of the cable after winding in the image frame sequence of the surface images of the cable after winding in the online monitoring industrial control computer to obtain the time series of the pitch; a pitch uniformity evaluation module 740, which is used to determine whether the pitch uniformity meets the preset requirements based on the time series of the pitch in the online monitoring industrial control computer; a production status abnormal warning module 750, which is used to generate a production status abnormal warning prompt in the online monitoring industrial control computer in response to the pitch uniformity not meeting the preset requirements.

[0054] The basic principles of the present application have been described in conjunction with specific embodiments. However, it should be noted that the advantages, benefits, effects, etc. mentioned in the present application are only examples and not limitations. It cannot be considered that these advantages, benefits, effects, etc. are essential for each embodiment of the present application. Additionally, the specific details disclosed above are only for illustrative and easy-to-understand purposes, not limitations. These details do not limit the present application to necessarily implementing with the above specific details.

[0055] The block diagrams of the devices, apparatuses, equipment, and systems involved in the present application are only illustrative examples and do not intend to require or imply that they must be connected, arranged, and configured in the manner shown in the block diagrams. As those skilled in the art will recognize, these devices, apparatuses, equipment, and systems can be connected, arranged, and configured in any manner. Words such as "including", "comprising", "having", etc. are open-ended terms, meaning "including but not limited to", and can be used interchangeably with each other. The word "or" and "and" used herein refer to the phrase "and / or", and can be used interchangeably with each other unless the context clearly indicates otherwise. The word "such as" used herein refers to the phrase "such as but not limited to", and can be used interchangeably with each other.

[0056] It should also be noted that in the devices, equipment, and methods of the present application, each component or each step can be decomposed and / or recombined. These decompositions and / or recombinations should be regarded as equivalent solutions of the present application.

[0057] The above description of the disclosed aspects is provided to enable any person skilled in the art to make or use the present application. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein can be applied to other aspects without departing from the scope of the present application. Therefore, the present application is not intended to be limited to the aspects shown herein, but rather to the broadest scope consistent with the principles and novel features disclosed herein.

[0058] The above description has been given for purposes of illustration and description. Additionally, this description does not intend to limit the embodiments of the present application to the forms disclosed herein. Although multiple example aspects and embodiments have been discussed above, those skilled in the art will recognize certain variations, modifications, changes, additions, and sub-combinations thereof.

Claims

1. An on-line monitoring method for the production of wet-winding water-resistant cables, characterized in that, Comprising: Continuously capturing images of the surface of the cable after winding by a high-speed industrial camera to obtain a sequence of image frames of the surface image of the cable after winding; Transmitting the sequence of image frames of the surface image of the cable after winding to an on-line monitoring industrial control computer; In the on-line monitoring industrial control computer, respectively performing image recognition processing on each surface image of the cable after winding in the sequence of image frames of the surface image of the cable after winding to obtain a time series of pitches; In the on-line monitoring industrial control computer, determining whether the pitch uniformity meets a preset requirement based on the time series of pitches; In the on-line monitoring industrial control computer, in response to the pitch uniformity not meeting the preset requirement, generating a warning prompt for abnormal production status; Wherein, in the on-line monitoring industrial control computer, respectively performing image recognition processing on each surface image of the cable after winding in the sequence of image frames of the surface image of the cable after winding to obtain a time series of pitches includes: performing edge detection on the surface image of the cable after winding to obtain an edge map of the cable after winding; performing line fitting based on the Hough transform on the edge map of the cable after winding to obtain an equation of the winding edge line; based on the equation of the winding edge line, identifying key positioning points from the edge map of the cable after winding; based on the key positioning points, identifying corresponding edges of two adjacent winding circles; based on the corresponding edges of the two adjacent winding circles, calculating an initial pitch; Among them, coordinate geometric relationship constraints are imposed on the initial pitch to obtain the pitch, including: for P1 and P2 corresponding to each initial pitch, the angular space representation of the Hough transform formula corresponding to P1 and P2 is calculated by the following formula to obtain the angular space representation of the key points corresponding to each initial pitch, where the formula is: ; where and are the spatial coordinate representations of key points P1 and P2 respectively, and are the angular space representations of the key points corresponding to each initial pitch; based on the angular space representations of the key points corresponding to each initial pitch, the vertical slope reference correction amount corresponding to each initial pitch is calculated by the following formula, where the formula is: ; where represents the initial pitch, represents the vertical slope reference correction amount; based on the angular space representations of the key points corresponding to each initial pitch, the axial intersection constraint correction amount corresponding to each initial pitch is calculated by the following formula, where the formula is: ; where represents the axial intersection constraint correction amount; based on the vertical slope reference correction amount and the axial intersection constraint correction amount, the initial pitch is corrected by the following formula, where the formula is: ; where represents the pitch.

2. The on-line monitoring method for the production of wet-winding water-resistant cables according to claim 1, characterized in that Performing edge detection on the surface image of the cable after winding to obtain an edge map of the cable after winding includes: performing edge detection on the surface image of the cable after winding based on the Canny operator to obtain the edge map of the cable after winding.

3. The online monitoring method for the production of wet-winding water-resistant cables according to claim 1, characterized in that Based on the equation of the winding edge line, identifying key positioning points from the edge map of the cable after winding includes: selecting the vertical center line of the image of the edge map of the cable after winding as a reference line; calculating the intersection point between the equation of the reference line and the equation of the winding edge line as the key positioning point.

4. The on-line monitoring method for the production of wet-winding water-resistant cables according to claim 1, wherein, Based on the corresponding edges of the two adjacent winding circles, calculating an initial pitch includes: setting the two adjacent winding circles as the i-th winding circle and the (i + 1)-th winding circle; selecting a point P1 on the i-th winding circle, and searching for a point P2 corresponding to the point P1 on the (i + 1)-th winding circle along a direction perpendicular to the winding direction; calculating the axial pixel distance between the point P1 and the point P2; multiplying the axial pixel distance by a pixel size ratio to obtain an initial pitch.

5. The on-line monitoring method for the production of wet-winding water-resistant cables according to claim 1, characterized in that In the on-line monitoring industrial control computer, determining whether the pitch uniformity meets a preset requirement based on the time series of pitches includes: defining a target pitch and an absolute tolerance band; calculating an acceptable range of pitches based on the target pitch and the absolute tolerance band; determining whether each pitch in the time series of pitches is within the acceptable range of pitches to obtain a set of out-of-tolerance judgment results; if the proportion of the number of out-of-tolerance judgment results in the set of out-of-tolerance judgment results that are not within the acceptable range of pitches exceeds a preset threshold, determining that the pitch uniformity does not meet the preset requirement.

6. An on-line monitoring system for the production of wet-winding water-resistant cables, which is used to execute the on-line monitoring method for the production of wet-winding water-resistant cables described in claim 1, characterized in that, Comprising: A cable surface image acquisition module, configured to continuously capture images of the surface of the cable after winding by a high-speed industrial camera to obtain a sequence of image frames of the surface image of the cable after winding; The cable surface image transmission module is used to transmit the image frame sequence of the surface image of the cabled cable after wrapping to the online monitoring industrial control computer; The cable surface image recognition and processing module is used to perform image recognition and processing on each surface image of the cabled cable in the image frame sequence of the surface image of the cabled cable after wrapping in the online monitoring industrial control computer to obtain the time series of pitches; The pitch uniformity evaluation module is used to determine whether the pitch uniformity meets the preset requirements based on the time series of pitches in the online monitoring industrial control computer; The production status abnormal warning module is used to generate a production status abnormal warning prompt in the online monitoring industrial control computer in response to the pitch uniformity not meeting the preset requirements.

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