Cable sheath comprehensive quality detection system and method

Abstract

The invention relates to the technical field of cable production and detection, and particularly discloses a cable sheath comprehensive quality detection system and method, and the system comprises an encoder, a deviation rectification device, and a detection and control integrated cabinet. The encoder is used for detecting the synchronization of the system and the tractor, measuring the running speed of the cable through the pulse frequency of the encoder, and controlling the acquisition line frequency of the line scan camera and the acquisition time of an image; the deviation rectifying device is used for aligning the twisted cable in operation; the detection and control integrated cabinet comprises an upper layer, a middle layer and a lower layer; the upper layer is a man-machine interaction module used for interaction between an operator and the detection system; the middle layer is an image acquisition module and is used for acquiring image information; and the lower layer is a signal and control processing module and is used for signal acquisition, image processing and system control. According to the cable sheath detection device, the encoder, the deviation rectifying device and the detection and control integrated cabinet are organically combined, so that high-precision, high-efficiency and automatic operation of cable sheath detection is realized.

Description

Technical Field

[0001] The present application relates to the technical field of cable production and detection, and more specifically, to a comprehensive quality detection system and method for cable sheaths. Background Art

[0002] In today's cable industry, the importance of cable sheaths is self-evident. It undertakes two key missions: on the one hand, it provides strong mechanical protection for the cores inside the cable, and can effectively resist the erosion and damage of many external adverse factors to the cable; on the other hand, a series of key information printed on the sheath surface, such as voltage, current, type, length, coding, etc., is of great significance to relevant staff, which can help them quickly and accurately identify the specific uses of the cables, so as to effectively avoid various electrical accidents that may be caused by improper use.

[0003] However, in the forming process of cable sheaths, it is often inevitable that there are many quality defects on the sheath surface, such as breakage, protrusion, indentation, abnormal wire diameter, etc.; when printing characters on the sheath, various defects such as wrong printing, missing printing, and blurred printing are also often encountered. In order to ensure the ex-factory quality of cable products, the industry usually conducts detection work on cable sheaths.

[0004] At present, the cable industry widely uses the method of manual sampling inspection to conduct detection. However, this detection method has many disadvantages: the detection speed is extremely slow, the detection efficiency is low, the detection standards are difficult to be unified, and it is impossible to achieve comprehensive coverage detection of products. In recent years, some universities and vision companies have been engaged in the research field of cable detection technology, and relevant literatures have been published and disclosed one after another.

[0005] However, these research results still have some defects that need to be solved urgently:

[0006] 1. The existing detection systems cannot be effectively docked with the production systems, and a large amount of information still needs to rely on manual input, resulting in a low degree of automation and intelligence in the whole detection process. Moreover, these detection systems have a high dependence on production personnel. The on-site operators must have a very familiar grasp of the detection systems, detection principles, detection software, etc. to ensure the normal use of the systems.

[0007] 2. Phenomena such as missed detection, false detection, and wrong detection are relatively common during the detection process, resulting in low detection accuracy and difficult to meet the actual needs of current cable production enterprises for detection accuracy and efficiency.

[0008] Therefore, a comprehensive quality detection system and method for cable sheaths are provided. Summary of the Invention

[0009] In order to solve the above technical problems, the present application is proposed.

[0010] Specifically, according to one aspect of the present application, a comprehensive quality detection system for cable sheaths is provided, which includes: an encoder, a deviation rectification device, and an integrated detection and control cabinet;

[0011] The encoder is used to keep the system synchronized with the traction machine, measure the running speed of the cable through the encoder pulse frequency, control the acquisition line frequency of the line scan camera, and the acquisition timing of the image;

[0012] The deviation rectification device is used to rectify the running and twisted cable;

[0013] The integrated detection and control cabinet includes upper, middle, and lower layers;

[0014] The upper layer is a human-machine interaction module for the interaction between the operator and the detection system;

[0015] The middle layer is an image acquisition module for image information acquisition;

[0016] The lower layer is a signal and control processing module for signal acquisition, image processing, and system control.

[0017] Preferably, the encoder is installed on the main shaft of the traction machine.

[0018] Preferably, the signal and control processing module includes a processor, and the processor is connected to the MES system of the cable enterprise to receive and execute the production instructions provided by the MES system. The production instructions include the brand, number, code, and printing characters of the cable.

[0019] Preferably, the signal and control processing module further includes a control board, and the control board includes: an STM32 single-chip microcomputer, a camera trigger control circuit, a constant current source control circuit, a USB communication circuit, an RS232 communication circuit, a PNP-type signal output circuit, an NPN-type signal output circuit, a PNP-type signal input circuit, and an NPN-type signal input circuit.

[0020] Preferably, the control board is connected to the inkjet printer on the cable production line to collect the start printing signal of the inkjet printer.

[0021] Compared with the prior art, the comprehensive quality detection system for cable sheaths provided by the present application has the following technical effects:

[0022] (1). Through the encoder, accurate measurement of the cable running speed and synchronous control of image acquisition are realized, ensuring accurate image acquisition timing, improving image quality, and thus improving the accuracy of detection.

[0023] (2). The addition of a deviation rectification device ensures the stability of the cable during detection and reduces false detection or missed detection caused by cable position deviation.

[0024] (3) The integrated design of the detection and control integrated cabinet integrates functions such as image acquisition, signal processing, and system control, simplifies the detection process, reduces manual intervention, and improves the degree of detection automation.

[0025] Specifically, according to another aspect of the present application, a comprehensive quality detection method for cable sheaths is provided, which includes:

[0026] S1. Receive the cable number, code, and character information to be printed of the cable to be produced provided by the MES system, and automatically complete brand switching;

[0027] S2. Determine whether a printing character signal from the inkjet printer is received. If so, after delaying N pulses, use multiple linear array cameras to scan the cable according to the encoder pulse frequency, and generate one image each after completing M rows of scanning;

[0028] S3. After the system receives the image, determine whether the image is the first image scanned after receiving the inkjet signal; if it is the first image, consider the image as an image with characters and proceed to step S4; if it is not the first image, consider the image as an image without characters and proceed to step S6;

[0029] S4. Use traditional algorithms and AI character recognition algorithms to perform image preprocessing, character contour area search, string positioning and segmentation cropping on the image with characters, and perform character recognition and comparison;

[0030] S5. If there are character errors, directly stop the machine or give an alarm reminder; if there are no character errors, use the image without characters to cover the characters in the image with characters, and use traditional machine vision and deep learning algorithms to align and perform appearance defect detection. If a defect is detected, stop the machine or give an alarm reminder;

[0031] S6. Use traditional machine vision and deep learning algorithms to perform appearance defect detection on the image without characters. If a defect is detected, stop the machine or give an alarm reminder.

[0032] Preferably, in S2, the number of delayed pulses N = S×P / L, and the number of rows M = 0.5×P / L; where N is the number of delayed pulses, S is the distance from the inkjet head to the camera, L is the length of the cable running when the encoder rotates one circle, and P is the number of encoder steps.

[0033] Compared with the prior art, a comprehensive quality detection method for cable sheaths provided by the present application has the following technical effects:

[0034] (1) Through MES system integration technology, it is possible to automatically receive the cable number, code, and character information to be printed of the cables to be produced provided by the MES system, and automatically complete brand switching. There is no need for manual input of production information, reducing human errors, improving production efficiency and information accuracy, and realizing the intelligent and automated production management of the detection system.

[0035] (2) By leading out the printing character start signal from the inkjet printer, the system can accurately locate the character position, thus greatly improving the character recognition rate.

[0036] (3) By using traditional algorithms and AI character recognition technology for operations such as string positioning, segmentation and cropping, and character recognition and comparison, it can effectively handle complex situations such as blurred character printing and deformed fonts, greatly improving the accuracy of character recognition and reducing quality problems caused by character errors. Brief Description of the Drawings

[0037] 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 accompanying drawings are used to provide a further understanding of the embodiments of the present application, and constitute a part of the specification. Together with the embodiments of the present application, they are used to explain 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.

[0038] Figure 1 The electrical principle block diagram of the embodiment of the present application is illustrated.

[0039] Figure 2 The block diagram of the control board circuit composition of the embodiment of the present application is illustrated.

[0040] Figure 3 The front external structure schematic diagram of the integrated cabinet of the embodiment of the present application is illustrated.

[0041] Figure 4 The side external structure schematic diagram of the integrated cabinet of the embodiment of the present application is illustrated.

[0042] Figure 5 The internal rear view of the embodiment of the present application is illustrated.

[0043] Figure 6 The internal side view of the embodiment of the present application is illustrated.

[0044] Figure 7 The software flow chart of the character surface camera of the embodiment of the present application is illustrated.

[0045] In the figure, 1. Alarm; 2. Display module; 3. Front upper panel; 4. Indicator light; 5. Wire wheel bracket; 6. Wire wheel; 7. Front light-shielding curtain; 8. Power switch; 9. Front lower panel; 10. Cooling fan; 11. Universal caster; 12. Rear upper cover plate; 13. Rear adjustment handwheel; 14. Roller; 15. Handle; 16. Rear lower cover plate; 17. Power socket; 18. LCD screen bracket; 19. Driver board power supply; 20. Touch screen driver board; 21. LCD screen; 22. Installation base plate; 23. Converter board power supply; 24. LVDS signal converter board; 25. Display module frame; 26. Light source bracket; 27. Upper camera; 28. Side adjustment handwheel; 29. Backlight source; 30. Back camera; 31. Front camera; 32. Front light source; 33. 24V power supply; 34. Terminal block; 35. Processor; 36. Right mounting bracket for processor; 37. Control board; 38. Base; 39. Filter; 40. Lower mounting bracket for processor; 41. Left mounting bracket for processor; 42. Upper mounting bracket for processor; 43. Indicator light press block; 44. Upper light source; 45. Rotary disk base; 46. Rotary disk; 47. Side light-shielding curtain. Detailed implementation manners

[0046] Next, embodiments according to 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 the embodiments of the present application. It should be understood that the present application is not limited by the example embodiments described herein.

[0047] Embodiment 1:

[0048] Figure 1 The electrical principle block diagram of the embodiment of the present application is shown. This electrical principle block diagram describes the hardware architecture of the comprehensive quality detection system for cable sheaths. As Figure 1 shown, for the comprehensive quality detection system for cable sheaths according to the embodiment of the present application, its core functional modules mainly include an encoder and a deviation rectifying device.

[0049] The encoder is used to keep the system synchronized with the tractor, measure the running speed of the cable through the encoder pulse frequency, control the acquisition line frequency of the line-scan camera, and the acquisition timing of the image.

[0050] Specifically, to ensure that the encoder can accurately track the movement of the cable and avoid missing character scanning, the encoder is directly installed on the main shaft of the tractor. This installation method can prevent the encoder from failing to correctly record the movement of the cable due to non-rotation when the cable slides on the wire wheel 6 of the control cabinet, thus ensuring the integrity and accuracy of character scanning.

[0051] The deviation correction device is used to straighten the running and twisted cable, ensuring that the character side of the cable faces in the same direction, so as to ensure that the camera can always capture the characters, reducing system false detections.

[0052] In addition, Figure 1 The line array cameras (upper camera 27, dorsal camera 30, front camera 31), line array light sources (dorsal light source 29, front light source 32, upper light source 44), display module 2, processor 35, control board 37, alarm 1, etc. in

[0053] are installed inside and outside the metal shell to form an integrated detection and control control cabinet. The integrated detection and control control cabinet is the core of the entire detection system. The display module 2 is used for human-computer interaction.

[0054] The processor 35 is used to run the operating system and the upper computer software. It is connected to the MES system of the cable enterprise, receiving and executing the production instructions provided by the MES system regarding the cable brand, number, code, and printed characters. This design can reduce manual participation and improve the automation and intelligence level of the detection process.

[0055] The working principle of the cable sheath comprehensive quality detection system is specifically as follows: When the system receives the signal from the inkjet printer, the control board 37 uses the pulse frequency information provided by the encoder to precisely control the three line array cameras to perform line-by-line scanning on the cable sheath, and transmits the scanned image data to the processor 35. The processor 35 stitches these image data into a complete image and uses image processing technology to analyze the image to identify the defects and character features of the cable sheath. The analysis results are then sent to the control board 37, and the control board 37 performs corresponding operations according to the results, such as triggering the alarm 1 to give an audible and visual alarm or instructing the tractor to stop running when a defect is detected, ensuring that quality problems are promptly discovered and processed, thus guaranteeing the high-quality production of the cable sheath.

[0056] Among them, the circuit block diagram of the control board 37 is as Figure 2 shown. The control board 37 provides expansion functions such as input, output, and communication for the processor 35, providing a "bridge" for the connection between the processor 35 and the line array camera, encoder, alarm 1, and inkjet printer. It can not only control the opening and closing of the camera and light source, but also provide input and output signal interfaces, USB2.0 interfaces, light source interfaces, communication interfaces, etc.

[0057] The circuit modules mainly included in the control board 37 are: STM32 single-chip microcomputer, camera trigger control circuit, constant current source control circuit, serial communication circuit (USB communication circuit, RS232 communication circuit), output circuit (PNP type signal output circuit, NPN type signal output circuit), input circuit (PNP type signal input circuit, NPN type signal input circuit), etc. Among them, the output circuit is used for the single-chip microcomputer to send an alarm signal to the alarm 1; the input circuit collects the signals of the external encoder and inkjet printer; the constant current source control circuit provides a constant current source for the linear array light source and controls the on and off of the constant current source; the camera trigger control circuit provides a trigger signal for the linear array camera.

[0058] The working principle of the control board 37 circuit is as follows: The control board 37 takes the STM32 single-chip microcomputer as the core, receives the "start printing" trigger signal of the inkjet printer in real time through the PNP / NPN type signal input circuit, combines the cable speed synchronization data of the encoder, and precisely controls the shooting timing of the line scan camera by the camera trigger control circuit to ensure that the character image is strictly aligned with the inkjet position; at the same time, the STM32 single-chip microcomputer exchanges data with the MES system through the USB / RS232 communication circuit, adjusts inkjet parameters such as character content and position, and stably drives the line scan light source by using the constant current source output circuit to ensure image quality. After the detection is completed, the PNP / NPN type signal output circuit feeds back the deviation correction instruction or inkjet correction signal to the actuator, forming a full-process automated link from signal acquisition, synchronous control to closed-loop adjustment, significantly improving the character positioning accuracy and system response reliability.

[0059] In particular, as Figures 3 - 6 shown, the integrated detection and control control cabinet is divided into upper, middle and lower layers. The upper layer is the human-computer interaction module for the interaction between the operator and the detection system, mainly including the alarm 1, display module 2, touch screen driver board 20, liquid crystal display 21, power supply module (driver board power supply 19, conversion board power supply 23), LVDS signal conversion board 24, etc.; the middle layer is the image acquisition module for image information acquisition, mainly including the indicator light 4, linear array camera (upper camera 27, back camera 30, front camera 31), linear array light source (back light source 29, front light source 32, upper light source 44), lens adapter ring, industrial lens, etc.; the lower layer is the signal and control processing module for signal acquisition, image processing and system control, mainly including the power switch 8, cooling fan 10, power supply (power socket 17, 24V power supply 33), processor 35, control board 37, filter 39, splitter, etc.

[0060] Among them, the alarm 1 is installed on the upper part of the rear cabinet of the display module 2, and the indicator light 4 is installed at the rear of the front upper panel 3; the wire wheel 6 is installed on the wire wheel bracket 5, and the wire wheel bracket 5 is installed on the side of the cabinet for the cable running track to limit the left and right fluctuations of the cable beyond the camera's field of view, and ensure that the distance from the cable surface to the reference plane of the camera for taking pictures remains unchanged by adjusting the height of the wire wheel bracket 5 and the height of the universal caster 11. The front light-shielding curtain 7 and the side light-shielding curtain 47 are made of soft rubber material to block external light from entering the cabinet and prevent the internal light source from shining into the eyes of the staff. The side adjustment handwheel 28 is installed on the side of the cabinet to adjust the tightness or angle of the side light-shielding curtain 47 to optimize the light-blocking effect. The power switch 8 is installed on the side of the cabinet, and the handle 15 is installed on the side of the power switch 8, close to the center of the cabinet. The front lower panel 9 wraps the lower part of the control cabinet. The cooling fan 10 is installed on the lower side to dissipate heat from the entire core component module. The rollers 14 are installed at the bottom of both sides of the rear upper cover 12, and the back adjustment handwheel 13 is installed on the back of the rear upper cover 12. The rear upper cover 12 can be easily removed through the rollers 14 and the back adjustment handwheel 13, which is beneficial to the installation of the internal structure of the control cabinet. The rear lower cover 16 is designed as a cabinet door, which can be easily opened for installation, wiring, and maintenance. The base 38 is installed at the bottom of the integrated detection and control cabinet to play a role in stable support. The power supply of the entire system is introduced from the power socket 17.

[0061] Specifically, as Figure 5 、 6 shown, the specific operations of the assembly process of the integrated detection and control cabinet are as follows:

[0062] 1. Installation of the display module 2: First, paste the touch screen onto the liquid crystal screen 21 and install them together on the liquid crystal screen bracket 18. Secondly, fix the liquid crystal screen bracket 18 to the display module frame 25. Then, install the drive board power supply 19, the touch screen drive board 20, the conversion board power supply 23, and the LVDS signal conversion board 24 onto the mounting base plate 22 respectively. Next, fix the mounting base plate 22 to the display module frame 25. Finally, connect the wires and cover the rear cover to complete the installation of the display module 2.

[0063] 2. Installation of the line array camera and the line array light source: First, use screws to install the rotary disk base 45 on the side of the cabinet. Then, place the rotary disk 46 into the guide groove of the rotary disk base 45 and fix it through the back adjustment handwheel 13. Next, install the backlight source 29, the front light source 32, and the upper light source 44 on their respective light source brackets 26 respectively, and then fix them together with the upper camera 27, the back camera 30, and the front camera 31 on the rotary disk 46.

[0064] 3. Installation of the power supply and the processor 35: First, fix the terminal block 34 to the 24V power supply 33 through the bottom plate, and then use screws to fix it together on the partition between the middle and bottom chambers. Next, install the processor lower mounting bracket 40 and the processor upper mounting bracket 42 on the left and right sides of the cabinet. Then, fix the processor right mounting bracket 36 and the processor left mounting bracket 41 on both sides of the processor 35, and then fix them together to the processor lower mounting bracket 40 and the processor upper mounting bracket 42. The control board 37 is directly fixed to the cabinet through the mounting plate.

[0065] 4. Installation of the indicator light 4: Use the indicator light press block 43 to press the indicator light 4 at the rear of the front lower panel, connect all the wires, and then install the rear cover plate to complete the installation.

[0066] Embodiment 2:

[0067] Figure 7 The method flow chart of the embodiment of the present application is illustrated. As Figure 7 shown, according to the comprehensive quality detection method of the cable sheath of the embodiment of the present application, which is applied to the above-mentioned comprehensive quality detection system of the cable sheath, the specific implementation steps are as follows:

[0068] 1. Before starting production, the system receives the cable number, code, and character information to be printed of the cable to be produced provided by the MES system, and automatically completes the brand switching.

[0069] 2. After the system is powered on and initialized, if it receives the start coding signal of the inkjet printer, then after delaying N pulses, the system controls three linear array cameras to scan the cable according to the encoder pulse frequency. After completing M rows of scanning, an image is generated for each.

[0070] Among them, the number of delayed pulses N = S×P / L, where N is the number of delayed pulses, S is the distance from the inkjet head to the camera, L is the length of the cable running when the encoder rotates one circle, and P is the number of steps of the encoder; M = 0.5×P / L, that is, the maximum length of the characters printed by the inkjet code is 0.5 meters, the cable is inkjet coded every 1 meter, and 1 meter is divided into two pictures for scanning and acquisition.

[0071] 3. After the system receives the image, first judge whether the image is the first image scanned after receiving the coding signal:

[0072] If it is the first image, it is considered that the image is an image with characters. Use the traditional algorithm and the AI character recognition algorithm to perform image preprocessing, character contour area search, string positioning and segmentation and cropping on the image, and then perform character recognition and comparison. If there are character errors, directly stop the machine or alarm. If there are no character errors, first cover the characters with an image without characters, and then use traditional machine vision and artificial intelligence to perform appearance defect detection.

[0073] If it is not the first image, the image is considered a characterless image. Only the appearance defects of the image are detected using traditional machine vision and artificial intelligence. If a defect is detected, the machine is stopped or an alarm is given.

[0074] That is, this method adopts a comprehensive detection method that combines traditional vision, deep learning, digitization, and AI character recognition technologies. While improving intelligence and automation, it can better identify smaller and more complex defects and characters. In the detection, defect detection is performed on characterless images, character recognition is first performed on images with characters, and then the characters are covered for defect detection, realizing multiple detection functions in a single detection system.

[0075] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above exemplary embodiments, and the present invention can be implemented in other specific forms without departing from the spirit or basic characteristics of the present invention.

[0076] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit of the technical solutions of the present invention.

Claims

1. An integrated quality detection system for cable sheaths, characterized in that, Including: An encoder, a deviation rectifying device, and an integrated detection and control cabinet; The encoder is used to keep the system synchronized with the tractor, measure the running speed of the cable through the encoder pulse frequency, control the acquisition line frequency of the line scan camera, and the acquisition timing of the image; The deviation rectifying device is used to straighten the running and twisted cable; The integrated detection and control cabinet includes upper, middle, and lower layers; The upper layer is a human-machine interaction module for the interaction between the operator and the detection system; The middle layer is an image acquisition module for image information acquisition; The lower layer is a signal and control processing module for signal acquisition, image processing, and system control.

2. The comprehensive quality inspection system for cable sheaths according to claim 1, wherein The encoder is installed on the main shaft of the tractor.

3. The integrated quality inspection system for cable sheaths according to claim 2, wherein, The signal and control processing module includes a processor, and the processor is connected to the MES system of the cable enterprise to receive and execute the production instructions provided by the MES system.

4. The comprehensive quality inspection system for cable sheaths according to claim 3, characterized in that, The production instructions include the brand, number, code, and printed characters of the cable.

5. The integrated quality inspection system for cable sheaths according to claim 4, wherein The signal and control processing module further includes a control board, and the control board includes: STM32 single-chip microcomputer, camera trigger control circuit, constant current source control circuit, USB communication circuit, RS232 communication circuit, PNP type signal output circuit, NPN type signal output circuit, PNP type signal input circuit, NPN type signal input circuit.

6. The comprehensive quality detection system for cable sheaths according to claim 5, characterized in that The control board is connected to the inkjet printer on the cable production line to collect the start printing signal of the inkjet printer.

7. A comprehensive quality inspection method for cable sheaths, characterized in that, Including: S1. Receive the cable number, code, and information of the characters to be printed of the cable to be produced provided by the MES system, and automatically complete brand switching; S2. Judge whether the printing character signal of the inkjet printer is received. If so, after delaying N pulses, use multiple line array cameras to scan the cable according to the encoder pulse frequency. After completing M-line scanning, generate an image respectively; S3. After the system receives the image, judge whether the image is the first image scanned after receiving the inkjet signal; if it is the first image, it is considered that the image is an image with characters, and go to step S4. If it is not the first image, it is considered that the image is an image without characters, and go to step S6; S4. Use traditional algorithms and AI character recognition algorithms to perform image preprocessing, character contour area search, string positioning and segmentation and cropping on the image with characters, and perform character recognition and comparison; S5. If there are character errors, directly stop the machine or give an alarm reminder; if there are no character errors, use the image without characters to cover the characters of the image with characters, and use traditional machine vision and deep learning algorithms to align and perform appearance defect detection. If defects are detected, stop the machine or give an alarm reminder; S6. Use traditional machine vision and deep learning algorithms to perform appearance defect detection on the image without characters. If defects are detected, stop the machine or give an alarm reminder.

8. The comprehensive quality inspection method for cable sheaths according to claim 7, characterized in that, The S2 includes: The number of delay pulses N = SP / L, and the number of rows M = 0.5P / L; Wherein, N is the number of delay pulses, S is the distance from the inkjet head to the camera, L is the length of the cable running when the encoder rotates one circle, and P is the number of steps of the encoder.

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