Automatic alignment flat cable detection alarm system

Abstract

The invention relates to the technical field of wire rod production, in particular to an automatic alignment wire arrangement detection alarm system which comprises a base. The flat cable correction mechanism is used for detecting the inclined state of the cable body; the defect detection mechanism is used for detecting surface defects of the wire body; the guide mechanism is used for adjusting the angle of the line body entering the defect detection mechanism; and the linear mechanism is used for driving the flat cable correction mechanism, the defect detection mechanism and the guide mechanism to linearly move. According to the automatic alignment flat cable detection alarm system, the flat cable correction mechanism is arranged, the inclination state of a cable body can be detected through cooperation of a stop sensor and two direction sensors, then the cable body is controlled to move through the linear mechanism, dynamic correction of the cable body is achieved, a vertical angle is kept between a cable and a cable coil, and friction is reduced; and by arranging the defect detection mechanism, the abrasion condition of the wire surface generated in the wire arranging process can be identified, the detection precision is improved, and the outgoing quality of the wire body is ensured.

Description

Technical Field

[0001] The present invention relates to the technical field of wire production, and in particular to an automatic alignment and wiring detection and alarm system. Background Art

[0002] In the production of new energy vehicle cables, scratches and abrasions on the surface of bare copper wire significantly impact its quality. Any surface defects caused by friction between the wires during payout will result in the entire reel being deemed defective. Furthermore, because testing is limited to spot checks, not the entire reel, defects in the middle of the wire may go undetected and be passed off as acceptable. This can negatively impact customers, leading to complaints and significant losses for the company.

[0003] Therefore, minimizing surface defects caused by friction between wires during the pay-off process and promptly detecting defective products are crucial in the production of new energy vehicle cables. However, traditional cable routing devices rely on mechanical limits or manual observation and adjustment, making it impossible to determine wire deviation and surface wear in real time, resulting in insufficient detection accuracy. Existing electronically controlled cable routing systems only provide a shutdown alarm function when cable routing anomalies (such as overlapped or skipped wires) occur, without the ability to dynamically correct the cable routing process, thus impacting production efficiency. Therefore, we propose an automatic cable alignment detection and alarm system. Summary of the Invention

[0004] The purpose of the embodiments of the present invention is to provide an automatic alignment and wiring detection and alarm system, which solves the problems in the background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] An automatic alignment and wiring detection alarm system includes a base;

[0007] The cable correction mechanism is used to detect the inclination of the cable;

[0008] Defect detection mechanism, used to detect surface defects of the wire body;

[0009] A guide mechanism, used to adjust the angle at which the wire enters the defect detection mechanism;

[0010] Linear mechanism, used to drive the cable correction mechanism, defect detection mechanism and guide mechanism to move linearly;

[0011] The cable arrangement correction mechanism includes a direction-changing wheel for guiding the cable body, a stop sensor is provided below the direction-changing wheel, and direction sensors are provided on both sides of the stop sensor.

[0012] Furthermore, after the direction sensor infraredly senses the wire body, it starts calculating the sensing time T1. When T1 exceeds the reference value A, the linear mechanism starts and drives the wiring correction mechanism and the defect detection mechanism to move in a straight line. When the stop sensor senses the wire body, it starts calculating the sensing time T2. When T2 exceeds the reference value B, the linear mechanism stops.

[0013] Furthermore, it also includes an alarm light. The defect detection mechanism senses electromagnetic waves on the surface of the wire body and generates an electromagnetic induction signal L2. When the difference L1 between L2 and the electromagnetic induction signal of the normal wire body surface reaches a reference value L, the alarm light outputs an alarm signal.

[0014] Furthermore, it also includes a central control unit and a waveform display, and the central control unit is electrically connected to the driving component, the direction sensor, the stop sensor, the defect detection mechanism, the alarm light and the waveform display respectively.

[0015] Furthermore, the reference value A and the reference value B are both 5s.

[0016] Furthermore, the cable arrangement correction mechanism further includes two fixed columns, a support frame is fixedly installed between the two fixed columns, the direction-changing wheel is rotatably installed on the support frame, and the direction sensor and the stop sensor are fixedly installed on the support frame.

[0017] Furthermore, the defect detection mechanism includes a sleeve for being sleeved on the outside of the linear body, the sleeve is fixedly mounted on the support frame, a plurality of detection probes are fixedly mounted on the inner wall of the sleeve, a baffle is arranged between two adjacent detection probes, and one end of the baffle is fixedly connected to the inner wall of the sleeve.

[0018] Furthermore, the bottom end of the sleeve is fixed and connected to a tube body, and the circumference of the tube body is connected to a negative pressure tube.

[0019] Furthermore, the guide mechanism includes a fixed frame, one end of the fixed frame is fixedly mounted on the support frame, a guide rod is slidably connected to the inner wall of the fixed frame, one end of the guide rod is fixedly connected to a movable frame, a guide wheel is rotatably mounted on the movable frame, the movable frame is fixedly connected to the tube body, one end of the movable frame is rotatably connected to an adjusting screw, and the adjusting screw is threadedly connected to the fixed frame.

[0020] Furthermore, the linear mechanism includes two fixed platforms, both of which are fixedly mounted on the base, a sliding guide rail is installed between the two fixed platforms, a movable plate is slidably mounted on the sliding guide rail, the movable plate is fixedly connected to the two fixed columns, a driving component is provided on the fixed platform, and the driving component is drivingly connected to the movable plate.

[0021] By means of the above technical solution, the present invention provides an automatic alignment and wiring detection alarm system. It has at least the following beneficial effects:

[0022] (1) The automatic alignment and wiring detection alarm system can detect the inclination of the wire body by setting up a wiring correction mechanism, using the cooperation of the stop sensor and the two direction sensors, and then controlling the movement of the wire body through the linear mechanism to achieve dynamic deviation correction of the wire body, so that the wire and the wire reel maintain a vertical angle to reduce friction. By setting up a defect detection mechanism, the wear condition of the wire surface generated during the wiring process can be identified, thereby improving the detection accuracy and ensuring the factory quality of the wire body.

[0023] (2) The automatic alignment and wiring detection alarm system can adjust the relative position between the defect detection mechanism and the changing wheel by setting a guide mechanism, and further adjust the angle at which the wire body passes through the defect detection mechanism, so that the wire body can pass vertically through the sleeve and the tube body without contacting the internal structure of the defect detection mechanism, thereby avoiding wear on the wire body. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The accompanying drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application:

[0025] Figure 1 A schematic diagram of the overall structure of an embodiment of the present invention from a first perspective;

[0026] Figure 2 A second perspective diagram of the overall structure of an embodiment of the present invention;

[0027] Figure 3 Schematic diagram of a linear mechanism according to an embodiment of the present invention;

[0028] Figure 4 Schematic diagram of a support frame and a movable frame in an embodiment of the present invention;

[0029] Figure 5 Schematic diagram of a defect detection mechanism in an embodiment of the present invention

[0030] Figure 6 Schematic diagram of a detection probe in an embodiment of the present invention.

[0031] In the figure: 1. Base; 2. Linear mechanism; 21. Sliding guide rail; 22. Fixed table; 23. Moving plate; 24. Driving component; 25. Screw; 3. Cable correction mechanism; 31. Fixed column; 32. Support frame; 33. Direction sensor; 34. Stop sensor; 35. Changing wheel; 41. Alarm light; 42. Central control unit; 43. Display; 5. Defect detection mechanism; 51. Sleeve; 52. Detection probe; 53. Baffle; 54. Tube body; 55. Negative pressure tube; 6. Guide mechanism; 61. Fixed frame; 62. Movable frame; 63. Guide rod; 64. Guide wheel; 65. Adjusting screw. DETAILED DESCRIPTION

[0032] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0033] See also Figures 1-6 , a technical solution provided by the present invention:

[0034] An automatic alignment and wiring detection and alarm system, comprising:

[0035] Base 1;

[0036] The linear mechanism 2 is provided on the base 1;

[0037] The line correction mechanism 3 is provided on the linear mechanism 2 and is used to detect the inclination state of the line body;

[0038] The defect detection mechanism 5 is provided on the cable correction mechanism 3 and is used to detect defects on the surface of the cable body;

[0039] The guide mechanism 6 is provided on the line correction mechanism 3 and is used to adjust the angle at which the line enters the defect detection mechanism 5;

[0040] The control mechanism 4 is connected to the linear mechanism 2, the line correction mechanism 3 and the defect detection mechanism 5;

[0041] Among them, by setting up the linear mechanism 2, it can be used to drive the line correction mechanism 3, the defect detection mechanism 5 and the guide mechanism 6 to move linearly, thereby adjusting the angle of the line body.

[0042] Specifically, the linear mechanism 2 includes two fixed platforms 22, both of which are mounted on the base 1. The two fixed platforms 22 are symmetrically arranged, and a sliding guide rail 21 is fixedly installed between the two fixed platforms 22. A movable plate 23 is slidably mounted on the sliding guide rail 21. There are two sliding guide rails 21, and the two sliding guide rails 21 are symmetrically distributed with the center line of the movable plate 23 as the symmetry axis. The movable plate 23 is limited by the sliding guide rails 21, making the movement of the movable plate 23 more stable. A driving component 24 for driving the movable plate 23 to move along the sliding guide rail 21 is provided on one side of the fixed platform 22. The driving component 24 is a linear motor, an electric push rod, or a combination of a motor and a screw 25. When the driving component 24 is a linear motor or an electric push rod, the output end of the linear motor or electric push rod is connected to one end of the movable plate 23 to drive the movable plate 23 to perform linear motion. When the driving component 24 is a combination of a motor and a screw rod 25, the screw rod 25 is rotatably installed between the two fixed platforms 22, the surface of the screw rod 25 is threadedly connected to the bottom of the movable plate 23, the motor is fixedly installed on one of the fixed platforms 22, and the output end of the motor is connected to one end of the screw rod 25 to drive the screw rod 25 to rotate, thereby driving the movable plate 23 to move horizontally. Through the combined transmission of the motor and the screw rod 25, deceleration and precise adjustment can be achieved.

[0043] In this embodiment, the cable alignment mechanism 3 includes two fixed columns 31, both fixedly mounted on the movable plate 23. The two fixed columns 31 are symmetrically arranged with the centerline of the movable plate 23 as the axis of symmetry. A support frame 32 is fixedly mounted between the two fixed columns 31. A direction-changing wheel 35 is rotatably mounted on the support frame 32. The direction-changing wheel 35 is used to guide the cable. A direction sensor 33 and a stop sensor 34 are fixedly mounted on the support frame 32. Both the direction sensor 33 and the stop sensor 34 are infrared sensors. The stop sensor 34 is located below the direction-changing wheel 35 and is used to detect whether the cable is tilted relative to the direction-changing wheel 35. There are two direction sensors 33, and the two direction sensors 33 are symmetrically arranged on either side of the stop sensor 34 to determine the degree of inclination of the cable relative to the direction-changing wheel 35.

[0044] The defect detection mechanism 5 is fixedly mounted on the support frame 32 and is located above the direction-changing wheel 35 for detecting surface defects of the wire body.

[0045] Specifically, the defect detection mechanism 5 includes a sleeve 51 for being sleeved on the outside of the wire body. The sleeve 51 is fixedly mounted on the support frame 32 to keep it stable. A plurality of detection probes 52 are fixedly mounted on the inner wall of the sleeve 51. The plurality of detection probes 52 are distributed in a circular array with the axis of the sleeve 51 as the center to increase the detection viewing angle, so that the defect detection mechanism 5 can fully scan the periphery of the copper wire. A baffle 53 is arranged between two adjacent detection probes 52. One end of the baffle 53 is fixedly connected to the inner wall of the sleeve 51. The baffle 53 is used to separate the detection probes 52, which can reduce mutual interference between the probes and avoid overlapping of the detection areas, which affects the accuracy of the detection results. The bottom end of the sleeve 51 is fixed and connected to the tube body 54. The peripheral side of the tube body 54 is connected to the negative pressure tube 55. The end of the negative pressure tube 55 away from the tube body 54 is connected to an external negative pressure fan, which is used to remove dust and other impurities on the surface of the copper wire to avoid interference with the detection results of the detection probe 52 due to the presence of solid impurities such as dust. By setting the tube body 54, the negative pressure can be more concentrated and the dust collection effect is better.

[0046] In order to allow the wire to pass vertically through the defect detection mechanism 5 without contacting the internal structure of the defect detection mechanism 5, the guide mechanism 6 includes a fixed frame 61, one end of which is fixedly mounted on the support frame 32. A guide rod 63 is slidably connected to the inner wall of the fixed frame 61, and one end of the guide rod 63 is fixedly connected to the movable frame 62. By providing the guide rod 63, the movable frame 62 can be limited so that the movable frame 62 can only move along the axis of the guide rod 63. Multiple guide rods 63 can be provided to make the movement of the movable frame 62 more stable. A guide wheel 64 is rotatably mounted on the movable frame 62, and the guide wheel 64 is used to guide the wire. An adjustment screw 65 is rotatably connected to one end of the movable frame 62 through a bearing. The adjustment screw 65 is threadedly connected to the inner wall of the fixed frame 61. A handle is fixedly mounted on the end of the adjustment screw 65 away from the movable frame 62, which facilitates manual rotation of the adjustment screw 65, causing the movable frame 62 and the guide wheel 64 to move horizontally, thereby adjusting the relative distance between the guide wheel 64 and the direction-changing wheel 35. The movable frame 62 is fixedly connected to the tube body 54. When the movable frame 62 moves, it can drive the guide wheel 64 to move synchronously with the sleeve 51 and the tube body 54, so that the wire body can pass vertically through the defect detection mechanism 5 without contacting the internal structure of the defect detection mechanism 5.

[0047] The control mechanism includes an alarm light 41, a central control unit 42, and a waveform display 43. The central control unit 42 is electrically connected to the drive unit 24, direction sensor 33, stop sensor 34, detection probe 52, alarm light 41, and waveform display 43, providing control. The waveform display 43 indicates defects on the wire gauge, while the alarm light 41 issues an alarm signal when a serious defect occurs on the wire gauge.

[0048] In the prior art, before the payoff begins, there is an angle between the payoff reel and the wire, and between the wire and the deflection wheel 35. This causes friction between the wires, resulting in wire surface defects and unqualified products. The automatic alignment and wire arrangement detection and alarm system provided by the present invention can automatically correct the wire and simultaneously detect wire surface defects. The specific usage method is described below.

[0049] First, the wire is passed through the automatic alignment and wiring detection alarm system of the device, so that one end of the wire is separated from the wire reel and passes under the bottom of the change-direction wheel 35. It then passes vertically upward through the tube 54, sleeve 51, and guide wheel 64 in sequence, and finally connects to the external winding device. The adjusting screw 65 is then rotated by the handle. As the adjusting screw 65 rotates, it moves horizontally relative to the fixed frame 61, driving the movable frame 62 to move horizontally relative to the support frame 32. The movable frame 62 also drives the guide wheel 64, sleeve 51, and tube 54 to move, allowing the wire to pass vertically through the sleeve 51 and tube 54.

[0050] 1. The method for automatically aligning and correcting the wires using this device is as follows:

[0051] The line body is infrared-sensed by the stop sensor 34 and the direction sensor 33. When any direction sensor 33 infrared-senses the line body, it means that the line body is offset by a certain angle relative to the changing wheel 35. At this time, the sensing time T1 is calculated. The longer the sensing time T1, the more serious the offset. The reference value A is set. In this embodiment, A is 5s.

[0052] When T1≤5s, the central control unit 42 does not generate a transmission signal;

[0053] When T1>5s, the central control unit 42 sends a transmission signal to the driving component 24, and the driving component 24 starts and drives the cable correction mechanism 3 to move linearly, thereby changing the angle between the cable body and the direction-changing wheel 35;

[0054] When the middle stop sensor 34 senses the copper wire, it indicates that the wire has returned to the correct position at this moment. At this time, the sensing time T2 is calculated. When T2 reaches a consistent value, it indicates that the wire has returned to the correct position and is stable. The reference value B is set. In this embodiment, B is 5s.

[0055] When T2≤5s, the central control unit 42 does not generate a stop signal;

[0056] When T2>5s, the central control unit 42 sends a stop signal to the driving component 24, and the driving component 24 is turned off to stop the wire arrangement and correction mechanism 3 from moving, and the device is in a normal wire-laying state.

[0057] This is a cycle, and the process will be repeated according to the actual situation.

[0058] 2. The method for detecting surface defects of wire bodies by this device is as follows:

[0059] First, the electromagnetic waves on the surface of the normal wire body are sensed by the detection probe 52. When the wire body passes through the changing wheel 35 and enters the detection probe 52, the electromagnetic waves on the surface of the wire body are sensed in real time by the detection probe 52 to generate an electromagnetic induction signal L2. The electromagnetic waves on the surface of the normal wire body and L2 are both displayed on the waveform display 43. When scratches occur on the surface of the wire body, the detection probe 52 senses that the electromagnetic waves at this time are inconsistent with the electromagnetic waves on the normal wire surface. The difference L1 between L2 and the electromagnetic induction signal on the surface of the normal wire body is calculated, and the length, width and depth of the wire surface defect is defined as a small defect of 0.2mmX0.2mmX0.2mm, the length, width and depth of the defect is 0.3mmX0.3mmX0.3mm as a medium defect, and the length, width and depth of the defect is 0.6mmX0.6mmX0.6mm as a large defect. At the same time, large, medium and small defects are defined numerically: an X, Y axis is defined in the middle of the waveform display 43, and a reference value L is set. In this embodiment, the reference value L is (300, 300), that is, a small defect. The coordinates of the circle are (300, 300). In addition, the coordinates of the middle circle are (450, 450), and the coordinates of the large circle are (900, 900). That is, the line waveform with a value below 300 is a normal product, the line waveform with a value between 300 and 450 is a small defect, the line waveform with a value between 450 and 900 is a medium defect, and the waveform with a value above 900 is a large defect. The image is specifically digitized, and the number of meters and specific time corresponding to the defect are displayed at the same time, so that the specific location of the line defect can be more easily determined. Specifically,

[0060] When L1≤(300, 300), the waveform display 43 shows no defect, and the central control unit 42 does not generate an alarm signal;

[0061] When (300, 300) < L1 ≤ (450, 450), the waveform display 43 shows a small defect, the central control unit 42 sends an alarm signal to the alarm light 41, and the alarm light 41 sends an alarm signal;

[0062] When (450, 450) < L1 ≤ (900, 900), the waveform display 43 displays a medium defect, the central control unit 42 sends an alarm signal to the alarm light 41, and the alarm light 41 sends an alarm signal;

[0063] When L1>(900,900), the waveform display 43 shows a major defect, the central control unit 42 sends an alarm signal to the alarm light 41, and the alarm light 41 sends an alarm signal.

[0064] The automatic alignment and wiring detection and alarm system provided by the present invention can realize automatic correction of the wire body, and at the same time detect and alarm for wire surface defects. It is easy to use and easy to operate, and can effectively solve the problems of wire friction and wire surface defects, significantly improve the quality of bare copper single wire products, and greatly reduce the cost of the enterprise.

[0065] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0066] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. An automatic alignment and wiring detection alarm system, characterized in that: include: Base (1); A wire alignment mechanism (3) is used to detect the inclination of the wire body; A defect detection mechanism (5) is used to detect surface defects of the wire body; A guide mechanism (6) for adjusting the angle at which the wire body enters the defect detection mechanism (5); A linear mechanism (2) is used to drive the cable arrangement correction mechanism (3), the defect detection mechanism (5) and the guide mechanism (6) to move linearly; The cable arrangement correction mechanism (3) comprises a direction-changing wheel (35) for guiding the cable body, a stop sensor (34) is provided below the direction-changing wheel (35), and direction sensors (33) are provided on both sides of the stop sensor (34).

2. The automatic alignment and wiring detection alarm system according to claim 1 is characterized in that: After the direction sensor (33) senses the line body through infrared, it starts to calculate the sensing time length T1. When T1 exceeds the reference value A, the linear mechanism (2) starts and drives the line correction mechanism (3) and the defect detection mechanism (5) to move linearly. When the stop sensor (34) senses the line body, it starts to calculate the sensing time length T2. When T2 exceeds the reference value B, the linear mechanism (2) stops.

3. The automatic alignment and wiring detection alarm system according to claim 1 is characterized in that: It also includes an alarm light (41), the defect detection mechanism (5) senses electromagnetic waves on the surface of the wire body to generate an electromagnetic induction signal L2, and when the difference L1 between L2 and the electromagnetic induction signal of the normal wire body surface reaches a reference value L, the alarm light (41) outputs an alarm signal.

4. The automatic alignment and wiring detection alarm system according to claim 3 is characterized in that: The device further comprises a central control unit (42) and a waveform display (43), wherein the central control unit (42) is electrically connected to the driving component (24), the direction sensor (33), the stop sensor (34), the defect detection mechanism (5), the warning light (41) and the waveform display (43).

5. The automatic alignment and wiring detection alarm system according to claim 2 is characterized in that: The reference value A and the reference value B are both 5s.

6. The automatic alignment and wiring detection alarm system according to claim 1 is characterized in that: The cable arrangement correction mechanism (3) further comprises two fixed columns (31), a support frame (32) is fixedly mounted between the two fixed columns (31), the direction-changing wheel (35) is rotatably mounted on the support frame (32), and the direction sensor (33) and the stop sensor (34) are fixedly mounted on the support frame (32).

7. The automatic alignment and wiring detection alarm system according to claim 6 is characterized in that: The defect detection mechanism (5) comprises a sleeve (51) for being sleeved on the outside of the linear body, the sleeve (51) being fixedly mounted on a support frame (32), a plurality of detection probes (52) being fixedly mounted on the inner wall of the sleeve (51), a baffle (53) being provided between two adjacent detection probes (52), and one end of the baffle (53) being fixedly connected to the inner wall of the sleeve (51).

8. The automatic alignment and wiring detection alarm system according to claim 7 is characterized in that: The bottom end of the sleeve (51) is fixed and connected to a tube body (54), and the peripheral side of the tube body (54) is connected to a negative pressure tube (55).

9. The automatic alignment and wiring detection alarm system according to claim 8, characterized in that: The guide mechanism (6) comprises a fixed frame (61), one end of the fixed frame (61) is fixedly mounted on the support frame (32), a guide rod (63) is slidably connected to the inner wall of the fixed frame (61), one end of the guide rod (63) is fixedly connected to a movable frame (62), a guide wheel (64) is rotatably mounted on the movable frame (62), the movable frame (62) is fixedly connected to the tube body (54), one end of the movable frame (62) is rotatably connected to an adjusting screw (65), and the adjusting screw (65) is threadedly connected to the fixed frame (61).

10. The automatic alignment and wiring detection alarm system according to claim 6, characterized in that: The linear mechanism (2) comprises two fixed platforms (22), both of which are fixedly mounted on the base (1), a sliding guide rail (21) is mounted between the two fixed platforms (22), a movable plate (23) is slidably mounted on the sliding guide rail (21), the movable plate (23) is fixedly connected to two fixed columns (31), a driving component (24) is provided on the fixed platform (22), and the driving component (24) is drivingly connected to the movable plate (23).

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