A device for detecting broken wires in parallel strands of metal wire and its control method.

Abstract

This invention discloses a device and control method for detecting wire tangling and breakage in metal wires. The detection device includes: a metal wire to be detected wound circumferentially around the sidewall of a reel assembly, with adjacent metal wires spaced at a first preset distance; the reel assembly and an eddy current sensor assembly are electrically connected to a control assembly; the eddy current sensor assembly is positioned at a corresponding position on the sidewall of the reel assembly, and the control assembly controls the eddy current sensor assembly to reciprocate along the axial direction of the reel assembly; as the eddy current sensor assembly moves along the axial direction of the reel assembly, it acquires voltage detection signals at two adjacent detection positions and performs differential calculations to obtain a voltage difference signal. If the voltage difference signal deviates from a preset voltage value range, it is determined that the metal wire wound on the reel assembly is tangled or broken. By constructing a high-precision defect identification mechanism based on spatial position differential calculations, common-mode noise such as reel rotation vibration and environmental electromagnetic interference is effectively filtered out, greatly improving the accuracy of defect identification.

Description

Technical Field

[0001] This invention relates to the field of eddy current sensor detection technology, and in particular to a device for detecting broken wires in parallel with metal wires and its control method. Background Technology

[0002] In the industrial production of metal wire, wire breakage and tangling are core defects affecting product quality. Current mainstream inspection technologies mainly include optical inspection, contact mechanical inspection, and single-point eddy current inspection. Optical inspection, which scans the surface morphology using a camera or laser, achieves non-contact inspection, but the high reflectivity of metal wires easily leads to image noise, especially when inspecting micron-sized wires (e.g., 55μm in diameter). It lacks sensitivity to minute changes in adjacent spacing (0.3mm), making it difficult to distinguish between broken wires (local missing parts) and tangled wires (multiple overlapping wires). Contact inspection uses probes or rollers to contact the wire surface, relying on mechanical feedback to determine defects. However, mechanical friction can damage the wire surface and is difficult to adapt to the real-time requirements of high-speed continuous production. While single-point eddy current inspection avoids contact problems, its single-sensor design is susceptible to environmental interference such as temperature drift and mechanical vibration, leading to signal drift or fluctuations, making it difficult to stably capture subtle changes in sparsity. Furthermore, existing methods generally lack the ability to accurately distinguish between broken and joined lines, typically relying on a single threshold to determine anomalies. They cannot dynamically adjust the criteria based on defect type (increase or decrease in sparsity), leading to a high false positive rate. Regarding detection coverage, traditional technologies often use fixed sensors or unidirectional scanning, failing to achieve full coverage detection along the circumferential and axial directions of the roll. This necessitates frequent equipment adjustments or manual intervention, resulting in low efficiency. These problems severely restrict the defect detection needs of high-precision, automated production scenarios, urgently requiring a non-contact detection solution that combines high sensitivity, strong anti-interference capabilities, and the ability to distinguish multiple defect types. Summary of the Invention

[0003] The purpose of this invention is to provide a metal wire breakage detection device and its control method. By constructing a high-precision defect identification mechanism and using differential operations based on spatial positional relationships, it can effectively filter out common-mode noise such as spool rotation vibration and environmental electromagnetic interference, retaining only the differential-mode signal caused by the change in the spacing between the metal wires, thus greatly improving the accuracy of defect identification.

[0004] To solve the above-mentioned technical problems, a first aspect of the present invention provides a metal wire breakage detection device, comprising: a reel assembly, an eddy current sensor assembly, and a control assembly;

[0005] The sidewall of the reel assembly is wound with the metal wire to be detected along its circumference, and adjacent metal wires are spaced apart by a first preset distance. The reel assembly and the eddy current sensor assembly are electrically connected to the control assembly.

[0006] The eddy current sensor assembly is disposed at a corresponding position on the side wall of the reel assembly, and the control assembly controls the eddy current sensor assembly to reciprocate along the axial direction of the reel assembly;

[0007] When the eddy current sensor assembly moves along the axial direction of the reel assembly, it acquires voltage detection signals at two adjacent detection positions and performs differential calculations to obtain a voltage difference signal. If the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire wound on the reel assembly is either twisted or broken.

[0008] Furthermore, if the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire wound on the reel assembly is either twisted or broken, including:

[0009] When the difference is greater than the upper limit of the preset voltage value range, it is determined that there is a wire strand connection between the corresponding position of the reel assembly and the eddy current sensor assembly;

[0010] When the difference is less than the lower limit of the preset voltage range, it is determined that there is a break in the metal wire at the corresponding position of the reel assembly and the eddy current sensor assembly.

[0011] Furthermore, when the difference is less than the lower limit of the preset voltage range and the original output signal of the eddy current sensor assembly at the current position is lower than the calibrated minimum effective value, it is determined that there is a break in the metal wire (21) at the corresponding position of the reel assembly and the eddy current sensor assembly.

[0012] Furthermore, the eddy current sensor includes: an eddy current sensor unit, a guide rail, a sensor bracket, and a reciprocating drive unit;

[0013] The eddy current sensor unit is disposed at one end of the sensor bracket and is spaced a second preset distance from the side wall of the roll assembly;

[0014] The reciprocating drive unit is electrically connected to the control component, and under the control of the control component, it drives the other end of the sensor bracket to reciprocate along the guide rail.

[0015] The guide rail is arranged parallel to the axis of the reel assembly.

[0016] Furthermore, the eddy current sensor unit includes a first eddy current sensor unit and a second eddy current sensor unit;

[0017] The first eddy current sensor unit and the second eddy current sensor unit are spaced apart along the axial direction of the reel assembly.

[0018] The first eddy current sensor unit and the second eddy current sensor unit are electrically connected to the control component, and the first eddy current sensor unit and the second eddy current sensor unit respectively acquire voltage detection signals at two adjacent detection positions and send them to the control component.

[0019] The control component performs differential calculations based on the voltage detection signals from the two detection positions to obtain the voltage difference signal.

[0020] Furthermore, the distance between the first eddy current sensor unit and the second eddy current sensor unit along the axial direction of the roll assembly is the same as the distance between two adjacent detection positions on the roll assembly.

[0021] Furthermore, under the control of the control component, the reciprocating drive unit drives the sensor bracket to move along the guide rail by the same distance in a single movement as the spacing between two adjacent metal wires on the reel assembly.

[0022] Furthermore, the reel assembly includes: a reel wound with metal wire, a reel support, and a rotation drive unit;

[0023] The rotation drive unit is electrically connected to the control component, and both ends of the reel are rotatably connected to the reel bracket;

[0024] The rotation drive unit drives the reel to rotate along its own axis under the control of the control component.

[0025] Furthermore, the metal wire breakage detection device further includes: a base;

[0026] Both the eddy current sensor assembly and the reel assembly are fixed on the base and spaced apart by a second preset distance.

[0027] Accordingly, a second aspect of the present invention provides a control method for a metal wire breakage detection device, which detects breakage of metal wires on a reel assembly based on the aforementioned metal wire breakage detection device, including the following steps:

[0028] Step S100: Control the eddy current sensor assembly to move from one end to the other end along the axial direction of the reel assembly at a first preset distance, acquire the voltage detection signal at the corresponding detection position and perform differential operation to obtain the voltage difference signal, compare the voltage difference signal with the preset voltage value range, and determine whether there is a broken or twisted wire in the metal wire at the corresponding position of the reel assembly.

[0029] Step S200: Control the reel assembly to rotate sequentially according to a preset angle value, and repeat step S100 after each rotation to determine whether there is a broken or tangled wire at the corresponding position after the reel assembly rotates, until the reel assembly completes one rotation.

[0030] The above-described technical solutions of the embodiments of the present invention have the following beneficial technical effects:

[0031] 1. By employing a differential eddy current sensor assembly and utilizing the symmetrical arrangement of dual sensor units and differential signal processing technology, the sensitivity and anti-interference capability of metal wire defect detection are significantly improved. Traditional single-point sensors are susceptible to environmental noise interference, while differential measurement effectively cancels common-mode interference through real-time differential calculation, and simultaneously amplifies the effective signal difference caused by changes in the sparsity of the metal wire. Combined with preset positive and negative threshold judgment logic, it can stably identify micron-level spacing anomalies in wires under complex working conditions. The detection accuracy and stability are significantly improved compared to traditional methods, and the risk of misjudgment is significantly reduced.

[0032] 2. By coordinating the axial scanning of the eddy current sensor assembly with the circumferential rotation of the reel, full coverage of the metal wire surface inspection is achieved, solving the blind zone problem in traditional inspection. The sensor moves sequentially along the axial direction of the reel at preset intervals, while the reel rotates step by step, forming an axial-circumferential linkage scanning path. This dynamic inspection mechanism can cover all areas of the reel surface without manual intervention, significantly improving inspection efficiency and adapting to the needs of high-speed continuous production. In addition, the real-time positioning and alarm functions reduce production interruptions caused by defect accumulation, providing reliable support for automated production lines.

[0033] 3. Based on the differential signal-based positive and negative threshold determination and intelligent analysis algorithm, the system accurately distinguishes between open and parallel wire defects. Traditional methods rely on a single threshold or subjective experience, making it difficult to differentiate the direction of sparsity changes. However, by setting a preset voltage threshold range and combining the polarity characteristics of the differential signal, the system clearly determines open wire defects (abnormally increased sparsity) and parallel wire defects (abnormally increased density). Furthermore, the system can be experimentally calibrated to adapt to metal wires of different materials or specifications, flexibly addressing diverse testing needs and providing a highly reliable classification basis for process optimization and quality traceability. The accuracy and practicality of defect identification are significantly enhanced. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the principle of the metal wire breakage detection device provided in the embodiment of the present invention;

[0035] Figure 2 This is a flowchart of the control method for the metal wire parallel breakage detection device provided in an embodiment of the present invention.

[0036] Figure label:

[0037] 1. Base; 21. Metal wire; 22. Reel; 23. Reel bracket; 31. Eddy current sensor unit; 32. Guide rail; 33. Sensor bracket. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and the accompanying drawings. It should be understood that these descriptions are merely exemplary and not intended to limit the scope of the invention. Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concept of the invention.

[0039] Please refer to Figure 1 The first aspect of this invention provides a metal wire tangling and breakage detection device, comprising: a reel assembly, an eddy current sensor assembly, and a control assembly; a metal wire 21 to be detected is wound around the sidewall of the reel assembly in its circumferential direction, with adjacent metal wires 21 spaced apart by a first preset distance; the reel assembly, the eddy current sensor assembly, and the control assembly are electrically connected; the eddy current sensor assembly is disposed at a corresponding position on the sidewall of the reel assembly, and the control assembly controls the eddy current sensor assembly to reciprocate along the axial direction of the reel assembly; when the eddy current sensor assembly moves along the axial direction of the reel assembly, it acquires voltage detection signals at two adjacent detection positions and performs differential calculations to obtain a voltage difference signal; if the voltage difference signal deviates from a preset voltage value range, it is determined that the metal wire 21 wound on the reel assembly is tangled or broken.

[0040] The aforementioned metal wire breakage detection device, through modular design, constructs a detection system integrating mechanical transmission, signal acquisition, and intelligent judgment. The reel assembly serves as the carrier of the metal wire to be tested, with metal wires 21 uniformly wound around its sidewalls at predetermined intervals, forming a regular detection reference array. The control component, on one hand, drives the rotation of the reel assembly and the axial movement of the eddy current sensor assembly via electrical connection, achieving full surface coverage of the detection area; on the other hand, it receives the voltage signals acquired by the sensors in real time and performs differential calculations using a built-in algorithm, converting physical spacing changes into quantifiable electrical signal differences. The reciprocating accuracy of the eddy current sensor assembly along the axial direction of the reel 22 directly affects the detection resolution. By coordinating with the control component, it ensures that the step distance of each movement is consistent with the spacing of adjacent metal wires, thereby enabling the sensor to accurately align with each group of adjacent detection positions, avoiding missed or repeated detections.

[0041] By constructing a mapping relationship between "spatial position and electrical signal characteristics": when the metal wires 21 are normally arranged, the eddy current signals at adjacent detection positions generate a stable voltage difference due to the same material properties and spacing, which is within a preset reasonable range; if a wire break occurs, the missing metal wire causes a sharp drop in the signal at one detection position, and the voltage difference after differentiation exceeds the preset upper limit due to the loss of the signal on one side; if paralleling occurs, the reduced spacing between adjacent metal wires enhances the superposition of electromagnetic induction, and the differential result negatively exceeds the preset lower limit. This detection mechanism based on differential operation has significant anti-interference capabilities, filtering out common-mode interference such as vibration noise during the rotation of the reel 22 and environmental electromagnetic fluctuations, retaining only the effective differential-mode signal caused by changes in the metal wire spacing, making defect identification highly specific.

[0042] The aforementioned detection device overcomes several limitations of traditional detection methods: First, it achieves accurate differentiation between parallel and broken wires through differential calculation, solving the problem that existing technologies cannot simultaneously identify two types of defects and avoiding misjudgments caused by single threshold judgments; second, it utilizes the axial movement of the sensor and the circumferential rotation of the reel 22 to form a spiral scanning coverage of the surface of the reel 22, significantly improving the comprehensiveness of detection compared to fixed-position detection; third, the non-contact measurement and automated coordination of the eddy current sensor and control components make it suitable for high-speed production scenarios, maintaining a detection accuracy of 0.05mm for spacing changes even when the metal wire winding speed reaches 50m / s, significantly higher than the 1mm resolution of traditional contact devices; fourth, the real-time processing of differential calculations keeps the detection delay within 5ms, meeting the immediate feedback requirements of online production and fundamentally improving the quality control efficiency of the metal wire 21 production process.

[0043] Furthermore, if the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire 21 wound on the reel assembly is either paralleled or broken, including: when the difference is greater than the upper limit of the preset voltage value range, it is determined that the metal wire 21 at the corresponding position of the reel assembly and the eddy current sensor assembly is paralleled; when the difference is less than the lower limit of the preset voltage value range, it is determined that the metal wire 21 at the corresponding position of the reel assembly and the eddy current sensor assembly is broken.

[0044] This wire breakage detection device utilizes an eddy current sensor to collect voltage signals (V_A and V_B) at two adjacent detection positions (position A and position B) as the wires move axially along the sidewall of the reel assembly, and performs a differential calculation (ΔV = V_A - V_B). Under normal conditions where the wire spacing is uniform, V_A and V_B values ​​are similar, and ΔV approaches zero, falling within a preset reasonable voltage difference range. When wire breakage occurs, causing the spacing between adjacent wires to decrease, electromagnetic field coupling causes V_A and V_B to increase synchronously, but the difference between them, ΔV, decreases significantly (increasing negatively), thus falling below the lower limit of the preset range. Conversely, when a wire breakage occurs, causing a missing wire at a certain position, the signal at that point (e.g., V_B) drops sharply, causing ΔV = V_A - 0 to increase dramatically, exceeding the upper limit of the preset range. The preset voltage difference range [V_min, V_max] needs to be calibrated experimentally and determined based on the stable differential value and its allowable fluctuation range under normal uniform spacing. For example, when the spacing is 2mm, ΔV = 0.5V ± 0.1V, then the range is set to [0.4V, 0.6V]. An alarm is triggered when ΔV ≤ 0.3V during parallel connection and when ΔV ≥ 1.0V during disconnection.

[0045] Furthermore, when the difference is less than the lower limit of the preset voltage range and the original output signal of the eddy current sensor assembly at the current position is lower than the calibrated minimum effective value, it is determined that there is a break in the metal wire 21 at the corresponding position of the reel assembly and the eddy current sensor assembly.

[0046] When the eddy current sensor probe approaches a metal wire, the alternating magnetic field generated by its excitation coil induces closed eddy currents on the surface of the wire, causing a change in the probe's impedance characteristics. Under normal conditions, the differential signal from the two probes reflects the change in wire displacement, exhibiting a characteristic of one increasing and the other decreasing. When the metal wire breaks, the conductor disappears, causing the eddy current effect of both probes to decay synchronously. The differential signal approaches zero (below a preset lower limit), while the original output signal of the single probe drops to the background noise level due to the absence of a conductor. This dual verification mechanism, by combining the anomaly of the differential signal with the failure of the original signal, can eliminate misjudgments caused by environmental interference, ensuring the reliability of the wire breakage detection.

[0047] During the calibration phase, the eddy current sensor assembly needs to be moved in an area free of metal wires to collect the raw output signals of each probe at various locations. The minimum effective value for calibration is determined through statistical analysis, representing the critical threshold for effective measurement. In the real-time detection phase, the absolute values ​​of the raw output signals from both channels and their differential signals are collected simultaneously. If, at the same time, the differential signal is below the lower limit of a preset voltage range, and the larger of the two raw signals is still below the minimum effective value for calibration, a break in the wire is determined at the current location. This process utilizes the physical characteristic of the disappearance of the eddy current effect to identify breakages, and its anti-interference capability and measurement stability are consistent with the design principles of differential measurement.

[0048] The dual-condition determination mechanism in this embodiment avoids the influence of electromagnetic noise or probe malfunction on a single signal, forming a synergistic enhancement with the anti-interference design of differential measurement. The calibration minimum effective value is derived from actual experimental data without introducing external parameters; the wire breakage determination is entirely based on the physical law that the absence of a metallic conductor leads to the disappearance of the eddy current effect.

[0049] In one specific embodiment of the present invention, the eddy current sensor includes: an eddy current sensor unit 31, a guide rail 32, a sensor bracket 33, and a reciprocating drive unit; the eddy current sensor unit 31 is disposed at one end of the sensor bracket 33 and is spaced apart from the side wall of the reel assembly by a second preset distance; the reciprocating drive unit is electrically connected to a control component and drives the other end of the sensor bracket 33 to reciprocate along the guide rail 32 under the control of the control component; the guide rail 32 is arranged parallel to the axial direction of the reel assembly.

[0050] The eddy current sensor includes a transmission mechanism consisting of a guide rail 32, a sensor bracket 33, and a reciprocating drive unit. The guide rail 32 is laid parallel to the axis of the reel 22, providing high-precision guidance for the movement of the sensor bracket 33. This ensures that the sensor unit maintains a constant second preset distance (typically 5-10 mm) from the side wall of the reel 22 during detection. This distance satisfies the optimal sensing range of the eddy current sensor, avoiding saturation due to excessive proximity and signal attenuation due to excessive distance, while also providing a safe space for radial runout during the rotation of the reel 22. The sensor bracket 33 is made of rigid aluminum alloy, with one end fixing the eddy current sensor unit 31 and the other end connected to the reciprocating drive unit, such as a servo motor or a lead screw and nut mechanism. Driven by pulse signals from the control component, it achieves micron-level precision movement and positioning error ≤ ±5 μm along the guide rail 32, ensuring that the sensor's trajectory during axial movement is strictly parallel to the axis of the reel 22, avoiding detection deviations caused by tilting.

[0051] The electrical connection between the reciprocating drive unit and the control component enables fully automated control of the detection process. When the control component issues a movement command, the drive unit drives the sensor bracket 33 to reciprocate along the guide rail 32 at a constant speed, such as 20 mm / s. The distance of each movement is exactly the same as the distance between adjacent metal wires on the scroll 22, i.e., the first preset distance, so that the sensor unit is aligned with each group of adjacent detection positions in sequence, ensuring no omissions in scanning. This linear reciprocating motion, combined with the circumferential rotation of the scroll 22, forms a spiral detection path that covers the entire surface area of ​​the sidewall of the scroll 22. Compared to traditional fixed sensors or manually adjusted detection devices, the above structural design significantly improves the detection coverage and positional accuracy. Even when the length of the reel 22 reaches 500mm, it can still achieve dense sampling with an interval of 0.1mm. Combined with the high-frequency signal acquisition of the eddy current sensor unit 31, such as a sampling rate of 10kHz, the device can still capture the subtle changes in the spacing of the metal wires in real time even when the speed of the reel 22 is 1500rpm in a high-speed production scenario. This provides a stable and reliable raw signal for differential calculation, ensuring the accuracy and comprehensiveness of defect detection from a hardware perspective.

[0052] Furthermore, the eddy current sensor unit 31 includes a first eddy current sensor unit and a second eddy current sensor unit; the first eddy current sensor unit and the second eddy current sensor unit are spaced apart along the axial direction of the reel assembly; the first eddy current sensor unit and the second eddy current sensor unit are electrically connected to the control component respectively; the first eddy current sensor unit and the second eddy current sensor unit respectively acquire voltage detection signals at two adjacent detection positions and send them to the control component; the control component performs differential calculation based on the voltage detection signals at the two detection positions to obtain a voltage difference signal.

[0053] The eddy current sensor unit 31 adopts a dual-sensor parallel layout design. The first and second eddy current sensor units are spaced apart along the axial direction of the reel 22. The axial distance between the two sensor units strictly matches the first preset distance between adjacent metal wires 21 on the reel 22, ensuring that during detection, each sensor unit corresponds exactly to the position directly above a metal wire, forming a "one-to-one" detection point mapping. This spatial layout allows the dual sensors to synchronously acquire voltage signals from two adjacent metal wires. When the metal wires are normally aligned, they generate voltage signals with similar amplitudes due to their identical material, spacing, and sensing distance. When a wire breaks or merges, the positional change of one or both metal wires directly reflects the difference in the signals from the two sensors, providing accurate raw data for subsequent differential calculations. The physical spacing design of the dual sensors not only avoids detection blind spots caused by positional offset of a single sensor but also establishes a dynamic reference benchmark through "adjacent comparison," allowing the signal at each detection position to be verified through adjacent states, ensuring the reliability of signal acquisition from a hardware perspective.

[0054] The control component performs differential processing on the signals from the two sensors, transforming the geometric changes in the spatial dimension into characteristic differences in the electrical signal dimension. After the first and second sensor units acquire voltage signals from adjacent detection positions, the control component calculates the difference between them in real time using a built-in algorithm: under normal conditions, the difference tends to zero due to symmetrical induction characteristics; when the wires are parallel, the sensor signal on the side missing the wire weakens, and the difference shifts positively; when the wires are broken, the reduced spacing leads to enhanced signals on both sides, and the difference shifts negatively. This dual-sensor collaborative working mode has a natural common-mode noise suppression capability. The effects of environmental vibrations, temperature drift, and other interference factors on the two sensors are essentially the same and are largely canceled out during differential processing, retaining only the effective differential-mode signal caused by changes in the wire spacing. Compared to traditional single-sensor solutions that rely on threshold judgment, the dual-sensor differential mechanism improves the detection resolution from 1mm to 0.05mm, while simultaneously increasing the anti-interference capability of defect identification by more than 60%. It is particularly suitable for real-time detection under high-speed winding conditions, such as maintaining signal stability even at a 2000rpm rotation speed on a 22-inch reel.

[0055] Furthermore, the distance between the first eddy current sensor unit and the second eddy current sensor unit along the axial direction of the roll assembly is the same as the distance between two adjacent detection positions on the roll assembly.

[0056] The axial spacing between the first and second eddy current sensor units is precisely matched to the first preset distance between adjacent metal wires 21 on the reel 22. This precise spatial alignment establishes a corresponding signal acquisition relationship. When the spacing between the two sensor units is exactly the same as the distance between adjacent detection positions, each sensor unit precisely covers the detection area directly above a single metal wire. This ensures that during uniform movement, the two sensors synchronously acquire real-time signals from adjacent metal wires. Under normal conditions, the symmetrical physical spacing generates a stable reference signal. In abnormal conditions, such as a broken wire causing a single-sided loss or wire merging causing a reduction in spacing, the signal difference directly corresponds to the actual arrangement change of the metal wires. This precise spatial coupling design avoids signal misalignment caused by sensor spacing deviations, such as acquiring signals from non-adjacent metal wires. This ensures that the input data for differential calculation strictly reflects the true state of adjacent detection positions, eliminating detection blind spots and signal confusion at the hardware level. With the control components driving the sensors to move axially at equal intervals, this layout ensures that each group of adjacent metal wires can be accurately covered by the dual sensors during the detection process, forming a continuous and non-overlapping signal acquisition array. This makes the spatial resolution of defect identification completely equivalent to the preset spacing accuracy of the metal wires, fundamentally guaranteeing the accuracy and reliability of the detection results.

[0057] Furthermore, under the control of the control component, the reciprocating drive unit moves the sensor bracket 33 along the guide rail 32 by a distance equal to the distance between two adjacent metal wires 21 on the reel assembly. The single movement distance of the reciprocating drive unit is strictly consistent with the distance between adjacent metal wires 21, achieving seamless coverage of the detection points through precise matching of motion control accuracy. When the control component drives the sensor bracket 33 to move along the guide rail 32, the single movement distance is precisely set to the first preset distance, i.e., the distance between adjacent metal wires. This ensures that after each movement, the first and second sensor units of the eddy current sensor unit 31 are precisely aligned with the detection position of the next set of adjacent metal wires, forming a "group-by-group scanning" detection rhythm. This synchronous design avoids signal acquisition misalignment during the detection process, such as cross-group detection or missed detection, ensuring that the dual sensors always acquire signals from two physically adjacent metal wires. In conjunction with the circumferential rotation of the roll assembly, this motion control mechanism enables the sensor to form equally spaced spiral scanning trajectories on the surface of the roll 22. This not only covers the entire detection area of ​​the sidewall but also ensures that the signal acquisition density at each detection position perfectly matches the wire arrangement density. In precision detection scenarios with a wire spacing of 0.5mm, the drive unit can achieve a movement accuracy of ±2μm, enabling the detection system to capture minute defects with spacing changes of less than 1%, such as a 0.005mm deviation in line alignment. This lays the hardware foundation for high-precision defect detection from a motion control perspective. By controlling the spatial positioning error of the sensor to within 1 / 100 of the detection spacing, the reliability and data consistency of the detection results are significantly improved, making it particularly suitable for online real-time detection in high-density wire winding scenarios.

[0058] In one specific embodiment of the present invention, the reel assembly includes: a reel 22 wound with metal wire 21, a reel bracket and a rotation drive unit; the rotation drive unit is electrically connected to a control component, and both ends of the reel 22 are rotatably connected to the reel bracket; the rotation drive unit drives the reel 22 to rotate along its own axial direction under the control of the control component.

[0059] The specific structure of the reel assembly constructs a dynamic bearing and angle control platform for the metal wire 21 under test. The coordinated operation of the rotation drive unit and the control component achieves circumferential detection coverage. The reel 22, on which the metal wire 21 is wound, is stably supported by reel supports at both ends. The rotation drive unit, such as a servo motor or stepper motor, is coaxially connected to the reel 22 and rotates precisely at a preset angle value, such as 1° / cycle, under the command of the control component. This causes the metal wire 21 on the side wall of the reel 22 to enter the detection area sequentially as it rotates circumferentially. The rotation mode of the reel assembly and the axial reciprocating movement of the eddy current sensor assembly form an orthogonal motion trajectory. The sensor scans line by line along the axial direction, and the reel 22 rotates synchronously to achieve circumferential line switching, together forming a spiral full-coverage detection of the surface of the reel 22. The high-precision position control angle error of the rotation drive unit, ≤±0.1°, ensures that the sensor can align with the undetected metal wire loop after each rotation, avoiding duplicate or missed detections. Simultaneously, a stable rotation speed, such as 5 rpm, matches the sensor's moving speed, allowing the eddy current sensor unit 31 to maintain a constant detection rhythm when acquiring signals from adjacent rows, providing a timing-synchronized voltage signal for differential calculations. This component transforms the circumferential arrangement of the metal wires 21 into controllable rotational motion, forming a three-dimensional detection space with the axial scanning of the sensor. This enables the device to perform seamless detection of spools 22 of arbitrary length and diameter, making it particularly suitable for quality inspection of multi-layer windings or large-size metal wire spools 21. From a mechanical transmission perspective, it ensures the comprehensiveness and automation of the detection process.

[0060] In addition, the metal wire breakage detection device also includes: a base 1; the eddy current sensor assembly and the reel assembly are both fixed on the base 1 and spaced apart by a second preset distance.

[0061] The base 1, serving as the fundamental support structure of the device, provides a stable mounting reference for the eddy current sensor assembly and the scroll assembly, ensuring the relative positional accuracy of the two components through rigid fixing. The eddy current sensor assembly and the scroll assembly are fixed to the base 1 at a second preset distance, typically set according to the effective detection range of the sensor, such as 5-15mm intervals. This ensures that the sensing distance between the eddy current sensor unit 31 and the side wall of the scroll 22 is within the optimal working range, while also providing sufficient space for the rotation of the scroll 22 and the reciprocating movement of the sensor. The base 1 is typically made of high-strength aluminum alloy or cast iron. Precision machining ensures a flatness error of ≤0.01mm on the mounting surface, eliminating mechanical installation deviations. Combined with shock-absorbing pads and other accessories, it reduces the interference of environmental vibrations on the detection signal, maintaining the stability of the relative position of the sensor and the scroll 22 during high-speed movement.

[0062] Accordingly, please refer to Figure 2The second aspect of the present invention provides a control method for a metal wire breakage detection device, which detects breakage of metal wires 21 on a reel assembly based on the aforementioned metal wire breakage detection device, including the following steps:

[0063] Step S100: Control the eddy current sensor assembly to move from one end to the other end along the axial direction of the reel assembly at a first preset distance, acquire the voltage detection signal at the corresponding detection position and perform differential calculation to obtain the voltage difference signal, compare the voltage difference signal with the preset voltage value range, and determine whether there is a broken or twisted wire 21 at the corresponding position of the reel assembly.

[0064] A defect detection mechanism for a single-layer metal wire was constructed through axial point-by-point scanning and differential calculation. The control component drives the eddy current sensor assembly to move at a constant speed along the axial direction of the reel 22 at a first preset distance, i.e., the spacing between adjacent metal wires, so that the dual sensor units are aligned with each group of adjacent detection positions in sequence, ensuring that the collected voltage signals strictly correspond to the two physically adjacent metal wires. During the movement, the first and second eddy current sensor units synchronously acquire the voltage signals of the detection positions on both sides in real time. The control component extracts the signal difference through differential calculation. When the difference is greater than the upper limit of the preset voltage value range, it is determined that there is a parallel wire 21 at the corresponding position of the reel assembly and the eddy current sensor assembly; when the difference is less than the lower limit of the preset voltage value range, it is determined that there is a broken wire 21 at the corresponding position of the reel assembly and the eddy current sensor assembly. This combination of sequential movement and real-time computation enables the detection system to perform high-density scanning of the single-layer surface of the roll 22 with the wire spacing as the minimum resolution. Even when the sensor moves at a speed of 100 mm / s, it maintains a signal acquisition density of 0.5 mm per interval, ensuring accurate identification of axial defects from the detection process.

[0065] Step S200: Control the reel assembly to rotate sequentially according to a preset angle value, and repeat step S100 after each rotation to determine whether there is a broken or tangled wire in the metal wire 21 at the corresponding position after the reel assembly rotates, until the reel assembly completes one rotation.

[0066] Full-surface coverage detection is achieved through circumferential rotation of the reel 22 and multi-layer scanning. After completing a single-layer axial scan, the control component drives the reel assembly to rotate sequentially at preset angle values, such as 1° to 5°, allowing undetected loops to enter the sensor detection area. The axial scanning process is then repeated, forming a spiral detection trajectory. The preset angle values ​​are set based on the wire winding density to ensure that the sensor's axial scan line does not overlap with the previous layer and is complete after each rotation. Finally, a 360° rotation completes the detection coverage of the entire sidewall of the reel 22. The coordinated control of "axial scanning + circumferential rotation" breaks the limitations of traditional fixed-position detection, enabling the device to perform blind-angle detection on reels 22 of any diameter. Even if dozens of layers of wire are wound on the surface of the reel 22, interlayer defects can still be distinguished through angular subdivision such as 0.5° precision rotation. Combined with the differential calculation mechanism in step S100, a complete detection process from single-point detection to full-surface analysis is finally constructed, controlling the missed detection rate to below 0.1%, significantly improving the automation level and comprehensiveness of the metal wire production quality inspection.

[0067] This invention aims to protect a device and control method for detecting wire tangling and breakage in metal wires. The detection device includes a reel assembly, an eddy current sensor assembly, and a control assembly. The metal wire to be detected is wound circumferentially around the sidewall of the reel assembly, with adjacent wires spaced at a first preset distance. The reel assembly, the eddy current sensor assembly, and the control assembly are electrically connected. The eddy current sensor assembly is positioned at a corresponding location on the sidewall of the reel assembly. The control assembly controls the eddy current sensor assembly to reciprocate along the axial direction of the reel assembly. As the eddy current sensor assembly moves along the axial direction of the reel assembly, it acquires voltage detection signals from two adjacent detection positions and performs differential calculations to obtain a voltage difference signal. If the voltage difference signal deviates from a preset voltage value range, it is determined that the metal wire wound on the reel assembly is tangled or broken. The above technical solution has the following advantages:

[0068] 1. By employing a differential eddy current sensor assembly and utilizing the symmetrical arrangement of dual sensor units and differential signal processing technology, the sensitivity and anti-interference capability of metal wire defect detection are significantly improved. Traditional single-point sensors are susceptible to environmental noise interference, while differential measurement effectively cancels common-mode interference through real-time differential calculation, while amplifying the effective signal difference caused by changes in the sparsity of the metal wire. Combined with preset threshold judgment logic, it can stably identify minute spacing anomalies in micron-level wires under complex working conditions, significantly improving detection accuracy and stability compared to traditional methods, and significantly reducing the risk of misjudgment.

[0069] 2. By coordinating the axial scanning of the eddy current sensor assembly with the circumferential rotation of the reel, full coverage of the metal wire surface inspection is achieved, solving the blind zone problem in traditional inspection. The sensor moves sequentially along the axial direction of the reel at preset intervals, while the reel rotates step by step, forming an axial-circumferential linkage scanning path. This dynamic inspection mechanism can cover all areas of the reel surface without manual intervention, significantly improving inspection efficiency and adapting to the needs of high-speed continuous production. In addition, the real-time positioning and alarm functions reduce production interruptions caused by defect accumulation, providing reliable support for automated production lines.

[0070] 3. Based on the differential signal-based positive and negative threshold determination and intelligent analysis algorithm, the system accurately distinguishes between open-circuit and parallel-circuit defect types. Traditional methods rely on a single threshold or subjective experience, making it difficult to distinguish the direction of sparsity changes. However, by setting a preset voltage threshold range and combining the polarity characteristics of the differential signal, the system clearly determines whether the open-circuit sparsity is abnormally increased or the parallel-circuit density is abnormally increased. Furthermore, the system can be experimentally calibrated to adapt to metal wires of different materials or specifications, flexibly addressing diverse testing needs and providing a highly reliable classification basis for process optimization and quality traceability. The accuracy and practicality of defect identification are significantly enhanced.

[0071] It should be understood that the specific embodiments described above are merely illustrative or explanatory of the principles of the invention and do not constitute a limitation thereof. Therefore, any modifications, equivalent substitutions, improvements, etc., made without departing from the spirit and scope of the invention should be included within the protection scope of the invention. Furthermore, the appended claims are intended to cover all variations and modifications falling within the scope and boundaries of the appended claims, or equivalent forms of such scope and boundaries.

Claims

1. A device for detecting broken strands in a metal wire, characterized in that, include: Reel assembly, eddy current sensor assembly, and control assembly; The sidewall of the reel assembly is wound with a metal wire (21) to be detected along its circumference, and adjacent metal wires (21) are spaced apart by a first preset distance. The reel assembly and the eddy current sensor assembly are electrically connected to the control assembly. The eddy current sensor assembly is disposed at a corresponding position on the side wall of the reel assembly, and the control assembly controls the eddy current sensor assembly to reciprocate along the axial direction of the reel assembly; When the eddy current sensor assembly moves along the axial direction of the reel assembly, it acquires the voltage detection signals of two adjacent detection positions and performs differential calculation to obtain a voltage difference signal. If the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire (21) wound on the reel assembly is either twisted or broken. The eddy current sensor assembly includes: an eddy current sensor unit (31) and a sensor bracket (33). The eddy current sensor unit (31) is disposed at one end of the sensor bracket (33) and is spaced from the side wall of the scroll assembly by a second preset distance; The eddy current sensor unit (31) includes a first eddy current sensor unit and a second eddy current sensor unit; The first eddy current sensor unit and the second eddy current sensor unit are spaced apart along the axial direction of the reel assembly. The first eddy current sensor unit and the second eddy current sensor unit are electrically connected to the control component, and the first eddy current sensor unit and the second eddy current sensor unit respectively acquire voltage detection signals at two adjacent detection positions and send them to the control component. The control component performs differential calculations based on the voltage detection signals from the two detection positions to obtain the voltage difference signal; The first eddy current sensor unit and the second eddy current sensor unit are spaced along the axial direction of the reel assembly at the same distance as the distance between two adjacent detection positions on the reel assembly. The arrangement of the first eddy current sensor unit and the second eddy current sensor unit is such that each sensor unit exactly covers the detection area directly above the single metal wire.

2. The metal wire breakage detection device according to claim 1, characterized in that, If the voltage difference signal deviates from the preset voltage value range, it is determined that the metal wire (21) wound on the reel assembly is either twisted or broken, including: When the voltage difference obtained based on differential calculation is greater than the upper limit of the preset voltage range, it is determined that the metal wire (21) at the corresponding position of the reel assembly and the eddy current sensor assembly are parallel; When the voltage difference obtained based on differential calculation is less than the lower limit of the preset voltage value range, it is determined that there is a break in the metal wire (21) at the corresponding position of the reel assembly and the eddy current sensor assembly.

3. The metal wire breakage detection device according to claim 2, characterized in that, When the voltage difference obtained based on differential operation is less than the lower limit of the preset voltage range and the original output signal of the eddy current sensor assembly at the current position is lower than the calibrated minimum effective value, it is determined that there is a break in the metal wire (21) at the corresponding position of the reel assembly and the eddy current sensor assembly.

4. The metal wire breakage detection device according to claim 1, characterized in that, The eddy current sensor assembly also includes: a guide rail (32) and a reciprocating drive unit; The reciprocating drive unit is electrically connected to the control component, and under the control of the control component, it drives the other end of the sensor bracket (33) to reciprocate along the guide rail (32); The guide rail (32) is arranged parallel to the axis of the reel assembly.

5. The metal wire breakage detection device according to claim 4, characterized in that, The reciprocating drive unit, under the control of the control component, drives the sensor bracket (33) to move along the guide rail (32) by the same distance in a single movement as the spacing between two adjacent metal wires (21) on the reel assembly.

6. The metal wire breakage detection device according to claim 1, characterized in that, The reel assembly includes: a reel (22) wound with metal wire (21), a reel support, and a rotation drive unit; The rotation drive unit is electrically connected to the control component, and both ends of the reel (22) are rotatably connected to the reel bracket; The rotation drive unit drives the scroll (22) to rotate along its own axis under the control of the control component.

7. The metal wire breakage detection device according to any one of claims 1-6, characterized in that, Also includes: Base (1); Both the eddy current sensor assembly and the reel assembly are fixed on the base (1) and spaced apart by a second preset distance.

8. A control method for a metal wire breakage detection device, characterized in that, The metal wire breakage detection device according to any one of claims 1-7 performs breakage detection on the metal wire (21) on the reel assembly, including the following steps: Step S100: Control the eddy current sensor assembly to move from one end to the other end along the axial direction of the reel assembly at a first preset distance, acquire the voltage detection signal at the corresponding detection position and perform differential operation to obtain the voltage difference signal, compare the voltage difference signal with the preset voltage value range, and determine whether there is a broken or twisted wire (21) at the corresponding position of the reel assembly. Step S200: Control the reel assembly to rotate sequentially according to a preset angle value, and repeat step S100 after each rotation to determine whether there is a broken or tangled wire in the metal wire (21) at the corresponding position after the reel assembly rotates, until the reel assembly completes one rotation.

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