Intelligent wrapping correction system based on finished product quality monitoring

Abstract

The invention discloses an intelligent wrapping correction system based on finished product quality monitoring, relates to the technical field of wrapping correction, and solves the technical problem of lack of systematicness and accuracy in adjustment of key parameters such as wrapping pitch and tension. On the basis of a scientific calculation formula, the pitch adjusting amount is accurately calculated through analysis of an overlapping ratio difference value, and then the wrapping pitch and the rotating speed are accurately adjusted. Compared with the prior art that the pitch is adjusted according to experience, the method is more accurate and scientific, the wrapping quality can be effectively improved, the secondary correction analysis module deeply analyzes the relation between the width of the wrapping material and the tension of the material, a scientific calculation model is established according to the material mechanics knowledge and Hooke's law, and the calculation accuracy is improved. And the target tension is accurately calculated and adjusted.

Description

Technical Field

[0001] The present invention relates to the technical field of wrapping correction, and in particular to an intelligent wrapping correction system based on finished product quality monitoring. Background Art

[0002] During the wrapping production process, the quality of the finished wrapped product is affected by many factors, such as parameters such as the thickness, pitch, width, and angle of the wrapping layer. Traditional wrapping quality control methods rely heavily on manual experience and simple parameter settings, and lack real-time and accurate collection and analysis of wrapping parameters. In terms of image detection, although there have been attempts to use image technology to detect the edges of wrapping materials, the detection accuracy and scientific nature of the processing methods need to be improved. In the quality correction link, the adjustment of key parameters such as wrapping pitch and tension lacks systematicity and precision, making it difficult to effectively respond to complex and changing production conditions. Existing technologies cannot meet the growing demand for high-quality and high-precision production of wrapped finished products, and an intelligent and precise wrapping quality monitoring and correction system is urgently needed. Summary of the Invention

[0003] In response to the shortcomings of the existing technology, the present invention provides an intelligent wrapping correction system based on finished product quality monitoring, which solves the problem of lack of systematicness and accuracy in adjusting key parameters such as wrapping pitch and tension.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solutions: an intelligent wrapping correction system based on finished product quality monitoring, comprising:

[0005] The quality detection and analysis module is used to analyze the wrapping parameters transmitted by the wrapping parameter acquisition module, obtain the edge parameters of the wrapping material based on the Canny edge detection algorithm, calculate the overlap rate, and compare it with the preset overlap rate to generate a normal or abnormal quality result, and then transmit the two respectively;

[0006] The wrapping correction analysis module is used to analyze the obtained quality abnormality results, calculate the overlap rate difference, and calculate the pitch adjustment amount according to the formula. At the same time, it compares it with the fixed value and generates a pitch increase or decrease signal;

[0007] Calculate the corresponding target pitch and the corresponding wrapping speed for the generated pitch increase or decrease signal, and use it as a standard to generate a speed adjustment result. Then, use the speed adjustment result to perform overlap rate detection, generate a secondary correction signal and a normal quality result, and transmit the secondary correction signal to the secondary correction analysis module.

[0008] The secondary correction analysis module is used to analyze the acquired secondary correction signal, establish the relationship between material tension and overlap rate, calculate the adjustment tension according to the preset overlap rate, and recalculate the adjusted overlap rate. If the result is satisfied, the tension adjustment result is generated. If not, the equipment fault information is generated and both are transmitted to the correction information output module.

[0009] As a further solution of the present invention, it also includes a wrapping parameter acquisition module and a correction information output module;

[0010] A wrapping parameter acquisition module is used to collect wrapping parameters and transmit them to the quality detection and analysis module, and the wrapping parameters include wrapping layer thickness, wrapping pitch, wrapping width and wrapping angle;

[0011] The correction information output module is used to display the obtained normal quality results, equipment failure information, speed adjustment results and tension adjustment results to the corresponding management personnel.

[0012] As a further solution of the present invention, the specific manner in which the quality detection and analysis module generates a normal or abnormal quality result is as follows:

[0013] Obtain the edge image of the wrapping material and convert it into a grayscale image, extract the edge parameters of the wrapping material, and use the formula The overlap ratio is calculated, where W total W is the actual width of the wrapping material. gap The distance between the edges of two adjacent circles of material;

[0014] The overlap rate is compared with the preset overlap rate. If the overlap rate is greater than the preset overlap rate, a quality abnormality result is generated and transmitted to the wrapping correction analysis module. Conversely, if the overlap rate is less than the preset overlap rate, a quality normal result is generated and transmitted to the correction information transmission module.

[0015] As a further solution of the present invention, the specific method of analyzing the quality abnormality result by the wrapping correction analysis module is:

[0016] According to the formula ΔO=O 实测 -O 预设 The overlap difference ΔO is calculated, and according to the formula The pitch P is calculated, where θ is the wrapping angle, and the overlap rate O is derived to obtain And combine the overlap rate difference ΔO to obtain the corresponding pitch adjustment amount At the same time, the obtained pitch adjustment amount ΔP is compared with 0;

[0017] If the pitch adjustment amount ΔP>value 0, a pitch increase signal is generated. Conversely, if the pitch adjustment amount ΔP≤value 0, a pitch decrease signal is generated. Both are adjusted and analyzed at the same time.

[0018] As a further solution of the present invention, the specific manner in which the wrapping correction analysis module adjusts and analyzes the two is as follows:

[0019] Analysis of pitch increase signal, according to formula P 目标 =P 当前 +ΔP is calculated to obtain the target pitch P 目标 , and P 当前 It is expressed as the current winding pitch, and according to the formula Calculate the target wrapping speed n 目标 , and use it as a standard to adjust the current winding speed n 当前 Perform adjustments and generate adjustment results;

[0020] For the pitch reduction signal analysis, according to the formula P 目标 =P 当前 -ΔP is calculated to obtain the target pitch P 目标 , and use the above formula to calculate the target winding speed, and use it as the standard to adjust the current winding speed n 当前 Make adjustments and generate speed adjustment results.

[0021] As a further solution of the present invention, the specific manner in which the wrapping correction analysis module generates the secondary correction signal and the normal quality result is:

[0022] The overlap rate is detected based on the adjustment result. If the overlap rate after adjustment is still greater than the preset overlap rate, a secondary correction signal is generated. Conversely, if the overlap rate after adjustment is less than the preset overlap rate, a normal signal is generated and the corresponding speed adjustment result is transmitted to the correction information output module.

[0023] As a further solution of the present invention, the specific manner in which the secondary correction analysis module analyzes the secondary correction signal is as follows:

[0024] The axial strain ε of the material is related to the width change, which is related to the Poisson's ratio υ, that is, the actual width W 实际 With nominal width W 标称 The relationship is W 实际 =W 标称 ×(1-ε·υ), and W 实际 =W 标称 ×(1-ε·υ) is substituted into the original overlap rate formula to obtain Overlap rate O, where W gap The distance between the edges of two adjacent layers of wrapping tape;

[0025] According to Hooke's law, the axial strain ε of the material is related to the tension T, elastic modulus E and cross-sectional area A, and the specific relationship is: Then Substituting into the above overlap formula we get

[0026] As a further solution of the present invention, the specific manner in which the secondary correction analysis module generates equipment fault information is as follows:

[0027] Get the preset overlap rate O 目标 , and substitute it into the overlap rate formula to calculate the tension T, and adjust the current tension based on the calculated tension T, generate the adjustment result, and test the quality of the finished product based on the adjustment result;

[0028] If the adjusted overlap ratio is still greater than the preset overlap ratio, a device fault message is generated. Conversely, if the adjusted overlap ratio is less than the preset overlap ratio, the tension adjustment result is used as a standard and transmitted to the correction information output module.

[0029] The present invention provides an intelligent wrapping correction system based on finished product quality monitoring. Compared with the existing technology, it has the following advantages:

[0030] The present invention utilizes a quality inspection and analysis module based on precise wrapping parameters, using scientific image processing and calculation methods to accurately detect the quality of finished wrapped products. For example, images of the wrapped material's edges are standardized, edge parameters are calculated using a sophisticated algorithm, and the overlap ratio is scientifically compared with a preset overlap ratio to determine quality. This effectively avoids misjudgments caused by imperfect detection methods in existing technologies, improving detection accuracy.

[0031] The present invention uses a wrapping correction analysis module to address quality anomalies. Based on a scientific calculation formula, it analyzes the overlap rate difference and accurately calculates the pitch adjustment value, thereby accurately adjusting the wrapping pitch and speed. The detailed calculation process and adjustment logic are more accurate and scientific than the existing empirical pitch adjustment method, which can effectively improve wrapping quality. The secondary correction analysis module deeply analyzes the relationship between wrapping material width and material tension, and establishes a scientific calculation model based on material mechanics and Hooke's law to accurately calculate the target tension and adjust it accordingly. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a block diagram of the system principle of the present invention. DETAILED DESCRIPTION

[0033] 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.

[0034] Example 1

[0035] See also Figure 1 This application provides an intelligent wrapping correction system based on finished product quality monitoring, including: wrapping parameter acquisition module, quality detection and analysis module, wrapping correction analysis module, secondary correction analysis module and correction information output module, and combined with Figure 1 It can be known that the functional modules are electrically connected in a unidirectional manner.

[0036] The wrapping parameter acquisition module is used to obtain the wrapping parameters and transmit them to the quality detection and analysis module, where the wrapping parameters include wrapping layer thickness, wrapping pitch, wrapping width and wrapping angle.

[0037] The quality inspection and analysis module is used to inspect and analyze the quality of the finished product according to the obtained wrapping parameters and generate corresponding quality inspection results. The quality inspection results include normal quality results and abnormal quality results. The specific method of generating quality inspection results is as follows:

[0038] Obtain the edge image of the wrapping material, and use a high-precision image acquisition device (such as an industrial camera) to obtain the edge image of the wrapping material. The camera must have a high resolution (for example, not less than 1280×720 pixels) and a suitable frame rate (such as 25fps or more), and at the same time, perform grayscale processing on it to obtain a grayscale image, and grayscale the collected color image to convert it into a grayscale image. Grayscale processing can effectively simplify image information, remove color interference, and facilitate subsequent processing. The weighted average method is used for grayscale conversion, and the formula is: Gray = 0.299*R+0.587*G+0.114*B, where R, G, and B are the red, green, and blue channel values ​​of the color image, respectively. The edge parameters of the wrapping material are obtained by the Canny edge detection algorithm, and the Canny edge detection algorithm here is a prior art, so it will not be described in detail here, and the edge parameters include the width of the overlapping part of the wrapping material and the total width, and according to the formula The overlap ratio is calculated, where W total W is the actual width of the wrapping material. gap The distance between the edges of two adjacent circles of material;

[0039] The obtained overlap ratio is compared with a preset overlap ratio, and the specific value of the preset overlap ratio is set by the operator. If the overlap ratio is greater than the preset overlap ratio, it indicates that the quality of the finished product is abnormal, and a quality abnormality result is generated. Conversely, if the overlap ratio is less than the preset overlap ratio, it indicates that the quality of the finished product is normal, and a quality normal result is generated.

[0040] The generated abnormal quality results are further transmitted to the wrapping correction analysis module, and the normal quality results are transmitted to the correction information transmission module.

[0041] The wrapping correction analysis module is used to analyze the obtained quality abnormality results. By analyzing the overlap rate, the wrapping pitch is analyzed and the speed is adjusted. The overlap rate is tested again after 3 seconds based on the adjustment result. If it does not meet the standard, a secondary correction signal is generated and transmitted to the secondary correction analysis module. If it meets the standard, the corresponding speed adjustment result is transmitted to the correction information output module. The specific method of generating the speed adjustment result is as follows:

[0042] The difference between the calculated overlap rate and the preset overlap rate is recorded as the overlap rate difference. The specific calculation formula is ΔO=O 实测 -O 预设 The overlap difference ΔO is calculated, and according to the formula The pitch P is calculated, where θ is the wrapping angle, and the overlap rate O is derived to obtain And combine the overlap rate difference ΔO to obtain the corresponding pitch adjustment amount At the same time, the obtained pitch adjustment amount ΔP is compared with the value 0;

[0043] If the pitch adjustment value ΔP>0, it means that the measured overlap rate is too high, and the pitch P needs to be increased to reduce the overlap, and a pitch increase signal is generated. Conversely, if the pitch adjustment value ΔP≤0, it means that the measured overlap rate is too low, and the pitch P needs to be reduced to increase the overlap, and a pitch decrease signal is generated. Adjustment processing is performed based on the generated adjustment signal.

[0044] For the generated pitch increase signal, further according to the formula P 目标 =P 当前 +ΔP is calculated to obtain the target pitch P 目标 , and P 当前 It is expressed as the current winding pitch, and according to the formula Calculate the target wrapping speed n 目标 , and use it as a standard to adjust the current winding speed n 当前 Perform adjustments and generate adjustment results;

[0045] For the generated pitch reduction signal, further according to the formula P 目标 =P 当前 -ΔP is calculated to obtain the target pitch P 目标 , and use the above formula to calculate the target winding speed, and use it as the standard to adjust the current winding speed n 当前 Perform adjustment and generate speed adjustment results;

[0046] Then, the overlap rate is detected based on the adjustment result. If the overlap rate after adjustment is still greater than the preset overlap rate, a secondary correction signal is generated. Conversely, if the overlap rate after adjustment is less than the preset overlap rate, a normal signal is generated, and the corresponding speed adjustment result is transmitted to the correction information output module.

[0047] For example, a cable wrapping process presets an overlap rate of O 预设 =20%, the current measured overlap rate O 实测 =25%, and after calculating the overlap difference ΔO=5%, we know that the overlap difference ΔO is greater than 0, increase the pitch to reduce the overlap, and get the current pitch P 当前 =8mm, linear speed v = 0.3m / s, the pitch adjustment ΔP = +1.5mm, then P 目标 =8+1.5=9.5mm, and the target speed n is further calculated according to the formula 目标 =189.5rpm, and the original speed n 当前 =225rpm, and according to the target speed n 目标 =189.5rpm to detect the overlap rate and obtain O 新 =21%, still greater than the preset overlap rate O 预设 =20%, thus generating a secondary correction signal.

[0048] The correction information output module is used to display the obtained speed adjustment results and normal quality results to the corresponding management personnel.

[0049] Example 2

[0050] As the second embodiment of the present invention, it is implemented on the basis of the first embodiment, and differs from the first embodiment in the following aspects:

[0051] The secondary correction analysis module is used to analyze the obtained secondary correction signal, adjust the relationship between the width of the wrapping material and the material tension, and generate an adjustment result. At the same time, the quality of the finished product is analyzed based on the adjustment result to generate a quality analysis result, where the quality analysis result includes a normal quality result and a quality result. The specific method of generating the quality analysis result is as follows:

[0052] According to the knowledge of material mechanics, when the wrapping material is subjected to tension, it will deform. The axial strain ε of the material is related to the width change, which is established through the Poisson's ratio υ, that is, the actual width W 实际 With nominal width W 标称 The relationship is W 实际 =W 标称 ×(1-ε·υ), and W 实际 =W 标称 ×(1-ε·υ) is substituted into the original overlap rate formula to obtain Overlap rate O, where W gap The distance between the edges of two adjacent layers of wrapping tape;

[0053] According to Hooke's law, the axial strain ε of the material is related to the tension T, elastic modulus E and cross-sectional area A, and the specific relationship is: Then Substituting into the above overlap formula we get And from the above formula, we can know that when the tension T increases, The value of will increase, and further The corresponding value will decrease, which will result in the actual width W of the material 实际 will decrease;

[0054] Then obtain the preset overlap rate O 目标 , and substitute it into the above formula to calculate the tension T. At the same time, the current tension is adjusted based on the calculated tension T to generate an adjustment result. The quality of the finished product is further tested based on the adjustment result. If the overlap rate after adjustment is still greater than the preset overlap rate, it indicates that the equipment is faulty and generates equipment fault information. On the contrary, if the overlap rate after adjustment is less than the preset overlap rate, the tension adjustment result is used as the standard and transmitted to the correction information output module.

[0055] For example, the copper tape wrapping of the high-voltage cable shielding layer can obtain its corresponding parameters as follows:

[0056] Copper tape: W 标称 =20mm, thickness t=0.1mm, E=110GPa, υ=0.3.

[0057] Process requirements: 0 目标 =30%, current W gap =12mm;

[0058] According to the formula, the corresponding tension is A=20×0.1=2, and T 目标 =9.17N, and according to the target tension T 目标 =9.17N, the overlap rate is calculated and analyzed, and the overlap rate is 29.5%. At the same time, it is compared with the preset overlap rate of 30%, which is smaller than the preset overlap rate. Therefore, the current tension is qualified, and the adjustment result is generated based on it.

[0059] Correction information output module, which is used to display the obtained tension adjustment results and equipment fault information to the corresponding management personnel.

[0060] Example 3

[0061] As the third embodiment of the present invention, the focus is on combining the implementation processes of the first and second embodiments.

[0062] Some of the data in the above formulas are calculated based on their numerical values ​​and are not substituted into parameter units for calculation. At the same time, the contents not described in detail in this specification belong to the existing technology known to those skilled in the art.

[0063] The above embodiments are only used to illustrate the technical method of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical method of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical method of the present invention.

Claims

1. Intelligent wrapping correction system based on finished product quality monitoring, characterized by: include: The quality detection and analysis module is used to analyze the wrapping parameters transmitted by the wrapping parameter acquisition module, obtain the edge parameters of the wrapping material based on the Canny edge detection algorithm, calculate the overlap rate, and compare it with the preset overlap rate to generate a normal or abnormal quality result, and then transmit the two respectively; The wrapping correction analysis module is used to analyze the obtained quality abnormality results, calculate the overlap rate difference, and calculate the pitch adjustment amount according to the formula. At the same time, it compares it with the fixed value and generates a pitch increase or decrease signal; Calculate the corresponding target pitch and the corresponding wrapping speed for the generated pitch increase or decrease signal, and use it as a standard to generate a speed adjustment result. Then, use the speed adjustment result to perform overlap rate detection, generate a secondary correction signal and a normal quality result, and transmit the secondary correction signal to the secondary correction analysis module. The secondary correction analysis module is used to analyze the acquired secondary correction signal, establish the relationship between material tension and overlap rate, calculate the adjustment tension according to the preset overlap rate, and recalculate the adjusted overlap rate. If the result is satisfied, the tension adjustment result is generated. If not, the equipment fault information is generated and both are transmitted to the correction information output module.

2. The intelligent wrapping correction system based on finished product quality monitoring according to claim 1 is characterized in that: It also includes a wrapping parameter acquisition module and a correction information output module; A wrapping parameter acquisition module is used to collect wrapping parameters and transmit them to the quality detection and analysis module, and the wrapping parameters include wrapping layer thickness, wrapping pitch, wrapping width and wrapping angle; The correction information output module is used to display the obtained normal quality results, equipment failure information, speed adjustment results and tension adjustment results to the corresponding management personnel.

3. The intelligent wrapping correction system based on finished product quality monitoring according to claim 1 is characterized in that: The specific way in which the quality detection and analysis module generates a normal or abnormal quality result is as follows: Obtain the edge image of the wrapping material and convert it into a grayscale image, extract the edge parameters of the wrapping material, and use the formula The overlap ratio is calculated, where W total W is the actual width of the wrapping material. gap The distance between the edges of two adjacent circles of material; The overlap rate is compared with the preset overlap rate. If the overlap rate is greater than the preset overlap rate, a quality abnormality result is generated and transmitted to the wrapping correction analysis module. Conversely, if the overlap rate is less than the preset overlap rate, a quality normal result is generated and transmitted to the correction information transmission module.

4. The intelligent wrapping correction system based on finished product quality monitoring according to claim 1 is characterized in that: The specific method for the wrapping correction analysis module to analyze the quality abnormality results is as follows: According to the formula ΔO=O 实测 -O 预设 The overlap difference ΔO is calculated, and according to the formula The pitch P is calculated, where θ is the wrapping angle, and the overlap rate O is derived to obtain And combine the overlap rate difference ΔO to obtain the corresponding pitch adjustment amount At the same time, the obtained pitch adjustment amount ΔP is compared with 0; If the pitch adjustment amount ΔP>value 0, a pitch increase signal is generated. Conversely, if the pitch adjustment amount ΔP≤value 0, a pitch decrease signal is generated. Both are adjusted and analyzed at the same time.

5. The intelligent wrapping correction system based on finished product quality monitoring according to claim 4 is characterized in that: The specific manner in which the wrapping correction analysis module adjusts and analyzes the two is as follows: Analysis of pitch increase signal, according to formula P 目标 =P 当前 +ΔP is calculated to obtain the target pitch P 目标 , and P 当前 It is expressed as the current winding pitch, and according to the formula Calculate the target wrapping speed n 目标 , and use it as a standard to adjust the current winding speed n 当前 Perform adjustments and generate adjustment results; For the pitch reduction signal analysis, according to the formula P 目标 =P 当前 -ΔP is calculated to obtain the target pitch P 目标 , and use the above formula to calculate the target winding speed, and use it as the standard to adjust the current winding speed n 当前 Make adjustments and generate speed adjustment results.

6. The intelligent wrapping correction system based on finished product quality monitoring according to claim 1 is characterized in that: The specific method for the wrapping correction analysis module to generate the secondary correction signal and the normal quality result is: The overlap rate is detected based on the adjustment result. If the overlap rate after adjustment is still greater than the preset overlap rate, a secondary correction signal is generated. Conversely, if the overlap rate after adjustment is less than the preset overlap rate, a normal signal is generated and the corresponding speed adjustment result is transmitted to the correction information output module.

7. The intelligent wrapping correction system based on finished product quality monitoring according to claim 1 is characterized in that: The specific method in which the secondary correction analysis module analyzes the secondary correction signal is as follows: The axial strain ε of the material is related to the width change, which is related to the Poisson's ratio υ, that is, the actual width W 实际 With nominal width W 标称 The relationship is W 实际 =W 标称 ×(1-ε·υ), and W 实际 =W 标称 ×(1-ε·υ) is substituted into the original overlap rate formula to obtain Overlap rate O, where W gap The distance between the edges of two adjacent layers of wrapping tape; According to Hooke's law, the axial strain ε of the material is related to the tension T, elastic modulus E and cross-sectional area A, and the specific relationship is: Then Substituting into the above overlap formula we get 8. The intelligent wrapping correction system based on finished product quality monitoring according to claim 1 is characterized in that: The specific method for the secondary correction analysis module to generate equipment fault information is as follows: Get the preset overlap rate O 目标 , and substitute it into the overlap rate formula to calculate the tension T, and adjust the current tension based on the calculated tension T, generate the adjustment result, and test the quality of the finished product based on the adjustment result; If the adjusted overlap ratio is still greater than the preset overlap ratio, a device fault message is generated. Conversely, if the adjusted overlap ratio is less than the preset overlap ratio, the tension adjustment result is used as a standard and transmitted to the correction information output module.

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