Winding defect and gas cylinder deformation monitoring device and method based on vision

Abstract

The invention provides a winding defect and gas cylinder deformation monitoring device and method based on vision. The device comprises a data collecting and processing mechanism, an operation table, a first monitoring mechanism, a second monitoring mechanism and a third monitoring mechanism, the first monitoring mechanism, the second monitoring mechanism and the third monitoring mechanism are all electrically connected with the data collecting and processing mechanism, and the first monitoring mechanism is used for monitoring fiber winding angle data of a cylinder body section; the data is transmitted to the data acquisition and processing mechanism; the second monitoring mechanism is used for monitoring fiber winding angle data of the end socket section of the gas cylinder and transmitting the data to the data acquisition and processing mechanism; the third monitoring mechanism is used for monitoring axial and radial deformation data of the gas cylinder in the winding process and transmitting the data to the data collecting and processing mechanism. The device is simple in structure and convenient to control, the winding angle and deformation of the carbon fiber full-winding gas cylinder in the winding process can be monitored in real time, and the intelligent level of the winding process and the product quality consistency are improved.

Description

Technical Field

[0001] The present invention relates to the field of fiber winding technology, and in particular to a device and method for monitoring winding defects and gas cylinder deformation based on vision. Background Art

[0002] The fiber winding process is the core technology for manufacturing fully wrapped carbon fiber gas cylinders. In the wet winding process, the carbon fiber is first fully contacted with the resin in the impregnation device, and then wound around the inner liner of the gas cylinder according to the preset winding angle. The winding angle is one of the key parameters that directly affects the bursting pressure of the gas cylinder. Current winding equipment generally assumes that the actual winding angle is equivalent to the theoretical set value, and lacks a real-time monitoring and feedback mechanism for the winding angle. Therefore, it is impossible to identify the winding error in real time during the production process, and the only way to verify whether the bursting pressure meets the standard is through a water pressure bursting test after the gas cylinder is manufactured. Since the water pressure bursting test is a destructive test, it is impossible to test every gas cylinder, and it is difficult to fully guarantee product quality and safety. Therefore, there is an urgent need for a device that can monitor the winding angle in real time and issue an alarm in time when it exceeds the allowable deviation, so as to improve winding accuracy and product consistency.

[0003] In addition, during the winding process, due to the effect of winding tension, the flexible liner (Type IV gas cylinder) will undergo obvious axial and radial deformation; even for the rigid liner (Type III gas cylinder) with less deformation, its external dimensions will gradually change as the number of winding layers increases. The axial and radial dimensional changes of the gas cylinder during the winding process are one of the key factors affecting the consistency of product quality in mass production. At present, the industry generally performs dimensional inspection through manual measurement after the gas cylinder is formed. This method is not only inefficient, but also cannot obtain real-time deformation data during the winding process, making it difficult to systematically study the interaction mechanism between process parameters and gas cylinder deformation, and also restricts the optimization and regulation of winding process parameters. At the same time, during the winding process of the flexible liner, defects such as fiber slippage, fiber overhead, and uneven fiber distribution are prone to occur, affecting the quality and performance of the winding layer. However, at this stage, the online monitoring technology for defects in the winding process is still insufficient, making it difficult to achieve real-time identification and accurate monitoring of the above defects. Summary of the Invention

[0004] In response to the aforementioned technical problem of the lack of real-time monitoring methods for winding defect and deformation detection in the existing carbon fiber fully wrapped gas cylinder manufacturing process, a vision-based winding defect and cylinder deformation monitoring device and method are provided to achieve online, dynamic, and non-contact monitoring of the winding process. The present invention can collect the winding angle and axial and radial deformation data of the gas cylinder in real time during the winding process, and automatically analyze and provide feedback, providing data support for the optimization and adjustment of process parameters, thereby realizing intelligent monitoring and quality control of the winding process, and meeting the consistency and safety requirements of mass-produced high-performance carbon fiber gas cylinders.

[0005] The technical means adopted in the present invention are as follows:

[0006] A vision-based winding defect and gas cylinder deformation monitoring device includes: a data acquisition and processing mechanism, an operating table, and a first monitoring mechanism, a second monitoring mechanism, and a third monitoring mechanism fixedly installed on the operating table. The first monitoring mechanism, the second monitoring mechanism, and the third monitoring mechanism are all electrically connected to the data acquisition and processing mechanism. The first monitoring mechanism is used to monitor the fiber winding angle data of the barrel section and transmit the data to the data acquisition and processing mechanism; the second monitoring mechanism is used to monitor the fiber winding angle data of the gas cylinder head section and transmit the data to the data acquisition and processing mechanism; and the first monitoring mechanism and the second monitoring mechanism are used to identify defects such as fiber slippage and fiber overhead during the winding process; the third monitoring mechanism is used to monitor the axial and radial deformation data of the gas cylinder during the winding process and transmit the data to the data acquisition and processing mechanism; the data acquisition and processing mechanism has image processing technology, and calculates the fiber coverage rate through the first monitoring mechanism, the second monitoring mechanism, and the third monitoring mechanism in combination with image processing technology to determine whether the fibers are evenly distributed.

[0007] Furthermore, the first monitoring mechanism includes a first infrared camera and a first six-degree-of-freedom robotic arm bracket, the first six-degree-of-freedom robotic arm bracket is fixedly mounted on the operating table, and the first infrared camera is fixedly mounted at the end of the first six-degree-of-freedom robotic arm bracket.

[0008] Furthermore, the infrared probe resolution of the first infrared camera is 640*480, the temperature measurement range is -20°C to 250°C, and the frame rate is 30Hz.

[0009] Furthermore, the second monitoring mechanism includes a second six-degree-of-freedom robotic arm bracket and a second infrared camera, the second six-degree-of-freedom robotic arm bracket is fixedly mounted on the operating table, and the second infrared camera is fixedly mounted on the end of the second six-degree-of-freedom robotic arm bracket.

[0010] Furthermore, the infrared probe resolution of the second infrared camera is 640*480, the temperature measurement range is -20°C to 250°C, and the frame rate is 30Hz.

[0011] Furthermore, the third monitoring mechanism is located between the first monitoring mechanism and the second monitoring mechanism, and includes an industrial camera and a third six-degree-of-freedom robotic arm bracket. The third six-degree-of-freedom robotic arm bracket is fixedly mounted on the operating table, and the industrial camera is fixedly mounted at the end of the third six-degree-of-freedom robotic arm bracket.

[0012] Furthermore, the industrial camera adopts a high-resolution image sensor.

[0013] Furthermore, the data acquisition and processing mechanism includes a host, a mouse, a display, a keyboard, and an adapter; the operating console includes an upper layer and a lower layer structure; the mouse, display, and keyboard are all arranged on the upper layer of the operating console; the host and the adapter are arranged on the lower layer of the operating console; the mouse, display, keyboard, and adapter are all connected to the host; the host is electrically connected to the first infrared camera of the first monitoring mechanism, the second infrared camera of the second monitoring mechanism, and the industrial camera of the third monitoring mechanism; the host has built-in image processing and analysis software and a threshold judgment module;

[0014] The host collects video signals from the first infrared camera, the second infrared camera, and the industrial camera through an adapter, performs winding angle recognition and deformation measurement on the collected images, and displays the winding angle and cylinder deformation data in real time through a software interface on the display. In combination with a threshold judgment module, an alarm is issued when the winding angle or deformation exceeds a preset allowable error range.

[0015] Furthermore, the display is provided with a graphical operation interface for real-time display of winding angle data / change curve, axial and radial deformation, and supports historical data backtracking and export;

[0016] The graphical operation interface is divided into three functional areas, corresponding to the head section winding angle monitoring, the barrel section winding angle monitoring and the cylinder deformation monitoring. The winding angle interface layout of the head section and the barrel section is the same, including:

[0017] The current winding angle is displayed in real time at the top of the interface;

[0018] The center of the interface displays video images captured by infrared cameras and industrial cameras. An adjustable rectangular area abcd is provided in the infrared camera image. When the fiber tape enters this area, the system begins calculating the winding angle. The output real-time winding angle is the angle when the fiber tape is closest to the diagonal line ad.

[0019] The output value and curve graph are displayed at the bottom of the interface. If the actual winding angle / deformation exceeds the preset error range, the system will mark the angle / deformation in red and annotate it in the curve graph.

[0020] The interface also synchronously displays the number of winding layers corresponding to the current winding angle / deformation.

[0021] The present invention also provides a monitoring method for a winding defect and gas cylinder deformation monitoring device based on vision, comprising the following steps:

[0022] S1. Equipment startup and self-test: After the device is turned on, it will first perform a self-test, including checking the system operating status, whether the infrared camera is imaging normally, whether the temperature display is clear, and whether the camera position is reasonable. If there are any problems, the formal monitoring process can only be started after debugging and position calibration.

[0023] S2. Image acquisition and monitoring start: Two infrared cameras monitor the fiber winding status of the cylinder head and cylinder body respectively, while an industrial camera monitors the overall contour changes of the cylinder. The video signals collected by all cameras are transmitted to the host computer in real time, and image processing and data analysis are performed by image processing and analysis software.

[0024] S3. Winding Angle and Deformation Calculation: The software system in the host computer calculates the winding angle based on the infrared image, identifies the axial and radial deformation of the cylinder based on the industrial camera image, and displays the results in real time on the graphical operation interface of the monitor;

[0025] S4. Error judgment and alarm processing: The monitored winding angle and deformation are compared with the preset design values. If any parameter exceeds the tolerance range, an alarm prompt will be immediately issued. The operator will determine whether to suspend or continue the winding operation based on the alarm information. If the monitoring result is within the tolerance range, the device will automatically continue monitoring until the entire cylinder winding process is completed.

[0026] S5. Based on the monitored winding angle, it can be determined whether the fiber is slipping; based on the infrared camera, it can be determined whether the fiber is hanging; combined with industrial cameras and image processing technology, the fiber coverage rate can be calculated to determine whether the fiber is evenly distributed;

[0027] S51, fiber slip: When the monitored actual fiber winding angle exceeds the tolerance range, it indicates that fiber slip has occurred;

[0028] S52. Fiber Hanging: During the winding process, the surface temperature of the fiber tape exhibits a distribution characteristic: the unwound area has the lowest temperature, followed by the wound area, and the initial temperature of the fiber tape before winding is the highest. Based on this pattern, an infrared camera is used to monitor the fiber surface temperature distribution in real time. If a certain area is found to have a higher temperature than adjacent areas, it can be determined that fiber hanging has occurred there.

[0029] S53. Fibers are not evenly distributed: Based on the monitoring device and combined with digital image processing technology, the trajectory of each fiber belt during the winding process is marked, and its covered position on the surface of the gas cylinder body is recorded; then, the coverage area of ​​all fiber belts is reproduced through CAD modeling, and the output fiber coverage rate is calculated to determine whether the wound fibers are evenly distributed.

[0030] Compared with the prior art, the present invention has the following advantages:

[0031] 1. The vision-based winding defect and cylinder deformation monitoring device and method provided by the present invention can realize real-time, non-contact monitoring of winding defects and cylinder deformation, and provide data support for the optimization design of winding process parameters.

[0032] 2. The vision-based winding defect and gas cylinder deformation monitoring device and method provided by the present invention have abnormal alarm and data marking functions, which help to improve product consistency and safety.

[0033] 3. The vision-based winding defect and gas cylinder deformation monitoring device and method provided by the present invention have a compact structure, are applicable to gas cylinders of various specifications and different winding scenarios, and have good engineering application prospects.

[0034] Based on the above reasons, the present invention can be widely promoted in fields such as fiber winding. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative labor.

[0036] Figure 1 Schematic diagram of the overall structure of the vision-based winding defect and gas cylinder deformation monitoring device in a specific embodiment of the present invention.

[0037] Figure 2 1 is a flowchart of the device working process in a specific embodiment of the present invention.

[0038] Figure 3 Schematic diagram of the software interface in a specific embodiment of the present invention.

[0039] In the figure: 1. Host; 2. Operating console; 3. Mouse; 4. First infrared camera; 5. First six-degree-of-freedom robotic arm bracket; 6. Industrial camera; 7. Third six-degree-of-freedom robotic arm bracket; 8. Second six-degree-of-freedom robotic arm bracket; 9. Second infrared camera; 10. Display; 11. Keyboard; 12. Adapter. DETAILED DESCRIPTION

[0040] It should be noted that, in the absence of conflict, the embodiments and features of the embodiments of the present invention can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0041] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. The following description of at least one exemplary embodiment is actually only illustrative and is in no way intended to limit the present invention and its application or use. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.

[0042] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, they indicate the presence of features, steps, operations, devices, components and / or combinations thereof.

[0043] Unless otherwise specified, the relative arrangement of the parts and steps, numerical expressions and numerical values ​​set forth in these embodiments do not limit the scope of the present invention. At the same time, it should be clear that, for ease of description, the sizes of the various parts shown in the accompanying drawings are not drawn according to actual proportional relationships. The technology, methods and equipment known to those of ordinary skill in the relevant art may not be discussed in detail, but in appropriate cases, the technology, methods and equipment should be considered as a part of the specification. In all examples shown and discussed here, any specific value should be interpreted as being merely exemplary, rather than as a limitation. Therefore, other examples of the exemplary embodiments can have different values. It should be noted that similar numbers and letters represent similar items in the following drawings, and therefore, once an item is defined in an accompanying drawing, it does not need to be further discussed in subsequent drawings.

[0044] In the description of the present invention, it should be understood that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "horizontal, vertical, vertical, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific direction or be constructed and operated in a specific direction. Therefore, they cannot be understood as limiting the scope of protection of the present invention: the directional words "inside and outside" refer to the inside and outside relative to the outline of each component itself.

[0045] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used herein to describe the spatial positional relationship of a device or feature to other devices or features as shown in the figures. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figures. For example, if the device in the drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below their position devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0046] In addition, it should be noted that the use of terms such as "first" and "second" to limit components is only for the convenience of distinguishing the corresponding components. Unless otherwise stated, the above terms have no special meaning and therefore cannot be understood as limiting the scope of protection of the present invention.

[0047] During the winding process of the flexible liner, defects such as fiber slippage, fiber hanging and uneven fiber distribution are prone to occur, affecting the quality and performance of the winding layer. However, the current online monitoring technology for winding process defects is still insufficient, and it is difficult to achieve real-time identification and accurate monitoring of the above defects. In view of the problem that the existing carbon fiber fully wrapped gas cylinder wet winding preparation process lacks real-time monitoring and feedback means for winding angles, gas cylinder deformation and winding defects, the present invention provides a vision-based winding defect and gas cylinder deformation monitoring device to achieve online, dynamic, non-contact monitoring of the winding process and solve the following problems:

[0048] 1) The winding angle cannot be fed back in real time, making it difficult to ensure the consistency of burst pressure;

[0049] 2) The lack of a monitoring and feedback device for the axial / radial deformation of the cylinders during the winding process affects the quality consistency of the cylinders in batch production;

[0050] 3) Lack of monitoring and feedback devices for defects in the winding process, which affects the performance of the wound products;

[0051] 4) The existing detection methods are inefficient and have delayed data, which is not conducive to the optimization of process parameters.

[0052] A vision-based winding angle and gas cylinder deformation monitoring device of the present invention includes a main unit 1, an operating table 2, a mouse 3, two infrared cameras (a first infrared camera 4, a second infrared camera 9) and corresponding six-degree-of-freedom robotic arm brackets (a first six-degree-of-freedom robotic arm bracket 5, a second six-degree-of-freedom robotic arm bracket 8), an industrial camera 6 and its third six-degree-of-freedom robotic arm bracket 7, a display 10, a keyboard 11 and an adapter 12. The operating table 2 includes an upper layer and a lower layer structure. The mouse 3, the first six-degree-of-freedom robotic arm bracket 5, the second six-degree-of-freedom robotic arm bracket 8, the third six-degree-of-freedom robotic arm bracket 7, the display 10 and the keyboard 11 are all arranged on the upper layer of the operating table 2, and the main unit 1 and the adapter 12 are arranged on the lower layer of the operating table 2.

[0053] The first infrared camera 4 is fixedly mounted on the end of the first six-degree-of-freedom robotic arm bracket 5, the second infrared camera 9 is fixedly mounted on the end of the second six-degree-of-freedom robotic arm bracket 8, and the industrial camera 6 is fixedly mounted on the end of the third six-degree-of-freedom robotic arm bracket 7. The third six-degree-of-freedom robotic arm bracket 7 is located between the first six-degree-of-freedom robotic arm bracket 5 and the second six-degree-of-freedom robotic arm bracket 8.

[0054] Both infrared cameras (the first infrared camera 4 and the second infrared camera 9) use FLIR's A70, with an infrared probe resolution of 640*480, a temperature measurement range of -20°C to 250°C, and a frame rate of 30Hz. They are used to monitor the fiber winding angles of the barrel section and the cylinder head section, respectively. The industrial camera 6 uses FLIR's BFS-U3-88S6M-C to monitor the axial and radial deformation of the cylinder during the winding process. In addition, the first infrared camera 4 and the second infrared camera 9 can identify defects such as fiber slippage and fiber overhead during the winding process. By combining the first infrared camera 4, the second infrared camera 9 and the industrial camera 6 with image processing technology, the fiber coverage rate can be calculated to determine whether the fibers are evenly distributed.

[0055] The first infrared camera 4, the second infrared camera 9 and the industrial camera 6 are respectively installed on the operating table 2 through corresponding six-degree-of-freedom robotic arm brackets (first six-degree-of-freedom robotic arm bracket 5, second six-degree-of-freedom robotic arm bracket 8, third six-degree-of-freedom robotic arm bracket 7). The six-degree-of-freedom robotic arm bracket is used to adjust the spatial position and angle of the camera to achieve accurate shooting of different winding areas.

[0056] The infrared cameras (first infrared camera 4 and second infrared camera 9) are used to identify the winding angle. The identification principle is as follows: after the fiber is impregnated with resin in the impregnation device, its temperature is higher than room temperature, usually between 30 and 60°C. During the winding process, the temperature of the currently wound fiber layer is higher than the temperature of the previously wound layer. The infrared camera can identify the position of the currently wound fiber tape by monitoring the temperature difference between the fibers. Combined with image processing software, the winding angle can be calculated and obtained in real time.

[0057] Industrial camera 6 is a high-resolution image sensor that can accurately identify tiny deformations on the surface of the test piece. It is used to identify the deformation of the gas cylinder during the winding process. Its recognition principle is as follows: before the winding begins, the industrial camera records the initial shape and size of the gas cylinder liner as a reference; during the winding process, the industrial camera 6 continuously collects gas cylinder contour images, and by comparing and analyzing the contour boundaries of the new and old images, combined with image processing software, the axial and radial deformation of the gas cylinder can be calculated.

[0058] The first six-degree-of-freedom robotic arm bracket 5, the second six-degree-of-freedom robotic arm bracket 8, and the third six-degree-of-freedom robotic arm bracket 7 are first position-calibrated before monitoring begins, and the camera is adjusted to a suitable position. After the adjustment is completed, it remains fixed to ensure that the camera is in a stable position during the entire monitoring process and is not subject to external interference, thereby improving monitoring accuracy and data reliability.

[0059] The host 1 collects video signals from the infrared cameras (the first infrared camera 4, the second infrared camera 9) and the industrial camera 6 through the adapter 12. The host 1 has built-in image processing and analysis software, which can identify the winding angle and measure the deformation of the collected images, and display the winding angle and cylinder deformation data in real time through the software interface on the display 10. Combined with the threshold judgment module, an automatic alarm function is realized, that is, an alarm is issued when the winding angle or deformation exceeds the preset allowable error range.

[0060] The display 10 is provided with a graphical operation interface for displaying the winding angle data / change curve, axial and radial deformation in real time, and supporting the backtracking and export of historical data.

[0061] like Figure 3 As shown in the figure, the software interface is divided into three functional areas, corresponding to the head section winding angle monitoring, the barrel section winding angle monitoring and the cylinder deformation monitoring. Among them, the winding angle interface layout of the head section and the barrel section is the same, mainly including the following contents:

[0062] 1) The current winding angle is displayed in real time at the top of the interface;

[0063] 2) The middle part displays video images captured by infrared cameras and industrial cameras;

[0064] 3) An adjustable rectangular area abcd is set in the infrared camera image. When the fiber tape enters this area, the system starts calculating the winding angle;

[0065] 4) The real-time winding angle output is the angle when the fiber tape is closest to the diagonal line ad;

[0066] 5) The output value and curve graph are displayed at the bottom of the interface;

[0067] 6) If the actual winding angle / deformation exceeds the preset error range, the system will mark the angle / deformation in red and annotate it on the graph;

[0068] 7) The interface also synchronously displays the number of winding layers corresponding to the current winding angle / deformation.

[0069] The present invention has a simple structure and is easy to control, and can realize real-time monitoring of the winding angle and deformation of the carbon fiber fully wrapped gas cylinder during the winding process, thereby improving the intelligence level of the winding process and the consistency of product quality.

[0070] like Figure 2 As shown, the workflow of the monitoring device of the present invention includes the following steps:

[0071] 1) Equipment startup and self-test: After the device is turned on, it will first perform a self-test, including checking the system operating status, whether the infrared camera is imaging normally (whether the temperature display is clear), and whether the camera position is reasonable. If there are any problems, debugging and position calibration are required before entering the formal monitoring process.

[0072] 2) Image Acquisition and Monitoring Startup: Two infrared cameras monitor the fiber winding status of the cylinder's head and barrel, respectively, while an industrial camera monitors the cylinder's overall contour. Video signals captured by all cameras are transmitted in real time to the host computer, where software performs image processing and data analysis.

[0073] 3) Winding angle and deformation calculation: The software system calculates the winding angle based on the infrared image, identifies the axial and radial deformation of the cylinder based on the industrial camera image, and displays the results in real time on the interface.

[0074] 4) Error Detection and Alarm Processing: The system compares the monitored winding angle and deformation with the preset design values. If any parameter exceeds the tolerance range, the system immediately issues an alarm. The operator determines whether to suspend or continue the winding operation based on the alarm information. If the monitoring result is within the tolerance range, the equipment will automatically continue monitoring until the entire cylinder winding process is completed.

[0075] 5) The device of the present invention can detect whether the fibers meet the conditions of no slippage, no hanging and uniform distribution during the actual winding process:

[0076] Based on the monitored winding angle, it can be determined whether the fiber is slipping; based on the infrared camera, it can be determined whether the fiber is hanging; combined with industrial cameras6 and image processing technology, the fiber coverage rate can be calculated to determine whether the fiber is evenly distributed;

[0077] (1) Fiber slip: When the actual fiber winding angle monitored exceeds the tolerance range, it indicates that fiber slip has occurred.

[0078] (2) Fiber hanging: During the winding process, the surface temperature of the fiber band shows a distribution characteristic: the temperature of the fiber band without hanging is the lowest, the hanging area is the second highest, and the initial temperature of the fiber band before winding is the highest. Based on this pattern, the fiber surface temperature distribution is monitored in real time using an infrared camera. If the temperature of a certain area is higher than that of the adjacent areas, it can be determined that fiber hanging has occurred in that area.

[0079] (3) Fibers are not evenly distributed: Based on this visual monitoring device, combined with digital image processing technology, the trajectory of each fiber band during the winding process is marked and the position it covers on the bottle surface is recorded. Subsequently, CAD modeling is used to reproduce the coverage area of ​​all fiber bands, calculate the output fiber coverage rate, and determine whether the wound fibers are evenly distributed.

[0080] This workflow realizes full-process monitoring and intelligent feedback of the winding process, ensuring the stability and safety of manufacturing quality.

[0081] It should be noted that the monitoring test piece of the present invention includes but is not limited to gas cylinders, and can monitor any rotating structural part prepared using a wet winding process.

[0082] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A vision-based monitoring device for winding defects and gas cylinder deformation, characterized in that: include: A data acquisition and processing mechanism, an operating table (2), and a first monitoring mechanism, a second monitoring mechanism, and a third monitoring mechanism fixedly mounted on the operating table (2); the first monitoring mechanism, the second monitoring mechanism, and the third monitoring mechanism are all electrically connected to the data acquisition and processing mechanism; the first monitoring mechanism is used to monitor the fiber winding angle data of the barrel section and transmit the data to the data acquisition and processing mechanism; the second monitoring mechanism is used to monitor the fiber winding angle data of the gas cylinder head section and transmit the data to the data acquisition and processing mechanism; and the first monitoring mechanism and the second monitoring mechanism are used to identify defects such as fiber slippage and fiber overhead during the winding process; the third monitoring mechanism is used to monitor the axial and radial deformation data of the gas cylinder during the winding process and transmit the data to the data acquisition and processing mechanism; the data acquisition and processing mechanism has image processing technology, and calculates the fiber coverage rate through the first monitoring mechanism, the second monitoring mechanism, and the third monitoring mechanism in combination with the image processing technology to determine whether the fibers are evenly distributed.

2. The vision-based winding defect and cylinder deformation monitoring device according to claim 1 is characterized in that: The first monitoring mechanism comprises a first infrared camera (4) and a first six-degree-of-freedom mechanical arm support (5), wherein the first six-degree-of-freedom mechanical arm support (5) is fixedly mounted on the operating table (2), and the first infrared camera (4) is fixedly mounted at the end of the first six-degree-of-freedom mechanical arm support (5).

3. The vision-based winding defect and cylinder deformation monitoring device according to claim 2 is characterized in that: The infrared probe resolution of the first infrared camera (4) is 640*480, the temperature measurement range is -20°C to 250°C, and the frame rate is 30Hz.

4. The vision-based winding defect and cylinder deformation monitoring device according to claim 1 is characterized in that: The second monitoring mechanism comprises a second six-degree-of-freedom mechanical arm support (8) and a second infrared camera (9); the second six-degree-of-freedom mechanical arm support (8) is fixedly mounted on the operating table (2); and the second infrared camera (9) is fixedly mounted at the end of the second six-degree-of-freedom mechanical arm support (8).

5. The vision-based winding defect and gas cylinder deformation monitoring device according to claim 4 is characterized in that: The infrared probe resolution of the second infrared camera (9) is 640*480, the temperature measurement range is -20°C to 250°C, and the frame rate is 30Hz.

6. The vision-based winding defect and gas cylinder deformation monitoring device according to claim 1 is characterized in that: The third monitoring mechanism is located between the first monitoring mechanism and the second monitoring mechanism, and comprises an industrial camera (6) and a third six-degree-of-freedom mechanical arm bracket (7); the third six-degree-of-freedom mechanical arm bracket (7) is fixedly mounted on the operating table (2); and the industrial camera (6) is fixedly mounted at the end of the third six-degree-of-freedom mechanical arm bracket (7).

7. The vision-based winding defect and gas cylinder deformation monitoring device according to claim 6 is characterized in that: The industrial camera (6) adopts a high-resolution image sensor.

8. The vision-based winding defect and cylinder deformation monitoring device according to claim 1 is characterized in that: The data acquisition and processing mechanism comprises a host (1), a mouse (3), a display (10), a keyboard (11) and an adapter (12); the operating table (2) comprises an upper layer and a lower layer structure; the mouse (3), the display (10) and the keyboard (11) are all arranged on the upper layer of the operating table (2); the host (1) and the adapter (12) are arranged on the lower layer of the operating table (2); the mouse (3), the display (10), the keyboard (11) and the adapter (12) are all connected to the host (1); the host (1) is electrically connected to a first infrared camera (4) of a first monitoring mechanism, a second infrared camera (9) of a second monitoring mechanism and an industrial camera (6) of a third monitoring mechanism; the host (1) has built-in image processing and analysis software and a threshold judgment module; The host (1) collects video signals from the first infrared camera (4), the second infrared camera (9) and the industrial camera (6) through the adapter (12), performs winding angle recognition and deformation measurement on the collected images, and displays the winding angle and cylinder deformation data in real time through a software interface on the display (10). In combination with a threshold judgment module, an alarm is issued when the winding angle or deformation exceeds a preset allowable error range.

9. The vision-based winding defect and gas cylinder deformation monitoring device according to claim 8 is characterized in that: The display (10) is provided with a graphical operating interface for real-time display of winding angle data / change curve, axial and radial deformation, and supports historical data backtracking and export; The graphical operation interface is divided into three functional areas, corresponding to the head section winding angle monitoring, the barrel section winding angle monitoring and the cylinder deformation monitoring. The winding angle interface layout of the head section and the barrel section is the same, including: The current winding angle is displayed in real time at the top of the interface; The center of the interface displays video images captured by infrared cameras and industrial cameras. An adjustable rectangular area abcd is provided in the infrared camera image. When the fiber tape enters this area, the system begins calculating the winding angle. The output real-time winding angle is the angle when the fiber tape is closest to the diagonal line ad. The output value and curve graph are displayed at the bottom of the interface. If the actual winding angle / deformation exceeds the preset error range, the system will mark the angle / deformation in red and annotate it in the curve graph. The interface also synchronously displays the number of winding layers corresponding to the current winding angle / deformation.

10. A monitoring method for a winding defect and gas cylinder deformation monitoring device based on vision according to any one of claims 1 to 9, characterized in that: The steps include: S1. Equipment startup and self-test: After the device is turned on, it will first perform a self-test, including checking the system operating status, whether the infrared camera is imaging normally, whether the temperature display is clear, and whether the camera position is reasonable. If there are any problems, the formal monitoring process can only be started after debugging and position calibration. S2. Image acquisition and monitoring start: Two infrared cameras monitor the fiber winding status of the cylinder head section and the cylinder body section respectively, and the industrial camera (6) is responsible for monitoring the overall contour changes of the cylinder; the video signals collected by all cameras are transmitted to the host (1) in real time, and the image processing and data analysis software performs image processing and data analysis; S3. Calculation of winding angle and deformation: The software system in the host (1) calculates the winding angle based on the infrared image, identifies the axial and radial deformation of the gas cylinder based on the industrial camera image, and displays the result in real time on the graphical operation interface of the display (10); S4. Error judgment and alarm processing: The monitored winding angle and deformation are compared with the preset design values. If any parameter exceeds the tolerance range, an alarm prompt will be immediately issued. The operator will determine whether to suspend or continue the winding operation based on the alarm information. If the monitoring result is within the tolerance range, the device will automatically continue monitoring until the entire cylinder winding process is completed. S5. Based on the monitored winding angle, it can be determined whether the fiber is slipping; based on the infrared camera, it can be determined whether the fiber is hanging; combined with the industrial camera (6) and image processing technology, the fiber coverage can be calculated to determine whether the fiber is evenly distributed; S51, fiber slip: When the monitored actual fiber winding angle exceeds the tolerance range, it indicates that fiber slip has occurred; S52. Fiber Hanging: During the winding process, the surface temperature of the fiber tape exhibits a distribution characteristic: the unwound area has the lowest temperature, followed by the wound area, and the initial temperature of the fiber tape before winding is the highest. Based on this pattern, an infrared camera is used to monitor the fiber surface temperature distribution in real time. If a certain area is found to have a higher temperature than adjacent areas, it can be determined that fiber hanging has occurred there. S53: Fibers are not evenly distributed: Using a monitoring device and digital image processing technology, the trajectory of each fiber strip during the winding process is marked and the position it covers on the surface of the gas cylinder is recorded; Subsequently, CAD modeling is used to reproduce the coverage area of ​​all fiber bands, calculate the output fiber coverage rate, and determine whether the wound fibers are evenly distributed.

Images