Factory electrical control cabinet wiring correctness detection method and device

Abstract

The invention discloses a factory electrical control cabinet wiring correctness detection method and device, and belongs to the technical field of factory electrical control cabinet wiring. Comprising the following steps: S1, according to an electrical control cabinet incoming wire schematic diagram, numbering the types of wiring terminals of an incoming wire cabinet to obtain a first criterion; s2, carrying out line sequence numbering on the incoming line sequence from bottom to top to obtain a fixed line sequence value, and taking the correct line sequence as a second comparison criterion; and S3, coding according to the signal acquired by the incoming line terminal signal acquisition device to obtain a third criterion. The type, the position and the connection state of the wiring terminal are automatically identified through an algorithm, it is ensured that the wiring terminal is consistent with a standard template, whether the wiring terminal is missing or not is detected, it is ensured that all the wiring terminals are correctly installed, the wiring detection process is monitored in real time, and the detection result and the detection state are displayed; when a wiring error or a quality problem is detected, the system can automatically give an alarm and record abnormal information.

Description

Technical Field

[0001] This invention belongs to the field of wiring technology for factory electrical control cabinets, specifically referring to a method and device for detecting wiring errors in factory electrical control cabinets. Background Technology

[0002] Electrical control cabinets are widely used in all aspects of the power system, from power plants to substations, distribution networks, and various industrial power consumption scenarios. They act as the "nerve center" of power transmission and distribution. The correctness of the incoming line sequence directly affects whether power can flow smoothly and stably into the control cabinet, thus impacting the power supply to subsequent equipment. Incorrect wiring sequence, such as reversed three-phase wiring, can lead to serious power accidents, such as three-phase motor reversal causing equipment damage, production line shutdowns, or even large-scale power outages, disrupting residents' lives and the normal order of social production. Through precise incoming line sequence detection and fault diagnosis, these potential hazards can be identified and corrected in advance, ensuring the unobstructed flow of the power system's "blood vessels" and a continuous and stable supply of electricity to society.

[0003] In modern industrial automation, numerous sophisticated and expensive pieces of equipment rely on electrical control cabinets for stable and precise power support. The continuous operation of production lines demands extremely high reliability of the power supply; any brief power outage or failure can trigger a chain reaction, leading to the scrapping of products being processed, interruption of the production process, and requiring significant time and cost for debugging and calibration before restarting the production line. This is especially true for hub-type electrical control cabinets, which have a large number of incoming wires, making it easy for workers to make mistakes during installation, potentially causing electrical accidents. Traditional wiring detection methods rely primarily on manual verification, which is not only inefficient but also prone to omissions and misjudgments. The difficulty and error rate of manual inspection increase significantly, particularly when dealing with complex, large electrical control cabinets. While some wiring detection equipment exists on the market, it suffers from low accuracy, complex operation, and limited functionality, failing to meet the demands of rapid and accurate testing of modern electrical control cabinets. Therefore, a new type of wiring correction and error detection device for hub-type electrical control cabinets is urgently needed to improve detection efficiency and accuracy while reducing labor costs and errors. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, the present invention provides a method and device for detecting wiring errors in factory electrical control cabinets, which effectively solves the problems currently on the market.

[0005] The technical solution adopted by this invention is as follows: This invention proposes a method for detecting wiring errors in factory electrical control cabinets, including:

[0006] S1. Based on the incoming line schematic diagram of the electrical control cabinet, the terminal types of the incoming line cabinet are numbered to obtain the first criterion;

[0007] S2. Number the incoming wires from bottom to top to obtain a fixed wire sequence value, and use this correct wire sequence as the second comparison criterion;

[0008] S3. Encode the signals collected by the incoming terminal signal collector to obtain the third criterion;

[0009] S4. By setting up a high-definition, high-precision camera to capture images, obtain the dynamic detection value sequence of worker wiring, automatically identify the type and position status of the wiring terminals through an algorithm, and compare the detected terminal type with the first criterion;

[0010] S5. After power is applied, the signal collected by the incoming terminal signal collector is compared with the third criterion.

[0011] S6. Through the algorithm, set the priority of the first criterion to be greater than that of the second criterion, which is greater than that of the third criterion;

[0012] S7. Through the algorithm, the system can automatically identify the type, serial number and connection status of the wiring terminals in real time. When any of the statuses or signals are abnormal, the corresponding reminder information will be output.

[0013] S8. Real-time monitoring of the wiring detection process, displaying detection results and status; when a wiring error or quality problem is detected, the system will automatically alarm and record abnormal information.

[0014] Furthermore, in step S4, if the terminal type is the same as the first criterion, the terminal type is determined to be correct. Then, the detected wiring sequence is compared with the second criterion. If they are the same, the wiring sequence is determined to be correct.

[0015] Furthermore, in step S5, if the signal collected by the incoming terminal signal collector is the same as the third criterion, it indicates that the wiring is correct and the wire connection is good, and the signal transmission is correct. If there is an error, the system generates a first reminder message based on the terminal type abnormality status; if there is an error, the system generates a second reminder message based on the incoming line sequence abnormality status; and generates a third reminder message based on the incoming line signal abnormality status.

[0016] Furthermore, the system also has data recording and analysis functions, recording the results of each test, including information such as wiring correctness, completeness, and quality; analyzing the test data to generate statistical reports, helping to optimize production processes and improve product quality.

[0017] Furthermore, a wiring error detection device for a factory electrical control cabinet includes: a high-precision industrial camera, a detection module, an industrial computer, a display module, a detection station, a conveying mechanism, an operation panel, and a storage module.

[0018] Furthermore, the high-precision industrial camera consists of two units: one is a top-view camera that inspects the wiring terminals laid flat in the control cabinet from above the inspection station, and the other is a side-view camera that inspects the wiring terminals inserted vertically into the control cabinet from the left side of the inspection station.

[0019] Furthermore, the high-precision industrial camera performs shooting and detection according to the preset shooting process in the industrial control computer. The captured images are transmitted to the industrial control computer via network cable and judged by recognition algorithm.

[0020] Furthermore, the industrial control computer controls the conveying mechanism to transport the product to be tested to the testing station.

[0021] Furthermore, to facilitate operation by on-site workers, several inspection modes are preset in the operation interface, such as side view inspection and top view inspection, so that on-site workers can quickly complete the inspection by following the inspection process.

[0022] The beneficial effects achieved by the present invention using the above structure are as follows:

[0023] (1) The system automatically identifies the type, location and connection status of the terminal blocks through an algorithm to ensure that the terminal blocks are consistent with the standard template, detects whether the terminal blocks are missing, ensures that all terminal blocks are correctly installed, monitors the wiring detection process in real time, and displays the detection results and status. When wiring errors or quality problems are detected, the system will automatically alarm and record abnormal information.

[0024] (2) Real-time detection of electrical signals in the cabinet wiring. When wiring errors or quality problems are detected, the system will automatically alarm and disconnect the incoming line from other components inside the electrical control cabinet to protect the internal modules and record abnormal information. Record the results of each test, including wiring correctness, integrity, quality and other information; analyze the test data and generate statistical reports to help optimize the production process and improve product quality.

[0025] (3) Through the above settings, the implementation of the wiring detection technology for factory electrical control cabinets has greatly improved the detection efficiency and accuracy of wiring in modern factory hub electrical cabinets, reduced labor costs and error rates, greatly adapted to the growing demand of industrial production and the need for complex and changing modern electrical circuits, and solved the urgent needs of enterprises. Attached Figure Description

[0026] Figure 1 This is a system composition diagram of a wiring error detection device for a factory electrical control cabinet proposed in this invention;

[0027] Figure 2 This is a schematic diagram of a method and device for detecting wiring errors in a factory electrical control cabinet, as proposed in this invention.

[0028] Figure 3 This is a top view of the control cabinet;

[0029] Figure 4 This is a schematic diagram of side-view detection;

[0030] Figure 5 This is the actual wiring diagram;

[0031] Figure 6 Here is a flowchart of the system's working algorithm;

[0032] Figure 7 A functional diagram of the incoming terminals and detection module of the hub electrical cabinet;

[0033] Figure 8 This is a schematic diagram of the signal detection function of the incoming terminal of the hub electrical cabinet.

[0034] The components include: 1. High-precision industrial camera; 2. Detection module; 3. Industrial control computer; 4. Display module; 5. Detection station; 6. Conveying mechanism; 7. Operation panel; and 8. Storage module.

[0035] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. Detailed Implementation

[0036] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0037] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0038] like Figures 1-8 As shown, this invention proposes a method for detecting wiring errors in factory electrical control cabinets, including:

[0039] S1. Based on the incoming line schematic diagram of the electrical control cabinet, the terminal types of the incoming line cabinet are numbered to obtain the first criterion;

[0040] S2. Number the incoming wires from bottom to top to obtain a fixed wire sequence value, and use this correct wire sequence as the second comparison criterion;

[0041] S3. Encode the signals collected by the incoming terminal signal collector to obtain the third criterion;

[0042] S4. By setting up a high-definition, high-precision camera to capture images, obtain the dynamic detection value sequence of worker wiring, automatically identify the type and position status of the wiring terminals through an algorithm, and compare the detected terminal type with the first criterion;

[0043] S5. After power is applied, the signal collected by the incoming terminal signal collector is compared with the third criterion.

[0044] S6. Through the algorithm, set the priority of the first criterion to be greater than that of the second criterion, which is greater than that of the third criterion;

[0045] S7. Through the algorithm, the system can automatically identify the type, serial number and connection status of the wiring terminals in real time. When any of the statuses or signals are abnormal, the corresponding reminder information will be output.

[0046] S8. Real-time monitoring of the wiring detection process, displaying detection results and status; when a wiring error or quality problem is detected, the system will automatically alarm and record abnormal information.

[0047] In step S4, if the terminal type is the same as the first criterion, the terminal type is determined to be correct. Then, the detected wire sequence is compared with the second criterion. If they are the same, the wire sequence is determined to be correct.

[0048] In step S5, if the signal collected by the incoming terminal signal collector is the same as the third criterion, it indicates that the wiring is correct and the wire connection is good, and the signal transmission is correct. If there is an error, the system generates a first reminder message based on the terminal type abnormality status; generates a second reminder message based on the incoming line sequence abnormality status; and generates a third reminder message based on the incoming line signal abnormality status.

[0049] The system also has data recording and analysis functions, recording the results of each test, including information such as wiring correctness, completeness, and quality; analyzing the test data to generate statistical reports, helping to optimize production processes and improve product quality.

[0050] A device for detecting wiring errors in a factory electrical control cabinet includes: a high-precision industrial camera 1, a detection module 2, an industrial computer 3, a display module 4, a detection station 5, a conveying mechanism 6, an operation panel 7, and a storage module 8.

[0051] Two high-precision industrial cameras are used: one is a top-view camera that inspects the wiring terminals laid flat in the control cabinet from above the inspection station 5 vertically downwards, and the other is a side-view camera that inspects the wiring terminals inserted vertically into the control cabinet from the left side of the inspection station 5.

[0052] The high-precision industrial camera 1 performs shooting and detection according to the preset shooting process in the industrial control computer 3. The captured images are transmitted to the industrial control computer 3 via network cable and judged by the recognition algorithm.

[0053] The industrial control computer 3 controls the conveying mechanism 6 to transport the product to be tested to the testing station 5.

[0054] To facilitate operation by on-site workers, several inspection modes are preset in the operation interface, such as side view inspection and top view inspection. On-site workers can quickly complete the inspection by following the inspection process.

[0055] Top-down inspection primarily examines the wiring terminals laid flat inside the control cabinet, such as... Figure 3 The black area inside is shown. Special attention should be paid to ensuring that the part of the sleeve with text is facing upwards when wiring, and that the camera is positioned overhead to check the position of the grooves to determine if it is inserted correctly. When wiring, the worker should first connect the flat conduit with the text side facing upwards, press the overhead inspection button on the control panel, and then take a picture for inspection.

[0056] Side-view inspection primarily checks the wiring terminals perpendicular to the control cabinet. Because simultaneously inspecting all vertical wires is extremely difficult, workers must connect the wires sequentially from farthest to nearest. Figure 2 The side-view camera shown is located on the left side of the inspection station. When wiring, the worker must first connect the rightmost wire harness and point the sleeve towards the left-side side-view camera. Figure 4 As shown, the worker must first connect the red wire harness, with the text on the sleeve tube facing left, and press the side-view inspection button on the operation panel to perform the first side-view inspection. After the inspection is completed, continue to inspect the yellow, green, blue, and purple wire harnesses according to the above procedure. The actual wiring diagram is shown below. Figure 5 As shown, if the side-view inspection station is on the left, then the wiring sequence is 1-7.

[0057] The worker first connects the laid-out wire harness, with the text portion of the sleeve tube facing upwards. After wiring, the control cabinet is placed at the conveyor belt loading position, and the overhead inspection button is pressed. The conveyor belt will then transport the control cabinet to the inspection station. To prevent deviation during movement, a fixing buckle is installed on the conveyor belt. The worker only needs to place the product to be tested into the buckle to determine its position. After arriving at the inspection station, the overhead camera begins inspection. After inspection, the worker removes the control cabinet and performs vertical wiring.

[0058] The worker first connects the wiring harness that is far from the side-view camera and aligns the sleeve tube with the side-view camera. After the wiring is completed, the worker presses the side-view test button. After arriving at the test station, the worker tests the camera. The worker then connects and tests the wiring in sequence from far to near until all wiring is completed.

[0059] If any wire harness is found to be improperly connected during the testing process, the control panel will sound an alarm and mark the location of the problem on the interface. After correction, the test will be repeated. If no errors are found, the test is complete. After all tests are completed, a product test report will be generated.

[0060] After the above process is completed, signal detection begins. All electrical control incoming lines will pass through the detection module for signal transfer. Simultaneously, the detection module identifies the incoming signals. After power is applied, the signal collected by the signal detection module is compared with a third criterion. If they match, it indicates correct wiring and good wire connection, and correct signal transmission. If there is an error, the system generates a first alert message based on the terminal type and abnormal status, which is sent out through the display module. This is the overall workflow of the invention. This step can be repeated for subsequent uses; the actual operation is very simple and easy to implement.

[0061] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0062] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

[0063] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A method for detecting wiring errors in a factory electrical control cabinet, characterized in that: include: S1. Based on the incoming line schematic diagram of the electrical control cabinet, the terminal types of the incoming line cabinet are numbered to obtain the first criterion; S2. Number the incoming wires from bottom to top to obtain a fixed wire sequence value, and use this correct wire sequence as the second comparison criterion; S3. Encode the signals collected by the incoming terminal signal collector to obtain the third criterion; S4. By setting up a high-definition, high-precision camera to capture images, obtain the dynamic detection value sequence of worker wiring, automatically identify the type and position status of the wiring terminals through an algorithm, and compare the detected terminal type with the first criterion; S5. After power is applied, the signal collected by the incoming terminal signal collector is compared with the third criterion. S6. Through the algorithm, set the priority of the first criterion to be greater than that of the second criterion, which is greater than that of the third criterion; S7. Through the algorithm, the system can automatically identify the type, serial number and connection status of the wiring terminals in real time. When any of the statuses or signals are abnormal, the corresponding reminder information will be output. S8. Real-time monitoring of the wiring detection process, displaying detection results and status; when a wiring error or quality problem is detected, the system will automatically alarm and record abnormal information.

2. The method for detecting wiring errors in a factory electrical control cabinet according to claim 1, characterized in that: In step S4, if the terminal type is the same as the first criterion, the terminal type is determined to be correct. Then, the detected wiring sequence is compared with the second criterion. If they are the same, the wiring sequence is determined to be correct.

3. The method for detecting wiring errors in a factory electrical control cabinet according to claim 2, characterized in that: In step S5, if the signal collected by the incoming terminal signal collector is the same as the third criterion, it indicates that the wiring is correct and the wire connection is good, and the signal transmission is correct. If there is an error, the system generates a first reminder message based on the terminal type abnormality status. A second alert message is generated based on the abnormal status of the incoming line sequence. A third alert message is generated based on the abnormal status of the incoming line signal.

4. The method for detecting wiring errors in a factory electrical control cabinet according to claim 3, characterized in that: The system also has data recording and analysis functions, recording the results of each test, including information such as wiring correctness, completeness, and quality; analyzing the test data to generate statistical reports, helping to optimize production processes and improve product quality.

5. A device for detecting wiring errors in a factory electrical control cabinet, characterized in that: It includes a high-precision industrial camera (1), a detection module (2), an industrial computer (3), a display module (4), a detection station (5), a conveying mechanism (6), an operation panel (7), and a storage module (8).

6. The method and apparatus for detecting wiring errors in a factory electrical control cabinet according to claim 5, characterized in that: The high-precision industrial camera (1) consists of two units: one is a top-view camera that detects the wiring terminals laid flat in the control cabinet from above the inspection station (5) vertically downwards, and the other is a side-view camera that detects the wiring terminals inserted vertically into the control cabinet from the left side of the inspection station (5).

7. The method and apparatus for detecting wiring errors in a factory electrical control cabinet according to claim 6, characterized in that: The high-precision industrial camera (1) performs shooting detection according to the preset shooting process in the industrial control computer (3). The shooting image is transmitted to the industrial control computer (3) via network cable and judged by the recognition algorithm.

8. The method and apparatus for detecting wiring errors in a factory electrical control cabinet according to claim 7, characterized in that: The industrial control computer (3) controls the conveying mechanism (6) to transport the product to be tested to the testing station (5).

9. The method and apparatus for detecting wiring errors in a factory electrical control cabinet according to claim 8, characterized in that: To facilitate operation by on-site workers, several inspection modes are preset in the operation interface, such as side view inspection and top view inspection. On-site workers can quickly complete the inspection by following the inspection process.

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