Method and system for automatically identifying position of ground wire in wrapping process

Abstract

The invention relates to a method and system for automatically identifying the position of a ground wire in the wrapping process, and the method comprises the following steps: enabling the ground wire to be wrapped at a preset position of a wire core, and collecting a ground wire image in real time through an image collection and processing device; processing the acquired image, identifying the position of the ground wire and calculating the deviation angle of the ground wire relative to the central axis of the wire rod; the calculated deviation angle is compared with a preset qualified angle threshold value, and whether the ground wire is qualified or not is judged; and if it is judged that the ground wire is unqualified, the position of the ground wire is adjusted through a dragging bag adjusting mold according to the deviation direction and amplitude, so that the position of the ground wire is restored to a qualified range. According to the invention, detection and correction of the position of the ground wire are realized, and the consistency of production efficiency and product quality is improved.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, and more specifically, to a method and system for automatically identifying the position of the ground wire during the wrapping process. Background Technology

[0002] In the cable manufacturing industry, especially in the ground wire wrapping process, the wrapping position of the ground wire has a significant impact on the electrical performance, mechanical strength, and overall structural stability of the product. In traditional wrapping processes, the centering and offset angle of the ground wire need to be strictly controlled. Typically, the offset angle of the ground wire wrapping is required to not exceed a set critical value (e.g., 20°) to ensure that the product meets relevant standards and drawing requirements.

[0003] Currently, the industry still relies on manual or semi-automated methods to detect the ground wire position. For example, this involves stopping the machine, cutting the wire, cutting the cross-section, and then manually judging the position using a magnifying glass or measuring instruments. Once an deviation is found to be unacceptable, the machine must be stopped and the longitudinal packaging fixture or mold adjusted manually to correct the ground wire position. This method is not only inefficient but also prone to production interruptions, increased product defect rates, and increased labor costs.

[0004] Furthermore, traditional detection methods struggle to achieve online, real-time, and high-precision monitoring, especially during continuous production processes, as they cannot provide immediate feedback and automatic adjustments, impacting production efficiency and product quality consistency.

[0005] Therefore, there is an urgent need for an automated method and system that can automatically detect the ground wire position, calculate the offset angle, judge the deviation, and automatically adjust it during the cable wrapping process, so as to overcome the shortcomings of the existing technology, improve the level of production automation, reduce manual intervention, and improve product qualification rate and production efficiency. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a method and system for automatically identifying the position of the ground wire during the wrapping process, in view of the above-mentioned defects of the prior art.

[0007] On the one hand, the technical solution adopted by the present invention to solve its technical problem is: a method for automatically identifying the position of the ground wire during the wrapping process, which includes the following steps: S10: After wrapping one or two ground wires around the predetermined position of the wire core, the ground wire image is acquired in real time through an image acquisition and image processing device. S20: Perform image processing on the acquired ground wire image, identify the position information of the ground wire, and calculate the offset angle of the ground wire based on the geometric relationship between the ground wire and the central axis of the wire. S30: Compare the calculated offset angle with the preset qualified angle threshold to determine whether the ground wire is within the qualified range; When the deflection angle of the ground wire is determined to be unqualified, the control of the trolley adjustment mold is adjusted according to the direction and magnitude of the ground wire offset to correct the position of the ground wire and restore it to the qualified range.

[0008] In the system described in this invention, the ground wire offset angle is calculated in step S20 using the following formula: A = sinα(0.5 × D1 + 0.5 × D2 + 0.03) Where A is the critical value; α is the maximum acceptable offset angle; D1 is the core wire height; D2 is the ground wire diameter; and 0.03 is the gap compensation constant.

[0009] The system of the present invention includes an image acquisition and image processing device comprising two industrial cameras that illuminate the wire, the two industrial cameras being symmetrically arranged on both sides of the wire.

[0010] In the system described in this invention, the adjustment direction of the bag adjusting mold includes fine adjustment in the up-down direction and fine adjustment in the axial rotation direction; when the image acquisition and image processing device detects that the ground wire adjustment has failed or has reached the preset upper limit of adjustment times, it generates an alarm signal to prompt manual intervention or shutdown.

[0011] In the system described in this invention, the adjustment action of the bag adjusting mold includes one of the following situations: (a) When both ground lines are tilted upwards, adjust the center position of the sling mold upwards; (b) When both ground lines are simultaneously tilted downwards, adjust the center position of the sling adjustment mold downwards; (c) When one ground line is slightly higher and the other ground line is slightly lower, the trolley mold rotates accordingly, adjusting the angle by 15° each time; (d) When one ground wire is normal and the other ground wire is offset, the trolley mold rotates accordingly, adjusting the angle by 5° each time.

[0012] In the system described in this invention, the mold is adjusted by a servo motor, the ground wire is adjusted up or down by 2mm, and the maximum angle adjustment range of the ground wire is 120°.

[0013] The system of the present invention includes an image processing procedure comprising image grayscale conversion, image edge detection, binarization, and contour extraction to improve the accuracy of ground line location identification.

[0014] On the other hand, the present invention also provides a system for automatically identifying the position of the ground wire during the wrapping process, using any of the methods described above for automatically identifying the position of the ground wire during the wrapping process, wherein the system includes: An image acquisition and processing device is installed on both sides of the cable to acquire ground wire images; The image processing module is used to process the acquired images and identify the location of the ground wire; Angle calculation module, used to calculate the ground wire offset angle according to a preset formula; The offset determination module is used to compare the calculated offset angle with a preset threshold. The towing adjustment mold is used to control the adjustment action of the mold based on the judgment result; The main control module is used to coordinate the operation of the above modules and control the servo motor to achieve mold adjustment; wherein, the image acquisition and image processing device, the angle calculation module, the offset judgment module, and the drag bag adjustment mold are all electrically connected to and controlled by the main control module.

[0015] The system of the present invention further includes an alarm module electrically connected to the main control module, which is used to issue an alarm signal when the ground wire adjustment fails or when the preset adjustment number limit is reached.

[0016] The system described in this invention further includes a human-machine interface electrically connected to the main control module, used to display the operating status and operation control of each module in the system.

[0017] The beneficial effects of this invention are as follows: The method and system for automatically identifying the ground wire position during the wrapping process are ingeniously designed. After the ground wire is wrapped around the core at a predetermined position, an image acquisition and processing device is used to acquire the ground wire image in real time. Combined with image processing technology, the position information and offset angle of the ground wire are identified. The calculated results are compared with a preset acceptable angle threshold, thereby achieving automatic detection and deviation judgment of the ground wire position. If the detected ground wire offset angle is unacceptable, the angle can be adjusted by adjusting the wrapping mold to restore the ground wire position to the acceptable range. Compared with the prior art, this invention achieves automatic detection and automatic correction of the ground wire position, significantly improving production efficiency and product quality consistency, reducing manual intervention and downtime for adjustments, and lowering production costs and defect rates. It has significant technological advancements and practical value. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the present invention will be further described below in conjunction with the accompanying drawings and embodiments. The drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort: Figure 1 This is a flowchart illustrating the structure for automatically identifying the ground wire position during the wrapping process according to Embodiment 1 of the present invention. Figure 2This is a flowchart illustrating an automatic identification process for the ground wire position during the wrapping process, as described in Embodiment 1 of the present invention. Figure 3 This is a cross-sectional view of the wire in Embodiment 1 of the present invention. Detailed Implementation

[0019] The terms "first," "second," "third," and "fourth," etc., used in the specification, claims, and accompanying drawings of this invention are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or apparatuses.

[0020] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0021] "Multiple" refers to two or more. "And / or" describes the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, or B alone. The character " / " generally indicates that the preceding and following related objects have an "or" relationship.

[0022] Furthermore, the terms indicating orientation, such as "up, down, front, back, left, right, upper end, lower end, longitudinal," etc., are all based on the posture and position of the device or equipment described in this solution during normal use.

[0023] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, a clear and complete description will be provided below in conjunction with the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0024] Example 1: A preferred embodiment of the present invention provides a method for automatically identifying the ground wire position during the wrapping process, such as... Figure 1-3 As shown, it includes the following steps: S10: Pass the wire core and ground wire through the drag pack adjustment mold 10 for positioning the wire core and ground wire. Then, the wire core and ground wire are wrapped and integrated into a wire using the wrapping mold 20; the wrapping mold 20 can be any common wrapping structure in this field; After one or two ground wires are wrapped around the predetermined position of the wire core, the ground wire image is acquired in real time by the image acquisition and image processing device 30. The image acquisition and image processing device 30 includes two industrial cameras 31 that illuminate the wire, and the two industrial cameras 31 are symmetrically arranged on both sides of the wire.

[0025] Two industrial cameras are symmetrically positioned on both sides of the wire, enabling independent image acquisition of the two ground wires from both left and right directions. This allows for synchronous monitoring of the wrapping status of the two ground wires, ensuring that the position and angle of each ground wire meet the process requirements.

[0026] Two cameras simultaneously acquire images, enabling parallel processing of image data, shortening the single detection cycle, and improving overall detection efficiency. At the same time, the complementarity of the left and right image information makes the automated system more efficient and reliable in judging the ground wire status, meeting the real-time detection needs of high-speed production lines.

[0027] Furthermore, a first positioning component 40 for preliminary positioning of the wire is provided between the image acquisition and image processing device 30 and the wrapping mold 20. The first positioning component 40 includes upper and lower positioning blocks, and the upper and lower positioning blocks are provided with positioning channels for the wire to pass through; the size of the positioning channel is adapted to the size of the wire.

[0028] S20: Perform image processing on the acquired ground wire image, identify the position information of the ground wire, and calculate the offset angle of the ground wire based on the geometric relationship between the ground wire and the central axis of the wire. like Figure 3 As shown, in step S20, the offset angle of the ground wire is calculated using the following formula: A = sinα(0.5 × D1 + 0.5 × D2 + 0.03) Where A is the critical value; α is the maximum acceptable offset angle (set as required, shown as 20° on the drawing); D1 is the core wire height; D2 is the ground wire diameter; and 0.03 is the gap compensation constant (aluminum foil thickness, etc.). The distance B measured between the center line of the ground wire and the center line of the conductor is compared with A. If the distance B is greater than A, an adjustment action is triggered. To avoid over-adjustment, the monitoring frequency, time interval, and number of adjustments can be set. When the automatic adjustment attempts reach the set number, the system will stop and trigger an alarm, prompting manual adjustment.

[0029] S30: Compare the calculated offset angle with the preset qualified angle threshold to determine whether the ground wire is within the qualified range; When the deflection angle of the ground wire is determined to be unqualified, the control of the trolley adjustment mold is adjusted according to the direction and magnitude of the ground wire offset to correct the position of the ground wire and restore it to the qualified range.

[0030] By comparing the calculated offset angle with a preset acceptable angle threshold, this method can determine in real time whether the ground wire is within the acceptable range. Once the offset angle exceeds the threshold, a correction mechanism is immediately triggered without manual intervention or machine shutdown, significantly improving production efficiency and automation. The offset angle calculated based on the algorithm is more accurate and consistent than manual visual inspection or traditional measuring instruments. This step ensures that the offset angle of the ground wire wrapping is always within the acceptable range, thereby improving product consistency and the stability of electrical and mechanical performance.

[0031] Furthermore, the image acquisition and image processing device 30 has a second positioning component 50 for secondary positioning of the wire on the side opposite to the first positioning component 40; the second positioning component 50 has the same structure as the first positioning component 40.

[0032] Furthermore, after the second positioning component 50 performs secondary positioning on the wire, it is then wound up by the take-up die 60. The take-up die 60 is a common take-up structure in this field.

[0033] In this embodiment, the bag adjustment mold can be a prior art bag mold, and its adjustment direction includes fine adjustment in the up and down direction and fine adjustment in the axial rotation direction; when the image acquisition and image processing device detects that the ground wire adjustment has failed or has reached the preset upper limit of adjustment times, it will generate an alarm signal to prompt manual intervention or shutdown.

[0034] Furthermore, the adjustment action of the bag adjusting mold includes one of the following situations: (a) When both ground lines are tilted upwards, adjust the center position of the sling mold upwards; (b) When both ground lines are simultaneously tilted downwards, adjust the center position of the sling adjustment mold downwards; (c) When one ground line is slightly higher and the other ground line is slightly lower, the trolley mold rotates accordingly, with each adjustment angle being 15° as one unit; (d) When one ground wire is normal and the other ground wire is offset, the trolley mold rotates accordingly, with each adjustment angle being 5° as a unit, and no more than 3 rotations.

[0035] Specifically, in this embodiment, the simultaneous upward and downward offset is adjusted first, and then the unilateral offset is adjusted.

[0036] Furthermore, the adjustment of the mold is achieved through a servo motor. As a commonly used drive component in industrial automation, the servo motor is easy to integrate with PLC and industrial control systems, and also provides a good hardware foundation for subsequent functional expansion (such as more complex AI algorithm control, remote monitoring, etc.). It not only improves the accuracy, efficiency and stability of ground wire correction, but also enhances the automation, intelligence and scalability of the system, and is a key technical support for realizing the intelligent upgrade of cable wrapping process.

[0037] In this embodiment, the ground wire can be adjusted upwards or downwards within a range of 2mm, which can cover the common offset error of the ground wire during the wrapping process, without affecting the wire structure or causing excessive wear on the mold due to excessive adjustment range, thus achieving a good balance between practicality and equipment safety. The maximum angle adjustment range of the ground wire is 120°, which can meet the correction requirements of large angle offsets, and is especially suitable for the rotational offset or directional deviation of the ground wire during the wrapping process, which significantly improves the adaptability and robustness of the system under different process conditions.

[0038] Furthermore, the image processing procedure includes image grayscale conversion, image edge detection, binarization, and contour extraction to improve the accuracy of ground line location identification; Among them, image grayscale conversion: converting a color image to a grayscale image can remove color interference, reduce the dimensionality of image data, reduce the amount of computation in subsequent processing, improve processing speed, and at the same time retain key information such as ground contour and edges, laying the foundation for subsequent edge detection and contour extraction. Image edge detection: By extracting the edge information of the ground wire in the image through edge detection algorithms (such as Canny, Sobel, etc.), the boundary between the ground wire and the wire core or other structures can be clearly identified, thereby more accurately determining the position and angle of the ground wire and improving the robustness of recognition; Image binarization: By setting an appropriate threshold, the image is converted into a black and white binary image, which can effectively distinguish the ground line from the background, highlight the contour features of the ground line, remove noise interference, and make subsequent contour extraction more accurate and stable. Contour extraction: Contour extraction based on binary images can accurately obtain the geometric shape and position information of the ground wire, which facilitates further calculation of the offset angle of the ground wire relative to the central axis of the wire core, providing high-precision input data for the system, thereby improving the overall recognition and correction accuracy; By employing grayscale conversion, edge detection, binarization, and contour extraction, the accuracy and stability of ground wire location identification are improved, and the system's anti-interference capability and automation level are enhanced. This provides important technical support for realizing automatic ground wire identification and intelligent correction, and has significant industrial application value.

[0039] Example 2: A system for automatically identifying the position of the ground wire during the wrapping process, employing the method for automatically identifying the position of the ground wire during the wrapping process as described in Embodiment 1, wherein the system includes: The winding mold is used to wrap and integrate the wire core and ground wire into a wire. An image acquisition and processing device is installed on both sides of the wire to acquire ground wire images, process the acquired images, and identify the location of the ground wire. The first positioning component is used for the initial positioning of the wire; Angle calculation module, used to calculate the ground wire offset angle according to a preset formula; The offset determination module is used to compare the calculated offset angle with a preset threshold. The towing adjustment mold is used to control the adjustment action of the mold based on the judgment result; The second positioning component is used for secondary positioning of the wire; A take-up die is used to take up wires after secondary positioning. The main control module is used to coordinate the operation of the above modules and control the servo motor to achieve mold adjustment; wherein, the image acquisition and image processing device, the angle calculation module, the offset judgment module, and the drag bag adjustment mold are all electrically connected to and controlled by the main control module.

[0040] Furthermore, it also includes an alarm module electrically connected to the main control module, used to issue an alarm signal when the ground wire adjustment fails or when the preset adjustment limit is reached.

[0041] Furthermore, it also includes a human-machine interface electrically connected to the main control module, used to display the operating status and operation control of each module in the system.

[0042] It should be understood that those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A method for automatically identifying the position of the ground wire during the wrapping process, characterized in that, Includes the following steps: S10: After wrapping one or two ground wires around the predetermined position of the wire core, the ground wire image is acquired in real time through an image acquisition and image processing device. S20: Perform image processing on the acquired ground wire image, identify the position information of the ground wire, and calculate the offset angle of the ground wire based on the geometric relationship between the ground wire and the central axis of the wire. S30: Compare the calculated offset angle with the preset qualified angle threshold to determine whether the ground wire is within the qualified range; When the deflection angle of the ground wire is determined to be unqualified, the control of the trolley adjustment mold is adjusted according to the direction and magnitude of the ground wire offset to correct the position of the ground wire and restore it to the qualified range.

2. The method according to claim 1, characterized in that, In step S20, the ground wire offset angle is calculated using the following formula: A = sinα(0.5 × D1 + 0.5 × D2 + 0.03) Where A is the critical value; α is the maximum acceptable offset angle; D1 is the core wire height; D2 is the ground wire diameter; and 0.03 is the gap compensation constant.

3. The method according to claim 1, characterized in that, The image acquisition and image processing device includes two industrial cameras that illuminate the wire, and the two industrial cameras are symmetrically arranged on both sides of the wire.

4. The method according to any one of claims 1-3, characterized in that, The adjustment direction of the towing adjustment mold includes fine adjustment in the up and down direction and fine adjustment in the axial rotation direction; when the image acquisition and image processing device detects that the ground wire adjustment has failed or has reached the preset adjustment limit, an alarm signal is generated, prompting manual intervention or machine shutdown.

5. The method according to claim 4, characterized in that, The adjustment action of the bag adjusting mold includes one of the following situations: (a) When both ground lines are tilted upwards, adjust the center position of the sling mold upwards; (b) When both ground lines are simultaneously tilted downwards, adjust the center position of the sling adjustment mold downwards; (c) When one ground line is slightly higher and the other ground line is slightly lower, the trolley mold rotates accordingly, adjusting the angle by 15° each time; (d) When one ground wire is normal and the other ground wire is offset, the trolley mold rotates accordingly, adjusting the angle by 5° each time.

6. The method according to claim 5, characterized in that, The mold is adjusted by a servo motor. The ground wire can be adjusted up or down by 2mm, and the maximum angle adjustment range of the ground wire is 120°.

7. The method according to any one of claims 1-3 and 5-6, characterized in that, The image processing procedure includes image grayscale conversion, image edge detection, binarization, and contour extraction to improve the accuracy of ground line location identification.

8. A system for automatically identifying the position of the ground wire during the wrapping process, employing the method for automatically identifying the position of the ground wire during the wrapping process as described in any one of claims 1-7, characterized in that, The system includes: An image acquisition and processing device is installed on both sides of the cable to acquire ground wire images; The image processing module is used to process the acquired images and identify the location of the ground wire; Angle calculation module, used to calculate the ground wire offset angle according to a preset formula; The offset determination module is used to compare the calculated offset angle with a preset threshold. The towing adjustment mold is used to control the adjustment action of the mold based on the judgment result; The main control module is used to coordinate the operation of the above modules and control the servo motor to achieve mold adjustment; wherein, the image acquisition and image processing device, the angle calculation module, the offset judgment module, and the drag bag adjustment mold are all electrically connected to and controlled by the main control module.

9. The system according to claim 8, characterized in that, It also includes an alarm module electrically connected to the main control module, which is used to issue an alarm signal when the ground wire adjustment fails or when the preset adjustment number limit is reached.

10. The system according to claim 9, characterized in that, It also includes a human-machine interface electrically connected to the main control module, used to display the operating status and operation control of each module in the system.

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