Jumper detection device for transposed conductor

Abstract

The invention relates to the technical field of transposed conductor production quality detection, in particular to a jumper detection device for a transposed conductor, which comprises a lower computer and an upper computer, the lower computer comprises a signal transmitting assembly and a signal receiving assembly, the signal transmitting assembly comprises an outer ring, an inner ring, a bearing, a rotating ball, a wire passing groove, a locking ring and an embedded signal transmitting module, and the signal transmitting assembly is used for transmitting a unique recognizable characteristic signal to each enameled flat wire of the wire group; according to the scheme, the self-adaptive signal transmission structure of the lower computer is combined with the intelligent management and control system of the upper computer, so that accurate identification, real-time monitoring and linkage control of transposed conductor jumper faults are realized. The problems of signal instability and response lag in traditional detection are solved, a closed-loop management mechanism from detection to production intervention is constructed, and the production quality and efficiency of the transposed conductor are effectively improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of quality detection of transposed conductor, and particularly relates to a jumper detection device for transposed conductor. BACKGROUND

[0002] The transposed conductor is a composite conductor which is composed of multiple enameled flat wires arranged according to a specific rule and woven through multiple transpositions, and is widely used in the winding manufacturing of power equipment such as transformers and reactors. The transposition quality directly affects the electrical performance and operation safety of the equipment. The jumper is a phenomenon that a single or multiple flat wires deviate from the preset transposition path due to mechanical stress, insufficient equipment precision and other reasons during the transposition of the conductor, which may cause uneven current distribution, local overheating and other hidden dangers. The jumper detection is a key link in the production process of the transposed conductor, which identifies the jumper fault through technical means and ensures the product quality.

[0003] The traditional jumper detection device has many limitations: the manual visual detection depends on the experience of the operator, has low efficiency and high misjudgment rate, and is difficult to adapt to the demand of high-speed production line; the relative position between the signal transmission component of the contact type detection device and the conductor is fixed, which cannot adapt to the dynamic offset during the transposition of the conductor, and the signal interruption is easy to occur; the detection system is in an independent working mode, which is disconnected with the control link of the production line, and it is difficult to realize the rapid response and intervention of the fault.

[0004] Therefore, the present application provides a jumper detection device for transposed conductor, which combines the adaptive signal transmission structure of the lower computer with the intelligent management and control system of the upper computer, realizes the accurate identification, real-time monitoring and linkage control of the jumper fault of the transposed conductor. The problems of unstable signal and slow response in the traditional detection are solved, and a closed-loop management mechanism from detection to production intervention is built, which effectively improves the production quality and efficiency of the transposed conductor. SUMMARY

[0005] The technical problem solved by the present application is the low detection precision and slow response of the traditional jumper detection.

[0006] In view of the deficiencies in the prior art, the present application provides a jumper detection device for transposed conductor, thereby solving the technical problems mentioned in the background.

[0007] To achieve the above purpose, the present application realizes the following technical solutions:

[0008] A kind of jumper detection device for transposed conductor, including lower computer and upper computer;The lower computer includes signal sending component and signal receiving component, signal sending component contains outer ring, inner ring, bearing, rotating ball, wire slot, lock ring and embedded signal transmitting module, for sending unique identifiable characteristic signal to each enameled flat wire of conductor group;Signal receiving component contains fixed plate, moving slot one, fixed frame, moving slot two, fixed part, spring piece and embedded signal receiving module, for picking up the characteristic signal of each flat wire after the transposition of conductor group is completed and judging whether jumper occurs;The upper computer is connected with lower computer, for receiving detection data and realizing real-time monitoring, data management, fault alarm and linkage control production line equipment.

[0009] In a possible implementation, the outer ring is rigidly connected with the production line rack as a fixed base, and an annular guide groove is arranged on the inner side;The inner ring is a rotating carrier, and the outer side protrusion is matched with the guide groove of the outer ring to limit axial displacement and only rotate around the central axis, and the inner side is associated with the rotating shaft of the pay-off stand through a shaft coupling.

[0010] In a possible implementation, the inner side of the outer ring is uniformly distributed with bearing mounting positions, and the bearing provides support for the rotating ball, which can rotate ± 30 ° around the bearing axis;The wire slot is opened on the rotating ball, and the inner side is inlaid with a conductive contact connected with the signal transmitting module, and the contact is attached to the surface of the conductor by spring force.

[0011] In a possible implementation, the lock ring is connected with the inner ring by M6 bolt, for fixing the relative position of the bearing and the inner ring, to prevent loosening during rotation, and the loosening amount is ≤0.01mm.

[0012] In a possible implementation, the fixed plate is installed as a receiving component base, and the surface is processed with moving slot one;The bottom of the fixed frame is matched with the moving slot one through a T-shaped sliding block, which can adjust the position horizontally / vertically, and the inner side is installed with a guide wheel to limit the lateral deviation of the conductor group, and the deviation is ≤1mm.

[0013] In a possible implementation, the moving slot two is opened in the middle of the upper fixed frame, and the fixed part is matched with the moving slot two through a sliding block, which can be adjusted along the width direction of the conductor, and the adjustment accuracy is ± 0.05mm;The spring piece is fixed on the fixed part, and the initial angle can be adjusted to 0-15 ° by bolt.

[0014] In a possible implementation, the spring piece is made of beryllium copper material, with a thickness of 0.1mm and a width of 3mm, and the free end is processed with a radius of 1mm arc surface, which forms a point contact with the surface of the conductor, and the contact area is ≤0.5mm 2 , and the elastic coefficient is 1.5N / mm.

[0015] In one possible implementation, the real-time monitoring unit of the host computer includes a data acquisition module, a visualization module, and a status diagnosis module. The data acquisition module communicates with the slave computer through an Ethernet interface and receives a data frame containing wire parameters, signal characteristics, and device status every 100ms, using a CRC16 check mechanism.

[0016] In one possible implementation, the fault alarm unit of the host computer includes an alarm triggering module, an alarm classification module, and an alarm recording module. The alarm triggering module can trigger an alarm based on conditions such as jumper fault (i.e., two consecutive cycles of code sequence mismatch and position deviation > 0.5 mm), signal abnormality, and equipment failure. The alarm classification module divides the alarm into three levels and corresponds to different warning methods.

[0017] In one possible implementation, in the signal receiving component of the lower-level machine, the signal picked up by the spring plate is amplified, filtered, and converted by A / D before being transmitted to the main control module. The main control module then sends the processing result to the upper-level machine. The linkage control unit of the upper-level machine communicates with the production line PLC through the Profinet protocol and can send control commands such as deceleration and shutdown. The communication delay is ≤100ms.

[0018] Beneficial effects compared to existing technologies:

[0019] 1. In this solution, through the synchronous rotation of the outer and inner rings of the lower-level signal transmission component, the multi-angle adaptive adjustment of the rotating ball, and the elastic contact design of the conductive contacts within the wire groove, a unique characteristic signal is stably injected into each enameled flat wire during high-speed wire transposition (transposition frequency 10-50 times / meter). Even with a path offset of ±2mm, the signal transmission efficiency can still be guaranteed to be ≥99%, solving the problems of easy signal interruption and poor contact in traditional detection, and providing a reliable "identification" basis for jumper wire identification.

[0020] 2. In this solution, the multi-dimensional adjustment structure of the fixing plate and fixing frame of the signal receiving component, combined with the high elasticity point contact design of the spring sheet, and the real-time signal comparison logic of the lower-level main control module, achieves accurate pickup and rapid judgment of the characteristic signals of the transposed wires. It can identify weak signals ≥1mV, the response time for judging jumper faults is ≤200ms, and the positioning accuracy reaches ±0.5m. It overcomes the shortcomings of low efficiency and large error of manual visual inspection, and significantly improves the accuracy and timeliness of jumper detection.

[0021] 3. In this solution, through the timing synchronization mechanism between the host computer and the slave computer, the dynamic visualization display of the host computer's real-time monitoring unit, the hierarchical warning of the fault alarm unit, and the collaborative control of the linkage control unit and the production line PLC, a closed-loop management of the entire process from "signal injection—relocation tracking—fault judgment—production intervention" is realized. When a jumper occurs, it can automatically trigger deceleration (≤2 seconds) or shutdown (≤1 second) according to the fault level, and record detailed data for traceability analysis, which not only reduces the risk of defective products flowing out, but also provides data support for production line quality optimization. Attached Figure Description

[0022] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, the preferred embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0024] Figure 2 This is a schematic diagram of the inner ring structure of the present invention;

[0025] Figure 3 This is a schematic diagram of the bearing structure of the present invention;

[0026] Figure 4 This is a schematic diagram of the fixing plate structure of the present invention;

[0027] Figure 5 for Figure 4 Enlarged view of point A in the image;

[0028] Figure 6 This is a schematic diagram of the spring sheet structure of the present invention;

[0029] Figure 7 This is a schematic diagram showing the contact between the wire transposition and the spring sheet in this invention;

[0030] Figure 8 This is a diagram of the host computer system framework of the present invention.

[0031] Legend: 1. Outer ring; 2. Inner ring; 3. Bearing; 4. Rotating ball; 5. Corrugated groove; 6. Locking ring; 7. Fixing plate; 8. Moving groove one; 9. Fixing frame; 10. Moving groove two; 11. Fixing component; 12. Spring plate. Detailed Implementation

[0032] Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention can also be implemented in various different forms, and therefore the present invention is not limited to the embodiments described below. In addition, for the purpose of more clearly describing the present invention, parts not connected to the invention will be omitted from the drawings.

[0033] The technical solution in this application embodiment is to solve the problems mentioned in the background art, and the overall idea is as follows:

[0034] Example:

[0035] Please refer to Figures 1 to 8 As shown in the figure, this embodiment introduces the specific structure of a jumper detection device for transposed wires, including a host computer and a slave computer, as detailed below:

[0036] I. Functional and structural coordination of the lower-level computer system

[0037] The lower-level machine includes a signal transmitting component and a signal receiving component. The signal transmitting component is used to send a unique and identifiable feature signal to each enameled flat wire in the conductor group to ensure that each flat wire carries an "identity mark" during the transposition process. The signal receiving component is used to pick up the feature signals of each flat wire after the conductor group has completed transposition and determine whether the signal position has deviated according to the preset transposition rules, thereby identifying whether a jumper has occurred. The two work together through a timing synchronization mechanism to achieve a closed-loop detection process from "signal injection - transposition tracking - signal identification - fault judgment".

[0038] (I) Signal Transmission Component

[0039] The signal transmission component includes an outer ring 1, an inner ring 2, a bearing 3, a rotating ball 4, a wire guide groove 5, a locking ring 6, and an embedded signal transmission module; its core function is to "bind" a unique characteristic signal to each flat wire before it enters the transposition mechanism, and to ensure that the signal transmission process is not affected by the movement or rotation of the wire.

[0040] Core components and functions

[0041] Outer ring 1: As a fixed base, it supports inner ring 2 and other rotating parts. It is rigidly connected to the production line frame, providing a stable installation reference for the entire assembly. The inner side of the outer ring is designed with an annular guide groove, which cooperates with the outer protrusion of the inner ring 2 to limit the axial displacement of the inner ring (displacement ≤ 0.1mm), ensuring that the inner ring can only rotate around the central axis.

[0042] Inner ring 2: As a rotating carrier, multiple bearing 3 mounting positions are evenly distributed on its outer side, and its inner side is indirectly connected to the rotating shaft of the wire feeding frame through a coupling; the core function of the inner ring is to "follow the rotation" - when the winch-type wire feeding frame rotates (it needs to rotate synchronously during the wire feeding process to avoid the wire from getting tangled), the inner ring rotates synchronously with the outer ring through a sliding fit (friction coefficient ≤ 0.02), so that the rotating ball 4) installed on the inner ring and the wire groove 5 remain relatively stationary with the wire, avoiding the wire from generating additional tension or wear due to rotation;

[0043] Bearing 3 and rotating ball 4: Bearing 3 provides multi-angle adjustable support for rotating ball 4. Rotating ball 4 can rotate ±30° around the bearing axis. Its core function is "adaptive conductor routing". Since there is a slight offset (±2mm) in the path of the enameled flat wire from the wire feeding frame to the wire changing head, rotating ball 4 can adjust the angle of the wire groove 5 in real time by rotating itself to ensure that the wire always passes through the center of the wire groove (deviation ≤0.5mm) and avoids damage to the insulation layer caused by friction between the wire and the groove wall.

[0044] Wire passage 5: Serves as a wire channel and signal injection point. Its inner side is inlaid with conductive contacts (made of beryllium copper, with gold plating to reduce contact resistance), which are connected to the signal transmitting module through a shielded wire. The diameter of the wire passage can be changed according to the wire diameter (adaptation range 0.5-5mm), and the contact position is designed as "elastic contact" - when the wire passes through, the contact is tightly attached to the wire surface under the action of spring force (contact pressure 0.2-0.3N), ensuring stable injection of characteristic signals (signal transmission efficiency ≥99%).

[0045] Locking ring 6: Used to fix the relative position of bearing 3 and inner ring 2. It is connected to the inner ring by M6 bolts (tightening torque 5-6 N·m) to prevent the bearing from loosening during rotation (loosening amount ≤0.01mm) and to ensure the adjustment accuracy of rotating ball 4.

[0046] Functional coordination and workflow of signal transmission components

[0047] The core objective of the signal transmission component is to assign a "unique and traceable characteristic signal" to each enameled flat wire, and its functional coordination logic is as follows:

[0048] Synchronous rotation: When the wire feeding frame is working, the cage structure will rotate at a speed of 50-300r / min, driving the wire to rotate synchronously; the inner ring 2 rotates synchronously with the rotation speed of the wire feeding frame through the sliding fit with the outer ring 1 (speed difference ≤1r / min), avoiding relative torsion between the wire and the wire groove 5, and ensuring that the contact position between the signal injection contact and the wire is stable (contact point offset ≤0.1mm);

[0049] Multi-angle adaptive coordination: When the path of the conductor from the wire feeding frame to the wire changing head has lateral or longitudinal deviation (such as ±1.5mm deviation due to tension fluctuation), the rotating ball 4 adjusts the orientation of the wire passage groove 5 in real time through the rotational degree of freedom of the bearing 3. When the conductor deviates to the left, the rotating ball rotates to the left by 5-10° to align the center of the wire passage groove with the conductor axis. Similarly, it can adapt to deviations to the right, up, or down, ensuring that the conductor always moves along the central path in the groove and avoiding signal injection interruption (interruption time ≤1ms).

[0050] Signal Encoding and Injection: The signal transmitting module generates a unique "low-frequency pulse coded signal" for each wire (encoding format is 16-bit binary, such as 0010110011010011), with a pulse frequency of 1kHz (period 1ms). Each pulse contains 3 status bits (start bit, data bit, and parity bit). The signal is injected into the wire through the conductive contact of the wire slot 5. Since the insulation layer of the enameled flat wire only covers the surface, the internal conductor can conduct low-frequency signals (attenuation rate ≤5% / m), ensuring that the signal can be transmitted along the wire to the signal receiving component.

[0051] (II) Signal Receiving Component

[0052] The signal receiving component includes a fixed plate 7, a movable slot 1 8, a fixed frame 9, a movable slot 2 10, a fixing piece 11, a spring sheet 12, and an embedded signal receiving module; its core function is to pick up the characteristic signal of each flat wire after the wire has been transposed, and to determine whether the signal position is abnormal (i.e., whether the wire has been jumped) according to the preset transposition rule.

[0053] Core components and functions

[0054] Fixed plate 7: Serves as the mounting base for the receiving component, supporting the mounting bracket 9 and the signal processing module. Its surface is machined with two sets of parallel moving grooves 8, providing horizontal / vertical adjustment space (adjustment range 0-100mm) for the mounting bracket 9, accommodating wire groups of different widths (10-50mm). The fixed plate is connected to the production line frame through anti-vibration pads (vibration reduction coefficient ≥80%), reducing the interference of production line vibration (amplitude ≤0.1mm) on signal pickup.

[0055] Moving slot 8 and fixed frame 9: Moving slot 8 is a T-shaped slot structure, which cooperates with the T-shaped slider at the bottom of the fixed frame 9. The slider is equipped with locking bolts (M8) on the side, which can lock the fixed frame in any position (positioning accuracy ±0.1mm); The fixed frame 9 has a total of 4 sets (1 set each in the top, bottom, left and right), and guide wheels (made of polyurethane, 20mm in diameter) are installed on its inner side to limit the lateral displacement of the wire group (offset ≤1mm) and ensure that the center of the wire group is aligned with the center of the receiving component;

[0056] Movable slot 2 10 and fixing component 11: Movable slot 2 10 is located in the middle of the upper fixing frame 9 and is a long slot (50mm in length). Fixing component 11 is in cooperation with the slot body through a slider and can be adjusted in position along the width of the wire (adjustment accuracy ±0.05mm). The core function of fixing component 11 is to fix the spring plate 12 and adjust the initial angle of the spring plate (0-15°) through bolts to ensure stable contact pressure between the spring plate and the surface of the wire.

[0057] Spring sheet 12: As the core component for signal pickup, it is made of beryllium bronze (thickness 0.1mm, width 3mm), which has high elasticity (elasticity coefficient 1.5N / mm) and high conductivity (resistivity ≤0.02μΩ·m); the free end of the spring sheet is machined with an arc surface (radius 1mm), which forms point contact (contact area ≤0.5mm2) when in contact with the surface of the conductor, which can ensure the sensitivity of signal pickup (can identify weak signals ≥1mV) and avoid scratching the insulation layer of the conductor;

[0058] Signal receiving module: including signal amplification circuit, filtering circuit, A / D conversion chip and microprocessor (STM32F103), used to convert the weak signal (mV level) picked up by spring sheet 12 into digital signal (16-bit precision) and transmit it to the main control module of the lower computer;

[0059] Functional coordination and workflow of the signal receiving component

[0060] The core objective of the signal receiving component is to accurately pick up the characteristic signals of each transposed flat wire and compare them with a preset pattern. Its functional logic is as follows:

[0061] Wire assembly positioning and coordination: After the wire assembly completes its transposition and enters the receiving component, the four sets of fixing brackets 9 adjust their positions through the moving slots 8—the left and right fixing brackets restrict the lateral displacement of the wire assembly (gap 0.5-1mm), and the upper and lower fixing brackets restrict the longitudinal displacement (gap 0.3-0.5mm), ensuring that the wire assembly passes through the receiving area in a stable posture (position fluctuation ≤0.2mm); the contact between the guide wheel and the wire assembly is rolling friction (friction coefficient ≤0.01), avoiding wear on the wire surface;

[0062] Spring contact fit: The spring sheet 12 of the upper fixing bracket 9 can be aligned with the center of the top surface of the conductor group (deviation ≤ 0.3 mm) by adjusting the fixing member 11 in the moving groove 2 10; the elastic design of the spring sheet allows it to adapt to the thickness fluctuation of the conductor group (± 0.2 mm) - when the thickness of the conductor group increases, the spring sheet bends upward (bending amount ≤ 1 mm), and the contact pressure is maintained at 0.2 ± 0.05 N; when the thickness decreases, the spring sheet rebounds downward to ensure that it is always in contact with the surface of the conductor (contact interruption time ≤ 0.5 ms);

[0063] Signal Acquisition and Recognition: During the transposition process of the conductor group, each flat wire will arrive at the top surface in sequence according to a preset pattern (e.g., the transposition pattern of 4 flat wires a, b, c, d is a→b→c→d→a→...). When a flat wire arrives at the top surface, the spring plate 12 contacts it and picks up the characteristic signal. After the signal is amplified (amplification factor 1000 times) and filtered (filtering out 50Hz power frequency interference and high frequency noise above 10kHz) by the receiving module, it is converted into a digital signal. The microprocessor parses out the corresponding code (e.g., if "0010110011010011" is recognized, it is determined to be wire a).

[0064] Jumper detection logic

[0065] The lower-level main control module pre-stores the transposition rules of the conductor group (such as the preset sequence of 4 flat wires being a→b→c→d→a→b...), and its judgment process is as follows:

[0066] The encoded sequence transmitted by the real-time signal receiving component (e.g., the actual sequence is a→b→a→d→...);

[0067] The actual sequence is compared with the preset sequence bit by bit (comparison period 0.1ms). If a mismatch occurs for two consecutive periods (e.g. the third bit should be 'c' but is actually 'a'), it is determined to be a "jump wire fault".

[0068] Record the fault location (based on the position data of the production line encoder, with an accuracy of ±0.5m), fault type (such as "C line missing, A line misaligned"), and fault time (accurate to ms), and transmit the data to the host computer.

[0069] II. Functions and Unit Composition of the Host Computer System

[0070] The host computer includes a real-time monitoring unit, a data management unit, a fault alarm unit, and a linkage control unit. Each unit works collaboratively through an industrial Ethernet network (TCP / IP communication protocol) to achieve full-process management, analysis, and control of the jumper detection process.

[0071] (I) Real-time monitoring unit

[0072] The real-time monitoring unit is the core interface for interaction between the host computer and the operator. It is used to dynamically display the detection data transmitted by the slave computer and the operating status of the equipment. Its components include a data acquisition module, a visualization display module and a status diagnosis module.

[0073] Data acquisition module

[0074] The data acquisition module communicates with the lower-level device via an Ethernet interface (100Mbps), receiving a data frame every 100ms (frame format: start bit + device ID + data length + detection data + check bit), containing the following core data:

[0075] Real-time parameters of the conductor assembly: laying speed (0-50m / min), transposition frequency (10-50 times / meter), conductor specifications (number of flat wires, single wire size);

[0076] Signal characteristic data: current top flat line encoding, signal strength (0-5V), signal-to-noise ratio (≥30dB);

[0077] Equipment status data: Lower-level machine operating temperature (0-60℃), power supply voltage (24±1V), and operating status of each component (normal / abnormal);

[0078] The module has a built-in data verification mechanism (CRC16 check) to ensure that the data transmission error rate is ≤0.001%. If the received data is abnormal (such as verification failure), it will automatically request retransmission (retransmission times ≤3 times).

[0079] Visualization module

[0080] The visualization module is developed using configuration software (such as WinCC), and the interface is divided into three areas to intuitively present the detection process:

[0081] Main view area: Displays the entire production line process in the form of a dynamic flowchart (feeding → pre-processing → transposition → inspection → wrapping → take-up). The "inspection" step marks the current position of the conductor group (based on encoder data) and the identification of the top flat wire (such as a, b, c, d displayed in different colors). When a jumper occurs, a red warning box flashes at the corresponding position and is marked with the word "jumper".

[0082] Data panel area: Displays key parameters in the form of a digital dashboard, such as laying speed (unit m / min, accuracy 0.1m / min), current code (e.g., "0010110011010011→a line"), signal strength (bar chart display, full scale 5V), and equipment temperature (thermometer icon, turns red when it exceeds 50℃).

[0083] Pattern Comparison Area: The left side displays the preset transposition pattern sequence (such as "a→b→c→d→a→b..."), and the right side displays the actual detection sequence (such as "a→b→a→d→..."). The two are updated in real time side by side. Mismatched positions are marked with a yellow background to help operators quickly locate anomalies.

[0084] Status Diagnostic Module

[0085] The status diagnostic module analyzes real-time data to automatically determine whether the device is in normal working condition. The diagnostic logic is as follows:

[0086] Signal anomaly diagnosis: When the signal strength is <1V or the signal-to-noise ratio is <25dB, it is determined as "signal transmission anomaly" and the prompt is "check the spring contact or the wire groove contact".

[0087] Speed ​​matching diagnosis: When the pay-off speed and the transposition frequency do not match (e.g., when the speed is 50m / min, the transposition frequency should be ≥30 times / meter), it is judged as "abnormal process parameters" and prompts "adjust the transposition mechanism parameters";

[0088] Component fault diagnosis: When the lower-level machine temperature is >65℃ or the power supply voltage is <22V, it is judged as "hardware fault" and prompts "check the lower-level machine heat dissipation or power supply";

[0089] The diagnostic results are displayed in real time in the "status bar" at the bottom of the interface and are automatically recorded in the log (including diagnostic time, fault code, and suggested measures);

[0090] (II) Data Management Unit

[0091] The data management unit is used to store, query, and analyze historical data generated during the testing process, providing a basis for production line quality optimization. It consists of a data storage module, a historical query module, and a statistical analysis module.

[0092] Data storage module

[0093] The data storage module uses a MySQL database (version 8.0), indexed by "time + device ID + wire specification", to store the following data:

[0094] Raw detection data: every 1 second, the conductor speed, coding sequence, signal strength, and position deviation (the difference between the actual position and the preset position, in mm) are recorded.

[0095] Fault log data: Each fault includes the occurrence time (accurate to milliseconds), fault type (e.g., "line A jumps to line C position"), fault duration, and processing result (e.g., "recovered after manual adjustment").

[0096] Equipment parameter data: configuration parameters such as lower-level machine signal transmission frequency, spring plate pressure threshold, upper-level machine alarm threshold, etc., and record the parameter modification time and operator ID;

[0097] Data storage adopts a "local + backup" mode: the local storage period is 90 days (occupying approximately 500GB of space), and it is automatically backed up to a remote server (NAS storage) every morning to ensure a data loss rate of 0.

[0098] Historical query module

[0099] The historical query module provides multi-dimensional search functionality, allowing operators to query data using combinations of the following conditions:

[0100] Time range: accurate to the minute (e.g., "2025-07-01 08:00 to 2025-07-01 12:00");

[0101] Conductor specifications: such as "16 flat wires, 2mm × 0.5mm";

[0102] Fault types: such as "single jumper", "multiple jumpers misaligned", "signal loss";

[0103] Equipment status: such as "normal operation period" or "abnormal operation period of lower-level machine";

[0104] The query results are displayed in a table (containing time, speed, coding sequence, and fault information) or a trend chart (such as the change in jumper frequency over a certain period of time). It supports exporting to Excel (.xlsx) or PDF format, and the export time is ≤10 seconds / 1000 records.

[0105] Statistical Analysis Module

[0106] The statistical analysis module performs automated analysis based on historical data and generates quality analysis reports. Its core functions include:

[0107] Fault frequency statistics: The occurrence frequency and percentage of different types of faults are calculated by day / week / month (e.g., "single jumper wire accounts for 70%, multiple faulty wires account for 20%), and displayed in a pie chart;

[0108] Trend Analysis: Plot the curve of jumper rate (number of jumpers / total number of tests) over time to identify high-incidence periods (e.g., "higher jumper rate from 10:00 to 12:00 every day"), and analyze the reasons in conjunction with production logs (e.g., "large fluctuations in tension during this period").

[0109] Equipment performance evaluation: Calculate the mean time between failures (MTBF) and mean time to repair (MTTR) of the lower-level machine, and evaluate the stability of the detection device (e.g., "MTBF ≥ 1000 hours"); The module automatically generates a "Quality Analysis Report of the Previous Week" every Monday and sends it to the production line management personnel's email address. The report includes data charts, problem summaries and improvement suggestions (e.g., "Adjust the tension parameter of No. 3 shifter to 50N").

[0110] (III) Fault Alarm Unit

[0111] The fault alarm unit is used to promptly remind operators to handle the situation when a jumper or equipment abnormality is detected, so as to prevent unqualified products from flowing into the next process. It consists of an alarm triggering module, an alarm classification module, and an alarm recording module.

[0112] Alarm triggering module

[0113] The alarm triggering module compares the detection data transmitted from the lower-level machine with the preset threshold in real time, and triggers an alarm when the following conditions are met:

[0114] Jumper fault: A mismatch in the encoded sequence is detected for two consecutive detection cycles (200ms), and the positional deviation is >0.5mm;

[0115] Signal abnormality: Signal strength < 1V for 5 seconds, or signal-to-noise ratio < 25dB for 3 seconds;

[0116] Equipment failure: Lower-level machine temperature > 65℃, power supply voltage < 22V, or communication interruption > 3 seconds;

[0117] The module supports custom alarm thresholds (e.g., for high-precision conductors, the position deviation threshold can be set to 0.3mm). Threshold modification requires the administrator password (hierarchical access control).

[0118] Alarm classification module

[0119] Based on the severity of the fault, alarms are divided into three levels, each corresponding to a different warning method:

[0120] Level 1 alarm (minor abnormality): If the signal strength is slightly low (1-1.5V) but does not affect the detection, a warning will be issued with a "yellow indicator light + beep (1000Hz, lasting 1 second)" and a pop-up message box will appear on the interface (such as "signal strength is low, it is recommended to check the spring contact"). This will not affect the operation of the production line.

[0121] Level 2 alarm (jumper fault): If a single flat jumper wire is faulty, a warning will be issued with a red indicator light and an alarm sound (2000Hz, lasting for 3 seconds, cycling every 2 seconds). The fault location will flash on the screen, and the team leader will be notified via SMS (including the time and location of the fault).

[0122] Level 3 alarm (serious fault): such as multiple flat wires being tangled or the equipment stopping, will be alerted by "a red indicator light that is constantly on + a high-decibel alarm sound (3000Hz, continuous ringing)", the fault information will be displayed on the full screen of the interface, and the production line will be automatically stopped (achieved through the linkage control unit).

[0123] Alarm logging module

[0124] The alarm logging module automatically records detailed information for each alarm, forming an "Alarm Ledger," which includes:

[0125] Basic alarm information: alarm time, alarm level, fault code (e.g., "E01" represents the A-line jumper);

[0126] Related data: wire speed, transposition frequency, and signal characteristics at the time of alarm occurrence;

[0127] Processing timeline: time the operator received the alarm, processing measures (e.g., "adjusting the position of the wire head"), fault recovery time, and signature of the person handling the incident;

[0128] The module supports filtering records by alarm level and processing status (unprocessed / processed), which makes it easy to track alarms that have not been processed in time (such as a level 2 alarm that has not been processed for more than 30 minutes, which will be automatically upgraded to a level 3 alarm).

[0129] (iv) Linkage Control Unit

[0130] The linkage control unit enables the host computer and production line equipment (such as wire feeding machine, transposition machine, and take-up machine) to work together and automatically intervene in the production process when a fault occurs. Its components include a communication interface module, a control logic module, and a status feedback module.

[0131] Communication interface module

[0132] The communication interface module uses the Profinet protocol (industrial Ethernet standard) to communicate with the production line PLC (Siemens S7-1200), and supports the following signal interactions:

[0133] Host computer → PLC: Control commands (such as "pause production" and "continue production"), fault location signals (meter positioning based on encoder data);

[0134] PLC → Host Computer: Production line status signals (running / stopping / fault), execution feedback (such as "pause command received");

[0135] Module communication latency ≤100ms, supports hot-swapping (communication can be automatically restored after the interface is disconnected and reconnected, with a recovery time ≤3 seconds);

[0136] Control logic module

[0137] The control logic module executes different linkage control strategies based on the fault type:

[0138] Level 2 alarm (single jumper): The host computer sends a "deceleration signal" to the PLC, and the PLC controls the wire feeding speed to decrease from the current value to 5m / min (deceleration time ≤ 2 seconds). At the same time, the production line HMI displays "Wire needs to be checked 5 meters ahead", prompting the operator to manually adjust the wire before it reaches the take-up end.

[0139] Level 3 alarm (serious fault): The host computer sends an "emergency stop signal" to the PLC. The PLC immediately cuts off the power to the wire feeding machine and the transposition machine (stop time ≤ 1 second), and at the same time controls the braking device to lock the wire group (to prevent the wire from loosening). After the fault is cleared, the operator sends a "reset signal" through the host computer, and the production line can be restarted.

[0140] Signal abnormality (does not affect detection): Only a "prompt signal" is sent to the PLC, and the PLC displays "Detection device signal abnormality" on the HMI, without interfering with production;

[0141] Status feedback module

[0142] The status feedback module receives the execution results returned by the PLC in real time and updates the status of the host computer interface in the following scenarios:

[0143] If the PLC successfully executes the pause / stop command, the interface will display "Production line has responded, status: decelerating / stopped";

[0144] If the PLC does not respond (e.g., communication is interrupted), the interface will display "Control command not delivered, manual shutdown recommended" and trigger a level 3 alarm.

[0145] After troubleshooting, the system receives a "production recovery" signal from the PLC, the interface returns to normal display, and the fault handling time (time from shutdown to recovery) is recorded.

[0146] III. Collaborative Workflow between Lower-Level and Upper-Level Computers

[0147] The lower-level computer and the upper-level computer achieve fully automated jumper detection through a closed-loop process of "signal acquisition - data transmission - analysis and processing - linkage control". The specific workflow is as follows:

[0148] Initialization phase

[0149] Operators can configure the lower-level signal code (assigning a unique 16-bit code to each flat wire), spring pressure (0.25N), and upper-level alarm threshold (position deviation > 0.5mm alarm) according to the wire specifications (e.g., 8 flat wires, 3mm × 0.8mm) through the upper-level computer parameter configuration unit.

[0150] Lower-level machine self-test: The signal transmitting component tests the continuity of each wire slot contact (conductivity resistance < 10Ω), and the signal receiving component tests the signal pickup sensitivity of the spring sheet (can identify 1mV signal). After the self-test passes, a "ready signal" is sent to the upper-level machine.

[0151] After the host computer receives the ready signal, the real-time monitoring unit displays "Equipment is normal, waiting for production to start", and the linkage control unit establishes a communication connection with the PLC (displaying "Profinet connection successful").

[0152] Testing phase

[0153] The production line starts, the wire feeding rack begins feeding the wire, and the enameled flat wire passes through the wire guide groove 5 of the signal transmitting component in sequence;

[0154] Signal transmission component: Inner ring 2 rotates with the wire feeding frame (speed synchronization error ≤1r / min), rotating ball 4 adjusts the angle through bearing 3 to ensure that flat wire passes through the center of the wire groove, and wire groove contacts inject a preset coded signal into each flat wire;

[0155] The flat wire enters the transducer and is transposed according to a preset pattern (such as 1→2→3→4→5→6→7→8→1...). After transposition, it enters the signal receiving component.

[0156] Signal receiving component: 4 sets of fixed brackets 9 position the wire group through the moving slot 8, and the spring plate 12 contacts the flat wire on the top surface to pick up its characteristic signal. After amplification and filtering, it is converted into a digital signal and transmitted to the lower computer main control module.

[0157] The lower-level main control module compares the received encoding sequence with the preset pattern (e.g., it should be flat line No. 3, but it actually receives code No. 2), calculates the position deviation (e.g., -0.6mm), and packages the data and sends it to the upper-level computer every 100ms.

[0158] Exception handling phase

[0159] If the position deviation is greater than 0.5mm and there is a mismatch for two consecutive cycles, the lower-level machine determines it as a "jumper fault" and sends fault data (including code, position, and time) to the upper-level machine.

[0160] The host computer real-time monitoring unit: The interface flashes a red warning box, displaying "No. 8 flat wire jumps to position 6, deviation -0.6mm", and at the same time triggers a level 2 alarm (red indicator light + alarm sound);

[0161] Fault alarm unit: Records fault information (number, type, time), and links the control unit to send a "deceleration signal" to the PLC, which then controls the wire laying speed to decrease to 5m / min;

[0162] The operator confirms the fault location (based on encoder data at 25.3 meters) through the real-time monitoring unit, manually adjusts the flat wire position before the wire reaches the take-up end, and sends a "recovery signal" through the host computer after the adjustment is completed.

[0163] After receiving the recovery signal, the host computer sends an "acceleration signal" to the PLC, the production line resumes normal speed, and the real-time monitoring unit displays "Fault has been handled, detection continues";

[0164] End Phase

[0165] When the production line stops and the last flat wire leaves the signal receiving component, the lower-level machine sends a "test end signal", which includes the total number of tests, the number of jumpers, and the pass rate (pass rate = (total number of tests - number of jumpers) / total number of tests × 100%).

[0166] The host computer data management unit automatically generates the "Production Inspection Report", which includes inspection data statistics (average speed, maximum deviation) and fault details (time, location, and handling method).

[0167] The operator exports the report through the historical query module, turns off the power to the host computer and the slave computer, and the equipment enters standby mode.

[0168] Finally, it should be noted that the above embodiments are merely examples for clearly illustrating the present invention and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A jumper detection device for transposed conductors, characterized in that, The application relates to a signal transmission and detection device for a wire group, which comprises a lower computer and an upper computer; the lower computer comprises a signal transmission component and a signal receiving component; the signal transmission component comprises an outer ring (1), an inner ring (2), a bearing (3), a rotating ball (4), a wire passing groove (5), a locking ring (6) and an embedded signal transmission module, is used for transmitting unique identifiable characteristic signals to each enameled flat wire of a wire group, and the signal receiving component comprises a fixed plate (7), a moving groove I (8), a fixed frame (9), a moving groove II (10), a fixing piece (11), a spring sheet (12) and an embedded signal receiving module, is used for picking up the characteristic signals of each flat wire after the wire group is transposed and judging whether wire skipping occurs; the upper computer is in communication connection with the lower computer, is used for receiving detection data and realizing real-time monitoring, data management, fault alarm and linkage control of production line equipment.

2. A patch cord detection device for a transposed conductor as recited in claim 1, wherein, The outer ring (1) is rigidly connected with a production line rack as a fixed base, and an annular guide groove is arranged on the inner side; the inner ring (2) is a rotating carrier, the outer side protrusion is matched with the guide groove of the outer ring (1), axial displacement is limited and only rotation around the central axis is allowed, and the inner side is associated with the rotating shaft of a wire paying rack through a shaft coupling.

3. A patch cord detection device for a transposed conductor as defined in claim 2, wherein, Uniformly distributed bearing (3) mounting positions are arranged on the outer side of the inner ring (2), the bearing (3) provides support for the rotating ball (4), the rotating ball (4) can rotate by 30 DEG around the bearing axis, and the wire passing groove (5) is arranged on the rotating ball (4) and inlaid with a conductive contact connected with the signal transmission module on the inner side; the contact is adhered to the surface of the wire through spring force.

4. A patch cord detection device for a transposed conductor as defined in claim 3, wherein, The locking ring (6) is connected with the inner ring (2) through an M6 bolt, is used for fixing the relative position of the bearing (3) and the inner ring (2), prevents loosening during rotation, and the loosening amount is less than or equal to 0.01 mm.

5. A patch cord detection device for a transposed conductor as recited in claim 1, wherein, The fixed plate (7) is a mounting base of the receiving component, and a moving groove I (8) is processed on the surface; the bottom of the fixed frame (9) is matched with the moving groove I (8) through a T-shaped sliding block, the position can be adjusted horizontally / vertically, and a guide wheel is arranged on the inner side to limit the horizontal deviation of the wire group, and the deviation is less than or equal to 1 mm.

6. A patch cord detection device for a transposed conductor as defined in claim 5, wherein, The moving groove II (10) is arranged in the middle of the upper fixed frame (9), the fixing piece (11) is matched with the moving groove II (10) through a sliding block, can be adjusted along the width direction of the wire, the adjustment accuracy is plus or minus 0.05 mm, and the spring sheet (12) is fixed on the fixing piece (11) and the initial angle can be adjusted to 0-15 DEG through a bolt.

7. A patch cord detection device for a transposed conductor as defined in claim 6, wherein, The spring piece (12) is made of beryllium copper material, with thickness of 0.1 mm, width of 3 mm, and free end processed with a radius of 1 mm arc surface, which forms point contact with the surface of the wire, with contact area ≤0.5 mm 2 , and elastic coefficient of 1.5 N / mm.

8. A patch cord detection device for a transposed conductor as defined in claim 1, wherein, The real-time monitoring unit of the upper computer comprises a data acquisition module, a visual display module and a state diagnosis module, the data acquisition module communicates with the lower computer through an Ethernet interface, receives a data frame containing wire parameters, signal characteristics and equipment states once every 100 ms, and adopts a CRC16 check mechanism.

9. A patch cord detection device for a transposed conductor as defined in claim 1, wherein, The fault alarm unit of the upper computer comprises an alarm triggering module, an alarm grading module and an alarm recording module, the alarm triggering module can trigger alarm according to wire skipping faults, that is, the matching of two continuous period coding sequences is not matched and the position deviation is greater than 0.5 mm, signal abnormalities, equipment faults and the like, the alarm grading module divides the alarm into three levels and corresponds to different alarm modes.

10. A patch cord detection device for a transposed conductor as defined in claim 1, wherein, The signal receiving assembly of the lower computer, the signal picked up by the spring sheet (12) is transmitted to the main control module after being amplified, filtered and A / D converted, and the main control module sends the processing result to the upper computer; the linkage control unit of the upper computer communicates with the production line PLC through the Profinet protocol, and can send control instructions such as deceleration and shutdown, and the communication delay is ≤100 ms.

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