Cable extrusion surface flaw online detection equipment and automatic sorting method thereof

Abstract

The invention relates to the technical field of cable production and processing, in particular to cable extrusion surface flaw online detection equipment and an automatic sorting method thereof, and by integrating a flattening assembly, a double-width detection assembly, a surface flaw detection assembly and a labeling mechanism, full-process automatic closed-loop control from pretreatment, detection to sorting marking is realized; the detection speed and precision are improved, and the large-batch production requirement is met. The labeling mechanism is precisely linked with the detection system, and automatic marking is completed after flaws are detected, so that instant marking and precise positioning of the flaws are realized, and the production efficiency and the flaw tracing accuracy are greatly improved. A bimodal detection technology of line laser scanning and industrial camera imaging is innovatively adopted, and an upper and lower surface synchronous detection scheme is matched, so that the equipment can accurately identify various flaws such as scratches, recesses and bubbles, and the problem of missing detection of tiny flaws is effectively solved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cable production and processing, in particular to a cable extrusion surface flaw online detection equipment and an automatic sorting method thereof. BACKGROUND

[0002] In the cable extrusion production process, surface flaws (such as scratches, depressions, bubbles, impurities, etc.) will directly affect the insulation performance, mechanical strength and service life of the cable. At present, the common detection equipment mainly adopts single sensing technology, which has the problems of limited detection dimension and insufficient anti-interference ability, and it is difficult to meet the precise detection needs of high-speed production lines.

[0003] The existing detection methods are often designed for specific types of defects and cannot fully cover the identification needs of various surface flaws. These devices have obvious shortcomings in detection accuracy, stability and adaptability, especially in high-speed production environments, which are prone to missed detection and misjudgment. Therefore, it is urgent to develop more advanced online detection solutions. SUMMARY

[0004] Therefore, the purpose of the present application is to provide a cable extrusion surface flaw online detection equipment and an automatic sorting method thereof.

[0005] The present application adopts the following technical solutions:

[0006] A cable extrusion surface flaw online detection equipment for flaw detection of a cable, comprising:

[0007] A preprocessing mechanism, which comprises a flattening assembly and a cooling and dust removal assembly; the flattening assembly is used to press the upper and lower surfaces of the cable, and the cooling and dust removal assembly is used to cool and remove dust from the cable;

[0008] A detection mechanism, which comprises a first width detection assembly, a surface flaw detection assembly and a second width detection assembly; the first and second width detection assemblies are used to detect the width of the cable, and the surface flaw detection assembly is used to detect the upper and lower surface flaws of the cable;

[0009] A labeling mechanism, which is used to label the cable segment detected with flaws;

[0010] The flattening assembly, cooling and dust removal assembly, first width detection assembly, surface flaw detection assembly, second width detection assembly and labeling mechanism are arranged in sequence along the cable conveying direction.

[0011] Preferably, the first width detection component and the second width detection component are identical in structure, and each of the first width detection component and the second width detection component comprises a laser emitter and a receiver arranged oppositely, and the laser emitter and the receiver are arranged on two sides of the cable respectively.

[0012] Preferably, the wavelength range of the laser emitter is 640-660 nm, and the spot diameter of the laser emitter is ≤0.5 mm.

[0013] Preferably, the surface defect detection component comprises an upper detection module arranged above the cable, a lower detection module arranged below the cable, and an air floating plate arranged below the cable; the air floating plate is provided with a plurality of vertically arranged compressed air holes, the air floating plate sprays air flow upward through the compressed air holes, so that the cable is suspended; the upper detection module and the lower detection module detect surface defects on the upper surface and the lower surface of the cable respectively.

[0014] Preferably, the upper detection module and the lower detection module are identical in structure, and each of the upper detection module and the lower detection module comprises a line laser emitter and an industrial camera; the included angle between the projected laser line of the line laser emitter and the axial direction of the cable is 45-90°, and the included angle between the optical axis of the industrial camera and the plane on which the projected laser line of the line laser emitter lies is 30-60°.

[0015] Preferably, the surface defect detection component further comprises a front height sensor and a rear height sensor, and the industrial camera and the line laser emitter are both provided with a height compensation member; the height compensation member comprises a driving cylinder and a sliding block mounted on the driving end of the driving cylinder; the industrial camera and the line laser emitter are mounted on the sliding block; the front height sensor and the rear height sensor detect the height of the cable; the driving cylinder drives the sliding block to move vertically, so as to adjust the vertical distance between the industrial camera, the line laser emitter and the cable.

[0016] Preferably, the flattening component comprises a connecting base, a floating seat connected to the connecting base, a pressing piece arranged above the floating seat, and a pressing cylinder connected above the pressing piece; the upper end of the connecting seat is provided with a guide sleeve, the bottom of the floating seat is provided with a guide column, the guide column is inserted into the guide sleeve, the outer side of the guide column is provided with a return spring, and the two ends of the return spring are connected with the connecting base and the floating seat respectively.

[0017] Preferably, the cooling and dust removal component comprises an air duct and a centrifugal fan; the air duct is in a cylindrical structure and is sleeved around the cable, and the inner wall of the air duct is provided with a spiral air guide plate; the air outlet of the centrifugal fan is connected with the inner side of the air duct.

[0018] Preferably, the labeling mechanism comprises a pitch adjustment module, a lifting module and a labeling head; the pitch adjustment module comprises a receiving seat and a connecting plate which are hingedly connected to each other; the lifting module comprises a screw rod connected to the connecting plate and a driving motor drivingly connected to the screw rod; and the labeling head is installed on the screw rod.

[0019] An automatic sorting method based on the above-mentioned cable extrusion surface flaw online detection equipment, comprising the following steps:

[0020] S1. tabletting process: pressing the upper and lower surfaces of the cable through a tabletting assembly;

[0021] S2. cooling and dust removal process: cooling and dust removal treatment is performed on the surface of the cable;

[0022] S3. first width detection process: detecting the width of the cable;

[0023] S4. surface flaw detection process: the surface flaw detection assembly detects the flaws on the upper and lower surfaces of the cable and records the coordinates;

[0024] S5. second width detection process: verifying the width of the cable in step S3;

[0025] S6. labeling process: labeling the cable segment according to the coordinates in step S4.

[0026] The present application has the following advantages:

[0027] The cable extrusion surface flaw online detection equipment and the automatic sorting method thereof according to the present application realize full-process automatic closed-loop control from pretreatment, detection to sorting marking by integrating a flattening assembly, a double-width detection assembly, a surface flaw detection assembly and a labeling mechanism, improve the detection speed and accuracy, and meet the demand of mass production. The labeling mechanism is accurately linked with the detection system, and automatic marking is completed after the flaw is detected, so that instant identification and accurate positioning of the flaw are realized, and the production efficiency and the accuracy of flaw tracing are greatly improved. The dual-mode detection technology of line laser scanning and industrial camera imaging is innovatively adopted, and the upper and lower surface synchronous detection scheme is adopted, so that the equipment can accurately identify various flaws such as scratches, depressions and bubbles, and effectively solve the problem of missing detection of small defects. The non-contact detection design is adopted, the air floating plate suspension technology and the laser shot width measurement scheme are adopted, the secondary damage caused by the traditional contact detection is completely avoided, and the equipment is especially suitable for the detection demand of high smoothness special cable, and the application range of the equipment is expanded. The equipment has excellent adaptive ability, the setting of the height compensation component and the pitch adjustment module makes it can adapt to cables of different diameters and allow appropriate up and down fluctuation, greatly enhances the working condition adaptability and stability of the equipment. In terms of energy saving and environmental protection, the innovative spiral air deflector dust removal design and the air floating pressure adaptive system greatly reduce the dust removal energy consumption, and reflect good economic benefit and environmental friendliness. BRIEF DESCRIPTION OF DRAWINGS

[0028] Figure 1 Structure diagram of cable extrusion surface flaw online detection equipment of the present application;

[0029] Figure 2 Structure diagram of cable extrusion surface flaw online detection equipment of the present application from another angle;

[0030] Figure 3 Front view of cable extrusion surface flaw online detection equipment of the present application;

[0031] Figure 4 Structure diagram of flattening assembly in the present application;

[0032] Figure 5 Structure diagram of cooling and dust removal assembly in the present application;

[0033] Figure 6 Structure diagram of first width detection assembly in the present application;

[0034] Figure 7 Structure diagram of surface flaw detection assembly in the present application;

[0035] Figure 8 Structure diagram of Figure 7 Local structure diagram of circle A in the present application;

[0036] Figure 9 Structure diagram of labeling mechanism in the present application;

[0037] Figure 10 Structure diagram of cable targeted by the present application;

[0038] Figure 11 Flow chart of automatic sorting method of the present application.

[0039] Reference numerals in the drawings:

[0040] 10 - pretreatment mechanism;

[0041] 11 - flattening assembly; 111 - connecting base; 112 - guide sleeve; 113 - floating seat; 114 - guide column; 115 - return spring; 116 - pressing piece; 117 - pressing cylinder; 12 - cooling and dust removal assembly; 121 - cylindrical air duct; 122 - spiral air deflector; 123 - centrifugal fan;

[0042] 20 - detection mechanism;

[0043] 21-first width detection assembly; 211-laser emitter; 212-receiver; 22-second width detection assembly; 23-surface flaw detection assembly; 231-upper detection module; 2311-linear laser emitter; 2312-industrial camera; 232-lower detection module; 233-air float plate; 2331-compressed air hole; 234-front height sensor; 235-rear height sensor; 236-driving air cylinder; 237-sliding block;

[0044] 30-labeling mechanism;

[0045] 31-pitch adjustment module; 311-accepting seat; 312-connecting plate; 32-lifting module; 321-screw rod; 322-driving motor; 33-labeling head;

[0046] 40-cable. DETAILED DESCRIPTION

[0047] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of the present application.

[0048] In the description of the present application, it should be noted that the orientations or positional relationships indicated by the terms "vertical direction", "upper", "lower", "horizontal" and the like are based on the orientations or positional relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, "first", "second", "third", "fourth" are only for the purpose of description, and cannot be understood as indicating or implying relative importance.

[0049] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "arrangement", "installation", "connection", "connection" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or it can be integrally connected, it can be mechanically connected, or it can be electrically connected, it can be directly connected, or it can be connected through an intermediate medium, it can be the communication between two elements. For those of ordinary skill in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0050] As Figures 1 to 9As shown, the cable extrusion surface defect online detection device of the present invention includes a pretreatment mechanism 10, a detection mechanism 20, and a labeling mechanism 30; the pretreatment mechanism 10 pre-treats the cable 40, the detection mechanism 20 performs multiple tests on the cable 40, and the labeling mechanism 30 labels the defective cable 40 segments. Figure 10 As shown, the cable 40 targeted by this invention has a rectangular cross-section.

[0051] Please see Figure 4 and Figure 5 The pretreatment mechanism 10 is used to pre-treat the cable 40, and mainly includes a flattening component 11 and a cooling and dust removal component 12.

[0052] The flattening assembly 11 includes a connecting base 111, a floating seat 113, a pressing component 116, and a pressing cylinder 117. The connecting base 111 serves as a support foundation, with a guide sleeve 112 at its upper end. A guide post 114 is correspondingly positioned at the bottom of the floating seat 113, precisely inserted into the guide sleeve 112 to form a stable guiding structure. A return spring 115 is positioned on the outside of the guide post 114, with both ends fixedly connected to the connecting base 111 and the floating seat 113, ensuring the floating seat 113 can accurately return to its original position after being pressed. When the pressing cylinder 117 is activated, it drives the pressing component 116 to apply precise and controllable pressure to the upper and lower surfaces of the cable 40. The coordinated movement of the floating seat 113 and the guide post 114 ensures the stability of the flattening process. The main function of the flattening assembly 11 is to eliminate surface warping and deformation generated during the extrusion of the cable 40 through precise mechanical pressing, ensuring that the upper and lower surfaces of the cable 40 achieve ideal flatness, creating the necessary conditions for subsequent high-precision testing.

[0053] The cooling and dust removal component 12 adopts a cylindrical air duct 121 structure, which is entirely fitted around the cable 40. The inner wall of the air duct is designed with a spiral guide plate 122, which is arranged in a continuous spiral shape. The outlet of the centrifugal fan 123 is directly connected to the inner side of the air duct, and the high-speed airflow generated during operation forms a rotating airflow field along the spiral guide plate 122. This design not only achieves efficient cooling but also effectively removes dust particles from the surface of the cable 40.

[0054] The pretreatment unit 10 effectively eliminates initial deformation and contaminants on the surface of the cable 40 through the synergistic effect of flattening and cooling / dust removal processes, creating ideal conditions for subsequent accurate testing. In particular, the floating design and adjustable pressure of the flattening component 11 enable it to adapt to cables 40 of different materials and specifications, greatly improving the versatility of the equipment.

[0055] Please see Figures 6 to 8The testing organization 20 is responsible for performing precise multi-dimensional testing on the pre-treated cable 40. The testing organization 20 mainly consists of three parts: a first width testing component 21, a surface defect testing component 23, and a second width testing component 22. Each component is arranged sequentially along the cable 40 conveying direction to form a complete testing production line.

[0056] The first width detection component 21 and the second width detection component 22 adopt the same structural design, both including a laser emitter 211 and a receiver 212. The laser emitter 211 and receiver 212 are respectively positioned on both sides of the cable 40, forming a precise through-beam measurement system. Specifically, the operating wavelength of the laser emitter 211 is controlled within the range of 640-660nm, and the spot diameter does not exceed 0.5mm. This parameter configuration ensures measurement accuracy while avoiding interference from ambient light. The two width detection components work together: the first width detection component 21 measures the reference width, and the second width detection component 22 verifies the reference width. By comparing the two measurement results, the width detection result is guaranteed.

[0057] The surface defect detection component 23 includes an upper detection module 231, a lower detection module 232, and an air-float plate 233. The air-float plate 233 is positioned below the cable 40 and has multiple vertically arranged honeycomb-shaped compressed air holes 2331 to ensure uniform and stable airflow distribution. By precisely controlling the airflow pressure, the cable 40 is kept in a stable suspended state within the detection area, maintaining an optimal detection distance of 0.5-3mm from the detection module. The upper detection module 231 and the lower detection module 232 use the same configuration, both including a line laser emitter 2311 and an industrial camera 2312. The projected laser line of the line laser emitter 2311 forms an angle of 45-90° with the axis of the cable 40, and the optical axis of the industrial camera 2312 forms an angle of 30-60° with the plane containing the laser line. This angular configuration allows for the simultaneous acquisition of three-dimensional contour information and two-dimensional texture images of the cable 40 surface.

[0058] The surface defect detection component 23 employs innovative dual-mode detection technology, enabling comprehensive and efficient detection of the surface quality of the cable 40. In the three-dimensional contour detection, the line laser emitter 2311 projects a laser line onto the surface of the cable 40, and the industrial camera 2312 captures the deformed laser stripes. The three-dimensional shape of the surface is reconstructed using triangulation, detecting depressions and protrusions on the upper and lower surfaces of the cable 40. In the surface texture detection, the industrial camera 2312 captures high-resolution surface images, and anomalies in the images are analyzed using a gray-level co-occurrence matrix.

[0059] Specifically, to ensure detection accuracy, the component is also equipped with a front height sensor 234 and a rear height sensor 235, as well as a height compensation component. The height compensation component consists of a drive cylinder 236 and a slider 237, with an industrial camera 2312 and a line laser emitter 2311 mounted on the slider 237. During operation, the height sensors monitor the position of the cable 40 in real time, and the drive cylinder 236 moves the slider 237 up and down, dynamically adjusting the distance between the detection module and the cable 40 to ensure that the measurement conditions are always optimal.

[0060] Please see Figure 9 The labeling mechanism 30 is a key component for achieving automated sorting, and its modular design ensures labeling accuracy and reliability. This mechanism mainly consists of three parts: a pitch adjustment module 31, a lifting module 32, and a labeling head 33. These components work in coordination to complete precise labeling.

[0061] Specifically, the pitch adjustment module 31 adopts an innovative hinged structure design, including a hinged support 311 and a connecting plate 312. The hinged design allows for ±5° angle adjustment, ensuring the label adheres tightly to the surface of the cable 40. The lifting module 32 includes a screw 321 connected to the connecting plate 312 and a drive motor 322 driven by the screw 321. The motor drives the screw 321, causing the labeling head 33 to move up and down to accommodate cables 40 of different diameters. The labeling head 33 uses rolled strips of sticker material and has a built-in precision cutting blade for quick cutting. The stickers use bright colors such as red and yellow, and different colors can be selected according to the type of defect for easy identification in subsequent processes.

[0062] Please see Figure 11 The present invention provides an automatic sorting method based on the aforementioned online detection equipment for surface defects of cable foundations, comprising the following steps:

[0063] S1. Pressing process: The upper and lower surfaces of the cable 40 are pressed by the pressing assembly to eliminate surface warping and deformation, and to provide a flat surface for subsequent testing;

[0064] S2. Cooling and dust removal process: The cooling and dust removal component 12 is used to treat the surface of the cable 40, and the airflow removes surface dust and reduces the temperature of the cable 40.

[0065] S3. First width detection process: Use the first width detection component 21 to measure the reference width of the cable 40 and obtain the initial width data;

[0066] S4. Surface defect detection process: The surface defect detection component 23 simultaneously scans the upper and lower surfaces of the cable 40 to identify and record the coordinate positions of defects such as scratches and dents;

[0067] S5. Second width detection process: Use the second width detection component 22 to re-measure the width of cable 40 to verify the dimensional stability of cable 40;

[0068] S6. Labeling process: Based on the recorded defect coordinates, control the labeling mechanism 30 to mark the corresponding positions, and use long strip stickers to accurately identify the defect segments.

[0069] This method achieves a fully automated process from preprocessing and detection to marking, with each step closely integrated to ensure stable detection and marking accuracy even under high-speed production conditions. The combination of dual-width detection and surface defect scanning significantly improves the accuracy and reliability of defect identification.

[0070] Compared to existing technologies, the online detection equipment and automatic sorting method for cable extrusion surface defects involved in this invention, through the integration of a flattening component 11, a dual-width detection component, a surface defect detection component 23, and a labeling mechanism 30, achieves fully automated closed-loop control from pretreatment and detection to sorting and marking; improving detection speed and accuracy to meet the needs of mass production. The labeling mechanism 30 is precisely linked with the detection system, automatically marking defects upon detection, achieving instant identification and precise positioning of defects, significantly improving production efficiency and the accuracy of defect traceability. The innovative use of dual-modal detection technology combining line laser scanning and industrial camera 2312 imaging, along with a simultaneous upper and lower surface detection scheme, enables the equipment to accurately identify various defects such as scratches, dents, and bubbles, effectively solving the problem of missed detection of minor defects. The non-contact detection design, through the suspension technology of the air-floating plate 233 and the laser beam width measurement scheme, completely avoids secondary damage caused by traditional contact detection, making it particularly suitable for the detection needs of high-gloss special cables, expanding the application range of the equipment. The equipment possesses excellent adaptability; the height compensation component and pitch adjustment module 31 allow it to accommodate cables 40 of different diameters and permit appropriate vertical fluctuations, greatly enhancing its operational adaptability and stability. In terms of energy conservation and environmental protection, the innovative spiral air guide plate 122 dust removal design and air flotation pressure adaptive system significantly reduce dust removal energy consumption, demonstrating good economic benefits and environmental friendliness.

[0071] The above description merely illustrates preferred technical solutions of the present invention, and while the description is relatively specific and detailed, it should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and the present invention also intends to include these modifications and variations.

Claims

1. An online inspection device for surface defects in extruded cables, used for defect detection in cables, characterized in that, include: The pretreatment mechanism includes a flattening component and a cooling and dust removal component; The flattening is used to press the upper and lower surfaces of the cable, and the cooling and dust removal assembly is used to cool and remove dust from the cable. The testing mechanism includes a first width testing component, a surface defect testing component, and a second width testing component; the first width testing component and the second width testing component are used to test the width of the cable, and the surface defect testing component is used to test defects on the upper and lower surfaces of the cable. A labeling mechanism for marking cable segments that have been found to have defects; The flattening component, cooling and dust removal component, first width detection component, surface defect detection component, second width detection component, and labeling mechanism are arranged sequentially along the cable conveying direction.

2. The online detection equipment for surface defects in extruded cables according to claim 1, characterized in that, The first width detection component and the second width detection component have the same structure. Both the first width detection component and the second width detection component include a laser emitter and a receiver arranged opposite to each other. The laser emitter and the receiver are respectively located on both sides of the cable.

3. The online detection equipment for surface defects in extruded cables according to claim 2, characterized in that, The wavelength range of the laser emitter is 640-660nm, and the spot diameter of the laser emitter is ≤0.5mm.

4. The online detection equipment for surface defects in extruded cables according to claim 1, characterized in that, The surface defect detection component includes an upper detection module located above the cable, a lower detection module located below the cable, and an air float plate located below the cable; the air float plate has multiple vertically arranged compressed air holes, and the air float plate sprays air upward through the compressed air holes, so that the cable is suspended in the air; The upper detection module and the lower detection module respectively detect surface defects on the upper and lower surfaces of the cable.

5. The online detection equipment for surface defects in extruded cables according to claim 4, characterized in that, The upper and lower detection modules have the same structure, and both include a line laser emitter and an industrial camera. The angle between the projected laser line of the line laser emitter and the cable axis is 45-90°, and the angle between the optical axis of the industrial camera and the plane containing the projected laser line of the line laser emitter is 30-60°.

6. The online detection equipment for surface defects in extruded cables according to claim 5, characterized in that, The surface defect detection component further includes a front height sensor and a rear height sensor. The industrial camera and line laser emitter are both equipped with height compensation components. The height compensation components include a drive cylinder and a slider mounted on the drive end of the drive cylinder. The industrial camera and line laser emitter are mounted on the slider. The front height sensor and the rear height sensor detect the height of the cable. The drive cylinder drives the slider to move vertically to adjust the vertical distance between the industrial camera and line laser emitter and the cable.

7. The online detection equipment for surface defects in extruded cables according to claim 1, characterized in that, The flattening assembly includes a connecting base, a floating seat connected to the connecting base, a pressing member disposed above the floating seat, and a pressing cylinder connected to the pressing member for driving. The upper end of the connecting base is provided with a guide sleeve, the bottom of the floating seat is provided with a guide post, the guide post is inserted into the guide sleeve, and the outer side of the guide post is provided with a return spring. The two ends of the return spring are respectively connected to the connecting base and the floating seat.

8. The online detection equipment for surface defects in extruded cables according to claim 1, characterized in that, The cooling and dust removal assembly includes an air duct and a centrifugal fan; the air duct is cylindrical and sleeved around the cable, and the inner wall of the air duct is provided with a spiral air guide plate; the air outlet of the centrifugal fan is connected to the inner side of the air duct.

9. The online detection equipment for surface defects in extruded cables according to claim 1, characterized in that, The labeling mechanism includes a pitch adjustment module, a lifting module, and a labeling head; the pitch adjustment module includes a receiving seat and a connecting plate that are hinged to each other; the lifting module includes a screw connected to the connecting plate and a drive motor that is drivenly connected to the screw; the labeling head is mounted on the screw.

10. An automatic sorting method, based on the online detection equipment for surface defects of extruded cables according to any one of claims 1-9, characterized in that, Includes the following steps: S1. Tableting process: The upper and lower surfaces of the cable are pressed by a tableting assembly; S2. Cooling and dust removal process: Cooling and dust removal treatment is performed on the surface of the cable; S3. First width inspection procedure: Inspect the cable width; S4. Surface Defect Detection Process: The surface defect detection component detects defects on the upper and lower surfaces of the cable and records the coordinates; S5. Second width inspection process: Verify the cable width in step S3; S6. Labeling process: Label the cable segments according to the coordinates in step S4.

Images