Breakdown point positioning system and method for insulated wire core of control cable, and electronic equipment

Abstract

The embodiment of the invention provides a breakdown point positioning system and method for an insulated wire core of a control cable, and electronic equipment. The system comprises a meter counter, a spark machine and a control device, a meter counter and a spark machine are sequentially installed on a production line of the control cable insulation wire core according to the production moving direction of the control cable insulation wire core. The control device is in communication connection with the meter counter and the spark machine. The meter counter is used for collecting the length parameter of the insulated wire core of the control cable in real time; the spark machine is used for triggering the control device to latch the current length parameter of the meter counter when a breakdown event of the insulated wire core of the control cable is detected; and the control device is used for determining the physical position of the breakdown point according to the distance parameter of the meter counter and the spark machine and the current length parameter. According to the method, the physical position of the breakdown point can be accurately obtained.

Description

Technical Field

[0001] This application relates to the field of cable manufacturing technology, and in particular to a system, method and electronic device for locating the breakdown point of the insulated core of a cable. Background Technology

[0002] In the high-speed production of control cables, the integrity of the insulated core directly determines the quality and safety of the product. The insulation layer of the control cable's insulated core is usually a thin-layer structure. Due to the thin-walled nature of the insulation layer, micron-level breakdown points are easily generated during high-speed extrusion, winding, and other processes. If such defects are not detected and repaired in time, the entire reel of product may be scrapped due to insulation failure.

[0003] Currently, the breakdown detection of insulation cores in control cables mainly relies on traditional EDM machines, whose core function is to detect insulation defects and count the number of breakdowns through high-voltage discharge.

[0004] However, traditional EDM machines only have a breakdown counting function and cannot provide information on the physical location of the breakdown point. It is difficult to find the breakdown point by manual visual inspection and the physical location of the breakdown point cannot be accurately obtained. Summary of the Invention

[0005] This application provides a system, method, and electronic device for locating the breakdown point of the insulation core of a control cable, so as to accurately obtain the physical location of the breakdown point.

[0006] In a first aspect, embodiments of this application provide a system for locating the breakdown point of a control cable insulated core, comprising: a meter counter, an EDM machine, and a control device; on a production line for control cable insulated cores, the meter counter and the EDM machine are installed sequentially according to the production movement direction of the control cable insulated cores; the control device is communicatively connected to both the meter counter and the EDM machine; the meter counter is used to collect the length parameters of the control cable insulated core in real time; the EDM machine is used to trigger the control device to latch the current length parameters of the meter counter when a breakdown event of the control cable insulated core is detected; the control device is used to determine the physical location of the breakdown point based on the distance parameters between the meter counter and the EDM machine, and the current length parameters.

[0007] In one possible implementation, the system for locating the breakdown point of the control cable insulation core further includes a labeling machine and an operation panel; the labeling machine and the operation panel are installed on the production line of the control cable insulation core; wherein the labeling machine is installed behind the EDM machine according to the production movement direction of the control cable insulation core; the control device is communicatively connected to both the labeling machine and the operation panel; the operation panel is used to respond to user input operations, acquire product parameters of the control cable insulation core, and send the product parameters of the control cable insulation core to the control device; the EDM machine is used to trigger the control device to control the labeling machine to affix product parameters to the control cable insulation core when a breakdown event of the control cable insulation core is detected.

[0008] In one possible implementation, the system for locating the breakdown point of the control cable insulation core further includes an infrared imaging scanning device; the infrared imaging scanning device is installed between the EDM machine and the labeling machine; when the EDM machine detects a breakdown event of the control cable insulation core, it triggers the control device to control the infrared imaging scanning device to perform thermal imaging scanning on the control cable insulation core to acquire multiple infrared images; the control device is used to receive the multiple infrared images sent by the infrared imaging scanning device and determine whether there is a breakdown point in the control cable insulation core based on the multiple infrared images.

[0009] Secondly, embodiments of this application provide a method for locating the breakdown point of a control cable insulated core, applied to a system for locating the breakdown point of a control cable insulated core. The system includes a meter counter, an EDM machine, and a control device. The method includes: the meter counter acquiring the length parameters of the control cable insulated core in real time; when the EDM machine detects a breakdown event, triggering the control device to latch the current length parameters of the meter counter; and the control device determining the physical location of the breakdown point based on the distance parameters between the meter counter and the EDM machine, and the current length parameters.

[0010] In one possible implementation, the control device determines the physical location of the puncture point based on the distance parameters between the meter counter and the EDM machine, as well as the current length parameter. This includes: the control device recalling pre-stored distance parameters between the meter counter and the EDM machine; and the control device adding the distance parameters between the meter counter and the EDM machine to the current length parameter to determine the physical location of the puncture point.

[0011] In one possible implementation, when the EDM detects a breakdown event, it triggers the control device to latch the current length parameter of the counter, including: when the EDM detects a breakdown event, it sends a breakdown signal to the input point of the control device; when the input point of the control device detects a breakdown signal, it reads the current length parameter of the counter; and the control device latches the current length parameter of the counter.

[0012] In one possible implementation, the system further includes a label reader and an operation panel; the method further includes: a control device receiving product parameters of the control cable insulation core sent by the operation panel; the control device acquiring the moving speed of the control cable insulation core on the production line; the control device recalling pre-stored distance parameters between the EDM and the label reader; the control device determining the time it takes for the breakdown point to move to the label reader based on the distance parameters between the EDM and the label reader and the moving speed; when the EDM detects a breakdown event, it triggers the control device to send a label pasting signal to the label reader after the specified time; wherein the label pasting signal carries product parameters; and the label reader pastes the product parameters as a label onto the control cable insulation core according to the label pasting signal.

[0013] In one possible implementation, before the meter counter collects the length parameters of the control cable insulation core in real time, the following steps are also included: the meter counter clears the historically collected length parameters of the control cable insulation core; and the EDM clears the historical breakdown counts.

[0014] In one possible implementation, the system further includes an infrared imaging scanning device; after the EDM detects a breakdown event, the system further includes: when the EDM detects a breakdown event, it sends a breakdown signal to the input point of the control device; when the input point of the control device detects a breakdown signal, it controls the infrared imaging scanning device to perform thermal imaging scanning on the insulation core of the control cable to acquire multiple infrared images; the infrared imaging scanning device sends the multiple infrared images to the control device; the control device determines whether there is a breakdown point in the insulation core of the control cable based on the multiple infrared images; if the control device determines that there is a breakdown point, it triggers the meter counter to latch the current length parameter; if the control device determines that there is no breakdown point, it does not perform the operation of triggering the meter counter to latch the current length parameter and determining the physical location of the breakdown point.

[0015] Thirdly, embodiments of this application provide an electronic device, including: a memory and a processor;

[0016] The memory stores computer-executed instructions;

[0017] The processor executes computer execution instructions stored in the memory, causing the processor to perform the first aspect and / or various possible implementations of the first aspect as described above.

[0018] The present application provides a system, method, and electronic device for locating the breakdown point of the insulated core of a control cable. The system includes a meter counter, an EDM machine, and a control device. When the EDM machine detects a breakdown event, it triggers the control device to latch the current length parameter of the meter counter. Since the meter counter measures the length of the insulated core of the control cable reaching the meter counter, while the breakdown event occurs at the EDM machine, there is a physical distance between them. This distance parameter needs to be compensated to obtain the true physical location of the breakdown point. The physical location of the breakdown point is determined by the distance parameter between the meter counter and the EDM machine, and the current length parameter. This eliminates the physical error between the EDM machine and the meter counter, ensuring the accuracy of the breakdown point location. Attached Figure Description

[0019] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0020] Figure 1 A schematic diagram of the structure of the control cable insulation core breakdown point location system provided in the embodiments of this application;

[0021] Figure 2 A flowchart illustrating the method for locating the breakdown point of the insulation core of a control cable provided in this application embodiment;

[0022] Figure 3 This is a schematic diagram of the process for assisting in the identification of breakdown points provided in an embodiment of this application;

[0023] Figure 4 A schematic diagram of the structure of the electronic device provided in this application.

[0024] Figure label:

[0025] 1- Meter counter;

[0026] 2-EDM machine;

[0027] 3-Control device;

[0028] 4-Label printer;

[0029] 5-Operation screen;

[0030] 6-Infrared imaging scanning device;

[0031] 7- Wire feeding device;

[0032] 8-Front-mounted traction;

[0033] 9-Alignment device;

[0034] 10-Extruder;

[0035] 11-Cooling water tank;

[0036] 12 - Control cable insulated core;

[0037] 13- Rear-mounted traction;

[0038] 14-Take-up device.

[0039] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0040] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0041] To address the aforementioned technical problems, this application proposes the following technical approach: Traditional EDM machines only have a breakdown counting function and cannot provide physical location information of the breakdown point. Manual visual inspection makes it difficult to detect the breakdown point, thus failing to accurately determine its physical location. The inventors devised a method using a meter counter to read the length parameter at the time of the breakdown event. Considering that the meter counter measures the length of the control cable insulation core reaching the meter counter, while the breakdown event occurs at the EDM machine, there is a physical distance between the two. This distance parameter needs to be compensated to obtain the true physical location of the breakdown point. By comparing the distance parameter between the meter counter and the EDM machine with the current length parameter, the physical location of the breakdown point can be determined. This eliminates the physical error between the EDM machine and the meter counter, ensuring the accuracy of the breakdown point location.

[0042] The technical solution of this application and how the technical solution of this application solves the above-mentioned technical problems are described in detail below with specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments. The embodiments of this application will now be described with reference to the accompanying drawings.

[0043] Figure 1 This is a schematic diagram of the structure of the control cable insulation core breakdown point location system provided in the embodiments of this application, as shown below. Figure 1 As shown, it includes: a meter counter 1, an EDM machine 2, and a control device 3.

[0044] In this embodiment, the meter counter 1 is a high-precision meter counter that uses a laser-type contactless encoder. Compared with the traditional wheel-type meter counter, it avoids causing indentations or damage to the surface of small-diameter wire cores.

[0045] In this embodiment, the control device 3 is a programmable logic controller (PLC).

[0046] On the production line of the control cable insulated core 12, a meter counter 1 and an EDM machine 2 are installed in sequence according to the production movement direction of the control cable insulated core 12.

[0047] In this embodiment, the distance between the meter counter 1 and the EDM machine 2 is predetermined, precisely shortened and solidified, and is usually controlled within 3 meters to reduce the cumulative error of signal transmission and mechanical conduction, and to adapt to the compact layout of the production line.

[0048] The control device 3 is communicatively connected to the meter counter 1 and the spark machine 2, respectively.

[0049] The meter counter 1 is used to collect the length parameters of the insulated core 12 of the control cable in real time.

[0050] The EDM machine 2 is used to trigger the control device 3 to latch the current length parameter of the meter counter 1 when a breakdown event of the insulation core 12 of the control cable is detected.

[0051] The control device 3 is used to determine the physical location of the penetration point based on the distance parameters between the meter counter 1 and the spark generator 2, as well as the current length parameter.

[0052] In this embodiment, on the production line of the control cable insulated core 12, the production movement direction of the control cable insulated core 12 is from left to right. From left to right, the following are installed in sequence: wire feeding device 7, front traction device 8, straightening device 9, extruder 10, cooling water tank 11, meter counter 1, EDM machine 2, infrared imaging scanning device 6, label machine 4, operation screen 5, rear traction device 13, and take-up device 14.

[0053] In this embodiment, the wire feeding device 7 is the starting point of production, responsible for feeding out the wire cores to provide a basic carrier for subsequent processes. The wire take-up device 14 winds the completed control cable insulated wire cores 12 into a spool for easy storage, transportation, or entry into subsequent processes.

[0054] In this embodiment, the front traction 8 provides the power for the wire core to move forward, controls the wire core to enter the subsequent process at a uniform speed, and avoids the wire core from loosening or stretching; the rear traction 13 cooperates with the front traction 8 to maintain the wire core conveying speed of the entire production line uniformly, and avoids the wire core from stretching or loosening.

[0055] In this embodiment, the straightening device 9 straightens any potentially bent conductor cores to ensure that the insulation layer is evenly coated in the subsequent extrusion process, avoiding uneven insulation layer thickness. The extruder 10 heats and melts the insulating material, then evenly coats it around the conductor core to form the control cable insulated conductor core 12.

[0056] In this embodiment, the cooling water tank 11 cools the newly extruded control cable insulation core 12 with cold water, allowing the insulation layer to quickly set and ensuring the stability of the insulation layer's shape and performance.

[0057] In this embodiment, the meter counter 1 collects the production length of the insulated core 12 of the control cable in real time, i.e., the length parameter, and transmits the length parameter to the control device 3.

[0058] In this embodiment, the EDM machine 2 applies high voltage to the insulated core 12 of the control cable to detect whether there are breakdown defects in the insulation layer, such as holes and thin spots; if a breakdown defect is detected, the control device 3 is immediately triggered to latch the current length parameter of the meter counter 1.

[0059] Specifically, when the EDM machine 2 detects a breakdown event, it sends a breakdown signal to the input point of the control device 3; when the input point of the control device 3 detects the breakdown signal, it reads the current length parameter of the meter counter 1; the control device 3 latches the current length parameter of the meter counter 1.

[0060] In this embodiment, the EDM machine 2 applies high voltage to the insulated core 12 of the control cable. When there is a micron-level breakdown point in the insulation layer, the built-in detection circuit, such as the current sensor, captures the discharge signal and immediately generates a breakdown signal.

[0061] In this embodiment, the breakdown trigger signal is transmitted to the input point of the Programmable Logic Controller (PLC) via a shielded cable. This input point is a high-speed interrupt input point. The use of a shielded cable avoids electromagnetic interference from high-voltage equipment and motors on the production line, ensuring that the signal is not falsely triggered. The input point achieves microsecond-level response, adapting to high-speed production of 200 meters per minute or higher.

[0062] In this embodiment, when the PLC input point detects a breakdown signal, the current normal program, such as data statistics, is immediately paused. The current length parameter of the meter counter 1 is read first, such as 125.32 meters. This length parameter is then latched into the PLC's local storage.

[0063] Specifically, the control device 3 calls the pre-stored distance parameters between the meter counter 1 and the spark machine 2; the control device 3 adds the distance parameters between the meter counter 1 and the spark machine 2 to the current length parameters to determine the physical location of the penetration point.

[0064] In this embodiment, the PLC retrieves the distance parameters between the meter counter 1 and the EDM machine 2 from local storage. This value is determined by actual measurement during production line installation, entered into the PLC before production, and remains unchanged once fixed. The distance parameters between the meter counter 1 and the EDM machine 2 are inherent error compensation values. The meter counter 1 measures the length of the insulated core 12 of the control cable reaching the meter counter 1, while the breakdown event occurs at the EDM machine 2. Since there is a physical gap between the two, this distance parameter needs to be compensated to obtain the true location of the breakdown point.

[0065] In this embodiment, the physical location of the breakdown point equals the current length parameter of the meter counter plus the distance parameter between the meter counter and the EDM machine 2. For example, if the current length parameter of the latched meter counter 1 is 125.32 meters and the distance parameter between the meter counter 1 and the EDM machine 2 is 2 meters, then the physical location of the breakdown point equals 125.32 + 2 = 127.32 meters. The purpose is to convert the length parameter of the meter counter into the physical location of the breakdown point, thus resolving the positioning deviation problem caused by the physical gap between the meter counter 1 and the EDM machine 2. This fundamentally eliminates the error caused by hardware layout spacing and improves positioning accuracy.

[0066] In this embodiment, the input point of the control device 3 is a high-speed interrupt input point, which ensures that the breakdown event is responded to within microseconds and the instantaneous value of the meter counter 1 is immediately latched to adapt to high-speed production operation exceeding 200 meters / minute.

[0067] In this embodiment, the system for locating the breakdown point of the control cable insulation core also includes a labeler 4 and an operation panel 5. The labeler 4 and operation panel 5 are installed on the production line of the control cable insulation core 12; the labeler 4 is installed behind the EDM 2, following the production movement direction of the control cable insulation core 12. The control device 3 is communicatively connected to both the labeler 4 and the operation panel 5. The operation panel 5 is used to respond to user input, acquire the product parameters of the control cable insulation core 12, and send these parameters to the control device 3. When the EDM 2 detects a breakdown event in the control cable insulation core 12, it triggers the control device 3 to control the labeler 4 to affix the product parameters to the control cable insulation core 12.

[0068] In this embodiment, before producing the insulated core 12 of the control cable, the meter counter 1 clears the historically collected length parameters of the insulated core 12 of the control cable; the spark gap machine 2 clears the historical breakdown count. Simultaneously, the operator uses the operation screen 5 to bind product parameters, including the cable number, specifications, and operator information of the current production batch, with the length parameters to be recorded, forming an independent, traceable data package to ensure that each breakdown point record has a complete data background. The purpose is to clear residual data from the previous batch, avoid confusion between historical length parameters and breakdown counts with the current batch, and ensure the accuracy of subsequent positioning and data traceability.

[0069] Specifically, the control device 3 receives the product parameters of the control cable insulated core 12 sent by the operation panel 5; the control device 3 acquires the moving speed of the control cable insulated core 12 on the production line; the control device 3 calls the pre-stored distance parameters between the EDM machine 2 and the labeling machine 4; the control device 3 determines the time it takes for the breakdown point to move to the labeling machine 4 based on the distance parameters and moving speed between the EDM machine 2 and the labeling machine 4; when the EDM machine 2 detects a breakdown event, it triggers the control device 3 to send a label pasting signal to the labeling machine 4 after the specified time; the label pasting signal carries the product parameters; the labeling machine 4 pastes the product parameters as a label onto the control cable insulated core 12 according to the label pasting signal.

[0070] In this embodiment, the product parameter information is used to form the label information to be pasted according to the preset label information template.

[0071] In this embodiment, the labeler 4 is a miniature labeling head, which is designed specifically for attaching small labels to small outer diameter wire cores to prevent the labels from falling off or affecting the winding.

[0072] In this embodiment, the PLC receives product parameters sent by the operation panel 5, such as batch number 20251109-03, wire diameter 3mm, operator ID 001, etc.

[0073] Optionally, the PLC obtains the real-time speed, such as 200 meters per minute, from the frequency converter of the traction device on the production line, or derives it from the unit time increment of the meter counter 1, such as the meter counter 1 increasing by 3.33 meters in 1 second, i.e., the speed = 3.33 meters per second.

[0074] In this embodiment, the PLC calls the pre-stored distance between the EDM machine 2 and the label machine 4, such as 1.5 meters, which is set according to the production line layout before production and stored in the PLC memory.

[0075] In this embodiment, the PLC calculates the time it takes for the penetration point to move to the label reader 4 using the formula: Distance between the EDM machine and the label reader ÷ Moving speed. For example, 1.5 meters ÷ (200 meters / 60 seconds) = 0.45 seconds, meaning that 0.45 seconds after the penetration event, the penetration point reaches the label reader 4. This calculation compensates for the time difference between penetration detection and label application, ensuring the label is accurately applied behind the penetration point.

[0076] In this embodiment, when the EDM machine 2 detects a breakdown event, the PLC synchronously starts a delay timer. After a delay of, such as 0.45 seconds, it sends a label pasting signal to the label printer 4, which carries product parameters. After receiving the label pasting signal, the label printer 4 prints a label and pastes it on the surface of the insulated core 12 of the control cable.

[0077] In this embodiment, the system for locating the breakdown point of the control cable insulation core also includes an infrared imaging scanning device 6; the infrared imaging scanning device 6 is installed between the EDM machine 2 and the tagging machine 4; when the EDM machine 2 detects a breakdown event of the control cable insulation core 12, it triggers the control device 3 to control the infrared imaging scanning device 6 to perform thermal imaging scanning on the control cable insulation core 12 and acquire multiple infrared images; the control device 3 is used to receive the multiple infrared images sent by the infrared imaging scanning device 6 and determine whether there is a breakdown point in the control cable insulation core 12 based on the multiple infrared images.

[0078] In this embodiment, the infrared imaging scanning device 6 is used to assist in identifying the physical characteristics of the breakdown point, thereby fundamentally eliminating random errors.

[0079] Specifically, when the EDM machine 2 detects a breakdown event, it sends a breakdown signal to the input point of the control device 3. When the input point of the control device 3 detects a breakdown signal, it controls the infrared imaging scanning device 6 to perform thermal imaging scanning on the insulation core 12 of the control cable to acquire multiple infrared images. The infrared imaging scanning device 6 sends the multiple infrared images to the control device 3. Based on the multiple infrared images, the control device 3 determines whether there is a breakdown point in the insulation core 12 of the control cable. If the control device 3 determines that there is a breakdown point, it triggers the meter counter 1 to latch the current length parameter.

[0080] Optionally, the control device 3 can synchronously collect real-time time, length parameters, and the physical location of the breakdown point, generating graphs and summary information tables, which can be displayed through the display panel of the control device 3. It can assist in full-process video traceability, including quality traceability, determining the location and time of breakdown of the insulated core 12 of the control cable, and allowing for the review of other anomalies caused by unforeseen circumstances through video recordings.

[0081] The breakdown point location system for the control cable insulation core of this application is not limited to control cable insulation cores, but is also applicable to other cable insulation cores.

[0082] In summary, the system for locating the breakdown point of the control cable insulation core includes a meter counter, an EDM machine, and a control device. When the EDM machine detects a breakdown event, it triggers the control device to latch the current length parameter of the meter counter. Since the meter counter measures the length of the control cable insulation core reaching the meter counter, while the breakdown event occurs at the EDM machine, there is a physical distance between them. This distance parameter needs to be compensated to obtain the true physical location of the breakdown point. By comparing the distance parameter between the meter counter and the EDM machine with the current length parameter, the physical location of the breakdown point is determined. This eliminates the physical error between the EDM machine and the meter counter, ensuring the accuracy of the breakdown point location. Furthermore, through precise positioning, cables with breakdown points can be repaired at specific points instead of being scrapped as a whole reel, thus reducing material waste and production costs.

[0083] Figure 2 This is a flowchart illustrating the method for locating the breakdown point of the insulation core of a control cable provided in an embodiment of this application. Figure 2 As shown, the method includes:

[0084] S201: The meter counter collects the length parameters of the insulated core of the control cable in real time.

[0085] In this embodiment, before executing step S201, the meter counter clears the historically collected length parameters of the control cable insulation cores; the EDM clears the historical breakdown counts. The purpose is to clear residual data from the previous batch, avoid confusion between historical length parameters and breakdown counts and the current batch, and ensure the accuracy of subsequent positioning and data traceability.

[0086] S202: When the EDM machine detects a breakdown event, it triggers the control device to latch the current length parameter of the meter counter.

[0087] Specifically, when the EDM detects a breakdown event, it sends a breakdown signal to the input point of the control device; when the input point of the control device detects the breakdown signal, it reads the current length parameter of the meter counter; the control device latches the current length parameter of the meter counter.

[0088] In this embodiment, the EDM machine applies high voltage to the insulated core of the control cable. When there is a micron-level breakdown point in the insulation layer, the built-in detection circuit, such as a current sensor, captures the discharge signal and immediately generates a breakdown signal.

[0089] In this embodiment, the breakdown trigger signal is transmitted to the input point of the Programmable Logic Controller (PLC) via a shielded cable. This input point is a high-speed interrupt input point. The use of a shielded cable avoids electromagnetic interference from high-voltage equipment and motors on the production line, ensuring that the signal is not falsely triggered. The input point achieves microsecond-level response, adapting to high-speed production of 200 meters per minute or higher.

[0090] In this embodiment, when the PLC input point detects a breakdown signal, the current normal program, such as data statistics, is immediately paused. The current length parameter of the meter counter is read first, such as 125.32 meters. This length parameter is then latched into the PLC's local storage.

[0091] Optionally, the control device receives product parameters of the control cable insulation core sent by the operation panel; the control device acquires the moving speed of the control cable insulation core on the production line; the control device calls up pre-stored distance parameters between the EDM and the labeling machine; the control device determines the time it takes for the breakdown point to move to the labeling machine based on the distance parameters between the EDM and the labeling machine and the moving speed; when the EDM detects a breakdown event, it triggers the control device to send a label pasting signal to the labeling machine after the specified time; wherein the label pasting signal carries product parameters; the labeling machine pastes the product parameters as a label onto the control cable insulation core according to the label pasting signal.

[0092] In this embodiment, the PLC receives product parameters sent by the operation panel, such as batch number 20251109-03, wire diameter 3mm, operator ID 001, etc.

[0093] Optionally, the PLC obtains the real-time speed, such as 200 meters per minute, from the frequency converter of the traction device on the production line, or derives it from the unit time increment measured by the meter counter, such as the meter counter increasing by 3.33 meters in 1 second, i.e., the speed = 3.33 meters per second.

[0094] In this embodiment, the PLC calls the pre-stored distance between the EDM machine and the label machine, such as 1.5 meters, which is set according to the production line layout before production and stored in the PLC memory.

[0095] In this embodiment, the PLC calculates the time it takes for the penetration point to move to the label reader using the formula: Distance between the EDM machine and the label reader ÷ Moving speed. For example, 1.5 meters ÷ (200 meters / 60 seconds) = 0.45 seconds, meaning that 0.45 seconds after the penetration event, the penetration point reaches the label reader. This calculation compensates for the time difference between penetration detection and label application, ensuring the label is accurately applied behind the penetration point.

[0096] In this embodiment, when the EDM machine detects a breakdown event, the PLC synchronously starts a delay timer. After a delay of, such as 0.45 seconds, a label pasting signal is sent to the label printer, carrying product parameters. After receiving the label pasting signal, the label printer prints a label and pastes it onto the surface of the insulated core of the control cable.

[0097] In this embodiment, the labeler is a miniature labeling head, specifically designed to attach small labels to small outer diameter wire cores, preventing labels from falling off or affecting wire take-up.

[0098] The electronic data of the breakdown point is converted into a physical tag, realizing a one-to-one correspondence between the breakdown point and the tag, which provides a basis for subsequent targeted repair.

[0099] S203: The control device determines the physical location of the puncture point based on the distance parameters between the meter counter and the EDM machine, as well as the current length parameters.

[0100] Specifically, the control device calls the pre-stored distance parameters between the meter counter and the EDM machine; the control device adds the distance parameters between the meter counter and the EDM machine to the current length parameters to determine the physical location of the penetration point.

[0101] In this embodiment, the purpose of step S203 is to convert the length parameter of the meter counter into the physical location of the puncture point, thereby solving the positioning deviation problem caused by the physical gap between the meter counter and the EDM machine.

[0102] In this embodiment, the PLC retrieves the distance parameters between the meter counter and the EDM machine from local storage. This value is determined by actual measurement during production line installation, entered into the PLC before production, and remains unchanged once fixed. The distance parameter between the meter counter and the EDM machine is an inherent error compensation value. The meter counter measures the length of the control cable insulation core reaching the meter counter, while the breakdown event occurs at the EDM machine. Since there is a physical gap between the two, this distance parameter needs to be compensated to obtain the true location of the breakdown point.

[0103] In this embodiment, the physical location of the breakdown point equals the current length parameter of the meter counter plus the distance parameter between the meter counter and the EDM machine. For example, if the latched current length parameter of the meter counter is 125.32 meters and the distance parameter between the meter counter and the EDM machine is 2 meters, then the physical location of the breakdown point equals 125.32 + 2 = 127.32 meters. This fundamentally eliminates errors caused by hardware layout intervals and improves positioning accuracy.

[0104] In summary, when the EDM machine detects a breakdown event, it triggers the control device to latch the current length parameter of the meter counter. Since the meter counter measures the length of the control cable insulation core reaching the meter counter, while the breakdown event occurs at the EDM machine, there is a physical gap between them. This distance parameter needs to be compensated to obtain the true physical location of the breakdown point. By comparing the distance parameter between the meter counter and the EDM machine with the current length parameter, the physical location of the breakdown point can be determined. This eliminates the physical error between the EDM machine and the meter counter, ensuring the accuracy of the breakdown point location. Furthermore, through precise positioning, cables with breakdown points can be repaired at specific points instead of being scrapped as a whole reel, thus reducing material waste and production costs.

[0105] Figure 3 This is a schematic diagram of the process for assisting in the identification of breakdown points provided in the embodiments of this application, such as... Figure 3 As shown, in this embodiment... Figure 2 Based on the embodiments, the process of assisting in the identification of breakdown points is described, which includes:

[0106] S301: When the EDM machine detects a breakdown event, it sends a breakdown signal to the input point of the control device.

[0107] In this embodiment, the EDM machine acts as an initial detector for breakdown events, capturing breakdown defects through the principle of high-voltage discharge, generating a breakdown signal, and transmitting it to the PLC.

[0108] S302: When a breakdown signal is detected at the input point of the control device, the infrared imaging scanning device is controlled to perform thermal imaging scanning on the insulation core of the control cable to acquire multiple infrared images.

[0109] In this embodiment, the infrared imaging scanning device monitors the surface temperature of the insulation core of the control cable in real time. After the PLC detects the breakdown signal at the input point, it sends a start scanning command to the infrared imaging scanning device via the industrial Ethernet interface. The command includes scanning parameters such as scan duration, frame rate, and field of view. Upon receiving the command, the infrared imaging scanning device immediately starts scanning and simultaneously captures five frames of infrared images before and after the breakdown moment.

[0110] S303: The infrared imaging scanning device sends multiple infrared images to the control device.

[0111] S304: The control device determines whether there is a breakdown point in the insulation core of the control cable based on multiple infrared images.

[0112] In this embodiment, three core features are extracted from the infrared image: local temperature peaks, temperature distribution, and temporal consistency.

[0113] Specifically, whether there is an instantaneous temperature rise of 0.5°C or more in the local temperature peak, which is a characteristic of breakdown discharge; whether the high-temperature area is point-like rather than a large-area uniform temperature rise (excluding environmental interference); and whether the temperature rise is synchronized with the EDM discharge signal.

[0114] In this embodiment, if all three characteristics are met, it is determined to be a real breakdown event, and the PLC performs latching and subsequent operations; if any one characteristic is not met, it is determined to be a false breakdown event, the PLC ignores the signal, does not latch the data or affix the label, and at the same time displays a suspected false trigger on the operation screen.

[0115] S305: If the control device determines that there is a breakdown point, it triggers the meter counter to latch the current length parameter.

[0116] In this embodiment, if all three characteristics are met, it is determined to be a real breakdown event, and the PLC performs latching and subsequent operations.

[0117] S306: If the control device determines that there is no breakdown point, it will not perform the operation of triggering the meter counter to latch the current length parameter and determining the physical location of the breakdown point.

[0118] In this embodiment, if any one of the features is not met, it is determined to be a false breakdown event. The PLC ignores the signal, does not latch the data, does not determine the physical location of the breakdown point, does not affix a label, and at the same time prompts a suspected false trigger on the operation screen.

[0119] In summary, when the EDM machine detects a breakdown event, it triggers the control device to control the infrared imaging scanning device to capture multiple infrared images of the control cable's insulated core. The infrared imaging scanning device sends these multiple infrared images to the control device, which then uses these images to determine whether there is a breakdown point in the control cable's insulated core. This helps to confirm the physical location of the breakdown point, reduces misjudgments caused by signal interference, and improves positioning accuracy.

[0120] Alternatively, this application can also be applied to other continuous material production fields that require online detection and precise location of defects, such as plastic pipe extrusion and medical catheters.

[0121] Optionally, the method for locating the breakdown point of the control cable insulation core in this application is not limited to control cable insulation cores, but is also applicable to other cable insulation cores.

[0122] Figure 4 A schematic diagram of the structure of the electronic device provided in this application. Figure 4 As shown, the electronic device provided in this embodiment includes at least one processor 401 and a memory 402. Optionally, the electronic device further includes a communication component 403. The processor 401, memory 402, and communication component 403 are connected via a bus.

[0123] In a specific implementation, at least one processor 401 executes computer execution instructions stored in memory 402, causing at least one processor 401 to perform the above-described method.

[0124] The specific implementation process of processor 401 can be found in the above method embodiments, and its implementation principle and technical effect are similar. It will not be repeated here.

[0125] Those skilled in the art will understand that all or part of the steps of the above-described method embodiments can be implemented by hardware related to program instructions. The aforementioned program can be stored in a computer-readable storage medium. When executed, the program performs the steps of the above-described method embodiments; and the aforementioned storage medium includes various media capable of storing program code, such as ROM, RAM, magnetic disks, or optical disks.

[0126] Finally, it should be noted that other embodiments of the invention will readily occur to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. This invention is intended to cover any variations, uses, or adaptations of the invention that follow the general principles of the invention and include common knowledge or customary techniques in the art not disclosed herein, and is not limited to the precise structures described above and shown in the accompanying drawings, and various modifications and changes can be made without departing from its scope. The scope of the invention is limited only by the appended claims.

Claims

1. A system for locating the breakdown point of a control cable insulation core, characterized in that, include: Meter counter (1), EDM machine (2) and control device (3); On the production line of the control cable insulated core, the meter counter (1) and the spark machine (2) are installed in sequence according to the production movement direction of the control cable insulated core. The control device (3) is communicatively connected to the meter counter (1) and the spark machine (2); The meter counter (1) is used to collect the length parameters of the insulated core of the control cable in real time; The spark generator (2) is used to trigger the control device (3) to latch the current length parameter of the meter counter (1) when a breakdown event of the insulation core of the control cable is detected; The control device (3) is used to determine the physical location of the penetration point based on the distance parameters of the meter counter (1) and the spark machine (2) and the current length parameter.

2. The system according to claim 1, characterized in that, The system for locating the breakdown point of the insulation core of the control cable also includes a label reader (4) and an operation panel (5). The label machine (4) and the operation panel (5) are installed on the production line of the control cable insulation core; wherein the label machine (4) is installed behind the EDM machine (2) according to the production movement direction of the control cable insulation core; The control device (3) is communicatively connected to the label printer (4) and the operation screen (5); The operation screen (5) is used to respond to the user's input operation, obtain the product parameters of the control cable insulation core, and send the product parameters of the control cable insulation core to the control device (3). The EDM machine (2) is used to trigger the control device (3) to control the labeling machine (4) to affix the product parameters to the insulation core of the control cable when a breakdown event is detected.

3. The system according to claim 2, characterized in that, The system for locating the breakdown point of the insulation core of the control cable also includes an infrared imaging scanning device (6). The infrared imaging scanning device (6) is installed between the EDM machine (2) and the label machine (4); When the EDM (2) detects a breakdown event of the insulation core of the control cable, it triggers the control device (3) to control the infrared imaging scanning device (6) to perform thermal imaging scanning on the insulation core of the control cable and acquire multiple infrared images. The control device (3) is used to receive multiple infrared images sent by the infrared imaging scanning device (6) and determine whether there is a breakdown point in the insulation core of the control cable based on the multiple infrared images.

4. A method for locating the breakdown point of a control cable insulation core, characterized in that, The system for locating the breakdown point of the insulation core of a control cable as described in claim 1, the system comprising a meter counter, a spark tester, and a control device; the method comprising: The meter counter collects the length parameters of the insulated core of the control cable in real time. When the EDM machine detects a breakdown event, it triggers the control device to latch the current length parameter of the meter counter. The control device determines the physical location of the penetration point based on the distance parameter between the meter counter and the EDM machine, as well as the current length parameter.

5. The method according to claim 4, characterized in that, The control device determines the physical location of the penetration point based on the distance parameter between the meter counter and the EDM machine, and the current length parameter, including: The control device calls the pre-stored distance parameters between the meter counter and the EDM machine; The control device adds the distance parameter between the meter counter and the EDM machine to the current length parameter to determine the physical location of the penetration point.

6. The method according to claim 4, characterized in that, When the EDM detects a breakdown event, it triggers the control device to latch the current length parameter of the meter counter, including: When the EDM machine detects a breakdown event, it sends a breakdown signal to the input point of the control device. When the input point of the control device detects the breakdown signal, it reads the current length parameter of the meter counter. The control device latches the current length parameter of the meter counter.

7. The method according to claim 4, characterized in that, The system also includes a label printer and an operation panel; the method further includes: The control device receives the product parameters of the insulation core of the control cable sent by the operation panel; The control device acquires the moving speed of the insulated core of the control cable on the production line; The control device calls the pre-stored distance parameters between the spark generator and the label generator; The control device determines the time it takes for the penetration point to move to the label machine based on the distance parameters between the EDM and the label machine and the moving speed. When the EDM machine detects a breakdown event, it triggers the control device to send a label pasting signal to the label machine after the specified time; wherein the label pasting signal carries the product parameters. The labeling machine affixes the product parameters as labels to the insulated core of the control cable according to the label affixing signal.

8. The method according to claim 4, characterized in that, Before the meter counter collects the length parameters of the control cable insulation core in real time, it also includes: The meter counter clears the historically collected length parameters of the insulation core of the control cable. The EDM machine clears the historical breakdown count.

9. The method according to claim 4, characterized in that, The system also includes an infrared imaging scanning device; after the EDM machine detects a breakdown event, it further includes: When the EDM detects a breakdown event, it sends a breakdown signal to the input point of the control device. When the input point of the control device detects the breakdown signal, it controls the infrared imaging scanning device to perform thermal imaging scanning on the insulation core of the control cable to acquire multiple infrared images. The infrared imaging scanning device sends the multiple infrared images to the control device; The control device determines whether there is a breakdown point in the insulation core of the control cable based on the multiple infrared images. If the control device determines that there is a breakdown point, it triggers the meter counter to latch the current length parameter; If the control device determines that there is no breakdown point, it will not perform the operations of triggering the counter to latch the current length parameter and determining the physical location of the breakdown point.

10. An electronic device, characterized in that, include: Memory, used to store computer programs; A processor, configured to implement the breakdown point location system for the control cable insulation core as described in any one of claims 1-3 when executing the computer program.

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