Defect detection method and system in cable production

Abstract

The invention discloses a defect detection method and system in cable production, relates to the technical field of cable production, and aims to solve the problem that the precision of a detection result is influenced because the influence of a high-voltage environment on defects is not considered in the prior art. The system comprises a water pressure simulation module, a sensor detection module, a data processing module and a defect judgment terminal, the water pressure simulation module is used for constructing a high-pressure and low-temperature detection environment consistent with the actual working condition of the deep sea; the sensor detection module is used for acquiring a pressure abnormal fluctuation value, a core wire displacement deviation value and a medium permeation rate parameter of the cable in a water pressure environment; the data processing module is used for processing parameters acquired by the sensor detection module; and the defect judgment terminal is used for carrying out defect judgment, positioning and result display on the cable according to the parameters processed by the data processing module. The cable detection device has the advantage that the cable detection precision is improved.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, and more specifically, to a method and system for defect detection in cable manufacturing. Background Technology

[0002] In the cable production process, especially in the production of deep-sea cables, the water pressure resistance and internal structural integrity of the insulation layer directly determine the safety and service life of the cable.

[0003] Deep-sea cables must withstand the pressure of seawater at depths of thousands of meters for extended periods. If the insulation layer has defects such as micro-cracks, delamination, or voids, seawater can seep into the cable, causing short circuits, damage, and other malfunctions, resulting in significant economic losses. However, existing cable defect detection systems for deep-sea cables often fail to consider the impact of the high-pressure environment on defects, thus affecting the accuracy of the detection results. Therefore, we propose a defect detection method and system for cable production. Summary of the Invention

[0004] The purpose of this invention is to provide a defect detection method and system in cable production, which aims to solve the problem that existing technologies often fail to consider the impact of high-voltage environments on defects, thus affecting the accuracy of detection results.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a defect detection system in cable production, the system comprising a water pressure simulation module, a sensor detection module, a data processing module, and a defect judgment terminal;

[0006] The water pressure simulation module is used to construct a high-pressure, low-temperature testing environment consistent with actual deep-sea working conditions.

[0007] The sensor detection module is used to collect the abnormal pressure fluctuation value, core wire displacement deviation and medium permeation rate parameter of the cable under water pressure environment.

[0008] The data processing module is used to process the parameters collected by the sensor detection module;

[0009] The defect determination terminal is used to determine, locate, and display the defects of the cable based on the parameters processed by the data processing module.

[0010] Preferably, the water pressure simulation module includes a water pressure simulation chamber, a water pressure control submodule, a temperature regulation submodule, and a medium circulation submodule;

[0011] The water pressure simulation chamber is made of high-strength, corrosion-resistant alloy material;

[0012] The water pressure control submodule includes a high-pressure pump, a pressure regulating valve, and a pressure feedback device, which are used to achieve precise adjustment and stable maintenance of the pressure inside the water pressure simulation chamber.

[0013] The temperature control submodule is equipped with a heating element, a cooling element, and a temperature sensor, which are used to achieve precise adjustment and stable maintenance of the temperature inside the water pressure simulation chamber.

[0014] The media circulation submodule is used to detect the injection, circulation filtration and recovery of the media in the water pressure simulation chamber, and also includes a media degassing unit for removing air bubbles from the detected media.

[0015] Preferably, the sensor detection module includes a pressure sensor for collecting abnormal pressure fluctuations of the cable under water pressure, a displacement sensor for collecting the core wire displacement deviation of the cable, and a humidity sensor for collecting the medium permeation rate of the cable.

[0016] Preferably, the data processing module includes a data receiving unit and a data processing unit;

[0017] The data receiving unit is used to receive parameters collected by the sensor detection module;

[0018] The data processing unit is used to apply an adaptive weighted moving average filtering algorithm to the parameters received by the data receiving unit to achieve accurate noise filtering, and to extract key feature parameters through a local eigenvalue decomposition algorithm.

[0019] Preferably, the defect determination terminal includes a threshold setting unit, a comparison and analysis unit, a defect location unit, and a touch screen.

[0020] The threshold setting unit is used to set the defect determination threshold for the cable;

[0021] The comparison analysis unit is used to compare the defect judgment threshold set by the threshold setting unit with the key feature parameters extracted by the data processing unit, and output the test result of whether the cable is qualified or unqualified based on the comparison result.

[0022] The defect location unit determines the location of the cable defect by combining the location information from the sensor detection module and the detection results from the comparison and analysis unit.

[0023] The touch screen is used to display the cable inspection results and defect locations in real time, and to support manual input of the defect judgment threshold of the threshold setting unit.

[0024] Preferably, the defect determination terminal further includes a data traceability unit, which is used to associate and store the cable's production information and test results to form a traceable file.

[0025] Preferably, the defect determination terminal further includes an audible and visual early warning unit, which is used to issue an early warning when the cable inspection result output by the comparison and analysis unit is unqualified.

[0026] This invention also discloses a defect detection method in cable production, the method comprising the following steps;

[0027] S1. A high-pressure, low-temperature testing environment consistent with actual deep-sea working conditions is constructed using the water pressure simulation module;

[0028] S2. Clean the cables that need to be tested, removing oil and impurities;

[0029] S3. Fix the cable that needs to be defect-detected during the production process in the water pressure simulation chamber, and then collect the abnormal pressure fluctuation value, core wire displacement deviation and medium permeation rate parameter of the cable under water pressure environment through the sensor detection module.

[0030] S4. Then, the data processing module processes the parameters collected by the sensor detection module.

[0031] S5. Finally, the defect determination terminal performs defect determination, location and results display on the cable based on the parameters processed by the data processing module.

[0032] Compared with the prior art, the beneficial effects of the present invention are:

[0033] 1. This invention constructs a high-pressure, low-temperature testing environment consistent with actual deep-sea working conditions through a water pressure simulation module. The water pressure control submodule enables precise adjustment and stable maintenance of the chamber pressure, while the temperature control submodule ensures precise control of the low-temperature environment. The medium circulation submodule's medium degassing unit removes air bubbles from the testing medium to avoid interfering with the test results. By addressing environmental parameters, hardware materials, and interference elimination, this invention ensures that the testing process closely matches the actual application scenario of cables, thereby improving the accuracy of cable testing.

[0034] 2. This invention ensures the comprehensiveness and relevance of the detection data by simultaneously collecting three key parameters of the cable under water pressure environment: abnormal pressure fluctuation, core wire displacement deviation, and medium penetration rate. The data processing module first uses an adaptive weighted moving average filtering algorithm to accurately filter noise interference, and then uses a local eigenvalue decomposition algorithm to extract the maximum eigenvalue of the local data matrix, enhancing the data mutation characteristics caused by cable defects, improving feature extraction sensitivity, and significantly reducing the judgment error caused by data interference and insufficient feature extraction, thus providing accurate data basis for accurate defect judgment. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the system architecture of the present invention;

[0036] Figure 2 This is a flowchart illustrating the method of the present invention. Detailed Implementation

[0037] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0038] Example 1

[0039] A defect detection system for cable production, comprising a water pressure simulation module, a sensor detection module, a data processing module, and a defect judgment terminal;

[0040] The water pressure simulation module is used to construct a high-pressure, low-temperature testing environment that is consistent with actual deep-sea working conditions;

[0041] The sensor detection module is used to collect abnormal pressure fluctuations, core wire displacement deviations, and medium permeation rate parameters of the cable under water pressure conditions.

[0042] The data processing module is used to process the parameters collected by the sensor detection module;

[0043] The defect determination terminal is used to determine, locate, and display the defects of cables based on the parameters processed by the data processing module.

[0044] In this embodiment, the water pressure simulation module includes a water pressure simulation chamber, a water pressure control submodule, a temperature regulation submodule, and a medium circulation submodule;

[0045] The hydraulic pressure simulation chamber is made of high-strength, corrosion-resistant alloy material;

[0046] The water pressure control submodule includes a high-pressure pump, a pressure regulating valve, and a pressure feedback device, which are used to achieve precise regulation and stable maintenance of the pressure inside the water pressure simulation chamber.

[0047] The temperature control submodule is equipped with heating elements, cooling elements and temperature sensors to achieve precise adjustment and stable maintenance of the temperature inside the water pressure simulation chamber;

[0048] The media circulation submodule is used for the injection, circulation filtration and recovery of media in the detection water pressure simulation chamber, and also includes a media degassing unit to remove air bubbles from the detection media.

[0049] In this embodiment, the sensor detection module includes a pressure sensor for collecting abnormal pressure fluctuations of the cable under water pressure, a displacement sensor for collecting the core wire displacement deviation of the cable, and a humidity sensor for collecting the medium permeation rate of the cable.

[0050] In this embodiment, the data processing module includes a data receiving unit and a data processing unit;

[0051] The data receiving unit is used to receive parameters collected by the sensor detection module;

[0052] The data processing unit is used to accurately filter noise from the parameters received by the data receiving unit using an adaptive weighted moving average filtering algorithm, and to extract key feature parameters using a local eigenvalue decomposition algorithm.

[0053] in,

[0054] The formula for the adaptive weighted moving average filtering algorithm is:

[0055]

[0056]

[0057] In the formula, For the first Filtered data at time 10:00 The sliding window length (range 5-15, adjusted according to the fluctuation characteristics of the detection data), For the first Raw data of time The weight, This is the weighting adjustment coefficient (value 1.2-2.0, default 1.5). For the first Filtered data at time 10:00 For the first The standard deviation of the original data within the sliding window at any time is used to reflect the degree of data fluctuation. The larger the standard deviation, the faster the weight decays, thus suppressing abnormal fluctuations in data.

[0058] The formula for the local eigenvalue decomposition algorithm is:

[0059]

[0060]

[0061] In the formula, For the first Characteristic parameters at any given time (abnormal pressure fluctuation value / core wire displacement deviation / medium permeation rate), This represents the number of local data blocks (values ​​range from 3 to 8, default is 5). For the first Time of the first Local data blocks The largest eigenvalue ( for 1-order data matrix (This represents the number of local data points, ranging from 10 to 20). For the first time The mean of the largest eigenvalues ​​of each local data block This represents the weighting coefficient for local data blocks (values ​​range from 0.8 to 1.2, with increased weighting coefficients for blocks closer to areas of data abrupt change; the default is 1.0). The matrix eigenvalue solving function enhances the characteristics of sudden data changes (such as sudden pressure changes or displacement changes caused by cable defects) and improves the sensitivity of feature extraction by extracting the maximum eigenvalue of the local data matrix.

[0062] In this embodiment, the defect determination terminal includes a threshold setting unit, a comparison and analysis unit, a defect location unit, and a touch screen.

[0063] The threshold setting unit is used to set the defect judgment threshold for the cable;

[0064] The comparison analysis unit is used to compare the defect judgment threshold set by the threshold setting unit with the key feature parameters extracted by the data processing unit, and output the test result of whether the cable is qualified or unqualified based on the comparison result.

[0065] The defect location unit combines the position information from the sensor detection module with the detection results from the comparison and analysis unit to determine the location of the cable defect.

[0066] The touch screen is used to display the cable inspection results and defect locations in real time, and to support manual input of the defect judgment threshold of the threshold setting unit.

[0067] This embodiment constructs a high-pressure, low-temperature testing environment consistent with actual deep-sea working conditions through a water pressure simulation module. This accurately replicates the actual application scenario of the cable, providing a foundational condition that closely matches real-world working conditions for subsequent testing. The water pressure simulation chamber is made of high-strength, corrosion-resistant alloy material and is equipped with a water pressure control submodule, a temperature regulation submodule, and a media circulation submodule. This ensures both the stability and accuracy of the testing environment and removes air bubbles from the testing medium through a media degassing unit, preventing air bubbles from interfering with the testing data.

[0068] The sensor detection module uses pressure sensors, displacement sensors, and humidity sensors to comprehensively collect abnormal pressure fluctuations, core wire displacement deviations, and medium permeation rate parameters of the cable under water pressure environment, ensuring the completeness and relevance of the detection data.

[0069] The data processing module uses an adaptive weighted moving average filtering algorithm to achieve precise noise filtering and effectively reduce the impact of irrelevant interference on the data. It then combines the local eigenvalue decomposition algorithm to extract key feature parameters, enhance the data mutation characteristics caused by cable defects, improve the sensitivity of feature extraction, and provide accurate data support for defect determination.

[0070] The defect determination terminal determines whether a cable is qualified or not by setting thresholds and comparative analysis. It combines the location information of the sensor detection module to locate defects and uses a touch screen to display the results in real time and supports manual input of thresholds. Overall, it realizes accurate detection, location and intuitive display of cable defects, and can effectively screen out cables that do not meet the requirements of deep-sea working conditions, ensuring the safety and reliability of cables in the deep-sea environment.

[0071] Example 2

[0072] The difference between this embodiment and Embodiment 1 is that the defect determination terminal also includes a data traceability unit. The data traceability unit is used to associate and store the production information and test results of the cable to form a traceable file.

[0073] Based on Embodiment 1, this embodiment adds a data traceability unit to the defect determination terminal, which can associate and store the cable's production information and test results to form a traceable file, so that the production information of each cable and various data generated during the testing process can be associated accordingly.

[0074] When subsequent cable quality issues arise or cable performance analysis is required, staff can quickly access the entire production and testing process information of the corresponding cable through this traceable file. This not only facilitates accurate tracing of the root cause of quality problems but also provides data support for optimizing cable production processes, further enhancing the precision of cable production quality control and the capability for full lifecycle management.

[0075] Example 3

[0076] The difference between this embodiment and Embodiment 1 is that the defect determination terminal also includes an audible and visual early warning unit, which is used to issue an early warning when the cable test result output by the comparison and analysis unit is unqualified.

[0077] Based on Example 1, this embodiment adds an audible and visual early warning unit to the defect judgment terminal. It responds to situations where the cable test results output by the comparison and analysis unit are unqualified, and can quickly transmit the test results of unqualified cables to on-site personnel.

[0078] A method for defect detection in cable production, the method comprising the following steps;

[0079] S1. Construct a high-pressure, low-temperature testing environment consistent with actual deep-sea working conditions using a water pressure simulation module;

[0080] S2. Clean the cables that need to be tested, removing oil and impurities;

[0081] S3. Fix the cable that needs to be defect-detected during the production process in the water pressure simulation chamber, and then collect the abnormal pressure fluctuation value, core wire displacement deviation and medium permeation rate parameter of the cable under water pressure environment through the sensor detection module.

[0082] S4. Then, the data processing module processes the parameters collected by the sensor detection module.

[0083] S5. Finally, the defect judgment terminal judges, locates, and displays the cable defects based on the parameters processed by the data processing module.

[0084] The embodiments disclosed in this invention are preferred embodiments, but are not limited thereto. Those skilled in the art can easily understand the spirit of this invention based on the above embodiments and make different extensions and variations, but as long as they do not depart from the spirit of this invention, they are all within the protection scope of this invention.

Claims

1. A defect detection system for cable production, characterized in that, The system includes a water pressure simulation module, a sensor detection module, a data processing module, and a defect determination terminal; The water pressure simulation module is used to construct a high-pressure, low-temperature testing environment consistent with actual deep-sea working conditions. The sensor detection module is used to collect the abnormal pressure fluctuation value, core wire displacement deviation and medium permeation rate parameter of the cable under water pressure environment. The data processing module is used to process the parameters collected by the sensor detection module; The defect determination terminal is used to determine, locate, and display the defects of the cable based on the parameters processed by the data processing module.

2. The defect detection system in cable production according to claim 1, characterized in that, The water pressure simulation module includes a water pressure simulation chamber, a water pressure control submodule, a temperature regulation submodule, and a medium circulation submodule. The water pressure simulation chamber is made of high-strength, corrosion-resistant alloy material; The water pressure control submodule includes a high-pressure pump, a pressure regulating valve, and a pressure feedback device, which are used to achieve precise adjustment and stable maintenance of the pressure inside the water pressure simulation chamber. The temperature control submodule is equipped with a heating element, a cooling element, and a temperature sensor, which are used to achieve precise adjustment and stable maintenance of the temperature inside the water pressure simulation chamber. The media circulation submodule is used to detect the injection, circulation filtration and recovery of the media in the water pressure simulation chamber, and also includes a media degassing unit for removing air bubbles from the detected media.

3. The defect detection system in cable production according to claim 1, characterized in that, The sensor detection module includes a pressure sensor for collecting abnormal pressure fluctuations of the cable under water pressure, a displacement sensor for collecting the core wire displacement deviation of the cable, and a humidity sensor for collecting the medium permeation rate of the cable.

4. A defect detection system for cable production according to claim 1, characterized in that, The data processing module includes a data receiving unit and a data processing unit; The data receiving unit is used to receive parameters collected by the sensor detection module; The data processing unit is used to apply an adaptive weighted moving average filtering algorithm to the parameters received by the data receiving unit to achieve accurate noise filtering, and to extract key feature parameters through a local eigenvalue decomposition algorithm.

5. A defect detection system for cable production according to claim 4, characterized in that, The defect determination terminal includes a threshold setting unit, a comparison and analysis unit, a defect location unit, and a touch screen. The threshold setting unit is used to set the defect determination threshold for the cable; The comparison analysis unit is used to compare the defect judgment threshold set by the threshold setting unit with the key feature parameters extracted by the data processing unit, and output the test result of whether the cable is qualified or unqualified based on the comparison result. The defect location unit determines the location of the cable defect by combining the location information from the sensor detection module and the detection results from the comparison and analysis unit. The touch screen is used to display the cable inspection results and defect locations in real time, and to support manual input of the defect judgment threshold of the threshold setting unit.

6. A defect detection system for cable production according to claim 5, characterized in that, The defect determination terminal also includes a data traceability unit, which is used to associate and store the cable's production information and test results to form a traceable file.

7. A defect detection system for cable production according to claim 5, characterized in that, The defect determination terminal also includes an audible and visual early warning unit, which is used to issue an early warning when the cable inspection result output by the comparison and analysis unit is unqualified.

8. A method for defect detection in cable production, applicable to the defect detection system in cable production as described in any one of claims 1-7, characterized in that, The method includes the following steps; S1. A high-pressure, low-temperature testing environment consistent with actual deep-sea working conditions is constructed using the water pressure simulation module; S2. Clean the cables that need to be tested, removing oil and impurities; S3. Fix the cable that needs to be defect-detected during the production process in the water pressure simulation chamber, and then collect the abnormal pressure fluctuation value, core wire displacement deviation and medium permeation rate parameter of the cable under water pressure environment through the sensor detection module. S4. Then, the data processing module processes the parameters collected by the sensor detection module. S5. Finally, the defect determination terminal performs defect determination, location and results display on the cable based on the parameters processed by the data processing module.

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