Intelligent detection system and method for zinc coating of electric power fitting

Abstract

The invention relates to the technical field of electric power fitting zinc coating quality detection, in particular to an electric power fitting zinc coating intelligent detection system and method.The electric power fitting zinc coating intelligent detection system is characterized in that a zinc coating measuring terminal is used for measuring a to-be-detected fitting in real time, and a measuring result is sent to a lower computer through a serial port; the lower computer is a measurement and control core unit, and performs data transmission on measurement data and a control instruction through a wireless module; the wireless module can carry out long-distance wireless transmission by adopting a WIFI or Bluetooth mode and the like; the upper computer analyzes the measurement data, gives a detection conclusion and exports a detection report; and the power supply module supplies power to the wireless module and the lower computer for the rechargeable module. Therefore, long-distance transmission and intelligent detection of zinc coating measurement data are realized. The problems of dependence on manpower and low detection efficiency in the prior art are solved.

Description

Technical Field

[0001] This invention relates to the field of zinc plating quality testing technology for power fittings, and in particular to an intelligent testing system and method for zinc plating of power fittings. Background Technology

[0002] Galvanizing involves coating the surface of steel with a layer of zinc, forming a protective film that prevents direct contact between the steel and oxygen and water, thus reducing the likelihood of corrosion. Galvanizing technology not only enhances the protective properties of steel but also significantly improves its economic efficiency and aesthetics. However, existing methods for detecting the zinc coating thickness of power fittings have the following shortcomings: (1) Poor compatibility: The measurement report format needs to be preset, and the program needs to be adjusted when adding or modifying the template. The host computer can only be matched with the specified device and cannot be adapted to general computers or tablets. (2) Cumbersome initialization process: The measurement terminal, host computer and slave computer need to be started manually in sequence, the power supply needs to be connected manually, and the report style needs to be selected manually. (3) Low integration: The power supply, slave computer, Wi-Fi communication module and measurement terminal are arranged separately, and the on-site wiring is messy. (4) The handheld device is large and heavy, which obstructs the probe's line of sight and is easy to cause fatigue during long-term operation. Summary of the Invention

[0003] The purpose of this invention is to provide an intelligent detection system and method for zinc coating on power fittings, aiming to solve the problems of reliance on manual labor and low detection efficiency in the prior art.

[0004] To achieve the above objectives, in a first aspect, the present invention provides an intelligent detection system for zinc plating of power fittings, comprising a measurement terminal, a lower-level machine, a wireless transmission module, a upper-level machine, a power supply module, and an integrated housing; The measuring terminal is used to collect the zinc coating thickness signal; The lower-level machine is used to run a poll-free serial port scanning program, a dual-mode detection program, and a data encapsulation and retransmission program. The wireless transmission module establishes a local area network wireless link with the host computer based on the TCP / IP protocol; The host computer is used to automatically receive, verify, statistically analyze measurement data, and generate an Excel test report. The power module supplies power to the lower-level machine and peripherals via a Type-C interface; The integrated housing is used to install the power supply, wireless transmission module, probe, and lower-level machine.

[0005] The lower-level machine includes a query-free serial port scanning program, a dual-mode detection program, and a data encapsulation and transmission program. The polling-free serial port scanning program automatically identifies the peripheral serial port number by listening to changes in GPIO pin levels and bus data interaction signals, and adaptively matches the baud rate and data bit parameters. The dual-mode detection program automatically switches the detection mode according to the substrate type. The data encapsulation and transmission program encapsulates thickness data, measurement time, and sample number information in JSON format and uploads them to the host computer via a wireless module.

[0006] The dual-mode detection program includes digital filtering, analog-to-digital conversion, and calibration algorithms.

[0007] The host computer includes a serial communication module, a data processing module, and a report generation module. The serial communication module is used to support custom configuration of serial port parameters; The data processing module is used to perform CRC check and outlier filtering after receiving data, and automatically calculate the maximum value, minimum value, average value and standard deviation; The report generation module is used to automatically fill in the detection data and generate conclusions.

[0008] Secondly, a method for intelligent detection of zinc plating on power fittings, used in the intelligent detection system for zinc plating on power fittings described in the first aspect, includes the following steps: Start the lower-level machine and the upper-level machine, and establish a local area network connection through the wireless module; The lower-level machine runs a serial port scanning program to complete peripheral matching and self-test; The probe is placed against the surface of the metal fitting being measured to collect thickness signals and transmit them to the lower-level computer for calculation. The lower-level machine encapsulates the data and uploads it to the upper-level machine, where the upper-level machine performs verification and statistical analysis. The host computer automatically generates an Excel test report by calling a standard template.

[0009] This invention discloses an intelligent detection system for zinc plating on power fittings. A zinc plating measurement terminal is used to measure the fitting in real time, and the measurement results are sent to a lower-level computer via a serial port. The lower-level computer is the core control unit, transmitting measurement data and control commands via a wireless module. The wireless module can use WIFI or Bluetooth for long-distance wireless transmission. The upper-level computer analyzes the measurement data, provides detection conclusions, and exports a detection report. A rechargeable power module supplies power to the wireless module and the lower-level computer. This system enables long-distance transmission and intelligent detection of zinc plating measurement data, solving the problems of reliance on manual labor and low detection efficiency in existing technologies. Attached Figure Description

[0010] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0011] Figure 1 This is a schematic diagram of an intelligent detection system for zinc plating on power fittings provided by the present invention.

[0012] Figure 2 This is the program flow of the host computer system.

[0013] Figure 3 This is the wiring diagram for the lower-level machine circuit.

[0014] Figure 4 It is the program design process.

[0015] Figure 5 It is the front-end interface of the host computer system.

[0016] Figure 6 This is a report template.

[0017] Figure 7 This is a flowchart of an intelligent detection method for zinc plating on power fittings provided by the present invention.

[0018] In the diagram: 1-Measurement terminal, 2-Lower unit, 3-Wireless transmission module, 4-Upper unit, 5-Power supply module, 6-Integrated casing, 21-No-query serial port scanning program, 22-Dual-mode detection program, 23-Data encapsulation and transmission program, 41-Serial communication module, 42-Data processing module, 43-Report generation module. Detailed Implementation

[0019] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0020] Please see Figures 1 to 6 In a first aspect, the present invention provides an intelligent detection system for zinc plating of power fittings, comprising a measurement terminal, a lower-level machine, a wireless transmission module, a higher-level machine, a power supply module, and an integrated housing; the higher-level machine is connected to the detection module, the wireless transmission module, and the power supply module via a GPIO interface; the output terminal of the signal conditioning circuit of the detection module is connected to the ADC pin of the higher-level machine; the wireless transmission module and the higher-level machine establish an IP connection via a local area network; the output terminal of the power supply module is connected to the power supply interface of each module respectively; The measuring terminal is used to collect the zinc coating thickness signal; The lower-level machine is used to run a poll-free serial port scanning program, a dual-mode detection program, and a data encapsulation and retransmission program. The wireless transmission module establishes a local area network wireless link with the host computer based on the TCP / IP protocol; The host computer is used to automatically receive, verify, statistically analyze measurement data, and generate an Excel test report. The power module supplies power to the lower-level machine and peripherals via a Type-C interface; The integrated housing is used to install the power supply, wireless transmission module, probe, and lower-level machine.

[0021] In this embodiment, the core control module uses a Raspberry Pi Model4b development board as the system's core computing and control unit. It connects to various peripheral modules via GPIO interfaces, handling signal processing, command issuance, and data forwarding. The detection module's probe connects to the Raspberry Pi through a signal conditioning circuit. The raw signal is pre-processed and converted into a digital signal before being transmitted to the core module. The wireless transmission module uses a WiFi communication module, connecting to the Raspberry Pi via a serial port to establish a local area network link. Based on the TCP / IP protocol, it enables wireless data interaction between the Raspberry Pi and the host computer, eliminating the constraints of wired connections. The power module uses a 5V lithium battery pack with a unified Type-C charging and discharging interface, supporting fast charging. It provides independent and stable power output to the lower-level machine and associated peripherals, adapting to the needs of continuous operation for extended periods in various scenarios. The integrated shell is manufactured using 3D printing technology, featuring an optimized ergonomic grip design for enhanced comfort during extended use. The handle, probe, and lower-level machine structure are all detachably connected with screws, facilitating future maintenance and module replacement. The printing infill density is set at 80%, ensuring both material fineness and high strength, guaranteeing a robust and durable shell. The probe utilizes a magnetic fixing structure for quick insertion and removal, adapting to the measurement needs of complex power fittings. The shell includes a USB data transmission interface and a network cable interface to meet data transmission and external power supply requirements. The overall structure combines portability and structural stability, adapting to various operational scenarios.

[0022] Furthermore, the lower-level machine includes a query-free serial port scanning program, a dual-mode detection program, and a data encapsulation and transmission program; The polling-free serial port scanning program automatically identifies the peripheral serial port number by listening to changes in GPIO pin levels and bus data interaction signals, and adaptively matches the baud rate and data bit parameters. The dual-mode detection program automatically switches detection modes based on the substrate type. The dual-mode detection program includes digital filtering, analog-to-digital conversion, and calibration algorithms. The data encapsulation and transmission program encapsulates thickness data, measurement time, and sample number information in JSON format and uploads them to the host computer via a wireless module.

[0023] In this embodiment, the lower-level software (Raspberry Pi side) development environment is based on Raspberry PiOS and developed using Python+C language (open source programming language).

[0024] 1. Core Program: No-question serial port scanning program: By listening to changes in GPIO pin levels and bus data interaction signals, it automatically identifies the peripheral serial port number and adaptively matches parameters such as baud rate and data bits, without requiring manual configuration.

[0025] Dual-mode detection program: Includes digital filtering algorithm (to remove signal noise), analog-to-digital conversion logic, and calibration algorithm (to calculate thickness value based on magnetic induction / eddy current principle), and can automatically switch detection modes according to substrate type.

[0026] Data encapsulation and transmission program: Encapsulates information such as thickness data, measurement time, and sample number in JSON format and uploads it to the host computer via a wireless module. It has a built-in data retransmission mechanism to ensure transmission reliability.

[0027] Furthermore, the host computer includes a serial communication module, a data processing module, and a report generation module; The serial communication module is used to support custom configuration of serial port parameters; The data processing module is used to perform CRC check and outlier filtering after receiving data, and automatically calculate the maximum value, minimum value, average value and standard deviation; The report generation module is used to automatically fill in the detection data and generate conclusions.

[0028] In this implementation, the host computer software (PC-side) development framework is based on Qt and relies on the openpyxl library. The serial communication module supports custom configuration of serial port parameters, employs asynchronous communication and signal slot mechanisms, monitors communication status in real time, and features automatic reconnection and data verification. The data processing module performs CRC checks and outlier filtering (removing data exceeding reasonable ranges) upon receiving data, and automatically calculates the maximum, minimum, average, and standard deviation. The report generation module includes built-in industry standard templates such as the "Measurement Record of Zinc Coating Thickness of 35kV and Above Bolts," automatically fills in test data and generates conclusions, highlights out-of-standard data in red, and supports dimensional filtering.

[0029] To verify the reliability and efficiency of the device's data measurement, the developed device was tested using standard specimens. Six standard specimens were used: A was a 25μm standard specimen, B was a 50μm standard specimen, C was a 97μm standard specimen, D was a 250μm standard specimen, E was a 500μm standard specimen, and F was a 1014μm standard specimen.

[0030] Serial Number Standard film total Number of correct answers Average value μm reliability% 1 A 100 97 34.2 97 2 B 100 99 63.4 99 3 C 100 100 121.5 100 4 D 100 98 309.8 98 5 E 100 96 516.3 96 6 F 100 100 1022.7 100 A 1-hour measurement experiment was conducted on four types of power fittings, and the measurement results are shown in Table 2.

[0031] Serial Number type Total quantity Qualified quantity pass rate % 1 UB-7 / 21 Power Fittings Right Angle Mounting Plate 217 217 100.0 2 Power line hardware extension ring 202 202 100.0 3 Chen Suspension Insulator Hanging Plate 214 213 99.5 4 Q-7 type hot-dip galvanized hanging ring 226 225 99.6 This invention addresses the one-stop quality inspection technology requirement for on-site measurement, analysis, conclusion generation, and report output of zinc plating thickness in power fittings. It proposes an intelligent inspection method based on wireless data transmission, enabling simultaneous processing of zinc plating data measurement, analysis, and conclusion export. A prototype was designed and developed, and standard parts testing and on-site trials were conducted. Experimental results show that the proposed method has a reliability exceeding 96% and an inspection efficiency exceeding 202 pieces / hour, significantly improving the efficiency and quality of power fitting quality inspection and greatly enhancing the level of lean quality inspection work.

[0032] Please see Figure 7 Secondly, a method for intelligent detection of zinc plating on power fittings, used in the intelligent detection system for zinc plating on power fittings described in the first aspect, includes the following steps: S1 starts the lower-level machine and the upper-level machine, and establishes a local area network connection through the wireless module; Specifically, the equipment is deployed by installing the detection probe onto the adapter, powering on the Raspberry Pi and the host computer, and establishing a local area network connection via the wireless module.

[0033] The S2 lower-level machine runs a serial port scanning program to complete peripheral matching and self-test; Specifically, it initializes automatically. The Raspberry Pi runs a serial port scanning program to complete peripheral matching and self-test (probe sensitivity calibration, network link verification). After the self-test passes, it enters standby mode.

[0034] The S3 probe is attached to the surface of the metal fitting being measured to collect thickness signals and transmit them to the lower-level computer for calculation. Specifically, substrate identification and detection. The substrate properties are determined through automatic identification (the probe emits a low-intensity detection signal, and the substrate type is determined based on the magnetic permeability) or manual input. The probe is then attached to the surface of the metal being tested to collect the thickness signal and transmit it to the Raspberry Pi for calculation.

[0035] The S4 lower-level machine encapsulates the data and uploads it to the upper-level machine, which then performs verification and statistical analysis. Specifically, data transmission and processing: The Raspberry Pi encapsulates the data and uploads it to the host computer via a wireless module, where the host computer performs data verification and statistical analysis.

[0036] The S5 host computer automatically generates an Excel test report by calling a standard template.

[0037] Specifically, report generation. The host computer calls the corresponding standard template to automatically generate an Excel test report, supporting data saving and export.

[0038] Beneficial effects: 1. Significantly improved scene adaptability: The integrated handheld structure is lightweight, and the built-in lithium battery pack supports long-term independent power supply. It can work stably in environments with temperatures ranging from -10℃ to 45℃ and humidity ≤85%RH without condensation, making it suitable for complex field scenarios such as outdoor areas and remote substations. 2. Improved initialization efficiency: No manual configuration of serial port parameters is required. It automatically completes peripheral matching and self-testing, reducing the initialization time from 5-10 minutes in traditional devices to within 30 seconds, with no parameter configuration errors.

[0039] 3. Data processing and transmission optimization: Transmission method: Supports WiFi wireless transmission, extending the transmission distance to 100 meters (local area network environment) compared to traditional wired methods, eliminating site limitations.

[0040] Processing efficiency: Data is automatically encapsulated, verified, and statistically analyzed. Report generation takes ≤1 second per group, requiring no manual intervention.

[0041] 4. Detection accuracy and stability: Repeatability: For measurements of standard samples in the range of 25μm to 1014μm, the reliability is ≥96% (the reliability of measurements of 97μm and 1014μm standard samples reaches 100%), and the measurement data fluctuation range is ≤±0.5μm, which meets the requirements of GB / T5267.3-2008 standard.

[0042] Interference resistance: The HRC820A thickness gauge has extremely strong anti-interference capabilities. In complex electromagnetic field environments, the fluctuation amplitude of the detection signal is ≤0.3μm, which is 75% more stable than traditional split-type equipment (fluctuation amplitude ≥1.2μm).

[0043] Improved testing efficiency: It can complete the testing of ≥202 electrical fittings per hour, which is 152.5% more efficient than traditional equipment (approximately 80 pieces / hour).

[0044] The above description is merely a preferred embodiment of the intelligent detection system and method for zinc coating of power fittings according to the present invention. It should not be construed as limiting the scope of the present invention. Those skilled in the art can understand that implementing all or part of the above embodiments and making equivalent changes in accordance with the claims of the present invention are still within the scope of the invention.

Claims

1. An intelligent detection system for zinc plating on power fittings, characterized in that, It includes a measurement terminal, a lower-level machine, a wireless transmission module, a upper-level machine, a power module, and an integrated housing; The measuring terminal is used to collect the zinc coating thickness signal; The lower-level machine is used to run a poll-free serial port scanning program, a dual-mode detection program, and a data encapsulation and retransmission program. The wireless transmission module establishes a local area network wireless link with the host computer based on the TCP / IP protocol; The host computer is used to automatically receive, verify, statistically analyze measurement data, and generate an Excel test report. The power module supplies power to the lower-level machine and peripherals via a Type-C interface; The integrated housing is used to install the power supply, wireless transmission module, probe, and lower-level machine.

2. The intelligent detection system for zinc plating of power fittings as described in claim 1, characterized in that, The lower-level machine includes a query-free serial port scanning program, a dual-mode detection program, and a data encapsulation and transmission program. The polling-free serial port scanning program automatically identifies the peripheral serial port number by listening to changes in GPIO pin levels and bus data interaction signals, and adaptively matches the baud rate and data bit parameters. The dual-mode detection program automatically switches the detection mode according to the substrate type. The data encapsulation and transmission program encapsulates thickness data, measurement time, and sample number information in JSON format and uploads them to the host computer via a wireless module.

3. The intelligent detection system for zinc plating of power fittings as described in claim 2, characterized in that, The dual-mode detection program includes digital filtering, analog-to-digital conversion, and calibration algorithms.

4. The intelligent detection system for zinc plating of power fittings as described in claim 1, characterized in that, The host computer includes a serial communication module, a data processing module, and a report generation module; The serial communication module is used to support custom configuration of serial port parameters; The data processing module is used to perform CRC check and outlier filtering after receiving data, and automatically calculate the maximum value, minimum value, average value and standard deviation; The report generation module is used to automatically fill in the detection data and generate conclusions.

5. A method for intelligent detection of zinc plating on power fittings, used in the intelligent detection system for zinc plating on power fittings as described in any one of claims 1-4, characterized in that, Includes the following steps: Start the lower-level machine and the upper-level machine, and establish a local area network connection through the wireless module; The lower-level machine runs a serial port scanning program to complete peripheral matching and self-test; The probe is placed against the surface of the metal fitting being measured to collect thickness signals and transmit them to the lower-level computer for calculation. The lower-level machine encapsulates the data and uploads it to the upper-level machine, where the upper-level machine performs verification and statistical analysis. The host computer automatically generates an Excel test report by calling a standard template.

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