Measurement image acquisition system based on steel strand surface detection and device thereof

Abstract

The application discloses a measuring image acquisition system based on steel strand surface detection and equipment thereof, relates to the technical field of steel strand surface detection image acquisition, and comprises an equipment platform and a first component; the first component comprises a guide plate fixedly connected on the equipment platform, a sliding rail is formed in the guide plate, and a transmission group is slidably connected on the sliding rail; in the prior art, the angle needs to be repeatedly measured and the position needs to be calibrated during multi-camera installation, and the process is complicated and time-consuming; the second component is designed in a sliding mode through cooperation of a support frame and a sliding groove, modular installation is realized, an operator does not need to manually measure the angle between the cameras, and installation can be completed only through a sliding operation, the installation process is greatly simplified, the installation time of the image acquisition device is effectively reduced, the dependence on the professional skills of the operator is reduced, the visual field of each camera can effectively ensure complete coverage of the circumference of the same position of the steel strand, blind areas are completely eliminated from the installation level, stable installation precision is maintained for a long time, and the accuracy of detection results is ensured.

Description

Technical Field

[0001] This invention relates to the field of image acquisition technology for steel strand surface inspection, specifically to a measurement image acquisition device for steel strand surface inspection. Background Technology

[0002] The surface quality of steel strands directly affects the safety and reliability of their subsequent engineering applications. To avoid surface defects affecting performance, the industry commonly employs various inspection methods to comprehensively screen the surface of steel strands. Linear scan cameras, due to their significant advantages of adapting to high-speed production lines and acquiring continuous images, have gained widespread attention and application in the inspection of steel strands in transit.

[0003] However, steel strands have a cylindrical structure, requiring comprehensive circumferential inspection to ensure no omissions. Existing line array cameras are mostly suitable for single-angle inspection of planar materials, making it difficult to meet the circumferential inspection requirements of steel strands. To achieve comprehensive circumferential coverage inspection of steel strands, multiple cameras must work in tandem. This places stringent requirements on camera installation: multiple cameras must be on the same mounting plane, not tilted towards the direction of steel strand transmission, and must be kept perpendicular. Simultaneously, all cameras must be able to capture a complete circumferential image of the same location on the steel strand, completely eliminating blind spots. These installation requirements are difficult to implement and involve a complex process, consuming significant time and effort. Maintaining stable installation accuracy over the long term is also challenging, and installation deviations can easily affect the inspection results.

[0004] Therefore, in the field of high-speed inspection of steel strands, the existing installation methods of line array cameras can no longer meet the actual application requirements. The industry urgently needs a camera installation auxiliary device that can help cameras achieve stable installation, simplify the installation process, and ensure installation accuracy, so as to solve the installation problem when multiple cameras are used to collaboratively inspect the circumferential direction of steel strands and improve inspection efficiency and reliability.

[0005] Therefore, this invention proposes a measurement image acquisition device for steel strand surface inspection to solve the above problems. Summary of the Invention

[0006] In view of this, a measurement image acquisition system and its equipment based on steel strand surface detection are proposed to solve the problems existing in the prior art.

[0007] To achieve the above objectives, this invention provides the following technical solution: a measurement image acquisition system method based on the surface quality inspection requirements of steel strands, using a line scan camera as the core, and achieving clear, full-coverage, and accurate acquisition of steel strand surface images through multi-device collaborative acquisition and hierarchical control; the acquisition control is achieved through five major processes, with the key processes as follows: Step 1: Selection, Layout and Installation of Data Acquisition Equipment Select a line scan camera with a pixel count ≥ 4k and a line frequency ≥ 20kHz, paired with a 12-25mm low-distortion industrial lens, and fitted with a dustproof and oil-proof protective lens cover; arrange three cameras in a ring around the steel line, with the field of view of adjacent cameras overlapping by ≥ 15%; the lens optical axis is perpendicular to the surface of the steel line with a deviation ≤ ±0.5°, and the object distance is fixed with an error ≤ ±2mm; the auxiliary strip diffuse coaxial light source is installed at a 30-45° angle to the camera, the encoder is directly connected to the camera signal interface, and all equipment is fixed on a shockproof bracket; Step 2: Parameter Calibration and Environmental Adaptation (Basic Data Acquisition) Connect the camera, encoder, industrial computer, and image acquisition card. Set the parameters according to the rebar line running speed of 0.5-10m / s: line frequency = line speed × 60px / mm pixel density, and adjust the exposure time to 1-8μs. Calibrate the lens focal length until the rebar surface texture is clear, verify the synchronization between the encoder and the camera, and ensure that the image is not stretched or misaligned. Clean the dust and oil stains in the acquisition area. The distance between the signal cable and the power line should be ≥30cm. If it exceeds 10m, use optical fiber to extend it to resist interference. Step 3: Hierarchical data acquisition and real-time control (core step) Start the light source and preheat for 5 minutes, then turn on the camera and encoder. Once the equipment is stable, control the transmission of the rebar line. Use encoder signal to trigger acquisition and test with standard defect samples to ensure clear imaging of defects such as cracks and scratches. Under normal operating conditions, continuously acquire data at a fixed frequency. When running at high speed (>5m / s), shorten the exposure and increase the line frequency. For rebar with rough surfaces, appropriately extend the exposure and simultaneously improve image contrast to ensure acquisition quality. Step 4: Anomaly Handling and Closed-Loop Verification (Data Acquisition Assurance) Real-time image preview, comparing acquisition status every second: if the image is stretched, check encoder synchronization and transmission equipment roller slippage; if blurry, clean the lens and tighten the camera; if defects are missed, adjust the camera angle and light source brightness; 10% of images from each batch are checked, and the defect recognition rate ≥98% and the size measurement deviation ≤±0.02mm are considered qualified; if unqualified, mark the corresponding rebar section, re-acquire and optimize parameters; Step 5: Data Management and System Optimization Images are stored in lossless BMP / RAW format and named according to "batch-time-rebar number", with dual backups on both local and cloud platforms; storage strategy is adjusted according to acquisition quality every unit of time, reserving ≥50% of hard disk space; equipment status is checked before daily acquisition, and parameters such as line frequency and synchronization accuracy are calibrated weekly; anomaly handling and parameter adjustment are recorded to form an operation log, and equipment layout and parameter settings are optimized regularly.

[0008] Furthermore, the measurement image acquisition equipment for steel strand surface inspection, applied to the measurement image acquisition system for steel strand surface quality inspection needs, includes an equipment platform and a first component; The first component includes a guide plate fixedly connected to the equipment platform. A slide rail is provided on the guide plate. A transmission group is slidably connected on the slide rail. The transmission group is adjusted within the slide rail according to specific conditions and then fixed by bolts. The transmission group consists of a support body and transmission wheels. A wire is driven between the two transmission wheels of the transmission group.

[0009] Preferably, a second component is also included; The second component includes a support frame that is fixedly connected to the guide plate by bolts. The support frame has a horizontally opened groove and through holes that are equally spaced through it. A sliding component A is slidably connected in the groove. An image acquisition device is fixedly connected to the sliding component A, and an external expansion column is fixedly connected to the side wall of the image acquisition device.

[0010] Preferably, the outer extension post is provided with a hole, a ring is provided on one side of the outer extension post, and slots are provided through the ring at equal intervals. A magnetic post is inserted into the slot, and the ring is connected to the outer extension post through the magnetic post, the slot, and the hole. The bottom of the ring is fixedly connected to an observation chamber, and the outer wall of the observation chamber is horizontally engraved with liquid level markings.

[0011] As a preferred option, a third component is also included; The third component includes a sliding member B slidably connected to the slide groove. A connecting piece is fixedly connected to the bottom surface of the sliding member B. A feedback cavity is fixedly connected to the bottom end of the connecting piece. A support piece is fixedly connected to the inner cavity of the feedback cavity. An electric contact ring A is fixedly connected to the support piece.

[0012] Preferably, a circular plate is slidably connected to the inner cavity of the feedback cavity, an electrical contact ring B is fixedly connected to the side of the circular plate near the support plate, a rope is fixedly connected to the wall surface of the circular plate near the support plate, and a screw is fixedly connected to the end of the rope away from the circular plate.

[0013] Preferably, the outer extension post is made of magnetic material, and the magnetic post is inserted into the insertion hole opened on the outer extension post; and the outer wall surface of the magnetic post is provided with a wire groove that is compatible with the screwing part.

[0014] Preferably, the observation chamber is provided with a solution that is used in conjunction with the liquid level mark.

[0015] Preferably, the sliding member B has a threaded groove adapted to the screwing member.

[0016] Compared with the prior art, the present invention provides a measurement image acquisition device based on steel strand surface detection, which has the following beneficial effects: 1. The design of the second component in this invention provides the following advantages: Significantly improves installation convenience and efficiency: In the existing technology, the installation of multiple cameras requires repeated angle measurement and position calibration, which is cumbersome and time-consuming; while the second component, through the sliding design of the support frame and the slide rail, realizes modular installation. Operators do not need to manually measure the angle between each camera, but can complete the installation simply by sliding, which greatly simplifies the installation process, effectively reduces the installation time of the image acquisition device, and reduces the dependence on the professional skills of the operators. Ensuring installation accuracy and testing reliability: In existing technologies, multiple cameras are prone to blind spots due to installation tilt, misalignment, or other deviations, affecting testing results. This component, through structural design, forces multiple line array cameras to be on the same installation plane and maintain a perpendicular state to the transmission direction of the steel strand. This ensures that the field of view of each camera can completely cover the circumference of the same position on the steel strand, completely eliminating blind spots from the installation level, maintaining stable installation accuracy over the long term, and ensuring the accuracy of testing results. Enhancing equipment adaptability and versatility: In existing technologies, camera mounting structures are mostly fixed, making it difficult to adapt to different specifications of wires or camera focal length adjustment requirements; while the support frame of this component can switch sizes according to actual conditions, flexibly adapting to steel strands of different diameters and line array cameras of different focal lengths, improving the applicability of the equipment in diverse production scenarios and reducing equipment replacement costs caused by changes in specifications.

[0017] 2. This invention, by employing an observation chamber with a feedback solution and a liquid level marker design, offers the following advantages: This design enables intuitive and visual verification of the installation status, significantly improving installation verification efficiency: In existing technologies, operators need to repeatedly calibrate the camera using professional measuring tools to determine whether it is installed vertically and on the same plane, a cumbersome and time-consuming process. However, this design transforms the abstract installation accuracy requirements into intuitive visual signals through the combination of colored aqueous solutions and liquid level marks. Operators do not need to rely on professional measuring equipment; they can quickly determine the camera's installation status simply by observing whether the solution is level and centered and aligned with the liquid level marks. This significantly shortens the installation verification time and reduces the complexity of the verification process. Accurate verification of installation compliance avoids hidden installation deviations from the source: In existing technologies, it is difficult to accurately judge whether the side camera and the top camera are on the same vertical plane and whether they meet the circumferential coverage requirements by visual inspection or simple measurement, which can easily lead to hidden deviations. This design, however, uses the horizontal state of the solution to reflect the vertical installation status of the top camera and the alignment status of the solution with the liquid level mark to reflect the coplanarity of the side and top cameras. This dual verification dimension accurately locks in the installation deviation, ensuring that multiple cameras are strictly on the same vertical plane. This ensures that the image can completely cover the same circumference of the steel strand after stitching, and further eliminates blind spots in the detection process from the installation verification stage. Lowering the operational threshold and reducing the risk of human error: In existing technologies, camera installation and calibration require a high level of professional skills and experience from operators, and human error can easily lead to unqualified installation. However, colored aqueous solutions and liquid level marks provide a clear judgment standard, eliminating the need for operators to have complex calibration knowledge. They only need to follow the intuitive criterion of "solution level in the middle + flush with the mark" to accurately identify whether the installation is qualified, greatly reducing the probability of human error and ensuring the consistency and stability of installation quality.

[0018] 3. The design of the third component in this invention brings the following advantages: Real-time monitoring and timely early warning of installation displacement are achieved to prevent the accumulation of hidden deviations: In existing technologies, image acquisition devices are easily loosened and displaced after installation due to external forces such as vibration. Such displacements are difficult to detect in the early stages and can easily lead to long-term deviations in detection accuracy. The third component, through the linkage design of the rope and the electric contact ring, can sense the installation status of the camera in real time. Once the camera becomes loose and causes the rope to slacken, the electric contact ring A and the electric contact ring B will separate, triggering the controller to drive the early warning device to remind the operator to detect the displacement problem as soon as possible and prevent the deviation from continuing to expand and affecting the detection results. Ensuring long-term stability of inspection accuracy and reducing rework and quality risks: Camera displacement can directly lead to field of view shift, incomplete circumferential coverage, or image stitching misalignment, thereby affecting the accuracy of defect identification; This component ensures that the camera always maintains its initial installation accuracy through active monitoring and timely early warning, avoiding problems such as blind spots and image distortion caused by displacement, and ensuring long-term stability in the accuracy of steel strand surface inspection, reducing finished product rework or quality risks caused by inspection errors; Simplify equipment maintenance processes and reduce labor costs and maintenance difficulty: Existing technologies require regular manual inspections of camera installation status by professional personnel, which is cumbersome and time-consuming. This component automates displacement monitoring and provides real-time early warnings, eliminating the need for frequent manual inspections, significantly reducing the maintenance burden on operators, and minimizing equipment downtime due to missed inspections, thereby improving the overall operational efficiency of the detection system. Attached Figure Description

[0019] Figure 1 This is a structural diagram of the main body of the present invention; Figure 2 For the present invention Figure 1 Enlarged view of the structure at point A in the middle; Figure 3 This is a side view of the main structure of the present invention; Figure 4 This is a diagram showing the structural locations of the first, second, and third components in this invention. Figure 5This diagram shows the installation states of sliding component A and sliding component B on the support frame, as well as the installation states of the outer expansion column, ring, magnetic column, and feedback cavity in this invention. Figure 6 This is a diagram illustrating the process of installing the ring onto the outward-expanding column in this invention. Figure 7 This is a half-section plan view of the support frame, outer expansion column, and feedback cavity in this invention; Figure 8 This is a diagram showing the working state of the third component in this invention.

[0020] In the picture: 1. Equipment platform; 2. First component; 201. Guide plate; 202. Slide rail; 203. Transmission assembly; 204. Wire; 3. Second component; 301. Support frame; 302. Slide groove; 303. Through hole; 304. Sliding part A; 305. Image acquisition unit; 306. Outer extension column; 307. Insertion hole; 308. Ring; 309. Slot; 310. Magnetic column; 311. Observation chamber; 312. Liquid level mark; 4. Third component; 401. Sliding part B; 402. Connecting piece; 403. Feedback cavity; 404. Support piece; 405. Electrical contact ring A; 406. Circular piece; 407. Electrical contact ring B; 408. Rope; 409. Tightening part. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0023] Example To address the problems mentioned in the technical solutions, this application provides a measurement image acquisition system method based on the surface quality inspection requirements of steel strands. Using a line scan camera as the core, it achieves clear, full-coverage, and accurate acquisition of steel strand surface images through multi-device collaborative acquisition and hierarchical control. The acquisition control is achieved through five major processes, with the key processes as follows: Step 1: Selection, Layout and Installation of Data Acquisition Equipment Select a line scan camera with a pixel count ≥ 4k and a line frequency ≥ 20kHz, paired with a 12-25mm low-distortion industrial lens, and fitted with a dustproof and oil-proof protective lens cover; arrange three cameras in a ring around the steel line, with the field of view of adjacent cameras overlapping by ≥ 15%; the lens optical axis is perpendicular to the surface of the steel line with a deviation ≤ ±0.5°, and the object distance is fixed with an error ≤ ±2mm; the auxiliary strip diffuse coaxial light source is installed at a 30-45° angle to the camera, the encoder is directly connected to the camera signal interface, and all equipment is fixed on a shockproof bracket; Step 2: Parameter Calibration and Environmental Adaptation (Basic Data Acquisition) Connect the camera, encoder, industrial computer, and image acquisition card. Set the parameters according to the rebar line running speed of 0.5-10m / s: line frequency = line speed × 60px / mm pixel density, and adjust the exposure time to 1-8μs. Calibrate the lens focal length until the rebar surface texture is clear, verify the synchronization between the encoder and the camera, and ensure that the image is not stretched or misaligned. Clean the dust and oil stains in the acquisition area. The distance between the signal cable and the power line should be ≥30cm. If it exceeds 10m, use optical fiber to extend it to resist interference. Step 3: Hierarchical data acquisition and real-time control (core step) Start the light source and preheat for 5 minutes, then turn on the camera and encoder. Once the equipment is stable, control the transmission of the rebar line. Use encoder signal to trigger acquisition and test with standard defect samples to ensure clear imaging of defects such as cracks and scratches. Under normal operating conditions, continuously acquire data at a fixed frequency. When running at high speed (>5m / s), shorten the exposure and increase the line frequency. For rebar with rough surfaces, appropriately extend the exposure and simultaneously improve image contrast to ensure acquisition quality. Step 4: Anomaly Handling and Closed-Loop Verification (Data Acquisition Assurance) Real-time image preview, comparing acquisition status every second: if the image is stretched, check encoder synchronization and transmission equipment roller slippage; if blurry, clean the lens and tighten the camera; if defects are missed, adjust the camera angle and light source brightness; 10% of images from each batch are checked, and the defect recognition rate ≥98% and the size measurement deviation ≤±0.02mm are considered qualified; if unqualified, mark the corresponding rebar section, re-acquire and optimize parameters; Step 5: Data Management and System Optimization Images are stored in lossless BMP / RAW format and named according to "batch-time-rebar number", with dual backups on both local and cloud platforms; storage strategy is adjusted according to acquisition quality every unit of time, reserving ≥50% of hard disk space; equipment status is checked before daily acquisition, and parameters such as line frequency and synchronization accuracy are calibrated weekly; anomaly handling and parameter adjustment are recorded to form an operation log, and equipment layout and parameter settings are optimized regularly.

[0024] A further embodiment: Please refer to Figure 1 , Figures 3 to 7 As shown: A measurement image acquisition device for steel strand surface inspection, applied to a measurement image acquisition system for steel strand surface quality inspection, includes a device platform 1 and a first component 2; the first component 2 includes a guide plate 201 fixedly connected to the device platform 1, a slide rail 202 opened on the guide plate 201, a transmission group 203 slidably connected on the slide rail 202, the transmission group 203 is adjusted within the slide rail 202 according to specific conditions and then fixed by bolts, the transmission group 203 consists of a support body and a transmission wheel, and a wire 204 is driven between the two transmission groups 203 transmission wheels; It also includes a second component 3; the second component 3 includes a support frame 301 fixedly connected to the guide plate 201 by bolts, a sliding groove 302 is opened laterally on the support frame 301, and through holes 303 are opened at equal intervals on the support frame 301. A sliding member A304 is slidably connected in the sliding groove 302; an image acquisition device 305 is fixedly connected to the sliding member A304, and an outer extension column 306 is fixedly connected to the side wall of the image acquisition device 305; an insertion hole 307 is opened on the outer extension column 306, and a ring 308 is provided on one side of the outer extension column 306. A slot 309 is opened at equal intervals on the ring 308, and a magnetic column 310 is inserted into the slot 309. The ring 308 is connected to the outer extension column 306 through the magnetic column 310, the slot 309, and the insertion hole 307; an observation chamber 311 is fixedly connected to the bottom of the ring 308, and a liquid level mark 312 is engraved laterally on the outer wall of the observation chamber 311.

[0025] in: The first component 2 is used for the initial feeding of wire 204.

[0026] The transmission group 203 can slide in the slide rail 202, and the spacing between the transmission groups 203 can be adjusted according to the usage.

[0027] It should be noted that the reinforcing steel wire, steel strand, and wire 204 in this design are all made of the same material.

[0028] The second component 3 is used for the stable and convenient installation of equipment for detecting whether the surface process of wire 204 is qualified; specifically, it can quickly and stably and effectively install multiple detection devices, i.e. multiple image acquisition devices 305, to ensure that multiple image acquisition devices 305 can acquire images of the entire circumference of wire 204, avoiding the situation where there are blind spots in the field of view when multiple image acquisition devices 305 are installed manually. The design of the support frame 301 in conjunction with the slide groove 302 allows the operator to directly slide and install the image acquisition device 305 without measuring the angle between each image acquisition device 305. This effectively ensures that there are no blind spots in the field of view when multiple image acquisition devices 305 are installed. The above-mentioned template installation can effectively reduce the installation time of the image acquisition device 305.

[0029] The support frame 301 can be switched in size and specifications according to different situations, so as to adapt to the different specifications of cables 204 and the different focal length adjustment requirements of the image acquisition device 305.

[0030] Once the operator inserts the bolt through the through hole 303 and finally installs it by matching the threaded groove on the sliding part, the sliding part can no longer slide within the groove 302.

[0031] Multiple through holes 303 are provided, and operators can install the sliding parts at different positions on the support frame 301 according to specific circumstances.

[0032] The sliding part A304 has a threaded groove that matches the bolt; a through hole can be made on the sliding part A304 as needed to facilitate the connection of the communication line of the image acquisition device 305.

[0033] The image acquisition unit 305 can be implemented as a line scan camera; multiple image acquisition units 305 can be arranged in a surrounding configuration with the wire 204 as the axis, depending on the specific situation.

[0034] The outer extension post 306 is made of magnetic material. When the magnetic post 310 is inserted into the socket 307, the two are relatively stable under the action of no external force and no longer change position.

[0035] The magnetic post 310 can fix the ring 308 to the outer post 306 through the slot 309.

[0036] The observation chamber 311 contains a colored aqueous solution, the presence of which can indirectly provide feedback on whether the image acquisition device 305 is in a state that meets the process requirements on the ground / equipment platform 1. For example, in this design, there are three image acquisition devices 305, one on top of the support frame 301 and two on the sides of the support frame 301. When the image acquisition device 305 is installed on the support frame 301, it can be observed whether the aqueous solution inside is horizontal and centered, and whether the liquid level is flush with the liquid level mark 312. If the solution in the observation chamber 311 is horizontal and centered, it indicates that the top image acquisition device 305 is installed perpendicular to the ground / equipment platform 1 / wire 204, which meets the process requirements. If the solution is horizontal and centered, but the solution inside is not flush with the liquid level mark 312, it indicates that the image acquisition device 305 on the side of the support frame 301 is not installed according to the process requirements, and the side image acquisition device 305 is not on the same vertical plane as the top image acquisition device 305, which needs to be adjusted.

[0037] The proper installation of the image acquisition device 305 should be such that the solution in the observation chamber 311 is horizontally centered and the solution is flush with and coincides with the liquid level mark 312; that is, multiple image acquisition devices 305 are all on the same vertical plane, and the combined images captured by multiple image acquisition devices 305 should be greater than or equal to the images of the same circumferential position of the sliding part A304, that is, it must be able to completely cover a circle of the same position of the cable 204, and can overlap.

[0038] A further embodiment: Please refer to Figure 1 , Figures 5 to 8 As shown: The third component 4 includes a sliding member B401 slidably connected to the slide groove 302. A connecting piece 402 is fixedly connected to the bottom surface of the sliding member B401. A feedback cavity 403 is fixedly connected to the bottom end of the connecting piece 402. A support piece 404 is fixedly connected to the inner cavity of the feedback cavity 403. An electrical contact ring A405 is fixedly connected to the support piece 404. A circular piece 406 is slidably connected to the inner cavity of the feedback cavity 403. An electrical contact ring B407 is fixedly connected to the side of the circular piece 406 near the support piece 404. A rope 408 is fixedly connected to the wall of plate 404, and a screw 409 is fixedly connected to the end of the rope 408 away from plate 406; the outer extension post 306 is made of magnetic material, and the magnetic post 310 is inserted into the insertion hole 307 opened on the outer extension post 306; and the outer wall of the magnetic post 310 is provided with a wire groove that matches the screw 409; the observation chamber 311 is provided with a solution, which is used in conjunction with the liquid level mark 312; the sliding member B401 is provided with a wire groove that matches the screw 409.

[0039] in: The third component 4 is used for position monitoring of the image acquisition unit 305 after installation, to prevent the image acquisition unit 305 from being displaced due to external forces such as vibration, which would affect the accuracy of image acquisition and detection on the surface of the wire 204.

[0040] The magnetic post 310 has a thread groove that is compatible with the screwing part 409.

[0041] An early warning device is installed on the feedback cavity 403. The early warning device is electrically connected to the electric contact rings A405 and B407 and the main controller of the device. When the image acquisition device 305 becomes loose, the image acquisition device 305 can indirectly cause the electric contact rings A405 and B407, which were originally tightly attached to each other, to separate through the loosening of the rope 408. At this time, the main controller of the device will control the early warning device to issue an early warning.

[0042] The support plate 404 has holes for the rope 408 to pass through.

[0043] Once the three image acquisition units 305 in this design are installed in accordance with the process requirements, the screwing parts 409, which are fixedly connected to the rope 408, can be rotated and screwed into the wire groove opened on the magnetic column 310 until the ring 308 is in a taut state and the electric contact ring A405 and the electric contact ring B407 are tightly fitted together.

[0044] in: The working principle of all the content in the above embodiments is as follows: Working process of measurement image acquisition equipment for steel strand surface inspection The working process of the measurement image acquisition equipment for steel strand surface inspection revolves around "installation and commissioning—parameter calibration—acquisition and operation—anomaly handling—data maintenance." The core is to achieve full coverage and high-precision acquisition of steel strand surface images through the collaboration of multiple components. The specific process is as follows: Phase 1: Equipment Installation and Layout First component 2 arrangement: fix the guide plate 201 on the equipment platform 1, slide the transmission group 203 on the slide rail 202, adjust the spacing of the transmission group 203 according to the specifications of the wire 204, and after fixing with bolts, set the wire 204 between the transmission wheels of the two transmission groups 203. Second component 3 installation: Support frame 301 is fixed to guide plate 201 with bolts, sliding part A304 slides into slide groove 302, and after adjusting the position, it is fixed with bolts through through hole 303; image acquisition unit 305 is installed with three devices in a ring layout to ensure that adjacent fields of view overlap ≥15%; Auxiliary component assembly: The ring 308 is inserted into the socket 307 of the outer extension post 306 through the slot 309 via the magnetic post 310, so that the ring 308 is fixed to one side of the outer extension post 306; the sliding part B401 slides into the sliding groove 302, the connecting piece 402 connects the sliding part B401 and the feedback cavity 403, and the screwing part 409 passes through the feedback cavity 403 and is tightened to the thread groove of the magnetic post 310, so that the rope 408 is taut and the electric contact ring A405 and the electric contact ring B407 are in contact; Phase Two: Installation Verification and Parameter Calibration Installation accuracy verification: Observe the colored aqueous solution in the observation chamber 311. If the solution is horizontal and centered and level with the liquid level mark 312, it means that the image acquisition device 305 is in the same vertical plane and perpendicular to the wire 204, and the installation is qualified; if it is not qualified, adjust the position of the sliding part A304. Equipment parameter settings: Connect the image acquisition unit 305, encoder to the industrial control computer and image acquisition card, and set the line frequency (line frequency = line speed × 60px / mm pixel density) and exposure time of 1-8μs according to the cable running speed of 2040.5-10m / s.

[0045] Environmental and Synchronization Calibration: The lens focal length is calibrated until the surface texture of the steel strand is clear, and the synchronization between the encoder and the image acquisition unit 305 is verified; dust and oil stains are cleaned from the acquisition area, and the distance between the signal cable and the power line is ≥30cm. For distances exceeding 10m, optical fiber is used to extend the cable to resist interference. Phase 3: Image Acquisition Operation Equipment preheating and start-up: First, start the strip diffused coaxial light source for preheating, then turn on the image acquisition unit 305 and encoder. After the equipment is stable, drive the cable 204 through the transmission group 203 for transmission. Hierarchical acquisition control: Encoder signal triggering acquisition is used, and standard defect sample testing is used to ensure clear imaging of cracks and scratches; under normal working conditions, continuous acquisition is carried out at a fixed frequency; when running at high speed (>5m / s), the exposure is shortened and the line frequency is increased; for steel strands with rough surfaces, the exposure is appropriately extended and the contrast is increased. Phase Four: Anomaly Handling and Closed-Loop Verification Real-time anomaly monitoring: The acquisition status is compared every second. If the image is stretched, the encoder synchronization and the slippage of the 203 roller of the transmission group are checked. If the image is blurry, the lens is cleaned and the equipment is tightened. If a defect is missed, the camera angle and the light source brightness are adjusted. Displacement warning response: If the image acquisition device 305 becomes loose, causing the rope 408 to slack, the electrical contact ring A405 and the electrical contact ring B407 will separate, the controller will drive the warning device to remind the operator to handle the situation in time. Batch verification closed loop: 10% of the images in each batch are sampled for verification. The defect recognition rate is ≥98% and the size measurement deviation is ≤±0.02mm to be considered qualified; if unqualified, the corresponding steel strand section is marked, and the data is re-collected and the parameters are optimized. Phase 5: Data Management and Equipment Maintenance Data storage and backup: Images are stored in lossless BMP / RAW format, named according to "batch-time-rebar number", with dual backups on both local and cloud platforms, reserving ≥50% of hard disk space, and adjusting the storage strategy according to the acquisition quality; Regular equipment maintenance: Check equipment status before daily data collection, calibrate parameters such as line frequency and synchronization accuracy weekly; record anomaly handling and parameter adjustment to form an operation log, and regularly optimize equipment layout and parameter settings.

[0046] Please refer to the above work process. Figures 1 to 8 .

[0047] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0048] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A measurement image acquisition system method based on the surface quality inspection requirements of steel strands, using a line scan camera as the core, and achieving clear, full-coverage, and accurate acquisition of steel strand surface images through multi-device collaborative acquisition and hierarchical control; characterized in that: Data acquisition and control are achieved through five major processes, with the key processes as follows: Step 1: Selection, Layout and Installation of Data Acquisition Equipment Select a line scan camera with a pixel count ≥ 4k and a line frequency ≥ 20kHz, paired with a 12-25mm low-distortion industrial lens, and fitted with a dustproof and oil-proof protective lens cover; arrange three cameras in a ring around the steel line, with the field of view of adjacent cameras overlapping by ≥ 15%; the lens optical axis is perpendicular to the surface of the steel line with a deviation ≤ ±0.5°, and the object distance is fixed with an error ≤ ±2mm; the auxiliary strip diffuse coaxial light source is installed at a 30-45° angle to the camera, the encoder is directly connected to the camera signal interface, and all equipment is fixed on a shockproof bracket; Step 2: Parameter Calibration and Environmental Adaptation (Basic Data Acquisition) Connect the camera, encoder, industrial computer, and image acquisition card. Set the parameters according to the rebar line running speed of 0.5-10m / s: line frequency = line speed × 60px / mm pixel density, and adjust the exposure time to 1-8μs. Calibrate the lens focal length until the rebar surface texture is clear, verify the synchronization between the encoder and the camera, and ensure that the image is not stretched or misaligned. Clean the dust and oil stains in the acquisition area. The distance between the signal cable and the power line should be ≥30cm. If it exceeds 10m, use optical fiber to extend it to resist interference. Step 3: Hierarchical data acquisition and real-time control (core step) Start the light source and preheat for 5 minutes, then turn on the camera and encoder. Once the equipment is stable, control the transmission of the rebar line. Use encoder signal to trigger acquisition and test with standard defect samples to ensure clear imaging of defects such as cracks and scratches. Under normal operating conditions, continuously acquire data at a fixed frequency. When running at high speed (>5m / s), shorten the exposure and increase the line frequency. For rebar with rough surfaces, appropriately extend the exposure and simultaneously improve image contrast to ensure acquisition quality. Step 4: Anomaly Handling and Closed-Loop Verification (Data Acquisition Assurance) Real-time image preview, comparing acquisition status every second: if the image is stretched, check encoder synchronization and transmission equipment roller slippage; if blurry, clean the lens and tighten the camera; if defects are missed, adjust the camera angle and light source brightness; 10% of images from each batch are checked, and the defect recognition rate ≥98% and the size measurement deviation ≤±0.02mm are considered qualified; if unqualified, mark the corresponding rebar section, re-acquire and optimize parameters; Step 5: Data Management and System Optimization Images are stored in lossless BMP / RAW format and named according to "batch-time-rebar number", with dual backups on both local and cloud platforms; storage strategy is adjusted according to acquisition quality every unit of time, reserving ≥50% of hard disk space; equipment status is checked before daily acquisition, and parameters such as line frequency and synchronization accuracy are calibrated weekly; anomaly handling and parameter adjustment are recorded to form an operation log, and equipment layout and parameter settings are optimized regularly.

2. A measurement image acquisition device for steel strand surface inspection, applied to the measurement image acquisition system based on the surface quality inspection requirements of steel strand as described in claim 1, characterized in that: Includes a device platform (1) and a first component (2); The first component (2) includes a guide plate (201) fixedly connected to the equipment platform (1). A slide rail (202) is provided on the guide plate (201). A transmission group (203) is slidably connected on the slide rail (202). The transmission group (203) is adjusted in the slide rail (202) according to the specific situation and then fixed by bolts. The transmission group (203) consists of a support body and a transmission wheel. A wire (204) is driven between the transmission wheels of the two transmission groups (203).

3. The measuring image acquisition device for steel strand surface inspection according to claim 2, characterized in that: It also includes a second component (3); The second component (3) includes a support frame (301) fixedly connected to the guide plate (201) by bolts. The support frame (301) has a horizontal groove (302) and through holes (303) equidistantly through it. A sliding member A (304) is slidably connected in the groove (302). An image acquisition device (305) is fixedly connected to the sliding component A (304), and an external expansion column (306) is fixedly connected to the side wall of the image acquisition device (305).

4. The measuring image acquisition device for steel strand surface inspection according to claim 3, characterized in that: The outer extension post (306) is provided with a socket (307), and a ring (308) is provided on one side of the outer extension post (306). The ring (308) is provided with slots (309) that are equidistantly through it. A magnetic post (310) is inserted into the slot (309). The ring (308) is connected to the outer extension post (306) through the magnetic post (310), the slot (309), and the socket (307). The bottom of the ring (308) is fixedly connected to an observation chamber (311), and the outer wall of the observation chamber (311) is horizontally engraved with liquid level markings (312).

5. The measuring image acquisition device for steel strand surface inspection according to claim 4, characterized in that: It also includes a third component (4); The third component (4) includes a sliding member B (401) slidably connected to the slide groove (302). A connecting piece (402) is fixedly connected to the bottom surface of the sliding member B (401). A feedback cavity (403) is fixedly connected to the bottom end of the connecting piece (402). A support piece (404) is fixedly connected to the inner cavity of the feedback cavity (403). An electric contact ring A (405) is fixedly connected to the support piece (404).

6. The measuring image acquisition device for steel strand surface inspection according to claim 5, characterized in that: A circular plate (406) is slidably connected to the inner cavity of the feedback cavity (403). An electric contact ring B (407) is fixedly connected to the side of the circular plate (406) near the support plate (404). A rope (408) is fixedly connected to the wall surface of the circular plate (406) near the support plate (404). A screwing component (409) is fixedly connected to the end of the rope (408) away from the circular plate (406).

7. The measuring image acquisition device for steel strand surface inspection according to claim 6, characterized in that: The outer extension post (306) is made of magnetic material, and the magnetic post (310) is inserted into the insertion hole (307) opened on the outer extension post (306); and the outer wall surface of the magnetic post (310) is provided with a wire groove that is compatible with the screwing part (409).

8. The measuring image acquisition device for steel strand surface inspection according to claim 4, characterized in that: The observation chamber (311) contains a solution that is used in conjunction with the liquid level mark (312).

9. The measuring image acquisition device for steel strand surface inspection according to claim 6, characterized in that: The sliding member B (401) has a thread groove that is compatible with the screwing member (409).

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