A porcelain insulator defect detection device and method based on optical imaging

Abstract

This invention discloses a porcelain insulator defect detection device and method based on optical imaging, including a frame, a back frame fixedly installed at the rear top of the frame, a servo screw linear module installed on the back of the back frame, and a hyperspectral camera fixedly mounted on the slide of the servo screw linear module; a cage turntable, fixed on the outer wall of the back frame away from the servo screw linear module, with a central shaft fixed at the central axis position inside the cage turntable. This invention utilizes a gear-type station conversion assembly to perform a single station conversion for the multi-station rotating fixture in the cage turntable. During the station conversion, a clearance-type double-roller drive assembly actively avoids the multi-station rotating fixture. After the station conversion is completed, the clearance-type double-roller drive assembly contacts the multi-station rotating fixture, causing the porcelain insulator at the inspection station to rotate until the inspection is completed, thereby solving the problems of multi-station motion interference and efficiency bottlenecks.

Description

Technical Field

[0001] This invention relates to the field of porcelain insulator surface defect technology, specifically to a porcelain insulator defect detection device and method based on optical imaging. Background Technology

[0002] As insulation and support components in power systems, the quality of the surface skirts of porcelain insulators directly affects the overall operational safety of transmission lines. Defect detection of finished porcelain insulators can effectively prevent power grid accidents caused by surface defects. Specifically, in a controlled environment, raw image data of the insulators is acquired using a standard light source and a hyperspectral camera. Black and white correction is performed to eliminate equipment noise and environmental influences, obtaining pure reflectivity information. To address the strong reflective interference that may arise from the glaze on the porcelain surface, image enhancement algorithms are used for preprocessing to restore details of defects or contamination obscured by light spots. Subsequently, given the massive amount of information in the hyperspectral data, the system uses feature extraction methods to select the key bands that best characterize different states (e.g., normal, cracked, different degrees of contamination), achieving data dimensionality reduction. The extracted feature spectra are then combined with a machine learning model to determine whether there are flaws, defects, or stains on the surface of the porcelain insulator skirts. As disclosed in CN120971446B, a device for detecting crack defects in porcelain insulators includes a housing. A fixing plate is fixedly connected to the upper side of the housing, and a receiving box is provided on the upper side of the fixing plate. An impregnation tank is provided inside the housing, and photochromic coating is provided in the impregnation tank. Two symmetrical supports are fixedly connected to the bottom of the impregnation tank, and the bottom of the supports is fixedly connected to the inner wall of the housing. An insulator body is provided inside the housing, and a high-contrast recognition module is provided on the outside of the insulator body. A high-definition camera and an ultraviolet lamp are provided inside the housing, both located outside the insulator body. A filter is provided on the high-definition camera, and a rapid feeding module is provided on the outside of the housing. The device immerses the insulator body, heated to above room temperature, into the room-temperature photochromic coating in the impregnation tank. Utilizing thermal expansion and contraction, the coating is drawn into the cracks on the insulator body after cooling, allowing the ultraviolet lamp to detect the cracks. When the body is irradiated, the paint in the crack changes color, indicating that the porcelain insulator under test in the above technical solution is mainly placed on the rotating fixture of the high-contrast recognition module. It is a single-station setting, that is, the motor drives the insulator to rotate at a constant speed around its own axis. At the same time, the hyperspectral camera above scans line by line to obtain the complete image information of the insulator skirt around one circumference. Since only one insulator can be loaded at a time, the entire detection process is carried out serially and cannot form a continuous detection flow. If it is to be changed to a multi-station structure, the drive motor on each station needs to be continuously powered. If the motor is a servo motor or a stepper motor, a real-time control signal line is also required. This part of the cable must be connected from the fixed cabinet to the rotating large disk, and then distributed from the large disk to each rotating station. As the large disk rotates continuously, these cables will be repeatedly twisted and tangled like telephone lines, eventually causing the cable sheath to crack, the internal core wire to break, and even the joint to be pulled off, causing the equipment to stop. Summary of the Invention

[0003] The purpose of this invention is to provide a porcelain insulator defect detection device and method based on optical imaging. Multiple porcelain insulators to be detected are clamped one by one on a multi-position rotating fixture inside a cage turntable. A servo screw linear module and a hyperspectral camera work together to complete the defect detection of the porcelain insulators at the inspection position. Then, a gear-type position conversion assembly causes the multi-position rotating fixture in the cage turntable to perform a position conversion. During the position conversion, a clearance-type double-roller drive assembly actively avoids the multi-position rotating fixture. After the position conversion is completed, the clearance-type double-roller drive assembly contacts the multi-position rotating fixture again, causing the porcelain insulator at the inspection position to rotate until the detection is completed, thereby solving the problems mentioned in the background art.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a ceramic insulator defect detection device based on optical imaging, comprising a frame, a back frame fixedly installed at the rear of the top of the frame, a servo screw linear module installed on the back of the back frame, and a hyperspectral camera fixedly mounted on the slide of the servo screw linear module. The cage turntable is fixed on the outer wall of the back frame away from the servo screw linear module, and a central shaft is fixed at the central axis position inside the cage turntable. The multi-station rotating fixture is set in the circumferential direction of the cage turntable and fixed to the lower end of the central shaft. It is used to clamp multiple porcelain insulators to be tested and can rotate freely relative to the cage turntable around its own axis. Gear-type station conversion assembly, which is located on one side of the cage turntable, is used to drive the central shaft to rotate; The L-shaped base frame is fixed to the bottom of the back frame, and the L-shaped base frame facing the multi-station tooling is equipped with a clearance-type double roller drive assembly on the outer wall. The PLC control panel is installed on one outer wall of the machine frame. The output terminal of the PLC control panel is electrically connected to the input terminal of the servo ball screw linear module, hyperspectral camera, gear-type station conversion assembly and avoidance-type double roller drive assembly.

[0005] Preferably, the cage turntable includes a bottom ring and a top ring fixed at intervals along the vertical direction on the outer wall of the back frame, and a plurality of side columns fixed at the edge position between the bottom ring and the top ring. The bottom ring and the top ring are both equipped with turntables that are rotatably mounted inside the cage via bearings.

[0006] Preferably, the central shaft passes through and is fixed between the two turntables, and multiple baffles are fixed at equal intervals along the circumferential direction at the upper end of the central shaft. The area between two adjacent baffles is a receiving area, and the lower end of the central shaft is rotatably connected to the bottom of the L-shaped base frame.

[0007] Preferably, the multi-station transfer fixture includes a multi-blade disk fixed at a lower position on the central shaft, several vertical shafts mounted vertically at the corners of the multi-blade disk via bearings, and a chuck fixed at the upper end of the vertical shafts. The bottom end of the L-shaped base frame is provided with a friction brake assembly for reducing the rotational speed of one of the vertical shafts.

[0008] Preferably, the gear-type station conversion assembly includes a servo motor mounted on the outer wall of the back frame via a motor mount, a hollow frame fixed at the top edge of the top ring, and a secondary gear shaft rotatably mounted inside the hollow frame. The top of the turntable is fixed with an external gear ring that meshes with the secondary gear shaft, and a primary gear is fixed at the lower end of the output shaft of the servo motor. The primary gear meshes with the secondary gear shaft.

[0009] Preferably, the avoidance-type dual-roller drive assembly includes an L-shaped front frame fixed to the back of the L-shaped base frame, an L-shaped rear frame fixed to the bottom of the L-shaped front frame, and a cylinder two installed on the inner wall of one side of the L-shaped rear frame. The piston rod end of the cylinder two passes through the L-shaped front frame and is fixed with a contact seat. Two elastic tensioning structures are provided on the inner wall of the L-shaped rear frame above the cylinder two. A rotating shaft one and a rotating shaft two are rotatably installed on the outer wall of the L-shaped front frame away from the L-shaped rear frame. An active roller rotating structure and a driven roller rotating structure are respectively fixed on the rotating shaft one and the rotating shaft two. The upper ends of the active roller rotating structure and the driven roller rotating structure are each connected to an elastic tensioning structure.

[0010] Preferably, the active roller rotation structure includes a lower connecting arm fixed on a rotating shaft, a C-shaped roller frame fixed at the lower end of the lower connecting arm, a drive roller vertically rotatably mounted inside the C-shaped roller frame, and a motor mounted on one side of the bottom of the C-shaped roller frame. The lower end of the motor's output shaft is equipped with a belt drive structure for driving the drive roller to rotate, and a pulley for contacting the contact seat is rotatably mounted on the back of the lower connecting arm.

[0011] Preferably, the elastic tensioning structure includes an upper connecting arm fixed to the upper end of the rotating shaft, a threaded rod with holes installed inside the L-shaped rear frame, and a tension spring connecting the upper connecting arm and the threaded rod with holes.

[0012] Preferably, the friction brake assembly includes a cylinder fixed to the lower end of the L-shaped base, a U-shaped seat fixed to the upper end of the piston rod of the cylinder, and protrusions integrally formed on the left and right inner walls of the U-shaped seat. A brake pad is fixed to the lower end of the vertical shaft, and the height of the brake pad is lower than the protrusions.

[0013] The present invention also provides a method for detecting defects in porcelain insulators based on optical imaging, using the aforementioned apparatus, comprising the following steps: S101: Multiple processed porcelain insulators are vertically clamped onto a multi-station rotating fixture to ensure that the porcelain insulators remain stable and their axes do not wobble during subsequent revolution and rotation. After loading, the parameters for this test are set through the PLC control panel, including the exposure time of the hyperspectral camera, the scanning band range, the lifting and moving speed and stroke of the servo screw linear module, and the interval time for each station conversion of the cage turntable and gear-type station conversion assembly. S102: The gear-type station conversion assembly drives the central shaft to rotate, so that the first insulator on the multi-station transfer fixture stops at the inspection station on the side of the hyperspectral camera. After the multi-station transfer fixture is in place and stationary, the avoidance double roller drive assembly contacts the multi-station transfer fixture and establishes a driving power connection through friction, so that the porcelain insulator on the inspection station slowly and uniformly rotates around its own axis. S103: The servo screw linear module carries the hyperspectral camera, which moves linearly along the axial direction of the insulator. During the movement, the hyperspectral camera continuously acquires hyperspectral image data of the insulator skirt surface and transmits the data in real time to the connected industrial control computer for storage and preliminary processing. After the hyperspectral camera completes the scan from one end of the insulator to the other, the servo screw linear module drives the hyperspectral camera back to the starting position. The avoidance double roller drive assembly stops rotating and disengages from the multi-station transfer fixture, preparing for the next station conversion. The gear-type station conversion assembly receives the working instructions from the PLC control panel and drives the central shaft to rotate by one station angle, so that the next insulator to be tested enters the inspection station. At this time, the avoidance double roller drive assembly has actively retracted and will not interfere with the multi-station transfer fixture. S104: After the new tooling is in place, the avoidance double roller drive assembly contacts the multi-station slave tooling again, and the servo screw linear module drives the hyperspectral camera to scan again until all the porcelain insulators clamped on the multi-station slave tooling have been inspected.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: The optical imaging-based porcelain insulator defect detection device and method are configured with a servo screw linear module, a hyperspectral camera, a gear-type station conversion assembly, a central shaft, a cage turntable, a multi-station slave-rotor fixture, and a clearance-type double roller drive assembly, etc., which cooperate with each other. The servo screw linear module and the hyperspectral camera cooperate to complete the defect detection of the porcelain insulator at the inspection station. Then, the gear-type station conversion assembly causes the multi-station slave-rotor fixture in the cage turntable to perform a station conversion. During the station conversion, the clearance-type double roller drive assembly actively avoids the multi-station slave-rotor fixture. After the station conversion is completed, the clearance-type double roller drive assembly contacts the multi-station slave-rotor fixture again. The clearance-type double roller drive assembly causes the porcelain insulator at the inspection station to rotate until the detection is completed, thereby solving the problems of multi-station motion interference and efficiency bottleneck. Multiple porcelain insulators are clamped inside the cage turntable on a multi-station slave rotating fixture. A servo screw linear module and a hyperspectral camera eliminate the need for auxiliary loading and unloading time, allowing continuous scanning of insulators arriving at the inspection station. This shortens the average inspection cycle time for a single workpiece, enabling the inspection speed to match the manufacturing speed of the upstream production line. Secondly, as the multi-station slave rotating fixture revolves with the cage turntable, the avoidance-type double-roller drive assembly actively retracts, disengaging from the fixture to create unobstructed movement space for the turntable's rotation, ensuring smooth revolution. After conversion and the new insulator's placement, the avoidance-type double-roller drive assembly re-engages with the multi-station slave rotating fixture. This achieves a shared drive system across multiple stations while avoiding the previous problems of cable following and entanglement. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the main structure of the present invention; Figure 2 This is a side view of the structure of the present invention; Figure 3 yes Figure 1 Sectional view at point AA; Figure 4 yes Figure 1 A three-dimensional structural cross-sectional view of point AA; Figure 5 This is a schematic diagram of the three-dimensional structure of the present invention. Figure 1 ; Figure 6 This is a schematic diagram of the three-dimensional structure of the present invention. Figure 2 ; Figure 7 This is a schematic diagram of the gear-type workstation conversion assembly of the present invention in three dimensions; Figure 8 This is a schematic diagram of the three-dimensional structure of the cage turntable of the present invention; Figure 9 This is a schematic diagram of the three-dimensional structure of the multi-station slave-to-tooling fixture of the present invention; Figure 10 This is a schematic diagram of the three-dimensional structure of the avoidance-type double roller drive assembly of the present invention. Figure 1 ; Figure 11 This is a schematic diagram of the three-dimensional structure of the avoidance-type double roller drive assembly of the present invention. Figure 2 ; Figure 12 This is a schematic diagram of the three-dimensional cross-sectional structure of the avoidance-type double roller drive assembly of the present invention; Figure 13 For the present invention Figure 8 Enlarged structural diagram at point A in the middle.

[0016] In the diagram: 1. Machine frame; 2. Back frame; 201. L-shaped base frame; 3. Servo screw linear module; 4. Hyperspectral camera; 5. Cage turntable; 51. Bottom ring; 52. Top ring; 53. Side column; 54. Turntable; 6. Gear-type station conversion assembly; 61. Hollow frame; 62. Servo motor; 63. Primary gear; 64. Secondary gear shaft; 65. External gear ring; 7. Central shaft; 71. Baffle; 72. Parts receiving area; 8. Multi-station slave tooling; 81. Multi-leaf disc; 82. Vertical shaft; 83. Chuck; 84. Brake pad; 9. Collision-type double roller drive assembly; 91. L-shaped... Front frame; 92. L-shaped rear frame; 93. Cylinder II; 931. Contact seat; 94. Rotating shaft I; 95. Rotating shaft II; 96. Elastic tensioning structure; 961. Threaded rod with hole; 962. Tension spring; 963. Upper connecting arm; 97. Active roller rotation structure; 971. Lower connecting arm; 972. C-shaped roller frame; 973. Motor; 974. Drive roller; 975. Belt drive structure; 976. Pulley; 98. Driven roller rotation structure; 10. Friction brake assembly; 1001. Cylinder I; 1002. U-shaped seat; 1003. Protrusion; 11. PLC control panel. Detailed Implementation

[0017] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0018] Example 1, by Figures 1 to 6 The present invention includes a frame 1, a back frame 2 fixedly installed at the rear of the top of the frame 1, a servo screw linear module 3 installed on the back of the back frame 2, and a hyperspectral camera 4 fixedly mounted on the slide of the servo screw linear module 3. Cage turntable 5 is fixed on the outer wall of the back frame 2 away from the servo screw linear module 3. A central shaft 7 is fixed at the central axis position inside the cage turntable 5. The multi-station rotating fixture 8 is set in the circumferential direction of the cage turntable 5 and fixed to the lower end of the central shaft 7. It is used to clamp multiple porcelain insulators to be tested and can rotate freely relative to the cage turntable 5 around its own axis. Gear-type station conversion assembly 6 is located on one side of the cage turntable 5 and is used to drive the central shaft 7 to rotate. L-shaped base frame 201 is fixed to the bottom end of the back frame 2, and an avoidance type double roller drive assembly 9 is installed on the outer wall of the L-shaped base frame 201 facing the multi-station tooling 8. PLC control panel 11 is installed on one side of the outer wall of the frame 1. The output terminal of PLC control panel 11 is electrically connected to the input terminal of servo screw linear module 3, hyperspectral camera 4, gear-type station conversion assembly 6 and avoidance type double roller drive assembly 9. During the inspection process, when the insulator begins to rotate at the inspection station, the PLC control panel 11 sends a pulse command to the servo screw linear module 3 to drive the servo motor in the module to rotate. The ball screw is driven to rotate through the coupling, converting the rotational motion into the linear movement of the slide table. The hyperspectral camera 4 mounted on the slide table moves up and down accordingly. Its movement speed is matched with the rotation speed of the insulator to ensure that the hyperspectral camera 4 can continuously and without distortion acquire images of the entire umbrella skirt surface during the scanning process. The hyperspectral camera 4 images the rotating porcelain insulator, and the acquired data is transmitted in real time to an external industrial control computer for processing. By analyzing the reflectivity characteristics under different bands, cracks or dirt on the outer surface of the porcelain insulator skirt are identified. During the inspection process, the insulators that have been inspected can be unloaded and new workpieces to be inspected can be loaded, thus realizing a continuous flow of workpiece defect inspection.

[0019] This embodiment of a method for detecting defects in porcelain insulators based on optical imaging, using the aforementioned apparatus, includes the following steps: S101: Multiple processed porcelain insulators are vertically clamped on the multi-station transfer fixture 8 to ensure that the porcelain insulators remain stable and their axes do not wobble during subsequent revolution and rotation. After loading, the parameters for this test are set through the PLC control panel 11, including the exposure time of the hyperspectral camera 4, the scanning band range, the lifting and moving speed and stroke of the servo screw linear module 3, and the interval time for each station conversion of the cage turntable 5 and the gear-type station conversion assembly 6. S102: The gear-type station conversion assembly 6 drives the central shaft 7 to rotate, so that the first insulator on the multi-station transfer fixture 8 stops at the inspection station on the side of the hyperspectral camera 4. After the multi-station transfer fixture 8 is in place and stationary, the avoidance double roller drive assembly 9 contacts the multi-station transfer fixture 8 and establishes a driving power connection through friction, so that the porcelain insulator on the inspection station slowly and uniformly rotates around its own axis. S103: The servo screw linear module 3 carries the hyperspectral camera 4 and performs linear feed motion along the axial direction of the insulator. During the movement, the hyperspectral camera 4 continuously collects hyperspectral image data of the insulator skirt surface and transmits the data in real time to the connected industrial control computer for storage and preliminary processing. After the hyperspectral camera 4 completes the scan from one end of the insulator to the other, the servo screw linear module 3 drives the hyperspectral camera 4 back to the starting position. The avoidance double roller drive assembly 9 stops rotating and disengages from the multi-station slave tooling 8, preparing for the next station conversion. The gear-type station conversion assembly 6 receives the working instructions from the PLC control panel 11 and drives the central shaft 7 to rotate by one station angle, so that the next insulator to be tested enters the test station. At this time, the avoidance double roller drive assembly 9 has actively retracted and will not interfere with the multi-station slave tooling 8. S104: After the new tooling is in place, the avoidance double roller drive assembly 9 contacts the multi-station slave tooling 8 again, and the servo screw linear module 3 drives the hyperspectral camera 4 to scan again until all the porcelain insulators clamped on the multi-station slave tooling 8 have been inspected.

[0020] Example 2, based on Example 1, is... Figure 7 , Figure 8 and Figure 9 The cage turntable 5 includes a bottom ring 51 and a top ring 52 fixed at intervals along the vertical direction on the outer wall of the back frame 2, and a plurality of side posts 53 fixed at the edge position between the bottom ring 51 and the top ring 52. The bottom ring 51 and the top ring 52 are both rotatably mounted with turntables 54 through bearings. The central shaft 7 runs through and is fixed between the two turntables 54. Multiple baffles 71 are fixed at equal intervals along the circumference at the upper end of the central shaft 7. The area between two adjacent baffles 71 is the receiving area 72. The lower end of the central shaft 7 is rotatably connected to the bottom of the L-shaped base frame 201. The receiving area 72 separates two adjacent insulator workpieces through the baffles 71 to reduce interference with the image of the hyperspectral camera 4. The multi-station transfer fixture 8 includes a multi-leaf disk 81 fixed at a lower position of the central shaft 7, several vertical shafts 82 vertically rotatably mounted at the corners of the multi-leaf disk 81 via bearings, and a chuck 83 fixed at the upper end of the vertical shafts 82. The upper end of the vertical shafts 82 is connected to the lower end of the porcelain insulator via the chuck 83, which can be used for post-type porcelain insulators. The bottom end of the L-shaped base frame 201 is provided with a friction brake assembly 10 for reducing the rotational speed of one of the vertical shafts 82. The gear-type station conversion assembly 6 includes a servo motor 62 mounted on the outer wall of the back frame 2 via a motor mount, a hollow frame 61 fixed at the top edge of the top ring 52, and a secondary gear shaft 64 rotatably mounted inside the hollow frame 61. An external gear ring 65 that meshes with the secondary gear shaft 64 is concentrically fixed at the top of the turntable 54. A primary gear 63 is fixed at the lower end of the output shaft of the servo motor 62, and the primary gear 63 meshes with the secondary gear shaft 64. When the gear-type station conversion assembly 6 drives the cage turntable 5 and the multi-station transfer fixture 8 to switch stations, the servo motor 62 receives the working instructions from the PLC control panel 11 and drives the first-stage gear 63 to rotate. The first-stage gear 63 drives the external gear ring 65 to rotate through the second-stage gear shaft 64, thereby causing the multi-station transfer fixture 8 to rotate out of the set station angle. To obtain the rotation angle of the servo motor 62, an encoder can be installed on the outer wall of the back frame 2, where the upper end of the encoder shaft is connected to the first-stage gear 63. The external gear ring 65 drives the turntable 54, the central shaft 7 and the multi-page disk 81 to rotate. At this time, the vertical shaft 82 will revolve around the central shaft 7 to switch the work position. During this process, the turntable 54 is installed in the bottom ring 51 and the top ring 52 through bearings, and bears the weight of the entire multi-work position tooling 8 and the insulator.

[0021] Example 3, based on Example 2, by Figure 10 , Figure 11 , Figure 12 and Figure 13 The avoidance type double roller drive assembly 9 includes an L-shaped front frame 91 fixed to the back of an L-shaped base frame 201, an L-shaped rear frame 92 fixed to the bottom of the L-shaped front frame 91, and a cylinder 93 installed on the inner wall of one side of the L-shaped rear frame 92. The piston rod end of the cylinder 93 passes through the L-shaped front frame 91 and is fixed with a contact seat 931. Two elastic tensioning structures 96 are provided on the inner wall of the L-shaped rear frame 92 above the cylinder 93. A rotating shaft 94 and a rotating shaft 95 are rotatably installed on the outer wall of the side of the L-shaped front frame 91 away from the L-shaped rear frame 92. An active roller rotating structure 97 and a driven roller rotating structure 98 are respectively fixed on the rotating shaft 94 and the rotating shaft 95. The upper ends of the active roller rotating structure 97 and the driven roller rotating structure 98 are each connected to an elastic tensioning structure 96. When the gear-type station conversion assembly 6 and the cage turntable 5 enable the multi-station slave tooling 8 to switch stations, the PLC control panel 11 instructs the piston rod of cylinder 2 93 to extend. Since the back of the active roller structure 97 and the driven roller structure 98 are in contact with the contact seat 931, as the contact seat 931 is gradually pushed out, the active roller structure 97 and the driven roller structure 98 unfold outward around the rotating shaft 1 94 and the rotating shaft 2 95 respectively. That is, the active roller structure 97 and the driven roller structure 98 are separated from the vertical shaft 82 until the active roller structure 97 and the driven roller structure 98 no longer block the revolution path of the vertical shaft 82. At this time, the multi-station slave tooling 8 can switch stations. The active roller structure 97 includes a lower connecting arm 971 fixed on a rotating shaft 94, a C-shaped roller frame 972 fixed at the lower end of the lower connecting arm 971, a drive roller 974 vertically rotatably mounted inside the C-shaped roller frame 972, and a motor 973 mounted on one side of the bottom of the C-shaped roller frame 972. A belt drive structure 975 for driving the drive roller 974 to rotate is mounted at the lower end of the output shaft of the motor 973. A pulley 976 for contacting the contact seat 931 is rotatably mounted on the back of the lower connecting arm 971. Before the avoidance type double roller drive assembly 9 performs the position conversion between the cage turntable 5 and the multi-position driven rotating fixture 8, the cylinder 2 93 pushes the active roller structure 97 and the driven roller structure 98 outward as a whole, so that they are disengaged from the multi-position driven rotating fixture 8, making room for rotation. After the conversion is completed, the cylinder 2 93 retracts, and the elastic tensioning structure 96 makes the active roller structure 97 and the driven roller structure 98 fit tightly against the vertical shaft 82. The active roller structure 97 drives the vertical shaft 82 and the insulator at the corresponding position to rotate at a constant speed through friction. The elastic tensioning structure 96 includes an upper connecting arm 963 fixed to the upper end of the rotating shaft 94, a threaded rod 961 with holes installed inside the L-shaped rear frame 92, and a tension spring 962 connecting the upper connecting arm 963 and the threaded rod 961. When the piston rod of the cylinder 93 extends, taking the rotating shaft 94 as an example, the rotating shaft 94 rotates due to the deflection of the active roller rotating structure 97. The tension spring 962 between the upper connecting arm 963 and the threaded rod 961 will be stretched to generate elastic force. After the work position is switched, the piston rod of the cylinder 93 returns to its original position, and the elastic tensioning structure 96 causes the active roller rotating structure 97 and the driven roller rotating structure 98 to reset. The motor 973 drives the drive roller 974 to rotate through the belt drive structure 975. The drive roller 974 contacts the vertical shaft 82, so that the vertical shaft 82 obtains rotational power, thereby driving the clamped insulator to rotate around its own axis. The friction brake assembly 10 includes a cylinder 1001 fixed to the lower end of an L-shaped base 201, a U-shaped seat 1002 fixed to the upper end of the piston rod of the cylinder 1001, and protrusions 1003 integrally formed on the left and right inner walls of the U-shaped seat 1002. A brake pad 84 is fixed to the lower end of the vertical shaft 82. The height of the brake pad 84 is lower than that of the protrusion 1003. When completing defect detection, in order to quickly bring the insulator from a rotating state to a stationary state, the operator can turn on the cylinder 1001 through the PLC control panel 11. The cylinder 1001 drives the U-shaped seat 1002 and the protrusion 1003 to move down, and the protrusion 1003 contacts the brake pad 84 until the vertical shaft 82 stops rotating.

[0022] 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 process, method, article, or apparatus.

[0023] 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 ceramic insulator defect detection device based on optical imaging, comprising a frame (1), a back frame (2) fixedly installed at the rear of the top of the frame (1), a servo screw linear module (3) installed on the back of the back frame (2), and a hyperspectral camera (4) fixedly mounted on the slide of the servo screw linear module (3), characterized in that: Cage turntable (5) is fixed on the outer wall of the back frame (2) away from the servo screw linear module (3). A central shaft (7) is fixed at the central axis position inside the cage turntable (5). Multi-station rotating fixture (8) is set on the circumferential direction of the cage turntable (5) and fixed to the lower end of the central shaft (7). It is used to clamp multiple porcelain insulators to be tested and can rotate freely around its own axis relative to the cage turntable (5). Gear-type station conversion assembly (6) is located on one side of the cage turntable (5) and is used to drive the central shaft (7) to rotate. L-shaped base frame (201), L-shaped base frame (201) is fixed at the bottom end of the back frame (2), and the L-shaped base frame (201) is mounted on the outer wall of the side facing the multi-station tooling (8) with a clearance-type double roller drive assembly (9). The PLC control panel (11) is installed on one side of the outer wall of the frame (1). The output end of the PLC control panel (11) is electrically connected to the input end of the servo screw linear module (3), hyperspectral camera (4), gear-type station conversion assembly (6) and avoidance-type double roller drive assembly (9).

2. The porcelain insulator defect detection device based on optical imaging according to claim 1, characterized in that: The cage turntable (5) includes a bottom ring (51) and a top ring (52) fixed at intervals along the vertical direction on the outer wall of the back frame (2), and a plurality of side columns (53) fixed at the edge position between the bottom ring (51) and the top ring (52). The bottom ring (51) and the top ring (52) are both equipped with turntables (54) through bearings.

3. The optical imaging-based porcelain insulator defect detection device according to claim 2, characterized in that: The central shaft (7) passes through and is fixed between two turntables (54). Multiple baffles (71) are fixed at equal intervals along the circumferential direction at the upper end of the central shaft (7). The area between two adjacent baffles (71) is a receiving area (72). The lower end of the central shaft (7) is rotatably connected to the bottom of the L-shaped base frame (201).

4. The porcelain insulator defect detection device based on optical imaging according to claim 3, characterized in that: The multi-station transfer fixture (8) includes a multi-blade disk (81) fixed at a lower position on the central shaft (7), several vertical shafts (82) mounted vertically at the corners of the multi-blade disk (81) via bearings, and a chuck (83) fixed at the upper end of the vertical shafts (82). The bottom end of the L-shaped base frame (201) is provided with a friction brake assembly (10) for reducing the rotational speed of one of the vertical shafts (82).

5. The porcelain insulator defect detection device based on optical imaging according to claim 2, characterized in that: The gear-type station conversion assembly (6) includes a servo motor (62) mounted on the outer wall of the back frame (2) via a motor mount, a hollow frame (61) fixed at the top edge of the top ring (52), and a secondary gear shaft (64) rotatably mounted inside the hollow frame (61). The top of the turntable (54) is fixed with an external gear ring (65) that meshes with the secondary gear shaft (64). The lower end of the output shaft of the servo motor (62) is fixed with a primary gear (63), which meshes with the secondary gear shaft (64).

6. The optical imaging-based porcelain insulator defect detection device according to claim 4, characterized in that: The avoidance type double roller drive assembly (9) includes an L-shaped front frame (91) fixed to the back of the L-shaped base frame (201), an L-shaped rear frame (92) fixed to the bottom of the L-shaped front frame (91), and a cylinder two (93) installed on the inner wall of one side of the L-shaped rear frame (92). The piston rod end of the cylinder two (93) passes through the L-shaped front frame (91) and is fixed with a contact seat (931). Two elastic tensioning structures (96) are provided on the inner wall of the L-shaped rear frame (92) above the cylinder two (93). A rotating shaft one (94) and a rotating shaft two (95) are rotatably installed on the outer wall of the side of the L-shaped front frame (91) away from the L-shaped rear frame (92). An active roller rotating structure (97) and a driven roller rotating structure (98) are fixed on the rotating shaft one (94) and the rotating shaft two (95), respectively. The upper ends of the active roller rotating structure (97) and the driven roller rotating structure (98) are each connected to an elastic tensioning structure (96).

7. The optical imaging-based porcelain insulator defect detection device according to claim 6, characterized in that: The active roller structure (97) includes a lower connecting arm (971) fixed on a rotating shaft (94), a C-shaped roller frame (972) fixed at the lower end of the lower connecting arm (971), a drive roller (974) vertically rotatably mounted inside the C-shaped roller frame (972), and a motor (973) mounted on one side of the bottom of the C-shaped roller frame (972). The lower end of the output shaft of the motor (973) is equipped with a belt drive structure (975) for driving the drive roller (974) to rotate. A pulley (976) for contacting the contact seat (931) is rotatably mounted on the back of the lower connecting arm (971).

8. The porcelain insulator defect detection device based on optical imaging according to claim 6, characterized in that: The elastic tensioning structure (96) includes an upper connecting arm (963) fixed to the upper end of the rotating shaft (94), a threaded rod with holes (961) installed inside the L-shaped rear frame (92), and a tension spring (962) connecting the upper connecting arm (963) and the threaded rod with holes (961).

9. The optical imaging-based porcelain insulator defect detection device according to claim 4, characterized in that: The friction brake assembly (10) includes a cylinder (1001) fixed to the lower end of an L-shaped base (201), a U-shaped seat (1002) fixed to the upper end of the piston rod of the cylinder (1001), and protrusions (1003) integrally formed on the left and right inner walls of the U-shaped seat (1002). A brake pad (84) is fixed to the lower end of the vertical shaft (82), and the height of the brake pad (84) is lower than that of the protrusion (1003).

10. A method for detecting defects in porcelain insulators based on optical imaging, using the apparatus as described in any one of claims 1-9, characterized in that: Includes the following steps: S101: The processed porcelain insulators are vertically clamped on the multi-station transfer fixture (8) to ensure that the porcelain insulators remain stable and the axis does not wobble during subsequent revolution and rotation. After loading, the parameters for this test are set through the PLC control panel (11), including the exposure time of the hyperspectral camera (4), the scanning band range, the lifting and moving speed and stroke of the servo screw linear module (3), and the interval time of each station conversion of the cage turntable (5) and the gear station conversion assembly (6). S102: The gear-type station conversion assembly (6) drives the central shaft (7) to rotate, so that the first insulator on the multi-station transfer fixture (8) stops at the test station on the side of the hyperspectral camera (4). After the multi-station transfer fixture (8) is in place and stationary, the avoidance double roller drive assembly (9) contacts the multi-station transfer fixture (8) and establishes a driving power connection through friction, so that the porcelain insulator on the test station slowly and uniformly rotates around its own axis. S103: The servo screw linear module (3) carries the hyperspectral camera (4) to perform linear feed motion along the axial direction of the insulator. During the movement, the hyperspectral camera (4) continuously collects hyperspectral image data of the surface of the insulator skirt and transmits the data to the connected industrial control computer in real time for storage and preliminary processing. When the hyperspectral camera (4) completes the scan from one end of the insulator to the other end, the servo screw linear module (3) drives the hyperspectral camera (4) back to the starting position. The avoidance double roller drive assembly (9) stops rotating and disengages from the multi-station transfer fixture (8) to prepare for the next station conversion. The gear station conversion assembly (6) receives the working instructions issued by the PLC control panel (11) and drives the central shaft (7) to rotate by one station angle so that the next insulator to be tested enters the test station. At this time, the avoidance double roller drive assembly (9) has actively retreated and will not interfere with the multi-station transfer fixture (8). S104: After the new tooling is in place, the avoidance double roller drive assembly (9) contacts the multi-station slave tooling (8) again, and the servo screw linear module (3) drives the hyperspectral camera (4) to scan again until all the porcelain insulators clamped on the multi-station slave tooling (8) have been inspected.

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