A test system and method for online detection of steel strip gap
By combining an online detection system with vision and laser rangefinders, the parameters of the armoring machine can be adjusted in real time, solving the problem of missing packages caused by uneven gaps during the steel strip wrapping process, thus improving cable quality and material utilization.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- XIAN XIDIANGUANG CABLE CO LTD
- Filing Date
- 2026-06-04
- Publication Date
- 2026-07-14
AI Technical Summary
Existing technologies are insufficient to effectively detect and control the uniformity of the gap during the wrapping of steel strips, which may lead to incomplete wrapping of the steel strips, affecting cable quality and wasting materials.
Design an online system for detecting steel strip gaps. The system uses a camera and laser rangefinder combined with a data processing module to detect steel strip gaps in real time. It is also connected to the PLC of the armoring machine to automatically adjust the equipment parameters to ensure that the gaps meet the standards.
It enables precise detection and automatic adjustment of steel strip gaps, reduces the risk of missing packages, improves cable quality and material utilization, and reduces manual repair time.
Smart Images
Figure CN122384697A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of steel strip production technology, specifically to a testing system and method for online detection of steel strip gaps. Background Technology
[0002] The armoring process is a crucial step in cable production, its core value lying in ensuring the long-term safe and reliable operation of cables in harsh environments. The armor layer primarily provides effective mechanical protection (resistance to compression, tension, and biting), a certain degree of environmental protection (corrosion resistance and moisture resistance), and excellent electromagnetic shielding performance.
[0003] CN120027718A discloses a method and system for measuring the gap of steel strip wrapping based on curvature statistics, including the following steps: Image acquisition: Under low-angle ring light illumination, the cable passes through the ring light, and an industrial camera is used to acquire images of the steel strip wrapping; Interference removal: Interference in the steel strip wrapping image is removed based on morphological operations and connected component analysis to obtain an image of the steel strip wrapping after interference removal; Steel strip edge positioning: For the steel strip wrapping image after interference removal, the steel strip contour is refined, and the steel strip edge is positioned by statistically analyzing the curvature of the contour points to obtain the steel strip edge line; Steel strip gap measurement: The steel strip gap value is calculated based on the steel strip edge line using a proportional analysis method.
[0004] To achieve uniform coverage of the cable core surface with steel strips, a two-layer steel strip wrapping structure is used during armoring. A certain gap is maintained between each layer of steel strips. To ensure that the gaps between each layer of steel strips meet standard requirements and to avoid incomplete wrapping, thereby improving product quality, this invention proposes a solution using a steel strip gap detector to prevent incomplete steel strip wrapping. Summary of the Invention
[0005] To address the problems in the existing technology, this invention provides a test method for online detection of steel strip gap, which uses the connection between the detection equipment and the industrial control computer to control the size of the steel strip gap.
[0006] This invention is achieved through the following technical solution: A test method for online detection of steel strip gap, comprising: Construct a steel strip gap detection system; Connect the steel strip gap detection system to the armoring machine PLC and modify the IP information of the steel strip gap detection system; The steel strip gap detection system is used to detect the steel strip gap, and the detection results are fed back to the PLC of the armoring machine. The PLC of the armoring machine adjusts the equipment parameters based on the detection results fed back by the steel strip gap detection system until the measured data is consistent with the target parameter range.
[0007] Preferably, the steel strip gap detection system includes a camera and a laser rangefinder. The camera's image sensor and the laser rangefinder's probe both face the steel strip gap. The output of the camera and the laser rangefinder are both connected to the input of the armoring machine's PLC.
[0008] Preferably, the IP address of the steel strip gap detection system is kept consistent with the IP address of the armoring machine PLC.
[0009] Preferably, the steel strip gap detection system is equipped with a data processing module, and the detection images from the camera and the measurement data from the laser rangefinder are both input into the data processing module for processing.
[0010] Preferably, the detection images from the camera and the measurement data from the laser rangefinder are both input into the data processing module for processing, including: The data processing module is used to acquire the steel strip gap data in the detection image; The steel strip gap data is compared with the measured gap data obtained by the laser rangefinder for the corresponding detection image. When the deviation between the two is less than 0.5mm, the steel strip gap data is valid, and the steel strip gap data of the detection image is used as the detection result for output. Otherwise, the measured gap data obtained by the laser rangefinder is used as the detection result for output.
[0011] Preferably, the data processing module uses the Canny operator combined with edge detection to obtain the steel strip gap data in the detection image.
[0012] Preferably, the armoring machine compares the detection results fed back by the steel strip gap detection system with the preset target gap data. If there is a deviation between the measurement data of the steel strip gap detection system and the target gap data... The PLC of the armoring machine automatically adjusts the equipment parameters until the test results are consistent with the target range.
[0013] Preferred, deviation >0.5mm.
[0014] An electronic device includes a memory and a processor, the memory storing a computer program, the processor executing the computer program to implement the steps of the method.
[0015] A storage medium having a computer program stored thereon, the computer program being executed by a processor to perform the steps of the method.
[0016] Compared with the prior art, the present invention has the following beneficial effects: This invention provides an online testing method for detecting steel strip gap. By designing a steel strip gap detection system in conjunction with a PLC for an armoring machine, the method can understand and control the steel strip gap value and the situation of missing strips. This can reduce material waste and manual repair time caused by missing steel strips. Furthermore, the steel strip gap detection system can control the armoring machine to achieve online adjustment of the steel strip gap, thus preventing the continuous occurrence of missing strips.
[0017] Furthermore, the steel strip gap detection system achieves a dual-sensor fusion mechanism of visual measurement and laser measurement by setting up a camera and a laser rangefinder. With the help of a deviation threshold, the data processing module can automatically identify and eliminate abnormal data to ensure the accuracy of the output detection results.
[0018] Furthermore, by adjusting the IP address of the steel strip gap detection system to be consistent with that of the armoring machine PLC, the common communication silos between different brands and different equipment can be broken, and data transmission latency can also be reduced.
[0019] Furthermore, when the deviation When the thickness is greater than 0.5mm, the PLC will automatically adjust the equipment parameters based on the feedback detection results. This not only reduces the labor intensity of operators, but also ensures that the steel tape wrapping quality of the entire optical cable / electrical cable is always in the best condition. Attached Figure Description
[0020] Figure 1 This is a schematic diagram of a test method for online detection of steel strip gap according to the present invention. Detailed Implementation
[0021] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.
[0022] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided to fully and completely disclose the invention and to fully convey its scope to those skilled in the art. The terminology used in the exemplary embodiments illustrated in the drawings is not intended to limit the invention. In the drawings, the same units / elements are referred to by the same reference numerals.
[0023] Unless otherwise stated, the terms used herein (including technical terms) have their common meaning as understood by one of ordinary skill in the art. Furthermore, it is understood that terms defined in commonly used dictionaries should be understood to have a meaning consistent with the context of their relevant field, and not to be interpreted as having an idealized or overly formal meaning.
[0024] The present invention will be further described in detail below with reference to specific embodiments. These descriptions are for explanation purposes only and are not intended to limit the scope of the invention.
[0025] Reference Figure 1 This invention discloses an online testing method for detecting the gap in steel strips, comprising: S1, Construct a steel strip gap detection system.
[0026] The steel strip gap detection system includes a camera and a laser rangefinder. The camera and the laser rangefinder probe are both directed toward the steel strip gap. The output of the camera and the output of the laser rangefinder are both connected to the input of the armoring machine PLC.
[0027] S2. Connect the steel strip gap detection system to the armoring machine PLC and modify the IP information of the steel strip gap detection system.
[0028] After the steel strip gap detection system is connected to the armoring machine PLC, the IP address of the steel strip gap detection system is modified to be consistent with the IP address of the armoring machine PLC.
[0029] S3 uses a steel strip gap detection system to detect the steel strip gap and feeds the detection results back to the armoring machine PLC.
[0030] Specifically, the steel strip gap detection system is equipped with a data processing module. The detection images from the camera and the measurement data from the laser rangefinder are both input into the data processing module for processing. The processing methods include: The data processing module is used to obtain the steel strip gap data in the detection image; for example, the data processing module uses the Canny operator combined with edge detection to obtain the steel strip gap data in the detection image.
[0031] The steel strip gap data is compared with the measured gap data obtained by the laser rangefinder for the corresponding detection image. When the deviation between the two is less than 0.5mm, the steel strip gap data is valid, and the steel strip gap data of the detection image is used as the detection result for output. Otherwise, the measured gap data obtained by the laser rangefinder is used as the detection result for output.
[0032] S4, the armoring machine's PLC adjusts equipment parameters based on the detection results from the steel strip gap detection system until the measured data matches the target parameter range. Specifically, the armoring machine compares the detection results from the steel strip gap detection system with the preset target gap data. If there is a deviation between the measured data from the steel strip gap detection system and the target gap data... If the error is greater than 0.5mm, the PLC of the armoring machine will automatically adjust the equipment parameters, such as the speed of the steel bag head and the wrapping pitch, until the detection result is consistent with the target range.
[0033] In S4, the steel strip gap detection system compares the detection results with the preset target gap data and feeds the comparison results back to the armoring machine PLC to achieve reverse control.
[0034] In one embodiment, a photoelectric trigger camera captures images, visual image processing is used to detect and analyze the gap in the steel strip, and the measurement results are then fed back to the PLC of the armoring machine, thereby achieving reverse control of the equipment. Specifically: Firstly, a photoelectric triggering and imaging subsystem is used to achieve high-precision, low-latency triggering and imaging. Specifically, a through-beam or reflective laser photoelectric sensor is placed above the running path of the steel strip. When the leading edge of the steel strip or a specific mark passes, a trigger signal is generated and connected to an industrial camera that supports hardware triggering. Extremely low trigger delay and fixed exposure time are set to eliminate motion blur. The camera triggers once at the steel strip joint or at fixed intervals (e.g., 1 meter), capturing clear images including the gaps in the steel strip and both sides of the edges.
[0035] Subsequently, the visual image processing subsystem in the data processing module preprocesses the acquired images, including Gaussian filtering for noise reduction and dynamic ROI extraction. Then, it uses the Canny operator or a deep learning-based edge segmentation model to extract the edge contours of the left and right ends of the steel strip, calculates the shortest pixel distance between the end of the left strip and the beginning of the right strip, and uses curve fitting to achieve sub-pixel interpolation, thereby improving the gap measurement accuracy to the 0.01mm level. Simultaneously, the photoelectric trigger camera continuously captures 3-5 images for multi-frame verification to eliminate outliers caused by vibration or flash.
[0036] In the data analysis and decision-making stage, the PLC of the armoring machine compares the detection results output by the data processing system with the preset standard gap to determine the deviation. A PID control strategy is then employed: if the gap is too large, the unloading speed of the armoring machine needs to be reduced or the tension increased; if the gap is too tight, the unloading speed needs to be increased or the tension decreased. The deviation is used as input to calculate the specific adjustment amount (such as the tension motor speed correction value). Finally, closed-loop control is completed through the PLC reverse control and execution subsystem. The gap measurement value and suggested adjustment amount are written into the designated register of the PLC, which then adjusts the servo drive or tension controller of the armoring machine accordingly to execute the adjustment.
[0037] In one embodiment, a data processing module acquires steel strip gap data from the detected image. For example, the data processing module uses the Canny operator combined with edge detection to extract the edge contours of the acquired steel strip gap image and calculates vision-based steel strip gap data through sub-pixel interpolation. Simultaneously, the laser rangefinder simultaneously inputs multi-point measured gap data obtained by pointing its probe towards the steel strip gap into the data processing module. Subsequently, the data processing module compares the visual steel strip gap data corresponding to the same detection image with the measured gap data obtained by the laser rangefinder at that moment, point by point. When the absolute value of the deviation between the two is less than 0.5mm, it is determined that the visual measurement result and the laser measurement result have good consistency. At this time, the steel strip gap data is valid, and the system outputs the steel strip gap data of the detection image as the final detection result to ensure that the two-dimensional panoramic information and high-resolution edge positioning capability provided by visual measurement are fully utilized. Conversely, if the deviation between the two reaches or exceeds 0.5mm, it indicates that the current visual measurement is affected by interference factors such as steel strip surface reflection, oil stains, oxide scale, or changes in lighting, resulting in unreliable image edge extraction. At this time, the system automatically switches to using the measured gap data obtained by the laser rangefinder as the detection result for output, which can ensure the continuity and accuracy of the measurement results.
[0038] This invention also discloses a computer device, including a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the method. The processor may be a Central Processing Unit (CPU), or other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. It is the computing and control core of the terminal, and is suitable for implementing one or more instructions, specifically suitable for loading and executing one or more instructions from a computer storage medium to implement the corresponding method flow or corresponding function. This invention also discloses a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps of the method. The computer-readable storage medium is a memory device in a computer device used to store programs and data. It is understood that the computer-readable storage medium here can include both built-in storage media in the computer device and extended storage media supported by the computer device. The computer-readable storage medium provides storage space containing the operating system of the terminal. Furthermore, this storage space also contains one or more instructions suitable for loading and execution by a processor, which can be one or more computer programs (including program code). It should be noted that the computer-readable storage medium here can be high-speed RAM or non-volatile memory, such as at least one disk storage device. One or more instructions stored in the computer-readable storage medium can be loaded and executed by a processor.
[0039] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.
[0040] This invention is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart illustrations and / or block diagrams. Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.
[0041] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1The function specified in one or more boxes.
[0042] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.
[0043] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the functions specified in one or more boxes. Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.
[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the technical solution of the present invention in any way. Those skilled in the art should understand that, without departing from the spirit and principles of the present invention, the technical solution can be modified and replaced in several simple ways, and these modifications and replacements are all within the scope of protection covered by the claims.
Claims
1. A test method for online detection of steel strip gap, characterized in that, include: Construct a steel strip gap detection system; Connect the steel strip gap detection system to the armoring machine PLC and modify the IP information of the steel strip gap detection system; The steel strip gap detection system is used to detect the steel strip gap, and the detection results are fed back to the PLC of the armoring machine. The PLC of the armoring machine adjusts the equipment parameters based on the detection results fed back by the steel strip gap detection system until the measured data is consistent with the target parameter range.
2. The online testing method for detecting steel strip gap according to claim 1, characterized in that, The steel strip gap detection system includes a camera and a laser rangefinder. The camera and the laser rangefinder probe are both directed toward the steel strip gap. The output of the camera and the output of the laser rangefinder are both connected to the input of the armoring machine PLC.
3. The test method for online detection of steel strip gap according to claim 1, characterized in that, Modify the IP address of the steel strip gap detection system to be consistent with the IP address of the armoring machine PLC.
4. The online testing method for detecting steel strip gap according to claim 1, characterized in that, The steel strip gap detection system is equipped with a data processing module, where the detection images from the camera and the measurement data from the laser rangefinder are both input into the data processing module for processing.
5. The online testing method for detecting steel strip gap according to claim 1, characterized in that, The detected images from the camera and the measurement data from the laser rangefinder are both input into the data processing module for processing, including: The data processing module is used to acquire the steel strip gap data in the detection image; The steel strip gap data is compared with the measured gap data obtained by the laser rangefinder for the corresponding detection image. When the deviation between the two is less than 0.5mm, the steel strip gap data is valid, and the steel strip gap data of the detection image is used as the detection result for output. Otherwise, the measured gap data obtained by the laser rangefinder is used as the detection result for output.
6. The test method for online detection of steel strip gap according to claim 5, characterized in that, The data processing module uses the Canny operator combined with edge detection to obtain the gap data of the steel strip in the detected image.
7. The online testing method for detecting steel strip gap according to claim 5, characterized in that, The armoring machine compares the detection results from the steel strip gap detection system with the preset target gap data. If there is a deviation between the measurement data of the steel strip gap detection system and the target gap data... The PLC of the armoring machine automatically adjusts the equipment parameters until the test results are consistent with the target range.
8. The online testing method for detecting steel strip gap according to claim 7, characterized in that, deviation >0.5mm.
9. An electronic device comprising a memory and a processor, wherein the memory stores a computer program, characterized in that, When the processor executes the computer program, it implements the steps of the method according to any one of claims 1 to 8.
10. A storage medium having a computer program stored thereon, characterized in that, When the computer program is executed by a processor, it implements the steps of the method according to any one of claims 1 to 8.