A plug-in device quality detection method and system applied to an electric energy metering box

Abstract

The application relates to a plug-in device quality detection method and system applied to an electric energy metering box, and relates to the technical field of flame retardation detection.The method comprises the following steps: in response to a detection signal, controlling an ignition device to ignite according to a preset ignition mode; after the ignition device completes ignition, acquiring a real-time combustion image; analyzing the real-time combustion image to accumulate a combustion time; when the combustion time is greater than a preset combustion time threshold, generating a detection unqualified signal according to the combustion time, and outputting the detection unqualified signal; when the combustion time is less than the combustion time threshold, acquiring a dripping image; analyzing the dripping image to obtain a carrier feature, wherein the carrier feature comprises a charred edge feature and a normal feature; when the carrier feature contains the charred edge feature, outputting a preset afterflame signal; and when the carrier feature only contains the normal feature, outputting a preset no-afterflame signal.The application has the effect of improving the efficiency and accuracy of flame retardation performance detection of the plug-in device.

Description

Technical Field

[0001] This invention relates to the field of flame retardant testing technology, and in particular to a method and system for testing the quality of plug-in devices used in electricity metering boxes. Background Technology

[0002] Plug-in devices are pluggable connection components used to connect circuits or signal lines. During operation, plug-in devices carry current or transmit signals. Under abnormal conditions such as poor contact, overload, or short circuit, their internal conductive components may generate high temperatures or even ignite. Therefore, testing the flame-retardant properties of plug-in devices is an important part of ensuring electrical safety.

[0003] In related technologies, the flame retardant performance testing of plug-in devices mainly involves operators reviewing videos and manually judging whether the burning time exceeds the standard and whether the load-bearing material shows charred edges, thereby assessing whether the flame retardant performance of the plug-in device is qualified and completing the quality inspection.

[0004] Regarding the aforementioned technologies, manual judgment of test results relies on the experience of the testers. Furthermore, manual testing requires following the entire testing process and verifying the results one by one, resulting in low testing efficiency. After prolonged operation, the accuracy of the testers' judgment will further decline, affecting the accuracy and reliability of the final quality test results. Summary of the Invention

[0005] To improve the efficiency and accuracy of testing the flame retardant performance of connectors, this invention provides a method and system for testing the quality of connectors used in power metering boxes.

[0006] In a first aspect, the present invention provides a method for quality testing of a plug-in device applied to an electricity metering box, employing the following technical solution: A method for quality testing of a plug-in device used in an electricity metering box, comprising: Step 1: In response to the detection signal, control the ignition device to ignite according to the preset ignition mode; Step 2: After the ignition device completes ignition, acquire a real-time combustion image; Step 3: Analyze the real-time combustion images to accumulate combustion time; Step 30: When the combustion time exceeds the preset combustion time threshold, generate a detection failure signal based on the combustion time and output the detection failure signal; Step 31: When the burning time is less than the burning time threshold, acquire the dripping image; Step 32: Analyze the droplet image to obtain the carrier features, which include focal edge features and normal features; Step 320: When the carrier features have focal edge features, output a preset reignition signal; Step 321: When only normal features exist in the characteristics of the carrier, output the preset non-reignition signal.

[0007] By adopting the above technical solution, ignition can be automatically controlled and combustion images can be analyzed in real time, reducing human error. When the combustion time is qualified, the charred edge characteristics of the dripping material can be used to determine whether reignition has occurred, thereby comprehensively assessing the continued danger of the material after the flame is extinguished, and significantly improving the accuracy and automation of flame retardant performance testing.

[0008] Optionally, optimization methods for controlling the ignition device to perform ignition include: Step 10: After the ignition device is activated, acquire the ignition image; Step 11: Analyze the ignition image to obtain the current clamping angle and flame angle; Step 12: Calculate the flame deviation angle based on the current clamping angle and flame angle; Step 13: When the flame deviation angle is greater than the preset deviation threshold, the flame deviation angle is split into a lateral adjustment angle and a radial adjustment angle; Step 14: Control the clamping device to adjust according to the lateral adjustment angle and the radial adjustment angle.

[0009] By adopting the above technical solution, ignition images can be acquired in real time and the deviation between the clamping angle of the plug-in device and the actual angle of the flame can be analyzed. The flame deviation angle can be automatically calculated and decomposed into lateral and radial adjustment amounts, thereby adjusting the clamping device so that the flame always accurately acts on the preset detection position, avoiding test result distortion caused by inaccurate initial positioning or flame deviation, thereby improving the consistency and repeatability of the detection.

[0010] Optionally, the method for adjusting the clamping device according to the lateral adjustment angle and the radial adjustment angle includes: Step 140: Obtain the adjustable angle range; Step 141: Obtain the adjusted clamping angle based on the current clamping angle, lateral adjustment angle, and radial adjustment angle; Step 142: When the adjusted clamping angle falls within the adjustable angle range, control the clamping device to adjust according to the lateral adjustment angle and the radial adjustment angle; Step 143: When the adjusted clamping angle does not fall within the adjustable angle range, traverse the adjustable angle range to obtain the predicted adjustment angle; Step 144: Calculate the angle difference based on the predicted adjustment angle and the flame angle; Step 145: Sort the angle differences in ascending order to obtain the minimum angle difference; Step 146: Control the clamping device to adjust according to the predicted adjustment angle corresponding to the minimum angle difference.

[0011] By adopting the above technical solution, when adjusting the clamping angle, it is first checked whether it is within the adjustable range. If it is outside the range, all feasible angles are automatically traversed, and the predicted adjustment angle that minimizes the difference between the flame angle and the target angle is selected for adjustment, thus ensuring the feasibility of detection under physical constraints.

[0012] Optionally, an optimization method is also included when the adjusted clamping angle does not fall within the adjustable angle range, the method comprising: Step 1460: After the control clamping device is adjusted according to the predicted adjustment angle corresponding to the minimum angle difference, the required offset angle of the flame is calculated based on the predicted adjustment angle and the flame angle. Step 1461: Search for the corresponding blowing angle and blowing intensity from the preset blowing database according to the required offset angle of the flame; Step 1462: Control the blowing device to blow air according to the blowing angle and blowing intensity.

[0013] By adopting the above technical solution, when the mechanical adjustment range of the clamping device cannot fully compensate for the flame deviation, the system will match the optimal blowing angle and intensity from the preset blowing database based on the difference between the predicted adjustment angle and the flame angle. The system will actively intervene in the flame direction through airflow, complementing the clamping adjustment, further expanding the flame attitude correction capability, and ensuring that standardized combustion test conditions can still be obtained even under deviation conditions.

[0014] Optionally, it also includes a control method prior to acquiring the droplet image, the method comprising: Step 310: Obtain the bearing pressure value; Step 311: When the bearing pressure value is greater than the preset pressure threshold, output the preset pressure change signal and obtain the size of the bearing, the dripping position and the dripping range; Step 312: Update the preset dripping range according to the dripping position and dripping range. The dripping range refers to the area occupied by all the dripping objects on the carrier. The initial value of the dripping range is 0. Step 313: Divide the size of the carrier according to the already dripped area to obtain the planned dripping position; Step 314: Generate a single movement path for the carrier based on the size of the carrier and the planned drip location; Step 315: In response to the pressure change signal, control the carrier to move according to the single movement path of the carrier.

[0015] By adopting the above technical solution, the system monitors pressure changes on the support in real time. When accumulated dripping material is detected, it automatically and dynamically plans unused dripping areas based on the existing dripping range, support size, and dripping location, and generates a single movement path. This mechanism ensures that each dripping material lands on a fresh support surface, avoiding overlapping or accumulation of dripping material that could affect the characteristic judgment of subsequent dripping material, thereby improving the reliability of reignition detection.

[0016] Optionally, a control method is also included when there is no planned drip location, the method comprising: Step 3130: When there is no planned dripping position, obtain the dripping gap; Step 3131: Sort the drip gaps in descending order to obtain drip gap groups; Step 3132: Select the largest drip gap from the drip gap group as the planned drip position, and remove the selected largest drip gap from the drip gap group.

[0017] By adopting the above technical solution, when all planable areas on the surface of the carrier are covered by dripping material and no new position can be found, the system automatically obtains the size of the gap between each dripping material and sorts them from largest to smallest, prioritizing the largest gap as the next dripping position. This strategy maximizes the use of the limited carrier area.

[0018] Optionally, it also includes a control method for verifying whether the dripping location is within the planned dripping location, the method comprising: Step 3150: After controlling the carrier to move according to the carrier's single movement path, obtain the actual dripping position; Step 3151: Calculate the drop position deviation based on the actual drop position and the planned drop position; Step 3152: Update the preset correction movement position according to the drop position deviation, wherein the initial value of the correction movement position is 0; Step 3153: Update the single movement path based on the corrected movement position.

[0019] By adopting the above technical solution, after the carrier moves along the planned path, the actual drop position is obtained and the deviation from the planned position is calculated. Based on this, the moving position is dynamically updated and corrected, and the subsequent moving path is modified. This can effectively compensate for mechanical transmission errors or cumulative positioning errors, ensuring that each drop can accurately land at the expected position, thereby maintaining the accuracy and stability of the detection over a long period of time.

[0020] Optionally, an optimized method for acquiring the droplet image is also included, the method comprising: Step 3100: In response to the pressure change signal, obtain the time of the first drop; Step 3101: After the ignition device completes ignition, obtain the ignition completion time; Step 3102: When the burning time is less than the burning time threshold, acquire an image of the carrier; Step 3103: Analyze the image of the substrate based on the ignition completion time and the first drip time to obtain the incomplete combustion drips; Step 3104: Define incomplete combustion drips as invalid drips, and remove invalid drips from the carrier image to obtain the drip image.

[0021] By adopting the above technical solution, and combining the ignition completion time and the first drip time, invalid drips that may have dripped due to incomplete combustion in the early stage of combustion can be identified from the image of the carrier and removed from the drip image. This reduces the misjudgment of incomplete combustion products, analyzes only the characteristics of valid drips, and improves the reliability of the reignition detection results.

[0022] Optionally, methods for obtaining the bearing pressure value include: Step 31000: Obtain the current load-bearing pressure value; Step 31001: If the current bearing pressure value falls within the preset normal pressure value range, then the current bearing pressure value is defined as the bearing pressure value; Step 31002: If the current bearing pressure value does not fall within the normal pressure value range, output a pressure value abnormality signal.

[0023] By adopting the above technical solution, when the bearing pressure value is obtained, it is first determined whether it falls within the normal pressure value range. If it exceeds the range, an abnormal pressure value signal is actively output to indicate that the sensor may be faulty or the bearing is installed abnormally, thereby ensuring that the starting conditions of the drip detection logic are accurate and reliable.

[0024] Secondly, the present invention provides a quality detection system for a plug-in device applied to an electricity metering box, employing the following technical solution: A quality inspection system for plug-in devices used in electricity metering boxes, comprising: The acquisition module is used to acquire real-time combustion images, dripping images, ignition images, adjustable angle range, bearing pressure value, dripping gap, and actual dripping position; A memory for storing a program for a method of detecting the quality of a plug-in device applied to an electricity metering box, as described above; The processor loads and executes programs from memory.

[0025] By adopting the above technical solution, the entire process from ignition, image analysis, clamping and flame calibration, droplet load control to result judgment and self-correction can be automatically executed, realizing a high degree of automation, intelligence and standardization in the flame retardant performance testing of plug-in devices, and effectively improving testing efficiency, accuracy and repeatability.

[0026] In summary, the present invention has at least one of the following beneficial technical effects: 1. By automatically controlling ignition in response to detection signals, analyzing combustion images in real time, and accumulating combustion time, it is possible to objectively determine whether the plug-in device is unqualified within the combustion time threshold, or further judge the risk of reignition by the charred edge characteristics of the dripping material, thus improving detection efficiency; 2. By analyzing the flame deviation angle through real-time acquisition of ignition images, combined with the adjustment of the clamping device and the auxiliary correction of the blowing device, the flame is always accurately applied to the detection area, avoiding the impact of positioning deviation on the detection results and improving the consistency of the detection. 3. By automatically planning the drip position through real-time monitoring of the bearing pressure, it can ensure that the drips are fully distributed in the effective detection area of ​​the bearing, avoid the overlap and accumulation of drips affecting the feature judgment, and improve the reliability of the reignition detection results. Attached Figure Description

[0027] Figure 1 This is a flowchart of a method for quality testing of a plug-in device applied to an electricity metering box, as described in an embodiment of this application. Figure 2 This is a flowchart of the control method prior to obtaining the dripping image in the embodiments of this application; Figure 3 This is a schematic diagram of the plug-in device in the open state in an embodiment of this application; Figure 4 This is a schematic diagram of the closed state of the plug-in device in an embodiment of this application. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0029] This invention discloses a method for quality testing of a plug-in device applied to an electricity metering box. (Refer to...) Figure 1 A method for quality testing of plug-in devices used in electricity metering boxes includes: Step 1: In response to the detection signal, control the ignition device to ignite according to the preset ignition mode.

[0030] The detection signal is the instruction to begin flame retardant testing of the connector. The detection signal is generated when the operator presses the detection button on the control terminal.

[0031] An ignition device is used to ignite a connector for flame retardant testing. An ignition mode refers to the method by which the ignition device ignites the connector. The ignition mode is pre-set by personnel according to testing standards, including fixed parameters such as ignition time, ignition location, and flame size.

[0032] like Figure 3 and Figure 4 As shown, the plug-in device is a plug-in structure inside the power metering box used to realize the electrical connection between the power metering module and the busbar inside the box. Its shell is mostly made of insulating flame-retardant plastic. The testing of the flame-retardant performance of the plug-in device is directly related to the fire safety level of the entire metering box.

[0033] Step 2: After the ignition device completes ignition, acquire a real-time combustion image.

[0034] Real-time combustion images refer to a series of continuous images captured by an image acquisition device during the ignition process of the connector, reflecting the changes in the combustion state of the connector from the moment it is ignited until the flame is extinguished or combustion stops. Real-time combustion images are obtained by continuously acquiring image data during the combustion process using a high-speed camera or industrial camera at a certain sampling frame rate (e.g., 30 frames per second).

[0035] Step 3: Analyze the real-time combustion images to accumulate combustion time.

[0036] Burning time refers to the total duration from the moment the plug-in device is successfully ignited by the ignition device until the flame completely extinguishes itself. Burning time is calculated by inputting real-time burning images frame by frame into an image recognition algorithm. The algorithm identifies whether a flame exists on the surface of the plug-in device in each frame, performs binarization on each frame, and identifies pixels that meet the flame detection threshold as flame pixels. The time corresponding to the first image frame in which a flame is detected is recorded as the start time, and the time corresponding to the last image frame in which a flame is detected is recorded as the end time. The time difference between the end time and the start time is calculated to obtain the cumulative burning time.

[0037] Step 30: When the combustion time exceeds the preset combustion time threshold, generate a failure signal based on the combustion time and output the failure signal.

[0038] The burning time threshold refers to an upper limit of the allowable burning duration set according to the flame retardant testing standard corresponding to the plug-in device, such as 30 seconds.

[0039] The unqualified detection signal refers to a signal for indicating that the current plug-in device fails the flame retardancy performance test. When the combustion time is greater than the combustion time threshold, the combustion time is associated with an unqualified identifier to generate an unqualified detection signal, and the signal is output to the staff through a display screen and an alarm lamp.

[0040] Step 31: When the combustion time is less than the combustion time threshold, a dripping image is acquired.

[0041] The dripping image refers to an image formed after molten matter generated by the plug-in device due to thermal melting or combustion during the combustion process of the plug-in device drips onto the lower carrier. The dripping image is obtained by photographing the surface of the carrier with an industrial camera, wherein the carrier is generally selected as silk paper.

[0042] Step 32: The dripping image is analyzed to obtain carrier characteristics, and the carrier characteristics include burnt edge characteristics and normal characteristics.

[0043] The carrier characteristics refer to the visual morphology change attribute generated on the surface of the carrier in the dripping image due to the influence of the dripping matter. The burnt edge characteristics refer to visual characteristics generated by excessive heating, such as yellowing, blackening, coking or carbonization, presented in the contact area between the edge of the carrier and the dripping matter. The normal characteristics refer to a state where no burnt edge, carbonization or abnormal discoloration appears on the surface of the carrier, and only slight thermal influence may exist or no visible change occurs. The carrier characteristics are obtained by processing the dripping image through a semantic segmentation model to segment the dripping matter acting area and the carrier area, then performing statistical analysis on the pixel grayscale and color channel values of the carrier area, and identifying and extracting the existence of the burnt edge characteristics and the normal characteristics.

[0044] Step 320: When burnt edge characteristics exist in the carrier characteristics, a preset re-ignition signal is output.

[0045] The re-ignition signal refers to a signal indicating that the dripping matter generated after the plug-in device is burned has a re-ignition phenomenon. When the burnt edge characteristics exist in the carrier characteristics, it indicates that the dripping matter can ignite the silk paper below, causing the silk paper to undergo a coking combustion reaction, which meets the judgment condition for re-ignition in the detection standard, so the re-ignition signal is directly output, and it is finally determined that the current plug-in device fails the flame retardancy performance test.

[0046] Step 321: When only normal characteristics exist in the carrier characteristics, a preset non-re-ignition signal is output.

[0047] The non-re-ignition signal refers to a signal indicating that the dripping matter does not ignite the silk paper as the carrier and no re-ignition phenomenon occurs. When only the normal characteristics exist in the carrier characteristics, it indicates that the dripping matter of the current plug-in device does not ignite the silk paper, and no re-ignition of the dripping matter occurs. It is finally determined that the current plug-in device passes the flame retardancy performance test, so the non-re-ignition signal is output.

[0048] Among them, the optimized methods for controlling the ignition device to ignite include: Step 10: After controlling the ignition device to ignite, acquire the ignition image.

[0049] An ignition image is an image showing the relative positions of the connector, clamping device, and flame generated by the ignition device when the ignition device is activated and ignites the connector. Ignition images are obtained by continuously acquiring image data during the ignition process using an industrial camera at a specific sampling frequency.

[0050] Step 11: Analyze the ignition image to obtain the current clamping angle and flame angle.

[0051] The current clamping angle refers to the actual angle in space when the plug-in device is fixed by the clamping device, that is, the deflection angle of the plug-in device relative to the reference baseline (such as a horizontal or vertical line).

[0052] The flame angle refers to the angle of deflection of the central axis of the flame emitted by the ignition device relative to the same reference baseline.

[0053] The current clamping angle and flame angle are obtained by inputting the ignition image into the image recognition algorithm, performing edge detection and centerline extraction on the clamping device area and flame area in the image respectively, and calculating the angle between the extracted clamping device clamping axis and the reference baseline, as well as the angle between the flame center axis and the reference baseline.

[0054] Step 12: Calculate the flame deviation angle based on the current clamping angle and flame angle.

[0055] The flame deviation angle refers to the actual deflection difference between the flame's central axis and the clamping posture of the connector. The flame deviation angle can be used to quantify whether the flame of the ignition device is perfectly aligned with the connector. The flame deviation angle is obtained by subtracting the current clamping angle from the flame angle and taking the absolute value of the difference.

[0056] Step 13: When the flame deviation angle is greater than the preset deviation threshold, the flame deviation angle is split into the lateral adjustment angle and the radial adjustment angle.

[0057] The deviation threshold is a threshold used to determine whether the flame of the ignition device adequately covers the connector. The deviation threshold is set according to flame retardant testing standards.

[0058] The lateral adjustment angle refers to the angular component required to rotate and adjust the clamping device in the horizontal plane, used to correct the deviation of the flame in the horizontal direction.

[0059] Radial adjustment angle refers to the angular component required to adjust the pitch or tilt of the clamping device in the vertical plane, used to correct the deviation of the flame in the vertical direction.

[0060] When the flame deviation angle is greater than the deviation threshold, the system uses the flame deviation angle as a vector value and orthogonally decomposes it in the horizontal and vertical directions. The horizontal component obtained by the decomposition is the lateral adjustment angle, and the vertical component is the radial adjustment angle.

[0061] Step 14: Control the clamping device to adjust according to the lateral adjustment angle and the radial adjustment angle.

[0062] A clamping device is a device used to clamp and fix a connector. The clamping device is controlled by adjusting the lateral and radial adjustment angles to adjust the clamping posture of the connector, reducing the angle between the flame's central axis and the connector's central axis to within a threshold deviation. This ensures the flame accurately and closely ignites the connector, reducing uneven combustion caused by flame position deviation, thereby improving the accuracy of the test results and reducing detection errors caused by ignition deviation.

[0063] The methods for adjusting the clamping device based on the lateral and radial adjustment angles include: Step 140: Obtain the adjustable angle range.

[0064] The adjustable angle range refers to the maximum rotational angle range that the clamping device can achieve in the horizontal and vertical directions; that is, the closed interval between the lower and upper limits of the angle that the clamping device is allowed to adjust in the lateral and radial directions, respectively. The adjustable angle range is obtained by reading the hardware specification parameters in the clamping device.

[0065] Step 141: Obtain the adjusted clamping angle based on the current clamping angle, lateral adjustment angle, and radial adjustment angle.

[0066] The adjusted clamping angle refers to the new attitude angle value that the clamping device is expected to achieve after superimposing the lateral adjustment angle and the radial adjustment angle onto the current clamping angle. The adjusted clamping angle is obtained by adding the horizontal component of the current clamping angle to the lateral adjustment angle, and adding the vertical component of the current clamping angle to the radial adjustment angle.

[0067] Step 142: When the adjusted clamping angle falls within the adjustable angle range, control the clamping device to adjust according to the lateral adjustment angle and the radial adjustment angle.

[0068] When the adjusted clamping angle falls within the adjustable angle range, it indicates that the clamping device has sufficient adjustment space to complete the posture adjustment. Therefore, the drive motor of the clamping device is directly controlled to complete the rotation adjustment according to the calculated adjustment amount, so that the posture of the insertion device reaches the expected angle.

[0069] Step 143: When the adjusted clamping angle does not fall within the adjustable angle range, traverse the adjustable angle range to obtain the predicted adjustment angle.

[0070] Predictive adjustment angle refers to enumerating all possible angle values ​​within the adjustable angle range and selecting the angle value that allows the clamping device to actually achieve its desired angle. The predictive adjustment angle is obtained by starting with the minimum angle value within the adjustable angle range and gradually increasing it to the maximum angle value, generating all possible combinations of lateral and radial angle candidate values.

[0071] Step 144: Calculate the angle difference based on the predicted adjustment angle and the flame angle.

[0072] The angle difference refers to the absolute value of the deviation between the clamping device and the flame angle after the predicted adjustment angle is adjusted. The angle difference is obtained by subtracting the flame angle from each predicted adjustment angle and taking the absolute value of the difference.

[0073] Step 145: Sort the angle differences in ascending order to obtain the minimum angle difference.

[0074] The minimum angle difference refers to the smallest angle difference among all predicted adjustment angles calculated by comparing the predicted adjustment angle with the flame angle. The minimum angle difference is determined by sorting all angle differences in ascending order and selecting the angle difference that is first in the sorted list.

[0075] Step 146: Control the clamping device to adjust according to the predicted adjustment angle corresponding to the minimum angle difference.

[0076] The control clamping device adjusts according to the predicted adjustment angle corresponding to the minimum angle difference, so that when the clamping device adjusts the insertion device within the adjustable angle range, the angle difference between the insertion device and the flame is minimized. This makes the flame fit the insertion device more closely after it is ignited, resulting in more uniform heating of the insertion device and reducing errors caused by uneven heating.

[0077] This also includes an optimization method when the adjusted clamping angle does not fall within the adjustable angle range, the method comprising: Step 1460: After the control clamping device is adjusted according to the predicted adjustment angle corresponding to the minimum angle difference, the required offset angle of the flame is calculated based on the predicted adjustment angle and the flame angle.

[0078] The required offset angle of the flame refers to the remaining deviation angle of the flame's central axis relative to the preset ignition area of ​​the sample after the clamping device has been adjusted according to the predicted adjustment angle corresponding to the minimum angle difference. The required offset angle of the flame is obtained by the difference between the predicted adjustment angle corresponding to the minimum angle difference and the flame angle.

[0079] Step 1461: Search for the corresponding blowing angle and blowing intensity from the preset blowing database according to the required offset angle of the flame.

[0080] A blower database refers to a set of data that records the correspondence between the required offset angle of a flame and the control parameters of a blower device. The blower database is obtained by operators through actual experiments calibrating the blower device by controlling various flame offset angles.

[0081] The blowing angle refers to the direction of airflow from the blowing device relative to the central axis of the flame, used to guide the flame to deflect towards the target direction. The blowing intensity refers to the wind speed or pressure output by the blowing device, used to control the amount of flame deflection. Both the blowing angle and blowing intensity are obtained by matching the desired flame deflection angle in a blowing database.

[0082] Step 1462: Control the blowing device to blow air according to the blowing angle and blowing intensity.

[0083] The blower is controlled to blow air at different angles and intensities. This air guides the flame to deflect at an angle toward the fitting connector, ensuring that the flame's central axis is aligned with the connector's central axis as closely as possible. This compensates for deviations caused by insufficient adjustment range of the clamping device and further guarantees uniform heating of the connector.

[0084] This also includes a control method prior to acquiring the droplet image, which includes: Step 310: Obtain the bearing pressure value.

[0085] The bearing pressure value refers to the pressure data detected in real time on the load-bearing object. It is obtained by converting the signal collected by a pressure sensor installed directly below the load-bearing object into a corresponding pressure value.

[0086] Step 311: When the bearing pressure value is greater than the preset pressure threshold, output the preset pressure change signal and obtain the size of the bearing, the dripping position and the dripping range.

[0087] The pressure threshold is a critical pressure value set for a carrier in a static state when no dripping material is received. The pressure threshold is set by staff based on the static pressure value of the carrier plus an allowable fluctuation margin.

[0088] When the bearing pressure value is greater than the preset pressure threshold, it indicates that there are drips generated by the combustion of the plug-in device that have dripped onto the surface of the bearing.

[0089] A pressure change signal is a signal used to indicate that a droplet has been detected falling onto a carrier. This signal is preset by the operator. When the carrier pressure exceeds a preset pressure threshold, the system outputs a pressure change signal to the control system, triggering subsequent control operations to move the carrier according to its single-step movement path.

[0090] The size of the load-bearing object refers to its geometric dimensions on a horizontal plane, including length and width. The size of the load-bearing object is measured in advance by staff.

[0091] The drop position refers to the coordinates of the point on the surface of the substrate where the droplet lands. The drop range refers to the diameter or boundary of the area where the droplet contacts the substrate surface. Both the drop position and drop range are obtained by capturing images of the substrate surface using image acquisition equipment and analyzing and identifying these images.

[0092] Step 312: Update the preset dripping range according to the dripping location and dripping range. The dripping range refers to the area occupied by all dripping objects on the carrier. The initial value of the dripping range is 0.

[0093] The dripped area refers to the total area occupied by all drips that have fallen onto the surface of the substrate from the start of the combustion test to the current moment. The dripped area is updated by comparing and merging the newly obtained drip positions and areas with the previously recorded dripped areas, removing overlapping areas, and then storing the updated total dripped area in the system.

[0094] Step 313: Divide the size of the carrier according to the already dripped area to obtain the planned dripping position.

[0095] The planned drip position refers to the target landing point on the surface of the support, based on the area occupied by the currently dripped area, to avoid the existing dripping area for the next drip. The planned drip position is obtained by dividing the complete support area corresponding to the size of the support into multiple grid cells or continuous coordinate points, marking the updated dripped area as an unusable area, and then selecting the first usable point from the remaining usable area in a spiral order outward from the selected distance of the dripped area as the planned drip position. Furthermore, each planned drip position, that is, each actual dripping point, has a pre-defined gap between it, rather than having the drips dripping adjacent to each other.

[0096] Step 314: Generate a single movement path for the carrier based on the size of the carrier and the planned drop position.

[0097] The single movement path of a carrier refers to the displacement trajectory required for the carrier to move from its current position to the target position where the planned dripping location is directly opposite the droplet's landing point. The single movement path is generated by acquiring the carrier's current real-time position coordinates and the planned dripping location coordinates, calculating the relative displacement vector between them (including lateral and longitudinal movement distances), and then converting this displacement vector into the carrier's movement direction.

[0098] Step 315: In response to the pressure change signal, control the carrier to move according to the single movement path of the carrier.

[0099] In response to pressure change signals, the carrier is controlled to move according to its single movement path. After each droplet lands on the carrier, the carrier is automatically moved so that the next droplet can land on an unoccupied clean area of ​​the carrier, reducing interference between different droplets landing in the same area.

[0100] This also includes a control method when there is no planned drip location, which includes: Step 3130: When there is no planned drip position, obtain the drip gap.

[0101] The drip gap refers to the unoccupied interval or space between the individual dripping areas on the surface of a substrate. The drip gap is obtained by performing edge detection and connected component analysis on the dripping area to extract the boundary intervals between the individual dripping areas, and then calculating geometric parameters such as the width, area, or minimum bounding rectangle size of each interval.

[0102] Step 3131: Sort the drip gaps in descending order to obtain drip gap groups.

[0103] A drip gap group is a sequence formed by sorting all drip gaps according to their size. A drip gap group is obtained by extracting the size value of each drip gap, applying a sorting algorithm to arrange these gaps in descending order from largest to smallest, and then storing the sorted gaps sequentially into a list.

[0104] Step 3132: Select the largest drip gap from the drip gap group as the planned drip position, and remove the selected largest drip gap from the drip gap group.

[0105] The maximum drip gap refers to the largest gap area among all drip gaps. The maximum drip gap represents the largest available space on the surface of the load that is not currently occupied by dripping material. Removing the maximum drip gap from the drip gap group means removing the gap from the sorting list to avoid selecting the same location repeatedly in the next planning.

[0106] This also includes a control method for verifying whether the dripping location is within the planned dripping location, the method comprising: Step 3150: After controlling the carrier to move according to the carrier's single movement path, obtain the actual dripping position.

[0107] The actual drop position refers to the true coordinates of the point where the next drop actually lands on the surface of the carrier after the carrier has moved along its single path. The actual drop position is determined by capturing an image of the carrier's surface after the carrier has moved, waiting for the next drop to be generated and fall on the surface, analyzing and identifying the contact area between the drop and the carrier in the image, and extracting the center point of the contact area as the actual drop position.

[0108] Step 3151: Calculate the drop position deviation based on the actual drop position and the planned drop position.

[0109] The drip position deviation refers to the positional error between the actual drip position and the planned drip position. The drip position deviation is obtained by subtracting the planned drip position coordinates from the actual drip position coordinates, calculating the difference in the lateral and longitudinal coordinates respectively, and further calculating the Euclidean distance as needed to obtain a comprehensive deviation.

[0110] Step 3152: Update the preset correction movement position according to the drop position deviation. The initial value of the correction movement position is 0.

[0111] The correction shift position refers to the amount of correction used to compensate for the deviation in the drop position. The correction shift position is updated by accumulating the drop position deviation with the currently stored correction shift position. That is, the original correction shift position is added to the current drop position deviation, and the accumulated result is stored in the system as the updated correction shift position. Initially, the correction shift position is 0.

[0112] Step 3153: Update the single movement path based on the corrected movement position.

[0113] The single-movement path is updated based on the corrected movement position, so that the next single-movement path can ensure that the droplet falls accurately at the planned drop position.

[0114] This also includes an optimized method for acquiring droplet images, which includes: Step 3100: In response to the pressure change signal, obtain the first drip time.

[0115] The first drip time refers to the moment when the pressure sensor first detects that the load pressure value is greater than the pressure threshold. The first drip time is obtained by reading the current value of the system clock while outputting the pressure change signal, recording and storing this moment as the first drip time.

[0116] Step 3101: After the ignition device completes ignition, obtain the ignition completion time.

[0117] Ignition completion time refers to the moment when the ignition device completes the ignition operation on the connector according to the ignition mode. The ignition completion time is obtained by reading the current time value of the system clock after the ignition operation is completed, recording and storing this time as the ignition completion time.

[0118] Step 3102: When the burning time is less than the burning time threshold, acquire an image of the carrier.

[0119] A carrier image refers to an overall view of the carrier's surface condition captured by an image acquisition device during or after a combustion test. The carrier image is obtained through image acquisition equipment.

[0120] Step 3103: Analyze the image of the carrier based on the ignition completion time and the first drip time to obtain the incomplete combustion drips.

[0121] Incomplete combustion drips refer to drips produced during the combustion of the insertion device sample when the angle of the flame and the angle of the insertion device are not aligned. At this time, the insertion device has not yet fully combusted before dripping molten material. These drips usually contain unburned organic components, which can interfere with the judgment of scorch edge characteristics. If the first drip occurs before the ignition completion time, then all drips that fall onto the support before the ignition completion time are considered incomplete combustion drips.

[0122] Step 3104: Define incomplete combustion drips as invalid drips, and remove invalid drips from the carrier image to obtain the drip image.

[0123] Invalid drips refer to drips that are not applicable to subsequent focal edge and normal feature analysis, i.e., incomplete combustion drips identified in step 3103.

[0124] A drip image refers to image data containing only valid drips remaining after invalid drips are removed from the carrier image. The specific method for obtaining a drip image is as follows: the image area containing the incompletely burned drips marked in step 3103 is removed from the carrier image, while retaining the original pixel information of other areas in the carrier image. The processed image is the drip image.

[0125] The methods for obtaining the bearing pressure value include: Step 31000: Obtain the current load pressure value.

[0126] The current load-bearing pressure value refers to the raw, unprocessed pressure data collected in real time by the pressure sensor at the current sampling moment. The current load-bearing pressure value is obtained by converting the output signal of the pressure sensor installed directly below the load into a corresponding pressure value.

[0127] Step 31001: If the current bearing pressure value falls within the preset normal pressure value range, then the current bearing pressure value is defined as the bearing pressure value.

[0128] The normal pressure range refers to the pressure fluctuation range under normal conditions when the dripping material falls onto the carrier. This range is determined through multiple tests conducted by staff to measure the pressure during the dripping process.

[0129] Step 31002: If the current bearing pressure value does not fall within the normal pressure value range, output a pressure value abnormality signal.

[0130] A pressure abnormality signal is an alarm command used to indicate that the pressure data collected by the pressure sensor exceeds the normal fluctuation range. If the current load pressure value does not fall within the normal pressure range, the system generates a pressure abnormality signal and outputs it to the staff through the display screen and audible and visual alarm to prompt inspection or maintenance.

[0131] Based on the same inventive concept, embodiments of the present invention provide a quality detection system for plug-in devices applied to electricity metering boxes.

[0132] A quality inspection system for plug-in devices used in electricity metering boxes, comprising: The acquisition module is used to acquire real-time combustion images, dripping images, ignition images, adjustable angle range, bearing pressure value, dripping gap, and actual dripping position; A memory for storing a program for a method of detecting the quality of a plug-in device applied to an electricity metering box; The processor loads and executes programs from memory.

[0133] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional modules is used as an example. In practical applications, the above functions can be assigned to different functional modules as needed, that is, the internal structure of the device can be divided into different functional modules to complete all or part of the functions described above. The specific working process of the system, device, and unit described above can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0134] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A method for quality inspection of a plug-in device applied to an electricity metering box, characterized in that, include: Step 1: In response to the detection signal, control the ignition device to ignite according to the preset ignition mode; Step 2: After the ignition device completes ignition, acquire a real-time combustion image; Step 3: Analyze the real-time combustion images to accumulate the combustion time; Step 30: When the combustion time exceeds the preset combustion time threshold, generate a detection failure signal based on the combustion time and output the detection failure signal; Step 31: When the burning time is less than the burning time threshold, acquire the dripping image; Step 32: Analyze the dripping image to obtain the carrier features. The carrier features include focal edge features and normal features. The carrier features are obtained by processing the dripping image through a semantic segmentation model to segment the dripping area and the carrier area. Then, the pixel grayscale and color channel values ​​of the carrier area are statistically analyzed to identify and extract the presence of focal edge features and normal features. Step 320: When the carrier features have focal edge features, output a preset reignition signal; Step 321: When only normal features exist in the characteristics of the carrier, output the preset non-reignition signal.

2. The method for quality inspection of a plug-in device applied to an electricity metering box according to claim 1, characterized in that, Optimization methods for controlling the ignition device to perform ignition include: Step 10: After the ignition device is activated, acquire the ignition image; Step 11: Analyze the ignition image to obtain the current clamping angle and flame angle; Step 12: Calculate the flame deviation angle based on the current clamping angle and flame angle; Step 13: When the flame deviation angle is greater than the preset deviation threshold, the flame deviation angle is split into a lateral adjustment angle and a radial adjustment angle; Step 14: Control the clamping device to adjust according to the lateral adjustment angle and the radial adjustment angle.

3. The method for quality inspection of a plug-in device applied to an electricity metering box according to claim 2, characterized in that, The methods for adjusting the clamping device based on the lateral and radial adjustment angles include: Step 140: Obtain the adjustable angle range; Step 141: Obtain the adjusted clamping angle based on the current clamping angle, lateral adjustment angle, and radial adjustment angle; Step 142: When the adjusted clamping angle falls within the adjustable angle range, control the clamping device to adjust according to the lateral adjustment angle and the radial adjustment angle; Step 143: When the adjusted clamping angle does not fall within the adjustable angle range, traverse the adjustable angle range to obtain the predicted adjustment angle; Step 144: Calculate the angle difference based on the predicted adjustment angle and the flame angle; Step 145: Sort the angle differences in ascending order to obtain the minimum angle difference; Step 146: Control the clamping device to adjust according to the predicted adjustment angle corresponding to the minimum angle difference.

4. The method for quality inspection of a plug-in device applied to an electricity metering box according to claim 3, characterized in that, It also includes an optimization method when the adjusted clamping angle does not fall within the adjustable angle range, the method including: Step 1460: After the control clamping device is adjusted according to the predicted adjustment angle corresponding to the minimum angle difference, the required offset angle of the flame is calculated based on the predicted adjustment angle and the flame angle. Step 1461: Search for the corresponding blowing angle and blowing intensity from the preset blowing database according to the required offset angle of the flame; Step 1462: Control the blowing device to blow air according to the blowing angle and blowing intensity.

5. The method for quality inspection of a plug-in device applied to an electricity metering box according to claim 1, characterized in that, It also includes a control method prior to acquiring the droplet image, which includes: Step 310: Obtain the bearing pressure value; Step 311: When the bearing pressure value is greater than the preset pressure threshold, output the preset pressure change signal and obtain the size of the bearing, the dripping position and the dripping range; Step 312: Update the preset dripping range according to the dripping position and dripping range. The dripping range refers to the area occupied by all dripping objects on the carrier. The initial value of the dripping range is 0. Step 313: Divide the size of the carrier according to the already dripped area to obtain the planned dripping position; Step 314: Generate a single movement path for the carrier based on the size of the carrier and the planned drip location; Step 315: In response to the pressure change signal, control the carrier to move according to the single movement path of the carrier.

6. The method for quality inspection of a plug-in device applied to an electricity metering box according to claim 5, characterized in that, It also includes a control method when there is no planned drip location, which includes: Step 3130: When there is no planned dripping position, obtain the dripping gap; Step 3131: Sort the drip gaps in descending order to obtain drip gap groups; Step 3132: Select the largest drip gap from the drip gap group as the planned drip position, and remove the selected largest drip gap from the drip gap group.

7. The method for quality inspection of a plug-in device applied to an electricity metering box according to claim 5, characterized in that, It also includes a control method for verifying whether the dripping location is within the planned dripping location, the method comprising: Step 3150: After controlling the carrier to move according to the carrier's single movement path, obtain the actual dripping position; Step 3151: Calculate the drop position deviation based on the actual drop position and the planned drop position; Step 3152: Update the preset correction movement position according to the drop position deviation, wherein the initial value of the correction movement position is 0; Step 3153: Update the single movement path based on the corrected movement position.

8. The method for quality inspection of a plug-in device applied to an electricity metering box according to claim 5, characterized in that, It also includes an optimized method for acquiring droplet images, which includes: Step 3100: In response to the pressure change signal, obtain the time of the first drop; Step 3101: After the ignition device completes ignition, obtain the ignition completion time; Step 3102: When the burning time is less than the burning time threshold, acquire an image of the carrier; Step 3103: Analyze the image of the substrate based on the ignition completion time and the first drip time to obtain the incomplete combustion drips; Step 3104: Define incomplete combustion drips as invalid drips, and remove invalid drips from the carrier image to obtain the drip image.

9. A method for quality inspection of a plug-in device applied to an electricity metering box according to claim 5, characterized in that, Methods for obtaining bearing pressure values ​​include: Step 31000: Obtain the current load-bearing pressure value; Step 31001: If the current bearing pressure value falls within the preset normal pressure value range, then the current bearing pressure value is defined as the bearing pressure value; Step 31002: If the current bearing pressure value does not fall within the normal pressure value range, output a pressure value abnormality signal.

10. A quality inspection system for a plug-in device applied to an electricity metering box, characterized in that, include: The acquisition module is used to acquire real-time combustion images, dripping images, ignition images, adjustable angle range, bearing pressure value, dripping gap, and actual dripping position; A memory for storing a program for detecting the quality of a plug-in device applied to an electricity metering box as described in any one of claims 1 to 9; The processor loads and executes programs from memory.

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