Armoured control cable appearance defect automatic detection method and system

Abstract

The application relates to an armored control cable appearance defect automatic detection method and system, and relates to the technical field of cable automatic detection.The application comprises the following steps: acquiring a cable real-time linear velocity and a roller real-time angular velocity; calculating the product of the roller real-time angular velocity and a preset roller radius to generate a roller surface real-time linear velocity; normalizing the difference between the cable real-time linear velocity and the roller surface real-time linear velocity according to the cable real-time linear velocity to generate a roller instantaneous slip rate; controlling a preset cable driving device to drive a preset armored control cable to move according to the roller instantaneous slip rate; and controlling a preset cable defect detection device to detect the appearance defect of the armored control cable to generate a cable defect detection result.The application has the effect of reducing the detection error rejection rate.

Description

Technical Field

[0001] This application relates to the technical field of automatic cable inspection, and in particular to an automatic detection method and system for appearance defects in armored control cables. Background Technology

[0002] Armored control cables are cables with an additional metal protective layer between the cable's insulation layer and outer sheath.

[0003] In related technologies, existing technologies for detecting appearance defects in armored control cables typically employ visual inspection methods. This involves continuously photographing the cable surface using an industrial camera, then using image processing algorithms to identify defects such as burrs, scratches, etc., and making a pass / fail judgment accordingly. When a defect is detected, the system triggers an alarm or stops the machine, requiring operator intervention.

[0004] Regarding the aforementioned technologies, during long-term operation, roller bearings may become stuck, roller surfaces may bulge, and roller mounting brackets may loosen, leading to axial misalignment. This can cause the roller edges or surface protrusions to scrape against the armored control cable, resulting in damage such as edge curling, burrs, and scratches on the armored control cable. Existing armored control cable appearance defect detection technologies cannot distinguish the cause of the damage to the cable surface, thus increasing the false rejection rate of the cable. There is still room for improvement. Summary of the Invention

[0005] To reduce the false rejection rate, this application provides an automatic detection method and system for appearance defects in armored control cables.

[0006] Firstly, this application provides an automatic detection method for appearance defects in armored control cables, employing the following technical solution: An automatic detection method for appearance defects in armored control cables includes: Obtain the real-time linear velocity of the cable and the real-time angular velocity of the roller; Calculate the product of the real-time angular velocity of the roller and the preset roller radius to generate the real-time linear velocity of the roller surface; The difference between the real-time linear velocity of the cable and the real-time linear velocity of the roller surface is normalized based on the real-time linear velocity of the cable to generate the instantaneous slip ratio of the roller. The preset cable drive device drives the preset armored control cable to move according to the instantaneous slip rate of the roller; The preset cable defect detection device is controlled to perform visual defect detection on the armored control cable to generate cable defect detection results.

[0007] Optionally, the step of controlling a preset cable drive device to move a preset armored control cable according to the instantaneous slip rate of the roller includes: Determine whether the instantaneous slip rate of the roller is greater than the preset warning instantaneous slip rate of the roller; If it is not greater than, continue to obtain the real-time linear velocity of the cable and the real-time angular velocity of the roller for cyclic judgment; If it is greater than that, then the lateral deflection force of the roller is obtained; The lateral deflection force of the rollers controls the cable drive device to move the armored control cable.

[0008] Optionally, the cable drive device includes a driven roller, and the step of controlling the movement of the armored control cable by the cable drive device according to the lateral deflection force of the roller includes: Determine whether the lateral deflection force of the roller meets the preset clamping force abnormal deflection force requirements; If not satisfied, the product of the preset deflection angle correction ratio coefficient and the lateral deflection force of the roller is calculated to generate a single deflection angle. The preset roller deflection module adjusts the angle of the driven roller according to the single deflection angle, and controls the cable drive device to drive the armored control cable to move. If satisfied, obtain the real-time cable tension and real-time cable contact wrap angle; The driven roller clamping force is adjusted by the preset roller clamping force adjustment module based on the real-time cable tension and real-time cable contact wrap angle, and the cable drive device is controlled to drive the armored control cable to move.

[0009] Optionally, the roller clamping force adjustment module includes a roller height adjustment module. The step of adjusting the driven roller clamping force according to the real-time cable tension and the real-time cable contact wrap angle by controlling the preset roller clamping force adjustment module includes: Real-time normal pressure is determined based on real-time cable tension and real-time cable contact wrap angle. The real-time normal pressure and the preset rated normal pressure are analyzed to generate the single-time reduction in wrap angle and the adjustment waiting time interval; The control roller clamping force adjustment module adjusts the driven roller clamping force based on the reduction of the single wrap angle and the adjustment waiting time interval, and obtains real-time adjustment feedback data, real-time defect spacing and roller circumference; The real-time adjustment feedback data, real-time defect spacing, roller circumference and preset wear judgment parameters are analyzed to generate wear detection results; Based on the wear detection results, the roller height adjustment module is controlled to disengage the driven roller from the armored control cable.

[0010] Optionally, the steps of analyzing the real-time normal pressure and the preset rated normal pressure to generate the single-cycle reduction in wrap angle and adjust the waiting time interval include: Calculate the difference between the real-time normal pressure and the rated normal pressure to generate the real-time normal pressure excess. Calculate the product of the real-time normal pressure excess and the preset wrap angle adjustment ratio to generate the initial wrap angle reduction. The initial reduction in the guard angle is compared with the preset maximum reduction in the guard angle to generate the single reduction in the guard angle. The real-time normal pressure excess is calculated based on a preset adjustment waiting time calculation formula to generate an adjustment waiting time interval.

[0011] Optionally, the step of controlling the roller height adjustment module to disengage the driven roller from the armored control cable based on the wear detection results includes: Determine whether the wear detection results are consistent with the preset irreversible wear detection results; If they are inconsistent, continue to obtain real-time adjustment feedback data and real-time defect spacing for iterative judgment; If they match, obtain the cable weight per unit length, the height of the upstream adjacent roller, and the height of the downstream adjacent roller; The maximum sag of the roller is generated by analyzing the weight per unit length of the cable and the real-time cable tension. The height of the upstream adjacent roller is compared with the height of the downstream adjacent roller to generate a reference roller height; Calculate the difference between the reference roller height, the maximum roller sag, and the preset safety clearance margin to generate the maximum adjusted roller height; The roller height adjustment module adjusts the driven roller height based on the maximum sag of the roller, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height.

[0012] Optionally, the step of analyzing the cable weight per unit length and real-time cable tension to generate the maximum sag of the roller includes: Obtain the horizontal center distance between adjacent rollers; Calculate the product of the cable's weight per unit length and the square of the horizontal center distance between adjacent rollers to generate the initial sag parameter; Calculate the product of real-time cable tension and a preset sag correction factor to generate the corrected sag parameter; Calculate the quotient of the initial sag parameter and the modified sag parameter to generate the maximum sag of the roller.

[0013] Optionally, the steps for controlling the roller height adjustment module to adjust the driven roller height based on the maximum roller sag, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height include: The height of the midpoint between adjacent rollers is determined based on the heights of the upstream and downstream adjacent rollers. Calculate the difference between the midpoint height of adjacent rollers, the maximum sag of the rollers, the safety clearance margin, and the roller radius to generate the adjustment height for the faulty rollers; The height of the driven roller is adjusted according to the height adjustment module of the faulty roller, and the real-time height of the faulty roller is obtained. Determine if the real-time fault roller height is not greater than the maximum adjusted roller height. If the height is not greater than the specified value, the control roller height adjustment module will stop adjusting the height of the driven roller. If it is greater than the value, continue to obtain the real-time fault roller height for cyclical judgment.

[0014] Secondly, this application provides an automatic detection system for appearance defects in armored control cables, employing the following technical solution: An automatic detection system for appearance defects in armored control cables includes: The acquisition module is used to acquire the real-time linear velocity of the cable and the real-time angular velocity of the roller; A memory for storing a program for an automatic detection method for appearance defects of an armored control cable as described in any of the preceding claims; The processor and the program in the memory can be loaded and executed by the processor to implement an automatic detection method for appearance defects of armored control cables as described in any of the above.

[0015] In summary, this application includes at least one of the following beneficial technical effects: 1. By calculating the product of the real-time angular velocity of the roller and the roller radius, the real-time linear velocity of the roller surface is obtained. Based on the real-time linear velocity of the cable, the difference between the real-time linear velocity of the cable and the real-time linear velocity of the roller surface is normalized to obtain the instantaneous slip ratio of the roller. Based on the instantaneous slip ratio of the roller, the cable drive device is controlled to drive the armored control cable to move. The cable defect detection device is controlled to perform appearance defect detection on the armored control cable and obtain the cable defect detection result. This realizes real-time perception of roller slippage fault based on abnormal slip ratio, thereby reducing the false rejection rate. 2. By determining whether the lateral deflection force of the roller meets the abnormal deflection force requirement of the clamping force, if it does not meet the requirement, the deflection angle correction ratio coefficient is calculated and the lateral deflection force of the roller is multiplied to obtain the single deflection angle. Based on the single deflection angle, the roller deflection module is controlled to adjust the angle of the driven roller and the cable drive device is controlled to drive the armored control cable to move. If it meets the requirement, the roller clamping force adjustment module is controlled to adjust the clamping force of the driven roller based on the real-time cable tension and the real-time cable contact wrap angle, and the cable drive device is controlled to drive the armored control cable to move. In this way, the normal clamping force is reduced by decreasing the wrap angle under the condition of no machine stop to reduce the degree of slippage, thereby avoiding secondary scratch damage caused by misalignment or abnormal clamping force. 3. By determining whether the wear detection results are consistent with the irreversible wear detection results, if they are consistent, the cable unit length weight and real-time cable tension are analyzed to obtain the maximum sag of the roller. The height of the upstream adjacent roller is compared with the height of the downstream adjacent roller to obtain the reference roller height. The difference between the reference roller height, the maximum sag of the roller, and the safety clearance margin is calculated to obtain the maximum adjusted roller height. Based on the maximum sag of the roller, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height, the roller height adjustment module is controlled to adjust the height of the driven roller. This ensures that the apex of the faulty roller is completely separated from the natural suspension envelope of the cable while leaving a safety clearance, achieving online bypass isolation of the irreversible wear roller. This avoids periodic scratch damage to the wear surface without stopping the machine or interrupting the detection. Attached Figure Description

[0016] Figure 1 This is a flowchart of an automatic detection method for appearance defects of armored control cables according to an embodiment of this application.

[0017] Figure 2 This is a flowchart illustrating the steps of controlling a preset cable drive device to move a preset armored control cable according to the instantaneous slip rate of the roller in this embodiment of the application.

[0018] Figure 3 This is a flowchart illustrating the steps of controlling the movement of the armored control cable by the cable drive device based on the lateral deflection force of the roller in an embodiment of this application.

[0019] Figure 4 This is a flowchart illustrating the steps of adjusting the driven roller clamping force according to the preset roller clamping force adjustment module based on the real-time cable tension and the real-time cable contact wrap angle in this embodiment of the application.

[0020] Figure 5 This is a flowchart illustrating the steps in this application embodiment to analyze real-time normal pressure and preset rated normal pressure to generate the single-time reduction in wrap angle and adjust the waiting time interval.

[0021] Figure 6 This is a flowchart of the steps in this application embodiment whereby the roller height adjustment module is controlled to disengage the driven roller from the armored control cable based on the wear detection results.

[0022] Figure 7 This is a flowchart of the steps in this application embodiment to analyze the weight per unit length of the cable and the real-time cable tension to generate the maximum sag of the roller.

[0023] Figure 8 This is a flowchart illustrating the steps in this application embodiment of controlling the roller height adjustment module to adjust the height of the driven roller based on the maximum sag of the roller, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height. Detailed Implementation

[0024] To make the purpose, technical solution, and advantages of this application clearer, the following description is provided in conjunction with the appendix. Figures 1 to 8 The present application will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of the application.

[0025] This application discloses an automatic detection method for appearance defects in armored control cables. This method primarily addresses the issue of reducing the false rejection rate. Specifically, it discloses an armored control cable, driven rollers, a condition monitoring device, a cable drive device, a cable defect detection device, and a processing terminal. The processing terminal is communicatively connected to the condition monitoring device, the cable drive device, and the cable defect detection device to achieve data interaction and control. After the condition monitoring device acquires real-time status data of the cable and rollers and uploads it to the processing terminal, the processing terminal analyzes the real-time status data to determine the working status and abnormal working type of each driven roller. Based on the abnormal working type of the abnormal driven roller, the driven rollers are adjusted, and the cable drive device is controlled to move the armored control cable. This, in turn, controls the cable defect detection device to perform appearance defect detection on the armored control cable, obtaining the cable defect detection result. This approach avoids equipment damage to the armored control cable and reduces the false rejection rate.

[0026] Reference Figure 1 This application discloses an automatic detection method for appearance defects in armored control cables, comprising the following steps: Step S100: Obtain the real-time linear velocity of the cable and the real-time angular velocity of the roller.

[0027] The real-time linear velocity of the cable refers to the instantaneous linear speed of the armored control cable moving along the direction of travel during the detection process, measured in m / s. In one embodiment, an incremental photoelectric rotary encoder is installed on the shaft of the active traction wheel downstream of the detection section to output pulse signals. The controller then counts and samples the signals at regular intervals to obtain the angular velocity of the traction wheel. The angular velocity of the traction wheel is then multiplied by the radius of the traction wheel. Since the traction wheel and the cable rely on a clamping mechanism to ensure pure rolling without slippage, the surface linear velocity of the traction wheel is equal to the linear velocity of the cable. Therefore, the real-time linear velocity of the cable can be obtained. The radius of the traction wheel is obtained by the processing terminal by searching the equipment's rated database according to the traction wheel model.

[0028] The real-time angular velocity of a roller refers to the instantaneous angular velocity of each driven roller rotating around its own axis, measured in rad / s. In one embodiment, the processing terminal reads the pulse count value within one sampling period from the miniature angular velocity sensor installed on each driven roller. The pulse count value is multiplied by 2π, the product is divided by the sampling time interval, and the quotient is divided by the number of pulses per encoder revolution to obtain the real-time angular velocity of the roller. The sampling time interval is 10ms, and the number of pulses per encoder revolution is 1000 pulses / revolution.

[0029] The equipment rating database refers to a database used to store relevant operating parameters of equipment such as driven rollers and traction wheels. In one embodiment, the operator searches for the relevant data manual according to the equipment model and uploads it to the processing terminal for classification and storage, thus obtaining the equipment rating database.

[0030] Driven rollers are guide rollers used to support and guide cables, which rotate entirely by the friction of the cable's movement; armored control cables are cables with an additional metal protective layer between the cable's insulation layer and outer sheath.

[0031] Step S101: Calculate the product of the real-time angular velocity of the roller and the preset roller radius to generate the real-time linear velocity of the roller surface.

[0032] The real-time linear velocity of the roller surface refers to the instantaneous value of the tangential linear velocity generated at any point on the edge of the cylindrical working surface where each driven roller contacts the armored control cable, due to the rotation of the roller. The processing terminal multiplies the real-time angular velocity of the roller by the roller radius to obtain the real-time linear velocity of the roller surface.

[0033] The roller radius refers to the radius of the contact cylinder surface between each driven roller and the armored control cable. The processing terminal can obtain the roller radius by searching in the equipment rating database according to the driven roller model. In one embodiment, the roller radius is 8cm.

[0034] Step S102: Normalize the difference between the real-time linear velocity of the cable and the real-time linear velocity of the roller surface based on the real-time linear velocity of the cable to generate the instantaneous slip ratio of the roller.

[0035] The instantaneous slip ratio of the roller is a parameter used to determine whether each driven roller has degenerated from normal pure rolling to abnormal slip. The processing terminal subtracts the real-time linear velocity of the corresponding roller surface from the real-time linear velocity of the cable of each driven roller, and divides the difference by the real-time linear velocity of the cable to obtain the instantaneous slip ratio of the roller.

[0036] Step S103: Control the preset cable drive device to drive the preset armored control cable according to the instantaneous slip rate of the roller.

[0037] In this process, after the processing terminal determines the instantaneous slip rate of each driven roller, it controls the cable drive device to move the armored control cable according to the instantaneous slip rate. The specific method is described in [reference needed]. Figure 2 The steps.

[0038] A cable drive device is a device that provides continuous, stable, and adjustable speed travel power for armored control cables. It includes a traction motor, a reducer, a drive traction wheel, a driven roller, a pneumatic or spring clamping module, a tension sensor, and a communication module. The processing terminal controls the rotation of the traction motor, which, after torque amplification by the reducer, drives the drive traction wheel, which has a high coefficient of friction, to rotate. At the same time, the pneumatic or spring clamping module tightly adheres the armored control cable to the surface of the drive traction wheel. By relying on static friction, the rotational power of the motor is converted into the linear travel motion of the cable, thereby stably outputting a stable and controllable real-time linear speed without slippage.

[0039] The armored control cable in this step is the same as the armored control cable in step S100 above, and will not be described again here.

[0040] Step S104: Control the preset cable defect detection device to perform appearance defect detection on the armored control cable to generate cable defect detection results.

[0041] The cable defect detection result refers to the data set output after the armored control cable is inspected, which includes data such as defect type, defect location, and defect size. The processing terminal control cable defect detection device can obtain the cable defect detection result by performing appearance defect inspection on the armored control cable.

[0042] A cable defect detection device is an online machine vision system installed within the inspection section for continuous imaging and defect identification of the surface of a moving armored control cable. It includes an illumination module, a high-speed industrial camera, an image processing and defect recognition module, and a communication module. The processing terminal triggers multiple illumination modules and high-speed industrial cameras arranged around the circumference of the cable to continuously image the entire circumference of the cable at fixed spatial intervals during its movement. Each frame is input into the image processing and defect recognition module, which uses deep learning semantic segmentation networks or image processing algorithms to segment abnormal areas such as scratches, burrs, and indentations. The module records the specific coordinates and defect size of each abnormal area along the cable's length and categorizes the defect areas to obtain the cable defect detection results.

[0043] Reference Figure 2 The steps of controlling the preset cable drive device to move the preset armored control cable according to the instantaneous slip rate of the roller include: Step S200: Determine whether the instantaneous slip rate of the roller is greater than the preset warning roller instantaneous slip rate.

[0044] The instantaneous slip rate of the warning roller is a parameter used to distinguish between normal slight slip and abnormal frictional slip during the sliding process of the armored control cable. In one embodiment, the instantaneous slip rate of the warning roller is 0.02.

[0045] The processing terminal determines whether the instantaneous slip rate of each driven roller is greater than the instantaneous slip rate of the warning roller, thereby determining whether the armored control cable is undergoing normal slight slip or abnormal friction slip when passing the driven roller during the sliding process.

[0046] Step S2001: If it is not greater than, continue to obtain the real-time linear velocity of the cable and the real-time angular velocity of the roller for cyclic judgment.

[0047] If the processing terminal determines that the instantaneous slip rate of the rollers is not greater than the instantaneous slip rate of the warning rollers, it means that the armored control cable is undergoing normal slight slip when passing the driven rollers during the sliding process. Therefore, the processing terminal continues to acquire the real-time linear velocity of the cable and the real-time angular velocity of the rollers for cyclic judgment, thereby realizing real-time monitoring of the defect detection process of the armored control cable.

[0048] Step S2002: If it is greater than, then obtain the lateral deflection force of the roller.

[0049] If the processing terminal determines that the instantaneous slip rate of at least one driven roller is greater than the instantaneous slip rate of the warning roller, it indicates that there is abnormal frictional slip during the sliding of the armored control cable. Therefore, the processing terminal determines the lateral deflection force of the abnormal driven roller, thereby providing data support for the subsequent control cable drive device to drive the armored control cable to move.

[0050] The lateral deflection force of the rollers refers to the lateral push-pull force applied by the armored control cable to each driven roller, perpendicular to the normal direction of travel. In one embodiment, a piezoelectric force sensor is embedded between the bearing housing and the mounting bracket of each driven roller. When subjected to lateral shear force, the crystal surface of the piezoelectric force sensor will generate a charge proportional to the force. This charge is converted into a voltage signal by a charge amplifier. The converted voltage signal is then divided by a sensitivity coefficient to obtain the lateral deflection force of the driven roller. The sensitivity coefficient is taken as 4mV / N.

[0051] Step S20021: Control the cable drive device to move the armored control cable according to the lateral deflection force of the roller.

[0052] In this process, after the processing terminal determines the lateral deflection force of the roller, it controls the cable drive device to move the armored control cable based on the lateral deflection force of the roller. The specific method is described in [reference needed]. Figure 3 The steps.

[0053] Reference Figure 3The steps for controlling the armored control cable to move based on the lateral deflection force of the rollers include: Step S300: Determine whether the lateral deflection force of the roller meets the preset clamping force abnormal deflection force requirements.

[0054] Among them, the abnormal deflection force requirement of clamping force refers to the condition that the lateral deflection force of the roller needs to meet when the abnormal friction and sliding during the sliding process of the armored control cable is caused by abnormal roller clamping force. In one embodiment, when the absolute value of the lateral deflection force of the roller is not greater than the lateral deflection force threshold of the roller, it indicates that the abnormal friction and sliding during the sliding process of the armored control cable is caused by abnormal clamping force of the driven roller.

[0055] The processing terminal determines whether the lateral deflection force of each driven roller meets the abnormal deflection force requirement of the clamping force, thereby determining that the abnormal friction and slippage of the armored control cable when passing through the driven roller is caused by roller misalignment or abnormal roller clamping force.

[0056] Step S3001: If not satisfied, calculate the product of the preset deflection angle correction ratio coefficient and the lateral deflection force of the roller to generate a single deflection angle.

[0057] If the processing terminal determines that the lateral deflection force of the driven roller does not meet the abnormal deflection force requirement of the clamping force, it indicates that the abnormal friction and slippage of the armored control cable when passing through the driven roller is due to the presence of abnormal friction and slippage. Therefore, the processing terminal determines the single deflection angle of the driven roller to provide data support for subsequent adjustment of the driven roller angle.

[0058] The single deflection angle refers to the amount of angular deflection when each reverse correction is performed. The processing terminal multiplies the deflection angle correction ratio coefficient with the lateral deflection force of the roller to obtain the single deflection angle.

[0059] The deflection angle correction ratio refers to the angle that needs to be corrected in the opposite direction for every 1N of lateral deflection force generated. In one embodiment, the deflection angle correction ratio is 0.1° / N.

[0060] Step S30011: Adjust the angle of the driven roller according to the preset roller deflection module based on the single deflection angle, and control the cable drive device to drive the armored control cable to move.

[0061] In this process, after determining the single deflection angle of each driven roller with abnormal friction and slippage, the processing terminal controls the roller deflection module to adjust the angle of the driven roller with abnormal friction and slippage according to the single deflection angle, and controls the cable drive device to drive the armored control cable to move.

[0062] The roller deflection module is a module that performs minute angle adjustments on faulty rollers. It includes a servo motor, a transmission mechanism, a bearing housing for the load-bearing roller, a high-rigidity base, and a communication module. After receiving a single deflection angle, the servo motor drives the worm gear in the transmission mechanism to rotate the high-rigidity base, which carries the bearing housing for the load-bearing roller, around the vertical axis at an extremely smooth speed. Under the premise of ensuring that the cable contact point is always in the large plane area of ​​the roller cylinder and that the mechanism is interlocked and controlled, the roller axis is precisely rotated through the angle in the direction of eliminating lateral force. Once in place, the reverse self-locking characteristic of the worm gear is immediately used to mechanically lock the roller in the new posture, and the system waits for the lateral force data to be collected again to determine whether to add or revert to the next fine adjustment, thus completing one driven roller adjustment operation.

[0063] Step S3002: If satisfied, obtain the real-time cable tension and the real-time cable contact wrap angle.

[0064] If the processing terminal determines that the lateral deflection force of the driven roller meets the abnormal deflection force requirement of the clamping force, it indicates that the abnormal friction and slippage of the armored control cable when passing through the driven roller is due to the abnormal clamping force of the roller. Therefore, the processing terminal determines the real-time cable tension and the real-time cable contact wrap angle, thereby providing data support for subsequent adjustment of the clamping force of the driven roller.

[0065] Real-time cable tension refers to the real-time axial tensile force borne by the armored control cable along the cable's travel direction. In one embodiment, a three-roller online tension sensor is installed upstream of the detection section. The cable passes over the three rollers sequentially with a fixed wrap angle. The cable tension acts symmetrically on the middle roller, and its resultant force is vertically downward, measured by a weighing sensor. Based on the vector composition formula of forces... The real-time cable tension can be obtained by calculation, where, This refers to cable tension. It refers to the resultant force. This refers to the fixed geometric wrap angle of a three-roller online tension sensor, taking 30° as an example.

[0066] The real-time cable contact wrap angle refers to the central angle corresponding to the actual contact arc segment when the armored control cable passes through a driven roller with abnormal roller clamping force. In one embodiment, two pairs of non-contact position sensors are installed on both sides of each driven roller, perpendicular to the cable travel direction. One sensor is arranged on the roller inlet side to detect the spatial position of the cable before entering the roller, denoted as . On the other side, a sensor is positioned at the roller outlet to detect the spatial position of the cable after it leaves the roller, denoted as... Let the coordinates of the roller center be... ,from Draw a tangent to the roller, and denote the point of tangency as . ,from Draw a tangent to the roller, and denote the point of tangency as . Then the real-time cable contact wrap angle is the vector. and The formula for calculating the real-time cable contact wrap angle is: (The angle between the two points is given by the formula below.) .

[0067] Step S30021: Adjust the driven roller clamping force according to the real-time cable tension and real-time cable contact wrap angle by controlling the preset roller clamping force adjustment module, and control the cable drive device to drive the armored control cable to move.

[0068] The processing terminal adjusts the driven roller clamping force based on the real-time cable tension and real-time cable contact angle using the roller clamping force adjustment module. For specific methods, please refer to... Figure 4 The steps involve changing the normal clamping force of the driven roller on the armored control cable without stopping the control cable drive device, thereby reducing friction and making pure rolling easier to recover.

[0069] The roller clamping force adjustment module is a module that can change the normal clamping force of the driven roller on the armored control cable without stopping the machine. It includes a deflection actuator driven by a stepper motor, installed between the roller bracket base and the fixed base plate; a clamping force adjustment module composed of a lateral force sensor and a tension sensor; a minimum wrap angle limit component composed of a mechanical stop set at the end of the deflection actuator's stroke; a communication module; and a roller height adjustment module. When it receives a clamping force adjustment command from the processing terminal, it controls the deflection actuator to gradually reduce the guide wrap angle of the roller on the cable according to the determined wrap angle adjustment amount. The minimum wrap angle limit component ensures that the adjustment does not exceed the safety boundary. During the adjustment process, the clamping force adjustment module is linked to the speed reduction protection to reduce the cable contact wrap angle. If the cable contact wrap angle adjustment is still unqualified and a command to adjust the roller height is received, it controls the roller height adjustment module to adjust the height of the corresponding driven roller, so that the driven roller is completely disengaged from the armored control cable.

[0070] The roller height adjustment module is a device used to control the vertical movement of the driven roller. It includes drive components such as a servo motor, a screw jack, a displacement sensor, a roller mounting base, and a communication module. After receiving the adjustment command sent by the processing terminal, the drive components drive the screw jack to smoothly lower the roller mounting base and provide real-time position feedback through the displacement sensor. The adjustment stops when the apex of the driven roller is completely lower than the envelope formed by the natural suspension of the cable between adjacent rollers and a safe gap is left, thus completely detaching the driven roller from the armored control cable.

[0071] Reference Figure 4 The steps for adjusting the driven roller clamping force according to the real-time cable tension and real-time cable contact wrap angle, using a preset roller clamping force adjustment module, include: Step S400: Determine the real-time normal pressure based on the real-time cable tension and the real-time cable contact wrap angle.

[0072] The real-time normal pressure refers to the pressure value applied to the surface of the driven roller when the cable passes the roller under the real-time cable contact wrap angle, which is perpendicular to the contact surface. The processing terminal calculates half of the sine value of the real-time cable contact wrap angle, multiplies the calculated sine value by the real-time cable tension, and finally multiplies the product by 2 to obtain the real-time normal pressure.

[0073] Step S401: Analyze the real-time normal pressure and the preset rated normal pressure to generate the single wrap angle reduction and adjustment waiting time interval.

[0074] Among them, the single-time reduction in envelope angle refers to the adjustment amount during a single envelope angle adjustment; the adjustment waiting time interval refers to the time interval between two adjacent envelope angle adjustments. The processing terminal analyzes the real-time normal pressure and the rated normal pressure to obtain the single-time reduction in envelope angle and the adjustment waiting time interval. Specific methods are described in [reference needed]. Figure 5 The steps.

[0075] Rated normal pressure refers to the pressure value that the cable theoretically applies to the surface of the driven roller, perpendicular to the contact surface. It is obtained by the processing terminal from the equipment's rated database. In one embodiment, the rated normal pressure is 300N.

[0076] Step S402: Based on the reduction in single wrap angle and the adjustment waiting time interval, control the roller clamping force adjustment module to adjust the driven roller clamping force, and obtain real-time adjustment feedback data, real-time defect spacing and roller circumference.

[0077] The processing terminal controls the roller clamping force adjustment module to adjust the clamping force of the corresponding driven roller based on the single wrap angle reduction and the adjustment waiting time interval. After a single adjustment, it acquires the real-time linear velocity of the cable and the real-time angular velocity of the roller to determine the latest instantaneous slip rate of the roller. If the instantaneous slip rate of the roller is not greater than the warning roller instantaneous slip rate, the adjustment stops. If it is greater than the warning roller instantaneous slip rate, it reacquires the real-time cable tension and real-time cable contact wrap angle to determine the single wrap angle reduction and adjustment waiting time interval for the next adjustment, and then applies the formula... Calculate the number of iterations, where, This refers to the excess of real-time normal pressure, which is obtained by subtracting the rated normal pressure from the real-time normal pressure. This refers to the reduction in the corner size per instance. This refers to real-time cable tension. This refers to the real-time cable contact wrap angle. When the instantaneous slip rate of the roller after each wrap angle adjustment is always greater than the instantaneous slip rate of the warning roller, it is determined whether the number of wrap angle adjustments is not less than the number of iterative adjustments. If it is less, iterative adjustments continue; if it is not less, adjustments are stopped. After the adjustment stops, the state of the cable and the driven roller is collected to obtain real-time adjustment feedback data, real-time defect spacing, and roller circumference.

[0078] Real-time adjustment feedback data refers to the set of parameters collected in real time during the wrap angle adjustment process, which reflects the adjustment effect and roller status, including the instantaneous slip rate of the roller and the lateral deflection force of the roller.

[0079] The instantaneous slip ratio of the roller in this step is the same as that in step S102 above, and the lateral deflection force of the roller is the same as that in step S2002 above.

[0080] Real-time defect spacing refers to the distance along the cable length between regularly repeating defects detected on the surface of the armored control cable. The processing terminal extracts the defect locations by reading the cable defect detection results from the cable defect detection device, calculates the distance between two adjacent defect locations, and then calculates the arithmetic mean of all spacings to obtain the average defect spacing. Next, the standard deviation of the defect spacing is calculated. Dividing the standard deviation by the average defect spacing yields the real-time defect spacing. The formula for calculating the standard deviation of the defect spacing is as follows: In the formula, This refers to the standard deviation of the defect spacing. This refers to the total number of spacings. It refers to the first Defect spacing, This refers to the average defect spacing.

[0081] The roller circumference refers to the surface circumference of the driven roller that is currently malfunctioning. The processing terminal finds the radius of the driven roller in the equipment's rated database and multiplies the radius of the driven roller by 2π to obtain the roller circumference. In one embodiment, all driven rollers have the same size, and the radius of the driven roller is taken as 8cm.

[0082] Step S403: Analyze the real-time adjustment feedback data, real-time defect spacing, roller circumference and preset wear judgment parameters to generate wear detection results.

[0083] The wear detection result refers to the conclusion used to determine whether the wear of the driven roller is reversible. The processing terminal calculates the absolute value of the difference between the real-time defect spacing and the roller circumference to obtain the periodic matching deviation. When the periodic matching deviation is less than the deviation matching tolerance, the instantaneous slip rate of the roller is greater than the instantaneous slip rate of the warning roller, and the absolute value of the roller's lateral deflection force is not greater than the abnormal deflection force threshold of the clamping force, it indicates that the armored control cable has periodic surface damage with a constant spacing. That is, there are embedded objects or local wear pits on the surface of the driven roller, which scrape the cable once per revolution. This is considered physical damage that cannot be repaired online, and therefore, the irreversible wear detection result is determined as the wear detection result. If the instantaneous slip rate of the roller is greater than the instantaneous slip rate of the warning roller, and the absolute value of the roller's lateral deflection force is greater than the abnormal deflection force threshold of the clamping force, it indicates that after deflection correction or wrap angle adjustment, there is abnormal friction and sliding, and the cause of the abnormal friction and sliding is roller misalignment. Therefore, the roller misalignment detection result is determined as the wear detection result. Returning to step S3001, the single deflection angle is redefined, and the roller deflection module is controlled to adjust the driven roller angle based on the single deflection angle. The cable drive device is then controlled to move the armored control cable. If the instantaneous slip rate of the roller is greater than the instantaneous slip rate of the warning roller and the absolute value of the roller's lateral deflection force is not greater than the abnormal deflection force threshold of the clamping force, it indicates that after deflection correction or wrap angle adjustment, there is abnormal friction and slippage, and the cause of the abnormal friction and slippage is abnormal roller clamping force. In this case, the abnormal roller clamping force detection result is determined as the wear detection result, and the process returns to step S3001 to redefined the real-time cable tension and real-time cable contact wrap angle. Based on the real-time cable tension and real-time cable contact wrap angle, the roller clamping force adjustment module is controlled to adjust the driven roller clamping force, and the cable drive device is controlled to move the armored control cable. If none of the above conditions are met, the special abnormality detection result is determined as the wear detection result, and the wear detection result is output, allowing the operator to perform manual inspection of the device.

[0084] Wear judgment parameters refer to a set of parameters used to determine whether there is wear on the driven roller, including the instantaneous slip rate of the warning roller, the abnormal deflection force threshold of the clamping force, and the deviation matching tolerance.

[0085] Deviation matching tolerance refers to the maximum permissible difference between the defect spacing and the roller circumference. In one embodiment, the deviation matching tolerance is 3 mm.

[0086] The instantaneous slip rate of the warning roller in this step is the same as that in step S200 above. The abnormal deflection force requirement of the clamping force is the same as that in step S300 above, and will not be elaborated here.

[0087] Irreversible wear test results refer to the judgment output when there are embedded objects or localized wear pits on the surface of the driven roller, which scrape the cable once per revolution, and constitute physical damage that cannot be repaired online; roller skew test results refer to the judgment output when abnormal friction and sliding exist after skew correction or wrap angle adjustment, and the cause of the abnormal friction and sliding is roller skew; abnormal roller clamping force test results refer to the judgment output when abnormal friction and sliding exist after skew correction or wrap angle adjustment, and the cause of the abnormal friction and sliding is abnormal roller clamping force; special abnormality test results refer to the judgment output when none of the above situations apply and manual inspection is required.

[0088] Step S404: Based on the wear detection results, control the roller height adjustment module to disengage the driven roller from the armored control cable.

[0089] The processing terminal controls the roller height adjustment module to disengage the driven roller from the armored control cable based on the wear detection results. For details, please refer to [the relevant documentation / method / reference]. Figure 6 The steps.

[0090] Reference Figure 5 The steps for analyzing real-time normal pressure and preset rated normal pressure to generate single-cycle reduction in envelope angle and adjust waiting time interval include: Step S500: Calculate the difference between the real-time normal pressure and the rated normal pressure to generate the real-time normal pressure excess.

[0091] The real-time normal pressure excess refers to the value at which the normal pressure exceeds the rated normal pressure at the current moment. The processing terminal subtracts the rated normal pressure from the real-time normal pressure to obtain the real-time normal pressure excess.

[0092] Step S501: Calculate the product of the real-time normal pressure excess and the preset wrap angle adjustment ratio coefficient to generate the initial wrap angle reduction.

[0093] The initial reduction in the wrap angle refers to the minimum wrap angle adjustment amount when adjusting the wrap angle. The processing terminal multiplies the real-time normal pressure excess amount by the wrap angle adjustment ratio coefficient to obtain the initial reduction in the wrap angle.

[0094] The wrap angle adjustment ratio is a conversion factor that maps normal pressure to angle. It represents the amount of wrap angle that needs to be reduced for every additional 1 N of normal pressure. In one embodiment, the wrap angle adjustment ratio is 0.25° / N.

[0095] Step S502: Compare the initial reduction amount of the wrap angle with the preset maximum reduction amount of the wrap angle to generate the single reduction amount of the wrap angle.

[0096] In this step, the reduction amount of the single-time corner is the same as that in step S401 above. The processing terminal compares the initial reduction amount of the corner with the maximum reduction amount of the corner, and the larger value is the reduction amount of the single-time corner.

[0097] The maximum reduction in wrap angle refers to the upper limit of the allowable reduction in wrap angle during the adjustment of clamping force. In one embodiment, the maximum reduction in wrap angle is 15°.

[0098] Step S503: Calculate the real-time normal pressure excess based on the preset adjustment waiting time calculation formula to generate the adjustment waiting time interval.

[0099] In this step, the adjustment waiting time interval is the same as the adjustment waiting time interval in step S401 above. The processing terminal substitutes the real-time normal pressure excess into the adjustment waiting time calculation formula to obtain the adjustment waiting time interval.

[0100] The formula for calculating the adjustment waiting time is: .

[0101] In the formula, This refers to adjusting the waiting time interval. This refers to the minimum waiting time; for example, 0.5 seconds. This refers to the baseline waiting time, taking 3 seconds as an example. This refers to the rate adjustment coefficient, in the form of 0.1N. -1 For example, This refers to the amount of real-time normal pressure exceeding the limit. When it is 0, the rhythm can be slowly adjusted according to the baseline waiting time, through... The limitation can prevent oscillations caused by continuous rapid adjustment movements; this rate adjustment coefficient Make in When it is large, Approaching To achieve rapid adjustment, in When smaller, Approaching This allows for slow, fine-tuning, enabling adaptive adjustment based on the level of urgency.

[0102] Reference Figure 6 The steps for controlling the roller height adjustment module to disengage the driven roller from the armored control cable based on wear detection results include: Step S600: Determine whether the wear detection result is consistent with the preset irreversible wear detection result.

[0103] The results of the irreversible wear test in this step are consistent with the results of the irreversible wear test in step S403 above, and will not be repeated here.

[0104] The processing terminal determines whether the wear detection results are consistent with the irreversible wear detection results, thereby determining whether the wear of the driven roller is a physical damage that cannot be repaired online, and further determining whether it is necessary to completely detach the driven roller from the armored control cable.

[0105] Step S6001: If there is a discrepancy, continue to obtain real-time adjustment feedback data and real-time defect spacing for iterative judgment.

[0106] If the processing terminal determines that the detection result is inconsistent with the irreversible wear detection result, it indicates that the wear of the driven roller is not a physical damage that cannot be repaired online. This means that it is not necessary to completely detach the driven roller from the armored control cable. Therefore, the processing terminal continues to acquire real-time adjustment feedback data and real-time defect spacing for cyclical judgment, thereby realizing real-time monitoring of the driven roller and avoiding damage to the armored control cable.

[0107] Step S6002: If they match, obtain the cable weight per unit length, the height of the upstream adjacent roller, and the height of the downstream adjacent roller.

[0108] If the processing terminal determines that the detection result is consistent with the irreversible wear detection result, it indicates that the wear of the driven roller is a physical damage that cannot be repaired online. This means that the driven roller needs to be completely detached from the armored control cable. Therefore, the processing terminal determines the cable weight per unit length, the height of the upstream adjacent roller, and the height of the downstream adjacent roller.

[0109] The weight per unit length of the cable refers to the gravity exerted on the armored control cable per unit length, measured in N / m. In one embodiment, the operator finds the cable weight per unit length in the corresponding technical manual based on the model of the armored control cable and uploads it to the processing terminal.

[0110] The height of the upstream adjacent roller refers to the height of the apex of the previous normal roller adjacent to the faulty driven roller. The processing terminal starts from the upstream driven roller adjacent to the faulty driven roller and reads the status data of each driven roller in sequence. The first normal driven roller is identified as the upstream adjacent roller. The distance between the roller and the ground is measured by the displacement sensor built into the roller, which is the height of the upstream adjacent roller.

[0111] The height of the downstream adjacent roller refers to the apex height of the next normal roller adjacent to the faulty driven roller. The processing terminal starts from the downstream driven roller adjacent to the faulty driven roller and reads the status data of each driven roller in sequence. The first normal driven roller is identified as the downstream adjacent roller. The distance between the roller and the ground is measured by the displacement sensor built into the roller, which is the height of the downstream adjacent roller.

[0112] The status data of the driven roller refers to the data used to reflect whether the driven roller is normal. Taking the instantaneous slip rate of the roller as an example, when the driven roller is normal, the instantaneous slip rate of the roller is not greater than the instantaneous slip rate of the warning roller.

[0113] Step S60021: Analyze the cable unit length weight and real-time cable tension to generate the maximum sag of the roller.

[0114] The maximum sag of the roller refers to the maximum downward displacement of the cable relative to the line connecting the apexes of two adjacent normal rollers, caused by its own weight, at the original support position of the faulty roller after the detachment command is executed. The processing terminal analyzes the cable's weight per unit length and real-time cable tension to obtain the maximum sag of the roller. The specific method is described in [reference needed]. Figure 7 The steps.

[0115] Step S60022: Compare the height of the upstream adjacent roller with the height of the downstream adjacent roller to generate a reference roller height.

[0116] The reference roller height refers to the ideal support plane height of the cable at the original location of the faulty roller when the faulty roller needs to execute the disconnect command. The processing terminal compares the height of the upstream adjacent roller with the height of the downstream adjacent roller, and determines the smaller value of the two heights as the reference roller height.

[0117] Step S60023: Calculate the difference between the reference roller height, the maximum roller sag, and the preset safety clearance margin to generate the maximum adjusted roller height.

[0118] The maximum adjusted roller height refers to the maximum height that the faulty roller can reach after adjustment so that it can completely detach from the armored control cable. The processing terminal subtracts the maximum sag of the roller from the reference roller height and then subtracts the safety clearance margin to obtain the maximum adjusted roller height.

[0119] The safety clearance margin refers to the additional vertical safety distance reserved on the basis of the theoretically calculated reference roller height to ensure that there is no contact between the roller apex and the lowest point of the cable's natural suspension when the faulty roller executes the descent command. In one embodiment, the safety clearance margin is 5mm.

[0120] Step S60024: Adjust the driven roller height using the roller height adjustment module based on the maximum sag of the roller, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height.

[0121] The processing terminal determines the maximum sag of the roller, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height. Based on these parameters, it controls the roller height adjustment module to adjust the height of the driven roller. The specific control method is described in [reference needed]. Figure 8 This process involves completely detaching the faulty driven roller from the armored control cable, thereby preventing further damage to the armored control cable from the faulty roller.

[0122] Reference Figure 7 The steps for analyzing the cable's weight per unit length and real-time cable tension to generate the maximum sag of the roller include: Step S700: Obtain the horizontal center distance between adjacent rollers.

[0123] The horizontal center distance between adjacent rollers refers to the straight-line distance between the projections of the rotation axes on the horizontal plane of the adjacent sides of the faulty driven roller along the cable travel direction. It is obtained by the processing terminal from the equipment rating database. In one embodiment, if the driven roller has executed a height adjustment command, a laser rangefinder is used to measure the closest distance and the farthest distance between the shaft end faces of two adjacent rollers respectively, and the average value of the closest distance and the farthest distance is calculated as the horizontal center distance between adjacent rollers.

[0124] Step S701: Calculate the product of the cable weight per unit length and the square of the horizontal center distance between adjacent rollers to generate the initial sag parameter.

[0125] The initial sag parameter refers to the data used to reflect the tendency of the cable to sag under the combined effect of the cable's own weight and the roller span. The larger the initial sag parameter, the heavier the cable or the larger the span, and the stronger the downward sag tendency of the cable. The processing terminal multiplies the weight per unit length of the cable by the square of the horizontal center distance between adjacent rollers to obtain the initial sag parameter.

[0126] Step S702: Calculate the product of real-time cable tension and preset sag correction coefficient to generate corrected sag parameters.

[0127] The corrected sag parameter refers to data that reflects the cable's ability to resist sag under tension. The greater the tension, the tighter the cable, and the stronger its resistance to sag. The processing terminal multiplies the real-time cable tension by the sag correction coefficient to obtain the corrected sag parameter.

[0128] The sag correction factor is a parameter used to assign the correct mathematical weight to the real-time cable tension, converting it into a value that can be calculated with the initial sag parameter. In one embodiment, the sag correction factor is 8.

[0129] Step S703: Calculate the quotient of the initial sag parameter and the corrected sag parameter to generate the maximum sag of the roller.

[0130] In this step, the maximum sag of the roller is the same as the maximum sag of the roller in step S60021 above. The processing terminal divides the initial sag parameter by the corrected sag parameter to obtain the maximum sag of the roller.

[0131] Reference Figure 8 The steps for adjusting the driven roller height using the roller height adjustment module based on the maximum roller sag, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height include: Step S800: Determine the midpoint height of adjacent rollers based on the heights of the upstream adjacent rollers and the downstream adjacent rollers.

[0132] The midpoint height of adjacent rollers refers to the average height of the normal rollers on both sides of the faulty roller from the ground. The processing terminal calculates the sum of the heights of the upstream adjacent rollers and the downstream adjacent rollers, and then divides the sum by 2 to obtain the midpoint height of adjacent rollers.

[0133] Step S801: Calculate the difference between the midpoint height of adjacent rollers, the maximum sag of the rollers, the safety clearance margin, and the roller radius to generate the adjustment height of the faulty rollers.

[0134] The faulty roller adjustment height refers to the height that the faulty driven roller needs to be lowered to avoid detaching from the armored control cable. The processing terminal subtracts the maximum sag of the roller from the height of the adjacent rollers, then subtracts the safety clearance margin, and finally subtracts the roller radius to obtain the faulty roller adjustment height.

[0135] Step S802: Adjust the height of the driven roller according to the height adjustment module of the faulty roller, and obtain the real-time height of the faulty roller.

[0136] The real-time fault roller height refers to the real-time height of the fault roller from the ground during the adjustment of the fault roller height. The processing terminal controls the roller height adjustment module to lower the height of the faulty driven roller based on the height adjustment of the faulty roller, and obtains the real-time fault roller height by measuring it in real time through the displacement sensor installed on the roller height adjustment module of the faulty driven roller.

[0137] Step S803: Determine whether the real-time fault roller height is not greater than the maximum adjusted roller height.

[0138] The processing terminal determines whether the height of the faulty roller in real time is not greater than the height of the roller after maximum adjustment, thereby determining whether the highest point of the faulty roller has completely detached from the armored control cable.

[0139] Step S8031: If it is not greater than, then control the roller height adjustment module to stop adjusting the driven roller height.

[0140] If the processing terminal determines that the real-time height of the faulty roller is not greater than the maximum adjusted roller height, it means that the highest point of the faulty roller has completely detached from the armored control cable. Therefore, the processing terminal controls the roller height adjustment module to stop adjusting the height of the driven roller.

[0141] Step S8032: If it is greater than, continue to obtain the real-time fault roller height for cyclic judgment.

[0142] If the processing terminal determines that the real-time height of the faulty roller is greater than the maximum adjusted roller height, it means that the highest point of the faulty roller has not completely detached from the armored control cable. Therefore, the processing terminal continues to control the roller height adjustment module to adjust the height of the driven roller and obtains the real-time height of the faulty roller for cyclic judgment, thereby ensuring that the highest point of the faulty roller is completely detached from the armored control cable, and thus avoiding further damage to the armored control cable by the faulty roller.

[0143] Based on the same inventive concept, embodiments of this application provide an automatic detection system for appearance defects in armored control cables, including: The acquisition module is used to acquire real-time cable linear velocity, real-time roller angular velocity, roller lateral deflection force, real-time cable tension, real-time cable contact wrap angle, real-time adjustment feedback data, real-time defect spacing, roller circumference, cable weight per unit length, height of upstream adjacent roller, height of downstream adjacent roller, horizontal center distance between adjacent rollers, and real-time faulty roller height. A memory for storing a program for an automatic detection method of appearance defects in armored control cables; The processor and memory can load and execute programs to implement an automatic detection method for appearance defects in armored control cables.

[0144] 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.

[0145] This application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed as an automatic detection method for appearance defects in armored control cables.

[0146] Computer storage media include, for example, USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, optical disks, and other media that can store program code.

[0147] Based on the same inventive concept, this application provides a smart terminal, including a memory and a processor. The memory stores a computer program that can be loaded and executed by the processor to perform an automatic detection method for appearance defects of armored control cables.

[0148] 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.

[0149] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Any feature disclosed in this specification (including the abstract and drawings) may be replaced by other equivalent or similar features unless specifically stated otherwise. That is, unless specifically stated otherwise, each feature is only one example of a series of equivalent or similar features.

Claims

1. An automatic detection method for appearance defects in armored control cables, characterized in that, include: Obtain the real-time linear velocity of the cable and the real-time angular velocity of the roller; Calculate the product of the real-time angular velocity of the roller and the preset roller radius to generate the real-time linear velocity of the roller surface; The difference between the real-time linear velocity of the cable and the real-time linear velocity of the roller surface is normalized based on the real-time linear velocity of the cable to generate the instantaneous slip ratio of the roller. The preset cable drive device drives the preset armored control cable to move according to the instantaneous slip rate of the roller; The preset cable defect detection device is controlled to perform visual defect detection on the armored control cable to generate cable defect detection results.

2. The automatic detection method for appearance defects of armored control cables according to claim 1, characterized in that, The steps of controlling the movement of a preset armored control cable by a preset cable drive device based on the instantaneous slip ratio of the roller include: Determine whether the instantaneous slip rate of the roller is greater than the preset warning instantaneous slip rate of the roller; If it is not greater than, continue to obtain the real-time linear velocity of the cable and the real-time angular velocity of the roller for cyclic judgment; If it is greater than that, then the lateral deflection force of the roller is obtained; The lateral deflection force of the rollers controls the cable drive device to move the armored control cable.

3. The automatic detection method for appearance defects of armored control cables according to claim 2, characterized in that, The cable drive device includes a driven roller, and the step of controlling the cable drive device to drive the armored control cable according to the lateral deflection force of the roller includes: Determine whether the lateral deflection force of the roller meets the preset clamping force abnormal deflection force requirements; If not satisfied, the product of the preset deflection angle correction ratio coefficient and the lateral deflection force of the roller is calculated to generate a single deflection angle. The preset roller deflection module adjusts the angle of the driven roller according to the single deflection angle, and controls the cable drive device to drive the armored control cable to move. If satisfied, obtain the real-time cable tension and real-time cable contact wrap angle; The driven roller clamping force is adjusted by the preset roller clamping force adjustment module based on the real-time cable tension and real-time cable contact wrap angle, and the cable drive device is controlled to drive the armored control cable to move.

4. The automatic detection method for appearance defects of armored control cables according to claim 3, characterized in that, The roller clamping force adjustment module includes a roller height adjustment module. The steps of adjusting the driven roller clamping force according to the real-time cable tension and real-time cable contact wrap angle include: Real-time normal pressure is determined based on real-time cable tension and real-time cable contact wrap angle. The real-time normal pressure and the preset rated normal pressure are analyzed to generate the single-time reduction in wrap angle and the adjustment waiting time interval; The control roller clamping force adjustment module adjusts the driven roller clamping force based on the reduction of the single wrap angle and the adjustment waiting time interval, and obtains real-time adjustment feedback data, real-time defect spacing and roller circumference; The real-time adjustment feedback data, real-time defect spacing, roller circumference and preset wear judgment parameters are analyzed to generate wear detection results; Based on the wear detection results, the roller height adjustment module is controlled to disengage the driven roller from the armored control cable.

5. The automatic detection method for appearance defects of armored control cables according to claim 4, characterized in that, The steps for analyzing real-time normal pressure and preset rated normal pressure to generate single-cycle envelope reduction and adjust waiting time intervals include: Calculate the difference between the real-time normal pressure and the rated normal pressure to generate the real-time normal pressure excess. Calculate the product of the real-time normal pressure excess and the preset wrap angle adjustment ratio to generate the initial wrap angle reduction. The initial reduction in the guard angle is compared with the preset maximum reduction in the guard angle to generate the single reduction in the guard angle. The real-time normal pressure excess is calculated based on a preset adjustment waiting time calculation formula to generate an adjustment waiting time interval.

6. The automatic detection method for appearance defects of armored control cables according to claim 4, characterized in that, The steps for controlling the roller height adjustment module to disengage the driven roller from the armored control cable based on wear detection results include: Determine whether the wear detection results are consistent with the preset irreversible wear detection results; If they are inconsistent, continue to obtain real-time adjustment feedback data and real-time defect spacing for iterative judgment; If they match, obtain the cable weight per unit length, the height of the upstream adjacent roller, and the height of the downstream adjacent roller; The maximum sag of the roller is generated by analyzing the weight per unit length of the cable and the real-time cable tension. The height of the upstream adjacent roller is compared with the height of the downstream adjacent roller to generate a reference roller height; Calculate the difference between the reference roller height, the maximum roller sag, and the preset safety clearance margin to generate the maximum adjusted roller height; The roller height adjustment module adjusts the driven roller height based on the maximum sag of the roller, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height.

7. The automatic detection method for appearance defects of armored control cables according to claim 6, characterized in that, The steps for analyzing the cable's weight per unit length and real-time cable tension to generate the maximum roller sag include: Obtain the horizontal center distance between adjacent rollers; Calculate the product of the cable's weight per unit length and the square of the horizontal center distance between adjacent rollers to generate the initial sag parameter; Calculate the product of real-time cable tension and a preset sag correction factor to generate the corrected sag parameter; Calculate the quotient of the initial sag parameter and the modified sag parameter to generate the maximum sag of the roller.

8. The automatic detection method for appearance defects of armored control cables according to claim 6, characterized in that, The steps for adjusting the driven roller height using the roller height adjustment module based on the maximum roller sag, the height of the upstream adjacent roller, the height of the downstream adjacent roller, and the maximum adjusted roller height include: The height of the midpoint between adjacent rollers is determined based on the heights of the upstream and downstream adjacent rollers. Calculate the difference between the midpoint height of adjacent rollers, the maximum sag of the rollers, the safety clearance margin, and the roller radius to generate the adjustment height for the faulty rollers; The height of the driven roller is adjusted according to the height adjustment module of the faulty roller, and the real-time height of the faulty roller is obtained. Determine if the real-time fault roller height is not greater than the maximum adjusted roller height. If the height is not greater than the specified value, the control roller height adjustment module will stop adjusting the height of the driven roller. If it is greater than the value, continue to obtain the real-time fault roller height for cyclical judgment.

9. An automatic detection system for appearance defects in armored control cables, characterized in that, include: The acquisition module is used to acquire the real-time linear velocity of the cable and the real-time angular velocity of the roller; A memory for storing a program for an automatic detection method for appearance defects of an armored control cable as described in any one of claims 1 to 8; The processor and the program in the memory can be loaded and executed by the processor to implement the automatic detection method for appearance defects of armored control cables as described in any one of claims 1 to 8.

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