Surface defect detection device, method and electronic equipment for a bushing

Abstract

The application relates to a surface defect detection device and method of a basin-type insulator and electronic equipment, wherein the device comprises: an image acquisition module configured to acquire image information of upper and lower surfaces of a basin-type insulator to be detected; at least one position adjusting component configured to adjust the position of the image acquisition module to meet detection conditions corresponding to a target detection task; and a logic control module configured to drive the at least one position adjusting component to adjust the position, to generate a surface image of the basin-type insulator to be detected according to the image information acquired by the image acquisition module, and to generate a surface defect identification result of the basin-type insulator to be detected based on the surface image. Thus, the problems in the prior art that the quality standard is difficult to unify due to low efficiency and strong subjectivity of manual visual detection, the detection cannot meet the needs of large-scale production, the risk of missed detection and misjudgment is high, the instrument detection has the problems of high cost, slow speed or complex operation, and the efficiency, coverage and automation degree are insufficient are solved.

Description

Technical Field

[0001] This application relates to the field of power equipment testing technology, and in particular to a surface defect detection device, method and electronic equipment for basin insulators. Background Technology

[0002] Currently, GIS (Gas-Insulated Switchgear) is a crucial component of high-voltage power transmission systems, and its operational reliability directly impacts the safety and stability of the power grid. Internal insulating components, such as basin-type insulators, are critical parts. During their production, improper operation, imperfect processes, poor mold quality, and insufficient equipment stability can lead to defects such as bubbles, cracks, and embedded metal particles. These defects degrade the insulation performance of the insulating components, easily causing surface flashover, breakdown, and breakage, seriously threatening the safe operation of the GIS. Therefore, the inspection of the surface condition of basin-type insulators is of paramount importance.

[0003] In related technologies, the surface condition inspection of basin-type insulators before grid connection relies on human visual defect identification. If the GIS (Gas Insulator System) after grid connection has long-term excessive partial discharge or other anomalies, it needs to be disassembled on-site, and a specialist must observe the surface of the disassembled basin-type insulator to eliminate potential defects. In addition, there are also technologies that utilize equipment to detect defects in basin-type insulators, mainly including X-ray imaging, industrial CT imaging, and ultrasonic flaw detection.

[0004] However, in related technologies, manual visual inspection is inefficient and cannot meet the needs of large-scale production. At the same time, the inspection results are highly dependent on personal experience and subjective state, making it difficult to unify the inspection standards. It is easy to miss or misjudge defects such as tiny metal particles, which poses a safety hazard to equipment operation. In instrument inspection, industrial CT equipment is not suitable for full inspection of the production line due to its high cost and low detection efficiency. Ultrasonic inspection has high requirements for the surface condition and coupling conditions of the sample, is complicated to operate, and has blind spots. X-ray imaging focuses on internal inspection and has low efficiency and cost-effectiveness in identifying tiny surface defects. As a result, there are shortcomings in efficiency, coverage and automation. It is limited in the rapid screening of tiny surface and near-surface defects, which restricts production efficiency and product quality consistency and urgently needs to be improved. Summary of the Invention

[0005] This application provides a surface defect detection device, method, and electronic equipment for basin insulators to solve the problems in related technologies, such as low efficiency and strong subjectivity of manual visual inspection, which makes it difficult to unify quality standards and meet the needs of large-scale production, difficulty in detecting small defects, high risk of missed detection and misjudgment, and the problems of high cost, slow speed, or complicated operation of instrument detection, which result in insufficient efficiency, coverage and automation.

[0006] A first aspect of this application provides a surface defect detection device for a basin-type insulator, comprising: an image acquisition module for acquiring image information of the upper and lower surfaces of the basin-type insulator to be detected; at least one position adjustment component for adjusting the position of the image acquisition module to meet the detection conditions corresponding to the target detection task; and a logic control module for driving the at least one position adjustment component to adjust the position, so as to generate a surface image of the basin-type insulator to be detected based on the image information acquired by the image acquisition module, and generate a surface defect identification result of the basin-type insulator to be detected based on the surface image.

[0007] Through the above-mentioned technical means, the embodiments of this application can acquire complete image information of the upper and lower surfaces of the pot-type insulator to be inspected through the image acquisition module, adjust the position of the image acquisition module to adapt to the inspection requirements through the position adjustment component, and then link the various components through the logic control module to complete the position adjustment and defect result generation, thereby realizing the automated detection of surface defects of pot-type insulators, ensuring the insulation performance and operational safety of GIS equipment, and thus breaking through the bottleneck of efficiency and accuracy of manual inspection, realizing efficient, accurate and intelligent detection of surface defects of pot-type insulators.

[0008] Optionally, in one embodiment of this application, the at least one position adjustment component includes: at least one vertical position adjustment component for adjusting the vertical height of the image acquisition module relative to the basin insulator to be tested; and at least one horizontal position adjustment component for adjusting the horizontal distance of the image acquisition module relative to the basin insulator to be tested.

[0009] Through the above-mentioned technical means, the embodiments of this application can adjust the vertical height and horizontal distance between the image acquisition module and the pot-type insulator to be tested, thereby flexibly adapting to pot-type insulators of different specifications, ensuring that the image acquisition module can accurately focus and completely cover the detection area, improving the versatility of the device and the quality of image acquisition, and laying a good foundation for subsequent defect identification.

[0010] Optionally, in one embodiment of this application, the at least one vertical position adjustment component includes at least one first servo driver, at least one first servo motor, and a vertical module; the at least one horizontal position adjustment component includes at least one second servo driver, at least one second servo motor, and a horizontal module.

[0011] Through the above-mentioned technical means, the embodiments of this application can use a vertical and horizontal adjustment component composed of a servo driver, a servo motor and a corresponding module to adjust the relative position of the image acquisition module and the basin insulator to be detected, thereby achieving high-precision and high-response-speed position control to obtain the best shooting effect.

[0012] Optionally, in one embodiment of this application, it further includes: at least one rotating element for adjusting the relative position between the image acquisition module and the basin insulator to be tested.

[0013] Through the above-mentioned technical means, the embodiments of this application can design a dedicated precision rotating platform, ensuring that the image acquisition module can cover the insulator's 360° full circumference and all curved surface details, effectively eliminating the visual blind spots existing in manual inspection or fixed shooting, and ensuring the integrity of the detection data.

[0014] Optionally, in one embodiment of this application, the image acquisition module includes: at least one light source and at least one linear scan camera; an encoder for controlling the operation of the at least one light source and the at least one linear scan camera according to the rotation state of the insulator to be detected.

[0015] Through the above-mentioned technical means, the embodiments of this application can control at least one light source and at least one linear array camera to work in real time according to the rotation state of the pot insulator to be tested, thereby providing uniform brightness adjustable light and monitoring the rotation of the pot insulator driven by the rotating mechanism, thereby improving the efficiency and quality of image acquisition and laying the foundation for subsequent defect feature extraction and identification.

[0016] Optionally, in one embodiment of this application, the logic control module includes: an interaction module for determining the hardware parameters of the device; and a controller for controlling the at least one position adjustment component to execute corresponding control commands.

[0017] Through the above-mentioned technical means, the embodiments of this application can set and adjust hardware parameters, store motor motion control code, and transmit instructions to the motor to control its movement, thereby achieving automated and rapid detection, significantly improving detection efficiency, and meeting the needs of mass production and rapid operation and maintenance.

[0018] Optionally, in one embodiment of this application, the logic control module is specifically used to input the surface image into a pre-built defect detection model, extract at least one defect feature, and output the surface defect identification result based on the at least one defect feature.

[0019] Through the above-mentioned technical means, the embodiments of this application can receive images captured by a high-definition line scan camera, and combine them with a pre-built defect detection model to achieve keen capture and accurate classification of surface defect identification results, greatly reducing the missed detection rate and false judgment rate. This solves the problems of strong subjectivity and difficulty in unifying quality standards in manual inspection, reduces interference from human factors, and ensures that the inspection results of different batches and different inspection personnel are consistent and traceable.

[0020] A second aspect of this application provides a method for detecting surface defects in a basin-type insulator, comprising the following steps: acquiring image information of the upper and lower surfaces of the basin-type insulator to be detected; adjusting the position of the basin-type insulator to be detected to meet the detection conditions corresponding to the target detection task; driving at least one position adjustment component to adjust the position, so as to generate a surface image of the basin-type insulator to be detected based on the image information acquired by the image acquisition module, and generating a surface defect identification result of the basin-type insulator to be detected based on the surface image.

[0021] Through the above-mentioned technical means, the embodiments of this application can acquire complete image information of the upper and lower surfaces of the pot-type insulator to be inspected through the image acquisition module, adjust the position of the image acquisition module to adapt to the inspection requirements through the position adjustment component, and then link the various components through the logic control module to complete the position adjustment and defect result generation, thereby realizing the automated detection of surface defects of pot-type insulators, ensuring the insulation performance and operational safety of GIS equipment, and thus breaking through the bottleneck of efficiency and accuracy of manual inspection, realizing efficient, accurate and intelligent detection of surface defects of pot-type insulators.

[0022] Optionally, in one embodiment of this application, adjusting the position of the image acquisition module to meet the detection conditions corresponding to the target detection task includes: adjusting the vertical height of the image acquisition module relative to the basin insulator to be detected; and adjusting the horizontal distance of the image acquisition module relative to the basin insulator to be detected.

[0023] Through the above-mentioned technical means, the embodiments of this application can adjust the vertical height and horizontal distance between the image acquisition module and the pot-type insulator to be tested, thereby flexibly adapting to pot-type insulators of different specifications, ensuring that the image acquisition module can accurately focus and completely cover the detection area, improving the versatility of the device and the quality of image acquisition, and laying a good foundation for subsequent defect identification.

[0024] Optionally, in one embodiment of this application, adjusting the position of the insulator to be tested to meet the detection conditions corresponding to the target detection task further includes: adjusting the relative position between the image acquisition module and the insulator to be tested.

[0025] Through the above-mentioned technical means, the embodiments of this application can design a dedicated precision rotating platform, ensuring that the image acquisition module can cover the insulator's 360° full circumference and all curved surface details, effectively eliminating the visual blind spots existing in manual inspection or fixed shooting, and ensuring the integrity of the detection data.

[0026] Optionally, in one embodiment of this application, acquiring image information of the upper and lower surfaces of the basin insulator to be tested includes: controlling at least one light source and at least one linear scan camera to operate according to the rotation state of the basin insulator to be tested.

[0027] Through the above-mentioned technical means, the embodiments of this application can control at least one light source and at least one linear array camera to work in real time according to the rotation state of the pot insulator to be tested, thereby providing uniform brightness adjustable light and monitoring the rotation of the pot insulator driven by the rotating mechanism, thereby improving the efficiency and quality of image acquisition and laying the foundation for subsequent defect feature extraction and identification.

[0028] Optionally, in one embodiment of this application, driving the at least one position adjustment component to adjust the position to generate a surface image of the pot-type insulator to be tested based on the image information acquired by the image acquisition module, and generating a surface defect identification result of the pot-type insulator to be tested based on the surface image, includes: determining the hardware parameters of the device; and controlling the at least one position adjustment component to execute corresponding control commands.

[0029] Through the above-mentioned technical means, the embodiments of this application can set and adjust hardware parameters, store motor motion control code, and transmit instructions to the motor to control its movement, thereby achieving automated and rapid detection, significantly improving detection efficiency, and meeting the needs of mass production and rapid operation and maintenance.

[0030] Optionally, in one embodiment of this application, driving the at least one position adjustment component to adjust the position to generate a surface image of the pot insulator to be tested based on the image information acquired by the image acquisition module, and generating a surface defect identification result of the pot insulator to be tested based on the surface image, includes: inputting the surface image into a pre-constructed defect detection model, extracting at least one defect feature, and outputting the surface defect identification result based on the at least one defect feature.

[0031] Through the above-mentioned technical means, the embodiments of this application can receive images captured by a high-definition line scan camera, and combine them with a pre-built defect detection model to achieve keen capture and accurate classification of surface defect identification results, greatly reducing the missed detection rate and false judgment rate. This solves the problems of strong subjectivity and difficulty in unifying quality standards in manual inspection, reduces interference from human factors, and ensures that the inspection results of different batches and different inspection personnel are consistent and traceable.

[0032] A third aspect of this application provides an electronic device, including: a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the program to implement the surface defect detection method for basin insulators as described in the above embodiments.

[0033] A fourth aspect of this application provides a non-volatile computer-readable storage medium storing a computer program that, when executed by a processor, implements the above-described method for detecting surface defects in a basin-type insulator.

[0034] A fifth aspect of this application provides a computer program product that stores a computer program that, when executed by a processor, implements the above-described method for detecting surface defects in a basin-type insulator.

[0035] This embodiment of the application can acquire complete image information of the upper and lower surfaces of the basin-type insulator to be inspected through an image acquisition module. The position of the image acquisition module is adjusted by a position adjustment component to adapt to the inspection requirements. Then, the logic control module links various components to complete the position adjustment and defect result generation, thereby achieving automated detection of surface defects in basin-type insulators. This ensures the insulation performance and operational safety of GIS equipment, and overcomes the bottlenecks in efficiency and accuracy of manual inspection, achieving efficient, accurate, and intelligent detection of surface defects in basin-type insulators. This solves the problems in related technologies, such as the low efficiency and strong subjectivity of manual visual inspection leading to difficulties in unifying quality standards and failing to meet the needs of large-scale production, the difficulty in detecting minute defects, and the high risk of missed detection and misjudgment. It also addresses the shortcomings in efficiency, coverage, and automation caused by the high cost, slow speed, or complex operation of instrument-based inspection.

[0036] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0037] The above and / or additional aspects and advantages of this application will become apparent and readily understood from the following description of the embodiments taken in conjunction with the accompanying drawings, wherein: Figure 1 This is a schematic diagram of a surface defect detection device for a basin-type insulator according to an embodiment of this application; Figure 2 This is a schematic diagram of the hardware logic connection of a device according to an embodiment of this application; Figure 3 This is a structural design drawing of a surface defect detection device for a basin-type insulator according to an embodiment of this application; Figure 4This is a schematic diagram of segmented testing of a basin-type insulator according to an embodiment of this application; Figure 5 This is a schematic diagram of the imaging and recognition results provided according to an embodiment of this application; Figure 6 This is a flowchart of a surface defect detection method for a basin-type insulator according to an embodiment of this application; Figure 7 This is a schematic diagram of the structure of an electronic device provided according to an embodiment of this application.

[0038] Figure label: 10-Surface defect detection device for basin-type insulators; 100-Image acquisition module; 200-At least one position adjustment component; 300-Logic control module; 101-Encoder; 102-Differential expansion module; 103-Light source; 104-Linear scan camera A; 105-Linear scan camera B; 201-Camera rotation mechanism; 202-Cylinder; 203-Air pump; 204-Servo driver; 205-Servo motor A; 206-Servo motor B; 207-Servo motor C; 208-Servo motor D; 209-Servo motor E; 210-Horizontal module; 211-Vertical module; 212-Rotation mechanism; 213-Basin-type insulator; 301-Computer; 302-Switch; 303-PLC controller; 304-Human-machine interface; 701-Memory; 702-Processor; 703-Communication interface. Detailed Implementation

[0039] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain this application, and should not be construed as limiting this application.

[0040] The following description, with reference to the accompanying drawings, outlines an embodiment of a surface defect detection device, method, and electronic device for basin-type insulators. Addressing the shortcomings of the aforementioned background technologies, manual visual inspection suffers from low efficiency and strong subjectivity, leading to difficulties in standardizing quality and failing to meet the demands of large-scale production. It also presents challenges in detecting minute defects, resulting in high risks of missed detections and misjudgments. Instrument-based inspection, on the other hand, suffers from high costs, slow speeds, and complex operations, resulting in deficiencies in efficiency, coverage, and automation. This application provides a surface defect detection device for basin-type insulators. In this device, a complete image of the upper and lower surfaces of the basin-type insulator to be inspected is acquired via an image acquisition module. The position of the image acquisition module is adjusted using a position adjustment component to suit the inspection requirements. A logic control module then links various components to complete position adjustment and defect result generation, thereby achieving automated detection of surface defects in basin-type insulators. This ensures the insulation performance and operational safety of GIS equipment, overcoming the efficiency and accuracy bottlenecks of manual inspection and achieving efficient, accurate, and intelligent detection of surface defects in basin-type insulators. This solves the problems in related technologies, such as the low efficiency and strong subjectivity of manual visual inspection, which makes it difficult to unify quality standards and meet the needs of large-scale production, making it difficult to detect minute defects and resulting in high risks of missed detection and misjudgment, and the high cost, slow speed or complicated operation of instrument inspection, which leads to deficiencies in efficiency, coverage and automation.

[0041] Specifically, Figure 1 This is a schematic diagram of the surface defect detection device for a basin-type insulator according to an embodiment of this application.

[0042] like Figure 1 As shown, the surface defect detection device 10 for the basin insulator includes: an image acquisition module 100, at least one position adjustment component 200, and a logic control module 300.

[0043] The image acquisition module 100 is used to acquire image information of the upper and lower surfaces of the basin insulator to be tested.

[0044] It is understood that the image acquisition module 100 in this embodiment may include a linear scan camera, which can be used to acquire visual information of the surface of the basin insulator to be inspected, providing raw data support for subsequent defect identification and analysis.

[0045] In actual implementation, this embodiment of the application can acquire image information of the upper and lower surfaces of the pot-type insulator to be tested using a line scan camera after receiving the detection signal. Since the pot-type insulator to be tested may be large in size and its outer surface is irregular in shape, the line scan camera needs to take pictures in multiple segments, and the camera lens needs to be perpendicular to the surface to be photographed during each segment.

[0046] The embodiments of this application can automatically acquire image information of the upper and lower surfaces of the basin insulator to be inspected, thereby replacing manual visual image acquisition, ensuring the objectivity and integrity of the image data, and laying a data foundation for accurate identification of surface defects.

[0047] Optionally, in one embodiment of this application, the image acquisition module 100 includes: at least one light source and at least one linear scan camera; and an encoder for controlling the operation of at least one light source and at least one linear scan camera according to the rotation state of the pot insulator to be detected.

[0048] It is understood that in the embodiments of this application, at least one light source can be used to provide uniform brightness adjustable light; at least one line scan camera can be understood as a camera that acquires images in a line-by-line scanning manner.

[0049] In actual implementation, two high-definition linear array cameras can be used in this application embodiment, each for image acquisition of the upper and lower surfaces of the basin-type insulator to be tested; the light source is placed next to the linear array camera to provide uniform brightness adjustable light to ensure that the light illuminates the surface of the insulator and highlights surface defects.

[0050] Furthermore, the encoder is used to monitor the rotation of the basin insulator driven by the rotating mechanism and transmits the signal to the high-definition line scan camera to ensure that the camera can capture clear, undistorted images. Since the basin insulator to be inspected may be large in size and have an irregular outer surface, the line scan camera needs to take pictures in multiple segments. During each segment, the camera lens must be perpendicular to the surface to be photographed.

[0051] For the extremely small (e.g., less than 2 mm in diameter) embedded metal particle defects, which are the most difficult to detect, as well as micro-defects such as bubbles and cracks, visual inspection is prone to omissions due to fatigue or lighting conditions. In the embodiments of this application, the uniform illumination provided by the light source enhances the contrast between the defects and the background, making micro-defects easier to identify.

[0052] The embodiments of this application can control at least one light source and at least one linear array camera in real time according to the rotation state of the basin insulator to be tested, thereby providing uniform and adjustable light and monitoring the rotation of the basin insulator driven by the rotating mechanism, thereby improving the efficiency and quality of image acquisition and laying the foundation for subsequent defect feature extraction and identification.

[0053] At least one position adjustment component 200 is used to adjust the position of the image acquisition module to meet the detection conditions corresponding to the target detection task.

[0054] It is understood that, in the embodiments of this application, at least one position adjustment component 200 can control the relative spatial relationship between the insulator and the image acquisition module through mechanical displacement, so as to ensure that the surface of the insulator is always in the optimal imaging area during the detection process.

[0055] In actual implementation, the embodiments of this application can first control the linear array camera to move to the set position during each shooting segment, and then the rotating mechanism drives the basin insulator to rotate 360° to complete the full circle shooting. After this shooting segment is completed, the camera moves to the next shooting position to start the next shooting segment. This cycle is repeated, and the image acquisition of the entire basin insulator surface is completed through multiple processes.

[0056] The embodiments of this application can adjust the position of the image acquisition module to meet the detection conditions corresponding to the target detection task, thereby completing the full-surface blind-zone-free scanning of the basin insulator based on the coordinated operation of "workpiece rotation-camera movement", which improves versatility and detection success rate.

[0057] Optionally, in one embodiment of this application, at least one position adjustment member 200 includes: at least one vertical position adjustment member for adjusting the vertical height of the image acquisition module relative to the basin insulator to be tested; and at least one horizontal position adjustment member for adjusting the horizontal distance between the image acquisition module and the basin insulator to be tested.

[0058] It is understood that in the embodiments of this application, the vertical position adjustment component can control the vertical distance between the image acquisition module and the basin insulator to be tested, and the horizontal position adjustment component can control the horizontal distance between the image acquisition module and the basin insulator to be tested. The two work together to achieve accurate positioning of the basin insulator to be tested.

[0059] In practical implementation, the embodiments of this application can calculate the optimal detection distance by combining the geometric parameters of the insulator. For example, the vertical position adjustment component is driven to control the relative position of the image acquisition module and the basin insulator. Subsequently, the horizontal position adjustment component fine-tunes the position of the image acquisition module according to the center position of the insulator. After positioning is completed, the rotation and acquisition process is started to avoid missed defects in the edge area due to perspective distortion.

[0060] The embodiments of this application can adjust the vertical height and horizontal distance between the image acquisition module and the pot-type insulator to be inspected, thereby flexibly adapting to pot-type insulators of different specifications. This ensures that the image acquisition module can accurately focus and completely cover the inspection area, improving the versatility of the device and the quality of image acquisition, and laying a good foundation for subsequent defect identification.

[0061] Optionally, in one embodiment of this application, at least one vertical position adjustment component includes at least one first servo driver, at least one first servo motor, and a vertical module; at least one horizontal position adjustment component includes at least one second servo driver, at least one second servo motor, and a horizontal module.

[0062] It is understood that, in the embodiments of this application, the servo driver can be understood as a power electronic device that controls the operation of a servo motor, and can precisely control the speed, torque and position of the motor; the servo motor can be understood as a precision motor with encoder feedback, which can achieve high-precision positioning; the vertical module and the horizontal module can be understood as mechanical devices that convert rotational motion into linear motion, and are usually composed of components such as guide rails and lead screws.

[0063] In actual implementation, the horizontal and vertical modules in this embodiment can be two sets, used to drive two line array cameras to move on the guide rail, so as to adjust their relative position with the pot-type insulator to be tested, so as to obtain the best shooting effect.

[0064] For example, in the embodiments of this application, servo motors A and D and their servo drivers are used to drive the horizontal module to move, and servo motors B and E and their servo drivers are used to drive the vertical module to move, so as to control the relative position of the camera and the basin insulator, thereby ensuring that the camera can capture a 360° range of the surface of the basin insulator.

[0065] The embodiments of this application can use a vertical and horizontal adjustment component consisting of a servo driver, a servo motor, and a corresponding module to adjust the relative position between the image acquisition module and the basin insulator to be detected, thereby achieving high-precision and high-response-speed position control to obtain the best shooting effect.

[0066] Optionally, in one embodiment of this application, it further includes at least one rotating element for adjusting the relative position between the image acquisition module and the basin insulator to be tested.

[0067] It is understood that at least one rotating component in the embodiments of this application can be understood as a rotating mechanism, which can be a mechanism for driving the basin insulator to rotate around its axis, thereby achieving a full scan of the circumferential surface.

[0068] In actual implementation, the embodiments of this application can drive the pot-type insulator to be tested to rotate 360° through at least one rotating component, and complete the image acquisition of the insulator surface in conjunction with a high-definition line array camera. The rotating component is powered by a servo motor C to drive its rotation. At the same time, an air pump and a cylinder can be used to provide power to the camera rotation mechanism. By driving the camera to rotate in the vertical plane, the relative angle between the camera and the insulator surface is changed, ensuring that the camera lens is perpendicular to the surface to be photographed during each segment of shooting.

[0069] For example, in this embodiment of the application, a servo motor C can be used to drive a rotating mechanism to rotate, thereby rotating the basin-type insulator fixed thereon. When performing surface defect detection on a basin-type insulator, the basin-type insulator to be tested needs to be placed on the rotating mechanism and simply fixed. Upon receiving a start detection signal, the rotating mechanism begins to rotate the insulator to be tested, and the line scan camera begins to capture segmented images of the basin-type insulator surface.

[0070] The embodiments of this application can design a dedicated precision rotating platform to ensure that the image acquisition module can cover the insulator's 360° full circumference and all curved surface details, effectively eliminating the visual blind spots present in manual inspection or fixed shooting, and ensuring the integrity of the test data.

[0071] The logic control module 300 is used to drive at least one position adjustment component 200 to adjust its position, so as to generate a surface image of the pot insulator to be tested based on the image information acquired by the image acquisition module 100, and generate a surface defect identification result of the pot insulator to be tested based on the surface image.

[0072] It is understood that the logic control module 300 in this embodiment can be understood as the core of control and data processing. It can be used to send instructions to the position adjustment component and the image acquisition module, coordinate the entire detection process, and analyze the acquired surface images to identify and mark defects.

[0073] In actual implementation, this application embodiment can receive image information captured by a high-definition line scan camera, issue commands, store image information, and identify the acquired images. Specifically, this application embodiment can perform image processing techniques such as grayscale processing or noise reduction on the image information to generate a surface image of the pot-type insulator to be inspected. This application embodiment can issue control commands to drive at least one position adjustment component 200 to adjust its position, receive image information acquired by the image acquisition module 100, generate a surface image of the pot-type insulator to be inspected based on the image information, and generate a surface defect identification result of the pot-type insulator to be inspected based on the surface image.

[0074] Furthermore, the embodiments of this application can integrate an insulator defect detection system architecture that combines automatic image acquisition, real-time deep learning inference and recognition, and data archiving management. It also has the functions of automatically storing image data, generating detection results, and establishing a defect database. Compared with the current situation where manual inspection makes it difficult to retain objective evidence, the embodiments of this application can digitally archive the quality status of each product, providing detailed data support for subsequent quality traceability, process improvement, and fault analysis, and realizing digital management and traceability of the detection process.

[0075] The embodiments of this application can realize centralized control and intelligent analysis of the entire inspection process through a logic control module, thereby achieving digital management of inspection data and full-process automation, reducing the surface defect inspection time of a single pot insulator to less than 7 minutes, significantly improving inspection efficiency, and meeting the needs of mass production and rapid operation and maintenance.

[0076] Optionally, in one embodiment of this application, the logic control module 300 includes: an interaction module for determining the hardware parameters of the device; and a controller for controlling at least one position adjustment component to execute corresponding control commands.

[0077] It is understood that in the embodiments of this application, the interaction module can be a human-machine interface (touch screen) that can set and adjust hardware parameters; the controller can be a PLC (Programmable Logic Controller) controller, used to store motor motion control code and transmit instructions to the motor to control the motor motion.

[0078] In actual implementation, the embodiments of this application can use a human-machine interface to set and adjust hardware parameters, use a PLC controller to store motor motion control code, and send it to at least one position adjustment component 200 to drive it to perform displacement actions.

[0079] For example, in this embodiment of the application, after the material loading is completed, the hardware position initialization can be automatically completed through the operation interaction module, i.e., the human-machine interface, and the insulator information can be input on the computer to give a start detection signal. During the detection process, the interaction module can display the running status and preliminary results in real time. The controller automatically calculates the position adjustment amount, movement speed and camera trigger frequency according to the parameters, and generates corresponding control signals to send to at least one position adjustment component 200 and image acquisition module 100.

[0080] This application embodiment achieves human-machine interaction and automated operation of the device through the cooperation of the interactive module and the controller. Users can flexibly configure parameters according to different testing tasks, improving the ease of use and adaptability of the device. The controller ensures the accuracy and real-time performance of command execution, thereby optimizing the overall testing efficiency. Compared with the traditional manual visual inspection of a single 550kV basin insulator, which takes more than 30 minutes, this application embodiment can shorten the testing time of a single product to less than 7 minutes. This several-fold efficiency improvement effectively solves the problems of slow manual inspection speed and inability to meet the needs of large-scale batch production of insulators, and greatly improves the turnover efficiency of the production line.

[0081] The embodiments of this application can set and adjust hardware parameters, store motor motion control code, and transmit instructions to the motor to control its movement, thereby achieving automated and rapid detection, significantly improving detection efficiency, and meeting the needs of mass production and rapid operation and maintenance.

[0082] Optionally, in one embodiment of this application, the logic control module 300 is specifically used to input the surface image into a pre-built defect detection model, extract at least one defect feature, and output a surface defect identification result based on the at least one defect feature.

[0083] It is understood that the defect detection model pre-built in the embodiments of this application can be an improved YOLO deep learning object detection algorithm.

[0084] In actual implementation, this embodiment of the application can automatically detect defects in all the captured images after shooting, relying on a pre-trained defect detection model, and store the images with defect annotation boxes and defect information in the database. This embodiment of the application has the functions of automatically storing image data, generating detection results and establishing a defect database. Compared with the current situation where manual inspection is difficult to retain objective evidence, this embodiment of the application can digitally archive the quality status of each product, providing detailed data support for subsequent quality traceability, process improvement and fault analysis.

[0085] For example, embodiments of this application can utilize a high-resolution line scan camera with a specially optimized line light source, combined with an improved YOLO deep learning target detection algorithm, to keenly capture micron-level features that are difficult to detect with the naked eye, significantly improving the ability to identify minute defects with a diameter of less than 1 mm. Embodiments of this application can employ an image data enhancement method based on improved Mosaic and small target copy-paste technology to address the insufficient number of insulator defect samples, and integrate automatic image acquisition, real-time deep learning inference recognition, and data archiving management functions to construct an insulator defect detection system architecture.

[0086] This application embodiment can receive images captured by a high-definition line scan camera and combine them with a pre-built defect detection model to achieve keen capture and accurate classification of surface defect identification results, significantly reducing the missed detection rate and false judgment rate. This solves the problems of strong subjectivity and difficulty in unifying quality standards in manual inspection, reduces interference from human factors, and ensures that the inspection results of different batches and different inspection personnel are consistent and traceable.

[0087] Specifically, it can be combined with Figures 2 to 5 As shown, the working principle of the surface defect detection device for basin-type insulators in this application is explained in detail with a specific embodiment.

[0088] like Figure 2As shown, embodiments of this application may include an image acquisition module 100, at least one position adjustment component 200, and a logic control module 300. The image acquisition module 100 includes: an encoder 101, a differential expansion module 102, a light source 103, a line scan camera A104, and a line scan camera B105; the at least one position adjustment component 200 includes: a camera rotation mechanism 201, a cylinder 202, an air pump 203, a servo driver 204, a servo motor A205, a servo motor B206, a servo motor C207, a servo motor D208, a servo motor E209, a horizontal module 210, a vertical module 211, a rotation mechanism 212, and a basin-type insulator 213; the logic control module 300 includes: a computer 301, a switch 302, a PLC controller 303, and a human-machine interface 304. The structural design diagram is shown below. Figure 3 As shown.

[0089] The encoder 101 can be used to monitor the rotation of the basin insulator driven by the rotating mechanism and transmit the signal to the high-definition line scan camera, namely line scan camera A104 and line scan camera B105, to ensure that the camera can capture clear and undistorted images.

[0090] The differential expansion module 102 can be used to split the differential signal of the encoder into two paths and transmit them to two cameras respectively, so as to achieve the purpose of simultaneous shooting by two cameras.

[0091] The light source 103 can be placed next to the linear array camera under test to provide uniform brightness adjustable light, ensuring that the light illuminates the surface of the insulator and highlights surface defects.

[0092] Linear array cameras A104 and B105 can be used to acquire images of the upper and lower surfaces of the basin-type insulator 213 to be inspected.

[0093] The camera rotation mechanism 201 can be used to drive the line array camera to rotate within a certain range in the vertical plane to ensure that the camera lens is perpendicular to the surface of the basin insulator 213 in order to obtain clear images.

[0094] Cylinder 202 and air pump 203 can be used to provide power to the camera rotation mechanism 201, causing it to rotate.

[0095] Servo driver 204 can be used to drive servo motors.

[0096] Servo motors A205, B206, D208, and E209 can be used to drive the horizontal module 210 and the vertical module 211 to control the relative position of the camera and the basin insulator.

[0097] The servo motor C207 can be used to drive the rotating mechanism to rotate, thereby rotating the basin insulator fixed on it, so as to ensure that the camera can capture a 360° range of the surface of the basin insulator.

[0098] The horizontal module 210 and the vertical module 211 have built-in guide rails, which can be used to drive two line scan cameras to move in the horizontal and vertical directions to adjust their relative position with the pot-type insulator 213 to be tested in order to obtain the best shooting effect. There are two sets of horizontal and vertical modules.

[0099] like Figure 4 As shown, in this embodiment, the camera can be controlled to move and rotate freely in a vertical plane by two sets of horizontal and vertical guide rails and a cylinder, keeping the lens approximately perpendicular to the surface of the insulator, and shooting in three segments to achieve approximately parallel normal direction between the camera lens and the surface normal of the insulator, thus achieving the best shooting effect.

[0100] The rotating mechanism 212 can be used to drive the pot-type insulator under test to rotate 360°, and work with the line array camera A104 and the line array camera B105 to complete the image acquisition of the insulator surface. The basin insulator 213 is a basin insulator that needs to be tested for surface defects.

[0101] Computer 301 can be used to receive images captured by a high-definition line scan camera, issue commands, store image information, and recognize the acquired images.

[0102] Switch 302 can be used to connect computer 301, PLC controller 303, line scan camera A104 and line scan camera B105, and the connection method can be Ethernet connection.

[0103] The PLC controller 303 can be used to store motor motion control codes and transmit instructions to the motor to control its movement.

[0104] The human-machine interface 304 can be used to set and adjust hardware parameters.

[0105] For example, since the size of the pot-type insulator 213 to be inspected may be large and its outer surface is irregular, the line array cameras A104 and B105 need to take pictures in multiple segments. During each segment, the camera lens must be perpendicular to the surface to be photographed. During each segment, the line array cameras A104 and B105 are first moved to the set position. Then, the rotating mechanism 212 drives the pot-type insulator to rotate 360° to complete a full circle of shooting. After this segment of shooting is completed, the camera moves to the next shooting position to start the next segment of shooting. This cycle is repeated, and the image acquisition of the entire surface of the pot-type insulator is completed through multiple segments.

[0106] Specifically, in this embodiment, when performing surface defect detection on a pot-type insulator 213, the pot-type insulator 213 to be tested needs to be placed on the rotating mechanism 212 and simply fixed. After loading, the human-machine interface 304 automatically completes hardware position initialization. The insulator information is input on the computer 301, and a start detection signal is given. The rotating mechanism 212 starts to drive the pot-type insulator 213 to be tested to rotate, and the line array cameras A104 and B105 start to take segmented pictures of the surface of the pot-type insulator 213. After the pictures are taken, the computer 301 automatically performs defect detection on all the pictures based on a pre-trained defect detection model, and stores the pictures with defect marking boxes and defect information in the database. Then the pot-type insulator unloading process can be completed. Repeating the above process can complete the defect detection of multiple pot-type insulators. The defect detection time for one pot-type insulator does not exceed 7 minutes. Examples of pot-type insulator images and recognition results captured by the device are shown below. Figure 5 As shown.

[0107] The surface defect detection device for basin-type insulators proposed in this application can acquire complete image information of the upper and lower surfaces of the basin-type insulator to be inspected through an image acquisition module. The position of the image acquisition module is adjusted by a position adjustment component to adapt to the inspection requirements. Then, the logic control module links various components to complete the position adjustment and defect result generation, thereby achieving automated detection of surface defects in basin-type insulators. This ensures the insulation performance and operational safety of GIS equipment, and overcomes the bottlenecks in efficiency and accuracy of manual inspection, achieving efficient, accurate, and intelligent detection of surface defects in basin-type insulators. This solves the problems in related technologies, such as low efficiency and strong subjectivity of manual visual inspection leading to difficulties in unifying quality standards and failing to meet the needs of large-scale production, difficulty in detecting minute defects, and high risks of missed detection and misjudgment. It also addresses the shortcomings in efficiency, coverage, and automation caused by the high cost, slow speed, or complex operation of instrument-based inspection.

[0108] Next, with reference to the accompanying drawings, a method for detecting surface defects in a basin-type insulator according to an embodiment of this application is described.

[0109] Figure 6 This is a schematic flowchart illustrating a surface defect detection method for a basin-type insulator provided in an embodiment of this application.

[0110] like Figure 6 As shown, the surface defect detection method for this basin-type insulator includes the following steps: In step S601, image information of the upper and lower surfaces of the basin insulator to be tested is acquired.

[0111] In step S602, the position of the image acquisition module is adjusted to meet the detection conditions corresponding to the target detection task.

[0112] In step S603, at least one position adjustment component is driven to adjust its position so as to generate a surface image of the pot insulator to be tested based on the image information acquired by the image acquisition module, and to generate a surface defect identification result of the pot insulator to be tested based on the surface image.

[0113] Optionally, in one embodiment of this application, adjusting the position of the image acquisition module to meet the detection conditions corresponding to the target detection task includes: adjusting the vertical height of the image acquisition module relative to the basin-type insulator to be detected; and adjusting the horizontal distance of the image acquisition module relative to the basin-type insulator to be detected.

[0114] Optionally, in one embodiment of this application, adjusting the position of the image acquisition module to meet the detection conditions corresponding to the target detection task further includes: adjusting the relative position between the image acquisition module and the basin insulator to be detected.

[0115] Optionally, in one embodiment of this application, acquiring image information of the upper and lower surfaces of the basin insulator to be tested includes: controlling at least one light source and at least one linear scan camera to operate according to the rotation state of the basin insulator to be tested.

[0116] Optionally, in one embodiment of this application, driving at least one position adjustment component to adjust its position to generate a surface image of the pot-type insulator to be tested based on image information acquired by the image acquisition module, and generating a surface defect identification result of the pot-type insulator to be tested based on the surface image, includes: determining the hardware parameters of the device; and controlling at least one position adjustment component to execute corresponding control commands.

[0117] Optionally, in one embodiment of this application, driving at least one position adjustment member to adjust the position to generate a surface image of the pot insulator to be tested based on the image information acquired by the image acquisition module, and generating a surface defect identification result of the pot insulator to be tested based on the surface image, includes: inputting the surface image into a pre-built defect detection model, extracting at least one defect feature, and outputting a surface defect identification result based on at least one defect feature.

[0118] It should be noted that the foregoing explanation of the surface defect detection device embodiment for basin-type insulators also applies to the surface defect detection method for basin-type insulators in this embodiment, and will not be repeated here.

[0119] The surface defect detection method for basin-type insulators proposed in this application can acquire complete image information of the upper and lower surfaces of the basin-type insulator to be inspected through an image acquisition module. The position of the image acquisition module is adjusted by a position adjustment component to adapt to the inspection requirements. Then, a logic control module links various components to complete the position adjustment and defect result generation, thereby achieving automated detection of surface defects in basin-type insulators. This ensures the insulation performance and operational safety of GIS equipment, and overcomes the bottlenecks in efficiency and accuracy of manual inspection, achieving efficient, accurate, and intelligent detection of surface defects in basin-type insulators. This solves the problems in related technologies, such as low efficiency and strong subjectivity of manual visual inspection leading to difficulties in unifying quality standards and failing to meet the needs of large-scale production, difficulty in detecting minute defects, and high risks of missed detection and misjudgment. It also addresses the shortcomings in efficiency, coverage, and automation caused by the high cost, slow speed, or complex operation of instrument-based inspection.

[0120] Figure 7 A schematic diagram of the structure of an electronic device provided in an embodiment of this application. The electronic device may include: The memory 701, the processor 702, and the computer program stored on the memory 701 and capable of running on the processor 702.

[0121] When the processor 702 executes the program, it implements the surface defect detection method for basin insulators provided in the above embodiments.

[0122] Furthermore, electronic devices also include: Communication interface 703 is used for communication between memory 701 and processor 702.

[0123] The memory 701 is used to store computer programs that can run on the processor 702.

[0124] The memory 701 may include high-speed RAM memory, and may also include non-volatile memory, such as at least one disk storage device.

[0125] If the memory 701, processor 702, and communication interface 703 are implemented independently, then the communication interface 703, memory 701, and processor 702 can be interconnected via a bus to complete communication between them. The bus can be an Industry Standard Architecture (ISA) bus, a Peripheral Component Interconnect (PCI) bus, or an Extended Industry Standard Architecture (EISA) bus, etc. Buses can be categorized into address buses, data buses, control buses, etc. For ease of representation, Figure 7 The bus is represented by a single thick line, but this does not mean that there is only one bus or one type of bus.

[0126] Optionally, in a specific implementation, if the memory 701, processor 702, and communication interface 703 are integrated on a single chip, then the memory 701, processor 702, and communication interface 703 can communicate with each other through an internal interface.

[0127] The processor 702 may be a central processing unit (CPU), an application specific integrated circuit (ASIC), or one or more integrated circuits configured to implement the embodiments of this application.

[0128] This application also provides a non-volatile computer-readable storage medium storing a computer program that, when executed by a processor, implements the above-described method for detecting surface defects in basin-type insulators.

[0129] This application also provides a computer program product storing a computer program that, when executed by a processor, implements the above-described method for detecting surface defects in basin-type insulators.

[0130] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0131] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "N" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0132] Any process or method described in the flowchart or otherwise herein can be understood as representing a module, segment, or portion of code comprising one or N executable instructions for implementing custom logic functions or processes, and the scope of the preferred embodiments of this application includes additional implementations in which functions may be performed not in the order shown or discussed, including substantially simultaneously or in reverse order depending on the functions involved, as should be understood by those skilled in the art to which embodiments of this application pertain.

[0133] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device. More specific examples (a non-exhaustive list) of computer-readable media include: an electrical connection having one or more wires (electronic device), a portable computer disk drive (magnetic device), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Alternatively, the computer-readable medium may be paper or other suitable media on which the program can be printed, since the program can be obtained electronically by optically scanning the paper or other medium, followed by editing, interpreting, or otherwise processing as necessary, and then stored in a computer memory.

[0134] It should be understood that the various parts of this application can be implemented using hardware, software, firmware, or a combination thereof. In the above embodiments, the N steps or methods can be implemented using software or firmware stored in memory and executed by a suitable instruction execution system. If implemented in hardware, as in another embodiment, it can be implemented using any one or more of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0135] Those skilled in the art will understand that all or part of the steps of the methods in the above embodiments can be implemented by a program instructing related hardware. The program can be stored in a computer-readable storage medium, and when executed, the program includes one or a combination of the steps of the method embodiments.

[0136] Furthermore, the functional units in the various embodiments of this application can be integrated into a processing module, or each unit can exist physically separately, or two or more units can be integrated into a module. The integrated module can be implemented in hardware or as a software functional module. If the integrated module is implemented as a software functional module and sold or used as an independent product, it can also be stored in a computer-readable storage medium.

[0137] The storage medium mentioned above can be a read-only memory, a disk, or an optical disk, etc. Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions, and variations to the above embodiments within the scope of this application.

Claims

1. A surface defect detection device for a basin-type insulator, characterized in that, include: The image acquisition module is used to acquire image information of the upper and lower surfaces of the basin insulator to be inspected; At least one position adjustment component is provided for adjusting the position of the image acquisition module to meet the detection conditions corresponding to the target detection task. A logic control module is used to drive the at least one position adjustment component to adjust the position, so as to generate a surface image of the pot insulator to be tested based on the image information acquired by the image acquisition module, and generate a surface defect identification result of the pot insulator to be tested based on the surface image.

2. The apparatus according to claim 1, characterized in that, The at least one position adjustment component includes: At least one vertical position adjustment component is provided for adjusting the vertical height of the image acquisition module relative to the pot-type insulator to be detected; At least one horizontal position adjustment component is provided for adjusting the horizontal distance between the image acquisition module and the basin insulator to be detected.

3. The apparatus according to claim 2, characterized in that, in, The at least one vertical position adjustment component includes at least one first servo driver, at least one first servo motor, and a vertical module; The at least one horizontal position adjustment component includes at least one second servo driver, at least one second servo motor, and a horizontal module.

4. The apparatus according to claim 2, characterized in that, Also includes: At least one rotating component is provided for adjusting the relative position between the image acquisition module and the pot-type insulator to be tested.

5. The apparatus according to claim 1, characterized in that, The image acquisition module includes: At least one light source and at least one line scan camera; An encoder is used to control the operation of at least one light source and at least one linear scan camera based on the rotational state of the pot insulator to be detected.

6. The apparatus according to claim 1, characterized in that, The logic control module includes: An interaction module is used to determine the hardware parameters of the device; A controller is used to control the at least one position adjustment component to execute corresponding control commands.

7. The apparatus according to claim 1, characterized in that, The logic control module is specifically used to input the surface image into a pre-built defect detection model, extract at least one defect feature, and output the surface defect identification result based on the at least one defect feature.

8. A method for detecting surface defects in a basin-type insulator, characterized in that, The surface defect detection device for basin-type insulators as described in any one of claims 1-7 is used, wherein the method includes the following steps: Acquire image information of the upper and lower surfaces of the basin-type insulator to be tested; Adjust the position of the basin insulator to be tested to meet the testing conditions corresponding to the target testing task; The position of at least one position adjustment component is adjusted to generate a surface image of the pot insulator to be tested based on the image information acquired by the image acquisition module, and a surface defect identification result of the pot insulator to be tested is generated based on the surface image.

9. An electronic device, characterized in that, include: The memory, the processor, and the computer program stored in the memory and capable of running on the processor, the processor executing the program to implement the surface defect detection method for basin insulators as described in claim 8.

10. A non-volatile computer-readable storage medium having a computer program stored thereon, characterized in that, The program is executed by the processor to implement the surface defect detection method for basin insulators as described in claim 8.

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