A tension machine integrated wire broken strand and wear online detection device and method

Abstract

The application discloses a tension machine integrated wire broken strand and wear online detection device and method, and belongs to the technical field of transmission line stringing construction detection. The method comprises the following steps: comparing the full-week outer contour data and the surface image data with the pre-stored standard wire contour data respectively to obtain corresponding contour deviation comparison results and surface image comparison results; identifying whether the wire has defect characteristics according to the contour deviation comparison results and the surface image comparison results; if not, maintaining the online detection state; if yes, determining the defect level and the defect position corresponding to the defect characteristics, and generating an alarm signal and a shutdown control signal according to the defect level; triggering an audible-light alarm according to the alarm signal, and controlling the tension machine to shut down according to the shutdown control signal, while recording the defect position and the pay-off length data corresponding to the defect position; storing the defect position, the pay-off length data and the defect determination result, and synchronously sending the defect determination result to a background monitoring terminal.

Description

Technical Field

[0001] This application relates to the field of transmission line construction and inspection technology, and more specifically, to a tension machine integrated online detection device and method for conductor strand wear. Background Technology

[0002] During the construction of power transmission lines, conductor laying operations are generally carried out by using a tensioning machine to continuously pull the conductor through a laying pulley. Due to the complex conditions of laying conductors in mountainous areas and at high altitudes, conductors are prone to defects such as broken strands, outer layer wear, and surface scratches during the laying process due to friction, collision, and abrasion. If these defects are not detected and addressed in a timely manner, they will seriously affect the operational safety and service life of the power transmission line, and may even lead to line accidents.

[0003] Existing methods for detecting defects in conductors generally suffer from the following problems: Firstly, manual inspections have a high rate of missed detections. During the laying process, the conductors move continuously at high speeds, and relying on manual visual observation of the conductor surface from a distance makes it difficult to identify minor broken strands and slight outer layer wear in a timely manner. A large number of defective conductors flow into subsequent laying processes, resulting in a large amount of rework and rectification work during the line acceptance stage.

[0004] Secondly, the adaptability of independent testing equipment is poor. Most existing laser flaw detection equipment for conductors has a separate frame structure, which cannot be integrated with the tensioning machine. It is necessary to set up a separate support frame on the outside of the tensioning machine for fixation. The transportation and disassembly of the equipment in mountainous construction sites are time-consuming, and there is a risk of falling when setting up the support frame at height.

[0005] Third, there is a lack of real-time online early warning mechanisms. Existing flaw detection equipment usually only has the function of storing detection data and does not have the ability to provide immediate on-site alarms. Defects can only be discovered after data is exported and analyzed. If the defective conductor is subjected to continuous stress and tension, it will further aggravate the strand breakage damage, directly causing the entire coil of conductor to be scrapped, and the cost of consumables will increase significantly.

[0006] Fourth, the detection coverage is incomplete. Most existing flaw detection equipment uses single-sided, single-point laser ranging, which can only collect local outer diameter data of the conductor in a single direction. Wear and broken strands on the upper, lower, and back sides of the conductor are easily missed, and the detection accuracy cannot meet the construction quality acceptance standards for high-voltage transmission lines.

[0007] Fifth, it lacks an equipment linkage shutdown function. After a defect is discovered manually, the tensioner must be shut down manually, which results in a delay in operation. The continued tension on the defective conductor can easily lead to major safety accidents such as conductor breakage and falling objects from heights.

[0008] Therefore, there is an urgent need for an online detection device and method for conductor strand breakage and wear that can be integrated with a tensioning machine, realize online detection of the entire circumference of the conductor without blind spots, and provide real-time on-site audible and visual alarms and automatic shutdown of the tensioning machine, in order to solve the above-mentioned problems existing in the prior art. Summary of the Invention

[0009] To overcome a series of shortcomings in the existing technology, the purpose of this application is to provide an online detection method for strand breakage and wear of conductors using an integrated tensioning machine, comprising the following steps: Acquire the full circumference outer contour data and surface image data of the wire that passes through the detection area at a constant speed; The full-circumference outer contour data and surface image data are compared with the pre-stored standard guide contour data to obtain the corresponding contour deviation comparison results and surface image comparison results. Based on the contour deviation comparison results and surface image comparison results, identify whether the conductor has defects such as broken strands, outer layer wear or surface scratches. If not, maintain the online detection status and continue to acquire the full circumference outer contour data and surface image data of the next section of the conductor; If so, determine the defect level and defect location corresponding to the defect characteristics, and generate alarm signals and shutdown control signals according to the defect level; The alarm signal triggers an audible and visual alarm, and the tension machine is stopped according to the stop control signal. At the same time, the location of the defect and the corresponding wire length data are recorded. Store the defect location, laying length data, and defect judgment results, and simultaneously send the defect judgment results to the background monitoring terminal.

[0010] In some embodiments, the method for obtaining full-circumference outer contour data and surface image data is as follows: The constraint wire continuously passes through the detection area along a preset center path; A circumferential multi-directional linear laser scan is performed on the conductors that continuously pass through the detection area to obtain the reflected light signal or the blocked light signal corresponding to each detection position on the outer periphery of the conductor. The reflected light signals or blocked light signals corresponding to each detection position are fused to reconstruct the full circumference outer contour data of the conductor. Based on the lighting conditions of the detection area, determine whether to use visual imaging or infrared scanning to obtain surface image data of the conductor. When using visual imaging, synchronous supplemental lighting is applied to the detection area. Based on the determined surface data acquisition method, the outer peripheral surface of the conductor is synchronously acquired to obtain surface image data of the conductor.

[0011] In some embodiments, the method for obtaining standard full-circumference outer contour data is as follows: Obtain qualified conductor samples; A circumferential multi-directional linear laser scan is performed on the conductor sample to obtain the reflected light signal or the occlusion light signal corresponding to each detection position on the outer periphery of the conductor sample. The reflected light signal or the blocked light signal is fused to obtain the full circumference outer contour data of the conductor sample; The full circumference outer contour data of the conductor sample is pre-stored as standard full circumference outer contour data.

[0012] In some embodiments, the method for identifying defect features is as follows: Based on the contour deviation comparison results, the degree of deviation of the conductor's external dimensions and peripheral morphology from the standard full-circumference external contour data is determined. The degree of deviation is compared with a preset profile deviation threshold, and when the degree of deviation exceeds the profile deviation threshold, it is determined that the transmission conductor has broken strands or outer layer wear morphology defects. Based on the surface image comparison results, determine the degree of texture or color difference of the transmission conductor surface relative to the standard surface image data; The degree of texture difference or color difference is compared with a preset surface difference threshold. When the degree of texture difference or color difference exceeds the surface difference threshold, it is determined that the transmission line has surface scratches and surface defects. When determining the presence of morphological or surface defects, the corresponding contour deviation comparison results or surface image comparison results are associated with the records to obtain the defect characteristics.

[0013] In some embodiments, the method for determining the defect level corresponding to a defect feature is as follows: The deviation of the shape of the defect feature is determined based on the contour deviation comparison results, and the range of the surface defect area of ​​the defect feature is determined based on the surface image comparison results. The deviation in shape and the range of the surface defect area are compared with the corresponding defect level thresholds, respectively. When both the deviation in shape and the extent of surface defects are below the corresponding higher-level threshold, the defect feature is determined to be of a lower defect level; when at least one of the deviation in shape or the extent of surface defects reaches the corresponding higher-level threshold, the defect feature is determined to be of a higher defect level. By associating the defect level with the defect location corresponding to the defect feature, the defect level determination result is obtained.

[0014] In some embodiments, the method for triggering an audible and visual alarm based on an alarm signal is as follows: Obtain the defect level corresponding to the alarm signal; Match the defect level with the preset alarm level to determine the corresponding alarm method; When the defect level is low, a yellow light alarm signal is output to drive a yellow strobe light for light alarm. When the defect level is high, a red light alarm signal and an audible alarm signal are output to drive the red strobe light and buzzer respectively to provide audible and visual alarms. Acquire the alarm trigger status of the yellow strobe light, red strobe light, and buzzer, and generate alarm trigger confirmation information based on the alarm trigger status.

[0015] In some embodiments, the method for controlling the tension machine to stop according to the stop control signal is as follows: The shutdown control signal is output to the main control circuit of the tension machine to stop the tension machine from running. The audible and visual alarms should remain active while the tensioner is not in operation. Obtain the handling confirmation information corresponding to the defect feature, and allow the receiving of a reset signal when the handling confirmation information indicates that the defect feature has been eliminated; In response to the reset signal, the stop control signal is released and the audible and visual alarm status is deactivated; After the shutdown control signal is released, the tensioner is restarted and the wire laying operation is resumed, and the online monitoring of the transmission conductor is restored.

[0016] An integrated online detection device for conductor strand breakage and wear using a tensioning machine, for implementing the aforementioned detection method, includes an integrated mounting base for the tensioning machine, a conductor limiting guide frame, a ring-shaped linear array laser scanning detection assembly, and a defect identification and control unit, wherein: The tension machine integrated mounting base is provided with a flange locking slot on the rear side. The flange locking slot is used to engage and fix with the tension machine outlet frame so as to integrate and install the online detection device on the tension machine. The conductor limiting guide frame is symmetrically arranged at both ends of the tension machine integrated mounting base to limit and guide the conductor, so that the conductor passes along the central axis of the detection area; The annular linear array laser scanning detection assembly is fixed in the middle of the tension machine integrated mounting base. It includes an annular hollow detection ring, and multiple sets of linear array laser emitters and receiving sensors corresponding to the linear array laser emitters are evenly arranged along the inner circumference of the annular hollow detection ring. Each set of linear array laser emitters emits a linear laser beam along the radial direction of the conductor to cover the outer circumferential surface of the conductor, and each receiving sensor is used to collect the outer contour data of the entire circumference of the conductor. The defect identification and control unit is fixed in a sealed protective box on the side of the tension machine integrated mounting base. It is used to receive the full circumference outer contour data, compare the full circumference outer contour data with the pre-stored standard conductor contour data, determine whether the conductor has broken strands, outer layer wear or surface scratches based on the comparison results, and output the corresponding alarm trigger signal and shutdown control signal when a defect is determined to exist.

[0017] In some embodiments, an audible and visual alarm execution module is further included. The audible and visual alarm execution module is electrically connected to the defect identification control unit and is used to receive an alarm trigger signal and execute an audible and visual alarm. The defect identification control unit is also electrically connected to the tension machine main control circuit and is used to output a shutdown control signal to the tension machine main control circuit to control the tension machine to stop.

[0018] In some embodiments, the defect identification control unit includes a data acquisition module, a contour comparison calculation chip, and a signal output terminal, wherein: the data acquisition module is used to receive and store the full circumference outer contour data of the conductor; the contour comparison calculation chip is used to perform a comparison calculation between the full circumference outer contour data of the conductor and a standard conductor contour database, and generate a defect judgment result based on the comparison result; the signal output terminal is used to generate and output corresponding alarm trigger signals and shutdown control signals based on the defect judgment results, wherein the alarm trigger signal is output to the audible and visual alarm execution module, and the shutdown control signal is output to the tension machine main control circuit.

[0019] Compared with the prior art, this application has the following beneficial effects: This application integrates a full-circumference laser scanning detection device into a tension machine, enabling real-time online detection and automatic linkage handling of defects such as broken strands and wear in the conductor during the laying process. This avoids missed detections and the continued laying of defective conductors, thereby improving construction safety and detection efficiency. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall isometric structure of the device of the present invention; Figure 2 This is a frontal cross-sectional view of the device of the present invention; Figure 3 This is a schematic diagram of the installation and assembly of the output terminal of the device of the present invention.

[0021] The diagram shows the following labels: 1-Tension machine integrated mounting base; 2-Wire limiting guide frame; 3-Annular linear array laser scanning detection assembly; 4-Defect identification and control unit; 5-Audio-visual alarm execution module. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of the embodiments of this invention will be described in more detail below with reference to the accompanying drawings. In the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The described embodiments are some embodiments of this invention, but not all embodiments.

[0023] Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] The embodiments and directional terms described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0025] In a broad embodiment of the present invention, a tension machine integrated online detection device for conductor strand breakage and wear includes a tension machine integrated mounting base, a conductor limiting guide frame, a ring linear array laser scanning detection assembly, and a defect identification and control unit. The tension machine integrated mounting base is provided with a flange locking slot on the rear side. The flange locking slot is used to engage and fix with the tension machine outlet frame so as to integrate and install the online detection device on the tension machine. The conductor limiting guide frame is symmetrically arranged at both ends of the tension machine integrated mounting base to limit and guide the conductor, so that the conductor passes along the central axis of the detection area; The annular linear array laser scanning detection assembly is fixed in the middle of the tension machine integrated mounting base. It includes an annular hollow detection ring, and multiple sets of linear array laser emitters and receiving sensors corresponding to the linear array laser emitters are evenly arranged along the inner circumference of the annular hollow detection ring. Each set of linear array laser emitters emits a linear laser beam along the radial direction of the conductor to cover the outer circumferential surface of the conductor, and each receiving sensor is used to collect the outer contour data of the entire circumference of the conductor. The defect identification and control unit is fixed in a sealed protective box on the side of the tension machine integrated mounting base. It is used to receive the full circumference outer contour data, compare the full circumference outer contour data with the pre-stored standard conductor contour data, determine whether the conductor has broken strands, outer layer wear or surface scratches based on the comparison results, and output the corresponding alarm trigger signal and shutdown control signal when a defect is determined to exist.

[0026] In some embodiments, an audible and visual alarm execution module is further included. The audible and visual alarm execution module is electrically connected to the defect identification control unit and is used to receive an alarm trigger signal and execute an audible and visual alarm. The defect identification control unit is also electrically connected to the tension machine main control circuit and is used to output a shutdown control signal to the tension machine main control circuit to control the tension machine to stop.

[0027] In some embodiments, linear laser emitters and receiving sensors are evenly distributed at equal intervals around the detection ring, and the laser beam coverage of two adjacent sets of linear laser emitters are connected to each other to achieve a full-coverage scan of the outer surface of the conductor without blind spots.

[0028] In some embodiments, the wire limiting guide frame has a built-in wear-resistant nylon guide wheel, which constrains the wire to pass horizontally through the detection area in a centered manner.

[0029] In some embodiments, the defect identification control unit includes a data acquisition module, a contour comparison calculation chip, and a signal output terminal, wherein: the data acquisition module is used to receive and store the full circumference outer contour data of the conductor; the contour comparison calculation chip is used to perform a comparison calculation between the full circumference outer contour data of the conductor and a standard conductor contour database, and generate a defect judgment result based on the comparison result; the signal output terminal is used to generate and output corresponding alarm trigger signals and shutdown control signals based on the defect judgment results, wherein the alarm trigger signal is output to the audible and visual alarm execution module, and the shutdown control signal is output to the tension machine main control circuit.

[0030] In some embodiments, the audible and visual alarm execution module includes a high-decibel buzzer and a red and yellow dual-color strobe LED light. The high-decibel buzzer and the red and yellow dual-color strobe LED light synchronously activate the audible and visual alarm prompt after receiving an alarm trigger signal.

[0031] In some embodiments, the tension machine integrated mounting base adopts an integral frame formed by bending and welding steel plates. The bottom of the tension machine integrated mounting base is provided with a wiring groove for storing power supply cables and signal transmission cables.

[0032] The purpose of this application is also to provide an integrated online detection method for wire strand breakage and wear using a tensioning machine, applied to the aforementioned detection device, comprising the following steps: Acquire the full circumference outer contour data and surface image data of the wire that passes through the detection area at a constant speed; The full-circumference outer contour data and surface image data are compared with the pre-stored standard guide contour data to obtain the corresponding contour deviation comparison results and surface image comparison results. Based on the contour deviation comparison results and surface image comparison results, identify whether the conductor has defects such as broken strands, outer layer wear or surface scratches. If not, maintain the online detection status and continue to acquire the full circumference outer contour data and surface image data of the next section of the conductor; If so, determine the defect level and defect location corresponding to the defect characteristics, and generate alarm signals and shutdown control signals according to the defect level; The alarm signal triggers an audible and visual alarm, and the tension machine is stopped according to the stop control signal. At the same time, the location of the defect and the corresponding wire length data are recorded. Store the defect location, laying length data, and defect judgment results, and simultaneously send the defect judgment results to the background monitoring terminal.

[0033] In some embodiments, the method for obtaining full-circumference outer contour data and surface image data is as follows: The constraint wire continuously passes through the detection area along a preset center path; A circumferential multi-directional linear laser scan is performed on the conductors that continuously pass through the detection area to obtain the reflected light signal or the blocked light signal corresponding to each detection position on the outer periphery of the conductor. The reflected light signals or blocked light signals corresponding to each detection position are fused to reconstruct the full circumference outer contour data of the conductor. Based on the lighting conditions of the detection area, determine whether to use visual imaging or infrared scanning to obtain surface image data of the conductor. When using visual imaging, synchronous supplemental lighting is applied to the detection area. Based on the determined surface data acquisition method, the outer peripheral surface of the conductor is synchronously acquired to obtain surface image data of the conductor.

[0034] In some embodiments, the method for obtaining standard full-circumference outer contour data is as follows: Obtain qualified conductor samples; A circumferential multi-directional linear laser scan is performed on the conductor sample to obtain the reflected light signal or the occlusion light signal corresponding to each detection position on the outer periphery of the conductor sample. The reflected light signal or the blocked light signal is fused to obtain the full circumference outer contour data of the conductor sample; The full circumference outer contour data of the conductor sample is pre-stored as standard full circumference outer contour data.

[0035] In some embodiments, the method for identifying defect features is as follows: Based on the contour deviation comparison results, the degree of deviation of the conductor's external dimensions and peripheral morphology from the standard full-circumference external contour data is determined. The degree of deviation is compared with a preset profile deviation threshold, and when the degree of deviation exceeds the profile deviation threshold, it is determined that the transmission conductor has broken strands or outer layer wear morphology defects. Based on the surface image comparison results, determine the degree of texture or color difference of the transmission conductor surface relative to the standard surface image data; The degree of texture difference or color difference is compared with a preset surface difference threshold. When the degree of texture difference or color difference exceeds the surface difference threshold, it is determined that the transmission line has surface scratches and surface defects. When it is determined that the morphological defect or the surface defect exists, the corresponding contour deviation comparison result or surface image comparison result is associated and recorded to obtain the defect feature.

[0036] In some embodiments, the method for determining the defect level corresponding to a defect feature is as follows: The deviation of the shape of the defect feature is determined based on the contour deviation comparison results, and the range of the surface defect area of ​​the defect feature is determined based on the surface image comparison results. The deviation in shape and the range of the surface defect area are compared with the corresponding defect level thresholds, respectively. When both the deviation in shape and the extent of surface defects are below the corresponding higher-level threshold, the defect feature is determined to be of a lower defect level; when at least one of the deviation in shape or the extent of surface defects reaches the corresponding higher-level threshold, the defect feature is determined to be of a higher defect level. By associating the defect level with the defect location corresponding to the defect feature, the defect level determination result is obtained.

[0037] In some embodiments, the method for triggering an audible and visual alarm based on an alarm signal is as follows: Obtain the defect level corresponding to the alarm signal; Match the defect level with the preset alarm level to determine the corresponding alarm method; When the defect level is low, a yellow light alarm signal is output to drive a yellow strobe light for light alarm. When the defect level is high, a red light alarm signal and an audible alarm signal are output to drive the red strobe light and buzzer respectively to provide audible and visual alarms. Acquire the alarm trigger status of the yellow strobe light, red strobe light, and buzzer, and generate alarm trigger confirmation information based on the alarm trigger status.

[0038] In some embodiments, the method for controlling the tension machine to stop according to the stop control signal is as follows: The shutdown control signal is output to the main control circuit of the tension machine to stop the tension machine from running. The audible and visual alarms should remain active while the tensioner is not in operation. Obtain the handling confirmation information corresponding to the defect feature, and allow the receiving of a reset signal when the handling confirmation information indicates that the defect feature has been eliminated; In response to the reset signal, the stop control signal is released and the audible and visual alarm status is deactivated; After the shutdown control signal is released, the tensioner is restarted and the wire laying operation is resumed, and the online monitoring of the transmission conductor is restored.

[0039] In some embodiments, the method for storing defect location, line length data, and defect determination results is as follows: When a defect feature is identified, the corresponding defect location and the length of the laid-out line are determined. Obtain the defect level, contour deviation comparison results, and surface image comparison results corresponding to the defect features; The defect location, line length data, defect level, contour deviation comparison results and surface image comparison results are correlated to generate corresponding defect detection records; Defect detection records are stored on local storage media.

[0040] The preferred embodiments of the present invention are described below with reference to the accompanying drawings, and the present invention will be further described in detail.

[0041] like Figure 1 As shown, this embodiment provides an online detection device for broken strand wear of a tension machine integrated with a tension machine, including a tension machine integrated mounting base 1, a wire limiting guide frame 2, a ring linear array laser scanning detection assembly 3, a defect identification control unit 4, and an audible and visual alarm execution module 5.

[0042] The tension machine integrated mounting base 1 is a one-piece frame formed by bending and welding steel plates, possessing sufficient structural strength to support all components of the device. For example... Figure 3 As shown, the tension machine integrated mounting base 1 has a flange locking slot on its rear side, which can be bolted to the tension machine's output end frame for secure mounting. This integrates the entire online detection device onto the tension machine's output end, eliminating the need for a separate external support frame. The bottom of the tension machine integrated mounting base 1 also has a pre-drilled wiring channel for storing the device's power supply cables and signal transmission cables, preventing exposed cables from being worn or tangled.

[0043] The conductor limiting guide frame 2 is symmetrically arranged at the front and rear ends of the tensioner integrated mounting base 1, such as... Figure 1 and Figure 3 As shown. The conductor limiting guide frame 2 has a built-in wear-resistant nylon guide wheel. After the conductor passes through the outlet of the tensioner, it is first constrained and centered by the front conductor limiting guide frame 2, and then horizontally passes through the detection area of ​​the annular linear laser scanning detection assembly 3. Then, it is guided and sent out to the wire feeding trolley by the rear conductor limiting guide frame 2, thereby ensuring that the conductor passes stably along the central axis of the detection area and avoiding missed detection by laser scanning due to conductor deviation.

[0044] The annular linear laser scanning detection assembly 3 is fixed in the middle of the tension machine integrated mounting base 1, such as... Figure 2 As shown, the system includes a hollow annular detection ring, and multiple sets of linear laser emitters and corresponding receiving sensors evenly distributed along the circumference of the inner ring. The linear laser emitters and receiving sensors are evenly spaced around the circumference of the detection ring, and the laser coverage areas of adjacent detection channels are interconnected, thus forming a complete, blind-spot-free scan of the outer surface of the conductor. Depending on the placement of the receiving sensors, this embodiment can use one of the following two detection channels to acquire full-circumference contour data: One type is the reflective detection channel: a linear laser emitter and its corresponding receiving sensor are arranged at the same angular position along the circumference of the detection ring. The linear laser emitter emits a linear laser beam radially towards the center of the detection area, covering a local surface on the outer periphery of the conductor. After the laser beam is reflected or scattered by the surface of the conductor, the receiving sensor at that angular position receives the reflected light signal according to the principle of laser triangulation, and calculates the local outer contour data of the conductor at that angular position. The local outer contour data obtained by multiple sets of reflective detection channels evenly arranged along the circumference of the detection ring are spliced ​​and fused together to obtain the full circumference outer contour data of the conductor.

[0045] The second type is the obstruction-type detection channel: the linear laser emitter and the receiving sensor on the opposite side of the detection ring are arranged radially along the conductor. The linear laser beam emitted by the linear laser emitter is obstructed by the conductor in the path of the receiving sensor on the opposite side. The receiving sensor collects the corresponding obstruction light signal, and calculates the contour boundary data of the conductor in that direction based on the width and position of the obstructed laser beam. The contour boundary data of each direction obtained by multiple sets of obstruction-type detection channels evenly arranged along the circumference of the detection ring are fused and processed to reconstruct the full circumference outer contour data of the conductor.

[0046] Both of the aforementioned detection channels can simultaneously acquire data on the outer contour of the conductor in all directions—upper, lower, left, right, and back—overcoming the missed detection problem of existing single-sided, single-point detection methods. Those skilled in the art can choose one or a combination of these channels based on actual working conditions such as dust and lighting. Furthermore, the ring-shaped linear laser scanning detection assembly 3 also integrates a supplementary lighting unit and an image acquisition unit. These units are arranged circumferentially around the detection ring, allowing for simultaneous acquisition of conductor surface image data in conjunction with the visual imaging method or infrared scanning method described below, while simultaneously acquiring full-circumference outer contour data. Both units share the same detection ring mounting space, eliminating the need for a separate support on the device.

[0047] The defect identification and control unit 4 is fixed inside a sealed protective box on the side of the tension machine integrated mounting base 1, such as... Figure 1 and Figure 3 As shown, it integrates a data acquisition module, a contour comparison calculation chip, and signal output terminals. The data acquisition module receives and stores the full circumference outer contour data of the conductor transmitted by the ring linear laser scanning detection assembly 3; the contour comparison calculation chip performs a comparison calculation between the full circumference outer contour data of the conductor and the pre-stored standard conductor contour database, and generates a defect judgment result based on the comparison result; the signal output terminals generate and output an alarm trigger signal and a shutdown control signal respectively based on the defect judgment result. The alarm trigger signal is output to the audible and visual alarm execution module 5, and the shutdown control signal is output to the tension machine main control circuit.

[0048] The audible and visual alarm execution module 5 is electrically connected to the defect identification control unit 4, such as... Figure 1 and Figure 2 As shown, it includes a high-decibel buzzer and a red and yellow dual-color flashing LED light. Upon receiving an alarm trigger signal, the sound and light alarm will be activated simultaneously, allowing on-site personnel to know the abnormal location of the conductor immediately. The defect identification control unit 4 is also electrically connected to the main control circuit of the tension machine, outputting a stop control signal to the main control circuit of the tension machine to control the tension machine to stop automatically, thus preventing the defective conductor from continuing to be stretched and further damaged.

[0049] The following section will further elaborate on the detection method and specific implementation methods of each step of the present invention, using a specific application scenario of a 500kV high-voltage transmission line construction project in a mountainous area as an example.

[0050] The construction site is located in a mountainous area with significant terrain undulations in the laying section. A tensioning machine is used to pull the conductor through multiple laying pulleys to complete the laying operation. Before construction, the operator secures the online detection device described in this invention to the tensioning machine's output end frame with bolts via the flange locking slot of the tensioning machine's integrated mounting base 1. Installation and debugging can be completed by a single person in a short time, without the need for additional independent support brackets. After the conductor is released from the conductor reel, it passes through the tensioning machine's output port, sequentially through the front conductor limiting guide frame 2, the detection ring of the annular linear array laser scanning detection assembly 3, and the rear conductor limiting guide frame 2, before being sent to the laying pulley for continuous laying.

[0051] After the tensioner starts releasing the wire, the conductor continuously passes through the detection area of ​​the annular linear array laser scanning detection assembly 3 at a uniform speed. At this time, the conductor's full circumference outer contour data and surface image data are acquired as follows: the conductor is constrained to continuously pass through the detection area along a preset center path; a multi-directional linear array laser scan is performed on the conductor continuously passing through the detection area to obtain the reflected light signal or occlusion light signal corresponding to each detection position on the outer circumference of the conductor; the reflected light signal or occlusion light signal corresponding to each detection position is fused to reconstruct the full circumference outer contour data of the conductor; based on the current lighting conditions of the detection area, it is determined whether to use visual imaging or infrared scanning to acquire the surface image data of the conductor. Specifically, an illuminance sensor can be installed on the annular linear array laser scanning detection assembly 3, controlled by defect identification. Unit 4 automatically determines and switches the acquisition mode based on the real-time collected illuminance data. Alternatively, on-site operators can manually set the mode through the control unit's operation panel according to the actual working conditions. For example, during the day when the on-site lighting is good, a visual imaging mode is used, with the supplementary lighting unit integrated into the detection assembly providing synchronous supplementary lighting to the detection area, and the image acquisition unit simultaneously capturing images of the conductor surface to ensure image clarity. At night or when laying the conductor in low-light sections such as tunnels or shaded areas, the mode is switched to infrared scanning, with the infrared thermal imaging component corresponding to the image acquisition unit acquiring surface image data. Based on the determined surface data acquisition mode, the outer surface of the conductor is synchronously acquired to obtain the surface image data of the conductor.

[0052] Correspondingly, the standard full-circumference outer contour data is pre-established and stored in the defect identification control unit 4 according to the following method: Before construction, qualified conductor samples are selected, and the conductor samples are subjected to the same circumferential multi-directional linear laser scanning as online detection. The reflected light signals or occlusion light signals corresponding to each detection position on the outer periphery of the conductor sample are obtained and fused to obtain the full-circumference outer contour data of the conductor sample; at the same time, the surface image data of the conductor sample is collected as standard surface image data. The standard full-circumference outer contour data and the standard surface image data are associated and stored in the data acquisition module of the defect identification control unit 4, which together constitute the standard conductor contour data mentioned above, as the benchmark for subsequent online comparison. The standard full-circumference outer contour data is used to compare and identify broken strands and outer layer wear defects, and the standard surface image data is used to compare and identify surface scratch defects.

[0053] During the wire laying process, the contour comparison calculation chip of the defect identification control unit 4 compares the real-time collected full-circumference outer contour data and surface image data with the pre-stored standard full-circumference outer contour data and standard surface image data to obtain the corresponding contour deviation comparison results and surface image comparison results. The following methods are used to identify whether the wire has defect features: Based on the contour deviation comparison results, the degree of deviation of the wire's external dimensions and outer morphology from the standard full-circumference outer contour data is determined. The degree of deviation is compared with a preset contour deviation threshold. If the deviation exceeds the contour deviation threshold, the wire is determined to have broken strands or outer layer wear morphology defects. Based on the surface image comparison results, the degree of texture difference or color difference of the wire surface relative to the standard surface image data is determined. This difference is compared with a preset surface difference threshold. If it exceeds the surface difference threshold, the wire is determined to have surface scratches or surface defects. When the above-mentioned morphology defects or surface defects are determined, the corresponding contour deviation comparison results or surface image comparison results are associated and recorded to obtain the defect features.

[0054] If no defect features are identified, the device maintains online detection and continues to acquire full-circumference outer contour data and surface image data of the next section of the conductor. This process is repeated to achieve continuous online detection of the entire laying section of the conductor.

[0055] If a defect feature is identified, the defect level corresponding to that feature is further determined as follows: the shape deviation of the defect feature is determined based on the contour deviation comparison result, and the surface defect area range of the defect feature is determined based on the surface image comparison result. The shape deviation and the surface defect area range are compared with the corresponding defect level thresholds respectively. When both the shape deviation and the surface defect area range are lower than the corresponding higher level threshold, the defect feature is determined to be a lower defect level, such as slight scratches or localized mild wear on the surface of the conductor. When at least one of the shape deviation or the surface defect area range reaches the corresponding higher level threshold, the defect feature is determined to be a higher defect level, such as obvious broken strands or large-area outer layer wear on the conductor. Subsequently, the defect level is associated with the defect location corresponding to the defect feature to obtain the defect level determination result, and the defect location is determined in conjunction with the wire length data.

[0056] The defect identification control unit 4 generates a corresponding alarm signal based on the defect level and triggers the audible and visual alarm execution module 5 to perform an audible and visual alarm as follows: It acquires the defect level corresponding to the alarm signal, matches this defect level with a preset alarm level, and determines the corresponding alarm method. When the defect level is low, it outputs a yellow light alarm signal, driving the yellow flashing light of the audible and visual alarm execution module 5 to provide a light alarm, prompting on-site personnel to pay attention. When the defect level is high, it outputs a red light alarm signal and an audible alarm signal, respectively driving the red flashing light and a high-decibel buzzer to provide a synchronized audible and visual alarm, reminding on-site personnel to take immediate action. Simultaneously, it acquires the alarm trigger status of the yellow flashing light, red flashing light, and buzzer, and generates alarm trigger confirmation information based on the alarm trigger status, facilitating on-site verification of whether the alarm has been effectively executed.

[0057] The shutdown control signal, generated synchronously with the alarm signal, controls the tension machine to stop as follows: the shutdown control signal is output to the main control circuit of the tension machine to stop its operation; during the shutdown period, the audible and visual alarm is maintained to alert on-site personnel that there is a defect in the conductor that needs to be addressed; after the personnel arrive at the defect location and inspect, repair, or replace the conductor, they input the confirmation information to the device through the on-site reset button on the defect identification control unit 4 or through a remote confirmation command issued by the background monitoring terminal. The defect identification control unit 4 receives the confirmation information and allows the receiving of a reset signal when the confirmation information indicates that the defect characteristics have been eliminated; after the personnel press the on-site reset button or the background monitoring terminal issues a reset signal, the device responds to the reset signal, releases the shutdown control signal, and deactivates the audible and visual alarm; after the shutdown control signal is released, the tension machine restarts and resumes its laying operation. The ring linear array laser scanning detection assembly 3 and the defect identification control unit 4 then resume online detection of the conductor, achieving timely handling of defective conductors and rapid recovery of laying operations.

[0058] The defect data obtained in this inspection is stored as follows: When a defect feature is identified, the defect location and laying length data corresponding to that feature are determined; the defect level, contour deviation comparison result, and surface image comparison result corresponding to that defect feature are obtained; the defect location, laying length data, defect level, contour deviation comparison result, and surface image comparison result are correlated to generate a corresponding defect detection record; the defect detection record is stored in the local storage medium of the defect identification control unit 4 and simultaneously sent to the background monitoring terminal, so that on-site management personnel and background technical personnel can view and summarize the conductor quality inspection data of the entire construction process at any time, providing a basis for line acceptance and quality traceability.

[0059] As can be seen from the above application scenarios, the device and method of the present invention can achieve full-circumference online detection of defects such as broken strands, outer layer wear, and surface scratches of conductors, real-time on-site audible and visual alarms, and automatic shutdown of the tensioning machine without changing the existing tensioning machine laying construction process. This significantly improves the detection efficiency and safety level of overhead line construction in complex conditions such as mountainous and high-altitude areas.

[0060] In other embodiments of the present invention, the foregoing components and method steps can also be implemented using the following alternative methods, which can also achieve the inventive objective of the present invention: 1) Replacement of scanning detection module: The linear array laser module in the ring linear array laser scanning detection assembly 3 can be replaced by a ring array CCD vision camera module arranged around the wire, which is used with image recognition algorithm to identify defects on the surface of the wire to adapt to complex outdoor lighting conditions such as dust and strong light; it can also be replaced by an infrared scanning module to adapt to nighttime wire laying detection scenarios. In this case, the aforementioned surface image data acquisition method is adjusted accordingly to array image acquisition or infrared thermal imaging acquisition.

[0061] 2) Replacement of integrated mounting base structure: The flange locking slot connection structure of the tension machine integrated mounting base 1 can be replaced with a quick snap connection structure, which can fix the device to the tension machine without bolt disassembly and assembly, further shortening the equipment changeover time; at the same time, height fine-adjustment legs can be added to the base to adapt to tension machine equipment of different models and different output heights.

[0062] 3) Alarm module replacement: The sound and light alarm execution module 5 can be upgraded with a sound and light + 4G wireless transmission module on the basis of the original high-decibel buzzer and red and yellow dual-color flashing LED light, so as to push the defect data to the background monitoring terminal in a synchronous manner and realize remote synchronous early warning; or a local defect storage card can be added to the defect identification control unit 4 to automatically record the defect location and laying length data as one of the specific implementation methods of local storage medium.

[0063] 4) Replacement of limiting guide structure: The wear-resistant nylon guide wheel built into the wire limiting guide frame 2 can be replaced with a ceramic wear-resistant guide sleeve to reduce wire sliding wear; an elastic buffer correction mechanism can also be added to the guide frame to adapt to the wire that has a large arc deviation during the wire laying process, and further ensure that the wire passes stably along the central axis of the detection area.

[0064] 5) Alternative power supply schemes: The device can be powered by a tension machine or replaced with a removable lithium battery independent power supply scheme to adapt to temporary mountain laying points without external power supply; a solar auxiliary charging component can also be added to the device to extend the continuous operation time in the field.

[0065] 6) Replacement of linkage control method: The hard-wired linkage shutdown structure between the defect identification control unit 4 and the main control circuit of the tension machine can be replaced by a wireless signal linkage module, which simplifies the on-site wiring and can be adapted to centralized linkage control in the scenario of multiple tension machines working simultaneously.

[0066] 7) Replacement of protective structure: The sealed protective box where the defect identification and control unit 4 is located can be equipped with a dustproof, waterproof and impact-resistant sheet metal protective cover on the basis of the original sealed protection, so as to adapt to the harsh mountain construction environment such as rain, snow and flying gravel, and further improve the environmental adaptability and service life of the device.

[0067] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for online detection of strand breakage and wear of conductors using an integrated tensioning machine, characterized in that, Includes the following steps: Acquire the full circumference outer contour data and surface image data of the wire that passes through the detection area at a constant speed; The full-circumference outer contour data and surface image data are compared with the pre-stored standard guide contour data to obtain the corresponding contour deviation comparison results and surface image comparison results. Based on the contour deviation comparison results and surface image comparison results, identify whether the conductor has defects such as broken strands, outer layer wear or surface scratches. If not, maintain the online detection status and continue to acquire the full circumference outer contour data and surface image data of the next section of the conductor; If so, determine the defect level and defect location corresponding to the defect characteristics, and generate alarm signals and shutdown control signals according to the defect level; The alarm signal triggers an audible and visual alarm, and the tension machine is stopped according to the stop control signal. At the same time, the location of the defect and the corresponding wire length data are recorded. Store the defect location, laying length data, and defect judgment results, and simultaneously send the defect judgment results to the background monitoring terminal.

2. The detection method according to claim 1, characterized in that, The method for obtaining the full-circumference outer contour data and surface image data is as follows: The constraint wire continuously passes through the detection area along a preset center path; A circumferential multi-directional linear laser scan is performed on the conductors that continuously pass through the detection area to obtain the reflected light signal or the blocked light signal corresponding to each detection position on the outer periphery of the conductor. The reflected light signals or blocked light signals corresponding to each detection position are fused to reconstruct the full circumference outer contour data of the conductor. Based on the lighting conditions of the detection area, determine whether to use visual imaging or infrared scanning to obtain surface image data of the conductor. When using visual imaging, synchronous supplemental lighting is applied to the detection area. Based on the determined surface data acquisition method, the outer peripheral surface of the conductor is synchronously acquired to obtain surface image data of the conductor.

3. The detection method according to claim 1, characterized in that, The method for obtaining standard full-circumference outer contour data is as follows: Obtain qualified conductor samples; A circumferential multi-directional linear laser scan is performed on the conductor sample to obtain the reflected light signal or occlusion light signal corresponding to each detection position on the outer periphery of the conductor sample. The reflected light signal or the blocked light signal is fused to obtain the full circumference outer contour data of the conductor sample; The full circumference outer contour data of the conductor sample is pre-stored as standard full circumference outer contour data.

4. The detection method according to claim 1, characterized in that, The method for identifying defect features is as follows: Based on the contour deviation comparison results, the degree of deviation of the conductor's external dimensions and peripheral morphology from the standard full-circumference external contour data is determined. The degree of deviation is compared with a preset profile deviation threshold, and when the degree of deviation exceeds the profile deviation threshold, it is determined that the transmission conductor has broken strands or outer layer wear morphology defects. Based on the surface image comparison results, determine the degree of texture or color difference of the transmission conductor surface relative to the standard surface image data; The degree of texture difference or color difference is compared with a preset surface difference threshold. When the degree of texture difference or color difference exceeds the surface difference threshold, it is determined that the transmission line has surface scratches and surface defects. When determining the presence of morphological or surface defects, the corresponding contour deviation comparison results or surface image comparison results are associated with the records to obtain the defect characteristics.

5. The detection method according to claim 1, characterized in that, The method for determining the defect level corresponding to a defect feature is as follows: The deviation of the shape of the defect feature is determined based on the contour deviation comparison results, and the range of the surface defect area of ​​the defect feature is determined based on the surface image comparison results. The deviation in shape and the range of the surface defect area are compared with the corresponding defect level thresholds, respectively. When both the deviation in shape and the extent of surface defects are below the corresponding higher-level threshold, the defect feature is determined to be of a lower defect level; when at least one of the deviation in shape or the extent of surface defects reaches the corresponding higher-level threshold, the defect feature is determined to be of a higher defect level. By associating the defect level with the defect location corresponding to the defect feature, the defect level determination result is obtained.

6. The detection method according to claim 1, characterized in that, The method for triggering an audible and visual alarm based on an alarm signal is as follows: Obtain the defect level corresponding to the alarm signal; Match the defect level with the preset alarm level to determine the corresponding alarm method; When the defect level is low, a yellow light alarm signal is output to drive a yellow strobe light for light alarm. When the defect level is high, a red light alarm signal and an audible alarm signal are output to drive the red strobe light and buzzer respectively to provide audible and visual alarms. Acquire the alarm trigger status of the yellow strobe light, red strobe light, and buzzer, and generate alarm trigger confirmation information based on the alarm trigger status.

7. The detection method according to claim 1, characterized in that, The method for controlling the tension machine to stop based on the stop control signal is as follows: The shutdown control signal is output to the main control circuit of the tension machine to stop the tension machine from running. The audible and visual alarms should remain active while the tensioner is not in operation. Obtain the handling confirmation information corresponding to the defect feature, and allow the receiving of a reset signal when the handling confirmation information indicates that the defect feature has been eliminated; In response to the reset signal, the stop control signal is released and the audible and visual alarm status is deactivated; After the shutdown control signal is released, the tensioner is restarted and the wire laying operation is resumed, and the online monitoring of the transmission conductor is restored.

8. A tensioning machine integrated online detection device for conductor strand breakage and wear, used to implement the detection method as described in any one of claims 1-7, characterized in that, This includes an integrated mounting base for the tension machine, a guide wire limiting frame, a ring-shaped linear laser scanning inspection assembly, and a defect identification and control unit, among which: The tension machine integrated mounting base is provided with a flange locking slot on the rear side. The flange locking slot is used to engage and fix with the tension machine outlet frame so as to integrate and install the online detection device on the tension machine. The conductor limiting guide frame is symmetrically arranged at both ends of the tension machine integrated mounting base to limit and guide the conductor, so that the conductor passes along the central axis of the detection area; The annular linear array laser scanning detection assembly is fixed in the middle of the tension machine integrated mounting base. It includes an annular hollow detection ring, and multiple sets of linear array laser emitters and receiving sensors corresponding to the linear array laser emitters are evenly arranged along the inner circumference of the annular hollow detection ring. Each set of linear array laser emitters emits a linear laser beam along the radial direction of the conductor to cover the outer circumferential surface of the conductor, and each receiving sensor is used to collect the outer contour data of the entire circumference of the conductor. The defect identification and control unit is fixed in a sealed protective box on the side of the tension machine integrated mounting base. It is used to receive the full circumference outer contour data, compare the full circumference outer contour data with the pre-stored standard conductor contour data, determine whether the conductor has broken strands, outer layer wear or surface scratches based on the comparison results, and output the corresponding alarm trigger signal and shutdown control signal when a defect is determined to exist.

9. The detection device according to claim 8, characterized in that, It also includes an audible and visual alarm execution module, which is electrically connected to the defect identification control unit and is used to receive alarm trigger signals and execute audible and visual alarms; the defect identification control unit is also electrically connected to the tension machine main control circuit and is used to output a shutdown control signal to the tension machine main control circuit to control the tension machine to stop.

10. The detection device according to claim 8, characterized in that, The defect identification and control unit includes a data acquisition module, a contour comparison calculation chip, and a signal output terminal. The data acquisition module receives and stores the full circumference outer contour data of the conductor. The contour comparison calculation chip performs a comparison calculation between the full circumference outer contour data of the conductor and a standard conductor contour database, and generates a defect judgment result based on the comparison result. The signal output terminal generates and outputs corresponding alarm trigger signals and shutdown control signals based on the defect judgment result. The alarm trigger signal is output to the audible and visual alarm execution module, and the shutdown control signal is output to the tension machine's main control circuit.

Images