High-speed vision detection system for surface quality of copper wire coated film

Abstract

The utility model relates to visual inspection technical field, and disclose copper wire film surface quality high -speed vision detection system, including device frame, the right side of device frame is equipped with the detection assembly for to copper wire surface detection, the inside of device frame is equipped with the cleaning assembly for to copper wire cleaning, the detection assembly includes mounting piece, mounting piece is equipped with two, two mounting piece all weld in the right side of device frame, the utility model discloses through vision sensor collection image, after gauss filter denoising, histogram equalization enhances image details, the image after processing can accurately identify scratch, bubble, wrinkle, film thickness uneven etc. defect type based on the semantic segmentation model U of depth learning Net, MaskR CNN, and the detection precision reaches 0.01mm 2 , and further effectively detect the defect of copper wire, and further reduce the subsequent processing of the copper wire with defect.

Description

Technical Field

[0001] This utility model relates to the field of visual inspection technology, specifically a high-speed visual inspection system for the surface quality of copper wire coating. Background Technology

[0002] High-speed visual inspection of copper wire coating surface quality is a method that uses machine vision technology to inspect the surface quality of copper wire coatings operating at high speeds. Its core lies in the real-time identification and feedback of micron-level defects through the collaborative work of a high-speed camera, light source, and intelligent algorithms. It is widely used in industrial fields with stringent requirements for coating integrity, insulation performance, and appearance quality, such as motor winding wires and enameled copper wires for transformers, to identify defects such as pinholes, peeling, and exposed copper on the coating surface, preventing the risk of inter-turn short circuits or breakdowns caused by insulation layer failure.

[0003] In existing technologies, such as the stranding machine for copper wire mesh disclosed in CN219225966U, the following components are included: a machine base; a stranding mechanism disposed on the machine base; a first lead-out mechanism disposed above the stranding mechanism and leading out the stranded copper wire; a second lead-out mechanism disposed at the lead-out end of the first lead-out mechanism; a winding mechanism disposed at the lead-out end of the second lead-out mechanism and providing winding tension; and a detection probe disposed on the side of the second lead-out mechanism. The detection probe uses a visual algorithm to analyze and identify the stranding intersections on the copper stranded wire, determining the spacing between adjacent stranding intersections. This enables real-time monitoring of the spacing between stranding intersections on the copper stranded wire. Combined with the real-time monitoring data, the controller coordinates and controls the winding speed of the winding mechanism and the stranding speed of the stranding mechanism, thereby adjusting the spacing between the stranding intersections of the copper stranded wire.

[0004] Existing devices use visual algorithms to analyze and identify the crossover points on copper stranded wires, and determine the spacing between adjacent crossover points, thus achieving real-time monitoring of the spacing between crossover points on copper stranded wires. However, during inspection, they can only detect the crossover points of copper wires and cannot detect the coating on the surface of the copper wires. This results in defective copper wires entering subsequent processing, affecting the overall quality of the product. Utility Model Content

[0005] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the present invention.

[0006] Given that the existing technology can only detect the intersection of copper wires and cannot detect the coating on the surface of the copper wires, defective copper wires are allowed to enter subsequent processing, affecting the overall quality of the product.

[0007] To achieve the above objectives, this utility model provides the following technical solution:

[0008] A high-speed visual inspection system for the surface quality of copper wire coating includes a device frame, a detection component for inspecting the surface of copper wire is provided on the right side of the device frame, and a cleaning component for cleaning copper wire is provided inside the device frame.

[0009] The detection component includes two mounting components, both of which are welded to the right side of the device frame. Each mounting component has a movable plate slidably connected to its right side. A stepper motor is fixed to the side wall of the movable plate by screws. A lead screw is fixed to the power output shaft of the stepper motor. An internally threaded tube is threaded to the end of the lead screw. A vision sensor is fixed to one end of the internally threaded tube.

[0010] As a further improvement of this utility model, two limiting rods that penetrate the interior of the movable plate are fixed on one side of the vision sensor.

[0011] As a further improvement of this utility model, a limiting block is fixed to the end of the limiting rod.

[0012] As a further improvement of this utility model: a fixing plate is fixed on one side of the movable plate and slidably connected to the mounting component, and a limiting bolt is installed on the outer wall of the mounting component and abuts against the movable plate.

[0013] As a further improvement of this utility model: a mounting plate is welded to one side of the device frame, and four mounting bolts are symmetrically installed inside the mounting plate.

[0014] As a further embodiment of this utility model: the cleaning component includes two cleaning parts, which are symmetrically arranged inside the device frame.

[0015] As a further improvement of this utility model: the inner walls of both cleaning components are equipped with cleaning brushes, and the side walls of both cleaning components are welded with movable rods that are slidably connected to the device frame.

[0016] As a further improvement of this utility model: the end of the movable rod is fixed with a movable block that slides inside the device frame, and a compression spring is abutted on one side of the movable block.

[0017] Compared with the prior art, the beneficial effects of this utility model are:

[0018] 1. This invention acquires images using a visual sensor, performs Gaussian filtering for noise reduction and histogram equalization to enhance image details, and then uses deep learning semantic segmentation models U-Net and MaskR-CNN to accurately identify defect types such as scratches, bubbles, wrinkles, and uneven film thickness, achieving a detection accuracy of 0.01mm. 2 This effectively detects defects in the copper wire, thereby reducing the need for defective copper wire in subsequent processing.

[0019] 2. This utility model uses a cleaning brush to clean the surface of the copper wire, thereby effectively reducing the impact of impurities adhering to the surface of the copper wire on the accuracy of visual inspection. Under the action of its own elasticity, the compression spring will push the movable block to move, so that the movable rod will drive the two cleaning parts to move closer to each other, ensuring the cleaning effect of the cleaning brush. Attached Figure Description

[0020] Figure 1 A three-dimensional structural diagram of a high-speed visual inspection system for the surface quality of copper wire coating.

[0021] Figure 2 A three-dimensional structural diagram of the device frame in a high-speed visual inspection system for the surface quality of copper wire coating;

[0022] Figure 3 A cross-sectional schematic diagram of the frame structure of a high-speed visual inspection system for copper wire coating surface quality.

[0023] Figure 4 A cross-sectional structural diagram of the mounting component in a high-speed visual inspection system for the surface quality of copper wire coating;

[0024] Figure 5 A three-dimensional structural diagram of the mounting components in a high-speed visual inspection system for the surface quality of copper wire coating.

[0025] In the diagram: 1. Device frame; 2. Mounting component; 21. Movable plate; 22. Stepper motor; 23. Lead screw; 24. Internally threaded pipe; 25. Vision sensor; 26. Limiting rod; 27. Limiting block; 3. Fixing plate; 4. Limiting bolt; 5. Mounting plate; 6. Mounting bolt; 7. Cleaning component; 71. Cleaning brush; 72. Movable rod; 73. Movable block; 74. Compression spring. Detailed Implementation

[0026] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the specific embodiments of this utility model will be described in detail below with reference to the accompanying drawings.

[0027] Many specific details are set forth in the following description in order to provide a full understanding of the present invention. However, the present invention may also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0028] Secondly, the term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a single or selective embodiment that excludes other embodiments.

[0029] Example 1

[0030] Please see Figures 1-5 This is the first embodiment of the present utility model. This embodiment provides a high-speed visual inspection system for the surface quality of copper wire coating, including a device frame 1. The right side of the device frame 1 is provided with a detection component for inspecting the surface of the copper wire, and the inside of the device frame 1 is provided with a cleaning component for cleaning the copper wire.

[0031] The detection component includes mounting parts 2, and there are two mounting parts 2. Both mounting parts 2 are welded to the right side of the device frame 1. Movable plates 21 are slidably connected to the right side of both mounting parts 2. Stepper motors 22 are fixed to the side walls of the movable plates 21 by screws. A lead screw 23 is fixed to the power output shaft of the stepper motor 22. An internally threaded tube 24 is threaded to the end of the lead screw 23. A vision sensor 25 is fixed to one end of the internally threaded tube 24.

[0032] Specifically, two limiting rods 26 are fixed to one side of the vision sensor 25, penetrating the interior of the movable plate 21, and a limiting block 27 is fixed to the end of the limiting rod 26.

[0033] Furthermore, the images acquired by the vision sensor 25 are transmitted to the PC via wires for image processing, thereby effectively detecting defects in the copper wire and reducing the number of defective copper wires entering subsequent processing.

[0034] Specifically, a fixing plate 3 is fixed on one side of the movable plate 21 and is slidably connected to the mounting component 2, and a limiting bolt 4 is installed on the outer wall of the mounting component 2 and abuts against the movable plate 21.

[0035] Furthermore, the limit block 27 can serve as a limit, and by loosening the limit bolt 4 on the mounting part 2, the fixation of the movable plate 21 is released, thus allowing the visual sensor 25 to be adjusted in the horizontal direction.

[0036] In use, the vision sensor 25 inspects the surface of the copper wire. The vision sensor 25 employs a high-speed linear array camera, combining a CCD sensor with a high-resolution lens, supporting millisecond-level frame rate acquisition to ensure clear image capture even when the copper wire is running at high speed. LED backlighting or coaxial illumination technology can be installed on the vision sensor 25 to eliminate interference from coating reflections and enhance the contrast of surface defects. Images acquired by the vision sensor 25 are transmitted to a PC via wires for image processing. Gaussian filtering for noise reduction and histogram equalization enhance image details. The processed images, based on deep learning semantic segmentation models U-Net and MaskR-CNN, can accurately identify defect types such as scratches, bubbles, wrinkles, and uneven film thickness, achieving a detection accuracy of 0.01mm. 2 This effectively detects defects in the copper wire, reducing the number of defective copper wires entering subsequent processing. The stepper motor 22 on the movable plate 21 drives the lead screw 23 to rotate. With the cooperation of the limit rod 26, the rotation of the lead screw 23 drives the internal thread tube 24 to move vertically, thereby adjusting the distance between the vision sensor 25 and the copper wire, facilitating sensor focusing. The limit block 27 can play a limiting role. By loosening the limit bolt 4 on the mounting part 2, the fixation of the movable plate 21 is released, which allows the vision sensor 25 to be adjusted in the horizontal direction. The fixed plate 3 can prevent the movable plate 21 from falling off when it is pulled.

[0037] In summary, during operation, the high-speed visual inspection system for copper wire coating surface quality transmits images acquired by the visual sensor 25 to a PC via wires for image processing. Gaussian filtering for noise reduction and histogram equalization for image detail enhancement are employed. The processed images, based on deep learning semantic segmentation models U-Net and MaskR-CNN, can accurately identify defect types such as scratches, bubbles, wrinkles, and uneven film thickness, achieving a detection accuracy of 0.01 mm. 2 This effectively detects defects in the copper wire, reducing the number of defective copper wires entering subsequent processing.

[0038] Example 2

[0039] Please see Figures 1-5 This is the second embodiment of the present utility model.

[0040] Specifically, a mounting plate 5 is welded to one side of the device frame 1, and four mounting bolts 6 are symmetrically installed inside the mounting plate 5.

[0041] Furthermore, the device frame 1 is fixed by mounting bolts 6 using mounting plate 5 provided on the device frame 1.

[0042] Specifically, the cleaning component includes two cleaning parts 7, which are symmetrically arranged inside the device frame 1. The inner walls of the two cleaning parts 7 are equipped with cleaning brushes 71, and the side walls of the two cleaning parts 7 are welded with movable rods 72 that are slidably connected to the device frame 1.

[0043] Furthermore, the cleaning brush 71 can clean the surface of the copper wire, thereby effectively reducing the impact of impurities adhering to the surface of the copper wire on the accuracy of visual inspection.

[0044] Specifically, the end of the movable rod 72 is fixed with a movable block 73 that slides inside the device frame 1, and a compression spring 74 is abutted on one side of the movable block 73.

[0045] Furthermore, the compression spring 74, under its own elasticity, will push the movable block 73 to move, causing the movable rod 72 to bring the two cleaning parts 7 closer to each other, ensuring the cleaning effect of the cleaning brush 71.

[0046] In use, the device frame 1 is placed in a suitable position. The device frame 1 is fixed by the mounting plate 5 and the mounting bolts 6, thereby effectively reducing the possibility of displacement of the device frame 1. In use, the copper wire to be tested is passed through the inside of the device frame 1, so that the copper wire is between the two cleaning brushes 71. Then, it is connected to the external winding equipment through the two vision sensors 25. The external equipment drives the copper wire to wind up. When the copper wire passes through the cleaning component 7, the cleaning brushes 71 can clean the surface of the copper wire, thereby effectively reducing the impact of impurities adhering to the surface of the copper wire on the visual detection accuracy and improving practicality. In addition, the compression spring 74 will push the movable block 73 to move under its own elasticity, so that the movable rod 72 will drive the two cleaning components 7 to move closer to each other, ensuring the cleaning effect of the cleaning brushes 71.

[0047] In summary, during operation, the high-speed visual inspection system for copper wire coating surface quality transmits images acquired by the visual sensor 25 to a PC via wires for image processing. Gaussian filtering for noise reduction and histogram equalization for image detail enhancement are employed. The processed images, based on deep learning semantic segmentation models U-Net and MaskR-CNN, can accurately identify defect types such as scratches, bubbles, wrinkles, and uneven film thickness, achieving a detection accuracy of 0.01 mm. 2 This effectively detects defects in the copper wire, reducing the number of defective copper wires entering subsequent processing. The cleaning brush 71 can clean the surface of the copper wire, and the compression spring 74, under its own elasticity, will push the movable block 73 to move, improving the cleaning effect of the cleaning brush 71.

[0048] It is important to note that the constructions and arrangements of this application shown in several different exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those who consult this disclosure will readily understand that many modifications are possible (e.g., changes in the size, dimensions, structure, shape and proportion of various elements, as well as parameter values ​​(e.g., temperature, pressure, etc.), mounting arrangements, use of materials, color, orientation, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in this application). For example, an element shown as integrally formed may be composed of multiple parts or elements, the position of elements may be inverted or otherwise altered, and the nature or number or position of discrete elements may be changed or altered. Therefore, all such modifications are intended to be included within the scope of this utility model. The order or sequence of any process or method steps may be changed or rearranged according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure described herein that performs the function, and not only structural equivalents but also equivalent structures. Without departing from the scope of this invention, other substitutions, modifications, alterations, and omissions may be made in the design, operation, and arrangement of the exemplary embodiments. Therefore, this invention is not limited to the specific embodiments, but extends to various modifications that still fall within the scope of the appended claims.

[0049] Furthermore, in order to provide a concise description of exemplary embodiments, not all features of actual embodiments (i.e., those features that are not relevant to the best mode of carrying out the present invention as currently considered, or those features that are not relevant to implementing the present invention) may be omitted.

[0050] It should be understood that numerous specific implementation decisions can be made during the development of any practical implementation, such as in any engineering or design project. Such development efforts may be complex and time-consuming, but for those skilled in the art who benefit from this disclosure, the development effort will be a routine work of design, manufacturing, and production without requiring much experimentation.

[0051] It should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solution of this utility model without departing from the spirit and scope of the technical solution of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.

Claims

1. A high-speed vision inspection system for the surface quality of copper wire braid, comprising a device frame (1), characterized in that: The right side of the device frame (1) is provided with a detection assembly for detecting the surface of copper wire, and the inside of the device frame (1) is provided with a cleaning assembly for cleaning the copper wire. The detection assembly comprises two mounting pieces (2), both of which are welded on the right side of the device frame (1), and both of which are slidably connected with a movable plate (21) on the right side, the side wall of the movable plate (21) is fixed with a stepping motor (22) through screws, the power output shaft of the stepping motor (22) is fixed with a lead screw (23), the distal end of the lead screw (23) is threadedly connected with an internally threaded tube (24), one end of the internally threaded tube (24) is fixed with a visual sensor (25).

2. The copper wire film surface quality high-speed vision detection system according to claim 1, characterized in that: One side of the visual sensor (25) is fixed with two limiting rods (26) penetrating the inside of the movable plate (21).

3. The copper wire film surface quality high-speed vision detection system according to claim 2, characterized in that: The distal end of the limiting rod (26) is fixed with a limiting block (27).

4. The copper wire film surface quality high-speed vision detection system according to claim 3, characterized in that: One side of the movable plate (21) is fixed with a fixed plate (3) slidably connected with the mounting piece (2), and the outer wall of the mounting piece (2) is provided with a limiting bolt (4) abuttingly connected with the movable plate (21).

5. The copper wire film surface quality high-speed vision detection system according to claim 1, characterized in that: One side of the device frame (1) is welded with a mounting plate (5), and the inside of the mounting plate (5) is symmetrically provided with four mounting bolts (6).

6. The copper wire film surface quality high-speed vision detection system according to claim 5, characterized in that: The cleaning assembly comprises two cleaning pieces (7), both of which are symmetrically arranged in the inside of the device frame (1).

7. The copper wire film surface quality high-speed vision detection system according to claim 6, characterized in that: The inner wall of each of the two cleaning pieces (7) is provided with a cleaning brush (71), and the side wall of each of the two cleaning pieces (7) is welded with a movable rod (72) slidably connected with the device frame (1).

8. The copper wire film surface quality high-speed vision detection system according to claim 7, characterized in that: The distal end of the movable rod (72) is fixed with a movable block (73) slidably connected with the inside of the device frame (1), and one side of the movable block (73) is abutted with a compression spring (74).

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