An insulation wire core defect detection device

Abstract

This utility model discloses an insulated wire core defect detection device, belonging to cable testing equipment. The technical problem to be solved by this utility model is how to achieve automated detection of insulated wire cores, meet the non-contact quality inspection requirements in the production process of insulated wire cores, and ensure the stability of detection accuracy. The technical solution adopted is as follows: it includes a frame, on which a detection box is set. A wire core inlet is set at the center of one side of the detection box, and a wire core outlet is set at the center of the opposite side of the detection box. A light-shielding component is set between the wire core inlet and the wire core outlet. The light-shielding component is set inside the detection box, and a supplementary light component is set at each end of the light-shielding component. A brush component is set on the inner side of the wire core inlet and the wire core outlet, and the brush component is installed on the inner side wall of the detection box. Three sets of imaging components are set inside the detection box, and the three sets of imaging components are distributed in a circular array around the light-shielding component.

Description

Technical Field

[0001] This utility model relates to cable testing equipment, specifically a device for detecting defects in insulation cores. Background Technology

[0002] During cable manufacturing, the insulation layer on the outer surface of the insulated conductor may develop defects such as particles, scratches, and damage due to impurities, production processes, or environmental factors. These defects can lead to accidents such as partial discharge and insulation breakdown after the cable is put into operation. Therefore, ensuring the quality of the insulated conductor production process is extremely important.

[0003] Currently, there are three main methods for detecting defects in insulated wire cores: physical testing methods that indirectly determine the insulation state by applying voltage or measuring electrical parameters; sensing and imaging methods that capture local changes based on sensors such as infrared thermal imagers; and manual inspection. However, physical testing methods can reflect the overall insulation performance but cannot identify the specific type and location of defects; sensing and imaging methods rely on high-precision equipment, which is costly; and manual inspection methods are affected by operator experience, posing a risk of subjective misjudgment.

[0004] Therefore, how to achieve automated testing of insulated wire cores, meet the non-contact quality inspection requirements during the production process of insulated wire cores, and ensure the stability of testing accuracy is a technical problem that urgently needs to be solved. Summary of the Invention

[0005] The technical objective of this invention is to provide an insulated wire core defect detection device to solve the problem of how to achieve automated detection of insulated wire cores, meet the requirements of non-contact quality inspection during the production process of insulated wire cores, and ensure the stability of detection accuracy.

[0006] The technical objective of this utility model is achieved as follows: an insulated wire core defect detection device includes a frame, a detection chamber mounted on the frame, a wire core inlet located at the center of one side of the detection chamber, a wire core outlet located at the center of the opposite side of the detection chamber, a light-shielding component located between the wire core inlet and the wire core outlet, the light-shielding component being disposed inside the detection chamber, and a supplementary light component being disposed at each end of the light-shielding component; a brush component is disposed on the inner side of the wire core inlet and the wire core outlet, and the brush component is mounted on the inner wall of the detection chamber.

[0007] The testing chamber contains three sets of imaging components arranged in a circular array around a light-shielding component. Each imaging component includes a line scan camera and an electrically adjustable focusing lens mounted on the line scan camera. The line scan camera is connected to the inner wall of the testing chamber via a connecting component. The light-shielding component includes two light shields, which are positioned opposite each other with a gap between them. The line scan camera captures images of the insulated wire core inside the light shield through the gap between the two light shields. The three line scan cameras capture images concentrically along a direction perpendicular to the insulated wire core.

[0008] Preferably, the supplementary lighting component adopts a ring-shaped lamp array, which is composed of several light particles distributed in a circular array, with the light particles located at the edge of the light shield near the inner wall of the detection chamber.

[0009] More preferably, the light source of the ring-shaped LED array is a high color rendering LED, and the illumination angle of each ring-shaped LED array is 30°-45° to ensure uniform illumination of the surface of the insulated wire core.

[0010] Preferably, the brush assembly includes a brush holder and a brush mounted on the brush holder. The brush holder is mounted on the inner side wall of the detection box and is located at the wire core inlet and wire core outlet. The brush is used to clean the surface of the insulated wire core entering the light shield and remove fine particles and dust.

[0011] The brush is made of conductive fibers to eliminate particles attracted by static electricity, and the contact pressure between the brush and the insulated wire core is adjustable.

[0012] Preferably, the connecting assembly includes a mirror camera mounting plate and a mounting bend plate. The mirror camera mounting plate is L-shaped. One side of the L-shaped mirror camera mounting plate is connected to a wire scanning camera. The other side of the L-shaped mirror camera mounting plate is detachably connected to one side of the mounting bend plate. Both ends of the mounting bend plate are fixedly mounted on the inner sidewall of the detection chamber.

[0013] The mounting plate has elongated holes for adjusting the mounting position of the mirror camera mounting plate.

[0014] Preferably, the light shield is connected to the inner wall of the bottom of the detection chamber via a connecting plate.

[0015] Preferably, a support column is provided on the outside of the detection box, and a connecting rod is provided on the support column. One end of the connecting rod is slidably connected to the support column, and a keyboard tray is provided on the other end of the connecting rod. The keyboard tray is L-shaped.

[0016] An adjustment frame is installed above the connecting rod. One end of the adjustment frame is slidably connected to the support column, and the other end of the adjustment frame is hinged to a display.

[0017] Preferably, an alarm light is provided on one side of the top of the detection box, an alarm horn is provided on the upper side of the outer side of the detection box with a wire core outlet, and an LED warning light strip is provided on the upper middle part of one outer side of the detection box without a wire core outlet and a wire core inlet.

[0018] Preferably, an industrial control computer enclosure is provided below the detection box, and the industrial control computer inside the enclosure is electrically connected to the line scan camera.

[0019] Preferably, the bottom of the frame is equipped with casters.

[0020] The insulation core defect detection device of this utility model has the following advantages:

[0021] (I) The circular LED array and line scan camera of this utility model follow a circular distribution, and together with the light shield, they form an independent image acquisition space, resisting external light interference and realizing clear, stable, and blind-angle-free imaging of the internal cables.

[0022] (ii) This utility model not only meets the non-contact quality inspection requirements in the production process of insulated wire cores, but also effectively avoids missed inspections and quickly achieves pixel-level positioning of defects.

[0023] (III) This utility model adopts a combination of multiple sound and light alarms, and combines the color of LED warning light strips to distinguish the defect type, which makes it easy to quickly remind workers of the defect type in noisy workshops and handle the defect in a timely manner. It does not require high-precision sensors and manual intervention, and has low cost and stable detection accuracy.

[0024] (iv) The support column of this utility model is installed on the side of the detection box. The display and keyboard tray are installed on the support column by means of the adjustment bracket and connecting rod. The height can be adjusted and rotated in the direction of the vertical plane. Workers can query and rate defects through the display and keyboard and mouse.

[0025] (v) The wire core inlet and wire core outlet of this utility model are respectively equipped with brush assemblies. The brush assemblies are fixed on the detection box and each of the wire core inlet and wire core outlet is included. They are responsible for cleaning the surface of the insulated wire core entering the light shield and removing fine particles, dust and other foreign objects.

[0026] (vi) The ring-shaped lamp array of this utility model is divided into two groups, each group consisting of multiple light particles arranged in a circle. The two groups of lamp arrays are installed at both ends of the light shield and are responsible for supplementing the light on the surface of the insulating wire core inside the light shield.

[0027] (vii) The two light shields of this utility model have a 3mm gap between them. The line scan camera takes pictures of the insulated wire core inside the light shield through the reserved gap. The light shield can provide independent supplementary lighting and acquisition environment to avoid the image acquisition being affected by external light.

[0028] (viii) This utility model can cover the entire outer surface of the insulated wire core by installing three line scanning cameras, and is used to collect the appearance image of the insulated wire core; the electric focusing lens installed in front of the line scanning camera can automatically focus to meet the requirements of collecting insulated wire cores of different diameters.

[0029] (ix) This utility model can identify production defects in the production process of insulated wire cores in real time, issue defect warnings in a timely manner, remind construction personnel to handle defects, and ensure the yield rate and production efficiency of the production line.

[0030] Therefore, this utility model has the characteristics of reasonable design, simple structure, easy processing, small size, convenient use, and multiple uses, and thus has great value for promotion and use. Attached Figure Description

[0031] The present invention will be further described below with reference to the accompanying drawings.

[0032] Appendix Figure 1 This is a schematic diagram of the structure of an insulated wire core defect detection device;

[0033] Appendix Figure 2 This is a schematic diagram of the insulation core defect detection device from another angle.

[0034] Appendix Figure 3 This is a schematic diagram of the internal structure of the detection box.

[0035] In the diagram: 1. Frame, 2. Detection box, 3. Wire core inlet, 4. Wire core outlet, 5. Line scan camera, 6. Motorized focusing lens, 7. Light shield, 8. Particle light, 9. Brush holder, 10. Brush, 11. Mirror camera mounting plate, 12. Mounting bend plate, 13. Long slot, 14. Connecting plate, 15. Support column, 16. Connecting rod, 17. Keyboard tray, 18. Adjustment bracket, 19. Monitor, 20. Alarm light, 21. Alarm horn, 22. LED warning light strip, 23. Base box, 24. Casters. Detailed Implementation

[0036] The following is a detailed description of an insulated wire core defect detection device according to the present invention, with reference to the accompanying drawings and specific embodiments.

[0037] In the description of this utility model, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description. They do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0039] Example:

[0040] As attached Figure 1 and 2 As shown, this embodiment provides an insulation core defect detection device, the structure of which includes a frame 1, a detection box 2 mounted on the frame 1, a core inlet 3 at the center of one side of the detection box 2, and a core outlet 4 at the center of the opposite side of the detection box 2, a light-shielding component installed between the core inlet 3 and the core outlet 4, the light-shielding component being installed inside the detection box 2, and a supplementary light component being installed at each end of the light-shielding component; a brush assembly is installed inside the core inlet 3 and the core outlet 4, respectively, the brush assembly being installed inside the detection box 2. On the side wall; inside the detection chamber 2, three sets of imaging components are installed, and the three sets of imaging components are arranged in a circular array around the light-shielding component; among them, the imaging components include a line scan camera 5 and an electrically adjustable focusing lens 6 mounted on the line scan camera 5. The line scan camera 5 is connected to the inner side wall of the detection chamber 2 through a connecting component; the light-shielding component includes two light shields 7, which are arranged opposite each other with a 3mm gap between them. The line scan camera 5 takes pictures of the insulated wire core inside the light shield 7 through the gap between the two light shields 7. The three line scan cameras 5 take pictures concentrically along the direction perpendicular to the insulated wire core.

[0041] As attached Figure 3As shown, the supplementary lighting component in this embodiment adopts a ring-shaped LED array, which is composed of several light particles 8 distributed in a circular array. The light particles 8 are located at the edge of the light shield 7 near the inner side wall of the detection box 2. The light source of the ring-shaped LED array is a high color rendering LED, and the illumination angle of each group of ring-shaped LED arrays is 30°-45° to ensure uniform illumination of the surface of the insulated wire core.

[0042] The brush assembly in this embodiment includes a brush holder 9 and a brush 10 mounted on the brush holder 9. The brush holder 9 is mounted on the inner wall of the detection box 2 and is located at the wire core inlet 3 and the wire core outlet 4. The brush 10 is used to clean the surface of the insulated wire core entering the light shield 7, removing fine particles and dust. The brush 10 is made of conductive fiber to eliminate particles attracted by electrostatic charge, and the contact pressure between the brush 10 and the insulated wire core is adjustable.

[0043] The connecting components in this embodiment include a mirror camera mounting plate 11 and a mounting bend plate 12. The mirror camera mounting plate 11 is L-shaped. One side of the L-shaped mirror camera mounting plate 11 is connected to the scanning camera 5, and the other side of the L-shaped mirror camera mounting plate 11 is detachably connected to one side of the mounting bend plate 12. Both ends of the mounting bend plate 12 are fixedly installed on the inner side wall of the detection box 2. The mounting bend plate 12 has an elongated hole 13 for adjusting the installation position of the mirror camera mounting plate 11.

[0044] In this embodiment, the light shield 7 is connected to the bottom inner wall of the detection box 2 via the connecting plate 14.

[0045] In this embodiment, a support column 15 is installed on the outside of the detection box 2. A connecting rod 16 is installed on the support column 15. One end of the connecting rod 16 is slidably connected to the support column 15, and a keyboard tray 17 is installed on the other end of the connecting rod 16. The keyboard tray 17 is L-shaped. An adjustment frame 18 is installed above the connecting rod 16. One end of the adjustment frame 18 is slidably connected to the support column 15, and the other end of the adjustment frame 18 is hinged to a display 19.

[0046] In this embodiment, an alarm light 20 is installed on one side of the top of the detection box 2, an alarm horn 21 is installed on the upper side of the outer side of the detection box 2 with the wire core outlet 4, and an LED warning light strip 22 is installed on the upper middle part of one outer side of the detection box 2 without the wire core outlet 4 and the wire core inlet 3.

[0047] In this embodiment, an industrial control computer housing 23 is installed below the detection housing 2, and the industrial control computer inside the industrial control computer housing 23 is electrically connected to the line scan camera 5.

[0048] In this embodiment, the bottom of the frame 1 is equipped with casters 24.

[0049] In this embodiment, the three line scanning cameras 5 can cover the entire outer surface of the insulated wire core and are used to acquire the appearance image of the insulated wire core; the motorized focusing lens 6 installed at the front end of the line scanning camera 5 can automatically focus to meet the acquisition of insulated wire cores of different diameters; the three line scanning cameras 5 are aligned and take pictures through the mirror camera mounting plate 11 and the mounting bend plate 12; the mounting bend plate 12 is fixed on the inner side wall of the detection box 2. The brush assembly includes a brush holder 9 and a brush 10. The brush assembly is fixed on the detection box 2. A set of brush assemblies is installed at the wire core inlet 3 and the wire core outlet 4, respectively, to clean the surface of the insulated wire core entering the light shield 7 and remove fine particles, dust and other foreign objects. The ring lamp array is divided into two groups, each consisting of 14 light particles 8 arranged in a circle. The two sets of lamp arrays are installed at the outer ends of the two light shields 7, respectively, to supplement the light on the surface of the insulated wire core inside the light shield 7. A 3mm gap is reserved between the two light shields 7. The line scan camera 5 takes pictures of the insulated wire core inside the light shield 7 through the reserved gap. The three-line line scan camera 5 takes pictures along the direction perpendicular to the cable. The light shield 7 is equipped with a light-absorbing cloth, which can provide an independent lighting and acquisition environment and avoid the image acquisition being affected by external light.

[0050] In this embodiment, the alarm light 20 is installed on the top of the detection box 2, the LED warning light strip 22 is installed on the side of the detection box 2, and the support column 15 is installed on the opposite side of the detection box 2. The display 19 and the keyboard tray 17 are respectively installed on the support column 15 via an adjustment bracket and a connecting rod 16, allowing for height adjustment and rotation along the vertical plane. Workers can use the keyboard and mouse on the display 19 and keyboard tray 17 to query and rate defects. When a defect is detected, the alarm horn 21 sounds, and the alarm light 20 and LED warning light strip 22 provide multi-directional light alarms. Depending on the defect type, the LED warning light strip 22 can provide different colors of warning, making it easy for workers to understand the defect type at a glance.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model 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 or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A device for detecting defects in insulated wire cores, characterized in that, The device includes a frame, on which a detection chamber is mounted. A wire core inlet is located at the center of one side of the detection chamber, and a wire core outlet is located at the center of the opposite side of the detection chamber. A light-shielding component is installed between the wire core inlet and the wire core outlet. The light-shielding component is located inside the detection chamber, and a supplementary light component is installed at each end of the light-shielding component. A brush component is installed on the inner side of the wire core inlet and the wire core outlet, and the brush components are mounted on the inner wall of the detection chamber. The testing chamber contains three sets of imaging components arranged in a circular array around a light-shielding component. Each imaging component includes a line scan camera and an electrically adjustable focusing lens mounted on the line scan camera. The line scan camera is connected to the inner wall of the testing chamber via a connecting component. The light-shielding component includes two light shields, which are positioned opposite each other with a gap between them. The line scan camera captures images of the insulated wire core inside the light shield through the gap between the two light shields. The three line scan cameras capture images concentrically along a direction perpendicular to the insulated wire core.

2. The insulation core defect detection device according to claim 1, characterized in that, The supplementary lighting component adopts a ring-shaped lamp array, which is composed of several light particles distributed in a circular array. The light particles are located at the edge of the light shield near the inner wall of the detection chamber.

3. The insulation core defect detection device according to claim 2, characterized in that, The light source of the ring-shaped LED array is a high color rendering LED, and the illumination angle of each ring-shaped LED array is 30°-45°.

4. The insulation core defect detection device according to claim 1, characterized in that, The brush assembly includes a brush holder and a brush mounted on the brush holder. The brush holder is mounted on the inner side wall of the detection box and is located at the wire core inlet and wire core outlet. The brush is made of conductive fibers.

5. The insulation core defect detection device according to claim 1, characterized in that, The connecting assembly includes a mirror camera mounting plate and a mounting bend plate. The mirror camera mounting plate is L-shaped. One side of the L-shaped mirror camera mounting plate is connected to a wire scanning camera. The other side of the L-shaped mirror camera mounting plate is detachably connected to one side of the mounting bend plate. Both ends of the mounting bend plate are fixedly installed on the inner side wall of the detection box. The mounting plate has elongated holes.

6. The insulation core defect detection device according to claim 1, characterized in that, The light shield is connected to the inner wall of the bottom of the detection chamber via a connecting plate.

7. The insulation core defect detection device according to claim 1, characterized in that, The outer side of the detection box is provided with a support column, and a connecting rod is provided on the support column. One end of the connecting rod is slidably connected to the support column, and the other end of the connecting rod is provided with a keyboard tray, which is L-shaped. An adjustment frame is installed above the connecting rod. One end of the adjustment frame is slidably connected to the support column, and the other end of the adjustment frame is hinged to a display.

8. The insulated conductor defect detection device according to claim 1, characterized in that, An alarm light is installed on one side of the top of the detection box, an alarm horn is installed on the upper side of the outer side of the detection box where the wire core outlet is located, and an LED warning light strip is installed in the upper middle part of one outer side of the detection box.

9. The insulation core defect detection device according to claim 1, characterized in that, Below the detection box is an industrial control computer enclosure, and the industrial control computer inside the enclosure is electrically connected to the line scan camera.

10. The insulation core defect detection device according to claim 1, characterized in that, The bottom of the frame is equipped with casters.

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