线缆表面缺陷CCD检测系统

CCD detection system for surface defects of wire cable

生产线缆还靠人工手摸吗? 质量控制还在靠人工手摸盲测吗?

虽然很努力了，还是人为因素不能避免，缺陷依然检测不出来?客户依然投诉?员工管理依然很难，复检依然费时费力?

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2.1线缆表面缺陷检测:

Detection for surface defects of wire cable

1、脱料划伤破裂突出的皮层斑点凸起凹陷叠接等缺陷,

Stripping, scratching and rupturing, protrudent skin layer, bulging spot, recession, overlapping, etc.

2、线缆变细,变粗等,

Wire cable thins or thickens, etc.

3、灵敏度参数可调

Adjustable sensitivity parameter

2.2、字符印刷质量检测

Detecting of letter quality of characters

1、线缆表面字符印刷质量检测

Detecting of letter quality of characters on surface of wire cable

2、对线缆长度数字的字符识别,并能自动累加数学计算

Character recognition for the digits of wire cable length, and can automatically accumulate mathematical computation

3.1.系统原理

System theory

3.2.实验图

Experiment figure

线缆表面缺陷检测是采用3条互成120度的视觉投影,可以无盲区的检测到产品的细小缺陷,即使缺陷很小而且高速也能检测到;线缆字符印刷质量检测是通过视频分析OCR字符识别来实现;同时具有系统软件管理与数据分析功能。

Adopting three visual projections which form 120 degrees between each other, detection of surface defects of wire cable can detect products' fine defects without dead zones, even the very small and rapidly moving ones. The detecting of letter quality of wire cable characters is realized via analysis on OCR character recognition on video, also is provided with system software management and data analysis.

4.1线缆表面缺陷检测

Detection for surface defects of wire cable

(1)、脱料划伤破裂突出的皮层斑点凸起凹陷叠接等缺陷,

Stripping, scratching and rupturing, protrudent skin layer, bulging spot, recession, overlapping, etc.

(2)、线缆变细,变粗等,

Wire cable thins or thickens, etc.

(3)、灵敏度参数可调

Adjustable sensitivity parameter

a.以下示意图表示了测量设备在一个轴向上的结构, 这种结构可以有效保证测量结果的准确性

Following schematic diagram shows the structure of measurement equipment in one axial direction. This structure can efficiently guarantee accuracy of measurement result.

b.以下示意图表示了测量设备在三个轴向上的结构采用三个维度的检测结构, 这种结构可以有效保证测量结果的准确性。

Following schematic diagram shows the structure of measurement equipment in three axial directions. This detection structure of three dimensions can efficiently guarantee accuracy of measurement result.

在电线线缆的外观缺陷检测中,采用3条互成120度,可以无盲区的检测到产品的细小缺陷,即使缺陷小而且高速也能检测到。

In detection of appearance defects for wire cable, three visual projects which form 120 degrees between each other are adopted to detect the find defects of products, even very small and rapidly moving ones.

c.以下示意图表示了测量设备的检测特征对于产品的特征缺陷特征,特别是缺陷较小不是非常明显是,基本能实现”零缺陷”,可以有效保证产品质量的准确性和精确度.

Following schematic diagram shows detection features of measurement equipment. "Zero defects" can basically be realized to effectively guarantee products’ accuracy and precision especially when the defects are very small and insignificant.

d.测量设备的技术参数

Technical parameters of measurement equipment

检测方向:3

Detection direction:3

检测方式:非接触式连续测量

Detection mode: non-contact continuous measurement

警报输出:红色LED亮,报警常开接点闭合

Alarm output: when red LED is on, normally open contact of alarm is closed

报警时间:0.1sAlarm time: 0.1s

使用温度:-5℃- +55℃

Service temperature:- 5℃- +55℃

功耗:10~200W

Power consumption: 10-200w

4.2字符印刷质量检测

Detection of letter quality of characters

(1)、线缆表面字符印刷质量检测

Detection of letter quality of characters on surface of wire cable

(2)、对线缆长度数字的字符识别,并能自动累加数学计算

Character recognition for the digits of wire cable length, and can automatically accumulate mathematical computation

a以下示意图表示了字符质量检测系统结果图

Following schematic diagram shows result of character quality detection system

b 测量设备的技术参数

Technical parameters of measurement equipment

检测方式:光学非接触式连续测量

Detection mode: optical non-contact continuous measurement

检测方向角:线缆字符旋转角度范围30度

Detection azimuth: scope of character rotation angles of wire cable is 30 degrees

警报输出:红色LED亮,报警常开接点闭合,数据输出

Alarm output: when red LED is on, normally open contact of alarm is closed, and data is outputted

报警时间:0.1s

Alarm time: 0.1s

使用温度:-5℃- +55℃

Service temperature:- 5℃- +55℃

(1)、线缆缺陷报警次数统计功能

Function of gathering statistics about alarms quantity of wire cable defects

(2)、线缆印刷质量报警次数统计功能

Function of gathering statistics about alarms quantity of letter quality of wire cable

(3)、线缆报警缺陷输出警报功能

Function of alarm of outputting alarm defects of wire cable

(4)、线缆印刷质量输出报警功能

Function of alarm of outputting wire cable letter quality

(5)、线缆质量输出图形界面功能

Function of graphical interfaces for output of wire cable quality

(6)、线缆数据支持二次开发功能

Function of wire cable data supporting redevelopment

线缆表面缺陷检测仪能够采集显示和分析产品表面每一平方毫米的工具。分析内容包括:电缆护套管道管件棒材和水溶胶带表面这是目前检测表面缺陷的方法表面缺陷检测器记录缺陷位置以及保存缺陷图片。操作员可以通过使用表面缺陷检测器来查看当前表面图片,最近一次的表面缺陷图片以及缺陷尺寸。工程和生产监督人员还可以通过表面缺陷检测器来检查缺陷,而无需去查看缺陷本身,并且根据生产批号,导出报表使用尖刀视智能科技表面缺陷检测器,您可确保发送给您客户的产品符合高标准要求,提高产品质量。

Wire cable surface detector is the only tool that is able to collect, display and analyze each square millimeter on the surface of product. The analyzed content covers: surface of cable sheath, conduit, pipe fittings, rod and hydrosoluble adhesive tape. This is the most thorough approach to detection of surface defects at present. The surface defect detector records defect position and stores defects picture. The operator can see picture of current surface, latest surface defect picture and defect size by surface defect detector. The engineering and manufacturing supervision personnel can further detect defects by dint of surface defect detector without need to check the defect itself, and can export report according to manufacturing batch number. Advance intelligent scientific surface defect detector enables you to guarantee the products delivered to customers meet high standard and improve the quality of products accurately and efficiently.

检测电线、电缆护套、金属管、裸线、尼龙、胶带上的小孔膨胀凹凸表面污点

Detect pinhole bulging, unevenness, surface stain on wire, cable sheath, metallic conduit, bare wire, nylon and adhesive tape

支持线速度高达400米/分钟；

The linear velocity supported is up to 400 meters/minute

根据所需覆盖范围和缺陷尺寸要求,可配置两个三个或四个摄像头；

2,3 or 4 cameras can be configured according to the required coverage and minimal defect size.

在发现任何缺陷的同时,警告操作员或其它生产设备；

Warn operator or other production unit when finding any defects.

记录所有缺陷,用于质量保证记录或用于操作员确认；

Record all defects to be used for quality assurance record or confirmation by operator

保存每个缺陷的位置信息,以便操作员轻易找到这些缺陷；

Store the position information of each defect to enable the operator to spot these defects with ease.

软件分析产品整个360度圆周以及保证轴向覆盖率；

Analyze the product's whole 360°circle with software and guarantee axial coverage.

图1 程序界面

Figure 1 Interface of program

图2 缺陷检测图

Figure 2 Defect detection figure

广泛应用于:光缆线缆网线金属线圆管胶管金属管护套尼龙胶辊轴类卷烟等在线光学检测领域

Extensively applied to: on-line optical detection regions such as optical fiber cable, wire cable, netting twine, metal wire, circular pipe, hose, metallic conduit, sheath, nylon, rubber roller axis and cigarette, etc.