漆包线缠绕缺陷的实时检测与修正方法研究

Research on Real Time Detection and Modification Method of Enameled Wire Winding Defects

针对线圈绕线设备在进行高精度绕线作业时,容易出现间隙错误、搭接错误等缠绕缺陷问题,为提高线圈绕制质量,提出了一种实时检测线圈缠绕过程中出现不同绕制状态并进行修正的方法.该方法在分析线圈的绕制特点基础上,给出了漆包线缠绕缺陷的实时检测算法,并设计了相应的视觉检测系统和绕线设备的控制系统.该方法基于1×3模板提出了对预处理后的效果图轮廓点的提取算法;基于轮廓点拟合的绕制状态检测给出了修正方法,从而实现了线圈绕制状态的实时检测,并根据视觉实时检测结果修正错误的绕制状态.通过视觉检测系统稳定性试验、系统准确率试验和正交试验的验证,该方法明显增加了线圈绕制的紧密性,使线圈绕制成品的生产效率及质量得到了有效提高.

In order to improve the quality of coil winding and detect the winding defects such as gap errors and overlap errors in high-precision winding operations,a method was proposed for real-time detection and modification of different winding states in the winding process.Considering the winding characteristics of the coil,a realtime detection algorithm was proposed for winding defects of the enameled wire,and a corresponding visual detection system and control system were designed for the winding equipment.Based on the 1×3 template,an extraction algorithm was developed for the contour point extraction of the preprocessed effect images.Based on the winding state detection of the contour point fitting,a modification method was provided to realize the real-time detection of the coil winding state,and to modify the wrong winding state according to the results of visual realtime detection.The verification results of visual detection stability test,system accuracy rate test and orthogonal test show that the proposed method can obviously increase the tightness of the coil winding,and effectively improve the production efficiency and quality of the coil winding products.