Copper flat wires are transposed and stacked to form Continuously Transposed Conductors (CTC). These conductors are essential for high-performance electrical systems, so maintaining their quality is critical.
Two common defects can occur during production:
● Roughness: Formed due to impurities during the enamel application.
● Bare Spots: Occur when the enamel is removed by transposing tools, leaving exposed copper.
Additionally, the transposing process requires maintaining a consistent pitch—the interval at which the wires are transposed. Variations in this pitch, such as short, long, or missing pitches, can impact the quality and performance of the CTC.
Key Features
01
High-Speed Inspection
• Camera Setup for Defect Detection: Three high-resolution cameras, mounted on cylindrical fixtures with LED lighting, are placed to capture detailed images of the CTC. These cameras monitor both the top and bottom of the conductor to detect surface defects such as roughness and bare spots.
• Pitch Monitoring: To ensure uniformity, the system measures the pitch by detecting the length between CTC intervals. Using pixel-to-mm conversion, the system can precisely calculate whether the pitch is short, long, or missing, which is critical for quality control.
02
AI-Based Defect Detection
The camera images are processed on an AI server. The AI model is trained to detect:
• Surface Defects: Identifying roughness and bare spots in the wire.
• Pitch Errors: Measuring the length between each CTC to ensure consistency and detecting abnormalities in the transposing pitch.
03
Integration with Transposing System
• Machine Control: The system is integrated with the transposing machine through a microcontroller. When a defect or pitch error is detected, the server sends a signal to stop the machine, preventing further production of defective CTC.
• Automatic Start/Stop: The system receives machine signals to start or stop the detection process based on the production cycle.
04
Operator Interface and Configuration
A user interface provides operators with the ability to:
• Monitor Live Detection: Operators can view real-time camera feeds, allowing them to oversee the production and detection process.
• Defect and Pitch Reports: The system logs all detected defects and pitch errors, along with images and timestamps, enabling operators to generate reports and review production data.
• Configuration Settings: Operators can input wire specifications such as the expected pitch and wire size, allowing the system to adjust its detection thresholds and ensure accurate monitoring.
Conclusion
The CTC Defect Detection and Pitch Monitoring System is designed to maintain the quality of Continuously Transposed Conductors by detecting surface defects and ensuring consistent pitch intervals. By using AI models and real-time monitoring, the system enhances the production process, automatically stopping the machine when defects or pitch errors are detected, ensuring high-quality output and reducing downtime. The user interface provides operators with full control and visibility into the process, further supporting qualityassurance and efficiency in the CTC production line.