In the production process of copper wires, maintaining the highest quality is essential. After the Enamel department, where the wire is coated, it is wound into spools. Before this winding stage, it is critical to detect any defects formed during the earlier processes to ensure the integrity of the wire.
Key Features
01
System Configuration
3D Laser and 2D Camera System: The system uses four pairs of cameras: one 3D laser-based camera and one 2D camera in each pair. These pairs are strategically placed to cover the top, bottom, and side surfaces of the copper wire, ensuring complete surface inspection. The wire itself has a rectangular cross-section. The 3D cameras detect surface irregularities by measuring the wire’s z-axis dimension. When a defect passes through the laser system, the algorithm running on the server identifies the defect, and the 2D cameras are triggered to capture detailed images of the specific defect area for further analysis.
02
Defect Detection and Reporting
The system is capable of detecting defects as small as 20 microns in the z-dimension. When a defect is detected:
1. 3D Camera Detection: The laser-based 3D camera measures the wire's surface and identifies any defect by analysing its z-axis.
2. 2D Camera Trigger: Upon detecting a defect, the corresponding 2D camera is triggered to capture an image of the defective area.
3. Defect Analysis: The size and severity of the defect are recorded, particularly focusing on the defect’s z-size.
03
User Interface Features
The system provides operators with an intuitive user interface that allows for real-time monitoring and reporting:
1. Live View: Operators can monitor the live feed from the cameras to view the inspection process in real-time.
2. Defect Graphs and Reporting: Detected defects are presented in a graphical format, showing the z-size of the defect and corresponding timestamp (datetime). This allows for easy analysis of when and where defects occurred during the production process.
3. Report Generation: Operators can generate and download reports from the user interface, containing detailed records of the detected defects, including the defect size and time of detection.
Conclusion
The 3D Laser-Based Copper Wire Defect Detection System is designed to ensure the highest quality of copper wire production by identifying defects before the wire is wound into spools. The integration of 3D laser-based cameras for defect detection and 2D cameras for image capture, combined with a robust user interface, allows operators to monitor, analyse, and report on defects as small as 20 microns. This system enhances product quality and reduces the chances of defective wire being wound and shipped.