Real-time vision-based detection of wire gapping on a rotating transformer core

Colin J. Taylor; Ethan Evans; John M. Dolan; Pradeep K. Khosla

doi:10.1117/12.198691

4 January 1995 Real-time vision-based detection of wire gapping on a rotating transformer core

Colin J. Taylor, Ethan Evans, John M. Dolan, Pradeep K. Khosla

Proceedings Volume 2349, Industrial Optical Sensors for Metrology and Inspection; (1995) https://doi.org/10.1117/12.198691
Event: Photonics for Industrial Applications, 1994, Boston, MA, United States

Abstract

High-quality transformer winding requires precise measurement and control of the gapping between adjacent wires. We take a vision-based approach to the measurement subtask of determining the gaps between copper wires wound onto an oval transformer. The oval core shape, which can have an eccentricity as high as 2-to-1, leads to significant variations in surface normal and viewing distance. We use special lighting, a secondary mandrel shape sensor, and the specular reflection off the wires to give us an accurate model of the experimental geometry. We further exploit the vertical symmetry of the viewed region to condense our 2D image to a simple 1D signal containing reflectance peaks. after utilizing pattern recognition and some additional safety features to separate the wire peaks from background noise, we perform a least squares curve fit of the peaks to determine the subpixel maxima. the final algorithm is computationally fast and yields the desired wire gap in an absolute metric.

Citation Download Citation

Colin J. Taylor, Ethan Evans, John M. Dolan, and Pradeep K. Khosla "Real-time vision-based detection of wire gapping on a rotating transformer core", Proc. SPIE 2349, Industrial Optical Sensors for Metrology and Inspection, (4 January 1995); https://doi.org/10.1117/12.198691

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KEYWORDS

Cameras

Sensors

Transformers

Reflection

Light sources and illumination

Specular reflections

Calibration

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