In the electronics manufacturing industry, coil is a key component, and its winding quality directly affects the performance and reliability of the product. Coil winding disorder (i.e., the arrangement of the coil is not neat or there are crosses, overlaps and other phenomena) is one of the common problems in the production process, which may not only lead to the decline of electrical performance, but also lead to short-circuits, circuit breaks and other serious failures. Therefore, it is of great significance to realize on-line inspection during the coil production process to detect and correct the disordered winding problem in time to ensure the quality of products.

In order to effectively detect whether the coil has the phenomenon of chaotic winding, there is a need for a testing equipment that can accurately measure the state of coil arrangement and automatically determine whether it is qualified or not. Specifically, the equipment needs to be able to:

Precision Measurement：The ability to accurately measure the relative position of parts in a coil, especially the distance between protrusions (such as the end of a coil or a specific marking point).

Intelligent Judgment：Based on the preset tolerance range, it automatically determines whether the alignment of the coil meets the requirements, i.e. whether it is OK (pass) or NG (fail).

Efficient and real time：Inspection is carried out in real time on the production line without affecting the overall speed of the production line, ensuring production efficiency.

Measurement program

In response to the above needs, we recommend the use of an online image measuring instrument for coil messy winding detection. The core of this solution lies in using a high-definition camera to capture the image of the coil, and realizing accurate measurement and intelligent judgment through image processing technology.

The specific steps are as follows:

1、Image Acquisition: The camera of the in-line image measuring instrument captures the image of the coil on the production line in real time and transmits it to the processing unit.

2、Image Processing: The processing unit utilizes built-in image processing algorithms to pre-process the coil image (e.g. denoising, contrast enhancement, etc.) in order to identify the coil contours and feature points more clearly.

3、Feature extraction: Extract key feature points (e.g. protrusions) in the coil image and calculate the distance between them through a combination of preset points or straight lines and other tools.

4、Intelligent judgment: Compare the measurement results with the preset tolerance range, and automatically judge whether the alignment of the coil is qualified. If the measurement result is out of the tolerance range, it will be judged as NG (unqualified) and an alarm signal will be issued; otherwise, it will be judged as OK (qualified) and allowed to continue production.

5、Data Recording: Measurement results and judgment results will be recorded in real time and saved in the database for subsequent quality tracing and analysis.