Alloy casting defect detection equipment with intelligent marking function

Abstract

The application discloses alloy casting defect detection equipment with intelligent marking function and relates to the technical field of detection equipment. The defect detection equipment comprises a defect sensing system, a marking mechanism, a positioning mechanism, a clamping mechanism and a conveying mechanism. The defect sensing system and the positioning mechanism are fastenedly connected. The marking mechanism and the defect sensing system are fastenedly connected. The positioning mechanism and the conveying mechanism are fastenedly connected. The clamping mechanism and the conveying mechanism are fastenedly connected. The defect sensing system is used for carrying out defect scanning on the surface and the interior of a casting in an ultrasonic wave or electric conductivity mode. The marking mechanism performs coating and solidification color marking operation on a defect area. The clamping mechanism clamps or releases a detected casting, and cooperates to realize multi-angle detection requirement. The detection precision and efficiency are improved, and the realization of defect identification, positioning and tracking marking is ensured.

Description

TECHNICAL FIELD

[0001] The application relates to the technical field of detection equipment, and particularly relates to alloy casting defect detection equipment with an intelligent marking function. BACKGROUND

[0002] With the continuous improvement of the quality requirements of key parts in the fields of high-end equipment manufacturing, aviation casting, rail transportation and energy chemical industry, the industrial casting defect detection technology gradually evolves from the traditional mode of'manual visual inspection-single probe-postmarking' to the high-integration, high-precision intelligent detection system of 'automatic scanning-intelligent identification-real-time marking'.

[0003] At present, some enterprises or research institutions have developed ultrasonic detection equipment with a servo scanning head to mark the defects of a surface defect visual system.

[0004] However, the following problems exist in the prior art: the traditional conveying device is a fixed horizontal structure, and cannot realize adaptive angle conveying according to the size and structure differences of workpieces, causing a detection blind area or positioning deviation; and the existing marking method mainly relies on manual visual guidance and lacks semi-permanent traceable marking. SUMMARY

[0005] The application aims to provide alloy casting defect detection equipment with an intelligent marking function to solve the problems in the prior art.

[0006] To achieve the above object, the application provides the following technical scheme.

[0007] The defect detection equipment comprises a defect sensing system, a marking mechanism, a positioning mechanism, a clamping mechanism and a conveying mechanism, the defect sensing system and the positioning mechanism are fixedly connected, the marking mechanism and the defect sensing system are fixedly connected, the positioning mechanism and the conveying mechanism are fixedly connected, and the clamping mechanism and the conveying mechanism are fixedly connected.

[0008] By adopting the above technical scheme, the defect sensing system is used for defect scanning of the surface and the interior of the casting in an ultrasonic wave or conductivity mode; the marking mechanism is fastened to the defect sensing system, and immediately performs the coating and curing color marking operation on the defect area after detecting the defect; the positioning mechanism precisely positions the defect sensing system to the target detection area through the control of the three-axis screw rods in the transverse, longitudinal and approaching directions; the clamping mechanism drives the clamping plate to clamp or release the detected casting through the clamping electric cylinder, adjusts the posture through the rotary motor, and realizes the multi-angle detection requirement; the conveying mechanism bears the moving and conveying functions of the entire casting, drives the clamping mechanism and the positioning mechanism to link, and makes the measured workpiece sequentially enter, position, detect and mark. After the workpiece is loaded and clamped by the conveying mechanism, the positioning mechanism moves the detection mechanism to the set detection path to scan the surface and the interior of the workpiece, the detection result is transmitted to the marking mechanism in real time, and the coupling agent marking and light curing treatment are quickly completed in the defect area. Finally, the conveying mechanism conveys the detected workpiece to the subsequent process. The structure improves the detection precision and efficiency through fastening connection, ensures the stability and reliability of the whole process of defect identification, positioning and marking, and has the advantage of high identification rate.

[0009] Further, the conveying mechanism includes a conveying frame, a conveying belt, a first roller, a second roller, a conveying motor, and an inclined lifting assembly. The positioning mechanism is fastened to the conveying frame. The conveying motor is in transmission connection with the second roller. The second roller is in transmission connection with the conveying belt. The inclined lifting assembly is in sliding connection with the conveying frame. The second roller is in sliding connection with the conveying frame. The conveying belt is in transmission connection with the first roller.

[0010] By adopting the above technical scheme, the conveying frame serves as a support base, bears all conveying components, and is fastened to the positioning mechanism to ensure the stability of the overall structure. The conveying motor serves as a driving source, is in transmission connection with the second roller, drives the second roller to rotate, and in turn drives the conveying belt to continuously move, thereby realizing the linear conveying of the workpiece. The conveying belt is in transmission connection with the first roller, and is kept stable in operation through the tensioning action of the two end rollers. The inclined lifting assembly is in sliding connection with the conveying frame, and is in sliding cooperation with the first roller, so that the second roller is lifted and lowered with the lifting assembly, thereby realizing the angle adjustment function of the entire conveying belt. The working process is as follows: when the conveying surface angle needs to be changed to adapt to the entry of different workpieces into the clamping position or cooperate with the detection angle, the inclined lifting assembly starts the driving structure to lift or lower, so that the position of the second roller changes, and in turn the angle of the belt is adjusted to adapt to the working height of the subsequent mechanism. Through the precise transmission and sliding cooperation, the structure not only realizes the conveying function, but also has the angle self-adaptation capability, effectively improves the universality and compatibility of the defect detection equipment, and enhances the flexibility and stability of the overall operation.

[0011] Further, the inclined lifting assembly comprises a lifting hydraulic cylinder, a lifting frame, a first sliding block, a second sliding block, a third sliding block, a magnetostrictive elastic element, a first electromagnetic block and a first magnetic block, the lifting hydraulic cylinder is fixedly connected with the conveying frame, the lifting hydraulic cylinder is in transmission connection with the lifting frame, the lifting frame is in sliding connection with the conveying frame, the first sliding block is in sliding connection with the conveying frame, the second sliding block is in sliding connection with the first sliding block, the first roller is in rotation connection with the second sliding block, the first roller is in rotation connection with the third sliding block, the third sliding block is in sliding connection with the lifting frame, the conveying motor is fixedly connected with the lifting frame, the first electromagnetic block is fixedly connected with the lifting frame, the first magnetic block is fixedly connected with the third sliding block, the magnetostrictive elastic element is fixedly connected with the first magnetic block, the magnetostrictive elastic element is fixedly connected with the first electromagnetic block, the first electromagnetic block and the first magnetic block are in magnetic pole attraction transmission, and the first roller is in sliding connection with the lifting frame.

[0012] By adopting the above technical scheme, the lifting hydraulic cylinder is fixed to the conveying frame and in transmission connection with the lifting frame, and the overall lifting of the lifting frame is realized through hydraulic driving; the lifting frame and the conveying frame are in sliding connection, which ensures smooth movement in the vertical direction. The first sliding block is in sliding connection with the conveying frame, serving as the basis of the sliding module, carrying the second sliding block and realizing horizontal adjustment through sliding; the second sliding block is in rotation connection with the first roller, so that the first roller adjusts the inclination angle along with the displacement thereof; the third sliding block is in sliding connection with the first roller and the lifting frame, guiding the first roller to move smoothly along the inclined trajectory when the lifting frame is lifted. The magnetostrictive elastic element is fixedly connected between the first electromagnetic block and the first magnetic block, and is micro-elongated and deformed under the mutual attraction of the first electromagnetic block and the first magnetic block, so as to modify the angle of the first roller, thereby enhancing the adaptability of the equipment to workpieces of different sizes and effectively improving the detection angle matching and conveying stability.

[0013] Further, the lifting frame is provided with an arc-shaped sliding groove, the arc-shaped sliding groove is a circular arc, the arc-shaped sliding groove takes the axis of the second roller as the center, and the third sliding block, the magnetostrictive elastic element, the first electromagnetic block and the first magnetic block are all located in the arc-shaped sliding groove.

[0014] By adopting the above technical scheme, the arc-shaped sliding groove is processed into a precise circular arc track, so that the geometric center is strictly coaxial with the axis of the second roller, the third sliding block is embedded in the arc-shaped sliding groove and in rotation connection with the first roller, so that the first roller realizes arc swinging on the lifting frame; the magnetostrictive elastic element is arranged in the arc-shaped sliding groove, connects the first magnetic block and the first electromagnetic block, and naturally bends or stretches along the moving path of the arc groove, so as to realize micro-displacement adjustment; the first electromagnetic block is fixed to the lifting frame and serves as a magnetic control source, and the first magnetic block is fixed to the third sliding block and generates an adsorption driving effect along the arc-shaped groove under electromagnetic excitation, so as to push the third sliding block to slide accurately along the preset circular arc, thereby providing support for dynamic adjustment of the inclination angle of the conveying system.

[0015] Furthermore, the conveying mechanism also includes a sorting box, a recycling box, and a cleaning brush. The cleaning brush is fastened to the conveyor belt. Both the sorting box and the recycling box are fastened to the conveyor frame. The sorting box is provided with a sorting groove, and the conveyor frame is provided with a sorting chute. The sorting chute and the sorting groove correspond one-to-one.

[0016] By adopting the above technical solution, the cleaning brush is fixedly connected to the conveyor belt and moves synchronously with the belt to continuously brush and clean the bottom surface of the workpiece, removing surface impurities and attachments, ensuring that the detection surface of the defect sensing system is free from interference. The sorting box and recycling box are both securely installed below the conveyor frame, forming a collection system after inspection. The sorting box has multiple sorting slots for receiving sorted workpieces, corresponding to the sorting chute on the conveyor frame. The sorting chute is designed as an inclined slide structure, which guides the workpieces on the conveyor path to slide into the corresponding sorting slot below. The conveyor belt delivers the workpiece to the end area, during which the cleaning brush completes its brushing, helping to clean the surface before inspection, thereby reducing inspection errors.

[0017] Furthermore, the clamping mechanism includes a clamping plate, a soft push-brush, a rotary motor, a clamping electric cylinder, and a position sensor. The clamping electric cylinder is fastened to the conveyor frame, the clamping electric cylinder is driven to the rotary motor, the rotary motor is driven to the clamping plate, the position sensor is fastened to the clamping plate, the soft push-brush is fastened to the clamping plate, and the soft push-brush abuts against the cleaning brush.

[0018] By adopting the above technical solution, the clamping electric cylinder is fixedly installed on the conveyor frame as a clamping drive source. Its output shaft is connected to the rotary motor for transmission. The rotary motor further drives the clamping plate to rotate, so that the clamping plate can drive the workpiece to adjust the angle or rotate to meet the detection requirements in the clamping state. The position sensor is fixed to the clamping plate to detect the position of the clamping plate and the posture of the workpiece in real time, so as to ensure that the clamping accuracy and rotation angle are controllable. The front end of the clamping plate is equipped with a soft push-sweep brush, which is set opposite to the cleaning brush. While clamping the workpiece, the push-sweep brush and the cleaning brush abut against each other to form a cleaning interface, so as to remove and wipe the residue on the surface or edge of the workpiece during the rotation of the clamping plate.

[0019] Furthermore, the positioning mechanism includes a positioning frame, a longitudinal motor, a transverse motor, a proximity motor, a first lead screw, a second lead screw, a third lead screw, a transverse moving frame, and a longitudinal moving frame. The positioning frame and the conveying frame are fastened together. The transverse motor and the positioning frame are fastened together. The transverse motor and the first lead screw are driven together. The first lead screw and the transverse moving frame are driven together. The longitudinal motor and the transverse moving frame are fastened together. The longitudinal motor and the second lead screw are driven together. The second lead screw and the longitudinal moving frame are driven together. The proximity motor and the longitudinal moving frame are fastened together. The longitudinal motor and the third lead screw are driven together. The third lead screw and the defect sensing system are driven together.

[0020] By adopting the above technical solution, the positioning frame and the conveying frame are firmly connected, serving as the installation reference platform for the entire positioning mechanism. The transverse motor is fixed on the positioning frame and drives the transverse frame to move along the X-axis direction through the first lead screw. The longitudinal motor is mounted on the transverse frame and drives the longitudinal frame to move along the Y-axis direction through the second lead screw. The proximity motor is firmly connected to the longitudinal frame and is used to control the proximity direction. It drives the defect sensing system to move precisely forward and backward along the Z-axis through the third lead screw. The first, second, and third lead screws correspond to the transverse, longitudinal, and proximity axes of motion, respectively, providing a stable spatial support foundation for the subsequent marking mechanism.

[0021] Furthermore, the defect sensing system includes a proximity block, an ultrasonic piezoelectric wafer probe, a coating assembly, and a telescopic cylinder. A third lead screw is driven to the proximity block, the telescopic cylinder is fastened to the proximity block, the telescopic cylinder is driven to the ultrasonic piezoelectric wafer probe, and the ultrasonic piezoelectric wafer probe is slidably connected to the coating assembly.

[0022] By adopting the above technical solution, in specific implementation, the proximity block is connected to the third lead screw to achieve overall forward and backward positioning along the approach direction; the telescopic cylinder is fixedly installed on the proximity block to drive the ultrasonic piezoelectric wafer probe to extend and retract in the vertical direction, ensuring that the probe can adaptively adjust its contact according to the undulations of the workpiece surface; the ultrasonic piezoelectric wafer probe is slidably connected to the coating assembly, achieving efficient energy coupling and defect echo acquisition under the action of the couplant during the detection process. Its working process is as follows: after the proximity block approaches the workpiece to a preset distance under the drive of the third lead screw, the telescopic cylinder is activated, slowly pushing the ultrasonic piezoelectric wafer probe to a position where it contacts the workpiece surface. Simultaneously, the coating assembly slides and cooperates, forming a uniform couplant film between the probe and the workpiece. Then, the ultrasonic probe emits a pulse signal and receives the reflected echo to identify the defect location and type. This structure, through rigid positioning combined with flexible extension, ensures stable contact of the detection head in a dynamic environment. Simultaneously, the couplant further enhances signal penetration and resolution, ensuring the sensitivity and accuracy of defect detection and providing high-quality raw data support for subsequent marking and classification.

[0023] Furthermore, the coating assembly includes a coupling agent applicator, a coating motor, an opening and closing block, and a reset elastic element. The coupling agent applicator has a roller-shaped structure. The proximity block has a coupling agent injection port and a closing port, which are connected. The ultrasonic piezoelectric crystal probe abuts against the closing port. The coupling agent applicator and the proximity block are rotatably connected. The coating motor and the coupling agent applicator are driven together. The opening and closing block and the coupling agent applicator are slidably connected. The opening and closing block and the reset elastic element are fastened together. The reset elastic element and the coupling agent applicator are fastened together. The ultrasonic piezoelectric crystal probe abuts against the opening and closing block. The opening and closing block has coating micropores, which are connected to the closing port.

[0024] By adopting the above technical solution, the coupling agent applicator has a roller-shaped structure that rotates around the proximity block. The surface rotation is achieved by the application motor, so that the coupling agent is evenly distributed on the bottom of the roller. The application motor and the coupling agent applicator rotate together, ensuring stable and reliable rotation. The proximity block has a couplant injection port and a sealing port, forming a sealed fluid cavity. The couplant injection port is used to inject couplant into the cavity, while the sealing port serves as the couplant output channel, communicating with the coating micropores. The micropores are located on the opening and closing block to control the release of couplant on the surface. The opening and closing block is slidably connected to the coater and slides backward when not subjected to the contact force of the ultrasonic piezoelectric crystal probe. At the same time, the reset elastic element resets, aligning the coating micropores with the sealing port, and the couplant is then released and adheres to the roller surface. During rotation, a thin coupling interface is formed between the probe and the workpiece surface through roller coating. During testing, the probe moves down, the opening and closing block opens, the probe contacts the couplant, the reset elastic element compresses, and the couplant injection port is sealed to prevent couplant leakage. This structure triggers coating through mechanical contact, avoiding the complex control of electronic valves, ensuring uniform and on-demand release of couplant before each test, while also having automatic closing and leak-proof effects, greatly improving the cleanliness, efficiency, and repeatability of the testing process.

[0025] Furthermore, the marking mechanism includes a conductivity head and a curing lamp, the conductivity head and the proximity block are fastened together, and the curing lamp and the conductivity head are fastened together.

[0026] By adopting the above technical solution, in a specific embodiment, the coupling agent material includes a hydrogel base liquid, electrochromic microcapsules, a pH stabilizer, a conductive ionic liquid, and a photocuring agent. The hydrogel base liquid provides adhesion, flexibility, and adjustable flowability to support ultrasonic coupling requirements. The electrochromic microcapsules cause an irreversible color change when acted upon by the conductivity head. The pH stabilizer maintains the color stability of the coupling agent under different surface pH conditions. The conductive ionic liquid provides controllable conductivity, facilitating sensing and positioning by the conductivity head. The photocuring agent receives UV light. The light-curing process forms a semi-permanent mark. The conductivity head is tightly connected to the proximity block and closely attached to the side of the ultrasonic piezoelectric crystal probe. It is used to simultaneously measure the conductivity distribution of the workpiece surface or local area during the detection process to determine the continuity of the material structure or the presence of areas with abnormal conductivity characteristics. When the conductivity head detects a sudden change or obvious deviation in conductivity, it immediately outputs a judgment command. At the same time, the curing lamp is tightly connected to it. After receiving the command, it starts ultraviolet light irradiation, which acts on the color-changing coupling agent that has been pre-coated on the defect area by the coating component, so that it quickly undergoes a light-curing reaction at the abnormal point and develops color to form a semi-permanent mark.

[0027] Compared with the prior art, the beneficial effects of this invention are as follows: In this device, the conveying mechanism constitutes a multi-point drive linkage system through a conveyor frame, conveyor belt, first roller, second roller, conveyor motor, and tilting lifting assembly. The tilting lifting assembly further comprises a composite adjustment structure consisting of a lifting hydraulic cylinder, lifting frame, three sets of sliding blocks, magnetostrictive elastic elements, electromagnetic blocks, and magnetic blocks. The lifting hydraulic cylinder controls the upward and downward sliding of the lifting frame, causing the height of the second roller to change dynamically. The first roller is controlled by a combination of multiple sliding blocks and magnetostrictive elastic elements to swing along an arc-shaped trajectory centered on the second roller, achieving continuous tilt angle adjustment. The magnetically controlled flexible structure ensures that the tilt angle adjustment simultaneously possesses micro-displacement correction and structural damping, effectively solving the problem of tilt angle adaptation when large workpieces enter and exit the clamping area. The ultrasonic piezoelectric crystal probe inside the defect sensing system achieves three-axis micro-motion control through a telescopic cylinder and a proximity block. The probe front end, together with a roller-type coupling agent applicator, an opening and closing block, and a reset elastic element, forms a dynamic liquid supply and automatic closing coating system. This ensures that the applicator releases the coupling agent under pressure trigger and closes immediately before the probe contacts the workpiece, avoiding redundant liquid consumption. At the same time, a conductivity head and a curing lamp are integrated around the probe to simultaneously acquire the electrical response of the material surface during the detection process, realizing the joint judgment of physical defects and material conductivity characteristics. This provides dual evidence for subsequent marking mechanisms, improving the reliability and accuracy of defect judgment. The coupling agent released by the coating component is composed of structural materials such as hydrogel base liquid, electrochromic microcapsules, conductive ionic liquid, and photocuring agent, which combines high adhesion, flexibility, and functional responsiveness. When the conductivity head detects an abnormal conductive area, the color-changing microcapsules are stimulated to release a color reaction. At the same time, the curing lamp is immediately activated to irradiate the photosensitive components in the defect area, forming a curing mark with color contrast that cannot be erased. This ensures that the defect point has a structural response and material memory, improving the accuracy of subsequent sorting and rework. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of the present invention;

[0029] Figure 2 This is a schematic diagram of the conveying mechanism of the present invention;

[0030] Figure 3 This is a schematic diagram of the tilting and lifting component structure of the present invention;

[0031] Figure 4 This is a schematic diagram of the classification box structure of the present invention;

[0032] Figure 5 This is a schematic diagram of the clamping mechanism of the present invention;

[0033] Figure 6 This is a schematic diagram of the positioning mechanism structure of the present invention;

[0034] Figure 7This is a schematic diagram of the coating component structure of the present invention;

[0035] Figure 8 This is a schematic diagram of the opening and closing block structure of the present invention.

[0036] In the diagram: 1. Defect sensing system; 11. Proximity block; 111. Closure port; 112. Coupling agent injection port; 12. Ultrasonic piezoelectric crystal probe; 13. Coating assembly; 131. Coupling agent applicator; 132. Coating motor; 133. Opening / closing block; 1331. Coating micro-hole; 134. Reset elastic element; 14. Telescopic cylinder; 2. Marking mechanism; 21. Conductivity head; 22. Curing lamp; 3. Positioning mechanism; 31. Positioning frame; 32. Longitudinal motor; 33. Lateral motor; 34. Proximity motor; 35. First lead screw; 36. Second lead screw; 37. Third lead screw; 38. Lateral movement frame; 39. Longitudinal movement frame; 4. Clamping mechanism; 41 42. Clamping plate; 43. Soft push-brush; 44. Rotary motor; 45. Clamping electric cylinder; 56. Position sensor; 57. Conveying mechanism; 58. Conveying frame; 59. Sorting chute; 50. Conveying belt; 51. First roller; 52. Second roller; 53. Conveying motor; 54. Tilting lifting assembly; 55. Lifting hydraulic cylinder; 56. Lifting frame; 56. Arc-shaped sliding groove; 56. First sliding block; 56. Second sliding block; 56. Third sliding block; 56. Magnetostrictive elastic element; 56. First electromagnetic block; 56. First magnetic block; 57. Sorting box; 58. Sorting trough; 59. Recycling box; 50. Cleaning brush. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] Please see Figure 1 - Figure 8 As shown, the present invention provides a technical solution for an alloy casting defect detection device with intelligent marking function:

[0039] The defect detection equipment includes a defect sensing system 1, a marking mechanism 2, a positioning mechanism 3, a clamping mechanism 4, and a conveying mechanism 5. The defect sensing system 1 and the positioning mechanism 3 are fastened together, the marking mechanism 2 and the defect sensing system 1 are fastened together, the positioning mechanism 3 and the conveying mechanism 5 are fastened together, and the clamping mechanism 4 and the conveying mechanism 5 are fastened together.

[0040] By adopting the above technical solution, the defect sensing system 1 is used to scan the surface and interior of the casting using ultrasonic or electrical conductivity methods; the marking mechanism 2 is tightly connected to it, and immediately performs coating and curing color marking operations on the defect area after detecting a defect; the positioning mechanism 3, through transverse, longitudinal, and proximity three-axis lead screw control, accurately positions the defect sensing system 1 to the target detection area; the clamping mechanism 4, through the clamping electric cylinder 44, drives the clamping plate 41 to clamp or release the casting to be tested, and cooperates with the rotary motor 43 to adjust the posture to achieve multi-angle detection requirements; the conveying mechanism 5 undertakes the movement and conveying function of the entire casting, and through the linkage of the clamping mechanism 4 and the positioning mechanism 3, the workpiece is sequentially entered, positioned, detected, and marked. After the workpiece is loaded and clamped by the conveying mechanism 5, the positioning mechanism 3 moves the detection mechanism to the set detection path, scans the surface and interior of the workpiece, and transmits the detection results to the marking mechanism 2 in real time, and quickly completes the coupling agent marking and light curing treatment in the defect area. Finally, the conveying mechanism 5 transports the detected workpiece to the subsequent process. This structure improves detection accuracy and efficiency through tight connections, ensuring stability and reliability throughout the entire process of defect identification, location, and marking, and has the advantage of high recognition rate.

[0041] Furthermore, the conveying mechanism 5 includes a conveying frame 51, a conveying belt 52, a first roller 53, a second roller 54, a conveying motor 55, and a tilting and lifting assembly 56. The positioning mechanism 3 is fastened to the conveying frame 51, the conveying motor 55 is driven to the second roller 54, the second roller 54 is driven to the conveying belt 52, the tilting and lifting assembly 56 is slidably connected to the conveying frame 51, the second roller 54 is slidably connected to the conveying frame 51, and the conveying belt 52 is driven to the first roller 53.

[0042] By adopting the above technical solution, the conveyor frame 51 serves as a supporting foundation, bearing all conveying components and being securely connected to the positioning mechanism 3, ensuring the overall structural stability. The conveyor motor 55 serves as a drive source, connected to the second roller 54, driving the second roller 54 to rotate and thus driving the conveyor belt 52 to move continuously, achieving linear conveying of the workpiece. The conveyor belt 52 is connected to the first roller 53, and the tension of the rollers at both ends maintains the stable operation of the conveyor belt 52. The tilting and lifting assembly 56 is slidably connected to the conveyor frame 51, and through sliding cooperation with the first roller 53, the second roller 54 rises and falls with the lifting assembly, realizing the tilt angle adjustment function of the entire conveyor belt 52. Its working process is as follows: when it is necessary to change the angle of the conveying surface to adapt to different workpieces entering the clamping position or to match the detection angle, the tilting and lifting assembly 56 activates the drive structure to raise or lower, causing the position of the second roller 54 to change, thereby adjusting the belt tilt angle to match the working height of the subsequent mechanism. This structure, through precise transmission and sliding cooperation, not only realizes the conveying function but also has the ability to adapt to angles, effectively improving the versatility and compatibility of the defect detection equipment and enhancing the overall operational flexibility and stability.

[0043] Furthermore, the tilting and lifting assembly 56 includes a lifting hydraulic cylinder 561, a lifting frame 562, a first sliding block 563, a second sliding block 564, a third sliding block 565, a magnetostrictive elastic element 566, a first electromagnetic block 567, and a first magnetic block 568. The lifting hydraulic cylinder 561 is fastened to the conveyor frame 51, the lifting hydraulic cylinder 561 is driven to the lifting frame 562, the lifting frame 562 is slidably connected to the conveyor frame 51, the first sliding block 563 is slidably connected to the conveyor frame 51, the second sliding block 564 is slidably connected to the first sliding block 563, and the first roller 53 and the second sliding block 565 are also connected. 64 Rotary connection, first roller 53 and third sliding block 565 are rotatably connected, third sliding block 565 and lifting frame 562 are slidably connected, conveyor motor 55 and lifting frame 562 are fastened, first electromagnetic block 567 and lifting frame 562 are fastened, first magnetic block 568 and third sliding block 565 are fastened, magnetostrictive elastic element 566 and first magnetic block 568 are fastened, magnetostrictive elastic element 566 and first electromagnetic block 567 are fastened, first electromagnetic block 567 and first magnetic block 568 are driven by magnetic pole attraction, first roller 53 and lifting frame 562 are slidably connected.

[0044] By adopting the above technical solution, the lifting hydraulic cylinder 561 is fixed to the conveyor frame 51 and is connected to the lifting frame 562 via transmission. The overall lifting of the lifting frame 562 is achieved through hydraulic drive. The lifting frame 562 and the conveyor frame 51 are connected by a sliding connection to ensure smooth vertical movement. The first sliding block 563 is slidably connected to the conveyor frame 51, serving as the foundation of the sliding module, supporting the second sliding block 564, and achieving horizontal adjustment through its sliding. The second sliding block 564 is rotatably connected to the first roller 53, allowing the first roller 53 to adjust its tilt angle with its displacement. The third sliding block 565 is slidably connected to both the first roller 53 and the lifting frame 562, guiding the first roller 53 to move smoothly along an oblique trajectory when the lifting frame 562 is raised or lowered. The magnetostrictive elastic element 566 is fixedly connected between the first electromagnetic block 567 and the first magnetic block 568. Under the mutual attraction between the first electromagnetic block 567 and the first magnetic block 568, it undergoes micro-stretching deformation, which modifies the angle of the first roller 53, enhances the equipment's adaptability to workpieces of different sizes, and effectively improves the matching of detection angles and the stability of conveying.

[0045] Furthermore, the lifting frame 562 is provided with an arc-shaped sliding groove 5621. The arc-shaped sliding groove 5621 is arc-shaped and has the axis of the second roller 54 as its center. The third sliding block 565, the magnetostrictive elastic element 566, the first electromagnetic block 567 and the first magnetic block 568 are all located in the arc-shaped sliding groove 5621.

[0046] By adopting the above technical solution, the arc-shaped sliding groove 5621 is processed into a precise arc trajectory, so that its geometric center is strictly coaxial with the axis of the second roller 54. The third sliding block 565 is embedded in the arc-shaped sliding groove 5621 and rotates and connects with the first roller 53, so that the first roller 53 can swing in an arc on the lifting frame 562. The magnetostrictive elastic element 566 is set in the arc-shaped sliding groove 5621, connecting the first magnetic block 568 and the first electromagnetic block 567, and naturally bends or extends with the movement path of the arc groove to realize micro-displacement adjustment. The first electromagnetic block 567 is fixed to the lifting frame 562 as a magnetic control source. The first magnetic block 568 is fixed on the third sliding block 565. Under electromagnetic excitation, it generates an adsorption driving effect along the arc groove, pushing the third sliding block 565 to slide precisely along the preset arc, providing support for the dynamic adjustment of the tilt angle of the conveying system.

[0047] Furthermore, the conveying mechanism 5 also includes a sorting box 57, a recycling box 58, and a cleaning brush 59. The cleaning brush 59 is fastened to the conveyor belt 52. The sorting box 57 and the recycling box 58 are both fastened to the conveyor frame 51. The sorting box 57 is provided with a sorting groove 571, and the conveyor frame 51 is provided with a sorting sloping groove 511. The sorting sloping groove 511 and the sorting groove 571 correspond one-to-one.

[0048] By adopting the above technical solution, the cleaning brush 59 is fixedly connected to the conveyor belt 52 and moves synchronously with the belt to continuously brush and clean the bottom surface of the workpiece, removing surface impurities and attachments, and ensuring that the detection surface of the defect sensing system 1 is free from interference. The sorting box 57 and the recycling box 58 are both firmly installed below the conveyor frame 51, forming a collection system after inspection. The sorting box 57 is provided with multiple sorting slots 571 for receiving sorted workpieces, corresponding to the sorting chute 511 set on the conveyor frame 51. The sorting chute 511 is designed as an inclined slide structure, which can guide the workpieces on the conveying path to slide into the corresponding sorting slots 571 below. The conveyor belt 52 delivers the workpiece to the end area, and the cleaning brush 59 completes the brushing during this process, helping to clean the surface before inspection, thereby reducing inspection errors.

[0049] Furthermore, the clamping mechanism 4 includes a clamping plate 41, a soft push-brush 42, a rotary motor 43, a clamping electric cylinder 44, and a position sensor 45. The clamping electric cylinder 44 is fastened to the conveyor frame 51, the clamping electric cylinder 44 is driven to the rotary motor 43, the rotary motor 43 is driven to the clamping plate 41, the position sensor 45 is fastened to the clamping plate 41, the soft push-brush 42 is fastened to the clamping plate 41, and the soft push-brush 42 abuts against the cleaning brush 59.

[0050] By adopting the above technical solution, the clamping electric cylinder 44 is fixedly installed on the conveyor frame 51 as a clamping drive source. Its output shaft is connected to the rotary motor 43 for transmission. The rotary motor 43 further drives the clamping plate 41 to rotate, so that the clamping plate 41 drives the workpiece to adjust the angle or rotate to meet the detection requirements in the clamping state. The position sensor 45 is fastened to the clamping plate 41 to detect the position of the clamping plate 41 and the posture of the workpiece in real time, so as to ensure that the clamping accuracy and rotation angle are controllable. The front end of the clamping plate 41 is provided with a soft push-sweep brush 42, which is set opposite to the cleaning brush 59. While clamping the workpiece, the push-sweep brush and the cleaning brush 59 abut against each other to form a cleaning interface, so as to remove and wipe the residue on the surface or edge of the workpiece during the rotation of the clamping plate 41.

[0051] Furthermore, the positioning mechanism 3 includes a positioning frame 31, a longitudinal motor 32, a transverse motor 33, a proximity motor 34, a first lead screw 35, a second lead screw 36, a third lead screw 37, a transverse moving frame 38, and a longitudinal moving frame 39. The positioning frame 31 is fastened to the conveyor frame 51. The transverse motor 33 is fastened to the positioning frame 31. The transverse motor 33 is driven to the first lead screw 35. The first lead screw 35 is driven to the transverse moving frame 38. The longitudinal motor 32 is fastened to the transverse moving frame 38. The longitudinal motor 32 is driven to the second lead screw 36. The second lead screw 36 is driven to the longitudinal moving frame 39. The proximity motor 34 is fastened to the longitudinal moving frame 39. The longitudinal motor 32 is driven to the third lead screw 37. The third lead screw 37 is driven to the defect sensing system 1.

[0052] By adopting the above technical solution, the positioning frame 31 is firmly connected to the conveying frame 51, serving as the installation reference platform for the entire positioning mechanism 3. The transverse motor 33 is fixed on the positioning frame 31 and drives the transverse frame 38 to move along the X-axis direction through the transmission connection of the first lead screw 35. The longitudinal motor 32 is installed on the transverse frame 38 and drives the longitudinal frame 39 to move along the Y-axis direction through the transmission connection of the second lead screw 36. The proximity motor 34 is firmly connected to the longitudinal frame 39 and is used to control the proximity direction. It drives the defect sensing system 1 to move precisely along the Z-axis through the transmission connection of the third lead screw 37. The first, second, and third lead screws 37 correspond to the transverse, longitudinal, and proximity three-axis movements, respectively, providing a stable spatial support foundation for the subsequent marking mechanism 2.

[0053] Furthermore, the defect sensing system 1 includes a proximity block 11, an ultrasonic piezoelectric wafer probe 12, a coating assembly 13, and a telescopic cylinder 14. The third lead screw 37 is drivenly connected to the proximity block 11, the telescopic cylinder 14 is fastened to the proximity block 11, the telescopic cylinder 14 is drivenly connected to the ultrasonic piezoelectric wafer probe 12, and the ultrasonic piezoelectric wafer probe 12 is slidably connected to the coating assembly 13.

[0054] By adopting the above technical solution, in specific implementation, the approach block 11 is connected to the third lead screw 37 to achieve overall forward and backward positioning along the approach direction; the telescopic cylinder 14 is fixedly installed on the approach block 11 to drive the ultrasonic piezoelectric crystal probe 12 to extend and retract in the vertical direction, ensuring that the probe can adaptively adjust its contact according to the surface undulations of the workpiece; the ultrasonic piezoelectric crystal probe 12 is slidably connected to the coating assembly 13, and can achieve efficient energy coupling and defect echo acquisition under the action of the couplant during the detection process. Its working process is as follows: after the approach block 11 approaches the workpiece to a preset distance under the drive of the third lead screw 37, the telescopic cylinder 14 is activated, slowly pushing the ultrasonic piezoelectric crystal probe 12 to the position of contact with the workpiece surface. At the same time, the coating assembly 13 slides and cooperates accordingly, forming a uniform couplant film layer between the probe and the workpiece. Subsequently, the ultrasonic probe emits pulse signals and receives reflected echoes to identify the location and type of defects. This structure combines rigid positioning with flexible extension to ensure stable contact of the detection head in dynamic environments. At the same time, the coupling agent further enhances signal penetration and resolution, ensuring the sensitivity and accuracy of defect detection and providing high-quality raw data support for subsequent marking and classification.

[0055] Furthermore, the coating assembly 13 includes a coupling agent applicator 131, a coating motor 132, an opening / closing block 133, and a reset elastic element 134. The coupling agent applicator 131 has a roller-shaped structure. The proximity block 11 has a coupling agent injection port 112 and a closing port 111. The coupling agent injection port 112 and the closing port 111 are connected. The ultrasonic piezoelectric crystal probe 12 abuts against the closing port 111. The coupling agent applicator 131 and the proximity block 11 are rotatably connected. The coating motor 132 and the coupling agent applicator 131 are drive-connected. The opening / closing block 133 and the coupling agent applicator 131 are slidably connected. The opening / closing block 133 and the reset elastic element 134 are fastened together. The reset elastic element 134 and the coupling agent applicator 131 are fastened together. The ultrasonic piezoelectric crystal probe 12 abuts against the opening / closing block 133. The opening / closing block 133 has coating micropores 1331, and the closing port 111 and the coating micropores 1331 are connected.

[0056] By adopting the above technical solution, the coupling agent applicator 131 has a roller-shaped structure, rotatably connected to the proximity block 11. Driven by the applicator motor 132, the surface rotates, ensuring the coupling agent is evenly distributed on the bottom of the roller. The applicator motor 132 and the coupling agent applicator 131 rotate in a transmission manner, ensuring stable and reliable rotation. The proximity block 11 is provided with a coupling agent injection port 112 and a sealing port 111, forming a sealed fluid cavity. The coupling agent injection port 112 is used to inject coupling agent into the cavity, and the sealing port 111 serves as a coupling agent output channel, communicating with the coating micro-hole 1331. The micro-hole is located on the opening / closing block 133 to control the release of coupling agent on the surface. The opening / closing block 133 is slidably connected to the applicator, sliding backward when not subjected to the contact force of the ultrasonic piezoelectric crystal probe 12. Simultaneously, the reset elastic element 134 resets, aligning the coating micro-hole 1331 with the sealing port 111, thus facilitating coupling. The coupling agent is then released and adheres to the surface of the roller. During rotation, a thin coupling interface is formed between the probe and the workpiece surface through roller coating. During testing, the probe moves down, the opening and closing block 133 opens, the probe contacts the coupling agent, the reset elastic element 134 is compressed, and the coupling agent injection port 112 is closed to prevent coupling agent leakage. This structure triggers coating through mechanical contact, avoiding the complex control of electronic valves, ensuring that the coupling agent is released evenly and as needed before each test, while also having automatic closing and leak-proof effects, greatly improving the cleanliness, efficiency and repeatability of the testing process.

[0057] Furthermore, the marking mechanism 2 includes a conductivity head 21 and a curing lamp 22, the conductivity head 21 and the proximity block 11 are fastened together, and the curing lamp 22 and the conductivity head 21 are fastened together.

[0058] By adopting the above technical solution, in a specific embodiment, the coupling agent material includes a hydrogel base liquid, electrochromic microcapsules, a pH stabilizer, a conductive ionic liquid, and a photocuring agent. The hydrogel base liquid provides adhesion, flexibility, and adjustable flowability to support ultrasonic coupling requirements. The electrochromic microcapsules undergo an irreversible color change when acted upon by the conductivity head 21. The pH stabilizer maintains the color stability of the coupling agent under different surface pH conditions. The conductive ionic liquid provides controllable conductivity, facilitating sensing and positioning by the conductivity head 21. The photocuring agent is used to receive UV light for curing. A semi-permanent mark is formed. The conductivity head 21 is tightly connected to the proximity block 11 and is attached to the side of the ultrasonic piezoelectric crystal probe 12. It is used to simultaneously measure the conductivity distribution of the workpiece surface or local area during the detection process to determine the continuity of the material structure or the presence of areas with abnormal conductivity characteristics. When the conductivity head 21 detects a sudden change in conductivity or a significant deviation signal, it immediately outputs a judgment command. At the same time, the curing lamp 22 is tightly connected to it. After receiving the command, it starts ultraviolet light irradiation and acts on the color-changing coupling agent that has been pre-coated on the defect area by the coating component 13, so that it quickly undergoes a photocuring reaction at the abnormal point and develops color to form a semi-permanent mark.

[0059] Working principle of the invention:

[0060] The marking mechanism 2 is securely connected to the proximity block 11 via a conductivity head 21, enabling real-time monitoring of the conductivity of the casting surface under test. When an abnormal conductivity is detected in a defect area, the conductivity head 21 transmits the signal from that area to the control circuit of the curing lamp 22. The curing lamp 22 immediately starts irradiation, causing the color-changing material, which has been pre-mixed with the coupling agent, to quickly cure and develop color in the abnormally conductive area, achieving accurate visual marking of defects. In specific implementation, the conductivity head 21 performs micro-current continuity testing on the contact point through a built-in microelectrode array. Combined with the positioning data from the ultrasonic piezoelectric crystal probe 12, it ensures that the marking only acts on the actual defect area. The curing lamp 22 adopts a high-frequency instantaneous curing mode, using LED ultraviolet light irradiation to rapidly polymerize the photosensitive component in the coupling agent, forming a marking spot with color contrast. Its workflow is as follows: when the ultrasonic piezoelectric crystal probe 12 detects an abnormal internal echo in the material and the conductivity head 21 detects a sudden change in the corresponding surface conductivity, the control system controls the curing lamp 22 to flash rapidly in the corresponding area, achieving non-contact, non-destructive automatic marking of surface defects. This structure eliminates the need for additional mechanical actions of the marking mechanism 2, utilizing only electrical and photocuring linkages to improve response speed and spatial adaptability, significantly enhancing detection efficiency and improving the accuracy of subsequent classification and identification.

[0061] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A defect detection device for alloy castings with intelligent marking function, characterized in that: The defect detection equipment includes a defect sensing system (1), a marking mechanism (2), a positioning mechanism (3), a clamping mechanism (4), and a conveying mechanism (5). The defect sensing system (1) and the positioning mechanism (3) are fastened together. The marking mechanism (2) and the defect sensing system (1) are fastened together. The positioning mechanism (3) and the conveying mechanism (5) are fastened together. The clamping mechanism (4) and the conveying mechanism (5) are fastened together. The conveying mechanism (5) includes a conveyor frame (51), a conveyor belt (52), a first roller (53), a second roller (54), a conveyor motor (55), and a tilting and lifting assembly (56). The positioning mechanism (3) is fastened to the conveyor frame (51). The conveyor motor (55) is driven to the second roller (54). The second roller (54) is driven to the conveyor belt (52). The tilting and lifting assembly (56) is slidably connected to the conveyor frame (51). The second roller (54) is slidably connected to the conveyor frame (51). The conveyor belt (52) is driven to the first roller (53). The tilting and lifting assembly (56) includes a lifting hydraulic cylinder (561), a lifting frame (562), a first sliding block (563), a second sliding block (564), a third sliding block (565), a magnetostrictive elastic element (566), a first electromagnetic block (567), and a first magnetic block (568). The lifting hydraulic cylinder (561) and the conveyor frame (51) are fastened together. The lifting hydraulic cylinder (561) and the lifting frame (562) are driven together. The lifting frame (562) and the conveyor frame (51) are slidably connected. The first sliding block (563) and the conveyor frame (51) are slidably connected. The second sliding block (564) and the first sliding block (563) are slidably connected. The first roller (53) and the second sliding block (564) are connected together. The first roller (53) and the third sliding block (565) are rotatably connected, the third sliding block (565) and the lifting frame (562) are slidably connected, the conveying motor (55) and the lifting frame (562) are fastened together, the first electromagnetic block (567) and the lifting frame (562) are fastened together, the first magnetic block (568) and the third sliding block (565) are fastened together, the magnetostrictive elastic element (566) and the first magnetic block (568) are fastened together, the magnetostrictive elastic element (566) and the first electromagnetic block (567) are fastened together, the first electromagnetic block (567) and the first magnetic block (568) are driven by magnetic pole attraction, and the first roller (53) and the lifting frame (562) are slidably connected.

2. The alloy casting defect detection device with intelligent marking function according to claim 1, characterized in that: The lifting frame (562) is provided with an arc-shaped sliding groove (5621). The arc-shaped sliding groove (5621) is arc-shaped and the axis of the second roller (54) is the center of the arc-shaped sliding groove (5621). The third sliding block (565), the magnetostrictive elastic element (566), the first electromagnetic block (567) and the first magnetic block (568) are all located in the arc-shaped sliding groove (5621).

3. The alloy casting defect detection device with intelligent marking function according to claim 2, characterized in that: The conveying mechanism (5) also includes a sorting box (57), a recycling box (58), and a cleaning brush (59). The cleaning brush (59) is fastened to the conveyor belt (52). The sorting box (57) and the recycling box (58) are both fastened to the conveyor frame (51). The sorting box (57) is provided with a sorting groove (571), and the conveyor frame (51) is provided with a sorting sloping groove (511). The sorting sloping groove (511) and the sorting groove (571) correspond one-to-one.

4. The alloy casting defect detection device with intelligent marking function according to claim 3, characterized in that: The clamping mechanism (4) includes a clamping plate (41), a soft push-brush (42), a rotary motor (43), a clamping electric cylinder (44), and a position sensor (45). The clamping electric cylinder (44) is fastened to the conveyor frame (51), the clamping electric cylinder (44) is driven to the rotary motor (43), the rotary motor (43) is driven to the clamping plate (41), the position sensor (45) is fastened to the clamping plate (41), the soft push-brush (42) is fastened to the clamping plate (41), and the soft push-brush (42) abuts against the cleaning brush (59).

5. The alloy casting defect detection device with intelligent marking function according to claim 4, characterized in that: The positioning mechanism (3) includes a positioning frame (31), a longitudinal motor (32), a transverse motor (33), a proximity motor (34), a first lead screw (35), a second lead screw (36), a third lead screw (37), a transverse frame (38), and a longitudinal frame (39). The positioning frame (31) and the conveyor frame (51) are fastened together. The transverse motor (33) and the positioning frame (31) are fastened together. The transverse motor (33) and the first lead screw (35) are connected in a transmission manner. A lead screw (35) and a transverse frame (38) are driven together. The longitudinal motor (32) and the transverse frame (38) are fastened together. The longitudinal motor (32) and the second lead screw (36) are driven together. The second lead screw (36) and the longitudinal frame (39) are driven together. The proximity motor (34) and the longitudinal frame (39) are fastened together. The longitudinal motor (32) and the third lead screw (37) are driven together. The third lead screw (37) and the defect sensing system (1) are driven together.

6. The alloy casting defect detection device with intelligent marking function according to claim 5, characterized in that: The defect sensing system (1) includes a proximity block (11), an ultrasonic piezoelectric wafer probe (12), a coating assembly (13), and a telescopic cylinder (14). The third lead screw (37) is driven to the proximity block (11), the telescopic cylinder (14) is fastened to the proximity block (11), the telescopic cylinder (14) is driven to the ultrasonic piezoelectric wafer probe (12), and the ultrasonic piezoelectric wafer probe (12) is slidably connected to the coating assembly (13).

7. The alloy casting defect detection device with intelligent marking function according to claim 6, characterized in that: The coating assembly (13) includes a coupling agent applicator (131), a coating motor (132), an opening / closing block (133), and a reset elastic element (134). The coupling agent applicator (131) has a roller-shaped structure. The proximity block (11) is provided with a coupling agent injection port (112) and a closing port (111). The coupling agent injection port (112) and the closing port (111) are connected. The ultrasonic piezoelectric crystal probe (12) abuts against the closing port (111). The coupling agent applicator (131) and the proximity block (112) are connected. The coating motor (132) and the coupling agent applicator (131) are connected by a rotating connection. The opening and closing block (133) and the coupling agent applicator (131) are connected by a sliding connection. The opening and closing block (133) and the reset elastic element (134) are connected by a fastening connection. The reset elastic element (134) and the coupling agent applicator (131) are connected by a fastening connection. The ultrasonic piezoelectric crystal probe (12) and the opening and closing block (133) abut against each other. The opening and closing block (133) is provided with a coating micropore (1331). The closing port (111) and the coating micropore (1331) are connected.

8. The alloy casting defect detection device with intelligent marking function according to claim 7, characterized in that: The marking mechanism (2) includes a conductivity head (21) and a curing lamp (22), the conductivity head (21) and the proximity block (11) are fastened together, and the curing lamp (22) and the conductivity head (21) are fastened together.

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