Automatic defect detection device in aluminum alloy hub forging process

Abstract

The invention discloses an automatic defect detection device in an aluminum alloy hub forging process, and relates to the technical field of aluminum alloy hub forging, and the automatic defect detection device comprises a conveying line body, a detection outer shell, a plurality of detection modules and a control mechanism. The conveying line body is responsible for conveying a to-be-detected hub to a detection station, a visual detection module, an ultrasonic detection module, an eddy current detection module and an X-ray detection module are sequentially arranged in the detection outer shell, and comprehensive detection is conducted on the surface and internal defects of the hub. Each detection module is correspondingly provided with a control mechanism, the hub can be automatically grabbed and controlled to rotate, and multi-angle detection is achieved. According to the invention, multiple advanced detection technologies are integrated, the automation degree is high, manual intervention is effectively reduced, the labor intensity is reduced, and the detection consistency is improved. The conveying system and the control mechanism ensure accurate positioning and rapid detection of the hub and adapt to the rhythm of a production line. And defects in the forging process can be found in time, the product quality is guaranteed, the production efficiency is improved, and remarkable economic benefits and market application prospects are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of aluminum alloy wheel hub forging, and more particularly to an automatic defect detection device during the aluminum alloy wheel hub forging process. Background Art

[0002] In recent years, the rapid development of the automotive industry has driven the continued expansion of the aluminum alloy wheel market. Aluminum alloy wheels not only effectively reduce vehicle weight, lower fuel consumption, and improve vehicle handling, but their excellent heat dissipation properties also help improve braking system stability and extend the life of brake pads. They also meet the personalized design needs of modern vehicles.

[0003] However, during the manufacturing process of aluminum alloy wheels, a range of defects can arise, from issues with the purity of the raw materials to even minor fluctuations in parameters such as temperature, pressure, and mold conditions during the forging process. For example, surface cracks, burrs, and dents can directly affect the wheel's appearance and quality, and may even cause fracture during use due to stress concentration. Internal pores, inclusions, and looseness can weaken the wheel's overall strength and toughness, posing safety risks.

[0004] Traditional manual visual inspection methods are insufficient when faced with the complex shapes and subtle defects of wheel hub exteriors. Inspectors easily fatigue after long hours of work, resulting in significantly increased rates of missed inspections and false positives. Furthermore, manual inspection cannot quantitatively assess the severity of defects, making it difficult to align with the precise standards of modern production quality management. While contact ultrasonic testing excels in detecting internal defects, its inspection process is cumbersome, requiring manual operation of the probe and application of coupling fluid for each inspection, making it difficult to keep up with the efficient pace of automated production lines. Furthermore, traditional non-destructive testing methods such as magnetic particle testing are completely ineffective for non-ferromagnetic materials such as aluminum alloys due to their limited working principles.

[0005] Against this backdrop, developing an integrated, automated defect detection system for aluminum alloy wheels has become a top priority. Such a system must integrate multiple advanced detection technologies, accurately capturing minute surface flaws while providing insight into the internal structure to promptly identify hidden defects. Furthermore, it must possess efficient automation capabilities and seamlessly integrate into existing wheel production lines, ensuring comprehensive, rapid, and reliable inspection of every wheel even in high-volume production, thus strengthening the quality defenses for the high-quality development of the automotive industry. Summary of the Invention

[0006] In view of this, the present invention provides an automated defect detection device during the forging process of an aluminum alloy wheel hub, aiming to solve the above technical problems.

[0007] In order to achieve the above object, the present invention adopts the following technical solutions:

[0008] An automatic defect detection device for an aluminum alloy wheel hub during forging, comprising:

[0009] A conveyor line body, the conveyor line body is used to convey a conveyor rack, the conveyor rack is used to place the wheel hub to be inspected, and the conveyor line body is provided with an inspection station;

[0010] An inspection outer shell is arranged at the inspection station, and an inlet and an outlet for the conveyor rack to enter and exit are opened on both sides of the inspection outer shell; a visual inspection module, an ultrasonic inspection module, an eddy current inspection module, and an X-ray inspection module are sequentially arranged on the inner side of the inspection outer shell along the conveying direction of the conveyor line;

[0011] The control mechanism includes four sets of control mechanisms installed on the top of the detection outer shell and corresponding to the visual detection module, the ultrasonic detection module, the eddy current detection module and the X-ray detection module respectively. The control mechanism is used to take the wheel hub to be detected which is transported by the conveyor line to the corresponding module, and control the wheel hub to be detected to rotate, thereby realizing detection.

[0012] Through the above-mentioned technical solution, the present invention integrates the conveyor line, the outer detection housing, various detection modules, and the control mechanism to achieve the comprehensive application of multiple detection methods for aluminum alloy wheels. This enables comprehensive and rapid detection of surface and internal defects on the wheel hub, improving detection efficiency and accuracy. The control mechanism automatically removes and rotates the wheel hub, automating the detection process, reducing manual intervention and labor intensity, and improving detection consistency and reliability.

[0013] Preferably, in the above-mentioned automated defect detection device during the forging process of an aluminum alloy wheel hub, the conveyor line body is formed with a fracture, and the detection station is set at the fracture, and the detection station is arranged in a right-angled U-shaped structure, and sequentially includes a first rotating conveyor line body, a first straight line body, a second rotating conveyor line body, a second straight line body, a third rotating conveyor line body, a third straight line body and a fourth rotating conveyor line body, and the first rotating conveyor line body, the second rotating conveyor line body, the third rotating conveyor line body and the fourth rotating conveyor line body all switch their transmission directions by a single rotation of 90°, and correspond to the subsequent straight line bodies. The fracture design of the conveyor line body and the detection station of the right-angled U-shaped structure, combined with multiple rotating conveyor lines and straight line bodies, enable the wheel hub to be flexibly turned and positioned during the detection process, adapt to the layout and detection requirements of different detection modules, and improve the flexibility and adaptability of detection.

[0014] Preferably, in the above-mentioned automated defect detection device in the forging process of an aluminum alloy wheel hub, four detection cylinders corresponding to the first rotating conveyor line, the second rotating conveyor line, the third rotating conveyor line and the fourth rotating conveyor line are fixed to the inner top wall of the detection outer shell, and there is a height difference between the bottom opening of the detection cylinder and the corresponding rotating conveyor line to allow the conveyor rack and the wheel hub to be inspected to pass through, and the visual detection module, the ultrasonic detection module, the eddy current detection module and the X-ray detection module are respectively arranged on the inner walls of the four detection cylinders. The four detection cylinders fixed on the top wall of the detection outer shell correspond to the rotating conveyor line of the conveyor line, ensuring that the wheel hub passes through each detection module in a predetermined order during the detection process, realizing the orderly progress of the detection process and avoiding confusion and omissions during the detection process.

[0015] Preferably, in the above-mentioned automated defect detection device in the forging process of an aluminum alloy wheel hub, the control mechanism includes a longitudinal hydraulic cylinder, a control frame, a transverse hydraulic cylinder, a driven gear, a drive motor and a driving gear; the cylinder body of the longitudinal hydraulic cylinder is rotatably connected to the top surface of the top wall of the detection outer shell, and the telescopic cylinder of the longitudinal hydraulic cylinder is downwardly inserted into the detection tube; the control frame is connected to the telescopic cylinder end of the longitudinal hydraulic cylinder; the number of the transverse hydraulic cylinders is two, and they are symmetrically connected on both sides of the control frame respectively, and the ends of the telescopic cylinders of the two transverse hydraulic cylinders have claws, and the two claws can realize the picking, placing and clamping of the wheel hub to be inspected; the driven gear is fixedly sleeved on the outside of the cylinder body of the longitudinal hydraulic cylinder; the drive motor is fixed on the top surface of the top wall of the detection outer shell; the driving gear is fixedly connected to the power output end of the drive motor and meshes with the driven gear. Through the coordination of longitudinal hydraulic cylinders, control frames, transverse hydraulic cylinders, clamping claws, gear transmission and other components, the wheel hub can be quickly taken and placed, accurately clamped and rotated stably, ensuring the posture adjustment and positioning accuracy of the wheel hub during the inspection process, and improving the inspection efficiency and quality.

[0016] Preferably, in the aforementioned automated defect detection device for aluminum alloy wheel hub forging, the control frame can extend downward through the bottom opening of the inspection cylinder under the control of the longitudinal hydraulic cylinder to facilitate the removal and placement of the wheel hub, allowing the wheel hub to enter and exit the inspection cylinder smoothly, thereby improving the smoothness of the inspection process.

[0017] Preferably, in the aforementioned automated defect detection device for the forging process of an aluminum alloy wheel hub, when the wheel hub to be inspected is conveyed onto the rotating conveyor line, the corresponding longitudinal hydraulic cylinder controls the control frame to move downward to below the bottom opening of the inspection cylinder, and the transverse hydraulic cylinder controls the clamping claw to open to form an opening, and the direction of the opening is the same as the conveying direction of the wheel hub to be inspected. When the wheel hub is conveyed onto the rotating conveyor line, the coordinated control of the longitudinal and transverse hydraulic cylinders enables the clamping claw to dock with the wheel hub in the correct posture and direction, ensuring accurate grasping and conveying of the wheel hub and reducing the risk of grasping failure or damage due to incorrect posture.

[0018] Preferably, in the above-mentioned automated defect detection device for the aluminum alloy wheel hub forging process, when the clamping claws clamp the wheel hub to be inspected and drive it upward to the inside of the inspection cylinder through the longitudinal hydraulic cylinder for rotational inspection, the rotating conveyor line below rotates and switches the conveying direction. After the rotation inspection of the wheel hub to be inspected inside the inspection cylinder is completed, it moves down and is placed on the corresponding rotating conveyor line. While the clamping claws clamp the wheel hub for rotational inspection, the rotating conveyor line below can rotate and switch the conveying direction, realizing the synchronization of inspection and transportation, saving time and improving the efficiency of the entire production process.

[0019] Preferably, in the above-mentioned automated defect detection device for the aluminum alloy wheel forging process, when the wheel hub to be inspected needs to be lowered and placed on the corresponding rotating conveyor line after the rotation inspection is completed, the initial opening direction is maintained and then lowered. After being lowered into place, the clamping claw is opened and moved upward to be offset from the wheel hub to be inspected; when the conveyor rack of the workstation is sent away, the clamping claw moves down to the clamping position and performs the next clamping action. After the inspection is completed, the clamping claw maintains the opening direction and lowers the wheel hub to the conveyor line, and quickly moves upward to be offset, preparing for the inspection of the next wheel hub, thereby achieving a rapid cycle of the inspection process and improving inspection efficiency.

[0020] Preferably, in the aforementioned automated defect detection device for aluminum alloy wheel forging, a cover is fixed to the top surface of the detection outer shell, the cover being used to cover the control mechanism. The provision of the cover not only protects the control mechanism from external interference and contamination but also provides integrated space for the signal transmission and processing components of the detection module, thereby improving the integrity and compactness of the device and facilitating management and maintenance.

[0021] Preferably, in the aforementioned automated defect detection device for the aluminum alloy wheel forging process, the central portion of the housing and the middle portion of the outer detection housing are used to integrate the signal transmission and processing components for the visual detection module, the ultrasonic detection module, the eddy current detection module, and the X-ray detection module. Integrating the detection module's signal transmission and processing components in the central portion of the housing and the outer detection housing shortens the signal transmission path, reduces signal interference, and improves signal transmission stability and processing efficiency.

[0022] It can be seen from the above technical solutions that, compared with the prior art, the present invention provides an automated defect detection device for the aluminum alloy wheel hub forging process, which has the following beneficial effects:

[0023] 1. Highly integrated and comprehensive testing capabilities: By integrating multiple advanced testing technologies such as visual inspection, ultrasonic testing, eddy current testing, and X-ray testing, it is possible to perform all-round, multi-dimensional inspections of aluminum alloy wheels, completing comprehensive screening for surface and internal defects in one go. This avoids the tedious process of multiple inspections and greatly improves inspection efficiency and accuracy.

[0024] 2. High degree of automation: A series of operations from wheel hub loading, conveying, clamping, rotation to detection are all automated, which not only reduces manual intervention, reduces labor costs and labor intensity, but also effectively improves the consistency and stability of detection, avoids detection errors caused by human factors, and ensures that each wheel hub can be accurately detected.

[0025] 3. Flexible and efficient conveying and positioning system: The unique design of the conveyor line, especially the right-angled U-shaped inspection station at the fracture and the combination of multiple rotating conveyor lines and straight lines, enables the wheel hub to be flexibly turned and accurately positioned during the inspection process, perfectly adapting to the needs of each inspection module, improving the smoothness and flexibility of the inspection process, and providing a strong guarantee for efficient inspection.

[0026] 4. Precise control mechanism: Equipped with a high-performance control mechanism, the coordinated action of the longitudinal hydraulic cylinder, transverse hydraulic cylinder, claws, gear transmission and other components can quickly and accurately realize the wheel hub's pick-up, clamping and rotation actions, ensuring the posture adjustment and positioning accuracy of the wheel hub during the inspection process, and providing a stable and reliable operating platform for the implementation of various inspection technologies.

[0027] 5. Synchronous detection and production process optimization: During the detection process, detection and transportation are carried out simultaneously. When the clamping claw clamps the wheel hub for rotation detection, the rotating conveyor line below can switch the conveying direction at the same time, which greatly saves time and improves the efficiency of the entire production process, helping to achieve efficient operation of the production line and increase production capacity.

[0028] 6. Good protection and integration: The design of the detection shell and cover not only provides effective protection for each detection module and control mechanism to prevent external interference and intrusion of pollutants, but also cleverly integrates signal transmission and processing components, shortens the signal transmission path, reduces signal interference, improves the stability of signal transmission and processing efficiency, enhances the integrity and compactness of the entire device, and facilitates installation, maintenance and management.

[0029] 7. Quality control and safety assurance: It can timely and accurately detect various defects produced in the forging process of aluminum alloy wheels, such as surface cracks, burrs, dents, and internal pores, inclusions, looseness, etc., providing a strong basis for product quality control, effectively avoiding the influx of unqualified products into the market, ensuring the safety of automobile driving, and also helping enterprises to improve product quality and brand reputation. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are merely embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on the provided drawings without paying any creative work.

[0031] Figure 1 The accompanying drawing is a schematic diagram of the overall structure of the inlet side of the automated defect detection device during the aluminum alloy wheel forging process provided by the present invention;

[0032] Figure 2 The accompanying drawing is a schematic diagram of the overall structure of the outlet side of the automated defect detection device during the aluminum alloy wheel forging process provided by the present invention;

[0033] Figure 3 The accompanying drawing is a schematic structural diagram of the conveyor line provided by the present invention;

[0034] Figure 4 The accompanying drawing is a bottom view of the internal structure of the detection outer shell provided by the present invention;

[0035] Figure 5 The accompanying drawing is a bottom view of the detection outer shell provided by the present invention;

[0036] Figure 6 The accompanying drawing is a schematic structural diagram of the control mechanism provided by the present invention;

[0037] Figure 7 The accompanying drawing is a schematic diagram of the arrangement of the control mechanism provided by the present invention relative to the conveyor line body.

[0038] in:

[0039] 1-Conveyor line body;

[0040] 11-Inspection station; 111-First rotating conveyor line; 112-First linear line; 113-Second rotating conveyor line; 114-Second linear line; 115-Third rotating conveyor line; 116-Third linear line; 117-Fourth rotating conveyor line; 12-Fracture;

[0041] 2-Detect the outer shell;

[0042] 21-inlet; 22-outlet; 23-visual detection module; 24-ultrasonic detection module; 25-eddy current detection module; 26-X-ray detection module; 27-detection tube;

[0043] 3-Control mechanism;

[0044] 31-longitudinal hydraulic cylinder; 32-control frame; 33-transverse hydraulic cylinder; 34-driven gear; 35-drive motor; 36-driving gear; 37-claw;

[0045] 4-Transfer rack;

[0046] 5-wheel hub to be tested;

[0047] 6-Hood body. DETAILED DESCRIPTION

[0048] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0049] See attached Figure 1 To the attached Figure 6 The embodiment of the present invention discloses an automatic defect detection device for an aluminum alloy wheel hub forging process, comprising:

[0050] The conveyor line body 1 is used to convey the conveyor rack 4, the conveyor rack 4 is used to place the wheel hub 5 to be tested, and the conveyor line body 1 is provided with a testing station 11;

[0051] The detection outer shell 2 is arranged at the detection station 11. An inlet 21 and an outlet 22 for the conveyor rack 4 to enter and exit are opened on both sides of the detection outer shell 2. A visual detection module 23, an ultrasonic detection module 24, an eddy current detection module 25 and an X-ray detection module 26 are sequentially provided on the inner side of the detection outer shell 2 along the conveying direction of the conveyor line 1.

[0052] Control mechanism 3, there are four sets of control mechanisms 3, which are installed on the top of the detection outer shell 2 and correspond to the visual detection module 23, ultrasonic detection module 24, eddy current detection module 25 and X-ray detection module 26 respectively. The control mechanism 3 is used to take the wheel hub 5 to be detected which is transported by the conveyor line 1 to the corresponding module, and control the wheel hub 5 to be detected to rotate, thereby realizing detection.

[0053] See attached Figure 3 The conveyor line body 1 is formed with a fracture 12, and an inspection station 11 is set at the fracture 12. The inspection station 11 is arranged in a right-angled U-shaped structure and includes a first rotating conveyor line body 111, a first straight line body 112, a second rotating conveyor line body 113, a second straight line body 114, a third rotating conveyor line body 115, a third straight line body 116 and a fourth rotating conveyor line body 117 in sequence. The first rotating conveyor line body 111, the second rotating conveyor line body 113, the third rotating conveyor line body 115 and the fourth rotating conveyor line body 117 all switch their transmission directions by a single rotation of 90°, and correspond to the subsequent straight line bodies.

[0054] See attached Figure 4 and attached Figure 5 Four detection cylinders 27 corresponding to the first rotating conveyor line 111, the second rotating conveyor line 113, the third rotating conveyor line 115 and the fourth rotating conveyor line 117 are fixed to the inner top wall of the detection outer shell 2. There is an avoidance height difference between the bottom opening of the detection cylinder 27 and the corresponding rotating conveyor line to allow the conveying rack 4 and the wheel hub 5 to be inspected to pass through. The visual detection module 23, the ultrasonic detection module 24, the eddy current detection module 25 and the X-ray detection module 26 are respectively arranged on the inner walls of the four detection cylinders 27.

[0055] See attached Figure 6 The control mechanism 3 includes a longitudinal hydraulic cylinder 31, a control frame 32, a transverse hydraulic cylinder 33, a driven gear 34, a drive motor 35 and a driving gear 36; the cylinder body of the longitudinal hydraulic cylinder 31 is rotatably connected to the top surface of the top wall of the detection outer shell 2, and the telescopic cylinder of the longitudinal hydraulic cylinder 31 downwardly penetrates into the detection tube 27; the control frame 32 is connected to the telescopic cylinder end of the longitudinal hydraulic cylinder 31; there are two transverse hydraulic cylinders 33, and they are symmetrically connected to both sides of the control frame 32. The ends of the telescopic cylinders of the two transverse hydraulic cylinders 33 have claws 37, and the two claws 37 can realize the picking and placing of the wheel hub 5 to be detected; the driven gear 34 is fixedly sleeved on the outside of the cylinder body of the longitudinal hydraulic cylinder 31; the drive motor 35 is fixed to the top surface of the top wall of the detection outer shell 2; the driving gear 36 is fixedly connected to the power output end of the drive motor 35 and meshes with the driven gear 34.

[0056] In order to further optimize the above technical solution, the control frame 32 can extend downward from the bottom opening of the detection tube 27 under the control of the longitudinal hydraulic cylinder 31 to achieve the picking, placing and clamping of the wheel hub 5 to be inspected.

[0057] See attached Figure 7 When the wheel hub 5 to be inspected is transported onto the rotating conveyor line, the corresponding longitudinal hydraulic cylinder 31 controls the control frame 32 to move down to below the bottom opening of the inspection cylinder 27, and the transverse hydraulic cylinder 33 controls the claw 37 to open to form an opening, and the direction of the opening is the same as the conveying direction of the wheel hub 5 to be inspected.

[0058] In order to further optimize the above technical solution, when the claw 37 clamps the wheel hub 5 to be tested and drives it upward to the inside of the testing cylinder 27 through the longitudinal hydraulic cylinder 31 for rotational testing, the rotating conveyor line below rotates to switch the conveying direction. After the rotation testing of the wheel hub 5 to be tested inside the testing cylinder 27 is completed, it moves down and is placed on the corresponding rotating conveyor line.

[0059] In order to further optimize the above technical solution, when the wheel hub 5 to be inspected needs to be moved down and placed on the corresponding rotating conveyor line after the rotation inspection is completed, the initial opening direction is maintained, and then lowered. After being lowered into place, the claw 37 is opened and moved up to be misaligned with the wheel hub 5 to be inspected; when the conveying rack 4 of the workstation is sent away, the claw 37 moves down to the clamping position and performs the next clamping action.

[0060] In order to further optimize the above technical solution, a cover 6 is fixed to the top surface of the detection outer shell 2 , and the cover 6 is used to cover the control mechanism 3 .

[0061] In order to further optimize the above technical solution, the middle position inside the cover body 6 and the middle position of the detection outer shell 2 are used to integrate the signal transmission and processing elements of the visual detection module 23, ultrasonic detection module 24, eddy current detection module 25 and X-ray detection module 26.

[0062] In this embodiment, the first linear body 112 , the second linear body 114 and the third linear body 116 are all linear chain transmission mechanisms, which are driven by separate motors and are conventional structures, and will not be described in detail.

[0063] The first rotating conveyor line 111, the second rotating conveyor line 113, the third rotating conveyor line 115 and the fourth rotating conveyor line 117 first include conveyor lines with the same structure as the first straight line 112, and the bottom is driven to rotate by a motor gear structure, which is also a conventional structure and will not be described in detail.

[0064] The working principle of the device provided in this embodiment is:

[0065] First, loading and conveying: The aluminum alloy test hub 5 is placed on the conveyor rack 4 and transported to the test station 11 via the conveyor line 1. The test station 11 is set at the fracture 12 of the conveyor line 1. The test station 11 is arranged in a right-angled U-shaped structure, including multiple rotating conveyor lines and straight lines. It can realize the steering and position adjustment of the test hub 5, ensuring the directional operation of the test hub 5 within the test outer shell 2.

[0066] Then, preparations for inspection begin: When the conveyor frame 4 reaches the entrance 21 of the inspection outer shell 2, the longitudinal hydraulic cylinder 31 of the control mechanism 3 controls the control frame 32 to move downward to below the bottom opening of the inspection cylinder 27. The transverse hydraulic cylinder 33 controls the claws 37 to open, forming an opening in the same direction as the wheel hub is conveyed. The conveyor frame 4 continues to advance, feeding the wheel hub 5 to be inspected between the opened claws 37. The transverse hydraulic cylinder 33 then controls the claws 37 to close, clamping the wheel hub 5 to be inspected. The longitudinal hydraulic cylinder 31 drives the control frame 32 upward, lifting the wheel hub to the inspection position. Once the wheel hub 5 is fully inside the inspection cylinder 27, it is ready for inspection.

[0067] Finally, after the inspection is complete, the longitudinal hydraulic cylinder 31 drives the control frame 32 downward, while the claws 37 maintain their initial opening orientation, lowering the wheel hub 5 to be inspected onto the corresponding rotating conveyor. Once lowered into position, the claws 37 open, releasing the wheel hub. The wheel hub rotates with the rotating conveyor, switching conveying direction and being carried by the conveyor frame 4, completing one inspection cycle. The claws 37 then move upward until they are offset from the wheel hub, waiting for the next conveyor frame 4 to pass before moving downward to the clamping position for the next clamping action.

[0068] It should be noted that the rotating conveyor line needs to be controlled to run and pause. When the wheel hub 5 to be tested is delivered to the right place, the conveying control of the rotating conveyor line needs to be paused first, and then restarted when the wheel hub 5 to be tested is put back.

[0069] According to the above steps, the wheel hub 5 to be inspected needs to go through the visual inspection module 23, the ultrasonic inspection module 24, the eddy current inspection module 25 and the X-ray inspection module 26 in sequence. Specifically:

[0070] The visual inspection module 23 includes the following structures:

[0071] Industrial camera: Connects to the image acquisition card through the camera interface and receives control signals for image acquisition.

[0072] Lens: Installed on the front of the camera, it focuses the light. Its aperture and focal length can be adjusted manually or electrically.

[0073] Light source system: driven by the light source controller, which adjusts the brightness and angle of the light source according to detection requirements.

[0074] Image acquisition card: inserted into the PCIe slot of the computer, receives the image signal from the camera and performs analog-to-digital conversion.

[0075] Image processing software: installed on the computer, it analyzes the collected images through image processing algorithms.

[0076] Circuit structure: mainly includes the camera's power circuit, signal transmission circuit, and the interface circuit between the image acquisition card and the computer.

[0077] Triggered by control signals, the industrial camera in the visual inspection module 23 captures the wheel hub 5 from multiple angles. The camera transmits the image signal to an image acquisition card, which converts the analog signal into a digital signal and sends it to image processing software. The software processes the image using algorithms such as grayscale conversion, filtering, and edge detection to identify surface defects on the wheel hub 5.

[0078] The ultrasonic detection module 24 includes the following structures:

[0079] Ultrasonic probe: connected to the ultrasonic instrument through the probe cable to transmit and receive electrical signals.

[0080] Pulse generator: Generates high voltage electrical pulses and is connected to the probe through a matching box.

[0081] Receiving amplifier: Receives the weak signal from the probe, amplifies it, and connects it to the signal processing circuit via a coaxial cable.

[0082] Signal processing circuit: performs filtering, rectification, detection and other processing on the amplified signal to convert it into a signal suitable for display and analysis.

[0083] Control and display unit: controlled by a microprocessor, parameters are set through the operation panel, and the display shows the test results.

[0084] Circuit structure: includes pulse generating circuit, receiving amplifying circuit, signal processing circuit and control and display circuit.

[0085] The probe of the ultrasonic testing module 24 contacts the surface of the wheel hub 5 to be inspected (or contacts it through a coupling agent) and emits high-frequency ultrasonic pulses. The ultrasonic waves propagate within the wheel hub 5 to be inspected, generating reflected waves when they encounter defects or interfaces. The probe receives the reflected waves and converts them into electrical signals. After amplification and filtering, the signals are transmitted to the control and display unit, where the reflected wave characteristics are analyzed to determine internal defects.

[0086] The eddy current detection module 25 includes the following structures:

[0087] Excitation power supply: Provides alternating current and is connected to the excitation coil of the sensor probe through wires.

[0088] Sensor probe: Contains an excitation coil and a detection coil. The detection coil is connected to the signal conditioning circuit through a signal line.

[0089] Signal conditioning circuit: amplifies, filters, and processes the weak signal picked up by the detection coil to convert it into a signal suitable for acquisition.

[0090] Data acquisition card: collects the conditioned signals and connects to the computer via USB or Ethernet interface.

[0091] Control and analysis software: installed on the computer, controls the detection process and analyzes the data.

[0092] Circuit structure: It consists of excitation power supply circuit, sensor probe circuit, signal conditioning circuit and data acquisition circuit.

[0093] The eddy current testing module 25's probe approaches the surface of the wheel hub 5 to be inspected. An alternating current flows through the excitation coil, generating an alternating magnetic field that induces eddy currents on the surface of the wheel hub 5. The detection coil picks up the induced current signal generated by the eddy current changes. After processing by the signal conditioning circuit, it is transmitted to the data acquisition card. Control and analysis software then analyzes the signal characteristics to identify surface and near-surface defects.

[0094] The X-ray detection module 26 includes the following structures:

[0095] X-ray tube: Connected to a high-voltage power supply via a high-voltage cable to generate X-rays.

[0096] High-voltage power supply: provides stable high voltage to control the intensity and energy of X-rays.

[0097] X-ray detector: converts X-ray signals into electrical signals and connects to the image acquisition and processing system through data transmission lines.

[0098] Image acquisition and processing system: collects the signals output by the detector, generates X-ray images and processes them.

[0099] Protective device: surrounds the X-ray tube and detector to prevent X-ray leakage.

[0100] Circuit structure: includes the high-voltage power supply circuit of the X-ray tube, the signal readout circuit of the detector, and the image acquisition and processing circuit.

[0101] The X-ray tube of the X-ray inspection module 26 generates X-rays. After the X-rays pass through the wheel hub 5 to be inspected, the X-ray intensity distribution after passing through the wheel hub 5 is uneven due to different tissue structures absorbing and scattering X-rays to varying degrees. The X-ray detector receives these X-rays of varying intensities and converts them into electrical signals. After processing by the image acquisition and processing system, an image is formed. By analyzing this image, internal defects can be detected.

[0102] In the above structure, the industrial camera is installed inside the detection tube 27, aimed at the surface of the wheel hub 5 to be detected, and is used to capture the image information of the wheel hub 5 to be detected. The ultrasonic probe is installed inside the detection tube 27, and is used to transmit and receive ultrasonic signals. The sensor probe is installed inside the detection tube 27, close to the surface of the wheel hub 5 to be detected, and is used to generate an alternating magnetic field and detect the induced current signal generated by the eddy current change. The X-ray tube is installed inside the detection tube 27, and is used to generate X-rays and penetrate the wheel hub 5 to be detected. The X-ray detector is installed inside the detection tube 27, opposite to the X-ray tube, and is used to receive the X-rays that pass through the wheel hub 5 to be detected and convert them into electrical signals. The other structures are integrated in the middle position inside the cover 6 and in the middle position of the detection outer shell 2.

[0103] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. Reference can be made to the common and similar parts between the various embodiments. For the devices disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple, and the relevant parts can be referred to the method description.

[0104] The above description of the disclosed embodiments is intended to enable one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not limited to the embodiments shown herein but is intended to conform to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An automated defect detection device for aluminum alloy wheel hub forging process, characterized in that: include: A conveyor line body (1), the conveyor line body (1) is used to convey a conveyor rack (4), the conveyor rack (4) is used to place a wheel hub (5) to be inspected, and the conveyor line body (1) is provided with an inspection station (11); An inspection outer shell (2), the inspection outer shell (2) being arranged at the inspection station (11), and having an inlet (21) and an outlet (22) for the conveying rack (4) to enter and exit on both sides of the inspection outer shell (2); a visual inspection module (23), an ultrasonic inspection module (24), an eddy current inspection module (25), and an X-ray inspection module (26) being sequentially provided on the inner side of the inspection outer shell (2) along the conveying direction of the conveying line (1); A control mechanism (3), wherein the number of the control mechanisms (3) is four and the control mechanisms (3) are installed on the top of the detection outer shell (2) and correspond to the visual detection module (23), the ultrasonic detection module (24), the eddy current detection module (25) and the X-ray detection module (26) respectively. The control mechanism (3) is used to take the wheel hub (5) to be detected that is transported by the conveying line (1) to the corresponding module and control the wheel hub (5) to be detected to rotate, thereby realizing detection.

2. The automatic defect detection device for aluminum alloy wheel hub forging process according to claim 1, characterized in that: The conveying line body (1) is formed with a fracture (12), and the detection station (11) is set at the fracture (12). The detection station (11) is arranged in a right-angled U-shaped structure and sequentially includes a first rotating conveying line body (111), a first straight line body (112), a second rotating conveying line body (113), a second straight line body (114), a third rotating conveying line body (115), a third straight line body (116) and a fourth rotating conveying line body (117). The first rotating conveying line body (111), the second rotating conveying line body (113), the third rotating conveying line body (115) and the fourth rotating conveying line body (117) all switch their transmission directions by a single rotation of 90 degrees and correspond to the subsequent straight line bodies.

3. The automatic defect detection device for aluminum alloy wheel hub forging according to claim 2, characterized in that: Four detection cylinders (27) corresponding to the first rotating conveyor line (111), the second rotating conveyor line (113), the third rotating conveyor line (115) and the fourth rotating conveyor line (117) are fixed to the inner top wall of the detection outer shell (2). There is an avoidance height difference between the bottom opening of the detection cylinder (27) and the corresponding rotating conveyor line to allow the conveying rack (4) and the wheel hub (5) to pass through. The visual detection module (23), the ultrasonic detection module (24), the eddy current detection module (25) and the X-ray detection module (26) are respectively arranged on the inner walls of the four detection cylinders (27).

4. The automatic defect detection device during the forging process of the aluminum alloy wheel according to claim 3, characterized in that: The control mechanism (3) includes a longitudinal hydraulic cylinder (31), a control frame (32), a transverse hydraulic cylinder (33), a driven gear (34), a drive motor (35) and a driving gear (36); the cylinder body of the longitudinal hydraulic cylinder (31) is rotatably connected to the top surface of the top wall of the detection outer shell (2), and the telescopic cylinder of the longitudinal hydraulic cylinder (31) is downwardly penetrated into the detection tube (27); the control frame (32) is connected to the telescopic cylinder end of the longitudinal hydraulic cylinder (31); the number of the transverse hydraulic cylinders (33) is two, and they are symmetrical. Connected to both sides of the control frame (32), the ends of the telescopic cylinders of the two transverse hydraulic cylinders (33) are provided with claws (37), and the two claws (37) can realize the picking, placing and clamping of the wheel hub (5) to be detected; the driven gear (34) is fixedly sleeved on the outer side of the cylinder body of the longitudinal hydraulic cylinder (31); the driving motor (35) is fixed on the top surface of the top wall of the detection outer shell (2); the driving gear (36) is fixedly connected to the power output end of the driving motor (35) and meshes with the driven gear (34).

5. The automatic defect detection device during the forging process of the aluminum alloy wheel according to claim 4, characterized in that: The control frame (32) can extend downward from the bottom opening of the detection cylinder (27) under the control of the longitudinal hydraulic cylinder (31) to achieve the picking, placing and clamping of the wheel hub (5) to be detected.

6. The automatic defect detection device during the forging process of the aluminum alloy wheel according to claim 5, characterized in that: When the wheel hub (5) to be inspected is conveyed onto the rotating conveyor line, the corresponding longitudinal hydraulic cylinder (31) controls the control frame (32) to move downward to below the bottom opening of the inspection cylinder (27), and the transverse hydraulic cylinder (33) controls the clamping claw (37) to open to form an opening, and the direction of the opening is the same as the conveying direction of the wheel hub (5) to be inspected.

7. The automatic defect detection device during the forging process of the aluminum alloy wheel according to claim 6, characterized in that: When the clamping claw (37) clamps the wheel hub (5) to be inspected and drives it upward to the inside of the inspection cylinder (27) through the longitudinal hydraulic cylinder (31), the rotation inspection is carried out while the rotating conveying line body below rotates to switch the conveying direction. After the rotation inspection of the wheel hub (5) to be inspected inside the inspection cylinder (27) is completed, it moves downward and is placed on the corresponding rotating conveying line body.

8. The automatic defect detection device for aluminum alloy wheel hub forging according to claim 7, characterized in that: When the wheel hub (5) to be inspected needs to be moved down and placed on the corresponding rotating conveyor line after the rotation inspection is completed, the initial opening direction is maintained and then lowered. After being lowered into place, the clamping claw (37) is opened and moved up to be misaligned with the wheel hub (5) to be inspected; when the conveying rack (4) of the workstation is sent away, the clamping claw (37) is moved down to the clamping position to perform the next clamping action.

9. The automatic defect detection device during the forging process of the aluminum alloy wheel according to claim 4, characterized in that: A cover (6) is fixed to the top surface of the detection outer shell (2), and the cover (6) is used to cover the control mechanism (3).

10. The automatic defect detection device during the forging process of aluminum alloy wheel hub according to claim 9, characterized in that: The middle position inside the cover body (6) and the middle position of the detection outer shell (2) are used to integrate the signal transmission and processing components of the visual detection module (23), the ultrasonic detection module (24), the eddy current detection module (25) and the X-ray detection module (26).

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