An automated weld seam detection system based on cup convex machine and a detection method thereof

Abstract

The application discloses an automatic welding seam detection system based on cup convex machines and a detection method thereof, and belongs to the technical field of welding seam detection. The system comprises a safety room, a feeding conveyor belt, a discharging conveyor belt, a visual monitoring device, a grabbing device and at least two cup convex machines arranged on the two sides of the feeding conveyor belt; the grabbing device responds to the visual signal and alternately moves and delivers the sample to the cup convex machines on the two sides for parallel detection. The grabbing device is provided with an electromagnetic adsorption assembly and an elastic buffer assembly, and the cup convex machine is provided with a sample piece supporting plate with a avoiding notch, an electromagnetic fixing piece and an anti-rotation lever base. The application can improve the detection efficiency, positioning accuracy and equipment operation stability.

Description

Technical Field

[0001] This invention relates to the field of metal sheet weld quality inspection technology, and in particular to an automated weld inspection system and method based on a cupping machine. Background Technology

[0002] On continuous production lines for cold-rolled strip steel and silicon steel, to ensure production continuity, the tail of one coil and the head of the next coil need to be joined together using a welding machine. The quality of the weld directly affects the smooth progress of subsequent processes and the performance and safety of the final product; therefore, weld quality inspection is essential.

[0003] Currently, the cupping test is widely used in the industry to evaluate the weld's resistance to deformation. This method applies pressure to the weld area of ​​a clamped sample using a spherical punch, causing it to cup-shaped deform until cracks appear. The weld quality is judged by observing the crack morphology or measuring the cupping depth. Traditional inspection methods are mostly manual, which has drawbacks such as low efficiency, poor consistency, and large human error, and cannot meet the needs of modern high-speed continuous production lines.

[0004] To improve the level of automation in weld inspection, several automated weld inspection devices have emerged in this field. Among them, Chinese patent CN117463800A discloses a weld inspection device for cold-rolled strip steel, which includes an inspection base, a conveyor belt running through the inspection base, a robotic arm positioned along the conveyor belt's transport direction, and a cupping machine. The device's workflow is as follows: the robotic arm picks up a cut sample from the conveyor belt and moves it to the cupping machine, where the cupping machine's punch pushes the sample into a die for weld seam bursting inspection. This achieves a certain degree of automation in weld inspection, reducing manual intervention.

[0005] However, in practical applications, the device disclosed in this patent still has the following technical defects:

[0006] (i) Low testing efficiency. The equipment is only equipped with a single cupping machine, and the robotic arm and the cupping machine must work in sequence: the robotic arm picks up the sample → sends it to the cupping machine → cupping test (usually around 30 minutes) → the robotic arm takes it away → picks up the next sample. During the cupping test, the robotic arm is in a waiting state, resulting in an excessively long average testing cycle for a single sample, which is difficult to match the rhythm of a high-speed continuous production line and becomes a bottleneck in the production line's efficiency.

[0007] (ii) Insufficient sample positioning accuracy and clamping stability. The end effector of the robotic arm in Reference Document 1 is a U-shaped plate and a magnet mounted on its bottom, with a relatively simple structure. After it adsorbs the sample, it lacks an effective fine-tuning mechanism and buffer structure, which can easily lead to poor alignment between the weld and the cupping punch due to sample shape tolerances or conveyor belt stop position deviations, affecting the accuracy of the test results. At the same time, the cupping machine in Reference Document 1 itself lacks a reliable sample fixing device. During the test, the sample is easily shaken or even falls off due to the impact of the punch, further reducing the stability and repeatability of the test.

[0008] (iii) There is a risk of collision during long-term operation of the equipment. The cupping machine of this patent does not have an anti-rotation structure. After long-term use, the pallet or other parts of the cupping machine may shift at an angle due to vibration or slight rotation of the hydraulic cylinder piston rod, causing the robot arm to interfere with or even collide with the cupping machine during loading and unloading, affecting the reliability and safety of the equipment in long-term operation and increasing maintenance costs.

[0009] Therefore, how to further solve the aforementioned technical problems such as detection efficiency, positioning and clamping stability, and long-term operational reliability based on existing automated weld inspection equipment is a pressing technical challenge in this field. Summary of the Invention

[0010] The present invention aims to overcome the shortcomings of the prior art and provide an automated weld inspection system and method based on a cupping machine, so as to solve the technical problems of low efficiency, inaccurate sample positioning and clamping, and risk of collision during long-term operation of existing single cupping machine inspection equipment.

[0011] To achieve the above objectives, the present invention adopts the following technical solution:

[0012] An automated weld inspection system based on a cupping machine includes:

[0013] Safe room;

[0014] A feeding conveyor belt is installed inside the safety room;

[0015] A discharge conveyor belt is arranged side-by-side with the feeding conveyor belt inside the safety room;

[0016] A visual monitoring device is installed above the feeding conveyor belt to monitor the position of the sample to be inspected;

[0017] A gripping device, located at the end of the feeding conveyor belt, is used to grip the sample to be inspected;

[0018] The cupping unit includes at least two cupping machines, which are respectively arranged on both sides of the feeding conveyor belt for cupping inspection of the weld seam of the sample.

[0019] The gripping device responds to the signal from the visual monitoring device by alternately transferring the sample to the cupping machines on both sides of the feeding conveyor belt for testing, and then transferring the tested sample to the discharge conveyor belt.

[0020] Furthermore, the gripping device includes a robotic arm and an end effector connected to the robotic arm; the end effector includes:

[0021] The clamping frame has a hollow structure on both sides;

[0022] An electromagnetic adsorption assembly is disposed at both ends of the clamping frame for adsorbing sample pieces;

[0023] An elastic buffer assembly is disposed between the clamping frame and the electromagnetic adsorption assembly or at the mounting location of the clamping frame.

[0024] Furthermore, the electromagnetic adsorption assembly includes an electromagnet and a magnetic holder for increasing the adsorption area, wherein the magnetic holder has a long strip structure.

[0025] Furthermore, the cupping machine includes:

[0026] The base provides overall support and a mounting reference.

[0027] A cup-shaped protrusion, mounted above the base, is used to provide test pressure;

[0028] The sample tray is installed in the middle of the cup-shaped cylinder to support the sample piece. It has clearance slots on both sides to facilitate loading, unloading and position adjustment of the gripping device.

[0029] An electromagnetic fixing component is installed below the sample tray and is automatically activated by the controller to adsorb and fix the sample.

[0030] The anti-rotation rod base is used to prevent the sample support plate from rotating with the piston rod of the cup-shaped cylinder.

[0031] Furthermore, the cupping machine also includes:

[0032] The light source bracket is installed above the base;

[0033] A strip light source, mounted at the front end of the light source bracket, is used to provide wide-angle, uniform illumination for weld inspection;

[0034] The photoelectric sensors are arranged on both sides of the cup-shaped cylinder to detect whether the sample is in place.

[0035] A protective cover is installed above the cup-shaped cylinder to protect the internal mechanism of the cup-shaped cylinder and ensure operational safety.

[0036] Furthermore, the width of the clearance slot is set to match the clamping size of the gripping device.

[0037] Furthermore, after the visual monitoring device detects that the sample has been transported to the predetermined area by the feeding conveyor belt, it controls the feeding conveyor belt to pause and triggers the gripping device to perform a gripping operation.

[0038] Furthermore, an automated weld inspection method based on a cupping machine includes the following steps:

[0039] S1: Transport the sample to the visual monitoring area;

[0040] S2: Perform visual positioning on the sample to obtain its location information;

[0041] S3: Grab the sample using the grasping device based on the location information;

[0042] S4: Transfer the grabbed sample to the left cupping machine for cupping detection, and simultaneously or subsequently grab another sample and transfer it to the right cupping machine for cupping detection;

[0043] S5: After the test is completed, the sample is taken out from the cupping machine and transferred to the discharge conveyor belt by the gripping device.

[0044] Preferably, in step S4, after the sample is placed on the cupping machine, the electromagnetic fixing component is automatically activated to adsorb the sample; after the test is completed, the electromagnetic fixing component releases the sample so that the gripping device can take it away.

[0045] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0046] 1. Significantly Improved Detection Efficiency: This invention achieves parallel processing of cupping detection by arranging at least two cupping machines on both sides of the feeding conveyor belt and coordinating with the alternating transfer control of the gripping device. While the gripping device feeds sample A into the left cupping machine for detection, it can immediately grab sample B and prepare it for feeding into the right cupping machine. This significantly reduces the waiting time of the robotic arm, shortening the average detection cycle of a single sample by nearly half, which can well match the rhythm of a high-speed continuous production line.

[0047] 2. Improved weld positioning accuracy and inspection stability: The gripping device of this invention adopts a combination structure of clamping frame, electromagnetic adsorption component, and elastic buffer component, which can stably adsorb the sample and provide cushioning during placement to avoid rigid impact. The clearance slots on both sides of the sample tray provide the robotic arm with ample fine-tuning space, facilitating precise adjustment of the alignment position of the weld and the cupping punch based on visual positioning results. In addition, the electromagnetic fixing component on the cupping machine is automatically activated after the sample is in place, firmly adsorbing the sample, effectively overcoming the inertial impact generated by the cupping cylinder's movement, preventing sample shaking or falling off, and ensuring the accuracy and repeatability of the inspection results.

[0048] 3. Enhance the safety and reliability of long-term equipment operation: The present invention sets an anti-rotation rod base on the cupping machine. This structure can effectively prevent the sample tray from rotating with the piston rod of the cupping cylinder, ensuring that the angle between the tray and the gripping device remains constant. This fundamentally avoids the risk of mechanical collision caused by positional deviation due to long-term use, significantly reduces the equipment failure rate and maintenance costs, and ensures the continuous and stable operation of the automated production line.

[0049] 4. High degree of automation and reduced human intervention: Through the high coordination of visual monitoring device, gripping device, cupping unit and control system, this invention realizes the fully automated operation of sample from transportation, positioning, gripping, detection to discharge, without human intervention, avoiding errors and inconsistencies caused by human detection, and reducing the labor intensity of operators. Attached Figure Description

[0050] Figure 1 A schematic diagram of the overall structure of the automated weld inspection system provided by the present invention;

[0051] Figure 2 A schematic diagram of the safe room structure provided by the present invention.

[0052] Figure 3 This is a schematic diagram of the structure of the cup-shaped machine provided by the present invention;

[0053] Figure 4 This is a schematic diagram of the execution terminal structure provided by the present invention;

[0054] Figure 5 This is a flowchart of the automated weld inspection method of the cupping machine of the present invention.

[0055] In the diagram: 1. Safety room; 2. Feeding conveyor belt; 3. Discharge conveyor belt; 4. Visual monitoring device; 5. Gripping device; 51. Robotic arm; 52. End effector; 521. Clamping frame; 522. Electromagnetic adsorption assembly; 523. Elastic buffer assembly; 6. Cupping machine unit; 61. Cupping machine; 611. Base; 612. Cupping cylinder; 613. Light source bracket; 614. Strip light source; 615. Protective cover; 616. Detection photoelectric device; 617. Sample tray; 618. Electromagnetic fastener; 619. Anti-rotation rod base. Detailed Implementation

[0056] 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.

[0057] Example 1

[0058] See Figures 1 to 5 .

[0059] like Figure 1 As shown in the figure, this embodiment provides an automated weld inspection system based on a cupping machine, including a safety room 1, a feeding conveyor belt 2, a discharging conveyor belt 3, a visual monitoring device 4, a gripping device 5, and a cupping machine unit 6.

[0060] Safety room 1 is enclosed by a metal frame and acrylic panels, forming a relatively closed inspection environment that effectively prevents external light from interfering with the vision system, while also providing safety protection and dust prevention. Feeding conveyor belt 2 and discharging conveyor belt 3 are arranged side-by-side inside safety room 1. Feeding conveyor belt 2 receives weld samples cut from upstream production lines (e.g., crescent shears) and transports them to the inspection station. Discharging conveyor belt 3 transports the inspected samples to a waste bin or collection device.

[0061] The visual monitoring device 4 is installed above the feeding conveyor belt 2, with its lens facing the surface of the conveyor belt. The visual monitoring device 4 is used to monitor the position of the sample on the feeding conveyor belt 2 in real time. When the sample is conveyed to the predetermined area in the center of its field of view, the visual monitoring device 4 sends a signal to the control system, which then controls the feeding conveyor belt 2 to stop and sends the coordinate information of the sample to the gripping device 5.

[0062] The gripping device 5 is located at the end of the feeding conveyor belt 2, and includes a multi-degree-of-freedom robotic arm 51 and an end effector 52 connected to the end of the robotic arm 51. Figure 4As shown, the execution end 52 specifically includes a clamping frame 521, an electromagnetic adsorption assembly 522, and an elastic buffer assembly 523. The clamping frame 521 is generally U-shaped or C-shaped, with hollowed-out structures on both sides to reduce weight. The electromagnetic adsorption assemblies 522 are located at both ends of the clamping frame 521. Each electromagnetic adsorption assembly 522 includes an electromagnet and a long strip-shaped magnetic holder. The long strip-shaped magnetic holder can increase the contact area with the sample and improve the adsorption stability. The elastic buffer assembly 523 is a spring assembly or elastic pad, located between the clamping frame 521 and the electromagnetic adsorption assembly 522. When the gripping device 5 places the sample onto the cupping machine sample tray, the elastic buffer assembly 523 can absorb the impact force and prevent the sample from being deformed or damaged due to rigid contact.

[0063] The cupping unit 6 includes at least two cupping machines 61, respectively arranged on the left and right sides of the feeding conveyor belt 2. The two cupping machines have identical structures; the cupping machine 61 will be used as an example for explanation. Figure 3 As shown, the cup protrusion machine 61 includes a cup protrusion cylinder 612, a sample support plate 617, an electromagnetic fixing component 618, an anti-rotation rod base 619, a strip light source 614, and a detection photoelectric sensor 616.

[0064] The cup-shaped cylinder 612 is a hydraulic cylinder with an upward-extending piston rod, the top of which is fitted with a spherical punch. The sample holder 617 is located above the cup-shaped cylinder 612 and is used to horizontally place the sample to be tested. Figure 3 As shown, symmetrical clearance slots are provided on the left and right sides of the sample tray 612. The width of the clearance slots matches the width of the clamping arm of the clamping frame 521 of the gripping device 5, so that the clamping frame 521 can safely enter and exit the clearance slots and make fine adjustments in the front and back directions within the slots to achieve precise alignment of the weld and the punch.

[0065] The electromagnetic fixing component 618 is an electromagnet installed below the sample holder 617. Once the sample is in place, the control system (such as a PLC) automatically energizes the electromagnetic fixing component 618, causing it to generate magnetic force and firmly attach the sample to the sample holder 617, preventing the sample from shaking or falling off due to impact during the cupping process. After testing, the electromagnetic fixing component 618 is demagnetized, and the sample can be removed.

[0066] The anti-rotation rod base 619 includes an anti-rotation rod base and an anti-rotation rod that cooperates with it. The anti-rotation rod base is fixed to the frame of the cupping machine 61. One end of the anti-rotation rod is connected to the sample tray 617, and the other end is inserted into the base and can slide axially but cannot rotate. This structure can effectively prevent the sample tray 617 from shifting at an angle due to the slight rotation of the piston rod of the cupping cylinder 612, ensuring that the relative angle between the tray and the gripping device 5 is constant and avoiding collisions after long-term use.

[0067] The strip light source 614 is a strip LED light source, installed above the cupping machine 61, providing wide-angle, uniform illumination to assist the vision system in accurately positioning the weld seam before gripping. The detection photoelectric sensor 616 is a photoelectric switch that can be symmetrically arranged on both sides of the cupping cylinder 612 to detect whether the sample is accurately placed on the sample support plate 617 and to feed back the positioning signal to the control system.

[0068] System working process (detection method):

[0069] Please see Figure 5 The flowchart of the method is shown.

[0070] Step S1: The crescent shears on the upstream production line cut off the weld seam sample, and the sample falls into or slides into the starting end of the feeding conveyor belt 2.

[0071] Step S2: The feeding conveyor belt 2 starts and transports the sample forward. When the sample passes the detection light curtain (which can be set at the entrance of the conveyor belt), the light curtain senses the sample, and the control system confirms that the sample has entered the conveyor belt.

[0072] Step S3: The sample is transported to the field of view of the vision monitoring device 4. The vision monitoring device 4 identifies the outline of the sample and the position of the weld by processing the image. When the sample reaches the predetermined photographing area, the control system pauses the feeding conveyor belt 2, and the vision monitoring device 4 takes a picture and calculates the coordinates, sending the center coordinates of the sample and the weld angle to the robotic arm controller.

[0073] Step S4: The robotic arm 51 of the gripping device 5 moves the execution end 52 above the sample according to the received coordinate information. The electromagnetic adsorption component 522 of the execution end 52 is energized and adsorbs the sample.

[0074] Step S5: The gripping device 5 transfers the first sample to the cupping machine 61 on the left and places it on the sample tray 617. During placement, the position is finely adjusted by avoiding the groove to ensure that the weld seam is aligned with the cupping punch. After the sample is in place, the photoelectric sensor 616 detects a signal, and the electromagnetic fixing component 618 automatically energizes and adsorbs the sample. Subsequently, the gripping device 5 retracts and releases, the cupping cylinder 612 actuates, and the punch presses upward against the weld seam of the sample for cupping detection. At the same time, the gripping device 5 returns to the feeding conveyor belt 2, grabs the second sample that has arrived, and transfers it to the cupping machine 61 on the right for detection according to the same process. In this way, the two cupping machines alternately receive samples, achieving parallel detection.

[0075] Step S6: After the left cupping machine 61 completes its inspection, the electromagnetic fixing component 618 is demagnetized, and the gripping device 5 re-enters to adsorb the inspected sample, removes it, and transfers it to the discharge conveyor belt 3. Similarly, after the right cupping machine 61 completes its inspection, the gripping device 5 removes its sample and transfers it to the discharge conveyor belt 3.

[0076] Step S7: The discharge conveyor belt 3 transports the tested sample to the waste bin or designated recycling location. At this point, a complete testing cycle ends, and the system automatically enters the next cycle.

[0077] Throughout the process, the control system (PLC) is responsible for coordinating the timing of actions and signal interactions of all components, including the vision system, robotic arm, conveyor belt, cupping machine, and electromagnet, to ensure that each action is executed under the correct signal feedback, thus achieving fully automated unattended operation.

[0078] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0079] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automated weld inspection system based on a cupping machine (61), characterized in that, include: Safe room (1); A feeding conveyor belt (2) is installed inside the safety room (1); The discharge conveyor belt (3) is arranged side by side with the feeding conveyor belt (2) inside the safety room (1); A visual monitoring device (4) is installed above the feeding conveyor belt (2) to monitor the position of the sample to be inspected; A gripping device (5) is located at the end of the feeding conveyor belt (2) and is used to grip the sample to be inspected; The cupping unit (6) includes at least two cupping machines (61), which are respectively arranged on both sides of the feeding conveyor belt (2) for cupping detection of the weld seam of the sample. The gripping device (5) responds to the signal of the visual monitoring device (4) by alternately transferring the sample to the cupping machine (61) on both sides of the feeding conveyor belt (2) for testing, and then transferring the tested sample to the discharge conveyor belt (3).

2. The automated weld inspection system according to claim 1, characterized in that, The gripping device (5) includes a robotic arm (51) and an end effector (52) connected to the robotic arm (51); the end effector (52) includes: The clamping frame (521) has a hollow structure on both sides; An electromagnetic adsorption component (522) is disposed at both ends of the clamping frame (521) for adsorbing sample pieces; An elastic buffer assembly (523) is disposed between the clamping frame (521) and the electromagnetic adsorption assembly (522) or at the mounting position of the clamping frame (521).

3. The automated weld inspection system according to claim 2, characterized in that, The electromagnetic adsorption component (522) includes an electromagnet and a magnetic chuck for increasing the adsorption area, wherein the magnetic chuck is a long strip structure.

4. The automated weld inspection system according to claim 1, characterized in that, The cup-shaped machine (61) includes: The base (611) provides overall support and a mounting reference. A cup-shaped cylinder (612) is mounted above the base (611) to provide test pressure; The sample tray (617) is installed in the middle of the cup-shaped cylinder (612) to carry the sample piece. It has clearance slots on both sides to facilitate loading, unloading and position adjustment of the gripping device (5). An electromagnetic fastener (618) is installed below the sample tray (617) and is automatically activated by the controller to adsorb and fix the sample. The anti-rotation rod base (611) is used to prevent the sample tray (617) from rotating with the piston rod of the cup-shaped cylinder (612).

5. The automated weld inspection system according to claim 4, characterized in that, The cup-shaped machine (61) also includes: A light source bracket (613) is installed above the base (611); A strip light source (614) is installed at the front end of the light source bracket (613) to provide wide-angle, uniform illumination for weld inspection; The photoelectric sensor (616) is arranged on both sides of the cup-shaped cylinder (612) to detect whether the sample is in place; A protective cover (615) is installed above the cup-shaped cylinder (612) to protect the internal mechanism of the cup-shaped cylinder (612) and ensure operational safety.

6. The automated weld inspection system according to claim 4, characterized in that, The width of the clearance slot is set to match the clamping size of the gripping device (5).

7. The automated weld inspection system according to claim 1, characterized in that, After the visual monitoring device (4) detects that the sample has been transported to the predetermined area by the feeding conveyor belt (2), it controls the feeding conveyor belt (2) to pause and triggers the gripping device (5) to perform a gripping operation.

8. An automated weld inspection method based on a cupping machine, characterized in that, The automated weld inspection system according to any one of claims 1 to 7 includes the following steps: S1: Transport the sample to the visual monitoring area; S2: Perform visual positioning on the sample to obtain its location information; S3: Based on the location information, the sample is grasped by the grasping device (5); S4: Transfer the grabbed sample to the left cupping machine (61) for cupping detection, and at the same time or subsequently, grab another sample and transfer it to the right cupping machine (61) for cupping detection; S5: After the test is completed, the sample is taken out from the cupping machine (61) and transferred to the discharge conveyor belt (3) by the gripping device (5).

9. The automated weld inspection method according to claim 8, characterized in that, In step S4, after the sample is placed on the cupping machine (61), the electromagnetic fixing component (618) is automatically activated to adsorb the sample; after the test is completed, the electromagnetic fixing component (618) releases the sample so that the gripping device (5) can take it away.

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