Automatic detection device for grid defects

Abstract

The present disclosure belongs to the field of nuclear power technology, and specifically relates to an automatic detection device for grid defects. The present disclosure can move and adjust the spatial position of the intelligent camera through the cooperation of the X-axis module, the Z-axis module, the Y-axis module, the intelligent camera, the slide, the rotating support, and the first strip light source in the vertical detection mechanism, so as to realize the collection of the image of the inner wall of the grid grid unit of the grid, and realize the collection of the image of the outer side of the grid to be tested on the positioning rotation mechanism through the cooperation of the lateral detection mechanism side shift module and the industrial camera, the ring light source, and the second strip light source, so as to efficiently and accurately collect the image of the inside and outside of the grid.

Description

Technical Field

[0001] The invention belongs to the technical field of nuclear power, and in particular relates to an automatic detection device for grid defects. Background Art

[0002] In the related technology, the quality of the grid needs to be inspected manually, which relies heavily on the experience of the inspectors. There is a high probability of false detection and missed detection, and the inspection efficiency is low, making it impossible to effectively control the quality of the grid products. Therefore, how to improve the efficiency and accuracy of grid quality inspection has become a problem that needs to be solved urgently. Summary of the invention

[0003] In order to overcome the problems existing in the related art, an automatic detection device for grid defects is provided.

[0004] According to one aspect of an embodiment of the present disclosure, there is provided an automatic detection device for grid defects, the automatic detection device for grid defects comprising: a vertical detection mechanism, a lateral detection mechanism and a positioning rotation mechanism;

[0005] The positioning and rotating mechanism is used to set the grid to be detected;

[0006] The vertical detection mechanism includes a support frame, an X-axis module, a Z-axis module, a Y-axis module, a smart camera, a slide, a rotating support, and a first strip light source;

[0007] The Y-axis module is fixedly connected to the supporting frame, the X-axis module is connected to the driving end of the Y-axis module, the Z-axis module is connected to the driving end of the X-axis module, the smart camera is connected to the driving end of the slide, the slide is connected to the driving end of the rotating support, the first strip light source is connected to the rotating support, and the rotating support is connected to the driving end of the Z-axis module;

[0008] The X-axis module can drive the smart camera to move along the horizontal X-axis direction, the Z-axis module can drive the smart camera to move along the vertical Z-axis direction, and the Y-axis module can drive the smart camera to move along the horizontal Y-axis direction;

[0009] The slide can drive the smart camera to move along the first direction, the rotating support can adjust the angle between the optical axis of the smart camera lens and the vertical direction, and the smart camera is used to collect images of the inner side surfaces of each grid unit of the grid to be tested on the positioning rotating mechanism;

[0010] The lateral detection mechanism includes a lateral shift module and an industrial camera, a ring light source, and a second strip light source, wherein the industrial camera is used to collect images of the outer side surface of the grid to be detected on the positioning and rotating mechanism;

[0011] The industrial camera is connected to the driving end of the side shift module, the annular light source surrounds the lens of the industrial camera, the second strip light source is connected to the driving end of the side shift module, and the side shift module can drive the second strip light source and the industrial camera to move together along the horizontal X-axis direction.

[0012] In a possible implementation, the lateral detection mechanism further includes a fine-tuning slide and a telescopic cylinder;

[0013] The industrial camera is connected to the driving end of the fine-tuning slide, the fine-tuning slide is connected to the driving end of the side shift module, and the fine-tuning slide can adjust the position of the industrial camera in the horizontal Y-axis direction;

[0014] The second strip light source is connected to the telescopic end of the telescopic cylinder, and the telescopic cylinder is connected to the driving end of the lateral shift module. The telescopic cylinder can adjust the position of the second strip light source in the horizontal Y-axis direction.

[0015] In a possible implementation, the positioning and rotating mechanism includes: a turntable and a rotating motor;

[0016] The turntable is connected to the rotor of the rotary motor, and the rotary motor is used to drive the turntable to rotate.

[0017] In one possible implementation, the turntable includes: a backlight source is arranged inside the turntable, a turntable panel on the upper surface of the turntable is made of a transparent material, the turntable panel is used to place the grid to be inspected, and the backlight source can illuminate the grid on the turntable panel through the turntable panel.

[0018] In a possible implementation, a first positioning block and a second positioning block are disposed on the upper surface of the turntable, and the first positioning block and the second positioning block are L-shaped and are used to limit two diagonal corners of the grid to be inspected.

[0019] In a possible implementation, the automatic detection device for grid defects includes a plurality of smart cameras arranged in a straight line, and the distribution of the lenses of each smart camera is adapted to the distribution of the grids of the grid to be detected, so that each smart camera lens can be aligned with a grid unit.

[0020] In a possible implementation, the automatic detection device for grid defects further includes a controller, and the controller performs the following control operations:

[0021] Step 100, the controller controls the vertical detection mechanism to adjust the optical axis of the smart camera lens to form a preset angle with the vertical direction, so that the camera lens faces the inner wall of one side of each grid unit, and then the controller drives the smart camera to traverse each grid unit through the X-axis module, the Z-axis module, and the Y-axis module to collect the image of the inner wall of each grid unit;

[0022] Step 101, the controller controls the lateral detection mechanism to drive the industrial camera starting from the end of an outer wall of the grid, and each time the industrial camera is driven to move a preset distance, the industrial camera is paused for a preset time. The controller controls the industrial camera to capture an image once during the pause period until the image of the outer wall is captured;

[0023] After the controller completes photographing the side of the grid, the controller controls the turntable to rotate 90 degrees so that the other inner wall of each grid unit faces the lens of the smart camera, and the other outer wall of the grid faces the industrial camera, and steps 100 and 101 are repeated until the images of the four inner walls of each grid unit and the four outer walls of the grid are collected;

[0024] Step 102: perform defect recognition based on the acquired image and mark the location of the defect on the acquired image.

[0025] The beneficial effects of the present disclosure are as follows: the present disclosure can move and adjust the spatial position of the smart camera through the cooperation of the X-axis module, Z-axis module, Y-axis module, smart camera, slide, rotating support, and the first strip light source in the vertical detection mechanism, thereby realizing the collection of the image of the inner wall of the grid grid unit of the grid; through the cooperation of the lateral detection mechanism lateral movement module and the industrial camera, the ring light source, and the second strip light source, it can realize the collection of the image of the outer side surface of the grid to be tested on the positioning rotation mechanism, thereby efficiently and accurately collecting the images of the inside and outside of the grid. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a schematic diagram of an automatic detection device for grid defects according to an exemplary embodiment.

[0027] Figure 2 It is a schematic diagram of some components of an automatic detection device for grid defects according to an exemplary embodiment.

[0028] Figure 3 It is a schematic diagram of some components of an automatic detection device for grid defects according to an exemplary embodiment.

[0029] Figure 4 It is a schematic diagram of some components of an automatic detection device for grid defects according to an exemplary embodiment.

[0030] Figure 5 It is a schematic diagram of some components of an automatic detection device for grid defects according to an exemplary embodiment.

[0031] Figure 6 It is a schematic diagram of a positioning and rotating mechanism of an automatic detection device for grid defects according to an exemplary embodiment.

[0032] Figure 7 It is a schematic diagram of a positioning and rotating mechanism of an automatic detection device for grid defects according to an exemplary embodiment.

[0033] Figure 8 It is a schematic diagram of a positioning and rotating mechanism of an automatic detection device for grid defects according to an exemplary embodiment.

[0034] In the figure:

[0035] 1. Left support, 2. Guide rail assembly, 3. Heightening pad, 4. Guide rail limit block, 5. X-axis module bracket,

[0036] 6.X-axis drag chain assembly, 7.X-axis module, 8.Z-axis drag chain assembly, 9.Z-axis module, 10.Y-axis module,

[0037] 11. Y-axis drag chain assembly, 12. Right support, 13. Smart camera, 14. Smart camera lens,

[0038] 15. Camera heightening block, 16. Camera back plate, 17. Slide table, 18. Rotating support, 19. Sliding bottom plate,

[0039] 20. Strip light source bracket, 21. First strip light source, 22. Lateral detection base plate, 23. Lateral shift module,

[0040] 24. Side-shift drag chain slot, 25. Side-shift drag chain, 26. Industrial camera, 27. Industrial camera lens,

[0041] 28. Camera bracket, 29. Fine-tuning bracket, 30. Fine-tuning slide, 31. Ring light bracket, 32. Ring light source,

[0042] 33. Strip light source, 34. Strip light bracket, 35. Strip light moving bottom plate, 36. Guide rail assembly, 37. Telescopic cylinder,

[0043] 38. Turntable bottom plate, 39. Turntable side plate 1, 40. First positioning block, 41. Turntable side plate 2,

[0044] 42. Turntable panel, 43. Turntable side panel three, 44. Second positioning block, 45. Turntable side panel four,

[0045] 46. ​​Sensor sheet, 47. Slot switch, 48. Backlight source, 49. Rotating motor. DETAILED DESCRIPTION

[0046] The present invention is further described in detail below with reference to the accompanying drawings and specific embodiments.

[0047] Figure 1 is a schematic diagram of an automatic detection device for grid defects according to an exemplary embodiment. Figure 2 It is a schematic diagram of some components of an automatic detection device for grid defects according to an exemplary embodiment. Figure 3 It is a schematic diagram of some components of an automatic detection device for grid defects according to an exemplary embodiment. Figure 4 It is a schematic diagram of some components of an automatic detection device for grid defects according to an exemplary embodiment. Figure 5 It is a schematic diagram of some components of an automatic detection device for grid defects according to an exemplary embodiment.

[0048] like Figure 1 As shown, the automatic detection device for grid defects includes: a vertical detection mechanism, a lateral detection mechanism and a positioning rotation mechanism, such as Figures 1 to 5 As shown, the support frame may include a left support 1 and a right support 12. The support frame is mainly formed by welding steel plates. The two are used in combination to fix the vertical detection mechanism components thereon to form a three-axis gantry structure, thereby realizing the automatic movement of the smart camera in the three directions of X-axis, Y-axis and Z-axis.

[0049] The guide rail assembly 2 is mainly used for carrying, flipping, moving and other actions during the grid inspection.

[0050] The heightening pad 3 is used for heightening support of the auxiliary end sliding of the X-axis module bracket 5 .

[0051] The guide rail limit blocks 4 are fixed at both ends of the guide rail assembly 2 to prevent the module from moving beyond the range, serving as the final hard limit.

[0052] The X-axis module bracket 5 is made of aluminum plate, which can reduce the weight of the body to the greatest extent while ensuring rigidity, and ensure smooth longitudinal movement with low resistance; the X-axis module bracket 5 is mainly used to fix the X-axis drag chain assembly 6, the X-axis module 7, the Z-axis drag chain assembly 8, the Z-axis module 9 and its fixings, etc.;

[0053] The Z-axis module 9 is mainly used to fix the smart camera 13, the smart camera lens 14, the camera heightening block 15, the camera back plate 16, the slide 17, the rotating support 18, the sliding base plate 19, the strip light source bracket 20, the strip light source 21, etc.

[0054] The Y-axis module 10 is fixed on the right bracket 12, and serves as a single-axis robot driving the Y-axis. The X-axis module bracket 5 and all the fixing parts on it are fixed on its slider, ensuring that the X-axis module bracket 5 and all the fixing parts on it move synchronously as a whole during operation.

[0055] The smart camera 13 and the smart camera lens 14 are matched and connected. For example, four sets of smart cameras can be provided, which are fixed on the camera pad blocks 15 respectively, and then fixed on the camera back plate 16 as a whole to form a four-camera integral component.

[0056] The slide 17 is fixed to the back of the camera back plate 16, one at each end, and is used for fine-tuning the overall components of the four cameras.

[0057] The rotating support 18 and the sliding base plate 19 form a structure with an angle that can be rotated. The four-camera overall component is fixed on the rotating support so that the angle of the four-camera overall component can be adjusted later.

[0058] The strip light source bracket 20 is fixed to both ends of the rotating support 18 , and the strip light source 21 is fixed to the strip light source bracket 20 .

[0059] The lateral detection base plate 22 is made of a whole steel plate, and is mainly used to fix the lateral shift module 23, the lateral shift drag chain groove 24, the lateral shift drag chain 25, the industrial camera 26, the industrial camera lens 27, the camera bracket 28, the fine-tuning bracket 29, the fine-tuning slide 30, the ring light source bracket 31, the ring light source 32, the second strip light source 33, the strip light bracket 34, the strip light moving base plate 35, the second guide rail assembly 36, the telescopic cylinder 37, etc., so that the lateral detection mechanism becomes a modular mechanism.

[0060] The lateral shift module 23 is mainly used for lateral movement of the industrial camera 26, the industrial camera lens 27, the camera bracket 28, the fine-tuning bracket 29, the fine-tuning slide 30, the ring light source bracket 31, the ring light source 32 and their accessories.

[0061] The industrial camera 26 is fixed on a camera bracket 28, and the camera bracket 28 is fixed on a fine-tuning bracket 29. During detection, the camera can be fine-tuned in the front-rear direction through the fine-tuning bracket 29.

[0062] The fine-tuning bracket 29 is fixed to the fine-tuning slide 30 by screws, and the fine-tuning slide 30 is used to fine-tune the camera assembly up and down.

[0063] The ring light source 32 is fixed on the ring light source bracket 31, and the ring light source bracket 31 is fixed on the fine-tuning bracket 29. The whole is located at the front end of the camera. The ring light is coaxial with the camera lens and the overall front-back position of the camera is relatively adjustable.

[0064] The second strip light source 33 is fixed on the strip light bracket 34 and has an adjustable angle; the strip light bracket 34 is fixed on the strip light moving base plate 35, and two sets of second guide rail assemblies 36 are fixed on the lower part of the strip light moving base plate 35, and the two sets of second guide rail assemblies 36 are fixed on the lateral detection base plate 22.

[0065] The telescopic cylinder 37 is fixed on the lateral detection bottom plate 22, and the front end is connected to the strip light bracket 34, so as to realize the function of moving the strip light forward and backward as a whole according to the system requirements.

[0066] Figure 6 It is a schematic diagram of a positioning and rotating mechanism of an automatic detection device for grid defects according to an exemplary embodiment. Figure 7 It is a schematic diagram of a positioning and rotating mechanism of an automatic detection device for grid defects according to an exemplary embodiment. Figure 8 FIG. 1 is a schematic diagram of a positioning and rotating mechanism of an automatic detection device for grid defects according to an exemplary embodiment. Figures 6 to 8 As shown, the turntable bottom plate 38 and the turntable side plate 1 39, the turntable side plate 2 41, the turntable side plate 3 43, and the turntable side plate 45 form a box-like structure, the backlight source 48 is fixed on the turntable bottom plate 38 inside the box-like structure, the turntable panel 42 is fixed on the upper part of the box-like structure, the first positioning block 40 and the second positioning block 44 are fixed diagonally on the upper part of the turntable panel 42, and the whole part forms a detection and positioning turntable table surface part, the rotating motor 49 is fixed at the lower end, and the sensor sheet 46 is fixed on the turntable bottom plate 38 outside the box-like structure, and the positioning and rotating mechanism is formed as a whole in cooperation with the slot-type switch 47.

[0067] The controller can convert the images and other signals obtained during the grid appearance inspection process into data that can be recognized and analyzed by the industrial computer, and all data are stored in the database. The controller's software system can analyze and process the data converted by the visual system and stored in the database for image recognition, classification and defect determination. The unqualified data system automatically identifies and statistically analyzes the inspection results to provide data support for quality management and auxiliary process analysis. The analysis and processing results are displayed on the interface of the "Positioning Grid Inspection System Software" for further analysis and processing by the operator. In addition to automatically recording and analyzing appearance inspection data, the software system also supports manual entry of inspection data and participation in statistical analysis.

[0068] The main body of the vertical detection mechanism is composed of X-axis, Y-axis, Z-axis, etc., which is mainly used to drive 4 parallel smart cameras to move as a whole with a spacing of four grid units to detect splash defects on the inner wall of the inner strip of the grid. The angle of the 4 groups of smart cameras when working is approximately 30° with the vertical direction. The camera and light source adjustment module is used to adjust the position and posture of the 4 groups of smart cameras to facilitate project debugging. The backlight source is used to assist the 4 groups of smart cameras to detect splash defects on the inner wall of the grid. With the assistance of a suitable backlight source, the splash features can be captured very clearly by the smart camera; since each square inside the grid has 4 walls, these four walls may have splash features, so these 4 walls must be detected. At this time, after each surface is detected, the positioning rotation mechanism rotates 90 degrees and repeats the previous detection action until all four inner wall surfaces are detected; according to the requirements of different types of grids, the camera field of view can only capture one side of the inner wall surface clearly at a time, so it is necessary to use an external loading and unloading mechanism, such as a manipulator to turn the grid over, and then continue to detect the four inner wall surfaces.

[0069] The lateral detection mechanism is designed with an industrial camera for detecting the outer strips; it is equipped with 3 sets of light sources, namely, a strip light source, a ring light source and a backlight source; different light sources are used to detect different objects. The strip light source is supported by a strip light bracket, and the ring light source is supported by a ring light bracket. Both the strip light bracket and the ring light bracket can easily adjust the position and posture of the light source, and the backlight source is used for overall lighting at the bottom of the grid; the combination of the strip light source and the industrial camera is suitable for detecting the numbering, scratches, weld length, linearity of the guide wing and other detection objects on the outer strips on the four sides of the grid, while the ring light source is suitable for detecting smoke color, oxidation color, dirt, welding quality and other detection objects. Since the above detection contents all need to be detected from the side of the grid, and since the time for the industrial camera to take a picture of the grid is particularly short, about 2ms milliseconds can be taken once, so the lateral detection mechanism can use an industrial camera to detect the outer strip module, and cooperate with the rotation of the positioning rotation mechanism to detect the above detection objects on each side of all grids. During normal operation, the positioning rotation mechanism is equipped with a diffuse reflection sensor, whose function is to detect whether the grid being detected is placed on the positioning rotation table.

[0070] In an application example, the specific detection process of the automatic detection device A disclosed in the present invention is as follows:

[0071] a. The external loading and unloading mechanism loads a grid onto the positioning surface of the positioning and rotating mechanism;

[0072] b. The vertical detection mechanism of the automatic detection device A drives 4 groups of intelligent cameras to traverse all the grids inside the grid in an "S" shape, detect and record the splashing of the first wall of each grid, and at the same time, the lateral detection mechanism drives the industrial camera to shoot the side of the grid in sections; the specific process is as follows: during the camera shooting and detection process, the linear module pauses after each section of the camera moves an effective field of view. During the pause, the camera cooperates with the strip light source and the ring light source to take pictures and detect once respectively, and then the linear module continues to move forward one section. Until one side of the grid is shot.

[0073] c Rotate the motor 90°.

[0074] d After switching the detection surface, the vertical detection mechanism of the automatic detection device A drives the four groups of intelligent cameras to traverse all the squares inside the grid in an "S" shape again, detecting and recording the splashing conditions of the second wall of each square.

[0075] e. Repeat steps b, c, and d to inspect and record the splash and side defects on the 3rd and 4th walls of each square.

[0076] After the above steps are completed, the external loading and unloading mechanism needs to flip the upward side of the grid 180° and then face it downward, and place it on the positioning rotating surface, and then repeat the above steps a to f for inspection again. The outer strip inspection does not need to be carried out, and a second re-inspection can be carried out simultaneously without affecting the beat.

[0077] The embodiments of the present disclosure have been described above, and the above description is exemplary, not exhaustive, and is not limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The selection of terms used herein is intended to best explain the principles of the embodiments, practical applications, or technical improvements to the technology in the market, or to enable other persons of ordinary skill in the art to understand the embodiments disclosed herein.

Claims

1. An automatic detection device for grid defects, characterized in that: The automatic detection device for grid defects comprises: a vertical detection mechanism, a lateral detection mechanism and a positioning and rotating mechanism; The positioning and rotating mechanism is used to set the grid to be detected; The vertical detection mechanism includes a support frame, an X-axis module, a Z-axis module, a Y-axis module, a smart camera, a slide, a rotating support, and a first strip light source; The Y-axis module is fixedly connected to the supporting frame, the X-axis module is connected to the driving end of the Y-axis module, the Z-axis module is connected to the driving end of the X-axis module, the smart camera is connected to the driving end of the slide, the slide is connected to the driving end of the rotating support, the first strip light source is connected to the rotating support, and the rotating support is connected to the driving end of the Z-axis module; The X-axis module can drive the smart camera to move along the horizontal X-axis direction, the Z-axis module can drive the smart camera to move along the vertical Z-axis direction, and the Y-axis module can drive the smart camera to move along the horizontal Y-axis direction; The slide can drive the smart camera to move along the first direction, the rotating support can adjust the angle between the optical axis of the smart camera lens and the vertical direction, and the smart camera is used to collect images of the inner side surfaces of each grid unit of the grid to be tested on the positioning rotating mechanism; The lateral detection mechanism includes a lateral shift module and an industrial camera, a ring light source, and a second strip light source, wherein the industrial camera is used to collect images of the outer side surface of the grid to be detected on the positioning and rotating mechanism; The industrial camera is connected to the driving end of the side shift module, the annular light source surrounds the lens of the industrial camera, the second strip light source is connected to the driving end of the side shift module, and the side shift module can drive the second strip light source and the industrial camera to move together along the horizontal X-axis direction; The lateral detection mechanism also includes a fine-tuning slide and a telescopic cylinder; The industrial camera is connected to the driving end of the fine-tuning slide, the fine-tuning slide is connected to the driving end of the side shift module, and the fine-tuning slide can adjust the position of the industrial camera in the horizontal Y-axis direction; The second strip light source is connected to the telescopic end of the telescopic cylinder, and the telescopic cylinder is connected to the driving end of the side shift module, and the telescopic cylinder can adjust the position of the second strip light source in the horizontal Y-axis direction; The automatic detection device for grid defects comprises a plurality of smart cameras, the plurality of smart cameras are arranged in a straight line, and the distribution of the lenses of each smart camera is adapted to the distribution of the grids of the grid to be detected, so that each smart camera lens can be aligned with a grid unit; The automatic detection device for grid defects also includes a controller, which performs the following control operations: Step 100, the controller controls the vertical detection mechanism to adjust the optical axis of the smart camera lens to form a preset angle with the vertical direction, so that the camera lens faces the inner wall of one side of each grid unit, and then the controller drives the smart camera to traverse each grid unit through the X-axis module, the Z-axis module, and the Y-axis module to collect the image of the inner wall of each grid unit; Step 101, the controller controls the lateral detection mechanism to drive the industrial camera starting from the end of an outer wall of the grid, and each time the industrial camera is driven to move a preset distance, the industrial camera is paused for a preset time. The controller controls the industrial camera to capture an image once during the pause period until the image of the outer wall is captured; After the controller completes photographing the side of the grid, the controller controls the turntable to rotate 90 degrees so that the other inner wall of each grid unit faces the lens of the smart camera, and the other outer wall of the grid faces the industrial camera, and steps 100 and 101 are repeated until the images of the four inner walls of each grid unit and the four outer walls of the grid are collected; Step 102: perform defect recognition based on the acquired image and mark the location of the defect on the acquired image.

2. The automatic detection device for grid defects according to claim 1, characterized in that: The positioning and rotating mechanism comprises: a turntable and a rotating motor; The turntable is connected to the rotor of the rotary motor, and the rotary motor is used to drive the turntable to rotate.

3. The automatic detection device for grid defects according to claim 2, characterized in that: The turntable includes: a backlight source is arranged inside the turntable, a turntable panel on the upper surface of the turntable is made of transparent material, the turntable panel is used to place the grid to be detected, and the backlight source can illuminate the grid on the turntable panel through the turntable panel.

4. The automatic detection device for grid defects according to claim 2, characterized in that: The upper surface of the turntable is provided with a first positioning block and a second positioning block, wherein the first positioning block and the second positioning block are L-shaped and are used to limit two diagonal corners of the grid to be inspected.

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