Intelligent online detection device for complex inner cavity casting defects

Abstract

The present invention relates to an intelligent online defect detection device for complex inner cavity castings, comprising a lens adjustment device, a stepper motor, a positioning switch, a PLC, a video splitter, an embedded computer and an intelligent defect detection program; wherein the lens adjustment device comprises a micro lens, a spring, an adjustment bolt, a mounting plate, a transfer interface, a rotating shaft and a pulley. The positioning switch determines that the complex inner cavity casting reaches a predetermined position, and the PLC instructs the stepper motor to rotate forward to drive the rotating shaft and the pulley to release the wire, so that the spring assembled on the adjustment bolt enters the inner cavity of the casting, and drives the micro lens fixed in the spring to the farthest end, and then the stepper motor reverses, so that the micro lens steadily recovers with the spring while photographing the complex inner cavity surface of the casting, and the image is transmitted to the embedded computer through the video splitter, and the defect intelligent detection program is used to identify online whether the complex inner cavity surface image of the casting contains defects. The present invention replaces manual detection and greatly improves production efficiency.

Description

Technical Field

[0001] The invention relates to an online product defect detection system, in particular to an intelligent online defect detection device for complex inner cavity castings. Background Art

[0002] At present, in the foundry industry, after the castings are manufactured, manual methods are generally used to detect defects in the products, especially for complex inner cavity castings, which lack automatic detection methods. The labor intensity of workers is high and the efficiency is low, and they are easily affected by manual errors. How to design a set of online detection devices for defects of complex inner cavity castings has become very necessary. The present invention provides an intelligent online detection device for defects of complex inner cavity castings, which effectively solves this problem. Summary of the invention

[0003] In order to solve the problem of low efficiency caused by manual detection of defects in complex inner cavity castings, the present invention provides an intelligent online detection device for defects in complex inner cavity castings, including a lens adjustment device, a stepping motor, a positioning switch, a PLC, a video splitter, an embedded computer and a defect intelligent detection program; wherein the lens adjustment device includes a micro lens, a spring, an adjustment bolt with a lock, a mounting plate, an adapter, a rotating shaft with a pull wire, and a pulley; the micro lens includes an integrated module and LED lighting.

[0004] In order to overcome the deficiencies of the prior art, the purpose of the present invention is to use a micro lens, an adjustment bolt, a spring, a stepper motor, a rotating shaft, a pulley, and a positioning switch, a PLC, a video splitter, an embedded computer and a machine vision detection program to enable the micro lens to enter the specified position of the complex inner cavity of the casting to take pictures, and transmit the image to the embedded computer, and the defect intelligent detection program is used to identify online whether the complex inner cavity surface image of the casting contains defects. This complex inner cavity casting defect intelligent online detection device replaces manual detection, which not only greatly improves production efficiency, but also eliminates the influence of manual errors on casting defect detection. At the same time, by adjusting the installation position of the micro lens, it can adapt to complex inner cavity castings of different specifications, and has good flexibility.

[0005] The present invention is implemented by the following technical solutions:

[0006] An online defect detection system for complex inner cavity castings based on machine vision is characterized in that: a positioning switch determines that the complex inner cavity casting reaches a predetermined position, at which time a PLC instructs a stepper motor to rotate forward to drive a rotating shaft and release a line through a pulley, so that a spring assembled on an adjusting bolt extends along the complex inner cavity of the casting, and drives a micro lens fixed in the spring including an integrated module and LED lighting to the farthest end, and then the stepper motor reverses according to the PLC instruction, so that the micro lens steadily recovers with the spring while photographing the complex inner cavity surface of the casting, and the image is transmitted to an embedded computer through a video splitter, and a defect intelligent detection program is used to identify online whether the complex inner cavity surface image of the casting contains defects.

[0007] By adopting the above technical solution, the stepper motor drives the shaft to rotate, and then releases the wire through the pulley. The wire is directly connected to the micro lens; the micro lens is installed at one end of the spring, and the other end of the spring is fixed on the adjustment bolt, so that the wire is kept straight with the help of the elastic force of the spring. When working, first use three positioning switches to determine the position of the complex inner cavity casting in three coordinate directions, and at the same time collect the position information by PLC to determine that the casting has reached the specified position, without blocking the micro lens from entering the inner cavity of the casting.

[0008] Furthermore, the positioning switch determines that the complex inner cavity casting has reached the predetermined position. At this time, the PLC instructs the stepper motor to rotate forward and drive the rotating shaft and release the wire through the pulley. Since the pull wire is connected to the micro lens fixed on the inside of the spring, the micro lens is pushed out along the complex inner cavity of the casting with the help of the deformation of the spring, so that the micro lens reaches the farthest end; then the stepper motor reverses according to the PLC instruction, and the rotating shaft reels the wire, so that the micro lens is steadily recovered with the spring until the micro lens and the spring return to the initial position.

[0009] By adopting the above technical solution, the step length of the stepper motor is equal to the extension or compression stroke of the spring, thereby accurately controlling the stroke of the micro lens; at the same time, a rotating shaft is used to connect multiple micro lenses, that is, one stepper motor controls multiple micro lenses, which simplifies the design and reduces costs.

[0010] Furthermore, the positioning switch determines that the complex inner cavity casting has reached a predetermined position. At this time, the PLC instructs the stepper motor to rotate forward to drive the rotating shaft and release the wire through the pulley, so that the spring extends along the complex inner cavity of the casting and drives the micro lens to the farthest end. Then the stepper motor reverses according to the PLC instruction, so that the micro lens steadily retracts with the spring while photographing the complex inner cavity surface of the casting. The image is transmitted to the embedded computer through the video splitter, and the micro lens and the spring return to their initial positions.

[0011] By adopting the above technical solution, the micro lens is fixed on the inner side of the spring and close to one end, and the other end of the spring is fixed on the adjusting bolt; through the coordinated use of the spring and the micro lens, on the one hand, the micro lens can penetrate into the complex inner cavity of the casting to shoot, and on the other hand, the deformation performance of the spring is utilized so that it can follow the curvature of the inner cavity and enter, and it still has elasticity after resetting, which is convenient for repeated use.

[0012] Furthermore, the adjusting bolt is fixed on the mounting plate, and its length is adjustable. At the same time, the spacing between the adjusting bolts is adjustable on the mounting plate. When the specifications of the complex inner cavity casting change, the position of the mounting plate can be adjusted to ensure that the spring is facing the inner cavity of the casting, and the degree of spring deformation can be ensured to be the same by changing the length of the adjusting bolt. When the length of the adjusting bolt is changed, the position of the pulley on its mounting plate is adjusted synchronously to ensure that the tension of the pull wire is maintained.

[0013] By adopting the above technical solution, the change in the length of the adjusting bolt should ensure that the stroke of multiple micro lenses entering the inner cavity of the casting is the same, that is, the deformation of each spring is the same; since the lengths of different inner cavities of the same casting are different, the distances from the inner cavity outlet to the initial position of the micro lens are also different, so the sum of the change in the length of the adjusting bolt and the stroke of the micro lens entering the inner cavity of the casting is equal to the arc length of the stepper motor rotation.

[0014] Furthermore, the positioning switch determines that the complex inner cavity casting has reached the predetermined position, and the PLC collects the position information and instructs the stepper motor to rotate forward to drive the rotating shaft and release the wire through the pulley, so that the spring extends along the complex inner cavity of the casting and drives the micro lens to the farthest end; then the PLC instructs the stepper motor to reverse, so that the micro lens is steadily recovered to the initial position with the spring; each preset step length of the stepper motor reverses corresponds to the corresponding position of the micro lens photographing the inner cavity of the casting.

[0015] By adopting the above technical solution, PLC serves as the controller of the intelligent online defect detection device based on complex inner cavity castings. Its main function is to collect the position information of the castings and start the operation of the stepper motor, control the speed and step length of the stepper motor, make the micro lens controlled to enter and exit the complex inner cavity of the casting, and send relevant information to the embedded computer.

[0016] Furthermore, the embedded computer is connected to the PLC to read and write data on the one hand, and is connected to multiple micro-lenses through a video splitter on the other hand, and the intelligent defect detection program runs on the embedded computer; when the positioning switch determines that the complex inner cavity casting has reached the predetermined position, the PLC instructs the stepper motor to rotate forward to drive the shaft and release the wire through the pulley, so that the spring extends along the complex inner cavity of the casting and drives the micro-lens to the farthest end, and the embedded computer instructs the micro-lens to start shooting; then the stepper motor reverses according to the PLC instruction, so that the micro-lens steadily recovers with the spring while shooting the complex inner cavity surface of the casting; when the micro-lens and the spring return to the initial position, the embedded computer instructs the micro-lens to stop shooting; the image is transmitted to the embedded computer through the video splitter, and the complex inner cavity surface image of the casting is identified online by the intelligent defect detection program, which can not only determine whether the image contains defects, but also determine the type of defects.

[0017] By adopting the above technical solution, the embedded computer, as the core of the online defect detection system for complex inner cavity castings based on machine vision, not only runs the machine vision detection program to complete the task of online automatic identification of whether the complex inner cavity surface image of the casting contains defects, but also monitors the working status of the stepper motor by reading the parameters of the PLC. At the same time, the step length of the stepper motor can be written into the PLC according to the specifications of the casting to be tested, realizing that one system can be applicable to complex inner cavity castings of various specifications.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] By using a micro lens, adjustment bolts, springs, lenses, stepper motors, rotating shafts, pulleys, and in conjunction with positioning switches, PLCs, video splitters, embedded computers, and machine vision detection programs, the micro lens can enter the designated position of the complex inner cavity of the casting to take pictures, and transmit the image to the embedded computer, where the defect intelligent detection program can identify online whether the complex inner cavity surface image of the casting contains defects. This complex inner cavity casting defect intelligent online detection device replaces manual detection, which not only greatly improves production efficiency, but also eliminates the influence of manual errors on casting defect detection. At the same time, by adjusting the installation position of the micro lens, it can adapt to complex inner cavity castings of different specifications, and has good flexibility. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention (simultaneous detection of two castings). Each set of detection devices includes a stepping motor controlling 4 sets of lens adjustment devices. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0021] Figure 1 The logic block diagram of the present invention is

[0022] Figure 2 It is a top view of the mechanical structure of the present invention;

[0023] Figure 3 It is a side view of the mechanical structure of the present invention;

[0024] Figure 4 It is a front view of the mechanical structure of the present invention;

[0025] Figure 5 It is a top view of the lens adjustment device of the present invention.

[0026] Figure 6 A side view of the lens adjustment device of the present invention

[0027] Figure 7 This is a front view of the lens adjustment device of the present invention

[0028] Figure 8 A lens adjustment device of the present invention and a partial cross-sectional view magnified three times DETAILED DESCRIPTION

[0029] All features disclosed in this specification, or steps in all methods or processes disclosed, except mutually exclusive features and / or steps, can be combined in any manner.

[0030] Any feature disclosed in this specification (including any additional claims, abstract and drawings), unless otherwise stated, may be replaced by other equivalent or alternative features with similar purposes. That is, unless otherwise stated, each feature is only an example of a series of equivalent or similar features.

[0031] like Figure 1-5As shown, a complex inner cavity casting defect intelligent online detection device of the present invention includes a lens adjustment device 5 and a stepper motor 16, a positioning switch 4, a PLC 3, a video splitter 2, and an embedded computer 1, on which a defect intelligent detection program is run; wherein the lens adjustment device includes a micro lens 21, wherein the micro lens includes an integrated module and LED lighting, a transfer interface 11, a spring 22, an adjustment bolt 12 with a lock, a mounting plate 13, a rotating shaft 14 with a pull line, and an adjustment pulley 15. The positioning switch determines that the complex inner cavity casting reaches a predetermined position, at which time the PLC instructs the stepper motor 16 to rotate forward to drive the rotating shaft and release the wire through the pulley, so that multiple springs assembled on the adjustment bolt extend along the complex inner cavity of the casting, and drive the micro lens fixed in the spring including the integrated module and LED lighting to the farthest end, and then the stepper motor reverses according to the PLC instruction, so that the micro lens steadily recovers with the spring while shooting the complex inner cavity surface of the casting, and the image is transmitted to the embedded computer through the video splitter, and the defect intelligent detection program is used to identify online whether the complex inner cavity surface image of the casting contains defects.

[0032] Advantageously, the positioning switch 4 determines that the complex inner cavity casting reaches the predetermined position, and at this time, the PLC instructs the stepper motor 16 to rotate forward to drive the rotating shaft 14 and release the wire through the pulley. The rotating shaft 14 is connected to the micro lens 21 fixed on the inner side of the spring through the pulley, so that the spring 22 extends along the complex inner cavity of the casting, so that the micro lens 21 reaches the farthest end; then the stepper motor 16 reverses according to the PLC instruction, and the rotating shaft 14 retracts the wire through the pulley, so that the lens is steadily recovered with the spring until the lens and the spring are reset. This embodiment uses one rotating shaft to connect four micro lenses, that is, one stepper motor controls four micro lenses, which simplifies the design and reduces the cost.

[0033] Advantageously, the adjusting bolt 12 is fixed on the mounting plate 13, and the distance from the mounting position to the micro lens 21 is adjustable. At the same time, the spacing between the adjusting bolts 12 is adjustable on the mounting plate 13. When the specifications of the complex inner cavity casting are different, the position of the mounting plate 13 can be adjusted to ensure that the spring 22 is facing the inner cavity of the casting, and the length of the adjusting bolt 12 can be changed to ensure that the degree of deformation of the spring 22 is the same; when the length of the adjusting bolt 12 is changed, the position of the pulley 15 on its mounting plate is adjusted synchronously to ensure that the tension of the pull wire is maintained.

[0034] Advantageously, the micro lens 21 is fixed on the inner side of the spring 22 and close to one end, and the other end of the spring 22 is fixed on the adjusting bolt 12; the positioning switch 4 determines that the complex inner cavity casting reaches the predetermined position, at which time the PLC3 instructs the stepper motor 16 to rotate forward to drive the rotating shaft and release the wire through the pulley, so that the spring 22 extends along the complex inner cavity of the casting and drives the micro lens 21 to the farthest end, and then the stepper motor 16 reverses according to the PLC3 instruction, so that the micro lens 21 steadily recovers with the spring 22 while photographing the complex inner cavity surface of the casting, and the image is transmitted to the embedded computer 1 through the video splitter 2, and the micro lens 21 and the spring 22 return to the initial position.

[0035] When a complex inner cavity casting defect intelligent online detection device is working, the embedded computer 1 is connected to PLC3 and reads and writes data on the one hand, and is connected to multiple micro lenses 21 through the video splitter 2 on the other hand, and the defect intelligent detection program runs on the embedded computer 1; when the positioning switch 4 determines that the complex inner cavity casting has reached the predetermined position, the PLC3 instructs the stepper motor 16 to rotate forward to drive the shaft and release the wire through the pulley, so that the spring extends along the complex inner cavity of the casting and drives the micro lens 21 to the farthest end, and the embedded computer 1 instructs the micro lens 21 to start shooting; then the stepper motor 16 reverses according to the PLC3 instruction, so that the micro lens 21 steadily recovers with the spring while shooting the complex inner cavity surface of the casting; when the micro lens 21 and the spring return to the initial position, the embedded computer 1 instructs the micro lens 21 to stop shooting; the image is transmitted to the embedded computer 1 through the video splitter 2, and the complex inner cavity surface image of the casting is identified online by the defect intelligent detection program, which can not only determine whether the image contains defects, but also determine the defect type.

[0036] The device of the present invention has a simple structure and is easy to use. The intelligent online detection device for defects in complex inner cavity castings adopts mechatronics technology to realize the entry and exit of the micro-lens in the complex inner cavity of the casting and the shooting of images, which effectively improves production efficiency and saves labor costs.

[0037] The above is only a specific implementation of the invention, but the protection scope of the invention is not limited to it. Any changes or substitutions that are not conceived through creative work should be included in the protection scope of the invention. Therefore, the protection scope of the invention should be based on the protection scope defined in the claims.

Claims

1. An intelligent online detection device for complex inner cavity casting defects, characterized by: It includes lens adjustment device, stepper motor, positioning switch, PLC, video splitter, embedded computer and intelligent defect detection program; The lens adjustment device includes a micro lens, a spring, an adjustment bolt with a lock, a mounting plate, an adapter, a rotating shaft with a pull wire, and a pulley; the micro lens includes an integrated module and LED lighting; the micro lens is fixed on the inner side of the spring and close to one end, and the other end of the spring is fixed on the adjustment bolt; the adjustment bolt is fixed on the mounting plate, and the distance from its mounting position to the micro lens is adjustable, and the spacing between the adjustment bolts is adjustable on the mounting plate; the positioning switch determines that the complex inner cavity casting reaches a predetermined position, at which time the PLC instructs the stepper motor to rotate forward to drive the rotating shaft and release the wire through the pulley, so that the spring assembled on the adjustment bolt extends along the complex inner cavity of the casting, and drives the micro lens fixed in the spring including the integrated module and LED lighting to the farthest end, and then the stepper motor reverses according to the PLC instruction, so that the micro lens steadily recovers with the spring while shooting the complex inner cavity surface of the casting, and the image is transmitted to the embedded computer through the video splitter, and the defect intelligent detection program is used to identify online whether the complex inner cavity surface image of the casting contains defects.

2. The intelligent online detection device for complex inner cavity casting defects according to claim 1, characterized in that: The positioning switch determines that the complex inner cavity casting has reached the predetermined position. At this time, the PLC instructs the stepper motor to rotate forward to drive the rotating shaft and release the wire through the pulley. The rotating shaft is connected to the micro lens fixed on the inner side of the spring through a pull wire, so that the spring extends along the complex inner cavity of the casting and the lens reaches the farthest end; then the stepper motor reverses according to the PLC instruction, and the rotating shaft retracts the wire through the pulley, so that the lens is steadily recovered with the spring until the lens and spring are reset.

3. The intelligent online detection device for complex inner cavity casting defects according to claim 1, characterized in that: The positioning switch determines that the complex inner cavity casting reaches the predetermined position. At this time, the PLC instructs the stepper motor to rotate forward to drive the rotating shaft and release the wire through the pulley, so that the spring extends along the complex inner cavity of the casting and drives the micro lens including the integrated module and LED lighting to the farthest end. Then the stepper motor reverses according to the PLC instruction, so that the micro lens steadily recovers with the spring while photographing the complex inner cavity surface of the casting. The image is transmitted to the embedded computer through the video splitter, and the micro lens returns to the initial position.

4. The intelligent online detection device for complex inner cavity casting defects according to claim 1, characterized in that: When the specifications of complex inner cavity castings are different, the position of the mounting plate can be adjusted to ensure that the spring is facing the inner cavity of the casting, and the degree of spring deformation can be ensured to be the same by adjusting the length of the bolt; when the length of the adjusting bolt is changed, the position of the pulley on its mounting plate is adjusted synchronously to ensure that the tension of the pull wire is maintained.

5. The intelligent online detection device for complex inner cavity casting defects according to claim 1, characterized in that: The positioning switch determines that the complex inner cavity casting has reached the predetermined position, and the PLC collects the position information and instructs the stepper motor to rotate forward to drive the rotating shaft and release the wire through the pulley, so that the spring extends along the complex inner cavity of the casting and drives the micro lens to the farthest end; then the PLC instructs the stepper motor to reverse, so that the micro lens is steadily recovered to the initial position along with the spring.

6. The intelligent online detection device for complex inner cavity casting defects according to claim 1, characterized in that: On the one hand, the embedded computer is connected to the PLC to read and write data, and on the other hand, it is connected to multiple micro-lenses through the video splitter, and the defect intelligent detection program runs on the embedded computer; when the positioning switch determines that the complex inner cavity casting has reached the predetermined position, the PLC instructs the stepper motor to rotate forward to drive the shaft and release the wire through the pulley, so that the spring extends along the complex inner cavity of the casting and drives the micro-lens to the farthest end, and the embedded computer instructs the micro-lens to start shooting; then the stepper motor reverses according to the PLC instruction, so that the micro-lens steadily recovers with the spring while shooting the complex inner cavity surface of the casting; when the micro-lens and the spring return to the initial position, the embedded computer instructs the micro-lens to stop shooting; the image is transmitted to the embedded computer through the video splitter, and the defect intelligent detection program online identifies whether the complex inner cavity surface image of the casting contains defects.

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