A steel material mixing detection system and method based on electromagnetic nondestructive testing

Abstract

A kind of steel mixing detection system and mode based on electromagnetic nondestructive testing, including mainframe, temperature measuring thermal imager, temperature display instrument, medium frequency heating furnace, signal generator, power amplifier circuit, signal processing circuit, excitation coil, detection coil, coil framework, data acquisition card, voice alarm module, programmable controller, feed pushing frame, photoelectric switch, industrial camera, motor, feeding and withdrawing conveying frame, mobile trolley and outer through type detection probe, outer through type detection probe is composed of coil framework, excitation coil and detection coil, and excitation coil and detection coil are wound and fixed on coil framework.For the problems that industrial steel mixing detection is difficult and time-consuming, a kind of steel mixing online detection system based on electromagnetic nondestructive testing is designed and developed, realizes the online automatic detection and control of steel mixing in factory, and detection efficiency is high.

Description

Technical fields:

[0001] This invention relates to the technical field of steel testing systems, and more specifically to a steel mixture testing system and method based on electromagnetic nondestructive testing. Background technology:

[0002] Bearings are an essential component in modern machinery. Their primary function is to support rotating mechanical parts, reduce friction during movement, and ensure rotational accuracy. Bearings can be divided into rolling bearings and sliding bearings. Rolling bearings consist of rings, balls, and a cage, with the rings being the main body. Ring production primarily involves forging from bar stock, followed by machining. Therefore, the material of the bar stock significantly impacts bearing performance. A major concern in ring production is the presence of different steel types within the bar stock, i.e., mixed materials. Bar stock material inspection cannot be performed visually; traditionally, manual inspection using handheld steel quality testing instruments is inefficient and physically demanding for workers. Summary of the Invention:

[0003] The purpose of this invention is to address the shortcomings of existing technologies by providing a steel mixture detection system and method based on electromagnetic nondestructive testing. This mixture detection system can replace manual labor to achieve automated detection with high efficiency.

[0004] A steel mixing detection system based on electromagnetic non-destructive testing includes a large computer, a thermal imager, a temperature display, a medium-frequency heating furnace, a signal generator, a power amplifier circuit, a signal processing circuit, an excitation coil, a detection coil, a coil frame, a data acquisition card, a voice alarm module, a programmable controller, a feeding pusher, a photoelectric switch, an industrial camera, a motor, a feeding and unloading conveyor, a mobile trolley, and an external through-type detection probe. The external through-type detection probe consists of a coil frame, an excitation coil, and a detection coil, which are wound and fixed on the coil frame. A feeding pusher, an external through-type detection probe, and a feeding and unloading conveyor are sequentially arranged on one side of the inlet of the medium-frequency heating furnace. The feeding and unloading conveyor is equipped with conveying rollers, which are directly opposite and close to the inlet of the medium-frequency heating furnace. A photoelectric switch is located between the feeding pusher and the external through-type detection probe, and an industrial camera is positioned above the feeding pusher.

[0005] The temperature display, signal generator, data acquisition card, voice alarm module, and programmable controller are electrically connected to and controlled by a large computer. The data acquisition card collects information data from the temperature display, power amplifier circuit, signal processing circuit, and industrial camera. The feeding pusher, photoelectric switch, and industrial camera are electrically connected to and controlled by the programmable controller. The signal generator is electrically connected to the excitation coil through the power amplifier circuit, and the detection coil is electrically connected to the signal processing circuit.

[0006] The external through-type detection probe is fixedly connected to the mobile trolley, and the programmable controller is connected to the mobile trolley and controls the movement of the mobile trolley.

[0007] The motor is mounted and fixed on the feeding and unloading conveyor frame, and the motor drives the conveying rollers on the feeding and unloading conveyor frame to rotate through chain belt transmission; the motor is electrically connected to and controlled by the programmable controller.

[0008] The feeding pusher is provided with a pusher rod opposite to the external through-type detection probe. The feeding pusher includes a frame and a pusher actuator on the frame, which drives the pusher rod to move.

[0009] The feeding and pushing frame has steel bars positioned directly opposite the pushing rod. The steel bars are inserted into an external through-type detection probe. A large computer-controlled signal generator sends pulse signals to generate a changing current, which causes the excitation coil to generate an excitation magnetic field. The steel bars in the excitation magnetic field are picked up and detected by the detection coil.

[0010] The temperature display device has a temperature display screen, and the large computer is equipped with an operation touch screen, a data display screen and a database; the voice alarm module can issue alarm prompts for "material shortage", "mixed materials" and "high temperature".

[0011] A method for detecting mixed steel materials based on electromagnetic non-destructive testing is disclosed. The aforementioned steel mixed material detection system can achieve control over the feeding and unloading of steel bars, control over mixed material non-destructive testing, and automatic alarm control. The specific detection method is as follows:

[0012] First, the operator sets the appropriate excitation frequency and excitation amplitude on the touch screen of the large computer according to the steel bar material. The temperature display shows the temperature of the medium frequency heating furnace and uploads the temperature data to the data acquisition card. The data acquisition card organizes the data and sends it to the large computer. When the temperature of the medium frequency heating furnace is within the specified temperature range, the large computer starts working and controls the moving trolley to move the external through-type detection probe to the detection position.

[0013] The programmable logic controller (PLC) receives commands from the mainframe computer and begins operation. The pusher rod on the feeding pusher pushes the steel bar material into the furnace. When the feeding pusher pushes the material up to the length of the pusher rod but before triggering the photoelectric switch, the feeding pusher stops pushing and sends an alarm signal to the mainframe computer. An industrial camera takes a picture of the feeding section and sends the image to the mainframe computer. The mainframe computer controls the voice alarm module to issue a "material shortage" voice alarm and displays the image on the data display screen. When the bar material triggers the photoelectric switch, the feeding pusher stops pushing and sends an electrical signal to the mainframe computer. The motor drives the conveyor rollers of the feed and return conveyor to rotate clockwise for transport. The rotating conveyor rollers transport the steel bar material into the medium-frequency heating furnace and then stop rotating.

[0014] As the steel bar passes through the through-type detection probe, a large computer controls a signal generator to produce various high-performance pulse signals based on the excitation frequency and amplitude. The pulse signals generated by the signal generator are amplified stably by a power amplifier circuit, generating a changing current that is transmitted to the excitation coil and generates signal data which is then sent to the data acquisition card. The excitation coil generates magnetic lines of force along its center through the changing current, producing an excitation magnetic field. When the steel bar is magnetized in the magnetic field, a series of discontinuous, abrupt electromagnetic pulse signals are generated inside the steel bar. These electromagnetic pulse signals are picked up by the detection coil, and the signal processing circuit amplifies the signals and eliminates most of the noise. The processed signal data is then sent to the data acquisition card.

[0015] The mainframe computer determines whether there is material mixing based on the signal data collected by the data acquisition card. If material mixing is found, the mainframe computer sends a signal to the programmable controller, causing the motor to drive the conveyor rollers of the feeding and unloading conveyor to rotate counterclockwise to perform the unloading operation. At the same time, it controls the voice alarm module to issue a "material mixing" voice alarm. If there is no material mixing, the mainframe computer sends a signal to the programmable controller, causing the motor to drive the conveyor rollers of the feeding and unloading conveyor to rotate clockwise to continue the feeding and transportation operation.

[0016] The beneficial effects of this invention are as follows:

[0017] 1. To address the challenges and time-consuming nature of industrial steel mixture detection, an online steel mixture detection system based on electromagnetic nondestructive testing was designed and developed. This system enables automated online detection and control of steel mixtures in factories, achieving high detection efficiency.

[0018] 2. This detection system has added a voice alarm module, which can accurately alarm for problems in the production process, speed up personnel's handling of the situation, and accelerate the problem repair speed. Attached image description:

[0019] Figure 1 A schematic diagram of the structure of this invention;

[0020] Figure 2 The control flowchart of the programmable controller of this invention;

[0021] Figure 3 Schematic block diagram of the mixing detection system of the present invention;

[0022] Figure 4 A schematic diagram of the external through-type detection probe in this invention.

[0023] In the diagram: 1. Mainframe computer; 2. Thermal imager; 3. Temperature display; 4. Medium-frequency induction heating furnace; 5. Signal generator; 6. Power amplifier circuit; 7. Signal processing circuit; 8. Excitation coil; 9. Detection coil; 10. Coil frame; 11. Data acquisition card; 12. Voice alarm module; 13. Programmable controller; 14. Feeding and pushing frame; 15. Photoelectric switch; 16. Industrial camera; 17. Motor; 18. Feeding and unloading conveyor; 19. Mobile trolley; 20. External through-type detection probe. Detailed implementation method:

[0024] Example: See Figures 1 to 4 As shown, a steel mixing detection system based on electromagnetic non-destructive testing includes a large computer 1, a thermal imager 2, a temperature display instrument 3, a medium-frequency heating furnace 4, a signal generator 5, a power amplifier circuit 6, a signal processing circuit 7, an excitation coil 8, a detection coil 9, a coil frame 10, a data acquisition card 11, a voice alarm module 12, a programmable controller 13, a feeding pusher 14, a photoelectric switch 15, an industrial camera 16, a motor 17, a feeding and unloading conveyor 18, a moving trolley 19, and an external through-type detection probe 20. The external through-type detection probe 20 is composed of the coil frame 10, the excitation coil 8, and the detection coil 9, which are wound and fixed on the coil frame 10. The feeding pusher 14, the external through-type detection probe 20, and the feeding and unloading conveyor 18 are sequentially arranged on one side of the inlet of the medium-frequency heating furnace 4. The feeding and unloading conveyor 18 is equipped with conveying rollers. The conveying rollers on the feeder and the inlet of the medium frequency heating furnace 4 are directly opposite and close to each other. A photoelectric switch 15 is provided between the feed pusher 14 and the external through-type detection probe 20. An industrial camera 16 is provided above the feed pusher 14.

[0025] The temperature display 3, signal generator 5, data acquisition card 11, voice alarm module 12, and programmable controller 13 are electrically connected to and controlled by the main computer 1. The data acquisition card 11 is connected to collect information data from the temperature display 3, power amplifier circuit 6, signal processing circuit 7, and industrial camera 16. The feeding pusher 14, photoelectric switch 15, and industrial camera 16 are electrically connected to and controlled by the programmable controller 13. The signal generator 5 is electrically connected to the excitation coil 8 through the power amplifier circuit 6, and the detection coil 9 is electrically connected to the signal processing circuit 7. The detection coil 9 is located inside the excitation coil 8.

[0026] The external through-type detection probe 20 is fixedly connected to the mobile trolley 19. The programmable controller 13 is connected to the mobile trolley 19 and controls the movement of the mobile trolley 19. The mobile trolley 19 moves in the horizontal direction.

[0027] The motor 17 is mounted and fixed on the feeding and unloading conveyor frame 18. The motor 17 drives the conveying rollers on the feeding and unloading conveyor frame 18 to rotate via a chain belt drive. The motor 17 is electrically connected to and controlled by the programmable controller 13. When the motor 17 rotates forward, it can drive the conveying rollers to rotate clockwise, realizing feeding into the medium-frequency heating furnace 4. When the motor 17 rotates in reverse, it can drive the conveying rollers to rotate counterclockwise, realizing unloading into the medium-frequency heating furnace 4.

[0028] The feeding pusher 14 is provided with a pusher rod opposite to the external through-type detection probe 20. The feeding pusher 14 includes a frame and a pusher actuator on the frame. The pusher actuator drives the pusher rod to move. The pusher actuator can adopt a hydraulic actuator or an electric actuator to realize the horizontal movement of the pusher rod.

[0029] The feed pusher 14 has steel bars on its frame that are directly opposite the pusher rod. The steel bars are inserted into the external through-type detection probe 20. The large computer 1 controls the signal generator 5 to send pulse signals, which generate a changing current to cause the excitation coil 8 to generate an excitation magnetic field. The steel bars in the excitation magnetic field are picked up and detected by the detection coil 9, thereby determining whether the steel is mixed.

[0030] The temperature display instrument 3 has a temperature display screen, and the large computer 1 is equipped with an operation touch screen, a data display screen and a database; the voice alarm module 12 can issue alarm prompts for "material shortage", "mixed materials" and "high temperature".

[0031] A method for detecting mixed steel materials based on electromagnetic non-destructive testing is disclosed. The aforementioned steel mixed material detection system can achieve control over the feeding and unloading of steel bars, control over mixed material non-destructive testing, and automatic alarm control. The specific detection method is as follows:

[0032] 1. First, the operator sets the appropriate excitation frequency and excitation amplitude on the touch screen of the large computer 1 according to the steel bar material. The temperature display instrument 3 displays the temperature of the medium frequency heating furnace 4 and uploads the temperature data to the data acquisition card 11. The data acquisition card 11 organizes the data and sends it to the large computer 1. When the temperature of the medium frequency heating furnace 4 is within the specified temperature range, the large computer 1 starts to work and controls the moving trolley 19 to move the external through-type detection probe 20 to the detection position.

[0033] 2. The programmable controller 13 receives the program command from the main computer 1 and starts working. The push rod on the feeding pusher 14 pushes the steel bar into the feed. When the feeding pusher 14 has pushed the push rod to 2 / 3 of its length but has not triggered the photoelectric switch 15, the feeding pusher 14 stops pushing and sends an alarm signal to the main computer 1. The industrial camera 16 takes a picture of the feeding part and sends the image to the main computer 1. The main computer 1 controls the voice alarm module 12 to issue a "material shortage" voice alarm and displays the image on the data display screen. When the bar triggers the photoelectric switch 15, the feeding pusher 14 stops pushing and sends an electrical signal to the main computer 1. The motor 17 drives the conveyor roller of the feed conveyor 18 to rotate clockwise for transportation. The conveyor roller rotates and transports the steel bar into the medium frequency heating furnace 4 and then stops rotating (the number of rotations of the conveyor roller can be set according to the length of the steel bar and the diameter of the conveyor roller. When the conveyor roller stops after a certain number of rotations, the feeding of the steel bar is completed).

[0034] 3. When the steel bar passes through the through-type detection probe 20, the large computer 1 controls the signal generator 5 to generate various high-performance pulse signals, such as square waves, sine waves, and triangular waves, according to the excitation frequency and excitation amplitude. The pulse signals generated by the signal generator 5 are stably amplified by the power amplifier circuit 6, generating a changing current that is transmitted to the excitation coil 8 and generates signal data that is sent to the data acquisition card 11. The excitation coil 8 generates magnetic lines of force along the center of the coil through the changing current, generating an excitation magnetic field. When the steel bar is magnetized in the magnetic field, a series of discontinuous and jumping electromagnetic pulse signals are generated inside the steel bar. The electromagnetic pulse signals are picked up by the detection coil 9. The electromagnetic pulse signals picked up by the detection coil 9 are amplified by the signal processing circuit 7 and most of the noise is eliminated. The processed signal data is sent to the data acquisition card 11.

[0035] 4. The main computer 1 determines whether there is material mixing based on the signal data collected by the data acquisition card 11. If material mixing is present, the main computer 1 sends a signal to the programmable controller 13, causing the motor 17 to drive the conveyor rollers of the feeding and unloading conveyor frame 18 to rotate counterclockwise to perform material unloading. At the same time, it controls the voice alarm module 12 to issue a "material mixing" voice alarm. If there is no material mixing, the main computer 1 sends a signal to the programmable controller 13, causing the motor 17 to drive the conveyor rollers of the feeding and unloading conveyor frame 18 to rotate clockwise to continue the material feeding and transportation work.

[0036] 5. When the medium-frequency heating furnace 4 needs to be shut down, when there is an abnormality in the product, when the equipment heating is abnormal, or when the product size and appearance are abnormal, the steel bars in the medium-frequency heating furnace 4 need to be removed. The large computer 1 sends a signal to the programmable controller 13, causing the conveying rollers of the feed conveyor frame 18 of the motor 17 to rotate counterclockwise to perform the material removal work. The thermal imager 2 continuously monitors the temperature near the inlet of the medium-frequency heating furnace 4. When it detects that the temperature exceeds the set threshold and is moving at a constant speed, the large computer 1 controls the voice alarm module 12 to issue a "high temperature" voice alarm. At the same time, the programmable controller 13 controls the moving trolley 19 to start moving with the external through-type detection probe 20 away from the medium-frequency heating furnace 4 to avoid high temperature damage to the probe and affect the detection.

[0037] The embodiments described are illustrative of the invention and are not intended to limit the invention. Any person skilled in the art can modify the embodiments without departing from the spirit and scope of the invention; therefore, the scope of protection of the invention should be as set forth in the claims.

Claims

1. A steel material mixing detection system based on electromagnetic nondestructive testing, comprising a mainframe computer (1), a temperature measurement thermal imager (2), a temperature display instrument (3), a medium-frequency heating furnace (4), a signal generator (5), a power amplification circuit (6), a signal processing circuit (7), an excitation coil (8), a detection coil (9), a coil skeleton (10), a data acquisition card (11), a voice alarm module (12), a programmable controller (13), a feeding pushing frame (14), a photoelectric switch (15), an industrial camera (16), a motor (17), a feeding and withdrawing conveying frame (18), a moving trolley (19), and an outer-through detection probe (20), characterized in that: The outer-through detection probe (20) is composed of a coil framework (10), an excitation coil (8) and a detection coil (9), the excitation coil (8) and the detection coil (9) are wound and fixed on the coil framework (10); one side of the inlet of the intermediate frequency heating furnace (4) is sequentially provided with a feeding pushing frame (14), the outer-through detection probe (20) and a feeding and discharging conveying frame (18), the feeding and discharging conveying frame (18) is provided with conveying rollers, the conveying rollers on the feeding and discharging conveying frame (18) are opposite to and close to the inlet of the intermediate frequency heating furnace (4), the feeding pushing frame (14) and the outer-through detection probe (20) are provided with a photoelectric switch (15) therebetween, the feeding pushing frame (14) is provided with an industrial camera (16) above. The temperature display instrument (3), the signal generator (5), the data acquisition card (11), the voice alarm module (12) and the programmable controller (13) are electrically connected with the large computer (1) and are controlled by the large computer (1); the data acquisition card (11) collects information data of the temperature display instrument (3), the power amplification circuit (6), the signal processing circuit (7) and the industrial camera (16); the feeding pushing frame (14), the photoelectric switch (15) and the industrial camera (16) are electrically connected with the programmable controller (13) and are controlled by the programmable controller (13); the signal generator (5) is electrically connected with the excitation coil (8) through the power amplification circuit (6), and the detection coil (9) is electrically connected with the signal processing circuit (7).

2. The steel mixture detection system based on electromagnetic non-destructive testing according to claim 1, characterized in that: The outer-through detection probe (20) is fixedly connected on the moving trolley (19), and the programmable controller (13) is connected with the moving trolley (19) and controls the movement of the moving trolley (19).

3. The steel mixture detection system based on electromagnetic non-destructive testing according to claim 1, characterized in that: The motor (17) is fixedly installed on the feeding and discharging conveying frame (18), and drives the conveying rollers on the feeding and discharging conveying frame (18) to rotate through chain belt transmission; the motor (17) is electrically connected with the programmable controller (13) and is controlled by the programmable controller (13).

4. The steel mixture detection system based on electromagnetic non-destructive testing according to claim 1, characterized in that: The feeding pushing frame (14) is provided with a pushing rod opposite to the outer-through detection probe (20), and the feeding pushing frame (14) comprises a rack and a pushing execution mechanism on the rack, and the pushing execution mechanism drives the pushing rod to move.

5. The steel mixture detection system based on electromagnetic non-destructive testing according to claim 1, characterized in that: The rack of the feeding pushing frame (14) is provided with a steel bar opposite to the pushing rod, the steel bar is inserted into the outer-through detection probe (20), the large computer (1) controls the signal generator (5) to send a pulse signal, generates a changing current to promote the excitation coil (8) to generate an excitation magnetic field, and the steel bar in the excitation magnetic field is picked up and detected by the detection coil (9).

6. The steel mixture detection system based on electromagnetic non-destructive testing according to claim 1, characterized in that: The temperature display instrument (3) has a temperature display screen, the large computer (1) is provided with an operation touch screen, a data display screen and a database; the voice alarm module (12) sends "material shortage", "material mixing" and "high temperature" alarm prompts.

7. A method for detecting the mixture of steel materials based on electromagnetic nondestructive testing, which realizes the feeding and discharging control of steel bars, the nondestructive testing control of the mixture and the automatic alarm control by using the detection system of claim 1. The specific detection mode is as follows: (1), first, the operator sets the appropriate excitation frequency and excitation amplitude according to the steel bar in the large computer (1) operation touch screen, temperature display instrument (3) display the temperature of the intermediate frequency heating furnace (4) and upload the temperature data to the data acquisition card (11), the data acquisition card (11) will send data to the large computer (1); when the temperature of the intermediate frequency heating furnace (4) is in the specified temperature range, the large computer (1) starts to run, controls the mobile trolley (19) to move the outer through type detection probe (20) to the detection position; (2), the programmable controller (13) receives the program command of the large computer (1) to start work, the feeding push frame (14) pushes the steel bar; when the feeding push frame (14) pushes the push rod to 2 / 3 of the length and still does not trigger the photoelectric switch (15), the feeding push frame (14) stops pushing and sends an alarm signal to the large computer (1), the industrial camera (16) takes a general picture of the feeding part and sends the image to the large computer (1), the large computer (1) controls the voice alarm module (12) to issue a "lack of material" voice alarm and displays the image on the data display screen; when the bar triggers the photoelectric switch (15), the feeding push frame (14) stops pushing and sends an electrical signal to the large computer (1), the motor (17) drives the feeding and withdrawing frame (18) to rotate clockwise to transport the work, and the rotating conveying roller stops rotating after conveying the steel bar into the intermediate frequency heating furnace (4); (3), when the steel bar passes through the outer through type detection probe (20), the large computer (1) controls the signal generator (5) to generate various high-performance pulse signals according to the excitation frequency and excitation amplitude, the pulse signals generated by the signal generator (5) are amplified by the power amplifier circuit (6), the pulse signals are stably amplified, the varying current is transmitted to the excitation coil (8), and the signal data is sent to the data acquisition card (11); the excitation coil (8) generates magnetic lines along the center of the coil through the varying current, and generates an excitation magnetic field; when the steel bar is magnetized in the magnetic field, a series of discontinuous and jumping electromagnetic pulse signals are generated inside the steel bar, the electromagnetic pulse signals are picked up by the detection coil (9), the electromagnetic pulse signals picked up by the detection coil (9) are amplified and most of the noise is eliminated by the signal processing circuit (7), and the processed signal data is sent to the data acquisition card (11); (4), the large computer (1) judges whether there is mixed material according to the signal data collected by the data acquisition card (11), when there is mixed material, the large computer (1) sends a signal to the programmable controller (13), so that the motor (17) drives the feeding and withdrawing frame (18) to rotate counterclockwise to withdraw the material, and controls the voice alarm module (12) to issue a "mixed material" voice alarm; when there is no mixed material, the large computer (1) sends a signal to the programmable controller (13), so that the motor (17) drives the feeding and withdrawing frame (18) to rotate clockwise to continue the feeding and transporting work.

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