Industrial product inspection system and inspection method

Abstract

The application relates to the technical field of industrial product detection, and discloses an industrial product detection system and a detection method.The industrial product detection system comprises a container pre-detection unit and a container positive-detection unit; the container pre-detection unit comprises a pre-detection transfer assembly, a pre-detection workpiece clamp mechanism and a first optical detection mechanism, the pre-detection workpiece clamp mechanism is installed on the pre-detection transfer assembly; the container positive-detection unit comprises a positive-detection transfer assembly, a positive-detection workpiece clamp mechanism, a second optical detection mechanism and a workpiece acoustic detection device, the positive-detection workpiece clamp mechanism is installed on the positive-detection transfer assembly, different positions of the workpiece are clamped, and multiple optical detection devices are combined, so that the surface of the workpiece is detected without any dead angle, the workpiece with unqualified size and surface defects is found in time, the precision is high, the product quality is guaranteed, the internal defects of the workpiece can be quickly and effectively detected through the arrangement of the acoustic detection device, and the unqualified workpiece is further detected and removed.

Description

Technical Field

[0001] This invention relates to the field of industrial product testing technology, specifically to industrial product testing systems and methods. Background Technology

[0002] In industrial production, manufactured products require inspection, including appearance inspection and strength testing. For products like ferrites, this involves inspecting for dimensional defects, surface defects, and internal structural defects. Ferrites are widely used in the automotive industry, primarily in the manufacture of high-frequency transformers, inductors, and noise filters. With industry development and market demands, the quality requirements for ferrites are becoming increasingly stringent. Currently, ferrite product strength is mainly tested through random sampling, which is inefficient and prone to errors due to the numerous and complex testing items. Furthermore, random sampling cannot meet current market requirements. Therefore, there is an urgent need for a system capable of automatically and efficiently inspecting hexahedral or polyhedral industrial products such as ferrites. This application addresses these issues. Summary of the Invention

[0003] The purpose of this invention is to provide an industrial product testing system and method to address the problem of low efficiency in current industrial product testing.

[0004] The present invention is achieved through the following technical solution.

[0005] The industrial product inspection system of the present invention includes a pre-inspection unit and a forward inspection unit.

[0006] The container pre-inspection unit includes a pre-inspection transfer assembly, a pre-inspection workpiece clamping mechanism, and a first optical inspection mechanism, wherein the pre-inspection workpiece clamping mechanism is mounted on the pre-inspection transfer assembly;

[0007] The containerized forward inspection unit includes a forward inspection transfer assembly, a forward inspection workpiece clamping mechanism, a second optical inspection mechanism, and a workpiece acoustic inspection device. The forward inspection workpiece clamping mechanism is mounted on the forward inspection transfer assembly.

[0008] The pre-inspection workpiece clamping mechanism and the forward inspection workpiece clamping mechanism have different clamping positions on the workpiece. After the workpiece is inspected by the first optical inspection mechanism and the second optical inspection mechanism, it is transferred from the pre-inspection workpiece clamping mechanism to the forward inspection workpiece clamping mechanism.

[0009] The first and second optical inspection mechanisms inspect the surface defects and dimensions of the workpiece, while the workpiece acoustic inspection device detects internal defects by striking the workpiece to make it vibrate.

[0010] Furthermore, the industrial product inspection system also includes a sorting unit, which includes a material collection and sorting conveyor belt, a positioning and sorting mechanism, a pushing and sorting mechanism, and a defective product recovery conveyor belt.

[0011] Furthermore, the industrial product inspection system also includes a stacking and conveying unit, which includes a workpiece transfer stacking fixture assembly, a stacking and conveying conveyor belt, and a defective parts conveying conveyor belt.

[0012] Furthermore, the first optical inspection mechanism includes a workpiece tilt optical inspection device and a workpiece side optical inspection device, and the second optical inspection mechanism includes a workpiece three-view optical inspection device.

[0013] Furthermore, the workpiece pitch-view optical inspection device, the workpiece side-view optical inspection device, and the workpiece three-view optical inspection device are all installed in the optical inspection isolation chamber.

[0014] Furthermore, the workpiece acoustic inspection device is installed in an acoustic inspection isolation chamber, and the workpiece acoustic inspection device includes a projectile launching assembly and an acoustic inspection sensor.

[0015] Furthermore, the bottom of the acoustic inspection isolation chamber is provided with a workpiece drop hole, and the acoustic inspection isolation chamber is located on the upper side of the stacking conveyor belt.

[0016] Furthermore, both the pre-inspection workpiece clamping mechanism and the forward inspection workpiece clamping mechanism are provided in multiple units, and the forward inspection workpiece clamping mechanism is provided with an air blowing port.

[0017] Furthermore, the pre-inspection transfer assembly is provided with at least two cutting fixture mechanisms and two sets of transfer mechanisms. The cutting fixture mechanism and the pre-inspection workpiece fixture mechanism are driven by different transfer mechanisms. The cutting fixture mechanism can pick up and change the workpiece on the pre-inspection workpiece fixture mechanism.

[0018] An industrial product testing method, based on the aforementioned industrial product testing system, is characterized by comprising the following steps:

[0019] The optical inspection mechanism is used to detect surface defects and dimensions of the workpiece, while the acoustic inspection device is used to detect internal structural defects. Workpieces that pass inspection are placed in the qualified workpiece area, and those that fail are placed in the defective workpiece area. During the optical inspection of the workpiece, when the form and position tolerances of the horizontal and / or vertical surfaces of the workpiece are suspected to be significantly out of tolerance, a fitting inspection step is initiated. The workpiece is oscillated within a certain angle by a fixture, so that the camera in the optical inspection mechanism can obtain the contour projection images of the workpiece from the front, back and side views at each oscillation angle. By fitting the workpiece contour and correlating it with the oscillation angle, the form and position dimensions of the workpiece with the front and rear end faces as reference surfaces are obtained, and thus the form and position tolerance data of the workpiece are obtained.

[0020] The beneficial effects of this invention are:

[0021] By setting up pre-inspection and forward inspection units, and by clamping the workpiece at different positions, combined with multiple optical inspection devices, the surface of the workpiece can be inspected without blind spots. Workpieces with unqualified dimensions or surface defects can be detected in a timely manner with high precision, ensuring product quality. At the same time, the sound inspection device can quickly and effectively detect internal defects in the workpiece, further identifying and rejecting unqualified workpieces.

[0022] By setting up a sorting unit and a stacking and conveying unit, the automatic loading and unloading of materials in the inspection process is realized, and the positive, bad and suspicious materials are automatically classified and placed, thus automating the entire inspection process, improving inspection efficiency and saving labor costs.

[0023] During optical inspection of a workpiece, fitting detection can be used to obtain the contour projection images of the workpiece at various swing angles from the front, back and side views. By fitting the workpiece contour and associating it with the swing angle, the form and position dimensions of the workpiece with the front and rear end faces as reference surfaces can be obtained, thereby obtaining the form and position tolerance data of the workpiece and improving the inspection accuracy. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0026] Figure 1 This is a schematic diagram of the overall structure of the industrial product testing system of the present invention;

[0027] Figure 2 A schematic diagram of the material collection and assembling conveyor belt and the adjusting and assembling mechanism.

[0028] Figure 3 This is a schematic diagram of the projectile launching assembly structure;

[0029] Figure 4 This is a structural diagram of the acoustic detection isolation chamber;

[0030] Figure 5 This is a flowchart of the testing process;

[0031] Figure 6 This is a schematic diagram of the pre-inspection and transfer assembly with a cutting fixture mechanism installed in Example 2;

[0032] Figure 7This is a schematic diagram of the overall structure of the industrial product testing system in Example 3;

[0033] Figure 8 This is a schematic diagram of the acoustic detection isolation chamber structure in Example 3;

[0034] Figure 9 This is a schematic diagram of the optical inspection isolation chamber structure;

[0035] Figure 10 This is a schematic diagram of the workpiece clamping mechanism for positive inspection. Detailed Implementation

[0036] The following is combined Figure 1-10 The present invention will be described in detail below.

[0037] Example 1:

[0038] like Figure 1 The industrial product appearance inspection system includes a sorting unit, a pre-inspection unit, a forward inspection unit, a stacking and conveying unit, an operation control unit, and auxiliary devices.

[0039] Among them, such as Figure 2 The sorting unit includes a material sorting conveyor belt (1.1), a sorting mechanism (1.2), a pushing and sorting mechanism (1.3), and a defective parts recovery conveyor belt (1.4).

[0040] The containerized pre-inspection unit includes a pre-inspection transfer assembly, a pre-inspection workpiece clamping mechanism (2.3), and a first optical inspection mechanism. The pre-inspection workpiece clamping mechanism (2.3) is mounted on the pre-inspection transfer assembly.

[0041] The containerized forward inspection unit includes a forward inspection transfer assembly, a forward inspection workpiece clamping mechanism (3.3), a second optical inspection mechanism, and a workpiece acoustic inspection device (3.6). The forward inspection workpiece clamping mechanism (3.3) is installed on the forward inspection transfer assembly.

[0042] The first optical inspection mechanism includes a workpiece tilt optical inspection device (2.5) and a workpiece side optical inspection device (2.6), and the second optical inspection mechanism includes a workpiece three-view optical inspection device (3.5).

[0043] The pre-inspection transfer assembly includes the inner frame of the container pre-inspection turret (2.1) and the outer frame of the container inspection turret, as well as the turret measurement and control substation assembly.

[0044] The positive inspection transfer assembly includes the inner frame of the container positive inspection turret (3.1), the outer frame of the container inspection turret, and the turret measurement and control substation assembly.

[0045] The stacking and conveying unit includes a workpiece transfer stacking fixture assembly (4.1), a stacking and conveying conveyor belt (4.2), and a defective parts conveying conveyor belt (4.3).

[0046] The operation control unit includes a measurement and control computer component, a measurement and control PLC component, and a modular drive component.

[0047] The auxiliary equipment includes a power supply and distribution unit, an air supply station and air compressor transmission network, a measurement and control frame, and a system enclosure.

[0048] In this embodiment, ferrite is used as the workpiece to be inspected. Workpieces of other shapes, such as hexahedrons, tetrahedrons, cylinders, spheres, etc., can also be inspected.

[0049] Team sorting unit

[0050] The sorting unit is a combination of devices used by the system to sort the workpieces to be inspected by feeding them in via a conveyor belt (or manual feeding).

[0051] like Figure 2 The material assembling conveyor belt (1.1) uses a small conveyor belt with a conveying surface of 200x800mm to provide translation and pushing for the workpieces fed into the hopper on the conveyor belt; the positioning and assembling mechanism (1.2) adjusts the position and posture of the workpieces on the assembling conveyor belt through 1-4 height limit gates and side creeping mechanism, eliminates various forms of stacking, and forces the workpieces to be sent to the pushing and sorting mechanism in a longitudinal upright or longitudinal reverse posture; the pushing and sorting mechanism then quickly moves the workpieces to the workpiece clamping position of the pre-inspection section; the suspected defective parts recycling conveyor belt uses a hopper and inclined conveyor belt to return the workpieces that need to be recycled due to clamping detachment, quality inspection defects, etc. in various links of the system to the hopper of the material assembling conveyor belt for re-queuing and sorting;

[0052] The detection and drive control of each device in this unit are centrally monitored and controlled by the operation control-related devices.

[0053] Container pre-inspection unit

[0054] The pre-inspection unit is mainly used to inspect the top, bottom and sides of the workpiece for visual defects, and to provide the first part of the data for the inspection of the workpiece's external dimensions and geometric tolerances.

[0055] The inner frame of the container pre-inspection turret of the container pre-inspection unit is installed on the outer frame of the container inspection turret (not shown in the figure). It consists of two layers, with the upper layer providing parallel operating space for four pre-inspection workpiece clamping mechanisms. The lower layer houses the turret measurement and control substation components of this unit, used to control the movement of each pre-inspection workpiece clamping mechanism on the turret.

[0056] The workpiece tilt-view optical inspection device uses two industrial high-definition cameras 2.42 (including lighting) mounted vertically to take time-sequential images of the workpiece's top and bottom surfaces. The workpiece side-view optical inspection device uses one industrial high-definition camera (including lighting) mounted sideways to take images of the workpiece's side surface. Both devices are equipped with optical inspection isolation chambers 2.41, which shield the workpiece from unnecessary ambient light interference during the imaging process. Each device is mounted on the equipment bracket provided by the turret's external frame.

[0057] During the counterclockwise rotation of the turret, the four pre-inspection workpiece clamping mechanisms respectively perform longitudinal end face clamping, upper and lower surface scanning observation, outer side scanning observation, and workpiece handover operation.

[0058] Container Inspection Unit

[0059] The containerized inspection unit is mainly used to inspect the front and rear end faces and sides of the workpiece to be inspected, providing a second set of data for the inspection of the workpiece's external dimensions and geometric tolerances, and further inspecting the internal structural defects of the workpiece through acoustic testing.

[0060] The inner frame of the containerized positive inspection turret of the containerized positive inspection unit (with the same structural form as the inner frame of the containerized pre-inspection turret of the containerized pre-inspection unit) is installed on the outer frame of the containerized inspection turret (not shown in the figure). It consists of two layers, with the upper layer providing parallel operating space for four positive inspection workpiece clamping mechanisms. The lower layer houses the turret control and measurement substation components of this unit, used to control the movements of each positive inspection workpiece clamping mechanism on the turret.

[0061] The workpiece three-view optical inspection device uses three (or four) industrial high-definition cameras 501 (including lighting lamps) orthogonally installed in front of, behind, and to the side (optional upper position) of the workpiece, with the workpiece as the origin of the coordinate system. It takes time-division images of the front, back, and sides of the workpiece. The device is equipped with an optical inspection isolation chamber, which shields the workpiece from unnecessary ambient light interference during the imaging process. The device is mounted on the equipment support of the container inspection turret.

[0062] like Figure 3 The workpiece acoustic inspection device consists of a shot blasting gun mechanism 81, a shot recovery mechanism 82, a shot elevator 83, a shot feeding mechanism 84, an acoustic sensor 85, and an acoustic inspection isolation chamber 86. The muzzle of the shot blasting gun mechanism 81 extends into the acoustic inspection isolation chamber 86 through a barrel inlet. The recovery port of the shot recovery mechanism 82 is located at the bottom of the acoustic inspection isolation chamber 86. After the clamped workpiece enters the acoustic inspection area, the shot blasting gun sprays metal shot onto a selected surface of the workpiece. The internal structural defects of the workpiece are detected by the self-vibration excited by the impact of the shot. The shot recovery mechanism, shot elevator, and shot feeding mechanism provide the shot retrieval capability for the blasting gun, while the acoustic inspection isolation chamber isolates the workpiece from environmental noise interference. The entire workpiece acoustic inspection device is mounted on an equipment support provided by the turret scaffold.

[0063] The workpiece acoustic inspection device can also be other impact devices, any component that can use a drive structure to quickly drive an impacting object to strike the workpiece.

[0064] During the counterclockwise rotation of the turret, the four workpiece clamping mechanisms perform the following operations: clamping the vertical end face of the workpiece (handing it over from the pre-inspection turret), scanning and observing the front, back and side of the workpiece, observing the workpiece's excited self-vibration, and stacking and handing over the workpiece.

[0065] Stacking transfer unit

[0066] The stacking and conveying unit is used to stack the intact workpieces detected by the container inspection unit and send them to the marking and packaging station, and to convey the detected defective parts to the defective parts recycling station.

[0067] The workpiece transfer and stacking fixture assembly consists of a transfer fixture mechanism and a stacking fixture mechanism, and is installed on the outer frame of the container inspection turret. The stacking conveyor belt is located below the workpiece transfer and stacking fixture assembly, and the defective part conveyor belt is located below the inner frame of the container inspection turret in the container inspection unit.

[0068] After the workpiece has passed all stages of inspection and its external dimensions, geometric tolerances, appearance quality, and internal structural quality all meet the requirements, the workpiece is rotated to the transfer and handover position by the workpiece clamping mechanism on the inner frame of the container inspection turret of the container inspection unit. The transfer clamping mechanism then hands over the workpiece to the inspection clamping fixture and clamps it out to the stacking area of ​​the stacking conveyor belt for unloading. The stacking clamping mechanism is used to arrange the stacking position of the workpieces unloaded to the stacking area. When the workpiece stack reaches the target stack number (generally 6-10), the stacking clamping mechanism unfolds and moves backward, and the stacked workpieces are sequentially pushed to the marking and packaging station by the conveyor belt.

[0069] When a workpiece is confirmed to be defective after inspection, the fixture releases its grip when the workpiece is at the discard station between the sound inspection station and the removal and handover station. The defective workpiece falls off under gravity onto the defective workpiece conveyor belt below, and is then transported to the defective workpiece collection station.

[0070] The detection and drive control of each device in this unit are centrally monitored and controlled by the operation control-related devices.

[0071] Operation control unit

[0072] The job control computer component of the job control unit is mainly used for signal processing in the optical and acoustic inspection processes, workpiece inspection process management, and workpiece quality database management. It consists of a high-performance graphics workstation computer and necessary interface modules.

[0073] The measurement and control PLC component is mainly used for signal input and conversion, process logic and algorithm control of other units in the system, except for the detection and control of the motion mechanism on the inner frame of the container inspection turret in the container pre-inspection unit and the container forward inspection unit. The PLC component communicates with the operation control computer, the container pre-inspection unit and the container forward inspection unit turret measurement and control substation through the communication bus to exchange measurement and control data and synchronize the process rhythm.

[0074] The container drive assembly mainly consists of motor drive controllers, control switches (contactors), and pneumatic control solenoid valve groups for each unit.

[0075] Auxiliary devices

[0076] The auxiliary equipment mainly consists of power supply, gas supply, frame and cabinet.

[0077] The system is powered by the municipal power grid. Due to the high quality of the grid power supply, no UPS backup power is required. The power supply converts the 220VAC mains power through several AC-DC conversion modules and then distributes it to each unit's monitoring and control mechanism via distribution lines. The primary distribution lines are planned to be 24VDC. Overcurrent and overvoltage protection is provided for the main lines and important branch lines.

[0078] The air supply station is the source of compressed air for the actuators of each unit in the system. It consists of an air compressor (including an air tank), air supply pipelines, pressure distribution valve assembly, pressure sensors, etc. Because the air compressor and its operation generate significant noise, it is recommended that the compressor be installed far away from the main system components, and that necessary noise insulation measures be implemented.

[0079] To facilitate maintenance, all components and mechanisms of the operation control unit are mounted on the measurement and control frame in the form of a plate frame, and signal and power lines are laid between the frame and the measurement and control equipment through cable conduits and cable trays.

[0080] The system's enclosed chamber is an isolation compartment constructed with an aluminum alloy frame and double-layered (opaque) glass walls, and is equipped with an air conditioning unit. It serves to semi-enclose the main body of the system's testing mechanism from other areas of the factory, providing basic dustproofing, noise reduction, heat insulation, and dehumidification. Besides the necessary maintenance doors, this chamber has only three openings (workpiece inlet, good parts outlet, and defective parts outlet) and two to three observation windows.

[0081] Workflow Design

[0082] The ferrite quality inspection system operates with ferrite products as its target and consists of 15 defined workstations and four work stages.

[0083] Workstation Definition

[0084] The workstations are divided into the following 16 workstations according to the four stages of the work process:

[0085] The sorting unit involves workstations

[0086] The first phase of the workstation consists of 4 workstations:

[0087] The ferrite workpiece collection and storage station 101 uses a conveyor belt with a collection hopper as its main component.

[0088] The 102-station ferrite workpiece repositioning and sorting system uses a repositioning and sorting mechanism as its main component.

[0089] At station 103, multiple ferrite workpieces are positioned, sorted, and awaited for picking, with the belt-changing buffer mechanism as the main component.

[0090] The 104 suspected component collection station collects and transfers suspected and defective components back into the collection station, with the suspected and defective component recycling conveyor belt and collection hopper as the main components.

[0091] The container pre-inspection unit involves workstations

[0092] The second stage of the workstation consists of 3 workstations:

[0093] The 201 sorting and clamping station pre-inspection workpiece fixture clamps ferrite workpieces from the assembly station exit using a longitudinal end-face clamping method.

[0094] Station 1 of the 202 optical inspection unit performs surface optical scanning inspection on the top and bottom surfaces of the workpiece, with the workpiece tilt optical inspection device as the main component.

[0095] Station 203 performs surface optical scanning inspection on the edges of workpieces, with the workpiece edge optical inspection device as the main component.

[0096] The container inspection unit involves workstations

[0097] The third stage of the workstation consists of 5 workstations:

[0098] The workpiece clamping method at the 301 clamping and handover station is changed to release the end face obstructed by clamping method two. At the intersection of the pre-inspection and forward inspection units, the workpiece is clamped out of the pre-inspection workpiece clamp by the forward inspection workpiece fixture, and the clamping method is changed to upper and lower end face.

[0099] The 302 optical inspection station #3 performs surface optical scanning inspection on the front, back, and side end faces of the workpiece, using the workpiece three-view optical inspection device as the main component.

[0100] The 303 acoustic inspection station performs excitation vibration structural defect detection on workpieces, with pneumatic guns and acoustic sensors as the main components.

[0101] At the 304 waste disposal station, the clamps at this station loosen and release, allowing defective parts to fall into the defective parts collection hopper.

[0102] Workpieces at the 305 main inspection station are transferred from the inspection fixture to the transfer fixture mechanism for stacking.

[0103] Stacking and conveying units involve workstations

[0104] The fourth stage workstation consists of 4 workstations:

[0105] Workpieces at stacking station 401 are stacked in the stacking operation area of ​​the stacking conveyor belt, with the stacking fixture mechanism as the main component.

[0106] The 402 marking and packaging station handles workpiece marking, packaging, and unloading, currently done manually.

[0107] The defective parts collection station at 403 primarily uses a defective parts conveyor belt and collection hopper as its main components.

[0108] 404 Defective Parts Accumulation Station: Collection and manual transfer of defective parts after they are conveyed out by the conveyor belt.

[0109] Overall process design

[0110] The quality inspection process for ferrite products' dimensions and structural defects consists of four stages: sorting, pre-inspection of appearance and defects, forward inspection of appearance and defects, and stacking and conveying. For example... Figure 4 As shown

[0111] Material collection station related processes

[0112] This section of the process involves the material collection conveyor belt of the sorting unit, the material collection hopper, the G1 height limit gate, and other mechanisms.

[0113] Before workpiece inspection, the upstream production equipment will transport the workpieces to be inspected in a single-piece serial manner (regardless of the workpiece placement posture) via a conveyor belt to the upper part of the collection hopper 90 of the collection station of this system, and they will fall into the collection hopper in sequence.

[0114] The workpieces entering the bucket are moved as a whole towards the height limit gate 91 at the bottom of the bucket by the conveyor belt 96. The height limit gate 91 is installed at a height of 1.1 times the workpiece height from the bottom of the gate to the reference surface of the conveyor belt. After passing through the height limit gate 91, all workpieces that may be stacked are pushed flat, and each workpiece moves in a single layer without stacking.

[0115] The operation control and status detection of the material collection conveyor belt and material collection hopper at this workstation are directly monitored by the operation control unit and the operation control station.

[0116] Team workstation related processes

[0117] This section of the process involves the height limit gate 91, height limit gate 92, adjustment wall 93, adjustment wall 94, adjustment wall 95, workpiece posture detector and its carriage mechanism, etc., of the sorting unit adjustment mechanism.

[0118] The height limit gates 91 and 92 are installed at a height of 1.1 times the workpiece height from the bottom of the gate blade to the reference surface of the conveyor belt; the width of the height limit gate 91 is 1.05 times the maximum diagonal length of the workpiece when it is laid flat; the width of the height limit gate 92 is 1.05 times the shortest side length of the workpiece when it is laid flat. Workpieces passing through the gates are detected and counted by laser detection switches installed on both sides of the gates.

[0119] When the workpiece enters the adjustment wall 93 area, the adjustment wall 93 (2 sides) creeps inward at a frequency of about 1Hz, pushing the workpiece to move and flipping over some of the reversed and oblique workpieces piled up on the side of the adjustment wall 93. After the workpiece passes through the adjustment wall 93, it can be ensured that it enters the adjustment wall 94 area in a non-stacking, flat upright or flat reversed posture.

[0120] After the workpiece enters the adjustment wall 94 area, the adjustment wall 94 (two sides) creeps inward at a frequency of about 1Hz, pushing the workpiece to move. After passing through the adjustment wall 94, the workpiece is ensured to enter the adjustment wall 95 area in a flat, upright or flat, reversed posture with no stacking and a small longitudinal yaw angle deviation (Yaw < ±5°). The workpieces passing through the gate are detected and counted by laser detection switches installed on both sides of the gate.

[0121] After the workpiece enters the adjustment wall 95 area, the adjustment wall 95 (2 sides) creeps inward at a frequency of about 1Hz and forms a clamping effect on the workpiece. When the clamping is formed, the forward movement of the workpiece is stopped, thereby creating a controllable gap between the preceding and following workpieces.

[0122] The workpiece posture detector (laser rangefinder) installed above the G4 adjustment wall quickly slides and scans on its carriage after the workpiece enters the slot formed by the adjustment wall 95 (completing 10 distance measurement samples within 1 second). The resulting distance measurement data is converted by the computer of the operation control unit to confirm whether the arched workpiece is upright or reversed.

[0123] The motion control and status detection of the workstation's adjustment walls 93, 94, and 95, the workpiece posture detector, and its carriage mechanism are directly monitored by the work control unit's work control station.

[0124] Related procedures for changing the buffer station

[0125] This section of the process involves components such as the workpiece inspection gate, the bridge push plate, the cross-belt bridge, and the picking buffer conveyor belt of the whole-team sorting unit's belt changing buffer mechanism.

[0126] When the workpiece passes through the adjustment wall 95, the laser detection switches installed on both sides of the gate detect the passage of the workpiece and confirm whether there is a gap of at least 3mm between the front and rear workpieces.

[0127] Optional operation: If there is no gap or the gap length is insufficient, the operation controller will then control the G4 positioning wall to clamp the workpiece and pause the material collection conveyor belt. This operation will create a queue gap between the two workpieces. At this time, the workpiece exit gate will immediately fall after the gap is formed, cutting off the workpiece queue, and then the material collection conveyor belt will restart in time.

[0128] The workpiece, which has passed the adjustment wall, moves forward under the push of the material collection and alignment conveyor belt and may come into contact with the cross belt bridge.

[0129] After the exit gate isolates the workpieces in front and behind it, a bridge pusher plate separates from the middle of the gate. Driven by the actuator (a slide carriage driven by a stepper motor), the bridge pusher plate directly pushes the workpiece across the cross-belt bridge at its rear end and onto the picking buffer conveyor belt (the belt surface is at the same height as the cross-belt bridge surface). The pushing distance of the bridge pusher plate is controlled by the operation controller, allowing the use of different workpieces within a specified size range. After completing the pushing operation, the bridge pusher plate retracts until it rejoins the exit gate.

[0130] After the foremost workpiece has been picked up, the picking buffer conveyor belt starts its conveying operation (driven by a stepper motor), carrying the workpiece away from the crossover position to make room for subsequent workpieces. The conveyor belt stops after pushing the second-to-last workpiece to the picking position. Under normal circumstances, the picking buffer conveyor belt should ensure that there are at least three workpieces in the queue waiting to be picked up, in order to avoid waiting delays caused by the chaotic adjustment process of the workpiece queue by the repositioning and queuing mechanism.

[0131] When the picking buffer conveyor belt is running, in order to avoid friction between the bridge surface of the cross belt bridge and the end of the workpiece on the belt, the cross belt bridge will sink 3mm under the drive of the actuator, and will be raised immediately after the picking buffer conveyor belt stops, so that the reference surfaces of the two components are flush.

[0132] If a workpiece needs to be discarded due to various reasons while passing through the adjustment and queuing mechanism (such as the workpiece's longitudinal length exceeding the tolerance, the workpiece's shape being incorrect (e.g., an arched workpiece being found to have no height change), or the workpiece being too thin (its height being much smaller than the specified height, etc.), the workpiece exiting the adjustment wall 95 will be pushed over the bridge pusher plate, over the cross belt bridge, and over the picking buffer conveyor belt until it falls to the outer edge of the picking buffer conveyor belt.

[0133] The motion control and status detection of the workpiece exit gate, bridge push plate, cross-belt bridge, and picking buffer conveyor belt of the belt changing buffer mechanism at this workstation are directly monitored by the work control unit and the work control station.

[0134] Sorting and clamping station related processes

[0135] This section of the process involves components such as the container pre-inspection turret inner frame of the container pre-inspection unit, the pre-inspection workpiece clamping mechanism, and the picking buffer conveyor belt of the belt changing buffer mechanism in the sorting unit. This process is a strongly synchronous control process.

[0136] Before or at the time the pre-inspection workpiece clamping mechanism rotates into position, the picking buffer conveyor pushes the workpiece to the picking position (calculated by the photoelectric switch shielding-connection negative edge pulse and the picking buffer conveyor pushing distance). With the clamping claws extended, the pre-inspection workpiece clamping mechanism lowers its height (Y1 axis) and extends (X2 axis) to the picking position. The clamping claws horizontally (Z3 axis) grasp the workpiece (clamping the longitudinal end face of the workpiece), and then immediately rises to the set height and retracts to the set position along the X2 axis. At the same time, it rotates (90° counterclockwise) along the central axis (Y0 axis) of the inner frame of the container pre-inspection turret towards the photoelectric inspection station #1.

[0137] If the workpiece is in an inverted position, the gripper will flip along the (X3 axis) during the lifting and rotation process, so that the workpiece is restored to an upright position.

[0138] Optional operation: If clamping fails (the clamping claw is equipped with a tactile sensor, and the clamping pressure obtained by the sensor does not meet the set requirements), the clamping mechanism will release the grip and lift it to the set safe position. The workpiece will be discarded (the picking buffer conveyor pushes the workpiece into the suspected defective part collection hopper) and prepare for the next workpiece to be placed.

[0139] The monitoring and control of the pre-inspection workpiece clamping mechanism is completed by the turret measurement and control substation component on the second layer of the container pre-inspection turret inner frame. Its movement rhythm is connected to and synchronized with the operation control unit PLC through the communication link.

[0140] Optical Inspection Station 1 Related Processes

[0141] This section of the process involves the container pre-inspection turret inner frame of the container pre-inspection unit, the pre-inspection workpiece clamping mechanism, the tilting camera (industrial high-definition camera) mounted on the upper and lower sides of optical inspection station #1, the lighting (monochrome line light source), and the optical inspection isolation chamber cover.

[0142] The pre-inspection clamping mechanism, positioned in the center, enters the isolation chamber through the central notch and proceeds to the optical inspection station #1. It immediately performs precise height adjustment to the focusing position of the upper and lower cameras. The clamping jaws extend along the X2 axis from the retracted position, with the extension distance determined by the workpiece's lateral dimension.

[0143] As the workpiece extends along the X2 axis in the gripper, the tilt camera alternately turns on its illumination lights, taking scanned images of the workpiece each time the lights are on. Typically, the total scan time at this position is approximately 600–800 ms, with 10 scans per camera.

[0144] If the workpiece is an arch shape coaxial with the X-axis of the workpiece, during the above scanning and shooting process, the pre-inspection workpiece fixture mechanism will simultaneously make fine adjustments to the height (Y1 axis) as it extends along the X2 axis according to the designed parameters, so as to ensure that the tilt camera is accurately focused on the workpiece, thereby effectively improving the image quality.

[0145] After the scanning and imaging are completed, the pre-inspection workpiece fixture mechanism returns to the height center position (Y1 axis) and then rotates towards the optical inspection station #2 (90° counterclockwise).

[0146] The motion monitoring and control of the workpiece clamping mechanism at this workstation is completed by the turret measurement and control substation component on the second layer of the container pre-inspection turret inner frame. Its motion rhythm is connected to and synchronized with the work control unit's measurement and control PLC through a communication link. The camera shooting and lighting motion control are directly monitored by the work control unit's work control station. The workpiece images obtained by shooting are entered into the work control unit's graphic workstation computer through a network link.

[0147] Optical Inspection Station 2 Related Processes

[0148] This section of the process involves the container pre-inspection turret inner frame, pre-inspection workpiece clamping mechanism, optical inspection station #2 side-view camera (industrial high-definition camera), lighting (monochrome line light source), and optical inspection isolation chamber cover of the container pre-inspection unit.

[0149] The pre-inspection clamping mechanism, which is in the middle position, moves out from the middle gap of the optical inspection 1# isolation chamber cover and enters the optical inspection 2# isolation chamber cover at the same height, and enters the optical inspection 2# workstation.

[0150] After being positioned, the pre-inspection clamping mechanism immediately performs precise extension adjustment along the X2 axis to the focus position of the side-view camera. Then, the clamping jaws begin to lift / lower along the Y1 axis at the midpoint of the height (Y1 axis). The fine-tuning distance is determined by the vertical dimension of the workpiece.

[0151] As the workpiece is lifted / lowered along the Y1 axis by the clamping jaws, the side-view camera turns on its illumination and takes scanned images of the workpiece as the illumination illuminates. Generally, the total scan time at this position is approximately 200–600 ms, with 3–10 scans per camera (the exact number depends on the height of the workpiece's side).

[0152] If the side of the workpiece is not vertical and the elevation dimension is large (generally greater than 10mm), during the above scanning and shooting process, the pre-inspection workpiece fixture mechanism will simultaneously perform X2 axis fine adjustment according to the designed parameters during the lifting / lowering process along the Y1 axis to ensure that the side-view camera accurately focuses on the workpiece, thereby effectively improving the image quality.

[0153] After the scanning and imaging are completed, the pre-inspection workpiece fixture mechanism returns to the height center position (Y1 axis) and simultaneously extends and retracts along the X2 axis. Then, it rotates out from the notch in the middle of the optical inspection isolation cover of this station and rotates (90° counterclockwise) towards the clamping and handover station.

[0154] The motion monitoring and control of the workpiece clamping mechanism at this workstation is completed by the turret measurement and control substation component on the second layer of the container pre-inspection turret inner frame. Its motion rhythm is connected to and synchronized with the work control unit's measurement and control PLC through a communication link. The camera shooting and lighting motion control are directly monitored by the work control unit's work control station. The workpiece images obtained by shooting are entered into the work control unit's graphic workstation computer through a network link.

[0155] Clamp changing and handover station related processes

[0156] This section of the process involves the container pre-inspection turret inner frame and pre-inspection workpiece clamping mechanism of the container pre-inspection unit, as well as the container forward inspection turret inner frame and forward inspection workpiece clamping mechanism of the container forward inspection unit. This process is a strongly synchronous control process.

[0157] When the pre-inspection turret inner frame with the pre-inspection workpiece clamping mechanism is in place and at the clamping handover station, the container forward inspection turret inner frame also moves the forward inspection workpiece clamping mechanism into place simultaneously. The workpiece is transferred from the pre-inspection workpiece clamping mechanism to the forward inspection workpiece clamping mechanism. The motion monitoring and control of the pre-inspection workpiece clamping mechanism at this station is completed by the turret measurement and control substation component on the second layer of the container forward inspection turret inner frame. Its motion rhythm is connected to and synchronized with the operation control unit measurement and control PLC through the communication link.

[0158] Optical Inspection Station 3 Related Processes

[0159] This section of the process involves the containerized inspection turret inner frame of the containerized inspection unit, the inspection workpiece fixture mechanism, the three-view camera (industrial high-definition camera) of optical inspection station #3, the lighting (monochrome line light source), and the optical inspection isolation chamber cover.

[0160] The low-position positive inspection clamping mechanism enters the isolation chamber through the bottom notch of the optical inspection isolation chamber and enters the optical inspection station #3. Immediately, the Y1 axis is precisely adjusted to the focus position of the front, rear and side view cameras on the workpiece (generally set to the height center position).

[0161] After the workpiece reaches the focusing position, a Y1-axis height rise / fall scan is performed for fine-tuning. The front, rear, and side cameras alternately turn on their illumination lights, taking scanned images of the workpiece as the lights illuminate. The number of scans per camera is 3–10 (the exact number depends on the workpiece's front, rear, and side view heights). Generally, the total scan time at this position is approximately 600–800 ms, with 3–10 scans per camera.

[0162] If there is suspicion that the horizontal surface form and position tolerances of this batch of workpieces (such as the excessive angle between the arched arc axis of an arched workpiece and the horizontal plane of the X-axis of the designed workpiece) may be significantly out of tolerance, a positive inspection fixture oscillation (Y2-axis rotation) fitting inspection can be initiated. That is, at a specified height (generally the midpoint of the height), the positive inspection fixture is oscillated at a small angle along the Y2 axis (oscillation angle range ±4°, resolution granularity 0.4°). A three-view camera obtains the contour projection images of the workpiece from the front, back, and side at each oscillation angle. By fitting the workpiece contour and correlating it with the oscillation angle, the form and position dimensions of the workpiece with the front and rear end faces as reference planes are obtained, thus obtaining the workpiece's form and position tolerance data. Inserting this form and position tolerance inspection step requires adding 600–800 ms to the original operation time.

[0163] If it is suspected that the vertical surface form and position tolerances of this batch of workpieces (such as irregular distortion of the vertical surface of a cubic workpiece) may be significantly out of tolerance, a longitudinal tilt (X3 axis rotation) fitting inspection of the inspection fixture can be initiated. This involves rotating the inspection fixture at a small angle along the X3 axis at a specified height (generally the midpoint of the height) (tilt angle range ±6°, resolution granularity 0.5°). A three-view camera acquires the front, rear, and side profile projection images of the workpiece at various tilt angles. By fitting the workpiece profile and correlating it with the tilt angles, the form and position dimensions of the workpiece with the front and rear end faces as reference planes are obtained, thus yielding the workpiece's form and position tolerance data. Inserting this form and position tolerance inspection step requires an additional 600–800 ms to the original operation time.

[0164] After scanning and imaging are completed, the workpiece clamping mechanism for forward inspection is raised to a high position (Y1 axis), and the workpiece is removed from the top exit of the optical inspection 3# isolation cover, and then rotated to the acoustic inspection station (90° counterclockwise).

[0165] The motion monitoring and control of the workpiece clamping mechanism at this workstation is completed by the turret measurement and control substation component on the second layer of the inner frame of the container inspection turret. Its motion rhythm is connected to and synchronized with the measurement and control PLC of the operation control unit through the communication link. The camera shooting and lighting motion control is directly monitored by the operation control unit operation control station. The workpiece images obtained by the camera are entered into the graphic workstation computer of the operation control unit through the network link.

[0166] Preferably, the workpiece clamping mechanism for positive inspection is as follows: Figure 10 As shown, an air nozzle 10 is installed on the workpiece fixture mechanism for positive inspection, which can blow away impurities on the workpiece surface and ensure the accuracy of the inspection.

[0167] Sound inspection station related processes

[0168] This section of the process involves the container inspection turret inner frame, inspection workpiece clamping mechanism, acoustic inspection station shot blasting gun mechanism, shot recovery mechanism, shot elevator, shot feeding mechanism, acoustic inspection sensor, and acoustic inspection isolation chamber, etc.

[0169] After the positive inspection clamping mechanism, which is at a high position (Y1 axis), enters the sound inspection station from the top opening of the sound inspection isolation chamber, it immediately descends to the projectile firing position to await firing.

[0170] After the projectile ejection gun mechanism of the acoustic inspection station pushes the projectile into the barrel, it immediately ejects the projectile. Following a set trajectory and kinetic energy, the projectile collides with the workpiece at a predetermined position and then falls into the projectile recovery mechanism ( into the projectile collection hopper). Simultaneously, the vibration audio detection window opens, and the workpiece begins to vibrate spontaneously. Two acoustic sensors, located at the front and rear ends respectively, begin to collect the audio signal of the workpiece's spontaneous vibration. After the sampling window is open for 100–1000 ms, it closes. The audio signal (analog signal) is amplified by a linear amplifier and then enters the audio interface of the work control unit's graphical workstation computer for high-speed sampling, fast Fourier transform, and spectrum analysis to obtain the spectral characteristic data of the workpiece's spontaneous vibration audio signal.

[0171] The sampling window opening time is determined by the rhythm of the relevant mechanical actions and must avoid periods of noise generated by structural movements. The sampling window duration is mainly determined by the workpiece's shape and dimensions, structural shape, and structural materials. Typically, five window duration constants (100ms, 200ms, 400ms, 600ms, and 1000ms) are provided for user selection. Vibration and noise signals outside the sampling window opening time are not allowed to enter the system, thus simplifying the audio signal processing flow and reducing algorithm complexity.

[0172] After the acoustic inspection is completed, the positive inspection clamping mechanism begins to rise to the highest position (Y1 axis), moves out of the acoustic inspection isolation chamber through the top opening of the acoustic inspection isolation chamber, and moves to the next work station under the drive of the inner frame of the container positive inspection turret.

[0173] When the sound inspection and previous inspection stages determine that the workpiece is defective, the positive inspection clamping mechanism clamps the workpiece and rotates it to the defective part disposal station (45° counterclockwise from the sound inspection station). The workpiece clamp is released, and the workpiece falls into the defective part collection hopper and then slides onto the defective part conveyor belt. When the sound inspection and previous inspection stages determine that the workpiece is suspicious, the positive inspection clamping mechanism clamps the workpiece and rotates it to the suspicious part disposal station (135° counterclockwise). The workpiece clamp is released, and the workpiece falls into the suspicious part collection hopper and then slides onto the suspicious part conveyor belt. When the sound inspection and previous inspection stages determine that the workpiece is valid, the positive inspection clamping mechanism clamps the workpiece and rotates it to the valid part handover station (90° counterclockwise). The workpiece clamping mechanism waits for the workpiece to be handed over.

[0174] After recovering 20-60 projectiles, the projectile elevator's lifting bucket waits at the bottom of the recovery hopper. The discharge gate at the bottom of the recovery hopper opens, and the projectiles roll into the lifting bucket under gravity. After 1-3 seconds, the discharge gate closes, and the elevator begins to rise until it reaches the height of the projectile feeding bowl. At this point, the discharge gate at the bottom of the lifting bucket is opened by an interlocking mechanism, and all the projectiles in the bucket tilt into the feeding bowl. The lifting bucket then returns to the bottom of the recovery hopper to wait. Due to the significant noise generated during the projectile recovery and transfer process, all potentially noisy actions are scheduled outside of the sampling window's opening hours.

[0175] The motion monitoring and control of the workpiece clamping mechanism at this workstation is completed by the turret measurement and control substation component on the second layer of the inner frame of the container inspection turret. Its motion rhythm is connected to and synchronized with the measurement and control PLC of the operation control unit through the communication link. The camera shooting and lighting motion control is directly monitored by the operation control unit operation control station. The workpiece images obtained by the camera are entered into the graphic workstation computer of the operation control unit through the network link.

[0176] Processes related to the handover of genuine parts

[0177] This section of the process involves the container inspection turret inner frame, inspection workpiece clamping mechanism, and workpiece transfer clamp of the container inspection unit. This process is a strongly synchronous control process.

[0178] After the workpiece clamping mechanism holds the workpiece at the workpiece transfer station, the workpiece transfer fixture performs a lifting (Y5 axis) and sliding (Z5 axis) motion on its carriage. Once the fixture is above the workpiece (avoiding spatial interference with the workpiece clamping jaws), it performs a fine-positioning operation, clamping and holding the workpiece from both ends. After the clamping action is completed, the workpiece clamping jaws release, and the workpiece transfer fixture disengages via a backward sliding (Z5 axis) motion. Driven by the inner frame of the workpiece turret, the workpiece clamping mechanism rotates towards the clamping transfer station and prepares for a height drop.

[0179] After the main part transfer fixture retracts to the push-stacking station position, it begins to descend in height (Y5 axis) to prepare for the stacking operation.

[0180] The motion monitoring and control of the workpiece clamping mechanism at this workstation is completed by the turret measurement and control substation component on the second layer of the inner frame of the container inspection turret. Its motion rhythm is connected to and synchronized with the work control unit's measurement and control PLC through a communication link; the motion control of the workpiece transfer clamp is directly monitored by the work control unit's work control station.

[0181] Stacking station related processes

[0182] This part of the process involves the transfer fixture mechanism, stacking fixture mechanism, and the delivery conveyor belt for the main parts.

[0183] Once the workpiece transfer fixture has returned to its position at the stacking station, it begins to descend. Following the workpiece stacking parameters (stack position, stacking increment height, number of workpieces, and safe stacking distance), the workpiece is released after falling to the set height. The workpiece lands on the stack on the workpiece delivery conveyor belt and is then raised to the standby height. The stacking fixture mechanism then shapes the stack (the fixture clamps quickly and then releases, avoiding and reducing stacking deviation noise). During the stacking process, the workpiece delivery conveyor belt remains stationary.

[0184] Once the number of workpieces stacked reaches the set requirements (number of workpieces, stacking height), the stacking fixture mechanism moves out of the stacking position along the transverse axis (Z6 axis) of the main part delivery conveyor belt. The stacking fixture removes its obstruction of the workpiece displacement along the belt. The main part delivery conveyor belt starts, moves the workpiece stack a set distance toward the main part outlet, and then stops. The stacking fixture moves back along the X6 axis to the stacking station to wait for the next stacking operation.

[0185] The operation control of the workstation's workpiece transfer fixture mechanism, stacking fixture mechanism, and workpiece delivery conveyor belt is directly monitored by the work control unit's work control station.

[0186] Work rhythm control

[0187] The MQDS magnetic detection system uses a small-to-medium-sized high-performance programmable logic controller (PLC) to control and adjust the actions and feedback of various mechanisms and devices in the detection operation. The measurement and control computer uses a high-performance industrial embedded computer to process optical detection video and acoustic detection audio signals in parallel. The PLC and measurement and control computer exchange data and synchronize status via a serial communication bus and Fast Ethernet. Operation speed control...

[0188] The system's operating speed is predefined and controlled by the job monitoring software;

[0189] The system's flow control rhythm cycle is better than 2 seconds, the signal sampling cycle is better than 50 ms, and the signal control cycle is better than 100 ms.

[0190] System power supply

[0191] The system is powered by the municipal power grid. Due to the high quality of the power grid, no UPS backup power supply is required.

[0192] The power supply and distribution unit converts 220VAC mains power through several AC-DC conversion modules and then supplies power to the monitoring and control mechanisms of each unit via distribution lines. The primary distribution line is planned to be 24VDC. Overcurrent and overvoltage protection are provided for the main line and important branch lines.

[0193] The air supply station and compressed air transmission network are the air source that provides compressed air to the actuators of each unit in the system. They consist of an air compressor (including an air tank), air supply lines, pressure distribution valve assemblies, pressure sensors, etc. Because air compressors generate significant noise during operation, it is recommended that the compressor be installed far away from the main system components, and that necessary noise insulation measures be implemented.

[0194] communication

[0195] The system uses a combination of wired and wired communication to achieve information interconnection among its constituent units.

[0196] The measurement and control computer of the operation control unit is interconnected with the factory production management system network via 100M Ethernet; it is interconnected with the measurement and control PLC controller via dual links of 100M Ethernet and RS232 / 422 serial bus. The connecting cables are generally general Category 5 / 6 cables; if there are many large electrical equipment in the workshop and the electromagnetic environment is complex, it is recommended to use Category 5 / 6 cables with shielding.

[0197] Example 2:

[0198] Unlike Embodiment 1 described above, the inner frame of the container pre-inspection unit is mounted on the outer frame of the container inspection turret (not shown in the figure), such as... Figure 6 It consists of three layers: upper, middle, and lower. The middle layer provides parallel operating space for four pre-inspection workpiece clamping mechanisms, and the upper layer provides operating space for two cutting clamping mechanisms 2210. The cutting clamping mechanism 2210 includes a gripper and a drive cylinder. The lower layer is equipped with the turret measurement and control substation of this unit, which is used to control the movement of each pre-inspection workpiece clamping mechanism and the cutting clamping mechanism on the turret. The middle layer turret and the upper layer turret are connected to different lifting mechanisms and rotating mechanisms, respectively. The specific industrial design is common knowledge to those skilled in the art and is specifically set according to the specific use environment, and is not limited to circumferential rotation.

[0199] In the above embodiment, when a workpiece is detected as a suspected or defective piece in the first inspection item of the pre-inspection, the piece still needs to go through subsequent inspection stations before it can reach the 104 suspected piece collection station, resulting in idle running and reducing the inspection cycle. This problem is better solved by setting an upper turret and at least two cutting clamping mechanisms.

[0200] The four pre-inspection / positive inspection workpiece clamping mechanisms function the same as in the above embodiment. The upper turret also has a lifting function. The cutting clamping mechanism on the upper turret is used to switch the ferrite workpieces on the four pre-inspection workpiece clamping mechanisms. The following is an example of the usage steps.

[0201] During the sorting and clamping process, after the workpiece clamping mechanism clamps the workpiece, the cutting clamping mechanism descends to clamp the workpiece from the workpiece clamping mechanism onto the cutting clamping mechanism. The two upper cutting clamping mechanisms always maintain one with material and the other empty. During pre-inspection, the workpiece is inspected at the 202 optical inspection station 1#. When a suspicious workpiece is detected, the empty cutting clamping mechanism descends to remove the workpiece from the workpiece clamping mechanism at the 202 optical inspection station 1#. Then, the cutting clamping mechanism rises and exits the 202 optical inspection station 1#. The other cutting clamping mechanism with material rotates and descends to the 202 optical inspection station 1#, transferring the new material to the middle turret workpiece clamping mechanism at the 202 optical inspection station 1# for inspection. The cutting clamping mechanism holding the suspicious workpiece rotates to the 104 suspicious workpiece collection station and releases the workpiece.

[0202] Optionally, at least one cutting fixture on the upper turret is connected to an independent rotary drive mechanism 2221. The rotary drive mechanism 2221 is an electric / starting guide rail. When one of the cutting fixture mechanisms removes the suspicious part, the other cutting fixture mechanism enters the 202 optical inspection station 1# for material change. At this time, the cutting fixture mechanism holding the suspicious part, which is directly driven by the independent rotary drive mechanism, rotates to the 104 suspicious part collection station to release the workpiece, and then moves to the pre-inspection workpiece fixture mechanism at the material pick-up point to pick up the workpiece. This maintains the effect of always having a cutting fixture mechanism holding the workpiece, thereby improving the inspection efficiency.

[0203] Optionally, the pre-inspection workpiece fixture mechanism is equipped with a rotating component 2.31, which is driven by a motor and is located at both ends of the ferrite clamp. When the workpiece is optically inspected, the workpiece is rotated around the axis. The optical inspection mechanism continuously captures multi-angle images to improve the inspection accuracy.

[0204] Example 3: Figure 7 As shown, unlike Embodiment 1, the container pre-inspection unit includes a pre-inspection transfer assembly, a pre-inspection workpiece clamping mechanism 2.3, and a first optical inspection mechanism. The pre-inspection workpiece clamping mechanism 2.3 is mounted on the pre-inspection transfer assembly.

[0205] The containerized forward inspection unit includes a forward inspection transfer assembly, a forward inspection workpiece clamping mechanism 3.3, a second optical inspection mechanism, and a workpiece acoustic inspection device 3.6. The forward inspection workpiece clamping mechanism 3.3 is mounted on the forward inspection transfer assembly.

[0206] The first optical inspection mechanism includes a first workpiece three-view optical inspection device 2.5, and the second optical inspection mechanism includes a second workpiece three-view optical inspection device 3.5.

[0207] The workpiece acoustic inspection device 3.6 is located on the upper side of the stacking conveyor belt 4.2, and the acoustic inspection isolation chamber 86 has the following structure. Figure 8As shown, the acoustic inspection isolation chamber 86 is also equipped with a workpiece drop hole 87, which contains a door panel assembly electrically connected to the control system. The workpiece drop hole opens after acoustic inspection, allowing qualified workpieces to fall from it. In this embodiment, the acoustic inspection station and the qualified workpiece dropping station are combined into one, and the two optical inspection stations in the pre-inspection unit are combined into one, effectively reducing the number of stations. The turret rotates 120° each time, improving inspection efficiency.

[0208] Preferably, a material vibrating disc 1.9 is added to one end of the material assembling conveyor belt 1.1.

[0209] Preferably, only three sets of pre-inspection workpiece clamping mechanism 2.3 and forward inspection workpiece clamping mechanism 3.3 are provided.

[0210] The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand and implement the present invention. They should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. An industrial product testing system, characterized in that: Includes container pre-inspection unit and container forward inspection unit; The containerized pre-inspection unit includes a pre-inspection transfer assembly, a pre-inspection workpiece clamping mechanism (2.3), and a first optical inspection mechanism. The pre-inspection workpiece clamping mechanism (2.3) is mounted on the pre-inspection transfer assembly. The containerized pre-inspection unit is used to provide a first part of the data for the form and position tolerance detection of the workpiece. The containerized forward inspection unit includes a forward inspection transfer assembly, a forward inspection workpiece clamping mechanism (3.3), a second optical inspection mechanism, and a workpiece acoustic inspection device (3.6). The forward inspection workpiece clamping mechanism (3.3) is mounted on the forward inspection transfer assembly. The containerized forward inspection unit is used to provide a second part of the data for the form and position tolerance inspection of the workpiece. The pre-inspection workpiece clamping mechanism (2.3) and the forward inspection workpiece clamping mechanism (3.3) have different clamping positions on the workpiece. After the workpiece is inspected by the first optical inspection mechanism and the second optical inspection mechanism, it is transferred from the pre-inspection workpiece clamping mechanism (2.3) to the forward inspection workpiece clamping mechanism (3.3). The first optical inspection mechanism and the second optical inspection mechanism complete the detection of surface defects and dimensions of the workpiece, and the workpiece acoustic inspection device (3.6) detects internal defects by striking the workpiece to make it vibrate. The workpiece acoustic detection device (3.6) is installed in the acoustic detection isolation chamber (86), and the workpiece acoustic detection device (3.6) includes a projectile launching assembly and an acoustic detection sensor (85). During the optical inspection of a workpiece, when the form and position tolerances of the horizontal and / or vertical surfaces of the workpiece are significantly out of tolerance, a fitting inspection step is initiated. The workpiece is swung within a certain angle by a fixture, allowing the camera in the optical inspection mechanism to obtain the contour projection images of the workpiece from the front, back, and side views at various sway angles. By fitting the workpiece contour and correlating it with the sway angle, the form and position dimensions of the workpiece with the front and rear end faces as reference surfaces are obtained, thereby obtaining the form and position tolerance data of the workpiece.

2. The industrial product testing system according to claim 1, characterized in that: The industrial product inspection system also includes a sorting unit, which includes a material collection and sorting conveyor belt (1.1), a positioning and sorting mechanism (1.2), a pushing and sorting mechanism (1.3), and a defective product recycling conveyor belt (1.4).

3. The industrial product testing system according to claim 2, characterized in that: The industrial product inspection system also includes a stacking and conveying unit, which includes a workpiece transfer stacking fixture assembly (4.1), a stacking and conveying conveyor belt (4.2), and a defective part conveying conveyor belt (4.3).

4. The industrial product testing system according to claim 3, characterized in that: The first optical inspection mechanism includes a workpiece tilt optical inspection device (2.5) and a workpiece side optical inspection device (2.6), and the second optical inspection mechanism includes a workpiece three-view optical inspection device (3.5).

5. The industrial product testing system according to claim 4, characterized in that: The workpiece pitch-view optical inspection device (2.5), the workpiece side-view optical inspection device (2.6), and the workpiece three-view optical inspection device (3.5) are all installed in the optical inspection isolation chamber (20).

6. The industrial product testing system according to claim 3, characterized in that: The bottom of the acoustic inspection isolation chamber (86) is provided with a workpiece drop hole (87), and the acoustic inspection isolation chamber (86) is located on the upper side of the stacking conveyor belt (4.2).

7. The industrial product testing system according to any one of claims 1 to 6, characterized in that: Both the pre-inspection workpiece clamping mechanism (2.3) and the forward inspection workpiece clamping mechanism (3.3) are provided in several units, and the forward inspection workpiece clamping mechanism (3.3) is provided with an air blowing port (71).

8. The industrial product testing system according to claim 7, characterized in that: The pre-inspection transfer assembly is provided with at least two cutting fixture mechanisms and two sets of transfer mechanisms. The cutting fixture mechanism and the pre-inspection workpiece fixture mechanism (2.3) are driven by different transfer mechanisms. The cutting fixture mechanism can pick up and change the workpiece on the pre-inspection workpiece fixture mechanism (2.3).

9. An industrial product testing method, based on the industrial product testing system according to any one of claims 1 to 8, characterized in that: The process includes the following steps: using a light inspection mechanism to inspect the surface defects and dimensions of the workpiece; using a sound inspection device to inspect the internal structural defects of the workpiece; placing qualified workpieces in the qualified workpiece area and unqualified workpieces in the defective workpiece area; during the light inspection of the workpiece, when the form and position tolerances of the horizontal and / or vertical surfaces of the workpiece are significantly out of tolerance, a fitting inspection step is initiated. The workpiece is oscillated within a certain angle by a fixture, so that the camera in the light inspection mechanism can obtain the contour projection images of the workpiece from the front, back and side views at each oscillation angle; by fitting the workpiece contour and correlating it with the oscillation angle, the form and position dimensions of the workpiece with the front and rear end faces as reference surfaces are obtained, thereby obtaining the form and position tolerance data of the workpiece.

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