Wear detection device and method for cleaning bristles of a sheet

Abstract

The present application relates to the technical field of automatic detection, and specifically provides a kind of wear detection device and method for cleaning the bristle of sheet material, comprising: swing mechanism, the swing mechanism includes drive motor and swing stick, the drive shaft of drive motor is fixedly connected swing stick, pressure sensor is equipped on the swing stick;The drive shaft is perpendicular to swing stick, the swing stick reciprocating swing in sector area, the sector area overlaps with sheet material passing surface, and the sheet material passing surface is the combined surface of two brush rollers;The drive motor is fixedly installed on lifting mechanism, and the lifting mechanism drives the drive motor to lift in vertical direction;The pressure sensor is connected with controller in communication.This application can not only reduce the cost of manual use, but also shorten the detection time, enhance the automation and intelligentization of production line, effectively improve the convenience of user use.

Description

Technical Field

[0001] This invention belongs to the field of automatic detection technology, and specifically relates to a wear detection device and method for brush bristles used in cleaning sheet metal. Background Technology

[0002] Before forming sheet metal, the sheet metal often needs to be cleaned. Dual-brush roller washing devices are widely used as a common type of equipment. They clean the upper and lower surfaces of the sheet metal simultaneously to ensure thorough cleaning. To guarantee the cleaning effect, the overlap between the brush bristles and the sheet metal needs to be controlled within a certain range to ensure sufficient brushing force. Excessive or insufficient overlap will reduce the cleaning effect. After a period of use, the bristles on the brush roller will experience wear. When the bristles are too short, excessive impurities will accumulate on the sheet metal surface, leading to defects or unacceptable appearance in the formed sheet metal. Due to the nature of mass production, this often results in a large batch of unsuitable parts being produced, causing significant losses.

[0003] Traditional inspection methods often rely on visual adjustments and checks by personnel, such as observing the gap between brush rollers or checking the impurities on the board surface. Firstly, there is no standardized method for human observation; different observers use different standards. Therefore, the results are highly random, and the brushing effect cannot be guaranteed. If the brushing effect is unsatisfactory, multiple manual adjustments are required, consuming a significant amount of time. Existing photoelectric automatic inspection methods are not suitable for opaque environments where the upper and lower brush rollers overlap, and cannot detect the amount of wear on the brush bristles. Summary of the Invention

[0004] In view of the above-mentioned shortcomings of the prior art, the present invention provides a wear detection device and method for cleaning the bristles of sheet metal to solve the above-mentioned technical problems.

[0005] In a first aspect, the present invention provides a wear detection device for brush bristles used in cleaning sheet metal, comprising:

[0006] The swing mechanism includes a drive motor and a swing rod. The drive shaft of the drive motor is fixedly connected to the swing rod, and a pressure sensor is provided on the swing rod. The drive shaft is perpendicular to the swing rod, and the swing rod swings back and forth in a fan-shaped area. The fan-shaped area overlaps with the material passing surface, which is the joint surface of the two brush rollers.

[0007] The drive motor is fixedly mounted on the lifting mechanism, and the lifting mechanism drives the drive motor to move up and down in the vertical direction;

[0008] The pressure sensor is communicatively connected to the controller.

[0009] In an optional implementation, the apparatus further includes:

[0010] The traveling mechanism includes a traveling track and a traveling component. The traveling component is movably connected to the traveling track and is driven by a track-traveling motor. The traveling component is fixedly connected to the lifting mechanism.

[0011] In an alternative implementation, the drive shaft is connected to the swing rod via a right-angle bend.

[0012] In one alternative implementation, the swing rod is equipped with multiple pressure sensors.

[0013] In one optional embodiment, the lifting mechanism includes a fixed base and a hydraulic lift, wherein the fixed end of the hydraulic lift is fixedly mounted on the fixed base by bolts; the fixed base is mounted on the traveling member by bolts; and the telescopic end of the hydraulic lift is connected to a drive motor.

[0014] In one optional implementation, the drive motor is connected to a power source via a first relay; the track-walking motor is connected to a power source via a second relay; and the hydraulic lift is connected to a power source via a third relay; the first, second, and third relays are all communicatively connected to the controller.

[0015] In one optional implementation, the controller is electrically connected to the control port of the drive motor; the pressure sensor is communicatively connected to the controller via a Bluetooth module; the controller includes a storage medium and a timer.

[0016] In an optional implementation, the controller is communicatively connected to a brush roller control device, which adjusts the distance between the two brush rollers.

[0017] Secondly, the present invention provides a control method for a wear detection device for brush bristles used in cleaning sheet metal, comprising:

[0018] Send a start signal to the brush roller control device to make the brush roller roll speed reach the set rolling speed;

[0019] The lifting mechanism is controlled to drive the swing mechanism to descend until the swing rod of the swing mechanism reaches the horizontal plane where the fan-shaped area is located;

[0020] The drive motor is started, and the drive shaft of the drive motor drives the swinging rod to swing in the direction of the brush roller until the swinging rod is perpendicular to the brush roller.

[0021] The control mechanism keeps the swinging rod perpendicular to the brush roller and continuously acquires pressure data collected by the pressure sensor during the holding period.

[0022] The walking mechanism is controlled to walk a preset step distance to reach a new collection point. The swing mechanism stays at the new collection point until the dwell time reaches a set time threshold. During the dwell time of the swing mechanism at the new collection point, pressure data collected by the pressure sensor is acquired.

[0023] Calculate the average pressure data of each collection point, and compare the average pressure of each collection point with a preset pressure threshold. Set the average pressure data below the pressure threshold as an outlier. If the number of outliers reaches a set threshold, a maintenance task is generated.

[0024] The drive shaft of the control motor drives the swing rod to rotate until the swing rod is parallel to the brush roller, and the control lifting mechanism raises the drive motor to the highest position.

[0025] In an optional implementation, the method further includes:

[0026] Calculate the average of the outliers to obtain the outlier pressure value;

[0027] Calculate the pressure difference between the abnormal pressure value and the standard pressure value;

[0028] The adjustment value for the bristle overlap length is calculated based on the pressure difference and the correspondence between pressure and bristle overlap length.

[0029] Set half of the adjustment value as the brush roller adjustment value, and reduce the distance between the two brush rollers based on the brush roller adjustment value until the reduction distance of the brush rollers reaches the brush roller adjustment value;

[0030] Record the brush roller adjustment value for this adjustment in the log, and clear the recorded data in the log after replacing the brush bristles;

[0031] The adjustment time and corresponding brush roller adjustment value recorded in the statistical log are used to fit the adjustment curve and obtain the relationship function between the brush roller adjustment value and time.

[0032] The available length is calculated based on the initial length of the brush bristles and the set minimum length, and the remaining available length is calculated based on the available length and the cumulative value of the brush roller adjustment values ​​from each adjustment.

[0033] The remaining usage time is predicted based on the remaining available length and the relationship function.

[0034] The beneficial effects of this invention are that the wear detection device and method for cleaning sheet metal brushes provided by this invention integrates a contact pressure sensor, a telescopic protective device, a swing device, a walking device, and a position control device, enabling automatic detection of wear at different positions of the brush. This leverages the advantages of automatic detection in reducing labor costs and detection time, enhancing production line automation and intelligence, and effectively improving user convenience.

[0035] Furthermore, the design principle of this invention is reliable, the structure is simple, and it has a very wide range of application prospects. Attached Figure Description

[0036] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0037] Figure 1 This is a schematic diagram of the structure of a wear detection device for cleaning the bristles of sheet metal according to an embodiment of the present invention.

[0038] Figure 2 This is a schematic diagram of the working state of a wear detection device for cleaning the bristles of a sheet metal according to an embodiment of the present invention.

[0039] Figure 3 This is another schematic diagram of a wear detection device for cleaning the bristles of sheet metal according to an embodiment of the present invention.

[0040] The components include: 1. Sheet material; 2. Brush roller; 3. Brush roller adjustment mechanism; 4. Pressure sensor; 5. Swinging mechanism; 6. Lifting mechanism; 7. Sheet material anti-collision plate; and 8. Walking mechanism. Detailed Implementation

[0041] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this invention.

[0042] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0043] To facilitate understanding of the present invention, the wear detection device and method for cleaning the bristles of sheet metal provided by the present invention will be further described below with reference to the principle of the wear detection device for cleaning the bristles of sheet metal.

[0044] For details, please refer to Figure 1 and Figure 2 The wear detection device for the brush bristles used to clean sheet metal includes:

[0045] The swing mechanism 5 includes a drive motor and a swing rod. The drive shaft of the drive motor is fixedly connected to the swing rod, and a pressure sensor 4 is installed on the swing rod. The drive shaft rotates in both forward and reverse directions to make the swing rod swing within a fan-shaped area. The fan-shaped area overlaps with the surface through which the sheet 1 passes, and the surface through which the sheet 1 passes is the mating surface of the two brush rollers 2. The drive motor is fixedly mounted on the lifting mechanism 6, which drives the drive motor to move up and down in the vertical direction. The pressure sensor 4 is communicatively connected to the controller. The drive shaft is connected to the swing rod through a right-angle bend, and multiple pressure sensors 4 are installed on the swing rod.

[0046] The brush roller 2 consists of upper and lower brush rollers. When the sheet material 1 passes through the brush roller 2, the brush roller 2 rotates to clean the upper and lower surfaces of the sheet material 1, thereby cleaning the upper and lower surfaces of the sheet material 1. The brush roller adjustment mechanism 3 is connected to the brush roller 2 and is used to raise and lower the brush roller 2. When the brush roller 2 cleans the sheet material 1, the upper and lower brush rollers 2 need to be adjusted in height by the brush roller adjustment mechanism 3 to make the upper and lower brush rollers 2 overlap to ensure that the brush roller 2 and the sheet material 1 are in full contact, thus ensuring the cleaning effect. The pressure sensor 4 is mounted on the swing mechanism 5. When not in use, the pressure sensor 4 is rotated by the swing mechanism 5 to a direction parallel to the axis of the brush roller 2 to avoid damage to the pressure sensor 4 caused by the movement of the brush roller 2.

[0047] The lifting mechanism 6 includes a fixed base and a hydraulic lift. The fixed end of the hydraulic lift is bolted to the fixed base; the fixed base is bolted to the traveling component; the telescopic end of the hydraulic lift is connected to a drive motor. The lifting mechanism 6 can lift the pressure sensor 4 to a certain height. When detection is required, the lifting mechanism 6 lowers, making the pressure sensor 4 flush with the contact surface of the brush roller 2. After this action, the swing mechanism 5 can swing. After the pressure sensor 4 has detected the pressure, the swing mechanism 5 retracts, and the lifting mechanism 6 lifts the pressure sensor 4 above the sheet metal anti-collision plate 7 to prevent the sheet metal 1 from impacting the pressure sensor 4 when passing through the brushing surface.

[0048] like Figure 3As shown, the device also includes: a traveling mechanism 8, which includes a traveling track and a traveling component. The traveling component is movably connected to the traveling track and is driven by a track-mounted motor; the traveling component is fixedly connected to the lifting mechanism 6. The traveling mechanism 8 carries the lifting mechanism 6 and the swing mechanism 5, and can run along the axis of the brush roller 2. Driven by the traveling mechanism 8, the pressure sensor 4 can be transported to any position on the brush roller 2. Combined with the position and range of the commonly used brushed sheet material 1, the pressure sensor 4 can detect the wear of the brush roller 2 at fixed times and points. When a certain degree of wear is reached, the operator is prompted to rework or replace the brush roller.

[0049] In terms of electrical control, the controller can employ a complex programmable logic device (FPGA), which connects to non-volatile memory and timers. The drive motor is connected to the power supply via a first relay; the track-walking motor is connected to the power supply via a second relay; and the hydraulic lift is connected to the power supply via a third relay. All three relays are communicatively connected to the controller. The controller achieves automatic control of the drive motor, track-walking motor, and hydraulic lift through these relays. The controller is electrically connected to the control port of the drive motor; the pressure sensor communicates with the controller via a Bluetooth module, thus achieving automatic control of the drive motor's rotation direction and angle.

[0050] The controller is connected to the brush roller control device (PLC), which adjusts the distance between the two brush rollers through the brush roller adjustment mechanism.

[0051] This embodiment provides a control method for a material brush roller wear detection device, executed by a controller, including the following steps:

[0052] S1. Send a start signal to the brush roller control device to make the brush roller roll speed reach the set rolling speed;

[0053] S2. Control the lifting mechanism to drive the swing mechanism to descend until the swing rod of the swing mechanism reaches the horizontal plane where the fan-shaped area is located;

[0054] S3. Control the start of the drive motor. The drive shaft of the drive motor drives the swinging rod to swing in the direction of the brush roller until the swinging rod is perpendicular to the brush roller.

[0055] S4. Control the swing mechanism to keep the swing rod perpendicular to the brush roller, and continuously acquire pressure data collected by the pressure sensor during the state maintenance.

[0056] S5. Control the walking mechanism to walk a preset step distance to reach a new collection point. The swing mechanism stays at the new collection point until the dwell time reaches a set time threshold. During the dwell time of the swing mechanism at the new collection point, the pressure data collected by the pressure sensor is acquired.

[0057] S6. Calculate the average pressure data of each collection point, and compare the average pressure data of each collection point with the preset pressure threshold. Set the average pressure data below the pressure threshold as an outlier. If the number of outliers reaches the set number threshold, a maintenance task is generated.

[0058] S7. Control the drive shaft of the drive motor to drive the swing rod to rotate until the swing rod is parallel to the brush roller, and control the lifting mechanism to raise the drive motor to the highest position.

[0059] Specifically, during initial use, the upper and lower brush rollers 2 overlap by h under the drive of the brush roller lifting mechanism 3. This value is the recommended value for new rollers. The traveling mechanism 8 drives the pressure sensor 4 to stop at several positions on both sides and in the middle of the brush roller 2. In further applications, it can stop at more positions. At this time, the pressure sensor 4 is located in a position that does not affect the movement of the sheet material 1 and the brush roller 2. After the traveling mechanism 8 stops in place, the upper and lower brush rollers 2 open a certain space under the drive of the lifting mechanism 3, allowing the pressure sensor 4 to enter. Then the lifting mechanism 6 falls to its position, and then the swing mechanism 5 can perform a rotation action. After the pressure sensor 4 swings into the overlapping part of the brush rollers 2, the upper and lower brush rollers 2 overlap under the drive of the brush roller lifting mechanism 3, and the pressure sensor 4 automatically records the pressure P11 at this time. Afterwards, the brush rollers reduce the overlap amount Δh under the drive of the lifting mechanism, and the pressure sensor automatically records the pressure P21 at this time.

[0060] Methods for adjusting the overlap of brush rollers include:

[0061] Calculate the average of the outliers to obtain the abnormal pressure value; calculate the pressure difference between the abnormal pressure value and the standard pressure value; based on the pressure difference and the correspondence between pressure and bristle overlap length, calculate the adjustment value of the bristle overlap length; set 1 / 2 of the adjustment value as the brush roller adjustment value, and reduce the distance between the two brush rollers based on the brush roller adjustment value until the reduction distance of the brush rollers reaches the brush roller adjustment value; record the brush roller adjustment value of this adjustment in the log, and clear the recorded data in the log after replacing the bristles;

[0062] Specifically, the brush roller adjustment mechanism 3 can reduce the brush roller overlap amount Δh multiple times and record the lifting position pressure P11-Pn1 multiple times. The above actions are performed multiple times at different positions of the brush roller, and the pressure sensor 4 automatically records the relevant position pressure P11-Pnn. Considering that the initial processing state of the brush roller 2 is not consistent, P11-Pnn can be used as the initial model of the new brush roller.

[0063] Based on the brush roller position, initial overlap, and P11-Pnn under different overlap, a multinomial fitting formula for the brush roller overlap is established: hc = ∈﹛h:△hn:Pnn﹜. This fitting formula can be used to calculate the current brush overlap based on the pressure sensing mechanism value after the brush has worn down to a certain extent.

[0064] Methods for predicting the remaining service life of brush rollers include:

[0065] The adjustment time and corresponding brush roller adjustment value recorded in the statistical log are used to fit the adjustment curve based on the adjustment time and corresponding brush roller adjustment value to obtain the relationship function between the brush roller adjustment value and time; the available length is calculated based on the initial length of the brush bristles and the set minimum length; the remaining available length is calculated based on the available length and the cumulative value of the brush roller adjustment value of each adjustment; the remaining usage time is predicted based on the remaining available length and the relationship function.

[0066] In practical use, at regular intervals ΔT, pressure sensor 4 detects the pressure generated after brush rollers 2 overlap, recording the brush wear amount hm at the contact point between brush roller 2 and sheet 1. Using the minimum brush overlap amount hs and the final usage time T as objectives, and ΔT and hm as variables, a fitting algorithm is established: T = ∈ {hs: ΔT: hm} to evaluate the final usage time of the brush and remind operators to replace or repair the brush rollers when they expire. This enhances the intelligence of the automatic brush roller detection system.

[0067] Although the present invention has been described in detail with reference to the accompanying drawings and preferred embodiments, the present invention is not limited thereto. Various equivalent modifications or substitutions can be made to the embodiments of the present invention by those skilled in the art without departing from the spirit and essence of the invention, and such modifications or substitutions should all be within the scope of the present invention. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should also be covered within the protection scope of the present invention.

Claims

1. A control method for a wear detection device for brush bristles used in cleaning sheet metal, characterized in that, include: The wear detection device includes: The swing mechanism includes a drive motor and a swing rod. The drive shaft of the drive motor is fixedly connected to the swing rod, and a pressure sensor is provided on the swing rod. The drive shaft rotates forward and backward to make the swing rod swing in a fan-shaped area. The fan-shaped area overlaps with the material passing surface, which is the joint surface of the two brush rollers. The drive motor is fixedly mounted on the lifting mechanism, and the lifting mechanism drives the drive motor to move up and down in the vertical direction; The pressure sensor is communicatively connected to the controller; The control method includes: Send a start signal to the brush roller control device to make the brush roller roll speed reach the set rolling speed; The lifting mechanism is controlled to drive the swing mechanism to descend until the swing rod of the swing mechanism reaches the horizontal plane where the fan-shaped area is located; The drive motor is started, and the drive shaft of the drive motor drives the swinging rod to swing in the direction of the brush roller until the swinging rod is perpendicular to the brush roller. The control mechanism keeps the swinging rod perpendicular to the brush roller and continuously acquires pressure data collected by the pressure sensor during the holding period. The walking mechanism is controlled to walk a preset step distance to reach a new collection point. The swing mechanism stays at the new collection point until the dwell time reaches a set time threshold. During the dwell time of the swing mechanism at the new collection point, pressure data collected by the pressure sensor is acquired. Calculate the average pressure data of each collection point, and compare the average pressure of each collection point with a preset pressure threshold. Set the average pressure data below the pressure threshold as an outlier. If the number of outliers reaches a set threshold, a maintenance task is generated. The drive shaft of the control motor drives the swing rod to rotate until the swing rod is parallel to the brush roller, and the lifting mechanism is controlled to raise the drive motor to the highest position. The control method further includes: Calculate the average of the outliers to obtain the outlier pressure value; Calculate the pressure difference between the abnormal pressure value and the standard pressure value; The adjustment value for the bristle overlap length is calculated based on the pressure difference and the correspondence between pressure and bristle overlap length. Set half of the adjustment value as the brush roller adjustment value, and reduce the distance between the two brush rollers based on the brush roller adjustment value until the reduction distance of the brush rollers reaches the brush roller adjustment value; Record the brush roller adjustment value for this adjustment in the log, and clear the recorded data in the log after replacing the brush bristles; The adjustment time and corresponding brush roller adjustment value recorded in the statistical log are used to fit the adjustment curve and obtain the relationship function between the brush roller adjustment value and time. The available length is calculated based on the initial length of the brush bristles and the set minimum length, and the remaining available length is calculated based on the available length and the cumulative value of the brush roller adjustment values ​​from each adjustment. The remaining usage time is predicted based on the remaining available length and the relationship function.

2. The control method for the wear detection device for cleaning sheet metal bristles according to claim 1, characterized in that, The device further includes: The traveling mechanism includes a traveling track and a traveling component. The traveling component is movably connected to the traveling track and is driven by a track-traveling motor. The traveling component is fixedly connected to the lifting mechanism.

3. The control method for the wear detection device for cleaning sheet metal bristles according to claim 1, characterized in that, The drive shaft is connected to the swing rod via a right-angle bend.

4. The control method for the wear detection device for cleaning sheet metal bristles according to claim 3, characterized in that, The swing rod is equipped with multiple pressure sensors.

5. The control method for the wear detection device for cleaning sheet metal bristles according to claim 2, characterized in that, The lifting mechanism includes a fixed base and a hydraulic lift. The fixed end of the hydraulic lift is fixedly mounted on the fixed base by bolts. The fixed base is mounted on the traveling component by bolts. The telescopic end of the hydraulic lift is connected to a drive motor.

6. The control method for the wear detection device for cleaning sheet metal bristles according to claim 5, characterized in that, The drive motor is connected to the power supply via a first relay; the track walking motor is connected to the power supply via a second relay; the hydraulic lift is connected to the power supply via a third relay; the first, second, and third relays are all communicatively connected to the controller.

7. The control method for the wear detection device for cleaning sheet metal bristles according to claim 6, characterized in that, The controller is electrically connected to the control port of the drive motor; the pressure sensor is communicatively connected to the controller via a Bluetooth module; the controller includes a storage medium and a timer.

8. The control method for the wear detection device for cleaning sheet metal bristles according to claim 1, characterized in that, The controller is communicatively connected to the brush roller control device, which adjusts the distance between the two brush rollers.

Images