A classification mechanism for detecting irregular hardware surface defects

Abstract

The present invention relates to a classification mechanism for detecting irregular hardware surface defects applied in the field of defect detection technology, which solves the problems of low efficiency, insufficient precision and difficulty in adapting to complex structures, especially detection at grooves, in existing hardware surface defect detection methods. Ultrasonic cleaning is used to effectively remove pollutants on the surface of hardware to ensure good contact between the eddy current detection probe and the surface of the hardware, and a signal processing algorithm is used to identify the location and type of hardware surface defects, thereby improving detection accuracy and reliability. Residual heat air drying is used to ensure that the surface of the hardware is dry to avoid water film affecting the coupling between the eddy current detection probe and the hardware, thereby improving the quality and accuracy of the detection signal. In addition, the residual heat air drying process is combined to reduce additional drying time and improve the overall detection speed. A probe with an adjustable angle is used for local detection to adapt to grooves of different angles, thereby achieving accurate detection of grooves of complex hardware and improving sensitivity to subtle defects.

Description

Technical Field

[0001] The invention relates to a classification mechanism for detecting irregular hardware surface defects, in particular to a classification mechanism for detecting irregular hardware surface defects applied in the technical field of defect detection. Background Art

[0002] Hardware refers to molds and mechanical accessories used for fixation and decoration obtained by processing and casting metals such as iron, copper, aluminum, gold, and silver. They are widely used in common scenes in daily life such as mechanical processing production, building panels, and household kitchen appliances. During the processing of hardware, there may be defects on its surface, so inspection is required to improve the overall quality of the product.

[0003] The specification of Chinese invention patent CN116754633B discloses a device for detecting surface defects of stamped hardware, including a detection box, an installation opening is provided on the outer wall of the detection box, and a light-shielding cylinder is fixedly arranged in the installation opening, a cylinder cover is rotatably arranged on the top of the light-shielding cylinder, a fixing opening is provided on the outer wall of the cylinder cover, and a camera is arranged in the fixing opening, a searchlight is also arranged on the lower surface of the cylinder cover, a magnetic field generator is arranged on the inner walls on both sides of the detection box, and a vertical cylinder is arranged on the bottom inner wall of the detection box. The present invention can synchronously realize the operation of hardware moving down, rotating, and being sprayed with magnetic suspension through the operation of a submersible pump. When the detection is completed and the submersible pump stops working, the magnetic suspension will no longer be sprayed from the nozzle, and the tray can also be moved up under the reset action of the elastic member 1, which is also convenient for picking up the hardware after detection, effectively realizing the rapid detection of stamped hardware, and having a better use effect.

[0004] Although the above design utilizes a method combining circulating magnetic suspension and rotating hardware to enhance defect display by changing the magnetic suspension flow rate and all-round spraying under the action of the magnetic field to ensure the accuracy and clarity of the detection results, it still has certain limitations. For example, it can only detect ferromagnetic materials. At the same time, the operation process of magnetic suspension detection has high requirements on the experience and technology of technicians. Improper operation may lead to inaccurate detection results, and it is difficult to spray the magnetic suspension into the grooves of irregular hardware. Summary of the invention

[0005] In view of the above-mentioned prior art, the technical problem to be solved by the present invention is the problems of low efficiency, insufficient accuracy and difficulty in adapting to complex structures, especially detection of grooves, in the existing methods for detecting surface defects of hardware. By means of automated detection process, eddy current detection technology, design of detection probe with adjustable angle and precise signal processing algorithm, the detection efficiency and detection accuracy are improved, the detection needs of hardware with complex structures, especially grooves, are adapted, and false alarms and missed detections are reduced.

[0006] In order to solve the above problems, the present invention provides a classification mechanism for detecting surface defects of irregular hardware parts, comprising an inner shell, a detection bracket is fixedly connected to the outer wall of the inner shell, a main detection coil is wound around the outer end of the detection bracket, the outer end of the detection bracket is fixedly connected to the outer shell, a plurality of detection devices are fixedly connected to the top of the detection bracket, and the plurality of detection devices are distributed in a circular array around the axis of the outer shell, the detection device comprises a mechanical arm fixedly connected to the top of the detection bracket, a support shell is fixedly connected to the top of the mechanical arm, a plurality of vacuum pumps are fixedly connected to the inner wall of the support shell, a detection arm is fixedly connected to the outer end of the support shell, a plurality of adjustment chambers are provided inside the detection arm, and the plurality of adjustment chambers are distributed in a circular array around the axis of the detection arm, and the plurality of adjustment chambers are slidably connected to the inside of the plurality of adjustment chambers;

[0007] The regulating chamber is fixedly connected with a negative pressure ring through a pipeline, and the negative pressure ring is connected with a vacuum pump through the pipeline. A through hole is opened inside the detection arm, and a hose is fixedly connected to the outer end of the through hole, and a spring is fixedly connected to the inner wall of the hose, and a plurality of regulating joints are fixedly connected to the outer wall of the hose, and the plurality of regulating joints are distributed in a linear array along the hose, and a plurality of regulating wires are slidingly connected inside the regulating joint, and the plurality of regulating wires penetrate the regulating joint and are distributed in a circular array around the axis of the hose, one end of the regulating wire is fixedly connected to the regulating joint at the end of the hose, and the other end of the regulating wire is fixedly connected to the regulating piston, and an annular bracket is fixedly connected to the end of the hose, and a second detection coil is fixedly connected to the outer end of the annular bracket, and a third detection coil is fixedly connected to the outer end of the second detection coil, and a heat dissipation layer is fixedly connected to the inner wall of the heat dissipation layer, and the third detection coil is fixedly connected.

[0008] As a further improvement of the present application, the through hole is interconnected with the detection bracket through a pipe, the bottom end of the detection bracket is fixedly connected to a partition, the outer end of the inner shell is fixedly connected to a plurality of ultrasonic generators, the plurality of ultrasonic generators are distributed in a circular array around the axis of the inner shell, and the outer end of the ultrasonic generator is fixedly connected to the partition.

[0009] As a further improvement of the present application, a plurality of condensation inlet pipes are fixedly connected to the outer end of the outer shell, the plurality of condensation inlet pipes all penetrate the outer shell, and the plurality of condensation inlet pipes are all connected to the cavity surrounded by the outer shell and the partition, and a plurality of drying tubes are fixedly connected to the inner wall of the inner shell, the drying tubes are distributed in a circular array around the axis of the inner shell, and the plurality of drying tubes penetrate the inner shell, and the plurality of drying tubes are all connected to the cavity surrounded by the outer shell and the partition.

[0010] As a further improvement of the present application, the bottom end of the outer shell is fixedly connected to a bottom plate, the inner end of the bottom plate is slidably connected to a lifting platform, and the top end of the lifting platform is fixedly connected to hardware.

[0011] As another improvement of the present application, the second detection coil and the third detection coil constitute a differential coil, the second detection coil and the third detection coil have the same geometric shape and size, and the spacing W between the second detection coil and the third detection coil is equal to the width W of the second detection coil or the third detection coil.

[0012] As another improvement supplement of the present application, the second detection coil and the third detection coil are wound in the same direction, and the output ends of the second detection coil and the third detection coil are connected to the signal processing unit in opposite ways, so that when the external magnetic field changes, the induced electromotive force generated by the second detection coil and the third detection coil is in opposite directions.

[0013] As another improvement supplement of the present application, a solenoid valve is fixedly connected to the pipeline between the regulating chamber and the negative pressure ring, and the solenoid valve is connected to the control system through a wire, a sensor is fixedly connected to the outer end of the annular bracket, and the sensor is connected to the control system through a wire, and a plurality of circular holes are opened at the bottom end of the detection bracket, and the plurality of circular holes are distributed in a circular array around the axis of the detection bracket.

[0014] As another improvement of the present application, the hose body is made of TPU material, the adjusting joint is made of stainless steel, the diameter of the hose is 10 mm, the thickness of the adjusting joint is 1 mm, and the diameter of the adjusting joint is 20-30 mm.

[0015] The steps include:

[0016] S1, ultrasonic cleaning;

[0017] The control system drives the lifting platform to the top, and the hardware is placed on the platform and then lowered into the cleaning liquid at the bottom. The high-frequency sound waves generated by the ultrasonic generator clean the surface of the hardware to ensure good contact and accuracy for subsequent inspections.

[0018] S2, residual heat air drying;

[0019] After cleaning, the lifting platform rises to the drying tube position, and the gas guided through the through holes at the bottom of the partition and the detection bracket is used to air-dry the hardware to reduce the impact of moisture on the detection results.

[0020] S3, eddy current testing;

[0021] The lifting platform cooperates with the main detection coil to carry out layered detection. The control system adjusts the appropriate detection frequency and identifies the location and type of surface defects of hardware through signal processing algorithms to ensure the accuracy and completeness of the detection.

[0022] S4, local detection;

[0023] The detection probe is adjusted to the bottom of the hardware groove through optical sensors and robotic arms, and the differential coil composed of the second detection coil and the third detection coil is used to perform accurate detection inside the groove, ensuring comprehensive detection of hardware with complex structures.

[0024] In summary, this application has the following beneficial effects:

[0025] 1. Improve detection accuracy and reliability; Ultrasonic cleaning can effectively remove pollutants on the surface of hardware, ensure good contact between the eddy current detection probe and the surface of the hardware, and reduce false alarms caused by surface contamination. Residual heat drying can ensure that the surface of the hardware is dry and avoid water film affecting the coupling between the eddy current detection probe and the hardware, thereby improving the quality and accuracy of the detection signal.

[0026] 2. Improve detection efficiency; Ultrasonic cleaning can effectively remove pollutants, shorten the pretreatment time of hardware, accelerate the overall detection process, and adopt an automated control system to quickly complete layered detection. At the same time, combined with the waste heat drying process, it reduces additional drying time and improves the overall detection speed.

[0027] 3. Enhance the detection capability of complex hardware. Local detection uses an adjustable angle probe that can adapt to grooves of different angles, achieving accurate detection of grooves of complex hardware and improving sensitivity to subtle defects. The design of the differential detection coil can effectively suppress background noise and external interference, improve the signal-to-noise ratio, and make detection more accurate.

[0028] 4. Non-destructive testing protects the integrity of hardware; eddy current testing is a non-contact test that will not cause any physical damage or chemical treatment to the hardware, maintaining the integrity and functionality of the hardware. The contact of the probe during local testing is also gentle, reducing the risk of mechanical wear.

[0029] 5. Intelligent operation and result visualization: The control system realizes automated detection by automatically adjusting the angle of the detection probe, combining the movement of the robotic arm and the lifting of the lifting platform, reducing the need for manual operation, signal processing and result visualization, and drawing signal waveforms, defect location maps and spectrum maps to facilitate rapid identification and classification of defects. At the same time, a detailed detection report is generated to facilitate subsequent analysis and decision-making. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 This is the first partial view of this application;

[0031] Figure 2 This is the second partial view of this application;

[0032] Figure 3 This is the third partial view of this application;

[0033] Figure 4 This is the fourth partial view of this application;

[0034] Figure 5 This is the fifth partial view of the present application;

[0035] Figure 6 This is the sixth partial view of the present application;

[0036] Figure 7 This is the front view of the application;

[0037] Figure 8 It is the AA cross-sectional view of this application;

[0038] Fig. 9 It is the BB cross-sectional view of this application;

[0039] Fig.10 It is the seventh partial view of this application;

[0040] Fig.11 This is a schematic diagram of the overall structure of this application.

[0041] Description of the numbers in the figure:

[0042] 1. Inner shell; 2. Detection bracket; 3. Main detection coil; 4. Outer shell; 5. Mechanical arm; 6. Support shell; 7. Vacuum pump; 8. Detection arm; 9. Adjustment chamber; 10. Adjustment piston; 11. Negative pressure ring; 12. Through hole; 13. Hose; 14. Spring; 15. Adjustment joint; 16. Adjustment wire; 17. Ring bracket; 18. Second detection coil; 19. Third detection coil; 20. Heat dissipation layer; 21. Partition; 22. Ultrasonic generator; 23. Condensation inlet pipe; 24. Drying tube; 25. Bottom plate; 26. Lifting platform. DETAILED DESCRIPTION

[0043] Three implementation modes of the present application are described in detail below with reference to the accompanying drawings.

[0044] The first implementation method:

[0045] Figure 1-11A classification mechanism for detecting surface defects of irregular hardware is shown, comprising an inner shell 1, a detection bracket 2 is fixedly connected to the outer wall of the inner shell 1, a main detection coil 3 is wound and connected to the outer end of the detection bracket 2, an outer shell 4 is fixedly connected to the outer end of the detection bracket 2, a plurality of detection devices are fixedly connected to the top of the detection bracket 2, and the plurality of detection devices are distributed in a circular array around the axis of the outer shell 4, the detection device comprises a mechanical arm 5 fixedly connected to the top of the detection bracket 2, a support shell 6 is fixedly connected to the top of the mechanical arm 5, a plurality of vacuum pumps 7 are fixedly connected to the inner wall of the support shell 6, a detection arm 8 is fixedly connected to the outer end of the support shell 6, a plurality of adjustment chambers 9 are provided inside the detection arm 8, and the plurality of adjustment chambers 9 are distributed in a circular array around the axis of the detection arm 8, and an adjustment piston 10 is slidably connected to the inside of the plurality of adjustment chambers 9;

[0046] The regulating chamber 9 is fixedly connected with a negative pressure ring 11 through a pipeline, and the negative pressure ring 11 is connected with the vacuum pump 7 through a pipeline. A through hole 12 is opened inside the detection arm 8, and a hose 13 is fixedly connected to the outer end of the through hole 12. A spring 14 is fixedly connected to the inner wall of the hose 13, and a plurality of adjusting joints 15 are fixedly connected to the outer wall of the hose 13, and the plurality of adjusting joints 15 are distributed in a linear array along the hose 13. A plurality of adjusting wires 16 are slidably connected inside the adjusting joint 15, and the plurality of adjusting wires 16 penetrate the adjusting joint 15 and are distributed in a circumferential array around the axis of the hose 13. One end of the adjusting wire 16 is fixedly connected to the adjusting joint 15 at the end of the hose 13, and the other end of the adjusting wire 16 is fixedly connected to the adjusting piston 10. An annular bracket 17 is fixedly connected to the end of the hose 13, and a second detection coil 18 is fixedly connected to the outer end of the annular bracket 17, and a third detection coil 19 is fixedly connected to the outer end of the annular bracket 17, and a heat dissipation layer 20 is fixedly connected to the outer end of the second detection coil 18, and the inner wall of the heat dissipation layer 20 is fixedly connected to the third detection coil 19.

[0047] The inner shell 1 serves as the basis of the entire detection equipment and provides structural support to ensure the stability and reliability of the entire detection equipment. The detection bracket 2 connects the inner shell 1 and the main detection coil 3 to carry and dissipate heat to ensure that the main detection coil 3 is at a normal working temperature. The main detection coil 3 is wound around the outer end of the detection bracket 2 to generate the magnetic field required for detection, providing a basic magnetic field environment for the detection process and helping to identify defects. The outer shell 4 is located at the outer end of the detection bracket 2 to protect the internal structure, provide protection and support, and prevent external factors from interfering with the detection process. The mechanical arm 5 is fixedly connected to the top of the detection bracket 2, and the position of the detection probe can be adjusted so that the probe can reach different positions of the hardware to meet the detection requirements of the groove shape. The support shell 6 is fixedly connected to the top of the mechanical arm 5 to bear The vacuum pump 7 and the detection arm 8 are carried to provide structural support, ensure the stability of the detection arm 8 and the working environment of the vacuum pump 7, the vacuum pump 7 is fixedly connected to the inner wall of the support shell 6, and is used to generate negative pressure, and the angle of the detection arm 8 is controlled by the negative pressure, the detection arm 8 is fixedly connected to the outer end of the support shell 6, and an adjustment chamber 9 is provided inside, which is used to carry the adjustment joint 15, the second detection coil 18 and the third detection coil 19 to adapt to the detection of irregular surfaces, the adjustment chamber 9 is distributed in a circular array around the axis of the detection arm 8, and the adjustment piston 10 is slidably connected inside, and the adjustment wire 16 is adjusted by moving the adjustment piston 10 to change the angle of the entire probe, and the angle of the hose 13 is adjusted by pulling the adjustment wire 16 to ensure that the second detection coil 18 and the third detection coil 19 are in contact with the surface of the hardware groove;

[0048] The negative pressure ring 11 is connected with the regulating chamber 9 and the vacuum pump 7 through a pipeline to form a negative pressure environment. The movement of the regulating piston 10 is controlled by controlling the solenoid valve to change the negative pressure of the regulating chamber 9. The through hole 12 is opened inside the regulating chamber 9 and is fixedly connected to the inner wall of the hose 13 to ensure that the regulating piston 10 can slide freely inside the regulating chamber 9. The inner wall of the hose 13 is fixedly connected to the spring 14, and the outer wall is fixedly connected to multiple adjusting joints 15. Through the cooperation of the adjusting joints 15 and the springs 14, the hose 13 can be freely bent to adapt to surfaces of different shapes. The spring 14 is fixedly connected to the inner wall of the hose 13 to provide elastic force. After the detection is completed, the detection probe is reset. The adjusting joints 15 are distributed in a linear array along the hose 13, and the internal sliding connection adjusting wire 16 is connected. The bending degree of the hose 13 is adjusted by moving the adjusting wire 16 to perform a specific angle adjustment. The adjusting wire 16 surrounds the hose The axes 13 are distributed in a circular array, one end is fixedly connected to the adjusting joint 15 at the end of the hose 13, and the other end is fixedly connected to the adjusting piston 10. The curvature of the hose 13 is adjusted by pulling the adjusting wire 16 by the adjusting piston 10 to ensure that the second detection coil 18 and the third detection coil 19 can fit the surface of the hardware groove. The annular bracket 17 is fixedly connected to the end of the hose 13 to carry the second detection coil 18 and the third detection coil 19 to ensure their stability. The second detection coil 18 is fixedly connected to the outer end of the annular bracket 17 for detecting surface defects and forming a differential structure with the third detection coil 19 to improve the detection accuracy. The heat dissipation layer 20 is fixedly connected to the outer end of the second detection coil 18, and the inner wall is fixedly connected to the third detection coil 19 to help the second detection coil 18 and the third detection coil 19 dissipate heat to ensure stability and reliability during the detection process.

[0049] The second implementation method:

[0050] Figure 1-11 It is shown that the through hole 12 is interconnected with the detection bracket 2 through a pipeline, allowing gas to flow, which is used to cool the detection coil and air-dry the groove of the hardware, which helps to maintain the temperature of the detection probe, ensure the stable operation of the electronic components, and help to quickly dry the surface of the groove to reduce the influence of moisture on the detection results. The bottom end of the detection bracket 2 is fixedly connected with a partition 21, and the partition 21 divides the space into two halves, which is conducive to the gas circulation and heat absorption. The outer end of the inner shell 1 is fixedly connected with a plurality of ultrasonic generators 22. The circular array distribution design ensures the uniform distribution of ultrasonic energy, thereby achieving all-round cleaning of the surface of the hardware. The fixed connection between the ultrasonic generator 22 and the partition 21 helps to stabilize its position, ensure that the ultrasonic source will not shift during the cleaning process, and ensure the consistency of the cleaning effect;

[0051] The outer end of the outer shell 4 is fixedly connected with a plurality of condensation inlet pipes 23. The setting of the condensation inlet pipes 23 allows external equipment to transport gas to the inside of the outer shell 4. The gas is used to cool the main detection coil 3 and the subsequent drying process of the hardware. The gas transported by the condensation inlet pipe 23 first cools the main detection coil 3, enters the cavity after absorbing heat, and is finally used for drying the hardware through the drying pipe 24. Such a design makes the gas utilization rate higher and also ensures the cooling effect of the main detection coil 3. The inner wall of the inner shell 1 is fixedly connected with a plurality of drying pipes 24. The circumferential array distribution of the drying pipes 24 allows the dry airflow to act evenly on the surface of the hardware, ensuring that all parts of the surface of the hardware can be effectively dried, providing good surface conditions for subsequent eddy current detection;

[0052] The bottom end of the outer shell 4 is fixedly connected with a bottom plate 25, the inner end of the bottom plate 25 is slidably connected with a lifting platform 26, and the top of the lifting platform 26 is fixedly connected with hardware. The design of the lifting platform 26 enables the hardware to be accurately positioned at the detection position. Whether it is ultrasonic cleaning or eddy current detection, it can be achieved by moving or rotating the lifting platform 26. The vertical movement ability of the lifting platform 26 helps to achieve layered detection of hardware, improves the comprehensiveness and accuracy of the detection, and through the movement of the lifting platform 26, the hardware can be moved from the cleaning position to the drying position, and then to the eddy current detection position, which simplifies the detection process and improves the detection efficiency.

[0053] The second detection coil 18 and the third detection coil 19 constitute a differential coil. The design of the differential coil can effectively suppress background noise and external interference and improve the signal-to-noise ratio of the signal. The differential coil structure can improve the detection accuracy because the signal difference between the two coils reflects the defects on the surface of the hardware rather than the environmental noise. The second detection coil 18 and the third detection coil 19 have the same geometric shape and size. The same geometric shape and size ensure that the two coils generate similar magnetic fields during the detection process, thereby ensuring the accuracy of the differential signal. The same design helps to maintain the stability and consistency of the detection process and reduce the uncertainty caused by the difference in coil design. The spacing W between the second detection coil 18 and the third detection coil 19 is equal to the width W of the second detection coil 18 or the third detection coil 19. This spacing design helps to optimize the signal output of the differential coil, making the signal change more obvious and easier to detect surface defects. Appropriate spacing helps to improve the sensitivity of detection, especially when detecting small-sized defects;

[0054] The second detection coil 18 and the third detection coil 19 are wound in the same direction. The same winding direction helps to ensure that the magnetic fields generated by the two coils are in the same direction, thereby generating similar responses during the detection process, helping to maintain the stability and consistency of the detection process and reduce the uncertainty caused by differences in coil design. The output ends of the second detection coil 18 and the third detection coil 19 are connected to the signal processing unit in opposite ways. When there is an external magnetic field change, the induced electromotive force generated by the two coils is in opposite directions, which helps to offset the influence of background noise and external interference and improve the signal-to-noise ratio of the signal. By connecting in this way, the signal processing unit can enhance its ability to identify real defect signals and reduce false alarms and missed detections.

[0055] A solenoid valve is fixedly connected to the pipeline between the regulating chamber 9 and the negative pressure ring 11, and the solenoid valve is connected to the control system through a wire. The control system can accurately control the opening and closing of the solenoid valve, thereby controlling the negative pressure level in the negative pressure ring 11, ensuring that the probe can accurately contact the surface of the hardware. The automatic control of the solenoid valve helps to realize the automatic adjustment of the probe angle and improve the efficiency of the detection process. A sensor is fixedly connected to the outer end of the annular bracket 17, and the sensor is connected to the control system through a wire. The sensor can be used to identify the position of the hardware groove to ensure that the probe can be accurately positioned at the groove of the hardware. Through the connection between the sensor and the control system, the automatic adjustment of the probe position can be realized to improve the detection accuracy. A plurality of circular holes are opened at the bottom end of the detection bracket 2, and the plurality of circular holes are distributed in a circular array around the axis of the detection bracket 2. These circular holes allow gas to pass through, which is used to cool the detection coil and air-dry the hardware.

[0056] The main body of the hose 13 is made of TPU material, which is a material with high elasticity, wear resistance and chemical resistance. The wear resistance and chemical resistance of TPU help the hose 13 maintain good performance during long-term use and reduce the effects of wear and chemical corrosion. The adjustment joint 15 is made of stainless steel. The high strength of stainless steel ensures that the adjustment joint 15 can remain stable and not easily deformed when subjected to external force. The diameter of the hose 13 is 10mm. The diameter of the hose 13 is small, and the smaller diameter helps to improve the flexibility of the hose 13. The thickness of the adjustment joint 15 is 1mm, and the thinner thickness helps to improve the flexibility of the adjustment joint 15 so that it can better adapt to the bending of the hose 13. The thinner thickness helps to reduce the weight of the adjustment joint 15 and reduce the overall weight of the probe. The diameter of the adjustment joint 15 is 20-30mm, and the diameter of the adjustment joint 15 is moderate. The moderate diameter helps to ensure that the adjustment joint 15 remains stable and not easily deformed when the hose 13 is bent.

[0057] The third implementation method:

[0058] Figure 1-11The following steps are shown:

[0059] S1, ultrasonic cleaning;

[0060] Before testing, the control system drives the lifting platform 26 to the top of the equipment, and the hardware is placed on the platform manually or with a clamping device. The control system lowers the lifting platform 26 to the bottom of the outer shell 4, and the bottom of the outer shell 4 is filled with a cleaning liquid. The control system starts the ultrasonic generator 22 to clean the hardware in all directions, using high-frequency sound waves to generate tiny cavitation bubbles in the liquid. These bubbles release energy when they burst, thereby removing dirt, grease and other contaminants on the surface of the hardware. After cleaning is completed, the lifting platform 26 continues to rise to the air-drying position.

[0061] Ultrasonic cleaning can effectively remove dust, grease and other contaminants on the surface of hardware, ensure good contact between the eddy current detection probe and the surface of the hardware, and improve the accuracy of detection. The clean surface reduces false alarms caused by contaminants, making the detection results more reliable. The clean surface can improve the signal transmission between the eddy current detection probe and the hardware, thereby improving the quality of the detection signal. Removing surface contaminants can reduce stray signals during the detection process and reduce interference factors. Ultrasonic cleaning can efficiently remove contaminants, shorten the pretreatment time of hardware, and improve the efficiency of the overall detection process. Clean hardware can reduce repeated detection due to surface contamination and improve work efficiency. Ultrasonic cleaning can reduce the spread of contaminants in the detection environment, keep the detection area clean, and facilitate subsequent detection work.

[0062] S2, residual heat air drying;

[0063] When the cleaning is completed, the lifting platform 26 is lifted to the position corresponding to the drying tube 24, and the external equipment transports the gas to the cavity formed by the outer shell 4 and the partition 21 through the condensation inlet pipe 23 to cool the main detection coil 3. After cooling the main detection coil 3, the gas enters the bottom of the partition 21 to further cool the ultrasonic generator 22. The gas that absorbs heat passes through the drying tube 24 to air-dry the hardware. At the same time, another part of the gas enters the detection bracket 2 through the circular hole on the bottom end of the detection bracket 2. After entering the detection bracket 2, it absorbs the heat generated by the main detection coil 3 again. Then the gas enters the through hole 12 through the pipeline, and then enters the hose 13 through the through hole 12. The gas flowing out of the hose 13 dissipates heat to the second detection coil 18 and the third detection coil 19. The gas after heat dissipation air-dries the grooves of the irregular hardware to remove moisture on the surface of the grooves to ensure the detection quality.

[0064] The dry surface of hardware can prevent water film, ensure good coupling between eddy current detection and hardware, and improve the accuracy of detection. The dry surface can reduce signal distortion caused by moisture, reduce false alarm rate, reduce additional signal changes, and improve detection efficiency.

[0065] S3, eddy current testing;

[0066] After drying, the regular surface of the hardware is inspected. While inspecting, the lifting platform 26 is controlled to rise and fall, and the hardware is inspected in layers. The control system controls the main detection coil 3 to generate an alternating magnetic field. The main detection coil 3 performs detection with self-inductance eddy current. The control system adjusts the detection frequency to a suitable frequency. The generated magnetic field passes through the hardware and generates eddy current in the hardware. The eddy current generates its own magnetic field, which interacts with the original magnetic field and affects the induced electromotive force in the original coil. When there are defects on the surface of the hardware, the path of the eddy current will be changed, resulting in a change in the induced electromotive force in the main detection coil 3. The signal output by the main detection coil 3 After amplification by the amplifier, the data acquisition system collects the amplified signal, uses a low-pass filter to remove high-frequency noise in the signal, and uses wavelet transform to further remove random noise in the signal. Then, the amplitude change of the signal is calculated, the abnormal point is found, and the phase change of the signal is calculated to identify the location of the defect. The signal is converted to the frequency domain using Fourier transform, and the frequency characteristics of the signal are analyzed. After extracting the signal features, the abnormal signal is identified according to the experimentally calibrated signal threshold, and the defect is classified. The location of the defect is determined in combination with the movement trajectory of the lifting platform 26, and the result is visualized by drawing the signal waveform diagram, defect location diagram and spectrum diagram.

[0067] Eddy current testing can quickly and effectively detect defects such as cracks, inclusions, pores, etc. in hardware, ensure the quality of hardware, and prevent hardware with potential safety hazards from being assembled into mechanical equipment. Eddy current testing does not require any physical destruction or chemical treatment of hardware. The testing process will not damage the object being tested and can maintain the integrity and functionality of the hardware. Since the detection is non-contact, it can reduce the risk of mechanical wear and manual operating errors, thereby improving detection efficiency and safety.

[0068] S4, local detection;

[0069] After the flat surface inspection of the hardware is completed, the lifting platform 26 continues to rise to the predetermined position, and the optical sensor at the outer end of the annular bracket 17 recognizes the position of the groove. The control system drives the mechanical arm 5 to move according to the recognized position information, and drives the main detection coil 3 to move to the bottom of the groove. The control system starts the vacuum pump 7 to draw the negative pressure ring 11 into a vacuum state, and then adjusts the angle of the probe according to the angle of the groove. The control system achieves this by controlling the switch of the solenoid valve. When the probe needs to bend upward, the control system controls the opening of the corresponding solenoid valve above the detection arm 8. Under the action of negative pressure, the adjusting piston 10 moves backward along the adjusting chamber 9. The movement of the adjusting piston 10 drives the adjusting wire 16 to move. The tightening of the adjusting wire 16 causes the spring 14 to bend, and the adjusting joint 15 moves closer to the contraction direction, so that the angle of the detection probe is consistent with the angle of the groove, and the end faces of the second detection coil 18 and the third detection coil 19 are parallel to the detection surface of the groove.

[0070] After the adjustment of the detection probe is completed, the gas passing through the detection bracket 2 enters the through hole 12 through the pipeline, and then enters the hose 13 through the through hole 12. The gas flowing out of the hose 13 dissipates heat to the second detection coil 18 and the third detection coil 19, and air-dries the groove to prevent the residual moisture from affecting the detection result. After air-drying, the control system energizes the differential coil composed of the second detection coil 18 and the third detection coil 19. The second detection coil 18 acts as an excitation coil to generate a stable electromagnetic field in the hardware, so that an eddy current effect is generated inside the material. The third detection coil 19 acts as a receiving coil. When a surface defect is detected, the lifting platform 26 is controlled to rotate intermittently to achieve a comprehensive detection effect. The third detection coil 19 will detect the magnetic field changes caused by the surface defects of the hardware. The signal collector collects the signal output by the differential detection coil, filters and amplifies the collected signal, and converts it into a digital signal. The digital signal is analyzed using a signal processing algorithm, and the characteristic position of the defect is identified according to the signal feature. The defect can be identified and classified by comparing the difference between the detection signal and the experimental calibration signal. At the same time, the detection result, including the location and type of the defect, is displayed on the operation interface, and a defect detection report is generated.

[0071] Since the probe is in direct contact with the inside of the groove, local focused detection can be achieved, and the sensitivity to subtle defects in the groove can be improved. The design of the differential detection coil can effectively suppress background noise and external interference, and improve the signal-to-noise ratio of the signal. For hardware with complex grooves, traditional detection methods may be difficult to implement, and the probe can flexibly adapt to various groove shapes. For certain groove structures, direct detection can be performed without additional processing of the workpiece, saving time and cost. Combined with the robot arm 5, continuous or batch detection can be achieved, and production efficiency can be improved. The detection results can be obtained in real time, and defective products can be discovered and eliminated in time, reducing the rework rate of subsequent processes. The position of the defect can be accurately located through signal analysis, reducing false alarms or missed detections caused by inaccurate positioning. Comprehensive judgment can be made through multiple methods such as spectrum analysis and phase analysis of the signal to reduce the uncertainty caused by a single judgment basis.

[0072] In view of current practical needs, the above-mentioned implementation mode adopted in this application is not limited to the scope of protection. Various changes made within the knowledge scope of technical personnel in this field without departing from the concept of this application still fall within the scope of protection of the present invention.

Claims

1. A classification mechanism for detecting irregular hardware surface defects, characterized in that: The invention comprises an inner shell (1), wherein the outer wall of the inner shell (1) is fixedly connected to a detection bracket (2), the outer end of the detection bracket (2) is wound with a main detection coil (3), the outer end of the detection bracket (2) is fixedly connected to an outer shell (4), the top end of the detection bracket (2) is fixedly connected to a plurality of detection devices, and the plurality of detection devices are distributed in a circular array around the axis of the outer shell (4), the detection device comprises a mechanical arm (5) fixedly connected to the top end of the detection bracket (2), the top end of the mechanical arm (5) is fixedly connected to a support shell (6), the inner wall of the support shell (6) is fixedly connected to a plurality of vacuum pumps (7), the outer end of the support shell (6) is fixedly connected to a detection arm (8), a plurality of adjustment chambers (9) are provided inside the detection arm (8), and the plurality of adjustment chambers (9) are distributed in a circular array around the axis of the detection arm (8), and the interiors of the plurality of adjustment chambers (9) are all slidably connected to adjustment pistons (10); The regulating chamber (9) is fixedly connected to a negative pressure ring (11) via a pipeline, and the negative pressure ring (11) is connected to a vacuum pump (7) via a pipeline. A through hole (12) is provided inside the detection arm (8), and a hose (13) is fixedly connected to the outer end of the through hole (12), and a spring (14) is fixedly connected to the inner wall of the hose (13). A plurality of regulating joints (15) are fixedly connected to the outer wall of the hose (13), and the plurality of regulating joints (15) are distributed in a linear array along the hose (13). A plurality of regulating wires (16) are slidably connected to the inside of the regulating joint (15), and the plurality of regulating wires (16) penetrate the surrounding of the regulating joint (15). The adjusting wires (16) are arranged in a circular array around the axis of the hose (13); one end of the adjusting wire (16) is fixedly connected to the adjusting joint (15) at the end of the hose (13); the other end of the adjusting wire (16) is fixedly connected to the adjusting piston (10); the end of the hose (13) is fixedly connected to an annular bracket (17); the outer end of the annular bracket (17) is fixedly connected to a second detection coil (18); the outer end of the annular bracket (17) is fixedly connected to a third detection coil (19); the outer end of the second detection coil (18) is fixedly connected to a heat dissipation layer (20); and the inner wall of the heat dissipation layer (20) is fixedly connected to the third detection coil (19); The through hole (12) is connected to the detection bracket (2) through a pipeline, the bottom end of the detection bracket (2) is fixedly connected to a partition (21), the outer end of the inner shell (1) is fixedly connected to a plurality of ultrasonic generators (22), the plurality of ultrasonic generators (22) are distributed in a circular array around the axis of the inner shell (1), and the outer ends of the ultrasonic generators (22) are fixedly connected to the partition (21); The outer end of the outer shell (4) is fixedly connected to a plurality of condensation inlet pipes (23), the plurality of condensation inlet pipes (23) all penetrate the outer shell (4), and the plurality of condensation inlet pipes (23) are in communication with a cavity surrounded by the outer shell (4) and the partition (21); the inner wall of the inner shell (1) is fixedly connected to a plurality of drying pipes (24), the drying pipes (24) are distributed in a circular array around the axis of the inner shell (1), the plurality of drying pipes (24) penetrate the inner shell (1), and the plurality of drying pipes (24) are in communication with a cavity surrounded by the outer shell (4) and the partition (21); the bottom end of the outer shell (4) is fixedly connected to a bottom plate (25), the inner end of the bottom plate (25) is slidably connected to a lifting platform (26), and the top end of the lifting platform (26) is fixedly connected to hardware.

2. The classification mechanism for detecting irregular hardware surface defects according to claim 1 is characterized in that: The second detection coil (18) and the third detection coil (19) constitute a differential coil; the second detection coil (18) and the third detection coil (19) have the same geometric shape and size; and the spacing W between the second detection coil (18) and the third detection coil (19) is equal to the width W of the second detection coil (18) or the third detection coil (19).

3. The classification mechanism for detecting irregular hardware surface defects according to claim 1 is characterized in that: The second detection coil (18) and the third detection coil (19) are wound in the same direction, and the output ends of the second detection coil (18) and the third detection coil (19) are connected to the signal processing unit in opposite ways, so that when the external magnetic field changes, the induced electromotive force generated by the second detection coil (18) and the third detection coil (19) is in opposite directions.

4. The classification mechanism for detecting irregular hardware surface defects according to claim 1 is characterized in that: A solenoid valve is fixedly connected to the pipeline between the regulating chamber (9) and the negative pressure ring (11), and the solenoid valve is connected to the control system via a wire. A sensor is fixedly connected to the outer end of the annular bracket (17), and the sensor is connected to the control system via a wire. A plurality of circular holes are formed at the bottom end of the detection bracket (2), and the plurality of circular holes are distributed in a circular array around the axis of the detection bracket (2).

5. The classification mechanism for detecting irregular hardware surface defects according to claim 1 is characterized in that: The main body of the hose (13) is made of TPU material, the adjusting joint (15) is made of stainless steel, the diameter of the hose (13) is 10 mm, the thickness of the adjusting joint (15) is 1 mm, and the diameter of the adjusting joint (15) is 20-30 mm.

6. The method for using a classification mechanism for detecting irregular hardware surface defects according to claim 1 comprises the following steps: S1, ultrasonic cleaning; The control system drives the lifting platform (26) to the top, and the hardware is placed on the platform and then lowered into the cleaning liquid at the bottom. The high-frequency sound waves generated by the ultrasonic generator (22) clean the surface of the hardware to ensure good contact and accuracy of subsequent testing; S2, residual heat air drying; After cleaning is completed, the lifting platform (26) is raised to the position of the drying tube (24), and the hardware is air-dried through the gas guided through the bottom of the partition (21) and the circular holes of the detection bracket (2) to reduce the influence of moisture on the detection results; S3, eddy current testing; The lifting platform (26) cooperates with the main detection coil (3) to perform layered detection, and the control system adjusts the appropriate detection frequency and identifies the location and type of surface defects of the hardware through a signal processing algorithm to ensure the accuracy and completeness of the detection; S4, local detection; The detection probe is adjusted to the bottom of the hardware groove by using an optical sensor and a mechanical arm (5), and the inside of the groove is accurately detected by using a differential coil composed of a second detection coil (18) and a third detection coil (19), thereby ensuring comprehensive detection of hardware with complex structures.

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