Chiller automatic marking and surface quality detection system and method for large casting molding

Abstract

The invention discloses an automatic marking and surface quality detection system and method for chilling blocks for large casting modeling, and belongs to the technical field of chilling block detection.The automatic marking and surface quality detection system comprises a stacking area, the chilling blocks and a detection mechanism, the detection mechanism is arranged in the stacking area, and the chilling blocks for modeling are stacked in the stacking area; the detection mechanism comprises a grabbing device, a recognition device, a marking device and a main control system, the grabbing device can grab the chilling block, and the recognition device can detect the chilling block and transmit a detection signal to the main control system; the marking device can be used for automatically marking the chilling block; the main control system can process detection signals, and the stacking area comprises a material stacking area, an arrangement area and a scrapping area. According to the invention, the detection mechanism is arranged in the stacking area, and the detection mechanism identifies the characteristics of the chilling blocks and processes the chilling blocks according to the characteristics. Therefore, the workload of manual detection of the chilling block is reduced, automatic identification and processing of the chilling block are realized, the use quality of the chilling block is ensured, and the production efficiency is improved.

Description

Technical Field

[0001] The invention relates to a system and method for automatically marking and detecting surface quality of a chill for large casting molding, belonging to the technical field of chill detection. Background Art

[0002] At present, large castings generally weigh several tons, dozens of tons or hundreds of tons. The castings have thick walls, large volumes, and high quality requirements. They need to undergo UT and MT flaw detection. The casting process mainly adopts resin sand molding technology. One of the key technologies in casting process design is the design of the quenching system, that is, a large amount of chillers are used to accelerate the local cooling of the castings, reduce the size of the shrinkage feeder, reduce the shrinkage cavity and shrinkage tendency of the castings, and improve the surface quality and mechanical properties of the castings. However, since the external chiller is in direct contact with the poured high-temperature molten metal, the surface of the chiller will oxidize and fail after repeated use, and the chilling ability will decrease. It will also cause defects such as pores and chiller adhesion on the surface of the casting. Therefore, the surface quality and reuse times of the chiller have a great impact on the quality of the casting. Often, improper use of a piece of chiller will cause the entire casting to be defective or scrapped.

[0003] During the casting process, castings require the use of a pouring system and a riser shrinkage-feeding system. Chills are a type of chiller used to accelerate the local cooling rate of castings during the casting process. They are used in conjunction with the pouring system and the riser system to reduce the size of the riser and prevent defects such as shrinkage cavities and shrinkage in castings. There are many types of chills, including flat straight, cylindrical, special-shaped, spiral, etc. In actual use, chillers of different shapes and materials need to be selected according to the size, shape and material of the casting to achieve the best chilling effect.

[0004] At present, the chiller itself is prone to certain defects during the casting process. This type of defect is related to the material, shape, placement and casting conditions of the chiller. Some defects such as oxidation, sand sticking, wear and corrosion can be eliminated by grinding; other defects such as fracture and deformation change the overall structure of the chiller and cannot be used anymore. After being used many times, the surface of the chiller will oxidize and fail, and the chilling ability will decrease. It will also cause defects such as pores and chiller adhesion on the surface of the casting. Therefore, the surface quality of the chiller and the number of times it is reused have a great impact on the quality of the casting. Often, improper use of a piece of chiller will cause the entire casting to be defective or scrapped.

[0005] At present, a large number of chillers of different sizes and quantities are needed in the resin sand molding process of large castings. They are manually classified and identified, and the surface of the chillers is scratched with angle grinders to mark the number of times the chillers are used. The surface quality of each chiller is observed by manual visual inspection, which greatly increases the workload and reduces production efficiency. It cannot meet the large-scale, high-demand, and automated production needs. To this end, it is necessary to develop and design a method for automatic marking and surface quality detection of chillers for large casting molding to ensure the quality of chillers, reduce the workload of workers, improve the quality of castings and production efficiency, and meet the industrialization requirements of intelligent casting, energy saving and carbon reduction, and green environmental protection. Summary of the invention

[0006] The technical problem to be solved by the present invention is to provide a system and method for cold iron marking and surface quality detection for large castings, which solves the problem of low efficiency in handling cold iron during casting.

[0007] The technical problem to be solved by the present invention is achieved by adopting the following technical scheme: a large casting molding cold iron automatic marking and surface quality detection system, comprising Stacking area, cold iron, testing agency, The detection mechanism is arranged in the stacking area, and the cold iron for shaping is stacked inside the stacking area. The detection mechanism includes a grasping device, an identification device, a marking device, and a main control system. The grasping device is provided with the identification device; the marking device is provided on one side of the grasping device; The grabbing device is capable of grabbing the cold iron, and the identification device is capable of detecting the cold iron grabbed by the grabbing device and transmitting a detection signal to the main control system; The marking device is capable of marking the cold iron at the bottom of the marking device; The main control system is capable of processing the detection signal and controlling the gripping device to move the cold iron to the bottom of the marking device or to the stacking area according to the detection signal; The stacking area includes a stacking area, an arrangement area, and a scrapping area. The cold iron is arranged in the stacking area. The stacking area is arranged on one side of the arrangement area, and the scrapping area is arranged on the other side of the arrangement area.

[0008] Preferably, the gripping device comprises a six-axis robot; the chill comprises a fitting surface and a separation surface, the fitting surface fits the casting, and the separation surface does not fit the casting.

[0009] Preferably, the gripping device is capable of controlling the posture of the gripped cold iron.

[0010] Preferably, the marking device comprises a fixed platform and a marking component, and the marking component is arranged on the fixed platform.

[0011] Preferably, the recognition device comprises a camera, which can recognize the posture, surface quality, and number of marks of the cold iron and convert them into signals.

[0012] Preferably, the main control system is connected to the identification device, and the main control system can receive a signal identified by the identification device.

[0013] Preferably, the main control system can control the grabbing device according to the signal recognized by the recognition device, and the grabbing device can grab the cold iron from the stacking area or the fixed platform, move it to the arrangement area for sorting or the scrap area, or move it to the fixed platform for marking.

[0014] A method for automatically marking and detecting surface quality of a chiller for large casting molding, preferably characterized by comprising the following steps: Step 1: The grabbing device grabs the cold iron from the stacking area; Step 2: The identification device detects the cold iron grabbed by the grabbing device and converts it into a signal to be transmitted to the main control system; Step 3: The main control system determines the surface quality status of the chill according to the signal; and controls the gripping device to move to the marking device for marking or to the scrap area according to the surface quality status of the chill.

[0015] Preferably, in step 3, the grasping device grasps the marked cold iron and moves it to the arrangement area for arrangement.

[0016] The beneficial effects of the present invention are: (1) Through the present invention, a detection mechanism is set in the stacking area, and the detection mechanism includes a grasping device, an identification device, and a marking device. The marking device is set on one side of the grasping device, and the identification device is set on the top of the grasping device. The grasping device includes a six-axis robot. The grasping device can grasp the cold iron, and the identification device can identify the characteristics of the grasped cold iron, and the cold iron is processed by the marking device according to the characteristics. The steps of manually detecting the cold iron are reduced, and the identification and processing of the cold iron are realized. The steps of manually processing the cold iron are reduced through automated processing, and the work efficiency is improved.

[0017] (2) Through the present invention, the stacking area includes a stacking area, an arrangement area, and a scrapping area. Chilled iron is arranged inside the stacking area, and the chilled iron after casting and use is stacked in the stacking area. The chilled iron in the stacking area is detected by a detection mechanism, and the detection mechanism can identify the state of the chilled iron, and the chilled iron is processed according to the state of the chilled iron. When the appearance and structure of the chilled iron are basically qualified, the captured chilled iron is controlled to move to the marking device, and the marking device is used to mark the chilled iron. The marked chilled iron is moved to the arrangement area, and the chilled iron is placed in a certain arrangement order in the arrangement area; when the appearance and structure of the chilled iron are unqualified or the number of times the chilled iron is used exceeds the standard number of times, the captured chilled iron is controlled to move to the scrapping area and the chilled iron is scrapped. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a structural schematic diagram of the present invention.

[0019] Figure 2 It is a schematic diagram of the structure of the grasping device and the identification device of the detection mechanism of the present invention.

[0020] Figure 3 It is a schematic structural diagram of the marking device of the present invention.

[0021] Figure 4 It is a structural schematic diagram of the cold iron of the present invention.

[0022] In the figure: 1-stacking area, 2-detection mechanism, 21-grasping device, 211-magnetic gripper, 22-identification device, 221-camera, 23-marking device, 231-marking component, 3-cold iron. DETAILED DESCRIPTION

[0023] In order to make the technical means, creative features, objectives and effects of the present invention easier to understand, the present invention is further described below in conjunction with specific embodiments.

[0024] Example 1 like Figure 1-Figure 4 As shown, a large casting molding chill automatic marking and surface quality detection system includes a stacking area 1, a chill 3, and a detection mechanism 2. The chill 3 is stacked in the stacking area 1, and the stacking area 1 is also provided with a detection mechanism 2.

[0025] Reference Figure 1 The detection mechanism 2 includes a grasping device 21, an identification device 22, a marking device 23, and a main control system, wherein the identification device 22 is arranged on the grasping device 21, and the marking device 23 is arranged on one side of the grasping device 21.

[0026] Reference Figure 2 , Figure 2 It is a schematic diagram of the structures of the grasping device 21 and the identifying device 22. Figure 2The grabbing device 21 is a six-axis robot, a magnetic gripper 211 is arranged on the top of the six-axis robot, and a recognition device 22 is arranged on one side of the magnetic gripper 211. In this embodiment, the recognition device 22 is a camera 221, which can recognize images and transmit them to the main control system.

[0027] The cold iron 3 is usually made of cast iron, cast steel, high carbon steel and other materials, which can be attracted by magnetic force; the grasping device 21 is provided with a magnetic gripper 211 at the top, and the magnetic gripper 211 can grasp the cold iron 3 by magnetic force. The identification device 22 provided on the grasping device 21 can detect the cold iron 3 grasped by the grasping device 21, and convert the detected image into a signal to be transmitted to the main control system.

[0028] Reference Figure 3 , Figure 3 It is a structural diagram of the marking device 23 , the marking component 231 includes a robot and a marking device arranged on the top of the robot. In this embodiment, the marking device is a laser marking device, which can mark the surface of the cold iron 3 .

[0029] As another embodiment, the marking component 231 uses an angle grinder to mark the surface of the chill 3.

[0030] In this embodiment, the marking device 23 includes a fixed platform and a marking component 231. The fixed platform is a platform arranged at the front end of the marking component 231, and the marking component 231 marks the cold iron 3 at the fixed platform.

[0031] The stacking area 1 is divided into multiple areas, including a stacking area, an arrangement area, and a scrapping area; the stacking area is arranged on one side of the arrangement area, and the scrapping area is arranged on the other side of the arrangement area.

[0032] In the stacking area, a detection mechanism 2 is provided in the stacking area, and chill 3 is stacked inside the stacking area, wherein the chill 3 inside the stacking area includes the chill 3 after casting and use. This type of chill 3 is transferred to the stacking area in the stacking area 1 through a conveyor belt after sand removal cleaning, shot blasting and other processing procedures; the chill 3 in the arrangement area is the chill that is confirmed to be qualified after being identified, detected and marked by the identification device 2, and is transferred to the arrangement area through the grabbing device 21 for classification and sorting; the chill 33 in the scrap area is the chill that is confirmed to be unqualified after being identified, detected and marked by the identification device 2, and is moved to the scrap area for processing.

[0033] In this embodiment, the main control system is arranged outside the detection mechanism 2 and connected to the detection mechanism 2 through a wire. The main control system can receive and control the detection mechanism 2, specifically: 1. The main control system can control the grabbing device 21 to grab the cold iron 3 from the stockpiling area of ​​the stockpiling area 1; 2. The recognition device 22 detects the cold iron 3 grabbed by the grabbing device 21 and transmits the detection signal to the main control system; 3. The main control system controls the grabbing device 21 to move the cold iron 3 to the fixed platform of the marking device 23 or to the scrapping area according to the detected signal; 4. The cold iron 3 moved to the marking device 23 is marked by the marking device 23; 5. The marked cold iron 3 is moved to the arrangement area by the grabbing device 21 for classification, arrangement and placement.

[0034] Cold iron 3 for resin sand molding of large castings, where cold iron 3 mainly adopts external cold iron, refer to Figure 3 , Figure 3 The structure diagram of the chill 3 is shown in FIG. During resin sand molding, a layer of paint is applied to the surface of the chill 3 and the chill is attached to the surface of the casting. Generally, one side of the chill 3 is attached to the casting, which is called the attachment surface; the other side that is not attached to the casting is called the separation surface.

[0035] During the use of the cold iron 3, there are certain quality requirements for the cold iron 3, specifically: 1. The surface of the chiller 3 must be smooth and flat to ensure a good chilling effect; 2. The surface of the cold iron 3 should be free of rust, molding sand, sand core and other dirt. If necessary, it can be sandblasted, shot blasted or pickled, or machined; 3. No cracks or bumps are allowed on the surface of the chill 3, so as not to affect the quality of the casting; 4. The defects such as pores and sand holes on the surface of the chill 3 should be controlled within a certain allowable range; 5. The surface oxide layer and graphite oxide layer thickness of the repeatedly used chilled iron 3 should meet the requirements. If it reaches 0.2-0.4mm, it should be stopped from use to prevent porosity defects from occurring during the casting process.

[0036] After being used many times, the surface of the chill 3 is severely oxidized, the graphite is oxidized, the matrix texture is changed, and the chilling ability is reduced, resulting in the failure of the chill 3 and the inability to perform the function of the chill 3. Therefore, the chill 3 is no longer used after being used a certain number of times. Generally, the number of times the chill 3 is used is within 10 times.

[0037] The identification device 22 needs to identify the entirety of the cold iron 3, the main control system controls the gripping device 21 to adjust the position of the cold iron 3, and the auxiliary identification device 22 identifies the cold iron 3. Specifically: The grasping device 21 grasps the cold iron 3 from the stacking area in the stacking area 1 through the magnetic gripper 211, and moves the cold iron 3 to the front of the grasping device 21 and lays it flat, and obtains the image of the top surface and each side surface of the cold iron 3 through the camera 221. The grasping device 21 grasps the cold iron 3 placed on the front side of the grasping device 21 and then rotates it, and controls the bottom surface of the cold iron 3 to flip over by rotation, and uses the camera 221 to obtain the top surface of the cold iron 3 after flipping.

[0038] The main control system identifies each plane of the chill 3, and determines the surface quality and number of marks of the chill 3 according to the image. When the surface quality of the chill 3 is qualified and the number of marks is less than the prescribed number of times used, the grasping device 21 is controlled to move the chill 3 to the marking device 23 for marking; when the surface quality of the chill 3 is qualified, the number of marks exceeds the prescribed number of times used or the surface quality of the chill 3 is unqualified, the grasping device 21 is controlled to move to the scrap area. The chill 3 marked by the marking device 23 is transferred to the arrangement area by the grasping device 21, and is placed in a classified manner according to the arrangement method set in the arrangement area.

[0039] The camera 221 acquires the surface image of the cold iron 3 and transmits it to the main control system. After receiving the image of the cold iron 3 acquired by the camera 221, the main control system processes and identifies the image, specifically: 1. Grayscale the image; 2. Process the image through a filter to remove noise from the image; 3. Increase the contrast of the image and obtain the texture of the image surface; By extracting the features of the processed image, the surface roughness of the image is judged. According to the grayscale changes of the processed image, the roughness of the surface of the chill 3, the holes on the surface of the chill 3, the cracks on the surface of the chill 3 and the number of markings on the surface of the chill 3 are judged.

[0040] The acquired image is divided into multiple areas for judgment. The roughness of the surface of the chill 3, whether there are cracks, whether the size of the surface holes is larger than the required standard, and the number of times the chill 3 is used are judged according to the number of markings on the chill 3.

[0041] When the surface roughness of the chill 3 is relatively large, the surface image of the chill 3 acquired by the camera 221 presents a state of silk spots after being processed, that is, a part of the surface of the image presents continuous wavy patches.

[0042] When there are large holes or cracks on the surface of the cold iron 3, the surface image of the cold iron 3 obtained by the camera 221 is processed, and there are some holes or irregular lines in the image. However, when the hole area exceeds the specified size or there are irregular lines in the image, the cold iron 3 is moved to the scrap area.

[0043] In the marking area of ​​the chill 3, it is necessary to detect the marking quantity of the chill 3, whether there are cracks, and whether defects such as pores and sand holes on the surface of the chill 3 are within the allowable range.

[0044] In this embodiment, the surface roughness of the cold iron 3 is: the surface flatness of the cold iron 3 is ≤0.2mm and the surface finish of the cold iron 3 is ≤Ra25μm. The dimensional tolerance of the surface of the cold iron 3 is ±1.0mm. The standard of the hole-type defect on the surface of the cold iron 3 is: within the range of 100×100mm, the number of holes is at most 3, and the diameter of the holes is 2<Ф≤3, and the spacing is ≥8mm or within the range of 100×100mm, the number of holes is at most 8, and the diameter of the holes is 1<Ф≤2.

[0045] The basic principles, main features and advantages of the present invention are shown and described above. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention. The scope of the present invention is defined by the attached claims and their equivalents.

Claims

1. A chiller automatic marking and surface quality inspection system for large castings, including Stacking area, cold iron, testing agency, The detection mechanism is arranged in the stacking area, and the cold iron for shaping is stacked inside the stacking area. Features: The detection mechanism includes a grasping device, an identification device, a marking device, and a main control system. The grasping device is provided with the identification device; the marking device is provided on one side of the grasping device; The grabbing device is capable of grabbing the cold iron, and the identification device is capable of detecting the cold iron grabbed by the grabbing device and transmitting a detection signal to the main control system; The marking device is capable of marking the cold iron at the bottom of the marking device; The main control system is capable of processing the detection signal and controlling the gripping device to move the cold iron to the bottom of the marking device or to the stacking area according to the detection signal; The stacking area includes a stacking area, an arrangement area, and a scrapping area. The cold iron is arranged in the stacking area. The stacking area is arranged on one side of the arrangement area, and the scrapping area is arranged on the other side of the arrangement area.

2. According to claim 1, a large casting molding chiller automatic marking and surface quality detection system is characterized by: The gripping device comprises a six-axis robot; the cold iron comprises a fitting surface and a separation surface, the fitting surface fits the casting, and the separation surface does not fit the casting.

3. The automatic marking and surface quality detection system for chillers used for large casting molding according to claim 2 is characterized in that: The gripping device is capable of controlling the posture of the gripped cold iron.

4. The automatic marking and surface quality inspection system for chillers used for large casting molding according to claim 1 is characterized in that: The marking device comprises a fixed platform and a marking component, wherein the fixed platform is provided with the marking component.

5. The automatic marking and surface quality detection system for chillers used for large casting molding according to claim 2 is characterized in that: The recognition device includes a camera, which can recognize the posture, surface quality, and number of marks of the cold iron and convert them into signals.

6. A large casting molding chiller automatic marking and surface quality detection system according to any one of claims 3 to 5, characterized in that: The main control system is connected to the identification device, and the main control system can receive a signal identified by the identification device.

7. A large casting molding chiller automatic marking and surface quality detection system according to claim 6, characterized in that: The main control system can control the grabbing device according to the signal recognized by the recognition device, and the grabbing device can grab the cold iron from the stacking area or the fixed platform, move it to the arrangement area for sorting or the scrap area, or move it to the fixed platform for marking.

8. A method for automatically marking and detecting the surface quality of a chiller for large castings, the method for automatically marking and detecting the surface quality of a chiller for large castings utilizing any one of claims 1 to 7, characterized in that: The following steps are involved: Step 1: The grabbing device grabs the cold iron from the stacking area; Step 2: The identification device detects the cold iron grabbed by the grabbing device and converts it into a signal to be transmitted to the main control system; Step 3: The main control system determines the surface quality status of the chill according to the signal; and controls the gripping device to move to the marking device for marking or to the scrap area according to the surface quality status of the chill.

9. A method for automatically marking and detecting surface quality of a chiller for large castings according to claim 8, characterized in that: In step 3, the grasping device grasps the marked cold iron and moves it to the arrangement area for arrangement.

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