Casting defect recognition device

Abstract

The invention discloses a casting defect identification device, and relates to the technical field of casting defect identification, the casting defect identification device comprises a support and a control module, the support is provided with a belt conveyor, the left part of the upper side of the support is provided with a visual initial detection mechanism, and the middle part of the upper side of the support is provided with an air coupling ultrasonic detection mechanism; the device comprises a support, a visual initial detection mechanism is arranged on the upper side of the support, a visual redetection mechanism is arranged on the right portion of the upper side of the support, a fixing block is fixedly connected to the right portion of the front side of the upper surface of the support, a distance measuring module is arranged on the fixing block, and the visual initial detection mechanism comprises four first visual detection modules which are symmetrically distributed on the upper side of a belt conveyor. Through linkage and function complementation of the structures, multi-level and high-accuracy casting defect recognition from initial detection to fine detection to recheck is achieved, the rejection rate is effectively reduced, the detection reliability is improved, and the casting defect recognition device has the advantages of being high in practicability, low in rejection rate and high in detection reliability.

Description

Technical Field

[0001] The present invention relates to the technical field of casting defect identification, and particularly to a casting defect identification device. Background Art

[0002] During the forming process of castings, various defects such as pores, shrinkage porosity, cracks, and slag inclusions are likely to occur. If they enter the subsequent processes without effective detection, it will have a serious impact on product quality, service performance, and production efficiency. Currently, the widely used casting detection methods mainly include manual visual inspection, X-ray flaw detection, ultrasonic testing, and machine vision recognition. Among them, machine vision technology has gradually become the main means for identifying casting surface defects due to its advantages such as non-contact, high speed, and easy integration into automated systems;

[0003] However, existing casting detection systems based on machine vision mostly focus on two-dimensional image acquisition, making it difficult to effectively identify tiny surface defects in areas with uneven illumination and specular reflection interference. At the same time, due to problems such as attitude changes and position deviations of workpieces during transmission, image offset is likely to occur, affecting the recognition accuracy;

[0004] To improve the recognition effect, some systems attempt to introduce multi-angle shooting and supplementary lighting components, but the overall still relies on light reflection, resulting in problems such as detection dead angles and different exposure degrees at different angles;

[0005] Therefore, there is an urgent need to design a casting defect identification device with reasonable structure, high detection accuracy, and capable of realizing multi-modal collaboration to improve the overall detection efficiency and reliability. Summary of the Invention

[0006] The purpose of the present invention is to provide a casting defect identification device to solve the problems raised in the above background art.

[0007] To solve the above technical problems, the present invention provides the following technical solution: A casting defect identification device includes a bracket and a control module. A belt conveyor is arranged on the bracket. A visual preliminary inspection mechanism is arranged at the upper left part of the bracket. An air-coupled ultrasonic detection mechanism is arranged at the upper middle part of the bracket. A visual re-inspection mechanism is arranged at the upper right part of the bracket;

[0008] A fixing block is fixedly connected to the front right part of the upper surface of the bracket, and a ranging module is arranged on the fixing block;

[0009] The visual preliminary inspection mechanism includes four first visual detection modules. The four first visual detection modules are symmetrically distributed above the belt conveyor and can perform visual detection on the workpieces passing through the surface of the belt conveyor;

[0010] The air-coupled ultrasonic detection mechanism includes three air-coupled ultrasonic detection modules. The three air-coupled ultrasonic detection modules are arranged on the right side of the visual preliminary inspection mechanism, and the three air-coupled ultrasonic detection modules are arranged in sequence from front to back and to the right;

[0011] The visual re-inspection mechanism includes a second visual detection module, and the second visual detection module can move in the front-back direction relative to the bracket.

[0012] According to the above technical solution, the distance measurement module, the first visual detection module, the air-coupled ultrasonic detection module, and the second visual detection module are all electrically connected to the control module, and the output end of the distance measurement module is arranged backward. The distance measurement module can measure the distance from the workpiece to the fixed block.

[0013] According to the above technical solution, the visual preliminary inspection mechanism further includes a dark box. The dark box is a box-shaped structure with openings on both the left and right sides. The lower side of the dark box is fixedly connected to the upper surface of the bracket. Four mounting holes are provided on the upper side of the dark box. The first visual detection module is arranged inside the mounting holes on the upper side of the dark box. A first supplementary light is fixedly connected to the middle of the dark box, and the first supplementary light can supplement light inside the dark box.

[0014] According to the above technical solution, the visual preliminary inspection mechanism further includes a limit strip. The limit strip is a strip-shaped rubber strip with a convex middle part to the left. The lower surface of the limit strip is fixedly connected to the surface of the conveyor belt of the belt conveyor. An extension box is fixedly connected to the left side of the dark box, and a resistance plate is hinged to the upper left part of the inner wall of the extension box through a torsion spring.

[0015] According to the above technical solution, the air-coupled ultrasonic detection mechanism further includes a support frame. A cross beam is fixedly connected to the upper side of the support frame. A hinge frame is fixedly connected to the outer wall of the cross beam. A fixed pile is fixedly connected to the front part of the right end of the hinge frame. The inner wall of the fixed pile is fixedly connected to the outer wall of the front air-coupled ultrasonic detection module. A first extension rod and a second extension rod are also arranged on the right side of the hinge frame. Fixed piles and air-coupled ultrasonic detection modules are arranged on the right sides of the first extension rod and the second extension rod.

[0016] According to the above technical solution, the first extension rod is arranged in the middle of the right side of the hinge frame, the second extension rod is arranged at the rear part of the right side of the hinge frame, the length of the second extension rod is greater than the length of the first extension rod, and the distance from the front air-coupled ultrasonic detection module to the middle air-coupled ultrasonic detection module is the same as the distance from the middle air-coupled ultrasonic detection module to the rear air-coupled ultrasonic detection module.

[0017] According to the above technical solution, the visual review mechanism also includes a column, the upper end of the column is fixedly connected to a limiting rod, the front side of the upper end of the column is fixedly connected to a motor, the output end of the motor is fixedly connected to a threaded rod, the outer wall of the threaded rod is threadedly connected to a moving block, the middle inner wall of the moving block is slidably connected to the outer wall of the limiting rod, the lower right part of the moving block is fixedly connected to the outer wall of the second visual inspection module, and the lower side of the moving block is also fixedly connected to a second fill light.

[0018] According to the above technical solution, a laser emitting module is fixedly connected to the right side of the column, and a laser receiving module is fixedly connected to the right side of the moving block, and the position of the laser emitting module is set corresponding to the position of the laser receiving module.

[0019] Compared with the prior art, the beneficial effects achieved by the present invention are as follows: the present invention can realize multi-angle image acquisition and uniform illumination of workpiece surface defects by providing the first visual inspection module and the first fill light, thereby improving the inspection clarity and recognition accuracy, and effectively identifying surface defects such as tiny cracks and pores;

[0020] By setting limit bars and resistance plates, the workpiece can be horizontally limited and vertically buffered before visual inspection to ensure the position consistency of the workpiece during inspection, significantly improving the stability and image consistency of visual inspection;

[0021] By setting up an air-coupled ultrasonic detection module and using segmented start-up and time-staggered method to perform longitudinal multi-point ultrasonic scanning, it can effectively detect shallow or hidden defects that are difficult to identify visually, reduce the detection blind spots caused by surface misjudgment, and improve the comprehensiveness of the overall defect identification of the system;

[0022] By providing a second visual inspection module and cooperating with a laser emitting module and a laser receiving module, it is possible to accurately move to the target position for image review based on the abnormal area fed back by ultrasonic detection. Combined with the second fill light to enhance the imaging effect, it can effectively determine whether the abnormality is a real defect or an acoustic artifact, avoid false alarms and misjudgments, and improve the final sorting accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0024] Figure 1 It is a three-dimensional structural schematic diagram of the present invention;

[0025] Figure 2 It is a schematic diagram of the rear structure of the bracket of the present invention;

[0026] Figure 3 It is a structural schematic diagram of the visual initial inspection mechanism of the present invention;

[0027] Figure 4 is a schematic structural diagram of the air-coupled ultrasonic detection mechanism of the present invention;

[0028] Figure 5 is a schematic structural diagram of the visual re-inspection mechanism of the present invention;

[0029] Figure 6 is a schematic structural diagram of the moving block of the present invention;

[0030] In the figure: 1, support; 2, belt conveyor; 3, visual preliminary inspection mechanism; 4, air-coupled ultrasonic detection mechanism; 5, visual re-inspection mechanism; 6, fixed block; 7, ranging module; 301, limiting strip; 302, dark box; 303, extension box; 304, resistance plate; 305, first fill light; 306, first visual detection module; 401, support frame; 402, cross beam; 403, hinge frame; 404, fixed pile; 405, air-coupled ultrasonic detection module; 406, first extension rod; 407, second extension rod; 501, column; 502, limiting rod; 503, motor; 504, threaded rod; 505, moving block; 506, second visual detection module; 507, second fill light; 508, laser emission module; 509, laser reception module. Detailed implementation manners

[0031] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0032] Please refer to Figure 1-6 , the present invention provides a technical solution: a casting defect identification device, including a support 1 and a control module. A belt conveyor 2 is arranged on the support 1. A visual preliminary inspection mechanism 3 is arranged on the upper left part of the upper side of the support 1. An air-coupled ultrasonic detection mechanism 4 is arranged in the middle of the upper side of the support 1. A visual re-inspection mechanism 5 is arranged on the upper right part of the upper side of the support 1. A fixed block 6 is fixedly connected to the front right part of the upper surface of the support 1. A ranging module 7 is arranged on the fixed block 6;

[0033] The visual preliminary inspection mechanism 3 includes four first visual detection modules 306, which are symmetrically distributed on the upper side of the belt conveyor 2 and can perform visual inspection on the workpieces passing through the surface of the belt conveyor 2. The visual preliminary inspection mechanism 3 also includes a dark box 302, which is a box-shaped structure with openings on both the left and right sides. The lower side of the dark box 302 is fixedly connected to the upper surface of the bracket 1. Four mounting holes are provided on the upper side of the dark box 302, and the first visual detection module 306 is arranged inside the mounting holes on the upper side of the dark box 302. A first supplementary light 305 is fixedly connected to the middle of the dark box 302, and the first supplementary light 305 can supplement light inside the dark box 302;

[0034] During use: The workpiece moves along a preset path under the drive of the belt conveyor 2. When the workpiece reaches the area of the visual preliminary inspection mechanism 3, since there are four first visual detection modules 306 arranged on the upper side of the dark box 302 and are symmetrically distributed, the workpiece image information can be obtained synchronously from multiple directions. With the uniform supplementary light provided by the first supplementary light 305, the rapid identification of defects such as pores and cracks on the surface of the workpiece can be realized;

[0035] The visual preliminary inspection mechanism 3 also includes a limit strip 301. The limit strip 301 is a strip-shaped rubber strip with a convex middle part to the left. The lower surface of the limit strip 301 is fixedly connected to the surface of the conveyor belt of the belt conveyor 2. The left side of the dark box 302 is fixedly connected to an extension box 303, and the upper left part of the inner wall of the extension box 303 is hinged with a resistance plate 304 through a torsion spring;

[0036] When the workpiece is placed on the belt conveyor 2, it should be located between the two limit strips 301 at this time. When the workpiece moves into the interior of the extension box 303 following the belt conveyor 2, due to the blockage of the resistance plate 304, the resistance plate 304 will generate resistance to the workpiece, thereby making the workpiece contact the left belt conveyor 2 more closely, and further ensuring that the position gap of the workpiece during the detection process is smaller. As the workpiece moves, it will push the resistance plate 304 to deflect, and at the same time, the torsion spring at the connection between the resistance plate 304 and the extension box 303 will contract and store energy. Subsequently, the workpiece enters the interior of the dark box 302 and breaks away from the resistance plate 304. The resistance plate 304 returns to its original position due to the elastic force of the torsion spring at the connection with the extension box 303, thereby ensuring that the position of the workpiece is consistent each time of detection and further improving the image quality;

[0037] As the workpiece continues to move to the right after completing the visual preliminary inspection in the area of the visual preliminary inspection mechanism 3, at this time, the distance measurement module 7 performs distance measurement and identification on the workpiece. The visual preliminary inspection mechanism 3 can detect in real time whether a workpiece passes through its rear side and send the workpiece passing information to the control module. The control module combines the set motion time parameters in the system to judge the order of this workpiece moving to the air-coupled ultrasonic detection mechanism 4 and moving to the visual re-inspection mechanism 5 positions, thereby realizing the one-to-one correspondence of multi-stage detection data;

[0038] The air-coupled ultrasonic detection mechanism 4 includes three air-coupled ultrasonic detection modules 405. The three air-coupled ultrasonic detection modules 405 are arranged on the right side of the visual preliminary inspection mechanism 3, and the three air-coupled ultrasonic detection modules 405 are arranged in sequence from front to back and from left to right. The air-coupled ultrasonic detection mechanism 4 further includes a support frame 401. A cross beam 402 is fixedly connected to the upper side of the support frame 401. A hinge frame 403 is fixedly connected to the outer wall of the cross beam 402. A fixed pile 404 is fixedly connected to the front part of the right end of the hinge frame 403. The inner wall of the fixed pile 404 is fixedly connected to the outer wall of the front air-coupled ultrasonic detection module 405. A first extension rod 406 and a second extension rod 407 are further arranged on the right side of the hinge frame 403. Fixed piles 404 and air-coupled ultrasonic detection modules 405 are arranged on the right sides of both the first extension rod 406 and the second extension rod 407. The first extension rod 406 is arranged in the middle of the right side of the hinge frame 403. The second extension rod 407 is arranged at the rear part of the right side of the hinge frame 403. The length of the second extension rod 407 is greater than that of the first extension rod 406, and the distance from the front air-coupled ultrasonic detection module 405 to the middle air-coupled ultrasonic detection module 405 is the same as the distance from the middle air-coupled ultrasonic detection module 405 to the rear air-coupled ultrasonic detection module 405;

[0039] When the workpiece enters the area of the air-coupled ultrasonic detection mechanism 4, due to the arrangement of three air-coupled ultrasonic detection modules 405 in sequence from front to back, air-coupled ultrasonic detection of multiple points on the surface of the workpiece can be realized, further confirming whether there are surface hidden defects that cannot be recognized visually, such as shallow cracks or tiny air holes, and then transmitting the above information to the control module. The three air-coupled ultrasonic detection modules 405 can cover the longitudinal range of the workpiece through spaced arrangement to ensure that the defects are completely scanned. Moreover, the three air-coupled ultrasonic detection modules 405 are staggeredly arranged and are started in sequence as the workpiece moves to the right, and their starting times are inconsistent, which can avoid acoustic wave interference. In addition, the positions of the three air-coupled ultrasonic detection modules 405 can be adjusted by adjusting the angle of the hinge frame 403;

[0040] When the workpiece passes through the air-coupled ultrasonic detection module 405, the control module makes a decision based on the detection result: if the first visual detection module 306 has detected an abnormality previously, the air-coupled ultrasonic detection module 405 will be silent, and the control module will trigger an abnormal handling process, sending signals to the operation terminal and the subsequent sorting device through the control module, and the visual re-inspection mechanism 5 area will remain silent;

[0041] If the first visual detection module 306 does not detect an abnormality and the air-coupled ultrasonic detection module 405 participates in the detection process and no abnormality is detected, the control module will default that the workpiece is qualified, not trigger subsequent detections, and directly enter the normal discharging path;

[0042] The visual re-inspection mechanism 5 includes a second visual detection module 506, and the second visual detection module 506 can move in the front-back direction relative to the bracket 1. The visual re-inspection mechanism 5 further includes a column 501. A limiting rod 502 is fixedly connected to the upper end of the column 501. A motor 503 is fixedly connected to the front side of the upper end of the column 501. The output end of the motor 503 is fixedly connected to a threaded rod 504. A moving block 505 is threadedly connected to the outer wall of the threaded rod 504. The inner wall of the middle part of the moving block 505 is slidably connected to the outer wall of the limiting rod 502. The lower right part of the moving block 505 is fixedly connected to the outer wall of the second visual detection module 506. A second supplementary light 507 is also fixedly connected to the lower side of the moving block 505. A laser emission module 508 is fixedly connected to the right side of the column 501. A laser reception module 509 is fixedly connected to the right side of the moving block 505. The position of the laser emission module 508 is set corresponding to the position of the laser reception module 509;

[0043] If the detection result of the first visual detection module 306 is normal, but the air-coupled ultrasonic detection module 405 detects an abnormal area, at this time, the control module will calculate the distance information of the workpiece from the fixed block 6 provided by the ranging module 7 and the position information of the abnormal area detected by the air-coupled ultrasonic detection module 405, calculate the specific coordinates of the abnormal area in the conveying direction, and drive the motor 503 to drive the threaded rod 504 to rotate. Since the outer wall of the threaded rod 504 is threadedly connected to the inner wall of the moving block 505 and the moving block 505 is restricted from rotating by the limiting rod 502, the rotation of the threaded rod 504 drives the moving block 505 to move, and then drives the second visual detection module 506 to move in the front-back direction to above this coordinate through the moving block 505 to complete precise alignment;

[0044] In this process, the laser emission module 508 and the laser reception module 509 are used in cooperation to determine whether the current position of the second visual detection module 506 coincides with the preset abnormal area through laser emission and reception, further improving the positioning accuracy;

[0045] When the second visual detection module 506 completes alignment, it cooperates with the second supplementary light 507 for supplementary lighting, starts image acquisition, and re-inspects and judges the abnormal area detected by the air-coupled ultrasonic detection module 405. If a visual defect is confirmed in this area, the control module determines it as a real defect and triggers the sorting action;

[0046] If no obvious abnormality is detected, it can be marked as internal damage caused by the process and acoustic artifacts, which helps the factory adjust the production process. Through the linkage and functional complementarity among the above structures, multi-level and high-accuracy casting defect identification from initial inspection, precise inspection to recheck is realized, effectively reducing the scrap rate and improving the detection reliability.

[0047] It should be noted that in this text, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0048] Finally, it should be noted that the above are only preferred embodiments of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A casting defect identification device, comprising a bracket (1) and a control module, characterized in that: A belt conveyor (2) is arranged on the bracket (1). A visual preliminary inspection mechanism (3) is arranged at the upper left part of the upper side of the bracket (1). An air-coupled ultrasonic detection mechanism (4) is arranged at the middle part of the upper side of the bracket (1). A visual re-inspection mechanism (5) is arranged at the upper right part of the upper side of the bracket (1). A fixing block (6) is fixedly connected to the front right part of the upper surface of the bracket (1). A distance measuring module (7) is arranged on the fixing block (6). The visual preliminary inspection mechanism (3) includes four first visual detection modules (306). The four first visual detection modules (306) are symmetrically distributed on the upper side of the belt conveyor (2) and can perform visual detection on the workpieces passing through the surface of the belt conveyor (2). The air-coupled ultrasonic detection mechanism (4) includes three air-coupled ultrasonic detection modules (405). The three air-coupled ultrasonic detection modules (405) are arranged on the right side of the visual preliminary inspection mechanism (3), and the three air-coupled ultrasonic detection modules (405) are arranged in sequence from front to back and from left to right. The visual re-inspection mechanism (5) includes a second visual detection module (506), and the second visual detection module (506) can move in the front-back direction relative to the bracket (1).

2. The casting defect recognition device according to claim 1, characterized in that: The distance measuring module (7), the first visual detection module (306), the air-coupled ultrasonic detection module (405), and the second visual detection module (506) are all electrically connected to the control module. The output end of the distance measuring module (7) is arranged backward, and the distance measuring module (7) can measure the distance between the workpiece and the fixing block (6).

3. The casting defect recognition device according to claim 2, wherein: The visual preliminary inspection mechanism (3) further includes a dark box (302). The dark box (302) is a box-shaped structure with openings on both the left and right sides. The lower side of the dark box (302) is fixedly connected to the upper surface of the bracket (1). Four mounting holes are opened on the upper side of the dark box (302). The first visual detection module (306) is arranged inside the mounting holes on the upper side of the dark box (302). A first supplementary light (305) is fixedly connected to the middle part of the dark box (302), and the first supplementary light (305) can supplement light inside the dark box (302).

4. The casting defect recognition device according to claim 3, characterized in that: The visual preliminary inspection mechanism (3) further includes a limiting strip (301). The limiting strip (301) is a strip-shaped rubber strip with a convex middle part to the left. The lower surface of the limiting strip (301) is fixedly connected to the surface of the conveyor belt of the belt conveyor (2). The left side of the dark box (302) is fixedly connected to an extension box (303). A resistance plate (304) is hinged to the upper left part of the inner wall of the extension box (303) through a torsion spring.

5. The casting defect recognition device according to claim 4, characterized in that: The air-coupled ultrasonic detection mechanism (4) further includes a support frame (401). A cross beam (402) is fixedly connected to the upper side of the support frame (401). An articulated frame (403) is fixedly connected to the outer wall of the cross beam (402). A fixed pile (404) is fixedly connected to the front part of the right end of the articulated frame (403). The inner wall of the fixed pile (404) is fixedly connected to the outer wall of the front air-coupled ultrasonic detection module (405). A first extension rod (406) and a second extension rod (407) are further arranged on the right side of the articulated frame (403). Fixed piles (404) and air-coupled ultrasonic detection modules (405) are arranged on the right sides of both the first extension rod (406) and the second extension rod (407).

6. The casting defect recognition device according to claim 5, characterized in that: The first extension rod (406) is arranged in the middle of the right side of the articulated frame (403). The second extension rod (407) is arranged at the rear part of the right side of the articulated frame (403). The length of the second extension rod (407) is greater than that of the first extension rod (406). And the distance from the front air-coupled ultrasonic detection module (405) to the middle air-coupled ultrasonic detection module (405) is the same as the distance from the middle air-coupled ultrasonic detection module (405) to the rear air-coupled ultrasonic detection module (405).

7. The casting defect recognition device according to claim 6, characterized in that: The visual re-inspection mechanism (5) further includes a column (501). A limiting rod (502) is fixedly connected to the upper end of the column (501). A motor (503) is fixedly connected to the front side of the upper end of the column (501). A threaded rod (504) is fixedly connected to the output end of the motor (503). A moving block (505) is threadedly connected to the outer wall of the threaded rod (504). The middle inner wall of the moving block (505) is slidably connected to the outer wall of the limiting rod (502). The lower right part of the moving block (505) is fixedly connected to the outer wall of the second visual detection module (506). A second supplementary light (507) is also fixedly connected to the lower side of the moving block (505).

8. An apparatus for identifying casting defects according to claim 7, characterized in that: A laser emission module (508) is fixedly connected to the right side of the column (501). A laser reception module (509) is fixedly connected to the right side of the moving block (505). The position of the laser emission module (508) is correspondingly arranged with the position of the laser reception module (509).

Images